HOW TO PREPARE YOURSELF AND YOUR SHOP EMPLOYEES TO TAKE AND PASS ATRAS CERTIFICATION TESTS

PREPARATORY TEST Instructions

REVIEW AND RESEARCH Give out the preparatory tests as soon as possible in order that the technicians have enough time to review and research each question. tests. All the questions listed will be on the actual We believe an

ATRA is no longer providing the answers to the prep test questions.

ATRA Certified Technician should either already know the answers or know how to find the answer using whatever resources are available. Examples of resources: Technical Manuals,

Seminar books, ATRA Online, Bulletins, HelpLine, etc.

Technicians may discuss the questions and use the glossary of definitions to make clear any words that are unfamiliar. There are two types of questions in these Preparatory Tests: True

or False and Multiple Choice. al Certification Tests.

These are the same type of questions you will find on the actu-

TAKING THE PREPARATORY TESTS: After researching the questions, it's a good idea to do a practice test. the actual Certification tests will be familiar. This way, the pace of

Apprx. time needed to test: Rebuilder R & R Diagnostician 1 hour 45 minutes 1 hour

The answers may be circled directly on in the booklet or written on a separate sheet of paper. The use of a calculator is allowed where necessary.

REVIEWING PREPARATORY TESTS: When the tests are completed, compare the answers from several technicians. Where there

are descrepancies, we recommend that you discuss those questions or problems as a group. This will help reinforce correct answers and the best way to find them.

ATRA works hard to provide testing that has as much value as possible... an ongoing effort that takes many things into consideration, including feedback from the industry. ate your input and would like to say Thank You! We appreci-

082102

ATRA PREPARATORY TESTS GLOSSARY OF DEFINITIONS

Accumulator:

A hydraulic-mechanical device used in a transmission to cushion or soften otherwise hard or

rough shifts by damping fluid-apply pressure. Additives: Chemicals which are added to the transmission fluid. Fluid which has been whipped or churned to the degree that it has air bubbles in it. Common reference to the adjusting of transmission bands or linkage or modulation system com-

Aerated Fluid: Adjustments:

ponents in order to get optimum transmission performance. ATF: Automatic transmission fluid. The oil in the automatic transmission (usually a petroleum derivative) which

Automatic Transmission Fluid:

transfers power, lubricates and cools components, and pressurizes various parts for automatic operation. Ballizing: See Burnishing in a lined manner. The undesirable expansion of a torque converter or other component due to excessive internal

Ballooning: pressures. Bands:

Lined metal straps which wrap around a drum, stopping and holding it at given times, or releasing it to

turn freely at other times. Bell Housing: The casting which houses the transmission torque converter. Sometimes it is bolted to the main

transmission case, and in some instances it is an integral, cast part of the main transmission case. Belleville Spring: pack. Boost Valve: Burnishing: covers. Burping: The condition which exists when ATF comes out of A valve which causes the control pressure regulator to boost mainline pressure. The process by which parts become worn. Line burnishing is often seen on bushings and pump A tempered, dished, steel plate which is often used as a lever to apply or release a clutch

the transmission vent or the filler tube. Bushing: The (usually) lined steel sleeve bearing which is usually inserted into or cast into the center of a case

or part, in which shafts or drums ride. Carrier Assembly: Case: C-B: That part of a planetary assembly to which the planet gears are caged or pinned. Often called the main case.

The casting which houses the main part of the transmission assembly. See rework and warranty.

Abbreviation for come back.

Cleaning Solutions: petroleum-based

Refers to the various solutions which are used in cleaning transmission parts, such as:

or carburetor type cleaning agents or caustic solutions. Clearances: The amount of necessary free space or tolerance between two or more parts, necessary to their

longevity and satisfactory operation. Clutches: Metal discs which are applied at a given time, to connect a driving unit to a driven unit. See lined

clutches and unlined clutches. Clutch Drum: Clutch Pack: Come-Backs: A metal drum in which clutches are contained. An assembly of clutches as a unit. See reworks and warranties. A planetary assembly which uses two sizes of pinions in one, or a transmission which

Compound Planetary:

uses two separate sets of planetary assemblies. Consumer: A customer. One who purchases a service or a product and who uses it.

Consumer Affairs:

Those activities which work to protect the rights of consumers by requiring manufacturers

and merchants to exhibit honesty in advertising, in representation, in packaging, in labeling, and in fair pricing. Contamination: Foreign agents or particles which are seen in transmission fluid or in the pan, such as metal fil-

ings or grindings, water, antifreeze, friction materials, etc. Control Valve Assembly: Converter: Cooler: See valves and valve body.

See torque converter.

A device through which transmission fluid is circulated, and by which air or liquid circulates in order to

cool the fluid. Cooler Lines: The metal tubes through which transmission fluid is pumped from the transmission to the cooler

and back again. Cycling: Dacron: Detent: The act of moving the selector lever through all gears or ranges. A synthetic mesh often used in the manufacture of transmission filters. A pawl, trigger, release mechanism. 082102 2

Dexron:

A transmission fluid type which was developed by General Motors Corporation. The thin, metal, bayonet-type stick used to measure the level of the transmission fluid. The state or stage of the transmission which has all units operating at a 1 to 1 ratio, with nothing

Dip Stick:

Direct Drive:

in a state of reduction or overdrive. Downshift: The act of the transmission shifting into a low range from a higher range. Either automatically or

manually shifting the selector into a lower range, or by detenting foot pressure on the accelerator in a positive manner. Downshift Valve: Drive Line: A detent valve which provides downshifting from 3rd to 2nd to 1st, etc.

See drive shaft. The selector lever range which will have the transmission eventually going into higher range. Or,

Drive Range:

the state or stage of being in high range in non-overdrive units. Electro-Mechanical Device: Engine Mount: A component which acts mechanically upon receiving an electrical signal.

The rubber and metal cushioning devices which hold the engine to the vehicle frame. Commonly called the output shaft housing.

Extension Housing:

The conical metal tube which is connected to or cast as a part of the rear of the transmission, which houses the output shaft. External Cooler: External Leaks: See cooler and radiator cooler. Fluid leaks which are ordinarily visible from the outside of the transmission, with the transmis-

sion still in the vehicle. Filler Tube: The metal tube located beneath the vehicle hood, through which fluid level is measured and the See dip stick.

transmission is filled with ATF . Filter:

A device through which ATF is screened in order to remove particles and contaminants. A relatively thin steel plate which is used to absorb torsional vibrations between engine output and

Flex Plate:

transmission torque converter input. Fluid Coupling: A fluid clutch used by some manufacturers in early years instead of a torque converter which

did not utilize a stator or one-way roller clutch, and which did not multiply torque. Fluid Leaks: Flywheel: See external leaks and internal leaks.

A heavy rimmed rotating wheel which is commonly bolted to the engine crankshaft output flange and

welded or bolted to the converter, in order to minimize variations in engine speed. Flywheel Flange: bolted. Forward Clutch: The clutch assembly which must engage in order to give most transmissions forward range. The ability of a material to grab and hold. The flat surface on the rear of the engine crankshaft onto which the flywheel or flex plate is

Friction Coefficient: Front Pump:

The engine driven transmission pump which provides sufficient fluid volume and pressure to actiSee also rear pump.

vate the transmission components and to lubricate and cool them. Gaskets:

Soft and unusually flat, thin, cork or paper components which are placed between machined parts so

that transmission fluid or air pressure or vacuum is retained. Gear Train: Those gears, shafts and drums which are designed to transfer power through the transmission. A pump that uses the diminishing space between a driving and driven gear and a crescent to

Gear Type Pump:

provide fluid pressure. Governor: A road speed signaling device which sends varying pressures of fluid to the control valves in the

transmission. Grade Retard: High Clutch: A band or clutch which applies as the vehicle decelerates, in order to assist in braking.

The clutch assembly which must apply satisfactorily in order to provide the transmission with

high range or direct drive. Hunting: speed. Hydraulics: area. Inner Race: Input Shaft: That inside segment of a bearing on which the balls or rollers ride. The shaft in the transmission through which input power is fed. The band which must apply in order for the transmission to deliver second or intermediate The science or technology of the static or dynamic application of fluids in a closed or confined The involuntary and unsatisfactory rapid upshifting and downshifting of a transmission at a given

Intermediate Band: range. Intermediate Clutch: ate range. Intermediate Shaft: components. Internal Leaks:

The clutch which must apply in order for the transmission to deliver second or intermedi-

The shaft through which the power is transferred from the input components to the output

Such leaks as exist or develop inside a transmission, some being ordinary and acceptable, and

some not in the face of component failure. In-Car Services: Those logical and periodical adjustments and corrections to the transmission or its related 082102 3

components while it is still mounted in the vehicle, which are made in order to assure peak operating efficiency and to extend its operational life. Journal: The surface on a shaft or housing on which a bushing or thrust washer rides, which acts as s support

or carrier. Kickdown Cable or Linkage: or needs full acceleration. Legislation: Laws which are established by legislators. Those clutch plates which have friction materials bound to their faces in the The connecting mechanism used to signal the valve body which the driver wants

Lined Clutch (or Friction) Plates: manufacturing process. Lip Seals: Lock Nut:

Rubber seals which display one or more lipped surfaces and which contain or control fluid pressure. A nut which serves to locate and fasten one component in a secure position to another component,

or to a case. Lock Rings: other. Lock Up: 1) The desirable locking up of a driving assembly or component to still another, in order to achieve The undesirable locking up of one or more components to still other Metal rings which lock one or more components, or which have notched ends which lock to each

straight through power application; or 2)

components, causing a malfunction in power flow characteristics. Lock Up Converter: Sometimes called a clutch type converter. A torque converter which utilizes an internal

clutch device to eliminate slippage at highway speeds, by creating a mechanical connection between engine and transmission. Manual Valve: Located in the control valve body, this valve permits the driver to select whichever driving range

is desired through moving the selector lever in the drivers compartment. Mechanic Certification: Mechanic Testing: The act of documenting a mechanics skills or knowledge.

An examination given a mechanic in order to document his or her acquired skills. Any linkage that works by rods, clevices, joints, etc., without the use of hydraulic or elec-

Mechanical Linkage: trical assists. Multiple Drive Shaft: ing joints. Neutral Safety Swift:

A drive shaft which contains 2 or more shaft sectors and 3 or more universal or connect-

The switch which is used either on the transmission or on related linkage, that permits the

engine to be started only when the transmission selector lever is placed in park or neutral position. Oil Circuitry: The visual diagrams which show the paths which the fluid takes in the operation of the transmis-

sion and its components. Oil Galleries: Fluid work tracks See sprag. or holes, located in a transmission case, casting or housing.

One Way Clutch: Orifice: O-Ring:

A hole through which fluids or gases can pass; usually small, and usually of critical size. A rubber ring which seals fluids, air pressure, or vacuum. The outer sector of a bearing or a one way steel sprag clutch assembly. The shaft in the transmission which delivers output power to the drive shaft. The casting which surrounds or contains the output shaft. Sometimes also referred to

Outer Race:

Output Shaft:

Output Shaft Housing:

as an extension housing. Over Drive: The effect which is had by holding the sun gear powering the planetary carrier, and taking power This delivers higher speed but lower torque power at the

output from the ring gear in a planetary assembly. output than was introduced at the input. Overhaul: See rebuild.

Overheating:

The heating of a transmission or its components to limits which it is not designed to endure,

either through excessive friction in the torque converter or transmission main body, or from external sources outside its control. Over Run Clutch: See one way clutch. See sprag.

Over Running Clutch: Pan:

A stamped or cast metal cover which houses a part or parts which can be removed for inspection purpos-

es, or to perform a service or repair. Pan Rail: The flat, flanged surfaces on the pan or transmission which permit the two assemblies to be fastened

together in an oil- tight manner. Parking Pawl: inadvertently. Parking Mechanism: Piston: Those components which lock the transmission in park so that the vehicle cannot move. The lug or dog which latches the transmission in such a manner that the vehicle cannot move

A solid cylinder or disk which operates within a slightly larger cylinder and moves back and forth under

pressure to convert fluid or gaseous energy to mechanical energy, or which displaces or compresses fluids or gases as in a pump. Planetary Gears: Toothed gears which act to create over drive, reduction or reverse in a transmission which are 082102 4

used as matched sets of 2 or more identical sizes. can turn, outside of which a ring gear can turn. Pressure Regulator Valve: Primary Pump:

Are pinned or dowelled to a cage, inside of which a sun gear

The control valve which automatically lets excessive pressure bleed away. The vaned, concave metal shell in the torque converter which drives

Also known as impeller.

the turbine through fluid force. Pump: Any mechanism which causes liquids or gases to flow. Sometimes called stator support. See gear, rotor and vane type pumps.

Pump Cover:

The rear casting which faces the pump housing and its

enclosed gears, rotor or vane mechanism. Pump Housing: The forward casting which surrounds the enclosed gears, rotors or vane mechanism and which

faces the pump cover or stator support. Radiator Cooler: Sometimes called heat exchanger. The small reservoir located in the bottom of the radiator

which is surrounded by cooling system coolant, through which transmission fluid is pumped in order that it can be cooled. Rear Pump: Nearly obsolete, a pump used in some transmissions as recently as 1975. Driven by the drive line,

ordinarily incorporated in order to give the vehicle push-to-start capabilities. Rebuild Mechanic: A mechanic whose main work involves the in depth processing and overhauling of trans-

missions or their components. Rebuilt Components: Parts which have been reprocessed to the degree that they may be expected to deliver

new part life and performance. Rebuilt Transmission: A transmission assembly which has been thoroughly dismantled, cleaned and inspected,

and which can be expected to deliver performance and life equal to or better than a new transmission of the same make and model. Reduction: See under drive. In government, guidelines for operation which are established by a bureau or agency, as opposed

Regulations:

to being authorized by legislative or judicial decision. Remanufactured: Repaired: Legally synonymous with and equivalent to overhauled or rebuilt.

Reconstituted or reworked to correct a specific and immediate problem, but not necessarily capable

of delivering new part performance or life (not synonymous with remanufactured, overhauled, or rebuilt). Retainer: That sector or segment of a part, or that part which acts to keep another part or parts in position. The control valve which is controlled by governor or direct drive oil pressure, which

Reverse Blocker Valve:

prevents reverse range from applying while the vehicle is moving forward. Reverse Clutch: The clutch assembly which provides reverse range in some transmissions and which may pro-

vide both reverse and high range as well. Rework: To repair or overhaul, again, especially under warranty. Sometimes referred to as fly wheel ring gear, the gear which is fixed to the outside edge of the planetary internal tooth gears

Ring Gear:

flywheel or converter, which acts with the starter drive to start the engine. Note: are also referred to as ring gears. Road Test:

The study which is made by driving the vehicle in order to determine that it is working or not work-

ing properly. Roller Clutch: See sprag. A pump which uses diminishing space between driving and driven cam-like rotors to create

Rotor Type Pump: fluid pressure. R & R:

To remove and replace a part or a transmission from a vehicle. A mechanic whose main work involves the removing and replacing of transmissions and the

R & R Mechanic:

external servicing of them. Screen: Mesh. The filtering media in a transmission which is made of metal wire. See dacron and filter.

Sealing Rings: Seals:

Metal rings designed into a transmission for the purpose of containing fluid pressure. It is used to contain fluid or limit its flow.

Commonly, a rubber doughnut or ringed device.

Service:

Most common reference to the changing of transmission fluid and adjusting bands and linkage as pre-

ventive maintenance in order to assure maximum transmission life and satisfactory performance. Servo: servo. Shift: Shift The passing of a transmission from one range or gear ratio to another. Lever: 1) In the drivers compartment, the lever which is used to determine which driving range is approThe device which responds to a fluid pressure and which actuates a mechanical part, such as a band

priate; 2)

At the transmission, the lever which actuates the manual valve. The driving characteristics which the transmission displays in its various ranges. A planetary gear assembly in which one common sun gear is used in conjunction with 2

Shift Pattern:

Simpson Gear Train:

different ring gears and 2 different planetary gear sets. Slip: The inability of one component to grab another component immediately, or to hold onto it once it has

grabbed it. 082102 5

Snap Ring:

A ring which is located on an internal or external groove, either to contain fluid pressure, or to

retain another part of parts. Solenoid: An electrical, air or vacuum operated switch which causes another application to occur under a given

set of circumstances. Spline: The projections and grooves on a shaft or drum which permit it to mate with another shaft or drum, to

drive it or be driven by it. Sprag: A one way clutch which acts in a wedging manner to permit a powered assembly to rotate in one direc-

tion while locking in another. Stall Speed: With the transmission in a driving range, the brakes fully applied and the engine under heavy

acceleration, the point at which engine speed will no longer increase. Stator: A stationary member of a given group of components. The element in a torque converter which must

remain stationary in order that the flow of fluid is redirected in an efficient manner from the primary pump to the turbine and back at lower speeds, increasing torque or power output. Steel Plates: Sun Gear: See unlined clutches.

The external tooth gear around which planetary gears Is either driven or acts as a driving sector of a planetary assembly. A drum which houses other assembled components, which features a sun gear as a part of its

can revolve.

Sun Gear Shell: design.

Swing Mechanic:

A mechanic who works as a rebuild mechanic and as an R & R mechanic at alternating times. A device which senses transmission hydraulic pressures and which

TCS Switch (Timing Control Switch):

delays engine timing advance until such time as transmission high range is desired. Teflon: A patented plastic with excellent anti-heat characteristics, which is sometimes used in transmissions in

bushing, thrust surface or sealing ring applications. Throttle Linkage: The linkage which connects the accelerator to the transmission, sometimes by rods and

sometimes by cable. Thrust: An engineering term meaning force delivered. A surface onto which force is applied. A washer onto which force is applied.

Thrust Surface: Thrust Washer: Torque:

Twisting force. The fluid wheel which is a part of the transmission, which is located to the rear of the engine It acts as a fluid clutch by multiplying effective engine power at low

Torque Converter:

and forward of the main transmission body.

speeds, and acts as a fluid coupling at higher speeds by delivering torsional force from the engine to the transmission main body. Torque Converter Valve: The valve in the transmission control system which limits the amount of pressure that

is fed to the torque converter. Torque Multiplication: Increase in effective power output over that of the input created in a properly operating

torque converter or through gear reduction. Torrington Bearing: Torsional Force: sion or its parts. Towing Kit: A specially prepared package of parts which, along with recommended labor operation, is designed A common name for a radical, needle thrust bearing.

Twisting force or movement, which if excessive can cause considerable damage to a transmis-

to modify the operating characteristics of transmissions used to tow heavy loads. Transmission Service: Transmission Mount: See service. The rubber and metal cushioning device or devices which hold the transmission to the

vehicle frame, located between the transmission and cross-member. Turbine: The part in the torque converter which receives a fluid driven thrust from the primary pump and which

in turn drives the input shaft. Under Drive: The condition wherein a planetary gear set is in reduction, delivering a lower speed, but higher

torque and more power at its output. Universal Joint: The coupling or couplings in a drive shaft which permit power to be efficiently transmitted

from transmission and differential, even though the transmission and differential may be considerably out of line with each other. Unlined Clutches: Steel clutches which feature no lining. See clutches.

Used Transmission:

A transmission which has not been subject to in depth reprocessing, since being subject-

ed to prolonged use. See rebuilt transmission. Vacuum: The absence of matter or pressure. Created by suction of downstroking pistons in an engine, and

used to control the actions of some types of transmissions. Vacuum Diaphragm: Vacuum Vacuum Gauge: The thin, rubberized, flexible disc in a vacuum modulator.

A tool which is used to check engine vacuum. A device which is used on some transmissions to regulate transmission shift points and/or 082102 6

Modulator:

pressure to engine torque and demands on the vehicle.Valve: mission components through fluid regulation. Valve Body: Sometimes called a valve block.

A device which controls the operation of trans-

The compound sensing device which receives both manual and

automatic instructions from the vehicle driver and or the transmission governor, which in turn relays the fluid pressures to cause still other transmission components to function. Variable Displacement Pump: Ordinarily a vane-type pump, in which output pressures and volume of fluid is

regulated within the pump itself. Waffle Grooves: Those closely spaced channels which are cut or molded into friction plate facings, with the

purpose of creating very exacting lubrication and frictional characteristics. Warranty: An assurance by the seller of property to a purchaser that the goods being conveyed are as repre-

sented or that they will be as promised. Worm Tracks: Yoke: See oil galleries.

The steel tubed device which slip-splines onto the transmission output shaft, and at its other end is

affixed to the drive shaft through a universal joint.

082102

REBUILDER PREPTEST
Multiple Choice (1-40) 1. The 5R55E has one more gear ratio than the 4R55E. This is provided by: A. B. C. D. Overdriving first gear. Overdriving second gear Overdriving third gear. Overdriving fourth gear

2.

The 4T60E transmission uses the 3rd clutch for: A. B. C. D. Third and fourth gear. Third gear only. Third and fourth gear, and engine braking in manual third. Third gear and engine braking in manual low.

3.

If an AX4S forward sprag fails, the vehicle: A. B. C. D. Will only have reverse. Will not have overdrive. Will not move. Will not shift out of first gear.

4.

Two meshed gears have a ratio of 4 to 1, which means: A. B. C. D. This gear set will provide overdrive. The drive gear will rotate once for each 1/4 turn of the driven gear. The output will be four times faster than the input. None of the above.

5.

Proper side clearance for a metal sealing ring is: A. B. C. D. 0.001" 0.004" - 0.006" 0.002" - 0.004" 0.005"

6.

The 4L80E uses a screen in the valve body, located behind the manual control valve. This screen commonly cracks which can cause: A. B. C. D. Second-gear starts. Low line rise. The manual control valve moving into reverse by itself. All of the above.

7.

Which of the following sections of a 41TE transmission must have end play, not a pre load: A. B. C. D. Transfer shaft. Output shaft. Differential carrier. None of the above.

8.

A given gear set has 38 teeth on the pinion gear, and 62 on the ring gear. The ratio of this gear set is: A. 0.61:1.
082102 8

B. C. D.

1.63:1 2.36:1 2.64:1

9.

T oyota's A140E is mechanically capable of: A. B. C. D. Six speeds forward, two in reverse. Six speeds forward, one in reverse. Four speeds forward, two in reverse. Four speeds forward, one in reverse.

10.

The second-gear feed orifice in the F4AEL is located: A. B. C. D. In the valve body separator plate. In the case. In a floating puck in the valve body. None of the above.

11.

The E4OD has which friction elements applied in fourth gear? A. B. C. D. Direct clutch, overdrive brake, and intermediate brake. Overdrive clutch, forward clutch, and direct clutch Forward clutches, intermediate brake, direct clutch, and overdrive brake. Overdrive clutch, direct clutch and forward clutch.

12.

The purpose of an accumulator in a clutch circuit is to: A. B. C. D. Control clutch overlap. Reduce clutch apply pressure during its application. Prevent leakage and fluid loss in the circuit. Reduce chattering during the clutch apply.

13.

The A4LD input sprag is locked in all forward ranges except: A. B. C. D. First gear. Second gear. Third gear. Fourth gear.

14.

How many end play checks are made when rebuilding a 3T40? A. B. C. D. 1. 2. 3. 4.

15.

The overdrive sprag in an E4OD must allow the overdrive planet to: A. B. C. D. Rotate clockwise as viewed from the bellhousing side. Rotate counter clockwise as viewed from the bellhousing side. Lock in overdrive. Rotate in all ranges unless the overdrive cancel button is activated.

16.

The low sprag of an F4A22 must allow the planet to: A. B. C. Rotate clockwise as viewed from the bellhousing side. Rotate counter clockwise as viewed from the bellhousing side. Lock in 1st and 2nd gear, but must rotate freely in 3rd and 4th.
082102 9

D.

Lock in manual low and reverse.

17.

When the AX4S goes to failsafe, which gear is it in? A. B. C. D. First Second Third Fourth

18.

When the A. B. C. D.

4L60E goes to failsafe, which gear is it in?

First Second Third Fourth

19.

When the 42LE goes to failsafe, which gear is it in? A. B. C. D. First Second Third Fourth

20.

How many endplay checks are there in the CD4E? A. B. C. D. 1 2 3 4

21.

The 1993-'95 A4LD, with the 4.0L engine, uses a shell that snaps onto the direct drum. T o set the endplay, for the main gear train, use: A. B. C. D. A selective bearing between the center support and the forward clutch drum. A selective bearing between the center support and the direct clutch drum. A selective washer between the pump and coast clutch drum.. None of the above. The endplay is not adjustable.

22.

A good rule of thumb for bushing-to-journal clearance is: A. B. C. D. 0.002" - 0.003" 0.003" - 0.005" 0.001" - 0.002" per inch in diameter. 0.0005" - 0.001" per inch in diameter.

23.

Proper pump gear/rotor end play for most units is: A. B. C. D. 0.002" - 0.004" 0.0025" - 0.003" 0.003" - 0.005" 0.0015" - 0.002"

24.

The 4L30E uses the following components for second gear: A. B. C. D. The overrun sprag, 1-2 band, and 2nd clutch The 1-2 band and input clutch The Low band and Direct clutch None of the above
082102 10

25.

Which of the following is not a factor with grooving in the sealing ring area of a drum? A. B. C. D. Line pressure. Drum bushing to support clearance. Excessive sealing ring endplay. Geartrain endplay.

26.

The inner pressure regulator spring, on an E4OD, is used to: A. B. C. D. Increase boost pressure in reverse. Increase boost pressure in Manual low and reverse. Delay the affects of EPC pressure on the boost valve. Reduce pressure regulator buzz.

27.

On most units, the direct clutch pack should be set to the looser side of the factory specifications in order help reduce: A. B. C. D. Soft forward and reverse engagements. Soft reverse engagements. Harsh forward and reverse engagements. None of the above. Clutch pack clearance does not affect clutch engagement feel.

28.

The term "line to lube" refers to introducing line oil into the: A. B. C. D. Cooler bypass circuit. Planet-regulator circuit. T orque converter charge circuit. Pressure regulator exhaust circuit.

29.

Rotating metal sealing rings: A. B. C. D. Hold to the drum and spin in the grooves of the pump support. Are held by the support and spin in the drum. Are free-floating with respect to both units. Should be used in place of T eflon.

30.

T o get an overdriven ratio from a simple planet, you must: A. B. C. D. Hold the planet and turn the sun gear. The ring gear will provide the output. Hold the sun gear and turn the planet. The ring gear will provide the output. Hold the ring gear and turn the sun gear. The planet will provide the output. Hold the sun gear and turn the ring gear. The planet will provide the output.

31.

T o get a reduction in ratio from a simple planet, you must: A. B. C. D. Hold the planet and turn the sun gear. The ring gear will provide the output. Hold the sun gear and turn the planet. The ring gear will provide the output. Hold the ring gear and turn the sun gear. The planet will provide the output. Hold the ring gear and turn the planet. The sun gear will provide the output.

32.

T o get reverse from a simple planet, you must: A. B. C. D. Hold the planet and turn the sun gear. The ring gear will provide the output. Hold the sun gear and turn the planet. The ring gear will provide the output. Hold the ring gear and turn the sun gear. The planet will provide the output. Hold the ring gear and turn the planet. The sun gear will provide the output.

33.

On most units, the forward clutch pack should be set to the tighter side of
082102 11

the factory specifications in order help reduce: A. B. C. D. Soft forward and reverse engagements Soft forward engagements. Harsh forward and reverse engagements. None of the above. Clutch pack clearance does not affect clutch engagement feel.

34.

A checkball used in a bathtub allows: A. B. C. D. A difference in flow rate in one direction versus the other. Two circuits to feed a single circuit. One circuit to feed two different circuits. None of the above.

35.

A regulator with a diameter of 0.375, and a spring with a tension of 7 lbs (when compressed to its working height) will offer a pressure of: A. B. C. D. 53.5 psi 63.4 psi 56.7 psi 68.9 psi

36.

The selective washer used on the overdrive piston of a 42RH is used to adjust: A. B. C. D. Rear end play. Overdrive clutch end play. Direct clutch end play. The timing between direct clutch release and overdrive brake apply.

37.

The sprag used in a CD4E: A. Provides the same function as the forward sprag in a 4L60, but rotates in the opposite direction. B. Provides the same function as the forward sprag in a 4L60, and rotates in the same direction. C. Provides the same function as the intermediate sprag used in an E4OD, but rotates in the opposite direction. D. Provides the same function as the intermediate sprag used in an E4OD, and rotates in the same direction.

38.

On a THM 4L60E transmission, the input drum contains: A. B. C. D. The reverse, 3-4 and forward clutches. The forward and 3-4 clutches The forward, overrun, and 3-4 clutches. The forward, direct, and overdrive clutches.

39.

Which of the following is not a consideration when changing the bellhousing bushing on a 4R55E? A. The replacement torque converter hub is usually softer than the original, and the factory bushing may wear out the hub. B. The original bushing is machined in place, and the replacement bushing may not be centered with the crankshaft. C. D. Bushing to hub clearance should be 0.002" - 0.004" The notch in the bushing must face toward the rear, and positioned toward the bottom of the suction side.
082102 12

True False (40-55) 40. The little hole in the "hockey puck" in the 4R55E valve body can be drilled to firm up the 1-2 shift.

41.

All 4T60Es use a TCC solenoid screen.

42.

Outer pump gear to body clearance should not exceed 0.003".

43.

Planet failure on an F4A33 can be caused by over tightening the filter.

44.

You should always resurface used steel clutch plates with 180 - 320 grit sand paper or emery cloth.

45.

All 1991 AX4Ss use an on/off lockup solenoid. In 1992 they went to the modulated lockup solenoid.

46.

The 4T40E is an overdrive version of the 3T40.

47.

The only difference between the 4R70W and the AODE is that the 4R70W uses a wide ratio planet.

48.

When overhauling an RE4R01A, you should make sure the sun gear bushing does not have more than 0.002" clearance between the bushing and the output shaft.

49.

Rear clutch damage on a 46RH can be caused by a damaged torque converter clutch.

50.

Dexron III was formulated to cover a wide range of applications, including models designed for Chrysler's 7176 and Mercon V.

51.

Second design 4L60 pump bodies can not be used with a first design stator support unless you modify the support.

52.

All Clutch pack clearances should be as tight as possible, while still allowing free play when not engaged.

53.

Some Ford ATX transmissions have a planetary set within the torque converter.

54.

An additional drain back hole behind the converter seal is a safe measure on most units.

55.

Synthetic ATF is a poor substitute for petroleum-based ATF .

END OF REBUILDER PREP-TEST

082102

13

DIAGNOSTICIAN PREP TEST

Multiple Choice (1-58) 1. A fluttering pressure gauge needle indicates: A. B. C. D. A worn pressure regulator valve Air in the pump intake A worn pump All of the above

2.

A slide bump shift is commonly caused by: A. B. C. D. An accumulator that strokes too quickly during the shift An accumulator that strokes too slowly during the shift An accumulator spring that is too heavy An accumulator spring that is too light

3.

The passing gear function on a 42RE transmission is controlled by: A. B. C. D. The computer. The governor solenoid. The transducer The TV link.

4.

A 42RE with a chatter on converter lockup could indicate: A. B. C. D. A lack of cooler flow. A worn clutch lining in converter. T oo much pump clearance. Any of the above.

5.

What must be done in order to properly adjust the T .V. linkage on a Ford equipped with an AOD: A. B. Hook up a vacuum gauge to the engine. Road test the vehicle and adjust according to shift points indicated by the speedometer. C. D. Install pressure gauge on the T .V. pressure tap. The linkage is not adjustable.

6.

Vacuum can be considered normal when: A. B. C. D. You have at least 12-14" at idle in Drive. Vacuum drops below 2" on stall test. Vacuum drops immediately when throttle is opened. All of the above.

7.

An accelerator pedal that is hard to press on a vehicle with an AXOD transaxle may be caused by: A. B. C. D. High TV pressure A bad FIPL sensor High line pressure A TV cable that is adjusted too loose

8.

An E4OD has 30 psi of line pressure in neutral at an idle.

When you disconnect the solenoid

082102 14

harness, line pressure rises to 110 psi. A. B. C. D. A computer problem An EPC solenoid malfunction

This indicates:

A broken pressure regulator spring A worn pump

9.

Which gear is failsafe on a Ford AX4N: A. B. C. D. First. Second. Third. Fourth.

10.

Which gear is failsafe on a Ford 5R55E: A. B. C. D. First. Second. Third. Fourth.

11.

Which gear is failsafe on a GM 4T65E: A. B. C. D. First. Second. Third. Fourth

12.

Which gear is failsafe on a Chrysler 41TE: A. B. C. D. First. Second. Third. Fourth

13.

A vehicle with a transmission that functions normally but has little power on takeoff could indicate: A. B. C. D. A bad torque converter. A broken flywheel. A seized fan clutch. A broken motor mount.

14.

A 4T60E modulator should be adjusted: A. B. C. D. By shift feel during a road test. By shift speed during a road test. With a pressure gauge. None of the above.

15.

A no drive condition on a 4L60E, in D4 only is usually caused by: A. B. C. D. A computer malfunction. A bad shift solenoid. Input sprag failure. All of the above.

16.

On most transmissions, a whining noise in gear while stationary but goes away in neutral
082102 15

indicates a problem with: A. B. C. D. The filter or screen Low fluid level T orque converter All of the above

17.

On a 4T60 transaxle, you can determine if a lock up shudder is a an engine problem by: A. B. C. D. T ouching the brake to see if the problem goes away. Unpluging lock up to see if the problem goes away. Monitoring converter slip on a scan tool. None of the above.

transmission problem or

18.

A no upshift condition on an ATX could be caused by: A. B. C. D. The torque converter. The direct drum roller clutch. The band. None of the above.

19.

After road testing a vehicle for about 20 minutes, it begins to slip, and then falls out of gear. After letting the vehicle sit (engine off) for several minutes, the transmission works fine but after a few minutes of driving the malfunction reappears. This scenario is commonly caused by: A. B. C. D. A worn pump A restricted filter A computer related problem that is cleared by turning off the engine A leak in the pump output circuit

20.

Dexron III fluid can be substituted for: A. B. C. D. Mercon V. Honda fluid Chrysler 7176 Dexron II.

21.

The front band on an 5R55E is applied in: A. B. C. D. Second and fifth. Second only. Third and fifth. Fifth only.

22.

A 4T60E modulator controls: A. B. C. D. Shift feel. Shift timing. Kickdown. None of the above.

23.

A no converter charge condition can be caused by: A. B. C. High line pressure A bad torque converter A clogged cooler
082102 16

D. 24.

A bad lockup solenoid

On most transmissions, a whining noise in gear while stationary that gets louder when you do a stall test but gets quieter as the vehicle begins to move indicates a problem with: A. B. C. D. The filter or screen Low fluid level T orque converter All of the above

25.

After an overhaul of a 4L60 transmission, a road test reveals a very severe converter clutch apply. A. B. C. D. What is a probable cause?

Defective solenoid. Stuck TV limit valve. Damaged check ball capsule in end of turbine shaft. Converter clutch apply valve stuck.

26.

A FULLY charged car battery should have: A. B. C. D. 12.6 volts. 12.4 volts. 12.2 volts. 12.0 volts.

27.

An F4A33 can get TCC lock-up in: A. B. C. D. Second, third, and fourth . Third, and fourth. Fourth only. Anytime the ECM gives the signal.

28.

The direct clutch on an AODE is applied in: A. B. C. D. Second and third. Third and fourth. Third and Reverse. Third only.

29.

The AODE forward clutch releases in: A. B. C. D. Second gear. Third gear. Fourth gear. Does not release while going forward.

30.

On most transmissions, which of the following pressures should increase increases: A. B. C. D. Mainline pressure Throttle pressure Both A and B None of the above

when engine load

31.

The wrong valve body spacer plate on the E4OD can cause no: A. B. C. First Second Third
082102 17

D. 32.

Fourth

An E4OD which kills the engine in Reverse could have a problem with: A. B. C. D. The computer. The pump. The lockup solenoid. All of the above.

33.

When checking the voltage drop in a ground circuit an acceptable number would be: A. B. C. D. 0 volts only . Less than .10 volts. Less than 1 volt. Doesn't matter because its ground.

34.

When checking voltage in a car battery the reading must be at least: A. B. C. D. 11.8 Volts. 12.0 Volts. 12.2 Volts. 12.4 Volts

The following are illustrations of valves used in the 4L60. Use this illustration in the next three questions to identify the valves.

C D

35.

Which valve is the MTV Upshift Valve? A B C D

36.

Which valve is the Line Bias Valve? A B C D

37.

Which valve is the TV Limit Valve? A B C D

082102 18

38.

Ford EEC-IV computers have a self test you enter by grounding the STI

wire (with the key

on), ungroundng the STI wire, then grounding it once again. This test is called. A. B. C. D. The Output State test. The Cylinder Balance test. The Wiggle test. The Solenoid Feedback test

39.

When you energize the shift solenoids of an Acura L5 transaxle, the pressure on the solenoid pressure taps should: A. B. C. D. Rise to at least 60psi. Fall to zero psi. The pressure varies based on the voltage you apply to the solenoid. None of the above. The L5 does not used shift solenoids.

40.

Main line pressure rise on a Honda PX4B transaxle is controlled by: A. B. C. D. The TV cable. The pressure control solenoid. T orque applied to the stator support. None of the above. Line pressure does not vary.

41.

A 1-2 chatter on a 41TE transmission is often caused by: A. B. The converter clutch applying on top of the 1-2 shift. The controller, which is why you should always upgrade it if it is one of the early models. C. D. The solenoid pack. Using the wrong type of ATF .

42.

Ford EEC-IV computers have a self test called the "Output State" test, which will turn on and off the various solenoids and actuators in the system. A. B. C. D. Go through the KOEO T o start this test you must:

and memory tests then press on the accelerator pedal.

Go through the KOER test then press on the brake. Short the STI lead to ground. Move the shifter through the various ranges, after continuous-memory codes have been displayed.

43.

Code 68 on a 4L80E is for a ratio error in fourth gear. Besides the overdrive clutch, what other friction component can cause this code? A. B. C. D. The forward clutch. The direct clutch. The converter clutch. None of the above. The overdrive clutch is the only friction component that will set this code.

44.

The 5R55E uses which friction components for third gear? A. B. C. D. Forward clutch and intermediate band. Forward clutch and direct clutch. Forward clutch and overdrive band. Forward clutch, intermediate band, and overdrive band.

45.

What would you suspect as a problem if an automobile had .8 volts in the ground circuit
082102 19

A. B. C. D.

No problem, That is a normal reading An open ground. Resistance in the ground. A short to ground.

46.

What if the circuit had more than 12 volts in the ground A. B. C. D. Excessive battery voltage An open ground. Resistance in the ground. A short to ground.

47.

A soft 1-2 shift on a 4L60E transmission can be caused by: A. B. C. D. A leaking checkball capsule in the servo. An open in the force motor circuit. A disconnected force motor circuit. Sanding the reverse input drum with course sand paper.

48.

What is the law for resistance in a parallel circuit A. B. C. D. T otal resistance will be less than the least resistive branch. The sum of the individual resistors equals the total resistance. The square root of the total resistance equals one half of the largest resistor. Resistance is added to circuits to increase the total current flow.

49.

What is the law for voltage in a parallel circuit A. B. C. D. Voltage is constant throughout the circuit. The voltage drop is the same across each branch. The sum of the voltage equals the applied voltage. Voltage leaving the source equals voltage entering the source.

50.

What is the law for amperage in a parallel circuit A. B. C. D. Amperage will increase to overcome increased resistance. Amperage will be the same at any point. Amperage is inversely proportional to voltage. The sum of the branch currents equals the total current.

51.

What would the amperage be in a series circuit running 12 volts with a 6 ohm and a 4 ohm load A. B. C. D. 2.0 1.2 6.4 10.0

52.

What would the voltage reading be in the same circuit between the two loads A. B. C. D. 8.0 4.8 6.0 4.0

53.

What is the law for resistance in a series circuit A. T otal resistance will be less than the least resistive branch.
082102 20

B. C. D.

The sum of the individual resistors equals the total resistance. The square root of the total resistance equals one half of the largest resistor. Resistance is added to circuits to increase the total current flow.

54.

What is the law for voltage in a series circuit A. B. C. D. Voltage is constant throughout the circuit. The voltage drop is the same across each branch. The sum of the voltage drops equals the applied voltage. Voltage leaving the source equals voltage entering the source.

55.

What would the resistance be in a circuit using 14 volts and 2 amps A. B. C. D. 28 7 14 12

56.

A stuck-on 3-4 shift solenoid on an A4LD will cause: A. B. C. D. A stacked 3-4 shift. A 1, 2, 4 shift An overdriven first gear, which feels like a second gear start. A fourth gear start

57.

What is the law for amperage in a series circuit A. B. C. D. Amperage will increase to overcome increased resistance. Amperage will be the same at any point. Amperage is inversely proportional to voltage. The sum of the branch currents equals the total current.

58.

What does the stripe on a diode indicate A. B. C. D. The anode The cathode The resistance The collector

True False (59-70) 59. The computer provides the positive (+) current to the solenoid on GM computer-controlled converter clutch transmissions.

60.

It is normal for transmission fluid to lose its red color.

61.

A slipping 1-2 shift can be corrected by installing a stronger spring on the 1-2 shift valve.

62.

Fluid that smells burnt means the transmission needs to be overhauled/replaced.

63.

Throttle pressure will exceed mainline pressure at W.O.T .

64.

Converter stall speeds have little effect on performance.

65.

A bad engine thermostat can cause a lock up problem.

082102

21

66.

A bad EGR valve will have no effect on transmission performance.

67.

It is normal for a 42LE to have a late 2-3 shift in the "D" position.

68.

An engine tune up will correct any engine problems that could affect the transmission.

69.

An oscilloscope will always detect engine problems that feel like lock up shudders.

70.

What feels like a lock up shudder can be caused by using the wrong fluid.

END OF DIAGNOSTICIAN PREP-TEST

R & R PREP TEST

MULTIPLE CHOICE (1-15) 1. You should adjust the A. B. C. D. TV cable of a 4L60 so that:

The TV plunger is bottomed out at WOT . Shift timing is approximately 15, 25 and 35 mph. The trans will kickdown to first gear above 25 mph. Line pressure is approximately 65 psi at an idle and 175 psi at a stall.

2.

Most transmissions have the fluid level: A. B. C. D. Level with the pan rail. One inch above the pan rail. Level with the pump intake port. Approximately 3 inched above the suction port of the filter.

3.

You should adjust the vacuum regulator for a diesel 400 so that at an idle is measures: A. B. C. D. 18 Hg. 16 Hg. 13 Hg. 10 Hg.

4.

You're filling a trans with ATF and once you get it to about 2/3 of its capacity it begins pouring oil out the vent. Which of the following is not a possible cause. A. B. C. D. High line pressure. A broken pump. A bad sprag in the torque converter, causing it not to fill. None of the above. All of them can cause this problem.

5.

T o verify proper cooler flow you should: A. B. C. D. Flush the cooler with a heated cooler-flushing machine Blow through the cooler lines with a regulated 50 psi of compressed air. Replace the cooler with an air-cooled cooler. Have the transmission pump the ATF through the lines and measure one quart in under 20 seconds.

6.

Voltage in a ground circuit should not exceed

082102 22

A. B. C. D.

0.5 volts 0.1 volts 1.0 volts 0.05 volts

7.

Charging voltage on most systems should be between 13.8 and 15.1 volts. T o check the charging voltage you should measure it with a DVOM: A. B. C. D. At the alternator At the battery posts. With the positive DVOM lead on the battery and the negative lead on the engine block. At the battery cable ends.

8.

Cranking voltage of a car battery will vary with temperature, however, the reading must never fall below: A. B. C. D. 11.0 volts 10.0 volts 9.0 volts 8.0 volts

9.

When checking voltage on a car battery the reading must be at least: A. B. C. D. 11.8 volts. 12.0 volts. 12.2 volts. 12.4 volts.

10.

Before making any repairs to a harness connector, you should: A. B. C. Make sure the circuit you're working on is turned off. Draw an illustration of the connector and wire colors. Confirm that any replacement components you're using fit properly and are the correct configuration. D. All of the above

11.

A 4T60E modulator should be adjusted: A. B. C. D. By shift feel. By shift timing. Both A and B above. With a pressure gauge.

12.

A seized console shift control cable is often caused by: A. B. C. D. Wear in the cable. Poor engine to body ground. Broken transmission mount. Manual linkage problem inside the transmission.

13.

Which Chrysler transmission can be successfully filled with the shifter in the Park range? A. B. C. D. 46RH 32TH 41TE 42RE

082102

23

14.

Before the disconnecting the battery cables on an OBD II vehicle, you should: A. B. C. D. Make sure someone has first checked for DTCs. Measure and document the battery voltage. Install a battery supply to the cigarette lighter socket. All of the above.

15.

What must be done in order to properly adjust the TV linkage on a Ford equipped with an AOD: A. B. C. D. Hook up a vacuum gauge to the engine. Road test vehicle and adjust according to shift points indicated by the speedometer. Use a gauge block on the TV link, and adjust TV pressure with a gauge.

The linkage is not adjustable.

TRUE or FALSE (16-55) 16. The TV link on a 32RH is only for kickdown, so its adjustment is not all that critical.

17.

It's OK to install a transmission in a car as long as one dowel pin is present on the back of the engine block.

18.

The weights on some T orqueflite converters are used to balance the engine crankshaft.

19.

A hissing sound under the hood with the engine running could indicate a vacuum leak.

20.

Adding a ground strap between the transmission and frame will always eliminate ground problems.

21.

Vacuum-related problems with the engine will have no affect on transmissions that do not use a vacuum modulator.

22.

A restricted vacuum line will cause a vacuum gauge to read low.

23.

A transmission that makes a whining noise that seems to be coming from the pump area could have a clogged filter.

24.

The TV cable/rod on a Chrysler 42RH is for passing gear only.

25.

Overfilling the transmission may cause the pump seal to leak.

26.

All ATFs (fluid) are really pretty much the same.

27.

If you must cut a cooling line during the removal of a transmission, the best way to rejoin the line is with the use of a brass compression coupling.

28.

When installing a cooler check valve, it must always go in the outgoing cooler line.

29.

The proper way to install converter bolts on a GM car is to thread them all in finger tight before wrench tightening any of them.

30.

The left side motor mount is broken on the car in which you've just installed a rebuilt trans mission. You don't have to replace the mount, since it can't affect the operation of the trans
082102 24

mission.

31.

The best way to clear trouble codes on any vehicle is to disconnect the battery.

32.

Putting a 41TE in gear before it is completely filled can set a trouble code.

33.

A 36RH converter drain plug is positioned 180 degrees opposite the small identification hole in the flex plate.

34.

Engine core plugs leaking on the back of an engine is really none of your concern, since your only interest is installing a rebuilt transmission in the car.

35.

A leak at the front pump of most units can always be repaired by simply replacing the front seal.

36.

A universal joint is bad when it won't move freely in both directions.

37.

When checking for a poor engine ground, it is best to remove the drive shaft.

38.

A stuck TV cable on an AXOD transaxle can be caused by a TV cable that is set too loosely.

39.

After installing the converter into a rebuilt transmission, the converter can be turned by hand, but only with difficulty. That is acceptable.

40.

It's normal for transmission fluid to lose its red color.

41.

It is a good idea to install another ground strap on vehicles with cable operated linkage.

42.

The vacuum modulator on a 4T60E is not used for shift timing so its adjustment is not critical.

43.

The oil pump is pumping whenever the vehicle's engine is running.

44.

Having changed a leaking rear seal on a transmission, it is good practice to accompany that with the installation of a new rear bushing.

45.

During a stall test, a car exhibits a tremendous thump, and some grinding with the lever in Drive position. It probably has a broken left front engine mount.

46.

A 41TE can go into failsafe, while filling the unit with ATF simply by , putting the shifter into drive before making sure the fluid level is correct.

47.

Installation of a T orqueflite converter into the transmission becomes easier, if you align the inner pump gears.

48.

If a Ford speedometer reads too fast, you can correct this by installing a driven gear with more teeth on it.

49.

Modifying an emission device is OK if the customer specifically asks for it.

50.

On a 37RH, the rear servo anchor pin "O" ring is a source of transmission fluid leak that is many times misdiagnosed as being a pan leak.
082102 25

51.

T o clear failsafe on a 41TE just shut off the key and restart the vehicle.

52.

Fluid that has a pink milkshake appearance indicates water in the transmission.

53.

A digital multi-meter is safer on electronics than an analog meter.

54.

The 41TE works best with Chrysler 7176 fluid.

55.

Honda's work best with Dexron III fluid.

END OF R&R TECHNICIAN TEST

082102

26