E4OD 4R100 Vac Interactive
2017-09-28
: Sonnax E4Od-4R100 Vac Interactive E4OD-4R100_Vac_Interactive 639 file tech_resource uploads
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Ford E40D, 4R100 TIME TESTED • INDUSTRY TRUSTED Critical Wear Areas & Vacuum Test Locations NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement. Lower Control Body • 4R100 Non-PTO Shown Engagement Control Valve NOTE: Worm tracks and test locations same for ‘96-’98 E40D. Worm tracks and test locations different for ‘89-’95 E40D. Worm tracks slightly different for PTO 4R100, test locations are the same. • Delayed Forward & Reverse engagement • Burnt Forward clutch • Burnt Direct clutch 1-2 Manual Transition Valve • Burnt intermediate band • Manual low gear bind-up Upper Control Body • 4R100 Non-PTO Shown Low/Reverse Modulator Valve Plunger & Sleeve NOTE: Worm tracks and test locations same for ‘96-’98 E40D. Worm tracks and test locations different for ‘89-’95 E40D. Worm tracks slightly different for PTO 4R100, test locations are the same. • Burnt Low/Reverse clutch • No engine braking • Low pressure at Low/Reverse clutch Replace with Sonnax Part No. 36947-06K Note: Check for wear at inside diameter of sleeve. 2-3 Shift Valve • 2-3 Shift complaints • Burnt Direct clutch Note: Seal port on opposite side. Low/Reverse Modulator & Low/Reverse Modulator Valves 3-4 Shift Valve & 4-3-2 Timing Valve • Burnt Low/Reverse clutch • Low pressure at Low/Reverse clutch • No engine braking • 3-4 Shift complaints • Burnt Direct clutch • Manual low concerns Coast Clutch Shift Valve • Burnt coast clutch Drive 2 Valve • Reverse complaints Solenoid Regulator Valve 1-2 Shift Valve • 2nd or 3rd Gear starts • Reduced lube oil from the center support • TCC cycling or slip • No 2nd gear • 1-2 Shift Complaints Test: Flip casting over and test at this orifice. Seal this side of casting with foam mat. 4-3-2 Timing Valve & Control Valve Shift Timing Plunger Replace with Sonnax Part No. 36947-14K Requires F-36947-TL14 & VB-FIX • Manual low concerns ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100_VacTestGuide 09-26-17 Page 1 TIME TESTED • INDUSTRY TRUSTED 20 15 Ford E40D, 4R100 10 25 5 0 30 VACUUM TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Accumulator Control Body • 4R100 Non-PTO Shown Overdrive Clutch Accumulator Regulator Valve • No 4th • Soft Shifts Replace with Sonnax Part No. 36948-09K Overdrive Clutch Accumulator Plunger Intermediate Clutch Accummulator Regulator Valve • No 3rd • Soft Shifts • Premature clutch failure Replace with Sonnax Part No. 36948-13K Intermediate Clutch Accumulator Plunger Note: Seal port on opposite side. • No 4th • Soft Shifts • Premature clutch failure • No 3rd • Soft Shifts • Premature clutch failure Direct Clutch Accumulator Plunger Line Pressure Modulator Valve • No 2nd • Soft shifts • Premature clutch failure • 1-2 Harsh • Harsh shifts • Soft shifts Direct Clutch Accumulator Regulator Valve • No 2nd • Soft shifts • Premature clutch failure Replace with Sonnax Part No. 36948-13K 09-26-17 E4OD-4R100_VacTestGuide Page 2 Replace with Sonnax Part No. 36948-19 Requires 36948-TL Line Pressure Modulator Valve & Sleeve • 1-2 Soft • 2-3 Soft • Intermitent harsh shifts • Low EPC pressure • Low line rise Replace with Sonnax Part No. 36948-03K .331" dia. 36948-05K .372" dia. 96948-01K .427" dia. 96948-05K .500" dia. ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Ford E40D, 4R100 TIME TESTED • INDUSTRY TRUSTED Critical Wear Areas & Vacuum Test Locations 20 15 10 25 NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement. 5 0 30 VACUUM TEST For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com. Pump Body • E4OD Shown NOTE: Test ports on 4R100 slighlty different. Main Regulator Valve • Code 62, 628, 1744 • Engine stall or engagement in Reverse • Engine stumble on engagement in Reverse • High line pressure • Overheated converter Main Regulator Valve & Sleeve • Delayed Reverse • Low line rise • Soft shifts Replace with Sonnax Part Nos. Replace with Sonnax Part Nos. 36424-04K 36424-01K Boost Valve Kit (with O-rings) 36424-03K Boost Valve Kit (without O-rings) Line-to-Lube Pressure Regulator Valve 36424-16K Oversized Line-to-Lube Pressure Regulator Valve Kit Requires F-36424-TL16C & VB-FIX Note: Test ports on opposite side while sealing this side against foam pad. Note: 4R100 has air bleed here that will need to be sealed. NOTE: 4R100 Port is different. Must seal indicated air bleed when testing these ports. Converter Regulator Valve • Excess converter pressure • Internal converter damage • Low converter & converter clutch apply pressure Replace with Sonnax Part Nos. 36424-11K Oversized Converter Regulator Valve Kit Requires F-36424-TL11C & VB-FIX Note: Seal holes on opposite side. Converter Clutch Control Valve • No lockup • TCC always applied • Lockup shudder • TCC cycling Replace with Sonnax Part Nos. 36424-08K TCC Control Plunger Valve Kit (4R100 PWM Only) 36424-15K Oversized TCC Control Valve (4R100 PWM Only) Requires F-36424-TL15C & VB-FIX ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100_VacTestGuide 09-26-17 Page 3 TIME TESTED • INDUSTRY TRUSTED Ford E40D, 4R100 OE Exploded View Lower Control Body 4R100 Non - PTO Shown Upper Control Body 4R100 Non - PTO Shown NOTE: E4OD is the same. NOTE: E4OD Worm tracks and valves vary slightly. 101 201 202 203* 204 < Lower Control Valve Body Descriptions I.D. No. Description 101 Engagement Control Valve 102 1-2 Manual Transition Valve 102 Upper Control Valve Body Descriptions > I.D. No. Description 201 2-3 Shift Valve 202 3-4 Shift Valve Low/Reverse Modulator Valve (Inboard) 203* Low/Reverse Modulator Valve (Center) Low/Reverse Modulator Valve Plunger & Sleeve (Outboard) 204 Manual Control Valve 205* Solenoid Regulator Valve 206 Coast Clutch Shift Valve 205* 206 4-3-2 Timing Valve (Inboard) 207* 208* Control Valve Shift Timing Plunger (Outboard) 208* * E4OD Different Drive 2 Valve (Inboard) 1-2 Shift Valve (Outboard) 207* 09-26-17 E4OD-4R100_VacTestGuide Page 4 ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Ford E40D, 4R100 TIME TESTED • INDUSTRY TRUSTED OE Exploded View Accumulator Control Body 4R100 Non - PTO Shown 301 Pump Body E4OD Pump Body Shown 302 < Accumulator Control Body Descriptions I.D. No. 301 302 303 304 Description Direct Clutch Accumulator Regulator Valve (Inboard) Direct Clutch Accumulator Plunger (Outboard) Overdrive Clutch Accumulator Regulator Valve (Inboard) Overdrive Clutch Accumulator Plunger (Outboard) Intermediate Clutch Accumulator Regulator Valve (Inboard) Intermediate Clutch Accumulator Plunger (Outboard) Line Pressure Modulator Valve (Inboard) Line Pressure Modulator Plunger Valve & Sleeve (Outboard) 403A 402 Pump Body Descriptions > I.D. No. Description Main Regulator Valve (Inboard) 304 401 Main Regulator Valve & Sleeve (Outboard) 402 Converter Regulator Valve 403A E4OD Converter Clutch Control Valve 403B 4R100 Non-PWM Converter Clutch Control Valve 403C 303 401 403B 403C 4R100 PWM Converter Clutch Control Valve (Inboard) Converter Clutch Control Plunger Valve & Sleeve (Outboard) ©2017 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com E4OD-4R100_VacTestGuide 09-26-17 Page 5
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