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

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1

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

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.

Engagement Control Valve

• Delayed Forward & Reverse engagement

• Burnt Forward clutch

• Burnt Direct clutch

1-2 Manual

Transition Valve

• Burnt intermediate band

• Manual low gear bind-up

Drive 2 Valve

• Reverse complaints

Upper Control Body • 4R100 Non-PTO Shown

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.

4-3-2 Timing Valve & Control

Valve Shift Timing Plunger

• Manual low concerns

1-2 Shift Valve

• No 2nd gear

• 1-2 Shift Complaints

Test: Flip casting over

and test at this orice.

Seal this side of casting

with foam mat.

3-4 Shift Valve &

4-3-2 Timing Valve

• 3-4 Shift complaints

• Burnt Direct clutch

• Manual low concerns

2-3 Shift Valve

• 2-3 Shift complaints

• Burnt Direct clutch

Solenoid Regulator

Valve

• 2nd or 3rd Gear starts

• Reduced lube oil from the

center support

• TCC cycling or slip

Replace with Sonnax Part No.

36947-14K

Requires F-36947-TL14 & VB-FIX

Coast Clutch Shift Valve

• Burnt coast clutch

Low/Reverse Modulator Valve

Plunger & Sleeve

• 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.

Low/Reverse Modulator &

Low/Reverse Modulator Valves

• Burnt Low/Reverse clutch

• Low pressure at Low/Reverse clutch

• No engine braking

Note: Seal port

on opposite side.

Ford E40D, 4R100

Page 2 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Accumulator Control Body • 4R100 Non-PTO Shown

For specic vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

VACUUM

TEST

Direct Clutch

Accumulator

Regulator Valve

• No 2nd • Soft shifts

• Premature clutch failure

Replace with Sonnax Part No.

36948-13K

Direct Clutch

Accumulator Plunger

• No 2nd • Soft shifts

• Premature clutch failure

Overdrive Clutch

Accumulator Plunger

• No 4th • Soft Shifts

• Premature clutch failure

Line Pressure

Modulator Valve

• 1-2 Harsh

• Harsh shifts

• Soft shifts

Replace with

Sonnax Part No.

36948-19 Requires 36948-TL

Intermediate Clutch

Accumulator Plunger

• No 3rd • Soft Shifts

• Premature clutch failure

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.

Intermediate Clutch

Accummulator Regulator Valve

• No 3rd • Soft Shifts • Premature clutch failure

Replace with Sonnax Part No.

36948-13K

Overdrive Clutch

Accumulator Regulator Valve

• No 4th • Soft Shifts

Replace with Sonnax Part No.

36948-09K

Note: Seal port

on opposite side.

Ford E40D, 4R100

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3

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.

For specic 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.

VACUUM

TEST

Main Regulator Valve

• Code 62, 628, 1744

• Engine stall or engagement in Reverse

• Engine stumble on engagement in Reverse

• High line pressure

• Overheated converter

Replace with Sonnax Part Nos.

36424-04K 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.

Main Regulator Valve & Sleeve

• Delayed Reverse • Low line rise • Soft shifts

Replace with Sonnax Part Nos.

36424-01K Boost Valve Kit (with O-rings)

36424-03K Boost Valve Kit (without O-rings)

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

Note: Seal holes

on opposite side.

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

Ford E40D, 4R100

Page 4 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

OE Exploded View

Lower Control Body

4R100 Non - PTO Shown

NOTE: E4OD is the same.

201

202 203*

208*

207*

204

206

205*

* E4OD Different

Upper Control Body

4R100 Non - PTO Shown

NOTE: E4OD Worm tracks and valves vary slightly.

Upper Control Valve Body Descriptions >

I.D. No. Description

201 2-3 Shift Valve

202 3-4 Shift Valve

203*

Low/Reverse Modulator Valve (Inboard)

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

207*

4-3-2 Timing Valve (Inboard)

Control Valve Shift Timing Plunger

(Outboard)

208* Drive 2 Valve (Inboard)

1-2 Shift Valve (Outboard)

< Lower Control Valve Body Descriptions

I.D. No. Description

101 Engagement Control Valve

102 1-2 Manual Transition Valve

102

101

Ford E40D, 4R100

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

TIME TESTED • INDUSTRY TRUSTED

402

403A

403B

403C

401

OE Exploded View

Accumulator Control

Body Descriptions

I.D. No. Description

301

Direct Clutch Accumulator

Regulator Valve (Inboard)

Direct Clutch Accumulator

Plunger (Outboard)

302

Overdrive Clutch Accumulator

Regulator Valve (Inboard)

Overdrive Clutch Accumulator

Plunger (Outboard)

303

Intermediate Clutch Accumulator

Regulator Valve (Inboard)

Intermediate Clutch Accumulator

Plunger (Outboard)

304

Line Pressure Modulator Valve

(Inboard)

Line Pressure Modulator Plunger

Valve & Sleeve (Outboard)

304

303

302301

Pump Body Descriptions >

I.D. No. Description

401

Main Regulator Valve (Inboard)

Main Regulator Valve & Sleeve

(Outboard)

402 Converter Regulator Valve

403A E4OD Converter Clutch Control

Valve

403B 4R100 Non-PWM Converter

Clutch Control Valve

403C

4R100 PWM Converter Clutch

Control Valve (Inboard)

Converter Clutch Control Plunger

Valve & Sleeve (Outboard)

Accumulator Control Body

4R100 Non - PTO Shown

Pump Body

E4OD Pump Body Shown

E4OD 4R100 Vac Interactive

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