Bench Test Procedure for a CX31 On-Highway Transmission and CX31-P600 Petroleum Transmission {3030, 3073} Caterpillar

Bench Test Procedure for a CX31 On-Highway Transmission and CX31-P600 Petroleum Transmission {3030, 3073}

Usage:

CX31 B3X

On Highway Truck: CT660S (S/N: TRK1-UP; TKL1-UP; TGT1-UP; TSW1-UP; TSY1-UP)
On-Highway Transmission: CX31 (S/N: D9F1-1393; S4H1-UP; S7H1-UP; D9R1-344; E2R1-UP; PTT1-303; EBW1-1301; PTW1-407; B3X1-UP); CX31 HT (S/N: HTC1-388)
Petroleum Transmission: CX31-P600 (S/N: PFW1-578; GFY1-UP)

Introduction

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Table 1
Revision	Summary of Changes in REHS3184
12	Added serial number GFY.
11	Added serial numbers S4H and S7H.
10	Updated serial number prefixes.
09	Updated Introduction and added "Think Safety" graphic.
08	Added HTC serial number prefix

© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This special instruction contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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Table 2
Machine Model	Transmission Arrangement
CT660	All
CX31	All
CX31-P600	All

Collecting The Test Data

Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

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Illustration 1	g02139237

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Illustration 2	g02060066

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Personal injury or death can result from escaping fluid under pressure.
Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

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Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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Personal injury or death can result from not following the proper procedures.

To avoid the possibility of injury or death, follow the established procedure.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Tools Needed

Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
A	43-4614	Hoist Ring⁽¹⁾	3




B	296-3645	Isolation Pan	1
C	6V-4429	Bolt	2
D	289-0219	Spindle Adapter	1
E	4C-4701	Adapter (Spindle Assembly)	1
F	1U-5999	Spindle Assembly	1
G	1U-6721	Adapter	1
H	1U-9359	Drive Adapter⁽²⁾	1
J	1U-9131	Drive Adapter⁽³⁾	1
K	FT-3057	Hose Group
L	4C-9913	Flow Meter	1
M	FT-3057	Hose Group
N	9U-5893	Heat Exchanger	1
P	FT-3057	Hose Group
Q	6V-3966	Nipple (Quick Disconnect)	1
Q	5P-2937	Adapter	1
R	4C-6265	Temperature Probe (RTD)	1
S	3D-8884	Elbow (Pipe)	1
	6V-3966	Nipple (Quick Disconnect)	1
	6V-4144	Coupler (Quick Disconnects)	1
T	3D-8884	Elbow (Pipe)	7
	6V-3966	Nipple (Quick Disconnect)	7
	6V-4144	Coupler (Quick Disconnects)	7
U	1U-6392	Valve (Pressure Regulator)	1
	6V-3966	Nipple (Quick Disconnect)	2
	6V-3965	Nipple (Quick Disconnect)	4
	8T-0856	Gauge (Pressure)	1
V	277-2362	Transmission Analyzer	1
	9U-7498	Extension Cable	1
	9U-7496	Cable (Test)	1
	1U-9480	Cable Adapter	1

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⁽¹⁾	Columbus McKinnon Corporation part number
⁽²⁾	This adapter is used with the small drive shaft.
⁽³⁾	This adapter is used with the large drive shaft.

Installation Procedure

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Illustration 3	g02060063

Install Tooling (A) to the input end of the transmission. Or, use hoist rings on the side of the transmission. Use the provided lift brackets on the Cat Truck transmission.
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Illustration 4 g02060059
Install Tooling (A) to the output end of the transmission.
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Illustration 5 g01275623
Install Tooling (B) on the test bench.
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Illustration 6 g01275636
Use a hoist to install the transmission on the test bench. The weight of the transmission is 440.0 kg (970 lb).
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Illustration 7 g01275642
Use Tooling (C) to secure the transmission to Tooling (B).
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Illustration 8 g01275648
Remove flywheel (1).
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Illustration 9 g01275651
Install Tooling (D).
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Illustration 10 g01275654
Install Tooling (E).
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Illustration 11 g01275674
Install Tooling (F).
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Illustration 12 g01275688
Tighten the collet on Tooling (F) in order to connect Tooling (F) to Tooling (D).
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Illustration 13 g01275693
Install Tooling (G).
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Illustration 14 g01275697
Install Tooling (H).
Note: Tooling (H) will adapt to the small drive shaft. If the large drive shaft is being used install Tooling (J) on Tooling (H).
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Illustration 15 g01275699
Align the transmission with the input drive shaft.
Connect the input drive shaft to Tooling (H).
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Illustration 16 g01275704
Install the drive shaft guard.
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Illustration 17 g01275709
Remove plug (2).
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Illustration 18 g01275724

(K) Torque Converter Outlet
Connect Tooling (K) from the transmission to Tooling (L).
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Illustration 19 g01276392
Connect Tooling (M) from Tooling (L) to Tooling (N).
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Illustration 20 g01276397
Remove plug (3).
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Illustration 21 g01276405

(P) Lubrication Inlet
Connect Tooling (P) from Tooling (N) to the transmission.
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Illustration 22 g01276421
Connect the water supply (4) to Tooling (N).
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Illustration 23 g01276459
Connect the water outlet (5) from Tooling (N) to a drain.
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Illustration 24 g01276463
Install Tooling (Q).
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Illustration 25 g01276470

Oil Temperature Sensor
Install Tooling (R).
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Illustration 26 g01276472
Install Tooling (S).
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Illustration 27 g01276473
Install Tooling (T).
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Illustration 28 g01276482
Install Tooling (U).
Connect lube line (6) from Tooling (Q) to Tooling (U).
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Illustration 29 g01279614

(7) Spindle Lubrication
Connect lube line (7) from Tooling (U) to Tooling (F). Adjust Tooling (U) in order to maintain a lubrication pressure of 275.8 kPa (40 psi).
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Illustration 30 g01279659

(8) Main Relief Valve Pressure
Connect a pressure gauge to pressure tap (8).
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Illustration 31 g01279671

(9) Transmission Lubrication Pressure
Connect a pressure gauge to pressure tap (9).
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Illustration 32 g01279685

(10) Cooler Inlet Pressure
Connect a pressure gauge to pressure tap (10).
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Illustration 33 g01279692

(11) Torque Converter Outlet Pressure
Connect a pressure gauge to pressure tap (11).
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Illustration 34 g01279698

(12) Torque Converter Inlet Pressure
Connect pressure gauge (12) to Tooling (S).
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Illustration 35 g01279644

(13) Lockup Clutch Pressure
(14) No. 1 Clutch Pressure
(15) No. 2 Clutch Pressure
(16) No. 3 Clutch Pressure
(17) No. 4 Clutch Pressure
(18) No. 5 Clutch Pressure

Connect pressure lines to the proper locations, as shown.

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Illustration 36	g01279641
Cable connector (6-F) for lockup clutch solenoid (19) Cable connector (1-A) for No. 1 clutch solenoid (20) Cable connector (2-B) for No. 2 clutch solenoid (21) Cable connector (3-C) for No. 3 clutch solenoid (22) Cable connector (4-D) for No. 4 clutch solenoid (23) Cable connector (5-E) for No. 5 clutch solenoid (24)

Connect Tooling (V) to the six clutch solenoids, as shown.
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Illustration 37 g01279728
Connect Tooling (V) to a suitable location, as shown.
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Illustration 38 g02629190

Tooling (V)
Connect Tooling (V) to a power source. Refer to Tool Operating Manual, NEHS0966 for the correct operating instructions.
Fill the transmission with oil to the correct operating level. The CX31 On-Highway Transmission uses Cat Synthetic ATF oil. The CX31-P600 Petroleum Transmission uses SAE10W TDTO oil. Refer to Operation and Maintenance Manual, SEBU8192, "CX31 Transmission", Operation and Maintenance Manual, SEBU8528, "CX31 Transmission" used in Cat Truck, or Operation and Maintenance Manual, SEBU8427, "CX31-P600 Petroleum Transmission" for the proper fill capacity.

Test Procedure

TA3 Navigation

Select "OEM Transmissions".
Select "CX31_OEM_Truck-12V".

Harness Test

Make sure that the harness is properly connected.
Use Tooling (V) to perform the Harness Test.
Record the results in Table 6.

Start Checks

Warm the Cat Synthetic ATF or TDTO oil to 50 °C (122 °F). Maintain this temperature for the duration of the test. Refer to Testing and Adjusting, KENR5090, "CX31 On-Highway Transmisson",Testing and Adjusting, UENR1833, "CX31 On-Highway Transmisson" used in Cat Truck, or Testing and Adjusting, KENR6986, "CX31-P600 Petroleum Transmission" for additional information.
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Illustration 39 g02720621
With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 600 ± 20 rpm.
Note: The input shaft will be rotated in a counterclockwise direction for the duration of this test. The direction is determined as you face the drive motor of the test bench.
Shift the transmission through all directions and all speed ranges in order to eliminate air from the transmission controls.
Verify that the active clutches are correct for each gear range. Refer to Table 4.
Stop the input rotation.

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Table 4
Transmission Clutch Assignments
Operation	Clutches
Operation	1	2	3	4	5	LU C
Neutral					X
Forward 1	X				X	X
Forward 2	X			X		X
Forward 3	X		X			X
Forward 4	X	X				X
Forward 5		X	X			X
Forward 6		X		X		X
Reverse			X		X

Low Idle Checks

Adjust the input rotation to 600 ± 20 rpm in the NEUTRAL position.
Record the values in Table 8 and Table 10 for each gear range.
Verify all test points with the values in Table 7 and Table 9.
Shift the transmission through each gear range and repeat Steps 2 and 3.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

High Idle Checks

Adjust the input rotation to 2100 ± 20 rpm in the NEUTRAL position.
Record the values in Table 12 and Table 14 for each gear range.
Verify all test points with the values in Table 11 and Table 13.
Adjust the input rotation to 600 ± 20 rpm.
Shift the transmission through each gear range and repeat Steps1 through 4.
Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

Contamination Control

Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
Record the results in Table 15.
Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

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Table 5
CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Harness Test

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Table 6
Harness Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5	Solenoid 6
Harness Test	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Low Idle Checks

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Table 7
Low Idle Checks				Input Speed (600 ± 20 rpm)
Gear	Cooler Flow	Lubrication Pressure	Main Relief Valve Pressure	Torque Converter Inlet Pressure	Lockup Clutch Pressure	Torque Converter Outlet Pressure

R
N	32 ± 4 L/min (9 ± 1 US gpm)	28 ± 14 kPa (4 ± 2 psi)	1896 ± 70 kPa (275 ± 10 psi)	207 ± 35 kPa (30 ± 5 psi)		221 ± 35 kPa (32 ± 5 psi)
1	32 ± 4 L/min (9 ± 1 US gpm)			207 ± 35 kPa (30 ± 5 psi)	1862 ± 70 kPa (270 ± 10 psi)
2	33 L/min (9 US gpm)			207 ± 35 kPa (30 ± 5 psi)
3	32 ± 4 L/min (9 ± 1 US gpm)			207 ± 35 kPa (30 ± 5 psi)
4	28 ± 4 L/min (8 ± 1 US gpm)			186 ± 35 kPa (27 ± 5 psi)
5	28 ± 4 L/min (8 ± 1 US gpm)			186 ± 35 kPa (27 ± 5 psi)
6	28 ± 4 L/min (8 ± 1 US gpm)			186 ± 35 kPa (27 ± 5 psi)

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Table 8
Low Idle Checks			Input Speed (700 ± 25 rpm)
Gear	Cooler Flow L/min (gpm)	Lubrication Pressure kPa (psi)	Main Relief Valve Pressure kPa (psi)	Torque Converter Inlet Pressure kPa (psi)	Lockup Clutch Pressure kPa (psi)	Torque Converter Outlet Pressure kPa (psi)
R	________	________	________	________		________
N	________	________	________	________		________
1	________	________	________	________	________	________
2	________	________	________	________	________	________
3	________	________	________	________	________	________
4	________	________	________	________	________	________
5	________	________	________	________	________	________
6	________	________	________	________	________	________

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Table 9
Clutch Pressures
Gear	Active Clutches		Clutch 1	Clutch 2	Clutch 3	Clutch 4	Clutch 5
R	3	5
N		5					1896 ± 138 kPa (275 ± 20 psi)
1	1	5	1862 ± 138 kPa (270 ± 20 psi)				1896 ± 138 kPa (275 ± 20 psi)
2	1	4	1862 ± 138 kPa (270 ± 20 psi)			1896 ± 138 kPa (275 ± 20 psi)
3	1	3	1862 ± 138 kPa (270 ± 20 psi)		1896 ± 138 kPa (275 ± 20 psi)
4	1	2	1862 ± 138 kPa (270 ± 20 psi)	1724 ± 138 kPa (250 ± 20 psi)
5	2	3		1724 ± 138 kPa (250 ± 20 psi)	1866 ± 138 kPa (270 ± 20 psi)
6	2	4		1724 ± 138 kPa (250 ± 20 psi)		1866 ± 138 kPa (270 ± 20 psi)

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Table 10
Clutch Pressures
Gear	Clutches		Clutch 1	Clutch 2	Clutch 3	Clutch 4	Clutch 5
R	3	5			___________		___________
N	-	5					___________
1	1	5	___________				___________
2	1	4	___________			___________
3	1	3	___________		___________
4	1	2	___________	___________
5	2	3		___________	___________
6	2	4		___________		___________

High Idle Checks

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Table 11
High Idle Checks				Input Speed (2100 ± 20 rpm)⁽¹⁾
Gear	Cooler Flow	Lubrication Pressure	Main Relief Valve Pressure	Torque Converter Inlet Pressure	Lockup Clutch Pressure	Torque Converter Outlet Pressure
R⁽¹⁾	76 ± 8 L/min (20 ± 2 US gpm)	138 ± 35 kPa (20 ± 5 psi)	2069 ± 138 kPa (300 ± 20 psi)	379.2 ± 34.5 kPa (55 ± 5 psi)		275.8 ± 34.5 kPa (40 ± 5 psi)
N⁽¹⁾	76 ± 8 L/min (20 ± 2 US gpm)	138 ± 35 kPa (20 ± 5 psi)	2069 ± 138 kPa (300 ± 20 psi)	379 ± 35 kPa (55 ± 5 psi)		276 ± 35 kPa (40 ± 5 psi)
1	114 ± 19 L/min (30 ± 5 US gpm)	310 ± 35 kPa (45 ± 5 psi)	2206 ± 138 kPa (320 ± 20 psi)	827 ± 69 kPa (120 ± 10 psi)	2137 ± 70 kPa (310 ± 10 psi)	552 ± 35 kPa (80 ± 5 psi)
2	114 ± 19 L/min (30 ± 5 US gpm)	310 ± 35 kPa (45 ± 5 psi)		758 ± 69 kPa (110 ± 10 psi)		552 ± 35 kPa (80 ± 5 psi)
3	114 ± 19 L/min (30 ± 5 US gpm)	310 ± 35 kPa (45 ± 5 psi)		758 ± 69 kPa (110 ± 10 psi)		552 ± 35 kPa (80 ± 5 psi)
4	95 ± 10 L/min (25 ± 2 US gpm)	207 ± 35 kPa (30 ± 5 psi)		621 ± 35 kPa (90 ± 5 psi)		448 ± 35 kPa (65 ± 5 psi)
5	95 ± 10 L/min (25 ± 2 US gpm)	207 ± 35 kPa (30 ± 5 psi)		621 ± 35 kPa (90 ± 5 psi)		448 ± 35 kPa (65 ± 5 psi)
6	95 ± 10 L/min (25 ± 2 US gpm)	207 ± 35 kPa (30 ± 5 psi)		621 ± 35 kPa (90 ± 5 psi)		448 ± 35 kPa (65 ± 5 psi)

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⁽¹⁾	The pressure that is recorded in REVERSE and the pressure that is recorded in NEUTRAL must be recorded at an input speed of 1240 rpm.

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Table 12
High Idle Checks			Input Speed (2200 ± 25 rpm)
Gear	Cooler Flow L/min (gpm)	Lubrication Pressure kPa (psi)	Main Relief Valve Pressure kPa (psi)	Torque Converter Inlet Pressure kPa (psi)	Lockup Clutch Pressure kPa (psi)	Torque Converter Outlet Pressure kPa (psi)
R	________	________	________	________		________
N	________	________	________	________		________
1	________	________	________	________	________	________
2	________	________	________	________	________	________
3	________	________	________	________	________	________
4	________	________	________	________	________	________
5	________	________	________	________	________	________
6	________	________	________	________	________	________

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Table 13
Clutch Pressures
Gear	Active Clutches		Clutch 1	Clutch 2	Clutch 3	Clutch 4	Clutch 5
R	3	5			2068 ± 138 kPa (300 ± 20 psi)		2068 ± 138 kPa (300 ± 20 psi)
N		5					2068 ± 138 kPa (300 ± 20 psi)
1	1	5	2172 ± 138 kPa (315 ± 20 psi)				2172 ± 138 kPa (315 ± 20 psi)
2	1	4	2137 ± 138 kPa (310 ± 20 psi)			2172 ± 138 kPa (315 ± 20 psi)
3	1	3	2172 ± 138 kPa (315 ± 20 psi)		2172 ± 138 kPa (315 ± 20 psi)
4	1	2	2206 ± 138 kPa (320 ± 20 psi)	2068 ± 138 kPa (300 ± 20 psi)
5	2	3		2000 ± 138 kPa (290 ± 20 psi)	2172 ± 138 kPa (315 ± 20 psi)
6	2	4		2000 ± 138 kPa (290 ± 20 psi)		2172 ± 138 kPa (315 ± 20 psi)

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Table 14
Clutch Pressures
Gear	Clutches		Clutch 1	Clutch 2	Clutch 3	Clutch 4	Clutch 5
R	3	5			___________		___________
N	-	5					___________
1	1	5	___________				___________
2	1	4	___________			___________
3	1	3	___________		___________
4	1	2	___________	___________
5	2	3		___________	___________
6	2	4		___________		___________

Contamination Control

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Table 15
Contamination Control	Sample the test bench oil supply. *ISO 4406 is 16/13 or better	________/________Particle Count

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Table 16
______________________________________ Technician	______________________________________ Supervisor

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Illustration 31	g01279671
(9) Transmission Lubrication Pressure




Illustration 33	g01279692
(11) Torque Converter Outlet Pressure




Illustration 34	g01279698
(12) Torque Converter Inlet Pressure




Illustration 35	g01279644
(13) Lockup Clutch Pressure (14) No. 1 Clutch Pressure (15) No. 2 Clutch Pressure (16) No. 3 Clutch Pressure (17) No. 4 Clutch Pressure (18) No. 5 Clutch Pressure




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Illustration 5	g01275623




Illustration 6	g01275636




Illustration 7	g01275642