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Welcome ToToday’s PresentationSponsored By:

Any Questions Or Comments PleaseSend Emails To [email protected] Questions That You May HaveDuring The Webinar Please Feel FreeTo Text Them In At Any Time

Webinar Schedule

AUGUST8/8/15 -- Albuquerque,NM8/15/15 -- Portland, OR8/22/15 -- Atlanta, GA8/29/15--Anaheim, CASEPTEMBER9/12/15 -- Billings, MT9/19/15 -- Chicago, IL9/26/15-- Clark-Newark,NJOCTOBERATRA's Powertrain ExpoOctober 29 - November 1NOVEMBER11/7/15 -- Baltimore, MD

Ford 6R140W Introduction“TorqShift 6”Presented by:Mike SouzaATRA SeniorResearch TechnicianFord 6R140W Intro Webinar 2015 ATRA. All Rights Reserved.

IntroductionThis is a 6-speed electronically controlled transmission .This transmission includes: Torque converter with an integral converter clutch Electronic shift and pressure controls Single planetary gear-set Double (Ravigneaux) planetary gear-set Two holding multi-disc clutch sets Three driving multi-plate clutch sets One one-way holding clutch Valve body unitThe (6) forward gears and one reverse gear are obtained from (2) planetary gear sets.The valve body assembly with solenoids inside the transmission and is controlled by a PCM forgas engine applications and a Transmission Control Module (TCM) for diesel engine applicationslocated outside the transmission.In the event of a system fault, the PCM or TCM also provides for Failure Mode Effect Managementto maintain maximum functional operation of the transmission with a minimum power reduction.In the event of a total loss of control or electrical power, the basic transmission functions P, R, Nand D are retained.Also 5th gear is retained by the hydraulic system.

Component OverdriveClutch(4-5-6)IntermediateClutch(2-6)Low OneWay Clutch(Sprag)Low Planet

Component Application ChartThe two overdrive gears create a shorter ratio. This, combined with different available rear axle ratios, gives theTorqshift the pulling power it needs

Shift Speed Chart Gas Engines

Shift Speed Chart Diesel Engines

Solenoid Body StrategyThe solenoid body strategy is a file programmed into the PCM or TCM.The solenoid body tag on the transmission case contains the 13-digit solenoid body strategy andthe 8-digit solenoid body identification.

Valve Body / Solenoid ReplacementAnytime a new valve body is installed, a new solenoid body strategy file is downloaded intothe PCM or TCM using a capable scan tool. A replacement solenoid body tag is supplied with thenew solenoid body which contains the 13-digit solenoid body strategy and the 8-digit solenoidbody identification. The new tag is placed over the original solenoid body tag.If the solenoid body strategy printed on the tag on the solenoid body does not match thesolenoid body tag on the side of the transmission case, a new valve body must be installedand the solenoid body strategy must be downloaded into the PCM or TCM or harsh shiftswill result.

Valve Body / Solenoid Replacement1. Using the scan tool, select Module Programming and Programmable Parameters then selecttransmission. Follow the instructions displayed on the scan tool.There are fields to enter the solenoid body eight-digit identification and thirteen-digit strategyrecorded from the tag on the main control.2. NOTICE: If the solenoid body information is not correct, transmission damage or driveabilityconcerns can occur. Enter the solenoid body identification and strategy.The scan tool verifies numbers entered are valid and displays a message if the information is notvalid. The scan tool checks to see if the file is present on the scan tool.If the file is present, the technician may proceed with downloading the file to the PCM orTransmission Control Module (TCM). If the file is not present, connect the scan tool to theProfessional Technician Society (PTS) server to download the file onto the scan tool orwww.motorcraft.com.3. Verify the file is present on the scan tool. If the file is present, go to Step 8. If the file is notpresent, continue with this procedure.4. Connect the scan tool to the PTS server. The screen displays a progress bar when connectingto the network.5. Follow the instructions on the network to download the strategy file to the scan tool.

Valve Body / Solenoid Replacement6. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.If the scan tool cannot download a strategy from the web site, a partial strategy is downloadedautomatically.7. Reconnect the scan tool to the vehicle.8. Follow the instructions displayed on the scan tool.9. If a new main control was installed, clean the existing solenoid strategy tag on thetransmission case and cover It with the replacement solenoid body tag provided with the maincontrol service kit.The scan tool automatically downloads the strategy file or partial strategy file to the PCM or TCM.The scan tool displays a message when its finished downloading the data stating the file wasdownloaded successfully.10. NOTICE: If the adaptive drive cycle has not been performed, the customer may feel erraticshifts and driveability concerns. Perform the adaptive drive cycle.Refer to Shift Point Road Test in this section.

Solenoid ReplacementThe solenoids are calibrated from the factory and are not all the same. There are (2) types ofsolenoids, normally high and normally low solenoids.The solenoids can be replaced separately, but only with the same type of solenoid. Thereplacement solenoid band number must match the band number of the solenoid being replaced.The band number is printed on the side of the solenoid and will be a 2, 3, 4 or 5.4

Solenoid Function4.8-5.4 Ohms4.8-5.4 OhmsSolenoidClutch TypeSolenoid TypeShift Solenoid A (SSA)Shift Solenoid B (SSB)Shift Solenoid C (SSC)Shift Solenoid D (SSD)Shift Solenoid E (SSE)Line Pressure Control (LPC) solenoidTorque Converter Clutch (TCC) solenoidForward (1,2,3,4)Direct (3,5,R)Intermediate (2,6)Low/reverse (1,R)Overdrive (4,5,6)Normally LowNormally HighNormally LowNormally LowNormally HighNormally HighNormally Low

Solenoid RemovalIt is recommended to use a scribe or electronic etching tool to mark the solenoids.This will ensure the proper placement after removal.

Solenoid Part NumbersSOLENOID BAND #Normally HIGH Solenoid BC3Z-7G383-M5BC3Z-7G383-NSOLENOID BAND #Normally LOW Solenoid BC3Z-7G383-U5BC3Z-7G383-V

Easiest Way To Determine NH & NL SolenoidsBlack “Normally High”Brown “Normally Low”

Solenoid Apply Chart

Case Connector Pin ion Solenoid Power Control 1Transmission Solenoid Power Control 2Shift Control Solenoid "A“ 4.8-5.4 OhmsShift Control Solenoid "B" 4.8-5.4 OhmsShift Control Solenoid "C" 4.8-5.4 OhmsShift Control Solenoid UD" 4.8-5.4 OhmsShift Control Solenoid "E" 4.8-5.4 OhmsLine Pressure Solenoid Control 4.8-5.4 OhmsTCC Solenoid Control 4.8-5.4 OhmsTransmission Range Sensor GroundTurbine Speed Sensor SignalTSS, OSS, TRS VPWRTransmission Range Sensor SignalNot UsedNot UsedNot UsedOutput Shaft Speed Sensor SignalTransmission Temperature Sensor SignalTransmission Temperature Sensor Signal Ground613191714

Range Sensor12 VoltsPWM SignalGroundPositionPRNDM21% Duty Cycle13.3 - 15.533.2 - 34.540.0 - 46.658 - 60.569.0 - 70.580.0 - 90.585.5 - 95.0

Speed SensorsThere is one Turbine and one Output Speed Hall Effect Type Sensor. These sensors produce afive volt D/C signal to the PCM or TCM.OSSTSS12 Volts RedSignal WhiteNot UsedGround Black

Transmission Fluid Temperature SensorDegrees (F)- 40 to - 4- 3 to 3132 to 6869 to 104105 to 158159 to 194195 to 230231 to 266267 to 302Degrees (C)- 40 to -20- 19 to - 10 to 2021 to 4041 to 7071 to 9191 to 110111 to l30131 to 150Resistance (K)967 - 284284 - 100100 - 3737 - 1616 - 55 - 2.72.7 - 1.51.5 - 0.80.8 - 0.54

Valve Body OverhaulTo remove the valve body, remove the nine (9) bolts shown in the picture on the left.To separate the valve body remove the two different size bolts shown in the picture on the right.

Valve Body OverhaulNote the location of the (3) check balls, the relief valves and the control valve inlet nozzle forassembly.Remove the (3) check balls, the (2) relief valves and the pump inlet nozzle.(3)(2)

Valve Body Overhaul

Valve Body Overhaul

Input Shaft Sealing Ring ReplacementUsing a suitable tool, remove the 4 solid input shaft and 1 Torque Converter Clutch (TCC) Teflon sealing ring.

Input Shaft Sealing Ring ReplacementInspect the overdrive (4,5,6) clutch cylinder and input shaft assembly for damage.Inspect the bushing surfaces, Teflon seal surfaces, ring gear and bushing surfaces for excessivewear or damage.If damage or excessive wear is found, install new components as necessary.Molded sealing ringsBushing SurfaceCylinder Bushing

Input Shaft Sealing Ring ReplacementInstall the Input Shaft Teflon Seal Sizer on the input shaft and adjust it so the bottom edge islined up just above the top edge of the bottom Teflon seal groove.Lubricate the Input Shaft Teflon Seal Sizer with clean transmission fluid and install a newTeflon seal by sliding it down the Input Shaft Teflon Seal Sizer into the groove.Adjust the Input Shaft Teflon Seal Sizer and install the remaining (3) input shaft Teflon sealsinto the grooves.Lubricate the Input Shaft Teflon Seal Sizer with clean transmission fluid and install it over theTeflon seals to size the seals. Do the same procedure on the other side of the drum.307-653/1307-653/4

Output Shaft Nut RemovalThe output shaft nut is coated with Loctite from the factory, then tightened to 150 lb. ft.(about 200 Nm). Failure to loosen the Loctite by applying heat to the output shaft nut can causedamage to the output shaft nut socket.NOTICE: Make sure to clean any debris from the Loctite that may have fallen into thetransmission case when removing the output shaft nut. Failure to clean the debris can resultin transmission fluid or filter contamination or damage to the transmission.Fixed flange/Four-Wheel Drive (4WD) shown, slip yoke similar. Apply heat to the output shaft nutto soften the Loctite . Using the output shaft nut socket, remove the output shaft nut.

Output Shaft Nut RemovalYou need to remove this nut to service the low/reverse piston assembly and the rear case seal.The output nut tool is identical to the Torqshift (5R110W) nut just bigger. This nut requires thespecial tool and lots of heat.The output shaft nut socket is available from Ford, part number #307-649, for about 250 to 300.Although, you can find them through the aftermarket for much less.#307-649

Other Tools RequiredThis unit weighs in at a hefty 350 lbs. (almost 160 kilos) with the torque converter installed. This isslightly heavier than the LCT 1000 which weights in at 330 lbs. (150 kilos).Now we can muscle this unit around and risk injuries, or we can take a few minutes and put sometools together that are going to make working on this unit easy and, more importantly safe.Use an engine hoistto get this unit on thebench for a teardown

Other Tools RequiredThe input drum assembly must be installed into the transmission as a unit. Using the engine hoistto install this assembly will also be much easier and safe.The easier way to assemble this unit is to stand it on end.You can use an old Allison case as a stand.Ford has a special lifting fixture, tool #307-651, for this operation.#307-651

Other Tools RequiredA duplicate tool can be made fairly quickly with a piece of square tubing, an eye bolt,and two pieces of flat steel.DuplicatedTool

Parts ComparisonA comparison in some parts sizes to the Ford 5R110W “TorqShift”.

One Way Clutch (Diode)A Ford-patented, rocker one-way clutch (diode) is integrated in the carrier to improve1-2 shift quality through the gear-set

Torque ConverterNote the spline on the converter hub much like a Honda transmission. There is also an internalspline to drive a PTO gear.The PTO is splined to the engine in this arrangement and spins constantly whenever the engineruns. This eliminates the need to apply another clutch or the torque converter clutch to engagethe PTO gear.As you can see here the converter is no lightweight either.Splined HubInternal Spline For PTO Gear

Pump & PTO GearSome vehicles with a Power Take Off unit will have a PTO gear located here on thestator support.Front sun gear for thesingle planet splines ontothe stator support also

Case SealsCase seals at back and center of case.GreenDark BlueBlack

Case SealsValve Body Seals to front of Case

Case Air Checks & Hydraulic PortsItem1234567891011DescriptionConverter InletConverter OutletOverdrive ClutchForward ClutchPump InletPump OutletDirect ClutchTorque Converter ClutchIntermediate ClutchLow/Reverse DynamicLow/Reverse Static

Line Pressure Tap LocationLine pressure Allan type tap threads are 10mm x 1.00mm located on the left side of thecase between the bellhousing and the linkage.

Line Pressure Specifications

Fluid Specifications

Clutch Quantity

Clutch Clearances

Selective Snap Ring Charts

Front & Rear Unit Endplay

Specifications

Data PID Identification

Data PID Identification

Data PID Identification

Data PID Identification

Today’sPresentationSponsored By:Any Questions?Thank You ForAttendingFord 6R140W Intro Webinar 2015 ATRA. All Rights Reserved.