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when-it-fits.indd 2 7/11/07 9:17:30 AM

GEARS FOR THE TRANSMISSION REBUILDING INDUSTRY

OCTOBER 2007
PHONE (805) 604-2000 FAX (805) 604-2006
TABLE OF CONTENTS

Chief Executive Officer Dennis Madden

Managing Editor Rodger Bland
Why is My Transmission Tech Educating the AF33-5 Four Wheel Drive Explorer
Technical Director Lance Wiggins Always under the Dashboard? Page 4 Chatters on Turns
Advertising Frank Pasley Page 40 Page 34
Senior Designer Jeanette Troub

Contributing Editors Steve Bodofsky,

Steve Jaussaud, Thom Tschetter
ATRA Technical Staff
Weldon Barnett Bill Brayton Mike Brown
Steve Garrett Pete Huscher
Chris Ondersma Randall Schroeder
Dave Skora Mike Van Dyke
Director of Membership & IT Svc Kelly Hilmer
Seminars & Convention Manager Vanessa Velasquez
Bookstore Manager Shaun Velasquez
The views expressed in this publication should not necessarily be interpreted as
the official policy of the Automatic Transmission Rebuilders Association (ATRA).
Publication of product information or any advertising does not imply recommenda-
tion by ATRA.
GEARS, a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030,
is published for the betterment of the transmission industry and is distributed
nine times per year. No part of this issue may be reproduced without prior written
permission of the publisher. Gears is distributed to members of the transmis-
sion industry in the United States, Canada, ATRA Members in Mexico & Europe,
and related automotive industry firms and individually. Send changes of address
to Gears in care of ATRA. Subscriptions are available by contacting Gears
in care of ATRA.
Advertisers and advertising agencies assume full liability for all content of
advertisements printed and also assume full responsibility for any claims arising
therefrom against the publisher. The publisher reserves the unqualified right to
reject any advertising copy as it deems appropriate, with or without cause.
Gears is designed to provide accurate and authoritative information in regard
to the subject matter covered. It is distributed with the understanding the publisher
is not engaged in rendering legal, accounting or other professional service. If legal
advice or other expert assistance, is required, the services of a competent profes-
sional person should be sought from a Declaration of Principles jointly adopted
SPECIAL INTEREST & TECHNICAL
4 LET'S PLAY BALL: Educating the AF33-5
by Lance Wiggins
10 THE NUTS AND BOLTS OF ELECTRICAL DIAGNOSIS
Introduction to Reprogramming/Reflashing, Part II
by Mike Van Dyke
18 How did Lubegard come about? The History of Lubegard
Reprinted with Permission From Swissmotor
30 PLAYING TO WIN: Have a Cup on Me
by Thom Tschetter
34 KEEP THOSE TRANNYS ROLLING: Four Wheel Drive Explorer
Chatters on Turns by Pete Huscher
40 Why is My Transmission Tech Always under the Dashboard?
by Dave Skora
46 The 4T65E and 4T45E Tap Shift Feature: Putting More
Control in the Drivers Hands by ATRA Tech Department
52 ACCURATE MEASUREMENTS: Reading a Micrometer
by Steve Bodofsky
60 Filler Up! by Steve Jaussaud
68 Then There Were Two: TRNi and TRNw
by Steve Bodofsky
70 Dacco Transmission Parts, efficiency, quality, value
76 ATRA'S POWERTRAIN EXPO INFORMATION 2007
wissm
otor.ch

DEPARTMENTS
www.s Association
s

by a Committee of the American Bar Association and Committee of Publishers.

Transport
Military
of Swiss
Federation

Gears also welcomes articles submitted by members of the industry.

Gears considers all articles for publication that contribute positively to the Read
The Story
welfare of the transmission industry, and reserves the right to edit all articles it Inside!
publishes. If you would like to submit an article to Gears, include background
information about the author and a telephone number where he/she may be reached.
2 FROM THE PRESIDENT: io n
ns um pt
s fu el co
If you want submissions returned, enclose a self-addressed, stamped envelope. Welcome to Las Vegas! Re du ce gs se rv ic e lif e
Pr ol on

by Jim Rodd On the Cover: The History of Lubegard

Reprinted with Permission From
Editorial and Business Offices 74 FROM THE TECH DIRECTOR: Swissmotor
2400 Latigo Avenue, Oxnard CA 93030 Page 18 (Paid advertisement)
Phone (805) 604-2000 Lifetime Warranty? Dont give up
Fax (805) 604-2006 just Yet by Lance Wiggins
www.gearsmagazine.com
www.atra.com 108 ATRA News
www.atraonline.com 116 Powertrain Industry News efficiency, quality, value
Publications Mail Agreement No. 40031403
Return Undeliverable Canadian Addresses to: 121 Shoppers and Classified
Station A , PO Box 54, Windsor, ON N9A 6J5 128 List of Advertisers
Email: gears@atra.com Dacco Transmission Parts,
efficiency, quality, value
Issue #125 Printed in U.S.A. Copyright ATRA 2007 Page 70 (Paid advertisement)
 Welcome
FROM THE PRESIDENT
to Las Vegas!
I
t seems like only yesterday we
were all in Orlando for the annu-
al ATRA Powertrain 2006 Expo.
Now here we are, just a year later, in
Las Vegas for Powertrain Expo 2007.
Vegas, as its more commonly
referred to, has become the entertain-
ment capital of the world. It became
famous for its massive, lavish hotels
and casinos. Vegas got its start when
Bugsy Siegel built the Flamingo Hotel
here in 1946. This was the first casino
in what was then the desert area of
southern Nevada. In 1989, the Mirage
became the first of the Mega Resorts
which now dominate the Las Vegas
Strip.
This year we find ourselves once
again at the Las Vegas Hilton. The
Hilton has a lot to offer for our event;
its a beautiful venue, with terrific ame-
nities and plenty of room. They always
have excellent shows and entertainment,
and from the Hilton lobby you can hop
right onto the Las Vegas Monorail,
which will take you all the way up and
down the Strip: from the MGM Grand
on the southern end to the Sahara Hotel
and Casino on the northern end.
ATRAs annual ATRA Powertrain
Expo is the largest event in the world
thats devoted exclusively to you: the
transmission rebuild professional. Expo
is always an exciting, valuable and edu-
cational experience, one I look forward
to all year. But in the years to come, this
Expo may well be considered to be the
greatest ever; certainly itll be remem-
bered as the beginning of a new era.
Well get started early Thursday morn-
ing with the 4th Annual Red Girdley
 GEARS
Memorial Golf Tournament, sponsored
by Toledo Trans-Kit.
Shop owners are always asking
us for more technical programs; well,
this year shouldnt disappoint, because,
for the first time ever, weve sched-
uled a full day of technical seminars
on Thursday. You wont find a greater
variety of up-to-the-minute technical
information anywhere in the world!
On Thursday evening, dont miss
the ATRA Members meeting, which
will begin promptly at 6 pm and end at
7:30 pm. This meeting will provide you
with the opportunity to meet ATRAs
staff and Board of Directors, and let
them know what you want from your
Association. You owe it to yourself to
be a part of this meeting.
We need to hear your views about
our industry: How do you feel about
all of the mergers and acquisitions that
have been taking place? Are they good
for the industry, or do you see them as
a problem? How have they affected
you? What are your thoughts on the
ATRA Golden Rule Warranty program?
Should warranties be longer? How do
you feel about offering Golden Rule
Warranties on over-the-counter jobs or
ship-outs? If youve ever had some-
thing to say about these or other issues
facing our industry or our Association,
I urge you to bring your views with you
to the Members meeting; I look forward
to meeting you there.
If youre a shop owner, you cant
afford to miss the Whats Working
Management Track on Thursday. The
Whats Working session starts at 9 am
and ends at noon. Is the transmission
by Jim Rodd
President ATRA
repair industry dying? Think again:
Many shop owners are enjoying their
heyday. So what are they doing that
other shops are missing?
After lunch youll take what you
learned about Whats Working in
todays market and discover new ideas
about Making It Work. A lot of time and
effort went into creating this program
by the ATRA and GEARS staff: As a
shop owner, you owe it to yourself to
attend this program, designed espe-
cially for you.
No Expo could be complete with-
out the Trade Show. Doors open imme-
diately after the Raybestos Luncheon
on Friday. Then, on Friday evening,
be sure to attend the Transtar recep-
tion, where you can meet and talk with
the folks whove graced the pages of
GEARS over the last year. It promises
to be an exceptional event, and every-
one is invited to attend.
Las Vegas: Its a fabulous place to
be, and this promises to be an Expo like
no other. Its great to see you here.
October 2007
 Booth Numbers
618 & 620

964 East Market St., Crawfordsville, IN 47933 Toll Free: 800-729-7763 Fax: 765-364-4576 Email: raypt@raybestospowertrain.com
* Raybestos Powertrain warrants that each electrical component manufactured or supplied by Raybestos Powertrain will be free from defects in material or factory workmanship for five
years or 50,000 miles from the date of sale. Please refer to Raybestos Powertrains website (www.raybestospowertrain.com) and catalog for details and limitations.

raybestos907.indd 3 8/7/07 9:27:20 AM

 LET'S PLAY BALL

Educating Sp
e a ker

the AF33-5 by Lance Wiggins

A
s 2007 quickly approaches its end and 2008 is in
sight, it occurred to me that my 20th high school
reunion is coming up next year. 20 years since
completing my high school education a lot has changed
since 1988; for one thing, todays technicians arent the
only ones in the shop who need an education: the cars
need it, too! Youll see what I mean in a minute.
In this article, were going to look at a new transmis-
sion from GM: the AF33-5, or AW55-50SN as the folks
from Aisin Warner call it (Figure 1).
The AF33-5 is a fully-automatic, five-speed, elec-
tronically-controlled transaxle. Its used in the Chevrolet
Equinox, but mainly appears in the Saturn Ion sedan and
the Vue.
Before we get into the transmission
control system and the idea of educating
it, lets take a closer look at the TCM
operation. The TCM controls most trans-
mission functions:
1. It commands shift solenoids in the
transmission on and off to control
shift timing.
2. It controls shift feel through the line
pressure control solenoid valve.
3. And it controls torque converter
clutch operation.

The AF33-5 is a fully-automatic,

five-speed, electronically-
controlled transaxle. Its used in
the Chevrolet Equinox, but mainly
appears in the Saturn Ion sedan
and the Vue.
Figure 1: the AF33-5, or AW55-50SN as the folks from Aisin Warner call it.

 GEARS October 2007


Take a look at the inputs used by
the TCM (Figure 2):
The AF33-5 uses a line pressure
control system which can adapt system
line pressure to compensate for normal
wear of clutch plates, seals, springs,
etc. In effect, it learns the condition
of the transmission, and adapts to that
condition to provide the best possible
operation.
The AF33-5 transmission uses
the adapt function for garage shifts,
upshifts, and TCC application. The
TCM monitors the input shaft speed
sensor and the output shaft speed sensor
(Figure 3) to determine the shift dura-
tion, and adjusts the pressure control
solenoid to maintain the correct shift
feel.
Of course, repairs can alter the
condition of the transmission, so its
important to perform a Transmission
Adaptive Learn after any of the follow-
ing repairs:
Transmission Control
Module(TCM) replacement
 GEARS
Figure 2: the inputs used by the TCM.
TCM calibration change
Valve body replacement
Transaxle overhaul
Transaxle replacement
In effect, an adaptive learn proce-
dure lets you educate the transmission
computer, to make it aware of the new
conditions, and allow it to adjust its
operation to compensate for them.
Adaptive Learn
Procedure
To perform the adaptive learn pro-
cedure, follow these steps carefully:
1. Vehicle in park, key off.
2. Set the parking brake.
3. Turn the Key to the ACC position.
4. Release the shift lock and place the
transmission shift lever in neutral.
5. Turn the Key to the off position.
6. Remove the shift cable from the
transaxle range switch lever.
7. Verify the two arrows on the TCM
are aligned.
8. Reinstall the shift cable on the
transaxle range switch lever.
9. Turn Key to the on position, engine
off.
10. Use a scan tool to implement the
N-position adaptive learn.
If N-position adaptation is
okay, skip to step11.
If the TCM doesnt learn the
N-position adaptation, go back
to step 5.
If N-position adaptation sets a
DTC, clear DTC and go back
to step5.
If the TCM cant learn N-
position after three attempts,
replace the TCM.
11. Shift the transmission to park.
12. Turn the Key to the off position.
13. Wait 10seconds.
14. Turn the Key to the on position,
engine off.
15. Verify the shift lever indicator
aligns in all gear positions. If they
dont align, check for DTCs.
16. Road test the vehicle to confirm
gear shift positions.
October 2007

Output Sensor
Figure 3: the input shaft speed sensor and the output shaft speed sensor.
Important: Perform all steps of the
adaptive learn procedure. The
engine will flare during shifting
and/or harsh shifts will occur if not
done correctly. When performing
the up/down shifting during 2-3
and 3-4 upshifts, a small shift flare
may occur the first or second time,
depending on transaxle internal
tolerances.
17. Drive the vehicle to warm the
transaxle fluid to 65110C (150
230F). The adaptive learn proce-
dure wont work unless transaxle
fluid is the correct temperature.
18. Reset the transaxle adaptive
learn using a scan tool. Go to the
Transmission Special Functions,
then Trans Output Controls menu
and select Reset Transmission
Adapts.
19. Perform the following steps for the
garage shifts adaptive learn:
a. Apply the parking brake and
the foot brake.
b. Shift from neutral to reverse,
and keep in reverse for 3 sec-
onds.
c. Shift from reverse to neutral.
d. Repeat the above two steps
five times.
 GEARS
e. Shift from neutral to drive and
keep in drive for 3 seconds.
f. Shift from drive to neutral.
g. Repeat the above two steps
five times.
20. Perform the following steps for the
up/down shifting adaptive learn:
a. Drive the vehicle in drive with
light (15-20percent) throttle
until above 50km/h (31MPH)
in 4th gear.
b. If the vehicle isnt connected goes into the education of todays
to a scan tool and you cant
monitor throttle position, take
30seconds for reaching the
50km/h (31MPH).
c. Decelerate and apply the
brakes until vehicle comes to a
stop. Brake slowly, so it takes
at least 14 seconds to come to
a complete stop.
d. Repeat the above steps five
times.
21. Perform the following steps for 2-1
manual downshift adaptive learn:
a. Drive the vehicle in 1st until
over 25km/h (16MPH) in
2nd, with any throttle posi-
tion.
Input
Sensor
b. Decelerate, shift from 1st to
L manually and stop the vehi-
cle.
c. Repeat the above steps ten
times.
22. Confirm shift quality.
Important: If shift quality doesnt
improve, make sure the TCM has the
correct transmission calibration.
As you can see, theres a lot that
AF33-5 transmission control system,
and when its done, it doesnt even get
to wear a cap and gown, or get a gradu-
ation present. On the other hand, it will
perform better, right out of the box.
In the next issue of GEARS, were
going to learn about the internal com-
ponents and operation of the AF33-5
transmission because transmissions
arent the only things that can always
use a little more education!
October 2007
 THE NUTS AND BOLTS OF ELECTRICAL DIAGNOSIS

Introduction to Sp
e a ker

Reprogramming/
Reflashing, Par t II by Mike Van Dyke

Reprogramming GM, Ford,

DaimlerChrysler and Toyota Vehicles

I n part I of this series on repro-

gramming and reflashing vehicle
computers, we discussed the basic
equipment needed, mainly the J2534
Pass Thru interface, which you connect
to your PC and plug into the vehicles
OBD-II diagnostic connector. In this
issue well discuss in detail whats
required to reprogram GM, Ford,
DaimlerChrysler and Toyota vehicles.

Important! The reprogram-

ming process can take up to one hour
on some vehicles. If the vehicles
battery runs down during the process,
you could damage the module perma-
nently. To avoid this, always start with
a fully charged battery, and connect
a trickle charger to maintain the bat-
tery charge during the reprogramming
process.
GM
To reprogram or reconfigure mod-
ules on a GM vehicle, you must first
purchase the ACDelco SPS CD-ROMs.
These discs contain the TIS (Technical
Information System) software and all
current GM vehicle calibration files.
The CDs are available from Ease
Diagnostics dealer Bob Sorenson (507-
359-1197), and many of the J2534 Pass
Thru interface dealers.
First, install the TIS software from
the application CD. Next, install the
Data CD to update the TIS software and
access calibration data.
The SPS CDs come with a USB
Figure 1
key, which youll need to plug into a
USB port on your computer and con-
figure it in the TIS software before
you can perform any reprogramming
service.
When you run the TIS software,
youll need to select which program-
ming interface you want to use. Were
selecting the Ease Diagnostics interface
(figure 1).
In the next box below, select
Reprogram ECU to update the mod-
ule thats currently running in the vehi-
cle, or select Replace and Reprogram
ECU if youre programming a new
module youve just installed in the
vehicle.
In the bottom box, select the ECU
location, which is typically on the
Vehicle. Off Board Programming for the current vehicle.
is used to program modules outside
the vehicle. It requires special adapter
cables, and is typically used by dealers
and parts suppliers who sell modules
over the counter.
After youve entered the VIN infor-
mation for the vehicle youre working
on, youll see a list of the on-board
controllers (figure 2). Select which con-
troller you want to program.
Look for the Select Programming
Type box right below the module
selection box. For updating the pro-
gramming or calibration of an existing
module on the vehicle, select Normal.
The Reconfigure selection is used
when installing a used module from
another vehicle that needs to be config-
ured for the engine size, options, etc.,

10 GEARS October 2007

 Part Number 5574
Part Number 5574

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Reprogramming GM, Ford, DaimlerChrysler and Toyota Vehicles
The VCI option is used for one-
time calibrations to fix problem vehi-
cles with a unique malfunction. You
probably wont use VCI unless youre
working directly with the dealer or fac-
tory on a problem for which theres no
calibration update available.
Next, select the system calibra-
tion you want to install (figure 3). The
calibration file numbers are displayed
in this window; the one on the bot-
tom is the most current. The problems
addressed by the calibration update
are also displayed in the bottom box.
Select the calibration, click Next,
and follow the prompts to complete the
programming process.
The TIS software will also allow
you to perform other configuration
Figure 2
functions, such as speedometer calibra-
tion for the axle ratios and tire sizes
that were available for that vehicle.

Ford
To reprogram a Ford vehicle, you
must first have a current reprogramming
subscription to the www.motorcraftser-
vice.com web site. To purchase a sub-
scription, click the Reprogramming
& Initialization link on the left side.
Scroll to the bottom of the page and
click the Purchase button. There are
daily, monthly and yearly subscrip-
tions, so you can buy time as needed.
Once youve activated your sub-
scription, log in, then download and
install the Ford Module Programming
software.
When you run the Ford Module Figure 3
Programming software, you must have
your computer connected to the inter-
net. Simply enter the vehicle infor-
mation, follow the prompts, and the
software will access and install the
calibration directly from Ford online.
Figure 4 shows the calibration
information for a 1999 Ford Taurus.
This vehicle had no engine braking
at highway speed when going down-
hill. This complaint was fixed with
a calibration update, which fixed a
software control problem with the Idle
Air Control motor: a prime example of
what might have been mistaken for an
internal transaxle problem being fixed
by a simple calibration update.

Figure 4

12 GEARS October 2007

 The Choice is Simple.
Genuine ZF.

ZF 6-speed (6HP)
automatic parts,
kits and fluid
now available!

800.451.2595
www.zf.com/na

A quality product, a seamless installation, and a satisfied customer the results of a genuine
remanufacturing process and the reasons why ZF makes the choice simple when it comes to
choosing a product that will exceed your customers expectations.

Mile-for-mile, Genuine ZF remanufactured automatic and manual transmissions last longer,

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Driveline and Chassis Technology

ZF-707.indd 43 6/6/07 2:48:19 PM

Reprogramming GM, Ford, DaimlerChrysler and Toyota Vehicles

Daimler/Chrysler
is similar to Ford,
in that you must
subscribe to the
web site to access
calibration files.
The Ford Module Programming
software also enables you to perform
speedometer calibrations for tire size
and axle ratio changes, as well as
antitheft key programming and other
configuration functions (figure 5).

Daimler/Chrysler Figure 5
Daimler/Chrysler is similar to
Ford, in that you must subscribe to
the web site to access calibration files.
First, go to the www.techauthority.com
web site and purchase a subscription
(daily, monthly or yearly). When you
log onto the web site, click the Flash
link at the top of the page. Then down-
load and install the DCX2534 soft-
ware.
On the Flash page, you can enter
the VIN, or vehicle year, model and
engine size to access a list of available
calibrations (figure 6). Next, select
the calibration you wish to install and
click Download. The calibration will
automatically be downloaded to your
computer for the DCX2534 software
to use.
When you run the DCX2534 soft- Figure 6
ware, itll display the downloaded cali-
bration file and ask you to verify and
proceed with programming the vehicle
module (figure 7). Click Yes to pro-
ceed, and follow the instructions on the
screen to complete the programming
process.

Toyota
To reprogram Toyota, Lexus, or
Scion vehicles, you must order the fac-
tory calibration CD-ROM from Toyota.
Call the Toyota Material Distribution
Center at (800) 622-2033; order part
number 00456-REPRG-001. This disc
contains the Toyota reprogramming
software, VIN update software, vehicle
calibration files, and all calibration-
related TSBs.
Figure 7

14 GEARS October 2007

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New TransTec ad 9326.indd 1 8/16/07 8:47:24 AM

Reprogramming GM, Ford, DaimlerChrysler and Toyota Vehicles

When you
reprogram a
Toyota, itll
typically erase
the VIN coding
from the module,
which will set
DTC P0630
(figure 8).
Figure 8

First, load the disc into your com-
puter and install the Calibration Update
Wizard application software. Then
install the VIN Update Wizard applica-
tion software.
Run the calibration update wizard,
then select the updated calibration you
wish to install from the TSB listings.
When you reprogram a Toyota, itll
typically erase the VIN coding from available on their respective web sites,
the module, which will set DTC P0630 typically under a link called J2534
(figure 8). To recode the VIN into the Reprogramming Information or
module, run the VIN Update Wizard Reprogramming and Initialization.
application, type in the VIN, and
follow the instructions in the applica-
tion window (figure 9).
Reprogramming information and
software for other manufacturers is

Figure 9

16 GEARS October 2007

 In part I, we inadvertently left out a table of the OEM
service information web sites; weve included that
in Table A of this issue. Each of the OEM sites has
information on reprogramming, as well as factory
TSBs and service information.

Table A

GEARS October 2007 17

This article was reprinted with the express permission and consent of Swissmotor.
No part of this article was altered or changed in any way. For the complete test results
and findings, visit www.lebert-alterung.ch
How did Lubegard come about?

The History of
Lubegard
rb // The concept of additives or supplements in motor oils, lubricants,
and fuels often evokes a slightly negative image in the mind of the consu-
mer first, because the user is not an expert in petrochemicals nor a spe-
cialist in combustion, and has little comprehension of that fields infinitely
complex materials, and second, because advertising would have us believe
that nothing works nowadays without the right additives.

As a rule, additives provide a basic Magic formula: the LXE

product with features that the pro-
duct lacks for its basic functionality.
As a consequence it used to be that
you were not allowed to mix diffe-
rent types of oil (this still applies
today to certain components), be-
cause the brand-specific additives
would interfere with one another,
either canceling their effect, or in the
worst case scenario even reversing
it. Older readers may still remember
what used to happen to an engine
that was accustomed only to single
viscosity oil when multiviscosity
oil was suddenly used for topping
up or an oil change. All too often,
catastrophic engine damage was
the result.
Dr. Phillip Landis was involved in the development of Lubegard
and Mobil 1.
molecule
Dr. Phillip S. Landis, who developed
the Liquid Wax Ester (LXE) Tech-
nology was also intimately invol-
ved in the development of Mobil 1.
LXE Technology optimizes existing
brand name products with all of the
additives that they already conta-
in: it raises the resistance to both
pressure and heat and achieves
significantly better heat dissipati-
on. Admittedly, magic formulas
have existed since the beginning of
the age of machine technology and
some have even enjoyed some re-
markable success...at least in the
beginning. The drawbacks came to
light only later, with many products
silently disappearing from the mar-
ket. As of today, thirty years after it
Lubegard is produced in
reactors like these
first entered the market, no flaw has
been found in Lubegard. Certain top
vehicle manufacturers even prescri-
be Lubegard in their repair manuals,
and most of the other manufactur-
ers have long given their approval.
The wide-spread problems with
automatic transmissions
Lubegard first made history in the
US, the birthplace of automatic
transmissions for passenger cars,
when sperm whale derivatives were
no longer available for use in lubri-
cants and hydraulic oils for the en-
gine industry due to the Convention
on Endangered Species of 1972.
Sperm oil had lent the petroleum-
based oils the qualities they lacked
in terms of resistance to both pres-
sure and heat. This was not known,
of course, to the general public.
Transmission failures went from less
than one million prior to 1972 to over
eight million by 1975. The cause:
overheating. 9 out of 10 transmis-
sions fail due to heat! Like others,
Philip Landis therefore directed his
efforts at fundamentally optimizing
hydraulic oil for automatic transmis-
sions by developing a new compo-

18 reprinted with permission from GEARS October 2007

 This article was reprinted with
nent. The heat resistance and heat for extracting and esterizing the the express permission and
conductivity of hydraulic oil first had desired LXE molecule from the car- consent of Swissmotor.
to be improved radically. Landis had bon chain of simple rapeseed oil is
already created a motor oil additive much more complicated; but meets
from plant extracts called Lubegard the same quality standard. Moreo- Editorial
which exhibited the aforementioned ver, it is biodegradable, which is an
qualities; all that was needed was to extremely important criterion today. Dear Readers,
adapt his product to hydraulic oils 
sufficiently to enable a marriage. This special edition of Swiss-
It took another five years, however, motor reports on a petroche-
Liquid Wax Ester
before Landis genius developed, ex- mical product with a unique
haustively tested, and patented such Botanical, polar, high-tech mono- mode of action: Lubegard.
an additive so that he could bring it ester LXE wax Known up to now only in the
onto the market successfully. United States, this unique
Temperature-resistant up to 300
supplement has also begun to
C (572 F) (currently the most heat
Rapeseed instead of jojoba oil conquer the European market.
resistant lubricating ester on the
Landis, an experienced petrochemi- market) And it is coming at just the
cal specialist, focused his research Increases the heat stability and right time. Apart from econo-
exclusively on oils and waxes of bo- oxidation stability of every lubri- mical diesel engines, the
cant motor vehicle industry has
The composition of the liquid ester wax LXE
Lowers the elevated lubricant almost nothing to counteract
(non-binding example)
temperature (protecting it from skyrocketing gas prices.
overheating) Beware of several various
Hydrogen
Carbon-
based
alcohol

Up to 50% less component wear alternative fuel substitutes:

Carbonic acid

Up to 30% less oxidation the consequential costs could

Long ester chain
20-22 carbonic acid atoms
Temperature-stable to 300
C (572 F)
Dual bond
Up to 60% less pentane insolubles
be far greater than the suppo-
Oxidation stability
Oxygen (polarized)

20 carbon alcohol atoms Lubricating ability in combination Composite bond

with oil
(sludge)
sed savings. In its diverse
areas of use, in our opinion,
Conclusion Lubegard appears to be the
tanical or biological origin, because In all areas of application, Lube- only way to save not only
the spermaceti derivative formerly gard is not a lubricant substitute. substantial amounts of fuel
mixed with lubricants had yielded In order to make use of its sen- and oil, but also to extend the
the desired result. Landis found an sational properties, Lubegard al- life of all mechanical compo-
ideal substitute in jojoba oil. Unfor- ways needs a base oil. Lubegard nents significantly. Lubegard
tunately, it turned out that jojoba oil does not repair any mechanical is not an additive in the
(which is actually not oil at all, but damage, but it can successfully conventional sense of the
liquid wax) was in extremely short prevent it. word. It merely optimizes the
supply, because the jojoba plant
existing lubricants. But it does
was difficult to cultivate in artificial Sole agency for Europe
so with truly sensational
settings. It preferred the habitat of Importers for the whole range of
the Sonora desert of Mexico, Arizo- Lubegard products:
results, as scientific tests have
na and California over all industrial Roten Trading AG confirmed. Moreover, Swiss-
farming methods. Moreover, the Keltenstrasse 13 motor has never endorsed a
cosmetic industry had already long CH-2563 Ipsach, Switzerland product that has not first been
displayed an almost overwhelming Telefone: +41 (0)32 355 38 24 tested for years both in-house
interest in jojoba oil. Jojoba oil pos- Fax: +41 (0)32 355 38 25 and in the field. You can put
sesses the rather unique property of E-Mail: info@rotentrading.ch your complete faith in the
neither easily oxidizing nor forming Website: www.lubegard.ch reports and descriptions that
sludge or varnish. But by then Lan- follow, because our name
dis had found a synthetic basis for In Switzerland, Lubegard is sold stands behind them.
Lubegard that was plentiful, and at retail by Derendinger AG and
neither endangered nor burdened Technomag AG.
Warmest regards,
by any sort of ethnic (or other) legal For a location near you contact
restrictions. The reaction process www.Lubegard.com.
Ruedi Baumann
Editor-in-Chief, Swissmotor

GEARS October 2007 19

Significantly reduces fuel consumption and more!!

Lubegard Bio/Tech
Engine Oil Protectant 30902
idling hum. We then had everyo-
BIO/TECH ENGINE OIL ne who had objected to the noise
PROTECTANT 30902 earlier test drive the vehicle again.
Have you installed additional noi-
se reduction mats under the hood
Swissmotor has been testing a wide range of products intensively since the last time? everybody
for many years. Products, of course, that have to do with cars, en- wanted to know. Since we were
gines and machines. These tests are only published after indis- having Siberia-like temperatures
putable results have been obtained, and are guaranteed never to at the time, we were pleasantly
be PR reports. After we stumbled across the Lubegard transmis- surprised by another feature: now
sion fluid additive at Automaten-Meyer, we discovered and tested the engine started right away even
other products from the same manufacturer first the motor oil after having been turned off for
additive Lubegard Bio/Tech Engine Oil Protectant, then other ad- long periods of time, which hadnt
ditives. always been the case before. We
immediately persuaded other die-
We first used the Bio/Tech Engi- to the motto: even if its of no use, sel owners to add Lubegard. The
ne Oil Protectant product, which it certainly cant hurt either. Becau- result was the same in every case.
is also based on the unique LXE se the oil level had to be checked And as a bonus, fuel consumpti-
technology, in diesel engines, so- again very precisely, we let the en- on was down significantly.
mewhat by chance. This was in gine idle for a while.
test vehicles, in which all co-tes-
Problems with the emergency
ters objected to the obtrusive en-
Diesels no longer diesel power system
gine noise. Not when starting cold,
because all diesel engines make an It took a couple of minutes until Because Lubegard engine protec-
audible knocking sound then, but everyone standing around noticed tant is described as having a wide
at driving speeds of about 80 kph that the engine suddenly was run- array of problem solutions at its
(50 mph) and up. As with the auto- ning perceptibly more quietly. The disposal, the author took on the
matic transmission, we mixed Lu- earlier annoying diesel knocking
begard into the motor oil according had been replaced by a powerful,

Bio/Tech
Engine Oil
Protectant not
only reduces wear
by up to 70 %, fuel consumption
also drops correspondingly.
Thanks to Lubegard, there is
no longer a risk of insufficient
lubrication in cold starts.

20 reprinted with permission from GEARS October 2007

next problem child, a gasoline-pow-
ered emergency power system. The
unit, which has to work for hours at
just slightly greater than idle speed,
tended toward disproportionab-
ly high plug fouling. Periodic visits
to the shop after a ridiculously low
number of operating hours were the
rule. Only after a vigorous cleaning
with compressed air and new spark
plugs was the engine ready to start
again. But lubricating oil consumpti-
on soon increased dramatically due
to carbon deposits on the piston
rings, causing the fouling to cripple
the engine at even shorter intervals.
Two tablespoons of Lubegard ad-
ded to the oil were able to prevent
the troublesome soot buildup only
partially; but the engine now ran
about an hour and a half longer per
tankfull! We had precisely the same
experience with a second engine of
almost identical construction. This
was clearly attributable to one of
Lubegards main features: the sen-
sational reduction of friction losses.
(A more permeable air filter then
also ended the fouling of the spark
plugs).
Not a cure-all after all?
The same sort of power increase
or an equally striking decline in fuel
production could not be expected in
cars, however, where different fac-
tors determine fuel consumption. It
is not by chance that top name oil
manufacturers conduct represen-
tative fuel consumption and dura-
bility tests predominantly with big
city transport systems, because the
different driving styles of the indivi-
dual drivers do not play a decisive
role there. In the emergency power
units the engine speed was always
the same, and because of the rec-
tifier the power demand was also
always about the same. Thus identi-
cal results were likewise obtained in
the knocking test with the second
emergency power unit. It is relatively
easy to explain why Lubegard could
not stop the carbon deposits in the
engine: soot buildup in the com-
bustion chamber is a by-product of
the constant low operating speed.
GEARS October 2007 21
Old-timers present real challenges for their owners. They simply cannot handle new multivis-
cosity oils. Strange as it may sound, Lubegard fulfills the same purpose here as it does with
highly tuned engines, because the supplement significantly optimizes the existing base oil.
Moreover, the engine does not have quently avoiding the gradual over-
to deliver any significant amount of acidification and oxidation of the
power during the entire operating motor oil.
period, which leads to unclean com-
bustion.
Getting to the essence of gasoli-
ne waste
A must for turbocharged engi-
For the car test, Swissmotor inten-
nes
tionally and specifically selected
Turbo diesel engines that are insu- well-known gas guzzlers. Purely
lated from structure-borne noise hypothetically, this is where one
and therefore completely packed could expect the largest measu-
in are particularly susceptible to rable difference. However, a con-
mechanical damage. The lack of sistent driving style through the
cooling air leads to serious pro- various driving cycles would be
blems here. The oil gets too hot required in order to determine the
very quickly in the turbocharger and measurable differences before and
subsequently ruins the healthy oil after Lubegard in the shortest time
in the engine. The better an engine possible. The results obtained were
is encased, the greater the heat blo- consistently positive, although the
ckage, especially in the vicinity of reports from the non-professional
the turbocharger. Most affected are drivers about the amount of gas
chip-tuned turbo engines. Oil that
has become too hot behaves just
like butter in a frying pan: when the
butter gets too hot it first assumes
the familiar brown color, and as the
heat increases it carbonizes. Butter
that has turned brown stays brown
even when cooled, and as a result
is unusable. The same thing hap-
pens with motor oil. Lubegard En-
gine Protection lends a significantly With Lubegard in the motor oil, this
higher level of heat resistance to the generator runs about an hour and a
base oil, thus preventing burning half longer per tankfull (when used
in the turbocharger and conse- as an emergency power unit).
they saved were too vague. In the
car used by our staff, however, we
were able to keep precise track of
driving behavior and style and the
kilometers driven by means of the
calibrated trip recorder.
Wow!
After 2000 kilometers (1243 miles) we
couldnt deny it any longer: before,
we could never manage to get the
fuel consumption of the 3.2 liter en-
gine below fifteen liters (four gallons)
per 100 km (62 miles) (fifteen liters
was already an economy record).
With Lubegard in the motor oil and
with the same driving style, the engi-
ne got by with only thirteen liters. A
look into the engine with the help of
a rod light revealed bright clean cy-
linder walls, where before there had
been a hard, blackish-brown resi-
nous coating. A slightly light-brown,
but still minimal coating on the pis-
ton floor, the valves and the spark
plugs testified to optimal combusti-
on. In addition, all of the mechanics
praised the extremely quiet running
of the six-cylinder in-line engine.
Nails with heads
Due to the fact that our staff car
with its full-time all-wheel drive had
other gas guzzling impediments in
the power train, it received a radi-
cal treatment: in brief, all its oil was
removed, replaced, and the pre-
scribed amount of Lubegard was
added. Automatic Transmission
Fluid Protectant was used for the
automatic transmission and transfer
case, and Gear Fluid Supplement
for the differential. We even inclu-
ded the power steering protectant
and the radiator treatment (parti-
cularly since the Lubegard product
22 reprinted with permission from
Highly tuned engines are particularly susceptible. Here Lubegard has a significant
effect on the life of the engine. Experienced car tuners have long known about the
effect of the sensational LXE molecule.
named KOOL-IT Supreme Coolant
Treatment promised significantly
better heat transfer.)
The proof
We had already done as much as
we could short of mechanical in-
terventions to reduce mechanical
friction loss by significant factors.
The results obtained through this
radical treatment were truly incre-
dible: now the gas consumption
for 100 kilometers (62 miles) was a
laughable 10.1 liters (2.67 gallons)!
Of course, the super economy dri-
ving style utilized in such tests was
absolutely no fun, and may have an-
noyed other drivers on the road, but
it was definitely worth the effort. A
surprising side effect truly amazed
all Lubegard users (most noticeable
with all-wheel drive): the braking re-
sponse of the entire drive train when
taking the foot off the gas pedal was
significantly lower. So it is necessa-
ry to step on the brake more often.
There could hardly be better proof
of reduced friction loss...
Boat motors rarely overhe-
at because the efficacy of
water cooling is guaranteed;
but oil still gets too hot in the
turbocharger. And certainly
nobody has any objections to
saving fuel.
An ideal solution
If one considers how many milli-
ons are invested in development
projects by vehicle manufacturers
to increase engine power and at
the same reduce fuel consump-
tion, and then compares that
amount to the ridiculous costs of
adding Lubegard, one can only
shake ones head in disbelief. Es-
pecially since Lubegard also sig-
nificantly prolongs the operating
life of any mechanism. 
Heres what Lubegard BIO/TECH
ENGINE OIL PROTECTANT does:
Reduces friction loss in the motor
by up to 29% (saving fuel)
Provides outstanding cold start
properties through polar behavior
Improves oxidation stability (the
main factor in oil aging)
Lowers oil consumption (especially
with long-life oils)
Reduces wear by up to 70%
Lowers the oil temperature
Improves oils compressive
strength
Excellent for supercharged or
high-performance engines (tuning)
Audibly and significantly reduces
the noises that arise through inner
friction
Application Instructions:
Add one bottle per car engine
(diesel or gasoline) with every oil
change.
GEARS October 2007
 Intertek Caleb Brett (Switzerland) AG, 8952 Schlieren
Test Report No. 160275/06
The temperature problems that oc-
cur in todays modern, small volume,
maximally supercharged turbo engi-
nes and power plants (due to engine
compartment encapsulation) may
exceed the 250 degree Celsius (482
F) mark. Permissible oil temperatures
are greatly exceeded, primarily at the
bearing points of a turbo superchar-
ger that require lubrication. But eve-
ry normal oil molecule breaks down
(cracks) into its component parts at
temperatures greater than 250 C
(482 F). The resulting residue may
cause engine damage or total des-
truction of the components.
The current trend towards thriftier
and at the same time higher perfor-
mance engines inevitably leads to
temperature-related problems, even
with so-called high-performance
oils. In a test of Lubegard Bio/Tech
Engine Oil Protectant 30902 con-
ducted by the testing institute In-
tertek Caleb Brett (Switzerland) AG,
artificial aging processes were cre-
ated in order to come as close as
possible to real conditions, given
these prerequisites, and to obtain
conclusive results. In order to simu-
late the oils long-term behavior and
aging process within the brief testing
time available, oxygen and nitrogen
(air) were carefully added to the test
substance. The amount of residue
from this process shows how long
that is to say, to what temperature
the oil can endure without marked
Brand name oil (left) after the tests and
the same oil (right), this time however
with Lubegard Bio/Tech Engine Oil Pro-
tectant 30902.
Photo: Intertek Caleb Brett (Switzerland) AG
GEARS October 2007 23
The test results speak for
themselves. The red line
shows the aging process of
a brand name oil. The blue
line shows the oil mixed with
Lubegard 1/10. The graph
depicts the amount of aging
residue insoluble in hexane at
290 C (554 F).
decomposition. The greater the resi-
due buildup, the lower the tempera-
ture stability.
Physical and chemical back-
ground
The hot tube test (HTT) accelerates
the aging of the test substance
through:
the increased temperature
the lesser coating thickness of the
substance in the glass tube
direct contact with the air.
Aging process
The aging process occurs in different
stages that cannot be isolated from
one another:
Thermal aging
Through thermally-induced decom-
position of the oil sample (that is to
say, through the application of heat)
(e.g., cracking of the oil molecules),
an unstoppable and in this case in-
tentional destruction of the chemical
structure takes place.
Oxidative aging
Through the influence of the oxy-
gen (about 20% by volume) present
in the pressurized air, the chemical
bonds in the oil sample are oxidized.
This process is dependent in part on
the measured temperature (the hot-
ter, the faster).
Catalytic effects
One may assume that the aging
products that arise through this
process exert an influence on the
(total) aging of the freshly introdu-
ced oil sample.
Total aging
Total aging is the sum of all the aging
factors. These are influenced in turn
by the measured parameters and
technical equipment conditions.
Evaluation of the aging
The following points may be used
as criteria for the aging :
Visual evaluation of the glass tube
(index based on the color scale)
Quantitative measurement of the
aging products (stated in mg)
Temperature and/or time elapsed
before the aging tube becomes
blocked (block point)
Chemical and physical examinati-
on of the aged test substance (for
example, tribological properties)
Measurements were performed
with the following parameters:
Maximum of 92 hours of testing
time or until the block point of the
aging tube
0.2 ml/hr (3.33 l/min) of oil
10 ml/min of air
Gravimetric determination after
cleansing with hexane
Gravimetric determination after
cleansing with toluene and ace-
tone
The fresh oil (brand name oil)
became blocked after about 80 to
90 hours; in other words, so many
aging products were produced that
the glass tube became complete-
ly filled and no longer permeable
(block point).
Read the complete test report at
www.lebert-alterung.ch
In German only
Lubegard Automatic Transmission Fluid Protectant 60902/63010

A transmission fluid supplement

that performs miracles
AUTOMATIC TRANSMISSION FLUID
PROTECTANT 60902

rb // The service life of an automatic transmission is limited, regar-

dless of whether it is in a car, a truck, or a construction machine.
In manual transmissions the clutch wears out sooner or later, be-
cause this device has the task of gradually converting the engines
power into propulsion, just like an automatic transmission. Auto-
matic transmissions also have clutches, sometimes even many of
them. Although they run in oil, wear nevertheless occurs. Drivers
can influence and reduce wear with their driving style, but the ab-
solute mortal enemy of automatic transmissions is the oil tempe-
rature. When it gets too high, which happens very quickly, and not
only when pulling a trailer, the automatic transmission quickly gi-
ves up the ghost. Then it costs you a small fortune.

Lubegard Automatic Transmissi-
on Fluid Protectant mixed with the
transmission fluid prescribed by the
manufacturer decisively increases
the heat resistance of the base oil,
among other things, and at the same
time provides better heat dissipati-
on, thus preventing the plastic parts
in the transmission from melting.
At the same time, Lubegard makes
the valves, pistons and slide valves
run more smoothly, which the driver
comes to notice after a few kilome-
ters of more precise, incisive and
faster gear shifting. Interestingly en-
ough, the individual gear shifts be-
come gentler.
Transmission fluid changes,
coolers and Lubegard
Automaten-Meyer in Littau LU,
Switzerlands number 1 automatic
transmission specialist, unhesita-
tingly recommends two things for
long automatic transmission life:
first, a complete fluid change eve-
ry 50,000 kilometers (31,068 miles),
and second, the installation of a
separate fluid cooler. The second
point applies primarily to vehicles
with trailers (including campers!).
Also adding Lubegard to the auto-
matic transmission fluid practical-
ly guarantees that there will be no
overheating nor resulting damage.
Photo: Ruedi Baumann
During a fluid change performed by
a top professional (which is highly
recommended), the professional will
immediately recognize any signs of
wear and can offer a precise pro-
gnosis on the condition of the trans-
mission. Consequently, your local
professional transmission repair
facility is also the best choice for a
simple fluid change, all the more so
because they have all of the special
apparatus for changing the entire
fluid content, even in torque con-
verter transmissions without bleed
screws (most cars today).

The founder of Automaten-Meyer, Werner Meyer, adds CEO Adrian Marty tests an overhauled automatic transmis-
Lubegard to the automatic transmission fluid. sion on the test bench.

24 reprinted with permission from GEARS October 2007


An automatic transmission with heat
damage and melted plastic parts.
Lubegard (red) is designed for use with
Dexron III automatic transmission fluid.
Lubegard instead of repairs
Swissmotor stumbled across
Lubegard a few years ago, quite
by chance. At the time, the author
was driving an automatic Mercedes,
which sometimes literally lost the
corresponding gears when starting
up from a stop into gears D and
R. The kickdown was also no lon-
ger working right, most of the time
there was only a rumbling in the
transmission. At first, Automaten-
Meyer found no wear particles in
excess of allowable levels in the
transmission fluid, and they claimed
this was due to pressure valves,
pistons, or valves that were stuck
due to low tolerances and gum-
ming. Result: a partial overhaul or
at least a replacement of the con-
trol unit. Here Adrian Marty, CEO of
Automaten-Meyer, suddenly had an
idea: instead of replacing the control
unit, only fresh fluid was added and
supplemented with the appropri-
ate amount of Lubegard Automatic
Transmission Fluid Protectant. Mar-
ty and the firms founder, Werner
Meyer, were rather skeptical, since
the US-produced miracle cure Lu-
begard was still quite new to them.
Both of them knew only the specifi-
cations, but they knew them in gre-
at detail. If its of no use, at least it
wont cause any damage, both of
GEARS October 2007 25
them thought. We can always still
install a new control unit if the ex-
periment goes awry. That would of
course cost the price of a bottle of
Lubegard many times over.
Even the expert was amazed
The miracle occurred: after just a few
miles the gear shifting underwent a
highly perceptible change, the kick-
down kicked in powerfully, and the
transmission no longer lost indivi-
dual gears from then on, about ano-
ther 150,000 kilometers (93,206 mi-
les). For 2 years we conducted very
thorough field tests with Lube-
gard, had numerous mechanics add
it to transmissions, some of which
could hardly be shifted any more,
or to automatic transmissions that
vibrated and shook intolerably. The
same surprising result everywhere:
as long as there was no purely me-
chanical damage, broken converter
blades, melted plastic parts due
to overheating, or pipes or pistons
clogged as a result, and so forth, all
automatic transmissions suddenly
functioned perfectly again!
A super investment
Automaten-Meyer, as well as me-
chanics less burdened with expert
knowledge, have since sworn by
Lubegard. The experience, know-
ledge, and results were continuo-
usly discussed and compared. Here
we certainly must mention that
many top auto names expressly
recommend Lubegard, and written
approval has been issued by mul-
tiple leading car manufacturers on
its use. If we compare the price of
a fluid change and adding Lube-
gard to an overhaul of the automa-
tic transmission, we come to a price
difference ranging between 4500
and 6000 Swiss Francs ($3,600 and
$4,800 USD), depending on the type
of transmission.
Unwanted sales branch
There are four different types of Lube
gard automatic transmission fluid
products available. The fourth type,
Lubegard Platinum Universal Auto-
matic Transmission Fluid Protectant
eliminates all automatic transmissi-
on fluid confusion and the need for
the other three Lubegard automatic
transmission fluid products. Until
now, Automaten-Meyer had to get
all Lubegard products directly from
the US, and since the stunning suc-
cesses (including according to our
publications) found itself having to
ship Lubegard products halfway
around the world. Of course, only
after a detailed telephone consul-
tation, which did not necessarily
match the companys original intent
in Littau. 
Heres what Lubegard Automatic
Transmission Fluid Protectant
does:
Provides smoother gear shifting
Improves gear shifting perfor-
mance
Reduces the fluid temperature in
the automatic transmission
Extends the life of the fluid
Loosens gummed valves
Suppresses clutch and torque
converter vibrations
Optimizes oxidation stability (the
main cause of fluid aging)
Indispensable for vehicles that pull
trailers
Approved and recommended by
manufacturers, and successfully
employed for over 20 years.
Application Instructions: 
Add 1 ounce (29.6mL) per quart
(Liter) of ATF fluid being replaced
with motor idling in park.
Important tip: If your not sure
what type of fluid a transmissi-
on takes contact your supplier
to obtain your copy of the FREE
Lubegard ATF Conversion & Refill
Chart.
This article was reprinted with
the express permission and
consent of Swissmotor.
Coolant additive with added benefits
Lubegard KOOL-IT
www.swissmotor.com
ACKNOWLEDGEMENTS KOOL-IT Supreme Radiator
Specialty Magazine for Consumers

Federation of Swiss Military Transport Associations

Treatment 96001
Eleventh year rb // Our experiences up to now, as well as those of others, have shown us
EditorinChief that all Lubegard products are full of pleasant surprises. Another additive,
Ruedi Baumann (member of the European KOOL-IT, has been known much longer in this country than oil or fluid addi-
Military Press Association)
tives. It is designed for use with coolants.
Editorial Offices
Swissmotor (Swissmotor-Online)
Ruedi Baumann The coolant does not necessarily The mode of operation and the
Florastrasse 10 / Bahnhof need to be replaced or exchanged composition of KOOL-IT are very
CH-8134 Adliswil for a new fill-up to add KOOL-IT. complex. Here is the technical de-
Telephone: +41 (0) 44 710 45 46
Cell: +41 (0) 79 700 45 46 Suctioning the approximate amount scription for those who would like
E-mail: swissmotor@bluewin.ch of the bottle contents of the addi- more details:
Editorial staff tive from the expansion container
Christian Matthys (Zurich Country Police), and replacing it with the supple-
Markus Hofmann (Shell Oil Switzerland), Manuel KOOL-IT Supreme Coolant
ment fulfills the goal. The mix lasts
Gemperle (Author), Heinz Suchy (Technical Treatment
support) a certain length of time, but the user
VSMMV (Verband Schweizerischer
will notice a markedly shorter warm Problems in a cars cooling system
Militr-Motorfahrer-Vereine) up period for the engine as early as circuit and the mode of operation
(Association of the Swiss military drivers) the next day, especially in the colder of KOOL-IT (KOOL-IT Supreme
First lieutenant Camille Meier
Emil Klti-Strasse 6
months. Clearly, the heater and the Radiator Treatment 96001)
CH-8406 Winterthur defroster will also deliver warm air
Swiss Army General Staff / Logistics
faster than before as a result.
directorate, movement and transportation
division Interestingly enough, the cooling
Lieutenant colonel Markus Oeggerli
system is also less likely to overhe-
Competence center for army driving at. This can be readily heard in the
education (CCADE)
Staff warrant officer Martin Plattner
radiator fans, which do not come on
as soon. This also results in consi-
Swissmotor Editorial Offices Germany
Holger Werner Volk derable fuel savings, because the
Stettinerstrasse 3 fans, regardless of whether they
D-71254 Ditzingen are electric or viscous-coupled fans
Telephone. 0049 715 617 0670
E-mail: Swissmotor@gmx.de powered by the fan belt, are ener-
gy guzzlers. KOOL-IT thus not only
Swissmotor Webmaster
Marianne Braun provides significantly better heat
E-mail: swissmotor@utanet.at transfer in the cooling system, but
Publisher also provides tangible fuel savings
BILDPRESS ZUERICH BPZ (like all other Lubegard products).
Florastrasse 10 / PO Box
CH-8134 Adliswil
Telephone: +41 (0) 44 710 45 46 The Lubegard research and deve-
E-mail: bildpress@bluewin.ch lopment team gave the additive one
Publication and Printing more additional feature: KOOL-IT
Vogt-Schild Druck AG contains a pH indicator. For use
Gutenbergstrasse 1, 4552 Derendingen only in straight water applications
Reprint only with the written consent of the this allows easy visual determina-
publisher. The contributions made by the tion of straight water coolant pH
authors only express the opinions of those
authors. The procurement of the original copies conditions. Coolant within a safe
of the photos printed here is normally not range is pink, but changes to clear
possible. No liability on the part of the publisher if the coolant pH falls dangerously
and the editorial staff for unsolicited material
sent to their offices. low, indicating another pint should
be added.
swissmotor webpage: www.swissmotor.com

26 reprinted with permission from GEARS October 2007

 Enemy number 1: cavitation
The coolant briefly exceeds boi-
ling temperatures on the very hot
outsides of the cylinder liners. The
resulting air bubbles are then implo-
ded by the vibrations of the cylin-
der liners. This process tears very
small metal parts from the surfaces.
This continuous process, building
up small deposit cavities, is called
cavitation erosion. The now unpro-
tected areas are exposed to increa-
sing corrosion.
Enemy number 2: electrolysis
Erosion of the metal surfaces takes
place due to the additional electroly-
sis that occurs through water pump
recirculation of the coolant (friction).
This same electrolysis generates
galvanic currents in the cooling sy-
stem, which, among other things,
causes gradual destruction of the
nonferrous metal parts.
Enemy number 3: overheating
The air bubbles contained in the
foam reduce the cooling surface
and contact surface of the radiator
by the area of their surface. This not
only slows down heat transfer, but
also significantly reduces the heat
exchange between the engine, coo-
lant, and radiator.
Enemy number 4: crystallization
Glycolic acid is generated by high
operating temperatures, and it par-
tially crystallizes and forms proble-
matic deposits.
Substances and their mode of
action
A variety of substances, some of
them very expensive, are added to
KOOL-IT Supreme Coolant Treat-
ment in order to prevent or even
eliminate these destructive pro-
cesses.
Lubegard, Kool-It, LXE, etc., are registered trademarks of
International Lubricants, Inc.
GEARS October 2007 27
(1) A special nitrate forms a protec-
tive coating on metal surfaces and
serves as a very efficient means of
protection against corrosion as a
shield, so to speak. Cavitation ero-
sion is thus prevented.
(2) Molybdate works as an anode
(an anode is a collector of electrons)
which functions on a principle of
self-sacrifice. Electrolysis is neu-
tralized by molybdate, and corrosi-
on due to electrolytic leakage cur-
rent is thus prevented. In addition,
molybdate forms a very thin (mo-
lecule-sized) coating on aluminum
surfaces, which counteracts the
transfer of electrons.
(3) Polymer dispersants prevent the
foaming of the coolant that occurs
due to water pump recirculation and
they also lubricate the water pump
for enhanced durability. Cooling
performance is thus improved signi-
ficantly (up to 30%).
(4) Sodium hydroxide breaks down
glycolic acid. In addition, carbono-
xylate provides long-term protec-
tion against corrosion.
Additional properties
For use only in straight water ap-
plications, phenolphthalein is used
as a pH indicator to indicate acid
formation that can cause engine
damage to head gaskets and intake
manifold gaskets. When the pH is
safe the coolant is pink and when
the coolant is unsafe the coolant
turns clear. For all applications the
neon pink color also makes any
LUBEGARD is manufactured by: International Lubricants, Inc.
possible leak sites visible (simpli-
fied diagnosis). Borate acts as a
pH buffer. Because borate is very
expensive, it is often replaced with
phosphates in coolant additives.
Phosphates can cause problems by
setting off dangerous reactions. Bo-
rate is an outstanding heat transfer
enhancer, however. KOOL-IT Su-
preme Coolant Treatment contains
the optimal mix of these compo-
nents and, as a result, significantly
increases the efficiency of any coo-
ling circuit. At the same time, the
entire system is superbly protected
and its life is lengthened.
Application Instructions: Add 1
bottle every year or 30,000 mi-
les, whichever comes first. After
5th consecutive year, drain, flush
& refill cooling system including
coolant. For complete instructions
refer to product package.
Suitable for every coolant
Optimizes the cooling performance
of the entire cooling system
Increases heat transfer/ reduces
the engine coolant temperature
Prevents cooling system corrosion
Prevents deposits that can lead to
overheating
Protects all metals from electroly-
sis
Reduces the buildup of corrosion
on the cylinder cooling walls
Prevents heat damage (for exam-
ple, of the head gasket)
Extends the life of the coolant
www.Lubegard.com
7930 Occidental South; Seattle WA 98166
206-762-5343 800-333-LUBE(5823)
Printed in the U.S.A.
GRTSAD-11-07-Spread 9/17/07 1:06 PM Page 1
Get the scoop on evaluation and repair of the 4L60-E,
5L40-E, CD4E and 5R55N/W/S, plus demonstrations
on reaming techniques, air testing and much more from
some of the most respected presenters in the industry
Sonnax technical staff.
At Sonnax Booth 819
3:00-3:45 PM: CD4E valve body, diagnostics and
reaming focusing on the pressure regulator, converter
regulator and bypass clutch valves.
Presenter: Scott Jackson
4:00-4:45 PM: 5L40-E valve body, diagnostic and
reaming focusing on the AFL & TCC regulator valves.
Presenter: Bob Warnke
5:00-5:45 PM: 5R55N/W/S servo pin bore repair.
Presenter: Gregg Nader
2007 Sonnax Industries, Inc.
6:00-6:45 PM: 4L60-E valve body diagnosis and
reaming focusing on the TCC isolator/regulator valve
and sleeve, as well as diagnosis using Air Test plates.
Presenter: Bob Warnke
T I M E T E S T E D I N D U S T R Y T R U S T E D TM
Automatic Drive P.O. Box 440, Bellows Falls, VT 05101-0440 USA 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com info@sonnax.com
Sonnax will hold four different seminars daily at our booth
on Friday, Oct. 12, from 3:00 to 6:45 p.m. and on Saturday,
Oct. 13, from 1:30 to 4:45 p.m. Each 45-minute presentation
will focus on a different valve body and highlight specific
problem areas and solutions.
1:30-2:15 PM: 5R55N valve body diagnosis and
reaming, showing diagnosis via Air Test plates.
Presenter: Bob Warnke
2:30-3:15 PM: 4L60-E valve body diagnosis and
reaming focusing on the TCC isolator/regulator valve
and sleeve, as well as diagnosis using Air Test plates.
Presenter: Scott Jackson
3:30-4:15 PM: 5R55N/W/S servo pin bore repair.
Presenter: Gregg Nader
4:00-4:45 PM: 5L40-E valve body, diagnostic and
reaming focusing on the AFL & TCC regulator valves.
Presenter: Scott Jackson
 Get your hands on Transmission Specialties Volume 7,
which includes nearly 150 new products, all designed to save you
time and money! The new catalog also includes a wealth of technical
information, valve body charts, and complete product listings.

Stop by Booth 819 to get your FREE copy of

TS7 in either print or CD versions. And while
youre there, visit with our knowledgeable
Sales and Technical staff and see some of our
latest root-cause solutions!

General Motors Chrysler

5L40-E A727, A904, 42-46-47-48RH/RE
Actuator Feed Limit Valve . . . . . . . . . . 55211-01K Governor Bore Plug Kit . . . . . . . . . . . . 22771-14K
TCC Regulator Valve & Sleeve . . . . . . 55211-04K
Boost Valve & Spacer Kit . . . . . . . . . . 55209-01K Imports
JF506E
4T60-E TCC Control Plunger
Isolator Valve Sleeve . . . . . . . . . . . . . . . 84754-06 Valve Assembly . . . . . . . . . . . . . . . . . 122892-01K
4T65-E Mercedes 722.6
Oversized Torque Signal Valve . . . . . . . 84754-44 Overlap Control Valve Sleeve Kit . . . . 68942-05K
4L80-E Toyota A540E ('98-'00)
Oversized Seal Rings . . . . . . . . . . . . . . . 34716-01 Boost Valve & Sleeve Kit . . . . . . . . . . . 89031-03K
Oversized Pressure Regulator Valve . 89010-04K
4L60-E & 4L65-E
Forward & Reverse Abuse Valve Kit . . 77754-35K VW 096,097,098,01M,01N,01P
Adapter Kit for Remote
Allison 1000/2000/2400 Transmission Cooler . . . . . . . . . . . . . 119814-01K
C1 Clutch Control Valve & Seal Kit . . . 37000-05K
ZF5HP30
Ford Retainer Kit for Manual Shifter
4R44E/55E, 5R44E/55E Shaft Seals . . . . . . . . . . . . . . . . . . . . . 85000-02K
TCC Regulator Valve Spring Kit . . . . . 37947-46K
Standard TCC Regulator Valve . . . . . . . 37947-38 Transfer Cases . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Venture/New Process
CD4E Transfer Case Pump Plate . . . . . . . . 100246-02K
Oversized Line Modulator Valve Kit . . 73840-27K

AOD & E, 4R70W & 75W More information on all our products
2-3 Accumulator Piston & Sleeve Kit . . 76890-21K is available at www.sonnax.com.
Have a Cup
PLAYING TO WIN
on Me
M
y most recent articles on
effective cross-promotions
have resulted in more feed-
back and interest than any other past
topic. With that in mind, Im sticking
with it until you ask me to stop or I run
out of ideas, whichever comes first.
Businesses often offer products or
services that are so similar, their cus-
tomers and potential customers have
a difficult time differentiating
between them. In these cases,
the successful businesses
choose to differentiate
themselves with effective
marketing and by pro-
viding superior service,
support and follow-up
to deliver an experience
that wows customers
and keeps them coming
back for more.
Many times the terms
marketing and advertis-
ing are used interchangeably,
but they arent the same. Advertising
is a paid placement in radio, TV, print,
on line, or other media that is designed
solely to generate leads. Advertising
is only one element of marketing, and
advertising in and of itself doesnt
necessarily increase sales. Marketing is
the full array of advertising, grassroots
campaigns to spread the word, build-
ing a company culture, defining an
image, and developing product knowl-
edge and sales procedures that results in
increased sales.
Cross-promotions are marketing
strategies that use unique, highly-tar-
geted advertising tactics that extend
your reach beyond your existing
30 GEARS
customer base to other businesss cus-
tomers.
Cross-marketing isnt just two
businesses giving out coupons for each
other to prompt the next customer visit
your store. Cross-marketing is a coor-
dinated set of activities between two
or more businesses with similar cus-
tomer demographics, which will result
in benefits for all businesses involved.
For example, a video game store might
cross-market with a pizza parlor by
advertising their store on the pizza
delivery boxes, thereby reaching all of
the pizza parlors customers.
This type of cross-promotion is
very effective because it extends the
awareness of the video game store to an
expanded customer base, and both busi-
nesses derive a clear benefit. The video
game store owner can buy the pizza
Sp
e a ker
by Thom Tschetter
delivery boxes on which its ads are
printed, saving the pizza store owner
the cost of buying the boxes, while get-
ting the name of the video game store
into the homes of the pizza parlors
customers.
When developing a cross-promo-
tional program, its critical to identify
a company which has a customer base
that shares important demographic
similarities with your target
market, such as age, income
and gender, but one that
isnt a competitor, sell-
ing the same or an
alternative product or
service. For example,
if you are the owner of
a beauty salon that tar-
gets wealthy women, a
cross-promotional pro-
gram with an automotive
wrecking yard probably
wouldnt be very effective.
However, a cross-promotional
program between the beauty shop
and a day-spa offers a great chance for
success provided the day-spa doesnt
also offer hair styling services.
I introduced a couple of effective
cross-promotional ideas in previous
issues of GEARS beginning last April.
Heres a quick review before I give
you one for this month. Be sure to go
back and read these articles. Why not
cut them out and start a marketing and
advertising notebook?
1. Use the back of your business
card for a promotional offer of a three-
day, two-night vacation. The vacation
is subsidized by a travel company thats
also trying to create greater market
October 2007
awareness of its website to attract mem-
berships in its discount travel program.
When you give your card out, youre
leaving more than just a business card;
its a gift card with tangible value.
When the customer takes advantage of
the offer, your business is talked about
and remembered every time the cus-
tomer shares pictures and events of the
trip with his friends and relatives.
2. You could cross-promote with
the local quick lubes in your area by
offering to warranty their fluid change
services until the next scheduled ser-
vice. I know this sounds nuts, but
all youre really doing is giving their
customers a credit toward repairs in
your shop in the amount the quick lube
charged for the service. Most of the
work youll get will be major jobs, and
youre only offering a discount that is
most likely going to be less than the
discount or referral commission youd
have been willing to give anyhow. The
quick lube will also appreciate having
you as an ally because the program
encourages customers to come back
every year for another service. There
are more mutual benefits to this pro-
gram: refer back to the original article
or contact me for more information.
3. There were also two articles
about how to reach customers in mean-
ingful ways to keep them coming back
and referring their friends. I have a
special guest in my tradeshow booth,
Rachel Jackson of Send Out Cards. She
was featured in my August article, The
Checks in the Mail. Be sure to stop by
and ask her how Send Out Cards can
put more dollars in your pocket.
Now heres my idea of the month:
Almost every part of the country has
espresso stands popping up on just
about every corner. Most of these stands
are independent operations; that is, they
arent part of a large chain. For this pro-
motion, youll have a greater likelihood
of setting up a cross-promotion with an
independent, because they most likely
will be using mass produced generic
paper cups.
Heres my script for the offer:
Mr. Espresso Stand Owner, I own
ABC Automotive just around the cor-
ner and I have an idea that I think could
be beneficial to both of our companies.
Correct me if Im wrong, but I think
32 GEARS
one
of your
significant
expenses each
month is the cost of
the paper cups that you use;
is that an accurate statement? I also
noticed your cups dont have your com-
pany logo on them, either, and Im sure
that would add quite a bit to the cost
if you did. Dont you think it would
be advantageous to have your logo
on the cups just like the big boys like
Starbucks, Tulleys, and Einsteins?
Mr. Espresso Stand Owner, heres
my proposal to you: Im willing to sup-
ply you with your paper cups with your
logo prominently printed on the front
of the cup if youll allow me to print
my company information on the back
of the cup. This is a win-win you get
custom cups with your logo, and I get
my name in the hands of more people,
too. What do you think? Can you see
any reason why this wouldnt work out
for both of us?
Notice, the espresso stand gets
top billing on the front of the cup and
youre willing to accept the lower status
of the back of the cup. This is just sales-
manship; is there really a front and back
of a paper cup? But trust me on this;
if you offered him the back, he most
likely would reject your offer.
There are two ways to approach
this particular promotion. You could
offer to pay for the printed cups or offer
to share the cost in some fashion. You
might even make a deal for free coffees
for your customers and employees in
return. There are many ways to slice
this one up. Be creative, and always
remember that the best cross-promo-
tions provide benefits to all companies
involved.
I believe theres no more effective
way to promote your business than
through cross-promotions. All adver-
tising is a waste of money unless its
backed by superior customer service and
follow-up. Getting to know your cus-
tomers on a first-name basis as well as
their personal
interests and prefer-
ences must be one of the cornerstones
of your corporate culture. The goal
is for each customer experience to be
personal and memorable so the good
word gets spread by word of mouth.
Customer recommendations are the
most cost-effective and believable type
of advertising there is, and referrals are
the highest order of cross-promotion.
If you want more detailed infor-
mation, on cross-promotions, send an
email to me at thom@atra.com with
the words Cross Promotions in the
subject line, or if youre at EXPO when
you read this article, stop by my booth;
its number 1160. I think those of you
who implement effective cross promo-
tions into your advertising will really
stretch your ad dollars and get better
results.
Thom Tschetter is a nationally
acclaimed business speaker, ATRA
management trainer, certified AMI
instructor, and radio personality.
Thom reminds us that much of the
success we enjoy comes from things
weve learned from others. We encour-
age you to help by sharing your own
successes, challenges and personal sto-
ries. Thom will turn them into articles
that are sure to be learning experiences
for everybody. If you want to keep it
confidential, well honor that request.
Mail your contributions to Thom
Tschetter c/o ATRA, 2400 Latigo
Avenue, Oxnard, CA 93030. My tele-
phone number is 480-883-6404; my
email is thom@atra.com or send a fax
to 888-274-3787. If you use email or
send a fax, please include the words
Management Info in the subject line.
I look forward to hearing from you.
October 2007
 /NLINE
-EANS/N4IME
Automotive RepairSolutions
Automotive Repair Solutions Shop Management Solutions Business Performance Services Commercial Vehicle Group

Mitchell 1 Transmission information is available in the full OnDemand5.com product or as a stand-alone transmission option.
Either way, you have access to the industrys latest transmission repair information available. The program requires no installation
discs and no quarterly updates to install.
OnDemand5.com Features:
New OnDemand Live - View & Share Tips 99.9% Reliable Component Locations CV Joints
Video Training No Software to Install Drive Axles and Axle Shafts Clutches
Redesigned Search Vintage Information Overhauls
Full Color Wiring Diagrams Color Oil Flow Diagrams
Automatic Monthly Updates Code Diagnostics 888.724.6742 x6313
mitchell1.com/od

2007 Mitchell Repair Information Company. The Mitchell 1 name is used here in by permission from Mitchell International, which has no ownership interest in Mitchell 1.
Keep Those Trannys Rolling
Four Wheel
Drive Explorer
Chatters on Turns
Figure 1: tire with unusual wear pattern
L
ast week I received a call to the
ATRA HotLine from a techni-
cian name Bill. Bill was work-
ing on a 1999 Ford Explorer equipped
with an Auto 4x4 system that was
chattering or shuddering while turn-
ing corners at times. The problem was
intermittent and, based on a check of
the 4WD clutch voltage, the GEM
module was commanding the transfer
case clutch to come on when the chat-
ter occurred. Bill didnt know why the
Auto 4x4 system was trying to engage,
but it appeared the GEM module was
commanding it.
Bill checked the GEM system for
codes using the latest-and-greatest scan
tool available, but he was unable to
communicate with the GEM module.
He was able to communicate with the
PCM, but when he requested the GEM
34 GEARS
system, the scan tool just sat there and
did nothing, so he was unable to read
any codes or view any data from the
4x4 system.
After discussing the operating char-
acteristics of the Auto 4x4 system and
explaining that Ford had issued several
technical service bulletins addressing
wiring, terminal corrosion, speed sen-
sor, encoder motor, and GEM reca-
librations, I explained that some of the
aftermarket scan tools were not able
to communicate with many domestic
4x4 systems, including Ford, General
Motors and Chrysler systems. I also
explained that if he wanted to diagnose
this 4x4 system, hed have to borrow a
scan tool that was able to communicate
with the GEM system. Bill didnt know
anyone with a compatible scan tool, so
he asked me to send him copies of the
Sp
e a ker
by Pete Huscher
GEM pinpoint tests and wiring sche-
matics.
I reminded him that he was dealing
with an intermittent problem, so he may
not be able to see a problem during the
pin voltage tests at the GEM. Bill under-
stood the complexity of performing the
pinpoint tests on an intermittent prob-
lem, but that was his only option. I faxed
him a copy of the pinpoint tests and a
copy of the transfer case system wiring
schematic. I also included copies of the
Ford bulletins we spoke of earlier.
A couple days passed and I hadnt
heard from Bill, so I called him. After
we spoke for just a few minutes it was
clear that he hadnt found the prob-
lem and was becoming frustrated. Bill
checked all the inputs and the powers
and grounds going to the GEM while
road testing the vehicle, and everything
appeared normal. Even though Bill
couldnt duplicate any irregularities,
he continued checking the inputs to the
GEM and found nothing.
After going over the inputs and
powers and grounds with Bill, it was
apparent that a pinpoint test wasnt
going to reveal the problem, especially
if he couldnt duplicate the problem
while performing the tests. And, after
working on the vehicle for four days,
Bill was at the end of his rope.
Knowing that Bills shop was rela-
tively close to ATRAs headquarters
in Oxnard, I invited Bill to bring the
vehicle by and let me look at it for
him. Bill was knocking on our door
within thirty-five minutes. After a few
minutes discussion, we jumped into
the Explorer and went for a test drive.
During the test drive we were unable
to duplicate the shudder while turning
October 2007
corners. So after several unsuccessful
attempts, we returned to the ATRA
shop. I pulled the Explorer into our
shop so itd be ready to check out first
thing in the morning.

The Visual Inspection

As with any type of diagnostic
routine, I started with a visual inspec-
tion, checking for anything obvious
that could contribute to the problem.
Everything looked okay except for one
of the front tires, which had a strange
wear pattern (figure 1). I then raised
the vehicle and inspected the 4X4 sys-
tem, including transfer case, drivelines,
U-joints, drive axles, and examined the
wiring for loose connections or cor-
roded terminals. Engine, transmission
and transfer case mounts were in good
condition, with no signs of deteriora-
tion or movement.
Finally I checked tire pressure and
circumference. After verifying that
all four tires had the correct pres-
sures, I pulled out my tape measure
and measured the circumference of all
four tires. I cant tell you how many
times Ive talked to technicians whove
fought a 4x4 chatter or shudder for
weeks, only to learn the Auto 4x4 sys-
tem was operating properly; the condi-
tion was caused by a tire mismatch
(tire circumference must be no more
than 1/8th inch difference) or tires
with uneven pressure (pressure must be
within 2 PSI).
In this case, the difference between
the tallest and shortest tire was less than
1/64th of an inch in circumference, so
the tires were within tolerances and not
the cause of the condition.
Everything looked okay, so the
next step was to connect our scan tool
and see if there were any codes in the
GEM system.

Checking the GEM

System
I connected our newest scan tool to
the vehicle data link connector (DLC),
but just as Bill had mentioned earlier, I
was also unable to communicate with
the GEM system. Knowing that some
aftermarket scan tools were having
problems communicating with comp-
anion modules, I continued to try dif-
ferent scan tools until I found one that
was able to communicate with this

GEARS October 2007 35

Four Wheel Drive Explorer Chatters on Turns
C282
Figure 2: radio and center dash panel removed
GEM system. The Snap-on MT2500 with the latest cartridge
worked, and I could monitor most of the 4X4 system inputs
and outputs.
There were several codes stored in the GEM system,
ranging from interior lighting system codes, to door-ajar sys-
tem codes, to 4x4 system codes. After documenting all of the
codes, I cleared the codes and started checking the inputs to
the GEM module.
With the MT2500 it was easy to check the inputs to the
GEM. I could see the power and ground circuits. While check-
36 GEARS
ing the transfer case system operation, I was able to monitor
the mode/select switch operation, the encoder circuits, the A/
B motor circuits, the transfer case clutch commands, and the
front and rear driveshaft speed sensors circuits, and verified
their power and ground circuits were intact.
After verifying that the GEM system power and ground
circuits were good and that the transfer case was capable of
performing all of its basic functions as commanded (except
for an intermittent no engagement into 4x4 low range), it was
time to take another test drive, but this time Id be able to see
what the 4x4 system was really doing.
The Test Drive
During the first few minutes of the test drive the 4x4
system seemed to work perfectly; no chatter or shudder while
turning and everything seemed fine. But as the vehicle started
to warm up, I started to feel a slight shudder while pulling
away from a stop and making a hard right turn.
It felt like a limited-slip differential shudder from the
old days. Remember the old posi-trac or limited-slip differ-
entials? Youd accelerate around a corner and the rear of the
vehicle would feel like it was wobbling around the corner.
It was called crow hopping or wheel hopping around a
corner, and in this case it indicated the Auto 4x4 system was
engaging.
While monitoring the transfer case clutch circuit, I could
see the GEM system commanding the transfer case clutch to
engage the 4x4 clutch in the transfer case. I could also see the
October 2007
mode/select switch input wasnt changing during the GEM
command to 4x4 mode.
While monitoring the front and rear driveshaft speed sen-
sors, I noticed that the rear driveshaft speed sensor became
slightly erratic just before the GEM commanded the transfer
case clutch to engage. As the GEM commanded the transfer
case clutch on, the front and rear driveshaft speed sensors
seemed to equalize and the GEM then commanded the trans-
fer case clutch to disengage.
After duplicating the chatter or shudder several times and
witnessing a rear driveshaft speed sensor circuit problem, it
was time to head back to the shop and check the front and rear
driveshaft speed sensor circuits.

Back at the Shop

While driving back to the shop, I was able to duplicate
the shudder more frequently as the vehicle got warmer. Each
time it occurred, the rear driveshaft speed sensor reading
would become erratic and the transfer case clutch would be
commanded on.
When I returned to the shop, I checked the GEM system
for codes and found P1837 (rear driveshaft speed sensor
circuit), B1330, B1332 and B1574 (door ajar) circuit codes.
With code P1837 (rear driveshaft speed sensor circuit) in the
GEM system and witnessing an erratic rear driveshaft speed
sensor signal on the scan tool during the test drive, it was a
pretty good bet we were looking for a rear driveshaft speed
sensor circuit problem.
Figure 3: back-probing GEM #C282 connector
After removing the radio, the center dash panel and the
mounting screw securing the GEM module to the dash frame,
I was able to access the GEM module connector #C282 (fig-
ure 2). I backprobed the rear driveshaft speed sensor circuit at
GEM module connector #C282 pin #5 (figure 3), and moni-
tored the signal from the sensor. It was apparent the GEM was
receiving an erratic rear driveshaft speed sensor signal.
Next, I performed continuity checks on the rear drive-
shaft speed sensor circuits, from the sensor to the GEM mod-
ule; the sensor signal wire was good all the way to the GEM
(figures 4a and b). The only thing left was a connection or

GEARS October 2007 37

Four Wheel Drive Explorer Chatters on Turns
Figure 4: 4a & 4b: performing continuity checks between GEM & rear speed sensor
sensor problem.
Knowing that Ford released sever-
al technical service bulletins related to
wiring and speed sensors, I replaced the
rear driveshaft speed sensor with the
updated sensor (part# XL2Z-7F293-
AA) and rechecked the signal with the
scan tool. The rear driveshaft speed
sensor signal was nice and steady, with
no signs of erratic operation. After
securing the GEM module to the dash
frame and reinstalling the center dash
panel and radio (figure 5), I cleared the
codes from the GEM system and took
the vehicle for another test drive.
The Final Test Drive
Knowing the vehicle would have
to be warm before the problem showed
Figure 5: GEM, center dash panel and radio reinstalled
38 GEARS
up, I sat back and prepared for a lengthy
test drive. I drove through city streets,
stop-and-go traffic, and for several
miles on the freeway, just to make sure
the vehicle was good and warm. I drove
through residential areas so I could stop
and make slow turning maneuvers.
I drove the vehicle for over 25
miles and couldnt duplicate the chatter
or shudder. During the test drive, I mon-
itored the rear driveshaft speed sensor
signal; it read perfectly. It looked like
we had this one whipped. After a flaw-
less test drive it was time to head back
to the shop and put this puppy to bed.
The Conclusion
The problem appeared to be cor-
rected, but before I could celebrate,
I had to recheck the GEM system to see
if code P1837 (rear driveshaft speed
sensor circuit) returned. It didnt, but
codes B1322 and B1574 (door ajar)
did.
While performing the final checks
on the 4x4 system, I found that the
GEM system wouldnt command a shift
to the 4x4 low range at times. After
verifying that all the parameters were
within range to allow a commanded
shift to 4x4 low, I cleared the door ajar
codes. With the code cleared, the GEM
allowed a commanded shift to 4x4
low range. When the door ajar codes
returned, the GEM module once again
disabled 4x4 low range engagement.
Apparently the door ajar circuit codes
were disabling engagement into 4x4
low range.
With the rear driveshaft speed sen-
sor circuit repair complete, it was time
to return the vehicle to Bill. Wed have
to wait for another day and another
article to check our intermittent no
engagement to 4x4 low range.
The next time youre using the
latest and greatest equipment and you
cant seem to get things to work out,
maybe all you need to do is take a step
back and try something else: in this
case an older, more reliable scan tool.
In our next article well continue
our look into todays domestic 4x4 sys-
tems, and check out the intermittent no
engagement into 4x4 low range we were
left with on the 1999 Ford Explorer.
Until then, Im counting on all of you
to Keep Those Trannys Rolling.
October 2007
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Why is My
Transmission Tech Sp
e a ker

Always under the by Dave Skora

Dashboard?
T his is a question that more shop
owners, technicians and rebuild-
ers are asking themselves. The
reasons vary; anything from a car with
a VSS signal that isnt coming from
the instrument panel, to a customer
who swears his car has a problem that
wasnt there before you fixed it.
So why not send these electrical
issues to someone who Specialized
in them? After all, most shops that
specialize in transmission service and
repair dont do tires or body and paint
work. Why expect them to handle elec-
trical repairs
Part of the perception of being
in the transmission business is, if we Figure 1: Pulling fuses to isolate the battery drain.
can rebuild, service and troubleshoot
an automatic transmission, we can do
anything. So customers and employers
alike expect their technicians to know
all about fixing electrical problems.
Before you read the main topic of
the article, lets review your ability to
troubleshoot electrical systems.
Troubleshooting automotive elec-
trical systems is a lot like knowing
the basics. Its like having basic table
manners. You should always hold your
fork with the tines up. If you hold it
the other way, it makes you look like
youre about to work the bead off a
tire. If you continue to hold your knife
after you cut something, it looks like
youre about to spread more bondo on
a fender. Figure 2: Dash assembly removed and set aside.
The most important thing to know
about electricity is Ohms Law. Several everything from the basics to very com- tionship between volts, ohms and amps:
excellent articles have been written plex diagnosis and troubleshooting. Volts = Amps x Ohms. And knowing
by Mike Van Dyke, Steve Bodofsky, But each article depends on under- that, we can calculate the value of any
Dan Marinucci, me, and countless oth- standing Ohms Law. All Ohms Law unknown value using the values of the
ers about electricity. The topics cover does is mathematically define the rela- other two characteristics of the circuit:

40 GEARS October 2007

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Why is My Transmission Tech Always under the Dashboard?

Volts = Amps x Ohms flow for the circuit to

Volts Amps = Ohms be about amp.
Volts Ohms = Amps If a PWM TCC
solenoid resistance
Heres a quick and simple way to value of 1114 ohms,
understand it: Most electrical circuits on the expected current
a vehicle that operate a relay, solenoid flow at 100% duty
or motor run on 12 volts. With the right cycle will be about 1
amount of current (amps), the circuit amp, because the volt-
will work the device. If the current flow age-to-resistance val-
is too low, the device cant work. If the ues are about 1-to-1.
current flow is too high, the device or Here is one more
circuit will run too hot and fail. example. If you find
Most of the time, the manufactur- the resistance of an
ers only give the resistance (ohms) or EPC solenoid is 3
current (amp) specification. But with ohms, the expected
Figure 3: Exposed harness behind dash looking for problems.
Ohms Law, thats okay. Because, if amp flow at 100%
we know the resistance specification of duty cycle is going to be about
the device or the operating current of 4 amps.
the complete circuit, we can use Ohms IMPORTANT: A duty-
Law to calculate the missing value. cycle controlled solenoid
Lets look at some common trans- current flow will always be
mission solenoid circuits. Say we have reduced by the exact duty cycle
a typical shift solenoid with resistance value. So at 50% duty cycle,
value of 24 ohms. If you compare this the current flow will always be
to the applied voltage, you can see it exactly half the current flow
is twice the voltage source. So Ohms of a full apply; in the case of Figure 4: Harnesses behind the dash typically arent
Law tells us we should expect current the EPC solenoid, thatll be 2 protected and can chafe against braces, etc.

42 GEARS October 2007

 VOLTS = AMPS X OHMS
12 0.5 24.0
12 1.0 12.0
12 2.0 6.0
12 3.0 4.0
12 4.0 3.0
12 6.0 2.0
12 8.0 1.45
12 12.0 1.0

amps.
This simple chart (above) shows
how Ohms Law defines the relation-
ship between resistance (ohms) and
current (amps) when the voltage stays
the same.
As I said earlier, our customers
expect more from us because no one
else in the industry can rebuild, service
and troubleshoot automatic transmis-
sions not even the dealers in many
cases!
The problem is that, unlike finding
a bad drum, pump or valve body, a lot
Figure 5: Steering wheel before removal.
of electrical problems are solved by ed it, took x-rays and had to insert
finding and correcting a loose connec- some pins to realign the bone until it
tion or bad wire. But you still have to mended. The bill came to just under
charge for your time. $10,000. It didnt involve replacing the
Heres how I justify it: My son bone or any parts just his time. He
swung his fist in the air and a telephone didnt even charge for the metal pins.
pole jumped out from behind a bush The important part is that my sons
and broke his hand. The doctor inspect- hand is fixed.

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2007, Chrysler, LLC. All rights reserved.

GEARS October 2007

12602_ATRA_GearsAd.indd 1 9/6/07 3:25:31 PM 43
Why is My Transmission Tech Always under the Dashboard?

Figure 6: Steering wheel removed and laid aside on the

Figure 7: With steering wheel removed,
workbench. CAUTION: Always set the steering wheel
its easier to work on the modules.
facing up in case the airbag deploys.

So how can you justify charging
for all the time it takes to fix an electri-
cal problem, even if there are no parts
involved? Take pictures. As long as
theres actual labor involved, you can
document each step of the diagnostic
procedure with a photograph. The fol-
lowing photos (see figures 1-8) were
taken to show a customer just what was
involved in troubleshooting a battery
drain problem.
The vehicle was a late model Volvo
that came to the shop with shifting
issues and an electrical problem. Since
the vehicle had a 4T65E, it was no
problem to verify the transmission was
worn out, and recommend a rebuild.
The next problem to tackle was the bat-
tery drain.
In the first picture, the drain was
confined to the courtesy light system.
Next couple of pictures shows
the dash removed and the area behind
the dash exposed to check for wiring
damage, etc. When no problems were
found, the steering column came out to
gain access to the main harness connec-

44 GEARS October 2007

tors and modules in the lower left
corner of the firewall.
The fault was finally found to
be a loose connection that caused
the courtesy light module to allow
the under dash courtesy lights to
dim down after closing the doors,
but not turn off completely.
The bottom line is that after
all the effort it takes to solve an
electrical problem, you should
expect to get paid for your time,
knowledge and expertise. Most
customers dont understand elec-
Loose
tricity or the knowledge it takes
to solve a problem. So do just
Connector
what the doctor who x-rayed my
sons hand and the technician
who documented his work with
digital pictures did. You can show
them visible proof of the problem
and make your customer aware of
how difficult some electrical jobs
can be. Figure 8: The arrow indicates the culprit: a loose connector.
One last bit of advice: Lets say abilities if you tell them you solved its simply a way to embellish the
you find that the fix for an electrical the problem by finding an open in the description, and make them feel better
problem was simply a bad fuse. The ignition feed circuit. Keep in mind this about the legitimate cost of the repair.
customer will be much more impressed isnt an excuse to cheat the customer,
with your electrical troubleshooting by exaggerating the depth of the repair;

GEARS October 2007 45

The 4T65E and 4T45E
Tap Shift Feature:
Putting More Control in
the Drivers Hands by ATRA Tech Department

W
e usually see cars after they've
been on the road about three
years or so. In 2004, Pontiac
Grand Prix GTP (W body) equipped
with the 4T65E and the 2004 Chevrolet
Malibu Classic (Z body) equipped
with the 4T40E/4T45E added a feature
referred to with the following terms:
Tap Shifts Touch Activated
Power
ERS Electronic Range Select
Mode
DSC Driver Controlled Shifts
depending on the application
and which literature youre reading.
Both applications give you the ability to
upshift and downshift the transmission
by moving a button. The button on
the Malibu is located in the shift lever
while the Grand Prix uses a set of
paddles mounted on the spoke of the
steering wheel.

Operation
The addition of the TAP shift
system led to several transmission
changes, including the valve body,
spacer plate, channel plate, and even
the friction materials, depending on
the application. Several changes were
also made to the vehicle wiring and to
Figure 1: The BCM monitors the shifter enable circuit C1.
the PCM/BCM to make the TAP shift
system function. controls the system; the Z car uses operation on Grand Prix (W body)
The system consists of: the Run/Crank fuse, located in cen- applications.
TAP switches The tap switches ter console fuse block. The PCM receives the input from
are momentary contact switches. The shift lever position indicator the TAP switches and then com-
In addition to the switch contacts, is attached to the shift lever and mands the transmission to shift
the switch assembly contains a is used to enable or disable TAP to the gear commanded by the
series of dropping resistors (a volt- operation on the Malibu (Z body) driver. The voltage value received
age divider circuit). application. by the PCM from the switches var-
A fuse controls power to the switch The Internal Mode Switch (IMS), ies based on whether the driver is
assembly. On the W car, the Cruise located inside the transmission, commanding an upshift or a down-
fuse located in the IP fuse block is used to enable or disable TAP shift.

46 GEARS October 2007

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The 4T65E and 4T45E Tap Shift Feature

8.25K

1.5K
4.42K

Figure 2: The shifter position on the W car is determined by the Internal Mode Switch (IMS),
which is mounted inside the transmission.

`+>/i A BCM interface via the serial data

line is used on the Malibu to tell the

ii>`7>V PCM when the shifter has been moved
into the proper position so the TAP
9 it shifts can be enabled.
Before you invest thousands of dollars on Malibu Operation
converter rebuilding equipment, make sure you
To operate the TAP system on the
choose a company that can deliver. With ATIs
CW3 Converter Welding and Overhaul System, Malibu, you must first place the shift
you can build quality, reliable converters for selector into the Low (L) position. If the
your customers and build profits for your shop! shifter is in any other position, the PCM
inhibits the shift. The BCM monitors the
ATIS CW3 CONVERTER shifter enable circuit C1. (Figure 1).
When you place the shifter in L,
WELDING & OVERHAUL SYSTEM
W3
the C
See t the the shift lever indicator switch pulls the
a Expo
e r t rain 7! voltage low, enabling the Tap Shifts to
Pow ooth 72 CW3 Converter Welder
function. When the voltage is pulled
B Accu-Balance Converter Balancer
low, the Driver Shift Control parameter
SHOW

Accu-Bonder
Quick Test Converter Leak Tester on the scan tool will display ACTIVE as
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a value. When the Driver Shift Control
Mention code PE1007 to receive free parameter reads ACTIVE, the BCM will
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CW3, Accu-Balancer and/or
Accu-Bonder on orders placed by the TAP shift function.
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inputs such as VSS and engine load to
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occur. When the shifter is in the L

48 GEARS October 2007

position, the transmission range sensor
(PRNDL switch) will indicate D3
range as the manual valve is actually in Slausons (New) Website is
D3 range. The PRNDL switch values
for circuits A, B, C and P will display Now Online!
LOW for all of the switch circuits.
When the shifter is in any other I s it Per f ec t ?
range, the voltage will be high and the
Tap Shift function wont operate. If the
shifter is in any range other than L, the
scan tool parameter displayed as Driver
Shift Control will read INACTIVE.
When the Driver Shift Control param-
eter reads INACTIVE, the BCM will
inform the PCM via serial data to dis-
able the TAP shift function.
When you press the upshift button,
battery voltage is fed through a 4.42k
resistor. The PCM recognizes the volt-
age drop as an upshift command. To
command a downshift, the driver press-
es the button in the opposite direction.
Battery voltage is fed through a 1.5k
resistor to the PCM.
The voltage level available at the
PCM when the switch is moved to the
You tell us.
downshift position is different than
the upshift command value. The scan
tool parameter that displays the shift Go to www.slauson.com and give it a whirl
switch voltage values is called the Shift
Voltage Request.
Typical TAP Shift switch values
with the engine running are: Try the new SmartPart parts identification and online ordering
No Button Pushed 0.65 Volts system for Free!
Upshift Button Pushed 1.78
Volts If youve used the award winning Slauson Digital Catalog
Downshift Button Pushed 3.4 CD, youll find all of the tools that youre used to and
Volts more, online, and always up to date.

Of course, these values will vary

with battery voltage. If youre monitor- Identify your parts using our year, make, and model indexes
ing the voltage with the key on, engine
off, the voltage values will be lower Easy to understand parts descriptions
than those listed.
On Z-body applications, the The same high quality photo layouts that youre used to
BCM communicates with the Internal
Pressure Control (IPC) regarding shift-
er position and TAP command values. Call us at 800.421.5580 - Or log on to www.slauson.com
When you place the shifter in the L
position, the PRNDL indicator in the
dash displays L3. If you press the
downshift TAP button, the indicator
will display L2, and then L1 if you
press the button again. If you command
a TAP upshift, the PRNDL will display
L2, and then L3 if the button is pressed Phone Hours:
again. Open 7:00 am to 5:00 pm/ PST . Call (800) 421-5580
Local (310) 768-2099 . FAX ( 310) 768-8298

GEARS October 2007 49

The 4T65E and 4T45E Tap Shift Feature

Figure 3: The W car uses two switches mounted on each side of the steering wheel center spoke. The left switch is
the master, which houses a series of resistors. The right switch is a simple single-pole, double-throw switch.

Pontiac Grand Prix
GXP Supercharged
Operation
To enable the TAP Shift system on
the Grand Prix, you must put the shifter
in the M position. If the shifter is in any
other position, the TAP shift feature
wont function.
The shifter position on the W car
is determined by the Internal Mode
Switch (IMS) (Figure 2), which is
mounted inside the transmission. When
the shifter is in the M position, the
HUD (Heads Up Display) digits will
become smaller. In addition, the HUD
will change from showing the PRNDL
position to showing the commanded
TAP gear.
If the engine isnt running, the
HUD will always read 3 in M range
and the scan parameter will indicate
only 3rd gear commanded, even if you
push or pull on the paddles to command
a shift.
The scan tool parameter for the
Internal Mode Switch will display Drive
3 when the shifter is in the M position.
Internal Mode Switch circuits A, B, C
and P will all display a LOW value on
the scan tool. In addition, the Driver
Shift Control parameter will change to
ACTIVE, enabling TAP shifts to occur.
The W car uses two switches
mounted on each side of the steering
wheel center spoke (Figure 3). The
left switch is the master, which houses
a series of resistors. The right switch
is a simple single-pole, double-throw
switch.
If you push one of the switches,
the PCM will command an upshift.
If you pull one of the switches, a
downshift will occur. When the PCM
commands an upshift, battery voltage
will be fed through a 4.42k resistor to
the PCM. A downshift command will
cause battery voltage to be fed through
a 1.5k resistor to the PCM.
Typical TAP Shift switch values
with the engine running are:
No Button Pushed 0.65 Volts

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50 GEARS October 2007

 Upshift Button Pushed 1.70
Volts
Downshift Button Pushed 3.35
Volts
Once again, these values will
vary with battery voltage. If youre
monitoring the voltage with the key on,
engine off, the voltage values will be
lower than those shown.
Diagnostics
Several new DTCs are available for
the TAP system; they include P0815,
P0816, P0826, P1876 and P1877.
P0815 will set if:
P0826 isnt set.
No PSM/PSA DTCs are set (Z
body).
No IMS DTCs (W body).
The engine is running.
Its been at least 6 seconds since the
shifter range had been changed.
The PCM detects the upshift sig-
nal for longer than 2 seconds in
park or 5 minutes in D4 range.
If a P0815 sets, the PCM will:
Disable the TAP shift function.
Default the shifter range to the D4
shift pattern.
P0816 will set if:
P0826 isnt set.
No PSM/PSA /Range DTCs are
set (Z body).
No IMS DTCs are set (W body).
The engine is running.
Its been at least 6 seconds since the
shifter range had been changed.
The PCM detects the downshift
signal for longer than 2 seconds in
park or 5 minutes in D4 range
If a P0816 sets, the PCM will:
Disable the TAP shift function.
Default the shifter range to the D4
shift pattern.
P0826 will set if:
The engines running.
The PCM detects an invalid
voltage value for longer than
5 seconds.
If a P0826 sets, the PCM will:
Disable the TAP shift function.
Default the shifter range to the D4
shift pattern.
P1876 (Z body only) will set if:
No TAP system DTCs are set.
No PSA/PSM/RANGE DTCs are
set.
Engine is running.
GEARS October 2007 51
The PCM detects the TAP enable circuit is INACTIVE and the trans-
circuit is ACTIVE and the trans- mission is in L range.
mission is in D4 range. The condition lasts longer than 3
The condition lasts longer than 3 seconds.
seconds. If a P1877 set, the PCM will:
If a P1876 set, the PCM will: Disable the TAP shift function.
Disable the TAP shift function. Default the shifter range to the D4
Default the shifter range to the D4 shift pattern.
shift pattern.
P1877 (Z body only) will set if: The TAP Shift system is a clever
No TAP system DTCs are set. new way to provide the driver with more
No PSA/PSM/RANGE DTCs are control of transmission operation. While
set. its still restricted to just a few vehicles,
Engine is running. dont be surprised to see it appear in
The PCM detects the TAP enable more models in the years to come.
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 by Steve Bodofsky
ACCURATE MEASUREMENTS

Reading a Micrometer

I
n the last issue of GEARS, we
looked at micrometers: What they
are, basic terminology, and how to
use them. In this issue, well discuss
how to read the scale on a micrometer,
or mic. While there are many differ-
ent types of mics, the scales are pretty
much the same.
As with the caliper, micrometers
are available in a digital format, and
can be had for a fairly reasonable price
if youre willing to shop around. For
that matter, a digital caliper will prob-
ably provide you with adequate accu-
racy and resolution for most of your
measurement needs.
But assuming youre willing to
spend the time necessary, and want to
be sure of the most accurate measure-
ment possible, a micrometer may be
the tool for you. Lets look at how to
read them, starting with a micrometer
thats calibrated for Imperial (inches)
measurement.
Choosing the
Right Size Mic
The first step in using a microm-
eter is choosing the right size mic.
Micrometers come in various sizes, but
are only designed to measure within a
range of about one inch. For example,
the set shown in figure 1 includes three
micrometers:
Zero to 1 inch
1 to 2 inches
2 to 3 inches
The thing to remember is that the
first digit in your measurement will
always be the smaller of the two mea-
surements in the range. That is, if
youre using a zero-to-one inch mic, the
first digit will always be a zero:
0.xxxx"
If youre using a 1-to-2 inch mic,
your first digit will always be a 1:
1.xxxx"
How do you choose the right size
mic? Thatll be pain-
fully obvious the first
time you try it: The
right mic is the one that fits over the
object youre measuring, and adjusts
tight enough to provide a measurement.
If the thimble rotates past the sleeve
measurements, and the part youre mea-
suring doesnt fit snuggly between the
anvil and spindle, youre using the
wrong mic.
Reading the Scale
Imperial (Inches)
Now were ready to look at the
scale. This is the part of using a mic
thats fairly consistent, regardless of
what type of mic youre using.
Start by looking at the sleeve (fig-
ure 2): It has a number of different-size
graduations. The largest graduations are
numbered, from zero to 9. Those each
indicate a tenth of an inch, or 0.1000.
Each of those graduations is divided
into four equal parts. So those smaller
graduations are each equal to 0.0250,
because 4 x 0.0250 = 0.1000.
Now look at the thimble (figure
3). Each full rotation of the thimble is
equal to one of the small graduations

Figure 1: Micrometers come in a wide range of sizes, with

a limited range of measurement. In virtually every case, the Figure 2: Each of the numbered graduations on the sleeve is
first digit of your measurement will be the lower range of equal to a tenth of an inch. Those are divided into four smaller
the mic. graduations, each equal to 0.0250.

52 GEARS October 2007

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Reading a Micrometer
on the sleeve, or 0.0250. The thimble is divided into dif-
ferent sized graduations, too. The longest graduations are
numbered by fives; each of them is equal to 0.0050.
Those graduations are divided again; how many times
depends on the resolution of your micrometer. In this case,
the larger graduations are each equal to 0.0010; the small-
er equal 0.0005, or five ten-thousandths of an inch.
Thats pretty good, but its not the limit of our resolu-
tion. Take another look at the sleeve. See those extra divi-
sions, running perpendicular to the first set we discussed
(figure 4)? Thats called the vernier scale; each graduation
on the vernier scale is equal to 0.0001. So this micrometer
can provide measurements that resolve down to one ten- Figure 3: A full rotation of the thimble equals one graduation
thousandth of an inch! The trick to reading the micrometer on the sleeve. And the thimble is divided into smaller gradua-
tions; in this case, down to 0.0005.
is to add the readings on each scale, to provide a single,
complete measurement of the object.
TIP: Not all micrometers have a vernier scale; in fact,
not all mics have a scale that reads down below 0.001
(figure 5). In that case, all you can do is estimate the ten-
thousandths measurement, based on the position of the
thimble in relation to the spindle.

Measuring with a Mic

Imperial (Inches)
Now lets see how to read the micrometer scales to
measure an object. For this measurement, Ive chosen a
small adjustable wrench. To make the measurement (figure
6):
Zero the micrometer. Figure 4: The vernier scale allows you to refine your measure-
Open the micrometer enough to allow the item to ment even further; down to just 0.0001.
fit between the anvil and spindle.
Close the micrometer against the area you want
to measure, using the ratchet to adjust it against the object
without overtightening it.
Lock the micrometer spindle using the locknut.
If youre unsure of any of these procedures, read
the Accurate Measurements article in the last issue of
GEARS.
Now were ready to read the measurement. To make
it easier to read and explain, Ive decided to cheat just a
bit: Im using a flattened drawing of the micrometer scale,
adjusted exactly the way the micrometer displayed its Figure 5: Not all mics have a vernier scale. If yours doesnt,
measurement (figure 7). This just makes it easier for you you can estimate the difference between the zero line and the
to read the display all at once, without having to rotate the graduations on the thimble.
micrometer to see all the different scales. Think of it like

Figure 6: The procedure for measuring an object with Figure 7: This is a flattened version of a micrometer scale; like
an outside mic is always pretty much the same. If youre using a world map instead of a globe. The advantage is it lets
unsure of the procedures, read the Accurate Measurement you examine all of the scales at once, without having to rotate
column in the last issue of GEARS. the mic to see the rest of the scale a big benefit in print!

54 GEARS October 2007

 )NSIDEEVERY4RANS4ECKITYOULLALWAYSlNDTHEHIGHESTQUALITYCOMPONENTSTHE
MOSTCOMPLETETECHNICALINFORMATIONANDLOGICALSUB PACKAGING.OBODYMAKES
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4s&sWWW4RANS4ECCOMs-ILAN/( 


)F)T#OMES"ACKADREVINDD 0-
Reading a Micrometer
using a map of the world instead of a globe; everythings
right there in front of you, instead of rotating it to see
whats on the back.
Since the micrometer we used was a zero-to-1 inch
mic, the first digit will be a zero:
0.xxxx

Next we look at the large, numbered graduations on
the sleeve. The thimble is back far enough to reveal the
third numbered graduation, so the measurement is at least
three tenths of an inch. Heres what we have so far:

0.3xxx

A closer look at the sleeve reveals at least one smaller
graduation is showing; maybe two. So which is it, one or
two? Its one; heres how we know:
Look at the graduations on the thimble (figure 8). Figure 8: Are we seeing one graduation or two past the 3 on
Notice were close to the 20; that is, were near the end of the sleeve? It has to be one, because were too close to the
its scale. Remember, each rotation of the thimble is equal to high end of the scale on the thimble.
one small graduation on the sleeve. So, since were near the
end of the scale on the thimble, were just short of the sec-
ond graduation on the sleeve. Thats why we can see a little
of the next graduation, even though we havent reached the
second graduation yet.
Okay, so we have one small graduation showing on the
sleeve; thats another 0.0250:
0.3000
+ 0.0250
0.3250

Next, look at the graduations on the thimble (figure 9).

The zero indicator line on the sleeve is lined up just a bit
shy of 21. 21 would be 0.0210; since this is less, itd be
0.0200. But theres another, short graduation, between the
20 and 21. Thats 0.0005, so the thimble reads 0.0205.
Thats how much we add to the formula:
0.3000 Figure 9: The graduations on the thimble tell you how much
0.0250 to add to your initial measurement. In this case, youll be
+ 0.0205 adding 0.0205.
0.3455

But wait; theres more! Notice that the zero indicator is
just a tiny bit past the 0.0005 mark. This is where the ver-
nier scale comes in. Look at the vernier scale, and find the
graduation that lines up with a graduation on the thimble
(figure 10). In this case, its the 3. Thats another 0.0003
to add to the total. So our final measurement is:

0.3000

0.0250


0.0205

+ 0.0003
0.3458

And thats the final measurement in inches: 0.3458.

Reading a Metric Mic

Some of you arent forced to fight with measuring Figure 10: To refine your measurement even further, see which
length in inches, feet, yards and miles. Some of you get to graduation on the vernier scale lines up with a graduation on the
work in simple decimal equivalents, known as the Metric thimble. Then add that number to the 1/10,000ths column.

56 GEARS October 2007

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Reading a Micrometer
system. For you, there are specially designed micrometers,
calibrated in millimeters.
One of the first things you might notice about this
Metric micrometer is that it doesnt have a vernier scale
(figure 11). It only measures down to hundredths of a milli-
meter. Why arent Metric micrometers calibrated to resolve
as well as an Imperial micrometer?
Actually, there isnt much difference between the
two. Remember, millimeters are a lot smaller than inches:
It takes 25.4 of them to equal just one inch. A hundredth
of a millimeter equals just under 0.0004. So the Metric
micrometer provides almost the same resolution as the Figure 11: I couldnt find a single Metric micrometer with a
Imperial one, even without a vernier scale. And you can vernier scale. The reason is probably because the Metric mic
still approximate more precisely, simply by paying atten- resolves low enough without needing it.
tion to how close the graduations are to the zero line.
NOTE: While there may be some Metric mics with a
vernier scale, I couldnt find one. I presume its because of
the inherent resolution in the Metric mics, eliminating the
need for it. If anyone has a Metric mic with a vernier scale,
Id be happy to use it to add a section to the upcoming
booklet for the ATRA web site.
The next thing to notice is the scale on the sleeve
(figure 12). There are two sets of graduations: one above
the zero line and a second below it. The set above the line
is the measurement in millimeters: Each graduation equals
one millimeter. The set below the line is calibrated in half- Figure 12: There are two sets of graduations on the sleeve of
millimeters, or 0.5 mm. the Metric mic: The one above the zero line is in millimeters.
And the scale on the thimble is divided into 50 gradua- The one below is half-millimeters.
tions. Each rotation moves the thimble a half millimeter, so
each graduation on the thimble equals 0.01 mm.
Lets use the Metric micrometer to measure the same
wrench, and see how close the two measurements are.
Well use the same technique to measure the wrench as
before, and then read the scale.
The sleeve shows 8 graduations above the zero line, so
its more than 8 mm, but less than 9 mm (figure 13). And
theres one additional graduation showing below the line,
so thats another half millimeter. So far, the wrench is at
least 8.5 mm.
Now look at the thimble. The zero lines up almost
exactly with the 28th graduation (figure 14); thats 0.28
Figure 13: The thimble lines up just past the graduation on the
mm. So we add the two measurements: sleeve thats halfway between 8 and 9 millimeters. That puts
8.50 mm the measurement at 8.5 mm so far.
+ 0.28 mm
8.78 mm

So the wrench is 8.78 mm thick, according to the

Metric micrometer. How does that compare with the mea-
surement in inches? 8.78 25.4 = 0.3457 just 0.0001
difference in the measurements and that difference could
have been cause by position of the mic, pressure, tempera-
ture any number of things that are beyond our control.
Thats all there is to using a micrometer. There are
no real tricks nothing special to memorize. Its mostly
about taking the time to measure carefully, and to add the
measurements together. Figure 14: The zero line on the sleeve lines up with the 28th
Or you can get a digital, and leave the math to some- graduation on the thimble. That means you have to add 0.28
one else! mm to the earlier measurement. So the wrench is 8.78 mm
thick.

58 GEARS October 2007

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Filler Up!
The Aisin Seiki 450-43LE has a very small diameter fill tube, and a very large
diameter torque converter. Its just about impossible to get fluid down the fill
tube fast enough to keep the pump from starving for oil.
O K, youre at the bench and
its complete. You have built
a great transmission. You
havent skimped its got the latest in
geartrain, hydraulic and electronic con-
trol upgrades. You spent the money for
a premium kit and top quality friction
plates, and you also have invested in a
premium torque converter. The torque
converter may have cost a little more,
but you know that your converter sup-
plier doesnt skimp on their products,
either. You even have the correct fluid
that goes with the unit, and that, in and
of itself these days, is not an inexpen-
sive item. All in all, you know how
important quality is your name is rid-
ing on the results.
Now, all that has to happen is that
somebody maybe an R&R person,
maybe a general repair shop, maybe the
owner of the vehicle, heck, maybe even
you yourself just has to get it installed
and filled with fluid. After a good, clean
installation (Congratulations! No extra
parts left over!), filling the transmission
with oil will be the easy part, right?
Dont be so sure.
There are units that fill from the
60 GEARS
By Steve Jaussaud
2007 Sonnax Industries
this information as you can get your
hands on, and make sure it is acces-
sible to the people doing the actual
initial oil fill and start up.
Instead, this article will describe
the failures (obvious as well as hid-
den) that can occur when a unit
starves for oil, and some of the gen-
eral practices that you can employ
to help prevent failures across the
board.
FAILURES THAT
CAN OCCUR WHEN
engine compartment, and there are
units that fill from under the vehicle.
There are units that fill from under
the vehicle, but you check the level by
accessing the dip stick from under the
YOU DONT FILL
THE TRANMSISSION
PROPERLY:
The obvious, and usually the first,
failure is the pump thats no surprise.
hood. There are units that fill the trans- Whether its a gear and crescent pump,
mission from the engine compartment, a gerotor pump, or a vane and rotor style
but then fill the differential separately pump, no automatic transmission pump
from under the vehicle. There are units is going to last long without enough
that fill from under the vehicle at one oil. But, what happens if you run the
plug, but then you check the level at unit low on oil for just a short time?
another plug. Some units require that Or the pump sucks air, then oil, then
you purchase a dip stick as a sepa-
rate tool. The point of this article is
not to give you specific instructions
about all of the different procedures
needed with all of the newer units.
The variables seem endless, and there
isnt enough room in a single article
to tackle that topic. Besides, ATRA
and others have done great work in
getting the specifics documented in
a variety of tech bulletins and other
informational sources. Another good
source of information on how to fill
This is what happens when you don't fill
the transmission on initial startup is
a KM Series in neutral.
the OEMs themselves in their factory
manuals and some of their tech bul-
letins. Collect and organize as much of
October 2007
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Filler Up!
air for a prolonged period? Running a
pump or any other transmission com-
ponent low on oil may not cause an
immediate or obvious failure, but the
component may be overly stressed to
the point that it might fail prematurely.
And if Murphys Law holds true, that
premature failure will probably occur
within your warranty period. But what
about other components besides the
pump? Other sub systems in the unit
are quickly at risk when you dont get
enough oil into the pump quickly. The
next is the unit that typically drives the
pump: the torque converter. Todays
converters typically have 3 bearings,
and those bearings are put into service
the instant that the engine turns over.
And those bearings do not like to run
without oil. By comparison, an earlier
style torque converter, like a C6 or a
727 for example, only has thrust wash-
ers no bearings. Clearly, the newer
Failure caused by lack of lubricant. torque converters are much more sensi-
tive to running dry. Although I dont
have any hard data to prove it, I believe
that the root cause of a significant per-
centage of aftermarket torque converter
bearing failures is due to lack of lube
on initial start up. Like the pump, the
converter may not fail immediately, but
premature failure is very possible if the
unit runs dry for any sustained length
of time. Another typical component
failure associated with lack of lube
upon start up is the various support
bushings. The bushing that supports the
converter in the pump, as well as bush-
ings or bearings that support the input
shaft in the stator support tube will fail
very quickly without proper oil flow.
Ever seen a pump bushing welded to
a torque converter hub? Lack of oil is
almost always the culprit.
Close up of the Aisin Seiki Drive hub and bushing welded on to the hub.
SUGGESTED PRACTICES
FOR FILLING UNITS:
Fill it in neutral. With your assistant behind In general, there are a few things
you can do to help prevent problems
the wheel, and as long as none of the tech while filling the transmission on initial
bulletins or factory manuals tell you otherwise, start up.

fill the unit with the engine running and Prelube anything that will
rotate as soon as the engine fires.
the selector in neutral. Some units will not When you build a transmission, you
always use assembly lube, right? Good
efficiently fill in park, but in neutral, they fill its good practice and cheap insurance
efficiently and quickly. to liberally coat all moving pump (and
other) parts with lube.

62 GEARS October 2007

 Prefill the torque converter.
Your torque converter (and your torque
converter builder) will thank you!
Know what you are dealing
with. Pull out your bulletins; get out
your fluid guides. How many quarts of
oil will you need? Do you check the
fluid level with a dipstick or at a fill
plug? Does it have to warm up before
all of the hydraulic circuits can pres-
surize? Are there any adaptive learn
issues that you also need to contend
with on start up? These and other issues
can have significant effects upon the fill
procedure.
Have all your resources ready
ahead of time. OK, you know how
much oil it takes, and you have enough
to do the job. But do you have the right
equipment to fill that unit from under-
neath the vehicle? Does your shop have
a pressurized oil dispensing system,
a hand pump set up, or do you have
to fill the unit by gravity? After you
have the vehicle started is not the time
to find out that the coffee can and fun-
nel method is not getting fluid into the
sump fast enough.
Get an Assistant. Even if its
only for the sake of safety, you need
to have somebody behind the wheel. I
have seen lots of strange things happen
in transmission shops, and it would not
be completely out of the realm of pos-
sibility for a vehicle with a fresh trans
to have linkage that falls from park or
neutral into gear on its own. Seeing a
driverless vehicle headed for the back
wall of your shop can be quite alarm-
ing. Besides being there for safety, a
person that is behind the wheel can be
there to immediately shut the engine off
if needed. If the car is up on the hoist,
and you are filling it from underneath,
it can take a long time to get from the
shop floor to the ignition switch if you
have to shut the engine off. The time it
would take to do that may be enough
time to cause immediate and substantial
damage.
Fill it in neutral. With your
assistant behind the wheel, and as long
as none of the tech bulletins or factory
manuals tell you otherwise, fill the unit
with the engine running and the selec-
tor in neutral. Some units will not effi-
ciently fill in park, but in neutral, they
fill efficiently and quickly.
Be prepared for units that
GEARS October 2007 63
are slow to fill. There are a number torque converter and without using any
of units out there that are very slow to assembly lube in the pump, you are
fill, even if you have a pressurized oil just about guaranteed to sustain major
dispensing system in your shop. A good pump and converter damage. As you
example of this is the Aisin Seiki 450- should with all units, this transmis-
43LE (Fig 1). The fill tube and dipstick sion should have the sump completely
for this model is very small in diameter, filled prior to starting the engine. On
and it has a very large diameter torque this transmission in particular, there are
converter. Its just about impossible to technicians that prefill the sump, prefill
get fluid down the fill tube fast enough the converter, and after they install the
to keep the pump from starving for converter into the transmission, they
oil. You cant assume that you can just hand spin the converter in an attempt
start to fill this transmission without to prime the pump so that upon instal-
first performing some basic tasks. If lation, the pump will immediately be
you start the unit without prefilling the able to pick up fluid as soon as the
AMORIMgears2006.qxp 12/14/06 1:37 PM Page 1
pan/sump and without prefilling the Continued on page 66
[ ]
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Eliminates oil migration through
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Controlled swell to enhance the seal
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C M Y CM MY CY CMY K
Filler Up! Continued from page 63
engine fires. With this procedure, they
have eliminated premature pump and
converter failures that they were seeing
in previous units. Also, with your assis-
tant behind the wheel, there is another
tactic you can employ in dealing with
units that are slow to fill: they can start
and stop the engine in conjunction with
you putting in the oil. For example,
on this 450-43LE, you have filled the
sump and converter before starting the
engine. Upon engine start, you begin to
(slowly theres that skinny fill tube!)
fill the sump as fluid is picked up by
the pump. However, the pump can
suck up fluid way faster than you can
fill the pan. After initial start up, have
your assistant turn off the engine after
about 10 seconds. This will allow you
to continue filling the sump until the
pan is full, and then the engine can be
restarted. You may have to go through
this procedure multiple times before
the unit is completely full, but you can
be confident that you will fill the unit
without damaging any components.
Once its full, drive the vehicle
and check the fluid again. Then check
it again. Checking ATF levels can be
tricky, especially with some of the very
66 GEARS
Significant Bearing Damage
thin oils that are in use today. It can be
tough to read the dipstick when the oil
is fresh! I have seen very experienced
techs get false readings on dip sticks,
and then proceed to test drive the car
when it was really a couple of quarts
low. It doesnt take much time to double
check that you have the correct amount
of fluid, especially when you are about
to put the unit through its paces with
a vigorous test drive and/or adaptive
learn process. It would be unfortunate
to get everything right only to damage
the unit upon the test drive because of a
lack of fluid.
In conclusion, when it comes to
getting oil into the transmission, dont
get lulled into a false sense of security.
Even though some of the topics dis-
cussed here may seem quite basic, you
cant assume that everyone is as critical
as you are about the details. You cant
expect general repair techs (much less
a do it yourselfer) to keep up with
all of the different procedures for all of
the different units. In the past, perhaps
you have filled more 4L60s, 4R100s
and 46REs than you care to remember.
But dont confuse the fill procedure on
one of these simple units with filling
a late model unit. Transmission builders
do not always have control over who
installs their products. Before turn-
ing that great transmission and torque
converter over to a complete stranger,
or even a seasoned technician, make
sure that they have a good understand-
ing of what it takes to properly get oil
into the unit. Otherwise, there is a good
chance that you may be going back into
that transmission, with at least another
pump and torque converter.
Steve Jaussaud is Vice
President of Sales and Marketing
for Sonnax.
Sonnax supports the Torque
Converter Rebuilders Association.
Learn more about the group at
www.tcraonline.com
Special thanks to Chris Lenox
at Camerota Truck Parts in Enfield,
CT and Mike Maravelas at Bobs
Transmission and Clutch Service
in Simi Valley, CA for help with this
article.
October 2007
 4L30E Shift Kit is the FIX
BUSHING: New Center Support Distribution Bushing
Would you like to replace the Rear Band only once?
Valve Body & Pump Parts/Upgrades Input Shaft Valve

George Reed
CJs Auto, Bruceton Mills, WV 26525
4L30E Isuzu Rodeo 2000
13 June 2007
Slips Forward and Reverse ----
CEL
99,356 miles. EBR
The rear band was shot and the rear drum scored up. ATE
The clutches were not worn at all. We installed band !
and drum, new clutches and a rebuilt converter, made
a road test, and gave it to the customer.

The very next day it was towed in

with no drive forward.
The 1-2 rear band was totally burned out - again.

I called TransGo and David told me the band burns up when the distribution bushing in the
center support wears or is to loose.
The distribution bushing leaks rear band release pressure which allows the 1-2 band to drag
on the drum in 3rd and 4th.
He said, if you will write a report on the problem we will send you a Center Support
Bushing with the right clearance and a precision installation tool at no charge. Otherwise,
David said, A new center support for prox $230 will, at least, get it out the door for awhile.
Parts came UPS overnight. I was totally relieved to have the fix in my little hot hands. This
letter is the report I promised.
We cleaned unit up, installed the TransGo bushing and a new band.
TransGos insisted on a thorough test, so we drove the car 4 days, 150 miles and made
sure we got it hot. It has been 2 weeks and the customer says its working better than ever.
Weve used TransGo kits for 15 years and firmly believe that they let us do a better job for
the customer, and also keep us out of trouble.
George Reed

 Putting our shop
online was one of the best
things weve done in a long
time. Best of all, ATRA
makes this process extremely
easy and affordable.
9 Year Member
"ATRA's
Technical Department
continues to be one of the
leaders in training and support.
The 'On-Line' help has broken
new ground and is
second to none!"
21 Year Member
Benefits of Membership
Technical & Educational
Technical Seminars
Technical HotLine
ATRAs Online Tech Center
Books & Monthly Bulletins
GEARS Magazine
ATRAs Powertrain Expo
Testing & Certification
Join ATRA Membership TODAY!
www.atraonline.com/member_center
atra memshp rv107.indd 53
"Having a
nationwide warranty to
offer my customers is a great
thing, but having a warranty
that works is even better."
4 Year Member
"ATRA is a
major contributor to the
advancement of the education
of auto technicians and I am
pleased to be a part of that
effort."
College Testimonial
Reduced Fees
Reduced insurance & credit card processing fees
Discounts for all ATRA Events & BookStore
Website, design & hosting at discount
Nationwide Warranty
With nearly 2000 members ATRAs network of
professional service centers can provide
nationwide warranty coverage to your
customers.
...and much more
866-GO-4-ATRA 866-464-2872
1/5/07 3:27:45 PM
 efficiency, quality, value
D
ACCO, Inc., founded in
1965, is the largest supplier
of torque converters in the
North American independent aftermar-
ket. They supply the broadest prod-
uct offering of transmission products,
including torque converters, hard and
soft transmission parts and complete
transmissions in the market. When
General Manager Ray Jones arrived in
2002, his first job was to put together
an experienced team with the talent and
technology to position the company to
reach its full potential. In five years,
he has made several major changes.
One was the implementation of the
new computer system in the company-
operated stores that links them in real
time to the main location in Cookeville,
Tennessee. In 2005, the semi-trucks
were equipped with the computer sys-
tem, and now function as rolling parts
stores. DACCO has also implemented
a disciplined quality control system to
continually improve and increase cus-
tomer satisfaction and torque converter
reliability.
Don Looper, Sales Manager, has
been with DACCO since 1978 and
is responsible for route salesmen,
overseeing new store openings, and
22 of the company-operated locations.
70 GEARS
When asked how he manages to juggle
all of these tasks, Don gives credit to
his team, They work well together and
help each other.
Randy Adams, Retail Operations
Manager, joined the DACCO team in
2004 bringing with him experience
in sales, marketing, manufacturing
and product distribution. Randy is
responsible for 29 of the company-
operated locations, and oversees the
Cookeville Distribution Center team.
Randy states, Our Retail Operations
team is hands on, going from store
to store to help build sales, improve
customer service and plan for future
expansion.
DISTRIBUTION OF PARTS
DACCOs products are sold to
aftermarket distributors, company-
operated stores and transmission
repair shops across the United States,
Canada, and Puerto Rico. They supply
virtually every type of torque converter
dating back to the 1950s for domestic
and import passenger cars, light
trucks, sport utility vehicles and other
mobile industrial equipment. These
product breadths is unparalleled in
the aftermarket, offering over 1,200
SKUs of torque converters alone from
200 different product families and
are considered best in class in the
aftermarket as they are produced to a
quality level that rivals OE parts.
Supplementing DACCOs industry
leading product offering is a highly
unique and efficient distribution system
providing transmission components
to thousands of customers daily.
This extensive company-operated
distribution system is comprised of
50+ company owned and operated
stores plus 35 route salesmen (over
the road salesmen), allowing DACCO
to control the supply chain for its
products. The DACCO system not
only delivers parts, but also recovers
95% of torque converter cores allowing
maximization of product offerings and
closely managing customer relations,
providing DACCO with a substantial
competitive advantage in the market
place. This efficiency is reflected in
the quality and value of DACCOs
products.
To complement DACCOs broad
torque converter product offering and
sales, the company carries thousands
of soft and hard parts for one stop
shopping convenience. These soft
transmission parts are an important
aspect to customer service. To further
October 2007
 In the middle of a group discussion, your Dacco Team hard at work:
Seated LR: Ray Jones, Don Looper, and David Carter.
Standing LR: Kelly Hammock and Jimmy Key.
differentiate its product offering,
DACCO has forged highly coveted
relationships with some of the industrys
most prominent suppliers, including
Timken, Freudenberg-NOK, Raybestos
and Borg/Warner.
DACCOs 50+ company owned
and operated stores and over 150
independent aftermarket distributors
are supported by DACCOs network
of 35 commissioned route salesmen, or
over-the-road (OTR) salesmen. These
route salesmen are integral to DACCOs
impressive customer service function.
In addition to delivering products, they
provide the following services:
Core collection support
Technical assistance
Total customer service
All route salesmen conduct trans-
actions, including product sales and
core recovery, leveraging the tech-
nology featured in each semi-truck.
These semi-trucks are highly sophis-
GEARS October 2007
dacco4pager.indd 71
ticated sales machines complete with
laptop computer, printer and bar code
scanner. Each semi-trucks computer is
linked in real time via a secure satellite
to the DACCO network. This invest-
ment in technology, allows DACCO
complete visibility over operations and
route salesmen, enabling management
to monitor sales performance, manage
core collection, ensure cash collection,
maintain standard pricing and efficient-
ly replenish and allocate inventory to
company-operated stores and trucks
while delivering unparalleled customer
service.
A DEVELOPED
PARTNERSHIP
Given the increasing complexity
of transmissions, DACCO is poised
to leverage its competencies in
remanufacturing to expand sales
volume. Launched in late 2006,
remanufactured transmissions are now
sold by DACCO through their company-
operated stores and select distributors.
As remanufactured transmissions
continue to capture additional shares of
the replacement transmission market,
DACCO partnered with sister company
Alma Products where DACCO
provides the torque converter, soft
parts and select hard parts and Alma
is responsible for the remanufacturing
process. This approach allows
Alma to leverage existing complete
transmission manufacturing capacity
and enables DACCO to expand product
offering to company-operated stores
and customers.
LEAN CELL
MANUFACTURING
DACCO began the process of
lean cell manufacturing in 2006. We
initially installed six assembly cells
looking to improve on labor efficiency
and quality. Ray Jones said, It has
improved labor significantly and
allowed for the additional installation
of two repair cells. This has reduced
line work in process by 20% and
71
9/21/07 3:10:42 PM
DACCO: efficiency, quality, value
improved our traceability of quality.
DACCO plans completion of eight
additional repair cells by end of 2007.
EXPANSION OF
LOCATIONS
DACCO currently has 50+
company-operated stores, over 150
distributors and 35 route salesmen
located throughout the United States,
Canada, and Puerto Rico. They will
open one more company-operated store
A working lean cell in action.
72 GEARS
by year-end and averages two new system to company-operated locations,
distributorships every year.
CUSTOMER SERIVCE
In the fast paced aftermarket world,
DACCO maintains customer relations
and personal service by product delivery
with company personnel as much as
possible. This is accomplished with
counter sales experts and experienced
drivers from the 50+ company-operated
locations, to having one of the DACCO
semi-trucks stop at the
customers shop. For hallmark of DACCO for the past 42
the times the customer
needs a part drop
shipped, DACCOs sales industry, DACCO is firmly set for the
department is linked in
real time to all stores and
salesmen to leverage the
inventory at all cross-
country locations.
DACCO has also
expanded their technical
help line for customers
who need assistance
identifying or cross
matching a torque
converter or other related
technical assistance.
With the addition of
their new computer
the semi-trucks and corporate, they can
see where inventory is more readily
and are capable of shipping more
efficiently. If a customer is get-ting
a quality product, with good value,
and professional service, they are not
only more likely to stay with us, but
to recommend us to other transmission
repair professionals says Jones.
TOMORROW
Quality and service have been the
years. Although there have been many
changes in the automotive aftermarket
future. By building and maintaining
strong partnerships with companies
like Alma and other suppliers, and
with the addition of the lean cells and
other manufacturing innovations, they
continue to provide quality products.
With these innovations and superior
customer service, DACCO will
continue to be the industry leader well
into the future.
October 2007
 GEARS October 2007 73

dacco4pager.indd 73 9/21/07 3:11:30 PM

FROM THE TECH DIRECTOR

Lifetime
Warranty?
Sp
e a ker

Dont give up just Yet

by Lance Wiggins

T
his past July
26, Chrysler
announced the
introduction of a new
limited lifetime warran-
ty on their basic car line.
Within hours, the auto-
motive newsgroups and
message boards were
abuzz this was it: the
end of the independent
auto repair industry!
Everybody close your
doors and sell off your
equipment while you
still get a few cents on
the dollar!
Well, maybe you
should hold off just a
bit on the going-out-of-
business sale.

Lifetime Limits
Yes, Chrysler does now offer a
limited lifetime warranty on cars sold
after July 26, 2007. This includes all
their regular cars for model year 2006
through 2008. Currently, theyre plan-
ning on extending this offer through the
end of the 2008 model year, but they
arent committing to any further than
that just yet.
The lifetime warranty doesnt cover
Chryslers trucks or their SRT perfor-
mance vehicles. You know: the ones
in which people regularly tear up the
transmissions. Most are still only cov-
ered for 3 years/36,000 miles. The new
lifetime warranty also doesnt cover
work vehicles: police cars, taxis, lim-
ousines, postal delivery, ambulances,
rental or government-owned vehicles
again, the ones that cant keep the
transmission going. Theyre also still
covered with the 3/36k warranty.
In addition, the lifetime warranty
only covers the powertrain, and only
applies to the original owner. If the
original owner sells the car even to a
family member the warranty reverts
to the standard warranty.
If that isnt enough, the car has to
be up to date on its maintenance for
the warranty to be enforced. Does that
mean your transmission warranty could
be void if you forgot to have your tires
rotated? I dont know: The wording on
the Chrysler web site is very vague, and
open to interpretation.
Probably the biggest exclusion is
the five-year anniversary inspection:
To maintain the warranty beyond 5
years, the owner must bring his car
to an authorized Chrysler dealer to be
inspected, within 60 days of each 5-
year anniversary of the warranty start
date of the vehicle.
Thats a good one: Most guys cant
even remember their wifes birthday or
their wedding anniversary youre
expecting them to remember the 5-year
anniversary of when they bought their
car? And the 10-year, too: remember,
it says each 5-year anniversary. Good
luck with that one!
Great Marketing Gimmick
So with all those exclusions and
fine print, why bother? Why offer a
warranty that almost no one will ever
be able to take advantage of oh, wait:
Now I get it.
This new lifetime warranty might
be one of the cleverest marketing gim-
micks anyones ever conceived. And

74 GEARS October 2007

 This new lifetime warranty 2006 issue of GEARS, those extend- thrilled. But think of how easy its
might be one of the cleverest ed warranties only pay for the actual going to be for you to sell a complete
marketing gimmicks any- repairs needed to the transmission. That rebuild for just $500 or $600 more.
ones ever conceived. And is, if the high clutches are burnt, theyll Youll make the sale, and gain a life-
look at the date: July 26. pay to replace the high clutches, includ- long customer who thinks youre the
Just about a month away ing the necessary cleaning, fluid, seals greatest, because you helped him get
from the introduction of the and gaskets, and R&R. But they wont the rebuild he wanted, without paying
new model year. pay to rebuild the entire unit. big bucks for it.
Thats actually great news for you; Will the new lifetime warranty have
look at the date: July 26. Just about a heres why: A customer comes in with an impact on your business? Maybe;
month away from the introduction of his extended warranty, 80,000 miles maybe not. Only time will tell for sure.
the new model year. I wonder just how on his trans, and a burnt set of clutch- But you can be sure that theres still
many cars they have sitting around that es. You estimate the repairs at $1400. plenty of work to be had, if youll go
they havent been able to move. Could Thats all the warranty company will out and sell it.
they be using the new warranty to help pay to fix the actual problem. And dont give up just yet.
them clear out their inventory, to make Sure, the customer might not be
room for the new models?
And lets face it: No one wants to
honor warranties. Warranties sell prod-
uct, but honoring them costs money.
Some businesses such as ATRA
members avoid having to honor
their warranties by providing quality
work that lasts far beyond the warranty
period.
Other businesses limit the number
of warranties they have to honor by
throwing in all sorts of limitations, such
as original owner, up-to-date mainte-
Ready to Shift to a Better
nance, and a regular, mandated inspec- Insurance Program?
tion. Its legal, and theyve spelled it all
out in advance, but whether anyone will Get into Gear with
ever be able to take advantage of their
lifetime warranty coverage remains Heffernan Insurance Brokers.
to be seen. We offer:

Take Advantage of
the New Warranties Property/Casualty Employee Benefits
In the meantime, Id put off closing Garage Liability/Garage Keepers Medical/Dental
your shop in a panic. Instead, you might
Property/Tool Coverage Vision/Life
want to go have a talk with your local
Chrysler dealership. They might be in Auto Disability
need of a quality transmission repair Workers Compensation HR Assistance
shop, to handle any warranty repairs
that slip through the exclusions.
Keep in mind that, while Chrysler Contact us today!
is the only manufacturer offering a fac-
Property/Casualty Employee Benefits
tory lifetime warranty, many other deal-
ers offer extended warranties. Not much Earl VanBuskirk Jani De La Rosa
wonder there: many of those dealers earlv@heffgroup.com janid@heffgroup.com
actually make more selling the war- Paul Wills Shauna Gilbert
ranty than they did on the car itself. paulw@heffgroup.com shaunag@heffgroup.com
Thats okay: You can take advan-
tage of those warranties, too. Make sure
800.234.6787
you add something to your Yellow Pages
www.heffgroup.com
ad that says: We Honor Aftermarket
License #0564249
Warranties. As ATRA Member Kit
ATRA program facilitated by
Lindsay explained in his article on
Heffernan Insurance Brokers and Brant Watson.
extended warranties in the September,

GEARS October 2007 75

 ATRAs
Powertrain
ATRAs

Expo 2007! Powertrain Expo

October 11-14, 2007
Las Vegas Hilton

Please download
seperately,
page 76
Exhibitor Directory
October 2007 Las Vegas, NV

76 GEARS October 2007

 ATRA NEWS

A.T.R.A.
Going Strong in
Australia
Being a shop owner and rebuilder
has its challenges as we all know.
Being a Technical Trainer in transmis-
sion repair is also a challenge. You must
be able to relay the proper informa-
tion in the correct fashion in order to
assist technicians in performance of
their trade.
John Sollazzo from Precision
International received a request from
ATRA Australia at the 2006 Expo in
Orlando and asked if I could put a
seminar together for Australia. Little
did I know when I said yes to Mr.
Ken McIntryes (ATRA Australia)
request to come to Australia and give
some training seminars that I would be
doing six seminars total in less than 10
days!! This covered the entire conti-
nent which is 24 hrs from my home by
plane!! After several months of e-mails
between myself and Ken McIntyre, I
fine-tuned a seminar for Australia.
Mr. McIntryre wanted the best
possible seminar for his membership.
The parent organization for ATRA
in Australia is I.A.M.E (Institute of
Automotive Mechanical Engineers)
whose president is Mr. Frank Burgess.
He also wanted the best possible train-
ing for his membership.
The trip was to start in Brisbane
on the northeast coast, proceed south to and shop owners, just like me, thou- I met Ken McIntyre, Manuel Busaca,
Sydney, go inland to Canberra, travel sands of miles from my home were Kym Page and Stu Bailey to name a
south to Melbourne, travel west to going through the same things that I few. I hope you enjoy these pictures
Adelaide, and travel all the way west to see in the USAtrying to fix vehicles and if you see someone from Australia
the foot of the Indian Ocean to Perth. properly and professionally. Jobs that I at this years Expo in Las Vegas say
Then upon completion, I flew back to left in my shop in New York I saw the hello. We are all closer than you
Sydney back to Los Angeles, and then same units in Australia! think.
back home to New York. All this took Before and after every class, there All the best
place in under 2 weeks time. Almost were conversations among the techs John Parmenter
every day I was on a plane or giving a about how they were tackling tough Precision International
seminar or visiting a shop and talking jobs, with the ATRA and I.A.M.E. rep- technical@transmisionkits.com
with the technicians. resentatives in each city making it pos-
As you can see by the pictures I sible. I met some exceptional people
made it! Tired and worn down, yet from the I.A.M.E. staff: Frank Burgess
with a great feeling inside. Technicians and Maria Alessi. From the ATRA staff,

108 GEARS October 2007

 375 TURNER INDUSTRIAL WAY
ASTON, PA 19014
PHONE (610) 485-9110
FAX (610) 485-9356
www.transmission-specialties.com

With over 30 years of hard work and dedication
to excellence, Transmission Specialties has
become one of the premiere manufacturers of
high performance automatic transmissions,
torque converters and related parts in the U.S.A.
Service is where Transmission Specialties
prevails, when you call to place an order, you will
get a person not an automated phone system to
waste your time. We pride ourselves on same
day shipping. We are a company large
enough to serve you and yet, we are
small enough to know you!
Some of our innovative products, such as the
XLS-Spragless Torque Converters, Pro-Line
Powerglide Transmissions, 1:80 Unbreakable
Gear Sets, Torque Converter Component Kits and
Transmission Related Parts are all manufactured
in-house. Every product is specified to meet or
exceed the toughest industry standards.
HOME OF THE
WORLDS QUICKEST
CONVERTER

trans-spec prof.indd 137 12/21/05 12:32:13 PM

 Meet the
ATRA HotLine!
Over the last few months we start-
ed to offer you a more intimate look at
some of the guys who spend their days
helping ATRA members dig through
those tough technical troubles. Here are
the next two on our list: Mike Brown
and Pete Huscher.
Mike Brown
Technical Advisor
Mike Brown got his first taste of
the auto repair business when he was
just a kid: His father used to buy used
cars that needed repair, and he and Mike
used to fix them up for sale, long before
Mike got his first drivers license.
His brother, Ken Racer Brown,
rebuilt Allison transmissions for the
city, and fixed transmissions for cus-
tomers on the side after work. Mike
would remove transmissions on the
driveway after school, and his brother
would rebuild them when he got home.
Those early years must have had a
profound effect on Mike: His first job
out of high school was in a local repair
shop. He began as a general technician,
doing brake work, engine repairs, and
so on. He worked there for nearly 16
years.
Back then, Mikes brother would
tell him, One day Ill open my own
shop, and youll come to work for me.
Ken opened Browns Transmissions,
and true to his word, he asked Mike
to join him. Thats where Mike got his
start with automatic transmissions. And
it really was Browns Transmission
at one point everyone working there
was a member of the Brown family.
Mike continued working with his
brother until he injured his shoulder.
During rehab, a career councilor asked
Mike what hed like to do with the rest
of his life. Thats when he remembered
seeing an ad in GEARS for the ATRA
HotLine. The councilor set up an inter-
view, and soon after Mike went to work
for ATRA.
Since coming to ATRA, Mike has
written a number of articles and bul-
letins, and is currently working on a
110 GEARS October 2007
Mike Brown
rebuild book for the Toyota A761E
transmission. Hes also planning for
his first seminar at this years Expo.
His topic? Toyotas A750E
5-speed, and the lightest 6-
speed automatic in the world:
the A761E.
Probably his greatest sat-
isfaction comes from help-
ing other technicians when
theyre having trouble. I love
being able to work through
transmission problems, and
helping find ways to make
them last longer, he says.
Working for ATRA is like
living my dream.
The rest of his dream
comes true when Mike goes
home at night to his family.
He and his wife Vicky have
been married for three years.
His baby daughter Ashley
just celebrated her first birth-
day, and he has a 13-year-old
stepdaughter named Haley.
Mike says he and Haley have
a terrific relationship.
Mike loves to play golf,
and is an avid NASCAR
fan. Hed like to go to
Bristol, Tennessee to watch myself by hand painted it myself
a NASCAR race. It looks like a great it was really something to see what it
track, he says. turned into. But he swapped that to
He used to spend much of his become a dad; I traded up, Mike says
free time restoring his 1956 Chevy; he with a chuckle.
bought it for $1800, and sold it five And theres little doubt that he
years later for $15,000. It was a basket means every word.
case when I bought it; I put it together
The New Transtar

Transtar Industries, Inc., headquartered in Cleveland, Ohio, is the leading worldwide distributor of
OE quality transmission parts to the aftermarket motor vehicle repair industry. Transtar distributes
a comprehensive line of Automatic and Standard Transmission Rebuilder Kits, Torque Converters,
Electrical Products, Hard Parts, Specialty Tools and Service Items, and other driveline products.

We all know that the transmission industry has gone through many changes and evolutions
throughout its history. However, one constant has remained: Transtars commitment to offer the
highest quality parts and service.

Service
Transtar delivers more than just parts to our customerswe deliver success. Our combined team
represents the most knowledgeable and experienced group in the industry. With Sales Reps who
know exactly what parts you need for your quality rebuild, and the technical expertise of our
expanded group of Product Managers, we can provide our customers with the best possible
service. They not only make sure you get the right part the first time, but that you get it on time.

Product
Transtar provides the most comprehensive product line in the industry. Our inventory represents
the highest quality array of products in both Original Equipment and Aftermarket products. In
addition, we have added RECON brand torque converters and hard parts to our product line.
RECON remanufactured torque converters and hard parts lead the industry in quality and
dependability.

Presence
It goes without saying that having more locations gives us the ability to provide better, faster
service. With our merged locations, we are able to serve approximately 90% of the top markets in
North America with same-day delivery. Best in class service from a world-class company!

Transtar, The One.

With all the quality products you need, outstanding service, on-time delivery, and the knowledge
to help keep your business running smoothly, Transtar is the first and last word in transmission
parts supply.

Toll free: (800) 359-3339

E-mail: info@transtar1.com
Web Address: www.transtar1.com
Corporate Headquarters:
7350 Young Drive
Cleveland, Ohio 44146
ATRA NEWS
Pete Huscher Pete Huscher
Technical Advisor
They say life is what happens
while youre making other plans. Pete
Huscher never really planned to be
an auto technician. He took academic
courses in high school, and after serv-
ing in the U.S. Army, went to UCSB in
Santa Barbara, CA, where he earned his
degree in marine biology.
Unfortunately for Pete, his real
education didnt begin until after he
graduated; thats when he learned that a
degree in marine biology wasnt nearly
as marketable as he had hoped. In fact,
the only job he could find in this field
was at Marineland, which would only
pay $1.25 an hour to start. Not nearly
enough to support himself and his fam-
ily.
Fortunately, he had more than a
little automotive experience: Hed spent
his early years working on his own car,
a 1968 Camaro, which gave him enough
of a background to work in the motor
pool when he joined the Army. There tired of traveling around and
he earned his certification in gas engine being retired, he decided to
repair, diesel engine repair and electri- go back to work.
cal system diagnosis, winning numer- Pete joined the ATRA Technical
ous awards and early promotions for his Department in 2001. Hes written
technical abilities. Pete was eventually numerous articles for Gears maga-
promoted to Motor Pool Sargent (acting zine and bulletins for the Technical guys half his age. And he likes obtain-
corporal) where he was responsible for Department. Pete is currently working ing dead cars, motorcycles, dune bug-
the maintenance and repair of hundreds on a seminar for this years Expo, called gies and boats (anything really) that
of jeeps, trucks, tanks, and armored per- Understanding Todays Domestic Four other people have given up on, rebuild
sonnel carriers. This unknowingly gave Wheel Drive Systems. or repair them, and give them a chance
him a terrific fallback position after his If you ask Pete whats your favor- to live again.
college years. ite part of working for ATRA? Hell But nothing in his life gives Pete
After a disappointing interview at say Every time that phone rings, its greater pride than in having raised his
Marineland, Pete found a job at a local another chance for me to help some- son. He and his wife separated when
Nissan dealership, as a lube technician one, he says. I love helping people. their son Joey was just over a year old.
and eventually made his way to the If I didnt work for ATRA, Id have to That was nearly 25 years ago,
local Ford dealership and worked his work for the Red Cross. Petes been a single parent for over 25
way up through the industry. One day, In fact, when he retires again, Pete years now and he never remarried. As
his boss asked him whether he could hopes to be able to devote his time to Pete points out: when youre a single
rebuild automatics. Sure, Pete said; helping others by volunteering with parent, your kid has to be your num-
if anybody can do it, I can do it. And the Peace Corps, the Red Cross, or ber one priority, your needs come last.
he then proceeded to work his way Habitat for Humanity. I love people; Some people think I made a mistake,
through learning how to rebuild trans- people are the best invention there is, but Im proud of my decision and of
missions. After spending over twenty he quips. my son.
years in Ford dealerships as a techni- In his spare time, Pete still thinks And while he may not have planned
cian and then as service manager, Pete hes a youngster: He enjoys going out his life this way, theres little doubt
retired at an early age of 42 years old. dancing, kayaking, snowboarding, ski- Petes pleased with how its turned out
Pete spent the first part of his retirement ing, surfing, scuba diving and riding his so far and the direction that its head-
traveling all around the U.S. and into motorcycle up and down the coast ing.
Mexico. Eventually Pete got sick and all activities we usually associate with

112 GEARS October 2007

Lets talk about
Chapters!
AT the IBO level, we have created
and assigned a new position to an exist-
ing staff member. Deon Olmos has
been in touch with many of the chapter
presidents already. She is our T&C
coordinator and is now also the Chapter
Liaison within the membership depart-
ment. She will be more active with
the chapters and getting them involved
as well. Both positions go hand in
hand with the educating of the industry
as well as getting the members more
involved so she is the perfect fit for the
new position.
In addition, we are creating a new
Chapter Handbook. Some of you may
be aware that we have 3 new chapters
currently in the process of being cre-
ated. Now that they have started the
process they would like some guid-
ance, so we are creating this handbook
mostly for them, however with some of
the new guidelines that we are putting
together, it will also benefit the existing
chapters.yes even the more active
ones.
We are setting up checklists as
guidelines for activities within the
chapters as well as the beginning stages
of a Chapter Champions program for
receiving the recognition they deserve
by being as active as they are. Overall,
this process is quite detailed but it is
definitely needed and will help all the
Members Directory Updates
These firms have recently applied for ATRA membership. Please add their names to your directory. If you know of any valid
reason these firms should not be members of ATRA, please contact ATRA Membership Services at 805-604-2000.
Certified Auto Repair
207 Olive St
Atlantic. IA 50022
(712) 243-1392
Mission Auto Care, Inc
3588 Mission Ave.
Oceanside, CA 92058
(760) 722-0231
Pro Auto
1910 S 7th St
Lebanon, OR 97355
(541) 259-2155
114 GEARS October 2007
chapters with gaining volunteers as
well as generating ideas for meetings
and hiring of new personnel. We plan
to have the new handbook ready for
distribution at the Chapter Presidents
meeting at this years EXPO.
ATRA and Industry
News
ATRA has taken a step forward
in its ability to reach out to you, the
transmission repair community, with
the ATRA eNewsletter. The ATRA
eNewsletter allows us to contact the
entire industry with a single click of a
mouse.
What? You dont receive the ATRA
eNewsletter? Lets take a quick look at
all youre missing:
First, the ATRA eNewsletter pro-
vides a wealth of special offerings
that you may not find anywhere else.
Whether its a waived application
fee for new members, free setup for
an ATRA-hosted website, or a free
months membership fee, youre sure to
see some great deals in every issue.
Each eNewsletter also includes the
ATRA Seminar schedule for the next
few months, complete with the dates,
locations and any special information
youll need to find the seminar thats
closest to you.
We also include important news
announcements about ATRA, our annu-
Proformance Transmission
#7 5041 Auto Road SE
Salmon Arm, BC V1E 1X1
(250) 832-6595
Vintage Trans & Gear
560 Valdry Ct
Brentwood, CA 94513
(925) 513-4095
al Expo, or issues that could have a
dramatic impact on you and your busi-
ness. Chapter announcements, ATRA
Board meeting information and elec-
tions, special voting issues, and new
ATRA member listings all appear first
in the ATRA eNewsletter.
Each announcement includes a
unique link to take you right to an
in-depth analysis or article covering
the issue at hand; with a single click,
you have all the information you need
to stay informed on the most critical
issues facing you and your industry.
Youve never received the ATRA
eNewsletter? Well, dont miss another
important issue: Visit our website at:
www.atraonline.com/eNews/ to add
your email address to the growing list
of eNewsletter subscribers.
Make sure you add the domain
www.atra.com to your spam blockers
white list, to prevent it from blocking
these important news bulletins. And
then you can get ready to stay in touch
with all the news thats fit to print: the
ATRA eNewsletter!
ATRA News Quote -October
Finish each day and be done with
it. You have done what you could;
some blunders and absurdities have
crept in; forget them as soon as you
can. Tomorrow is a new day; you
shall begin it serenely and with too
high a spirit to be encumbered with
your old nonsense..
Ralph Waldo Emerson
 2007

2007 2007

POWERTRAIN INDUSTRY NEWS
Former Gears Editor
Pens Military Thriller
Set For Release
Paul Morton
Former Senior Editor for GEARS
magazine, Paul Morton, has signed a
deal with Los Angeles-based publisher
Bonus Books to publish his first novel,
TRACK OF THE DRAGON, set to
release in October 2007. Morton, who
currently serves as the Psychological
Services Case Manager for the Homer,
Alaska, Police Department, is also an
experienced feature writer and Vietnam
veteran who served with the U.S. Army
in Southeast Asia in security and intel-
ligence-gathering operations.
Set in 1970when public opinion
against the Vietnam War had brought
riots to the streets of America
DRAGON focuses on what is often
referred to as the secret war, involv-
ing U.S. special operations troops that
were training the CIAs private army
in an intense effort to thwart the spread
of communism. Morton addresses the
human side of the conflict as he follows
one young soldiers journey into the
blurred moral boundaries of a war that
at the time, most Americans had no idea
was being fought.
Very few first-time novelists are
able to create page-turners, said Jeff
Stern, president and publisher of Bonus
Books and its imprint, Volt Press. But
with his extensive background as a
magazine writer combined with his
own firsthand military experience, Paul
has managed to bring us a story that is
not only thrilling and smart, but also
jarringly relevant in the face of todays
conflict.
116 GEARS
GEARS does not endorse new products but makes this new information available
to readers. If you have a new product, please email the press release information
with applicable digital photo or drawing to pressrelease@gearsmagazine.com or
send by mail to GEARS, 2400 Latigo Avenue, Oxnard, CA 93030.
During his military service, Morton
served two years with the National
Security Agency and went on to spend
over two decades in law enforcement in
Ventura, California. His career includ-
ed a lengthy tenure on the Special
Weapons and Tactics team and he was
awarded two Medals of Valor. After
an injury cut short his law enforcement
career, he obtained a masters degree
in counseling psychology and began
his work with veterans, peace officers
and crime victims on issues involving
post-traumatic stress. Over the past
20 years, Morton has also written over
300 articles for a range of consumer
and trade publications, and has received
three international writing awards. He
and wife Jeannette have three children
and currently reside in Homer, Alaska.
For more information or to pre-
order Track of the Dragon, you can go
to: http://www.bonusbooks.com/book-
page.asp?BookID=1361
New Governor Bore
Plug Kit Introduced by
Sonnax
A new governor bore plug kit from
Sonnax prevents critical oil leakage
and provides improved shift timing
and throttle control in a wide variety of
Chrysler rear wheel drive units.
Wear in the valve body casting at
the large diameter of either the 1-2 or
2-3 governor plugs causes governor
oil pressure to leak past the shift valve
governor plugs in A727, A904 and
42-46-47-48RH/RE applications. This
wear can cause shift timing changes at
different operating temperatures, and
often causes a shuttle or late shift.
When this leak is combined with
a governor solenoid and transducer
feedback, they are often too slow to
compensate. The throttle circuit is also
prone to wear and has TV pressure
variation from crossleaks, which then
effect shift timing.
The Sonnax governor bore plug
kit 22771-14K fits both the 1-2 and 3-4
governor bore locations and comes with
Teflon seals (one extra) to eliminate
these leaks: a real valve-body saver.
For more information on this or
any of the Sonnax repair kits, stop by
the Sonnax web site at www.sonnax.
com.
ProfitBoost Tablet PC
Allows Full Wireless
Access to Its PIF
Software
ProfitBoost, LLC the mak-
ers of the PIF Pro Shop Management
Software announce the release of
the ProfitBoost Tablet PC. The Tablet
PC has been optimized to allow total
wireless access to the complete shop
management system from anywhere in
a business.
The ProfitBoost Tablet supports
laser barcode scanning, which dramati-
cally speeds up data entry in a number
of areas. Adding parts to a repair order is
now as simple as scanning the barcode
and selecting the quantity. Inventory
audits can be done at the shelf, wire-
lessly showing real-time information.
Vehicle Identification Numbers (VINs)
can be scanned from the car, guarantee-
ing fast and accurate entry.
The device, developed by Samsung,
October 2007
has a long battery life, allowing the
device to be used continuously for
hours. The Tablet PC is smaller than
conventional tablets and can be easily
held in one hand.
Bottom line: the ProfitBoost Tablet
PC saves time and increases accuracy
by bringing the computer where it needs
to be in the shop, said Scott Johnson,
president of ProfitBoost Software. Its
easy to use and we are very excited to
offer this to our customers.
ProfitBoost Software will be dem-
onstrating the Tablet PC and their com-
plete Shop Management System at the
annual ATRA Powertrain Expo 2007.
Stop by booth #1001 for a complete
explanation of how it can benefit your
business. Information is also available
on the web at www.ProfitBoost.com or
phone 1-888-274-3776.
Kit Available for
Damaged Oxygen
Sensor Port Thread
A l c o a
Fastening Systems
(AFS), makers of
the Fix-A-Thred
repair product
line, is now offering the Fix-A-Thred
Oxygen Sensor Thread Repair Kit.
The kit, housed in a sturdy case,
contains an installation tool and high-
temperature Inconel inserts, supply-
ing all necessary equipment needed to
permanently repair damaged oxygen
sensor port threads in the exhaust mani-
fold. The repairs made possible with
this kit eliminate the need for exhaust
manifold replacement.
For more information, contact
Alcoa Fastening Systems at 800-732-
3470, or online at www.alcoafastening-
systems.com.
GEARS October 2007 117
Winona Van Norman
Launches Redesigned
Web Site
converters for automotive and heavy
Winona Van Norman, headquar-
tered in Wichita, Kansas is pleased to
announce it has updated and launched
their web site, www.winonavannorman.
com.
Through this faster and more user-
friendly web site, current and prospec-
tive clients can learn about the company
and its products, request information
and download literature. The web site is
a step toward achieving the companys
goal of becoming the engine machine
shop company of choice. Updated infor-
mation and a comprehensive site profile
the wide range of equipment, including
boring, cleaning, grinding, honing and
milling machinery.
Weve made it easier to find infor-
mation, explains Britton Harper, mar-
keting director, and simply by creating
a user profile, company literature can
be downloaded. Updated photography
with a complete line of equipment is
now available. Literature will include
specifications, features and benefits of
the products.
Winona Van Norman is a premier
manufacturer of engine and engine
component machining equipment.
Since 1888, the company has designed
and manufactured machining equip-
ment and continues to offer new, inno-
vative solutions. A full range of equip-
ment includes machinery for motorcy-
cles, small engines, automobile, diesel,
marine and high performance engine
rebuilding
For additional information on
Winona Van Norman, contact the com-
pany toll-free at 1-800-533-8008 or
visit their web site at www.winonavan-
norman.com.
ETX, Inc. Acquires
Accurate Transmissions
ETX, Inc. announced today that
theyve acquired substantially all of
the assets of Accurate Transmissions,
Inc. Accurate Transmissions is one of
the largest production remanufacturers
of complete transmissions and torque
truck applications, supplying the fleet,
retail and warehouse distributor mar-
kets since 1984.
Jeff Anderson has been appoint-
ed general manager of Accurate
Transmissions. Anderson has 36 years of
remanufacturing experience with Remy
International (Williams Technologies),
Stanadyne Automotive and Bendix
Corp. At Williams Technologies he was
responsible for remanufacturing trans-
missions for OE service and warranty
replacement for Ford, GM, Allison and
others.
Alan Gatlin, president and CEO
of ETX, Inc., stated, This is a very
strategic acquisition for ETX, Inc. This
is a market we were actively trying
to penetrate, and Accurate is a strong
complement to our other companies.
Our number one priority today is serv-
ing the current customer base with qual-
ity transmissions.
The company will continue to
operate from the Accurate facilities in
Mundelein and has retained the majority
of the management team and employ-
ees. According to Anderson, We have
reopened the supply lines and are in full
production today, shipping high quality
transmissions to our customers.
For more information, visit their
web site at www.etxinc.com.
New Mobil Delvac
Synthetic ATF for
Severe-Duty Allisons
Allison Transmission, Inc. teamed
with ExxonMobil to release new
Mobil Delvac Synthetic ATF, a fully
synthetic TES 295 certified automat-
ic transmission fluid, formulated to
enhance the performance of Allison
automatics operating in the most severe
conditions.
Mobil Delvac Synthetic ATF will
be available worldwide through both
Allison and ExxonMobil. It replaces
POWER INDUSTRY NEWS
the current severe-application ATF sold
under the same name and will be sold in
drums, pails and gallon containers.
The TES 295 certification is one of
the industrys most stringent specifica-
tions for automatic transmission fluids.
Delvac Synthetic ATF meets or exceeds
these specifications and is ideal for use
in trucks, buses, utility vehicles, haulers
and delivery vans.
Allison designs fully automatic
transmissions for the most severe on-
and off-highway conditions, so any
fluid that is TES 295 certified has
to deliver first-rate performance under
extreme applications, according to
Lou Gilbert, Allison Transmission
North American Marketing Manager.
ExxonMobil manufactures industry-
proven products, so we were happy to
work with them to develop new Mobil
Delvac Synthetic ATF. This collabora-
tion not only benefits our customers
worldwide by offering them a new TES
295 certified fluid, it is a good comple-
ment to the Allison Transmission total
value equation.
Delvac Synthetic ATF was certified
by Allison as a TES 295 fluid based on
its exceptional results in a number of
different tests, including the fluids
resistance to oxidation, viscosity stabil-
ity, antifoaming capabilities, extreme
temperature performance and antiwear
properties. Its performance was tested
in the laboratory as well as extended
field test conditions.
For more information about new
Mobil Delvac Synthetic ATF, visit
www.allisontransmission.com or www.
mobildelvac.com.
AES Wave Introduces
the Scan/Scope Tool
Ready Bag
The Scan/Lab Scope Tool Ready
Bag is a new and better way to store,
organize, and use your scan tool or por-
118 GEARS
table lab scope. Its designed to secure-
ly hold the most popular lab scopes and
scan tools, including accessories. The
bag is designed to fit in most toolbox
deep drawers.
The Scan/Lab Scope Tool Ready
Bag sets up in seconds with your instru-
ment in working position, ready to go.
Adapters and cables are stored conve-
niently together with the scan tool for
quick and easy access. Test drives are
safer and easier with the instrument
held more securely and the car seat bet-
ter protected.
Every detail of the Scan/Lab Scope
Tool Ready Bag is designed for the pro-
fessional automotive technician: From
the best materials and workmanship to
the patent pending design.
For more information please visit
www.aeswave.com.
Superflow
Technologies Group
Announces New
Schaffer Shifter
Adapters
Superflow is announcing newly
released applications for the Schaffer
Shifter . In the last 8 months, twelve
new adapters have been made available
for use with the Shifter. Shown above
are examples of the Subaru 20-way,
5L40E, BMW 4L30E, F4EAT, and
the U140E/240E. Contact Superflow
at www.superflow.com or call 1-866-
SHIFTER for more information.
BD Introduces the X2 Redefines
Ultimate Diesel
Monitoring System
BDs new X2 Digital LCD monitor ADVANCEDrequires FORMULA.
represents the latest in monitoring
technology for the serious diesel For special application
enthusiast. The X2 allows digital
monitoring of up to seven parameters
at the same time. And when used with
a BD X-Tuner or other power module,
it provides ultimate engine control and
protection.
The X2 has the ability to data
log monitored parameters so they can
be played back or downloaded onto a
laptop. Its even capable of controlling
multiple modules at the same time
great for stacked applications. The
large LCD screen features an adjustable
white backlight for easy night viewing,
and an application-specific, molded A-
pillar housing makes mounting easy.
For more information, contact BD
Diesel Performance, toll-free, at 800-
887-5030, or stop by their web site, at
www.dieselperformance.com.
Smart Blend Introduces
One Formula Intake
and Fuel System
Cleaner
For Immediate Release
SMART BLEND
NEW SMART BLEND SYNTHETIC
Smart Blends new one formula
ONE FORMULA
TOTAL totalINTAKE intake & and FUEL fuelSYSTEM system CLEANERS cleaners
withFOR advanced
GAS ORsynteum-fi DIESEL ENGINES technology
redefineswithhow ADVANCED SYNTEUM-FI Technology.
TM
you provide a fuel sys-
Smart Blends NEW One Formula Total Intake and Fuel System Cleaners with advanced SYNTEUM - FI Technology
TM
tem cleaning
Time and requires service,
NO special applicationby eliminating
how you provide a fuel system cleaning service by eliminating hydrostatic engine lock-GUARANTEED, with
only a Five
engine and
Minute Service
hydrostatic engine
intake systems from the plenum lock
to the catalytic converter.
Tools! One Formula Total Intake Cleaner
provides complete intake system cleaning by safely and effectively removing carbon build up, cleaning vehicles upper
guaranteed!
Smart Blends One Formula Fuel System Cleaners for Gas or Diesel Engines cleans injectors, carbs, intake valves
Smart Blends fuel cleaning system
and combustion chambers. NEW ONE FORMULA Total Intake & Fuel System Cleaners help eliminate rough idling,
knocking, pinging and engine run-on while reducing emissions and improving power and performance in ONE
only five-minutes to service Total Intake & Fuel System Cleaning 2-Part Kits
Gasoline Kit (#17025-K)
most fuel systems, and requires no Diesel Kit (#17030-K)
more information contact
tools. One Lifeformula
your Transmission Parts Distributor or Automotive
at1-800-525-6816 901-522-8244 or FAX: 901-525-6833
call Products
www.smartblend.com
total intake cleaner cleans engine and
intake systems from the plenum to the
catalytic converter.
October 2007
 Smart Blends one formula fuel
system cleaners for gas or diesel engines
cleans injectors, carbs, intake valves
and combustion chambers. New one
formula total intake and fuel system
cleaners help eliminate rough idling,
knocking, pinging and engine run-on,
while reducing emissions and improv-
ing power and performance all in one
advanced formula.
For more information, stop by the
Life Automotive web site at www.life-
automotive.com.
MundoMecanico.com
ATRA member ShiftsGood
Transmission is proud to announce the
release of its new online services for
Spanish speaking automobile techni-
cians.
ShiftsGood president and creator
of MundoMecanico, Reese Blalock,
spoke in Guadalajara, Jalisco Mexico at
the RUJAC automotive EXPO regard-
ing the new sites features.
With the booming expansion of
modern vehicles in Latino markets
worldwide, technicians and shop own-
ers alike find themselves in want of
more technical related tips or sugges-
tions for common problems in diagnos-
tics and auto repairs. As a former Tech
Advisor for ATRA, Reese Blalock has
been eager to assist Spanish-speaking
members within the automatic trans-
mission industry and after nearly a year
of hard work, the site is now complete.
How does it work? For a modest
annual fee, members may search the
online database for keyword specific
data. The simple format in which it was
created will make it easy to use even
for computer novices. If a member is
unable to find useful data, an option
to upload a question appears, allow-
ing other members to offer sugges-
tions. These suggestions are compiled
automatically into the main database
and are immediately made available to
members.
While the site is designed exclu-
sively for Spanish speaking techni-
cians, navigational content is available
in English to explain how it works and
ways in which suppliers can make use
of it as well.
Look for Reese Blalock at the
ATRA EXPO 2007 in Las Vegas.
GEARS October 2007 119
VBX Welcomes Jeff
Parlee
Jeff Parlee
VBX-ValveBody Xpress is proud
to welcome Jeff Parlee as its new direc-
tor of product support.
Jeff possesses a vast knowledge
of the transmission industry, including
employment as a builder, shop owner
and international technical consultant.
He brings over 30 years of diverse tech-
nical experience to the VBX team, but
more importantly, Jeff has a rare dedi-
cation to professionalism and a unique,
person-to-person approach to customer
service that compliments VBXs com-
mitment to providing the industry with
the highest quality product, along with
the best possible product support!
Please join us in warmly welcom-
ing Jeff to our team!
For more information, you can
contact VBX toll-free at 1-866-2GET-
VBX.
Transmission Specialties,
Inc. Introduces New
High Performance
Bolt-Together Torque
Converter
Transmission Specialties of Aston,
Pennsylvania, is proud to introduce its
new, high performance, bolt-together
torque converter.
This torque converter was designed
to handle 1300-2500 horsepower. Its
unique, bolt-together design allows the
serious drag racer the ability to disas-
semble his torque converter at the track.
This creates flexibility for racers to fine
tune the characteristics of the converter,
or, in the event of transmission failure,
it gives them the opportunity to service
and clean their torque converter with-
out ever missing a round.
For more information, contact
Transmission Specialties, Inc., at 610-
485-9110 or write to them at kenktsi@
comcast.net.
Bradley Norton
Appointed President of
Corteco Americas
The appointment of Bradley
Norton as the president of Corteco
Americas, the aftermarket business of
Freudenberg-NOK that offers premium
brands including TransTec transmis-
sion and power steering kits and com-
ponents, becomes effective September
5, 2007.
Norton brings to his new position
20 years experience growing business-
es primarily in the commercial vehicle
market. His senior management expe-
rience with multinational companies
including Borg Warner, Nissan North
America, and Honeywell (Bendix Truck
Brakes and Garrett Turbocharging) pro-
vides Norton with the expertise neces-
sary to implement Cortecos strategic
goals. Norton holds an MBA from
Ashland University and a BS in finance
from Akron University.
Norton will succeed Thomas
Musgrave as president of Corteco.
Musgrave, who greatly improved
Cortecos operations and positioned it
for future growth, will now become
the president of Freudenberg-NOKs
Automotive Sales.
I am honored to lead Corteco
Americas and build on the great legacy
Tom Musgrave and the Corteco Team
have shaped, said Norton.
With the completion of the
divestiture of its North American
Traditional Aftermarket Business,
Norton and Corteco will work to increase
global market share and expand into
other markets, regions and products for
its TransTec brand. In addition, Corteco
will continue to focus on improving
POWER INDUSTRY NEWS
product quality and reducing costs to
better serve OEs and co-manufacturing
customers.
Corteco Americas, the aftermarket
business of Freudenberg-NOK, pro-
vides solutions and value to its custom-
ers through high-velocity supply chain
management, production kitting and
packaging, distribution and logistics,
full-line application development, and
premium, high-quality products and
services.
Rebuilds Look New
with TRANNY COAT
TRANNY COAT
Aluminum-Finish
Refinish your rebuilt transmissions!
Dont just paint them!
TRANNY COAT
Cast Iron-Finish
Refinish your rebuilt transmissions!
Dont just paint them!
G-TEC introduces two new ways
to make your rebuilds look like new:
TRANNY COAT Aluminum Finish and
TRANNY COAT Cast Iron Finish.
These new,environmentally-for-
mulated coatings apply like spray paint,
but they wont trapheat in the transmis-
sion or torque converter like enamel or
epoxy paints do.This allows positive
heat transfer, prolonging the life of the
rebuild.
TRANNY COAT covers blem-
ishes, and wont smudge or dissolve
through contact withATF. TRANNY
COAT providesa new aluminum or
cast iron finish to transmission cases,
transfer cases, and torqueconverters.
120 GEARS
Both are non-smudge and VOC com-
pliant.
TRANNY COAT is available
in 16 oz aerosol cans. For additional
information,contact G-TEC AT417-
725-6400 and be sure to visit our booth
at ATRAs Expo in Las Vegas.
ATEC Trans-Tool
Announces New
Website and Expanded
Tool and Equipment
Program
ATEC Trans-Tool has increased
its tool and equipment program for
transmission shops that are entering the
general repair market. ATEC can now
service all your tool and equipment
needs.
ATEC offers a complete line of
name-brand tools and equipment for A/
C and cooling, brake and wheel, engine
diagnostic, engine and fuel, lubrication,
undercar and underhood repairs, power
and air tools, plus quality, brand-name
hand tools.
Visit ATECs new web site, www.
atec-trans-tool.com, featuring all of our
new products and promotion specials.
Make sure you check us out when
you need any type of tool or piece of
equipment. You may also contact Bob
Safstrom at (800) 531-5978.
ODYSSEY Battery
displays unique two-
door Dodge Charger
Coupe at SEMA Show
Who:
ODYSSEY battery by EnerSys
What and Why:
A custom 2006 Dodge Charger
SRT-8 two-door coupe - a one of a kind
muscle car in the industry - built by
Force Performance (www.forceperfor-
mance.biz).
The muscle cars electrical system,
including a high-powered audio/visual
system, operates from ODYSSEY bat-
teries
Engine - 6.1 liter hemi, stroked to
7.0 liters (CID); twin turbos feeding a
positive displacement supercharger
Projected horsepower - 1,000 to
1,200 at 18-20 psi of boost
High-powered and advanced
audio/visual system powered by
Odyssey batteries
When and Where:
October 30, 2007 through
November 2, 2007
SEMA Show
Las Vegas Convention Center
EnerSys/ODYSSEY Booth #25155
October 2007
 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed

SHOPPER CLASSIFIED ADS

elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.
For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

ERICA O RT E D ERIKSSON INDUSTRIES

AMAutomatic N IMP Division of Wentworth Engineering
Standard
Transmission
1946 - 2007
Transmission
1960-2007
1-800-388-4418
Authorized Parts Distributor

800-835-1007 Remanufactured Units * DYNO TESTED*

5HP30, 5HP24, 5HP19, 5HP18, 4HP24, 4HP22,
Tools Soft Parts 4HP18, 4HP14
Equipment New & Used Specializing in SAAB 900/9000 5SP,
as well as T-37 A/T
Supplies Hard Parts
1 YEAR UNLIMITED MILE WTY
Transfer
Hard Parts: NEW / USED / REMANUFACTURED
Case
1970-2007 Soft Parts / Friction Kits / Steel Kits / Repair Manuals
Lifetime Fluids / Rebuild Kits / Valvebody Kits
Helping rebuilders get the 1-800-388-4418
job done for over 33 years Fax: (860) 395-0047
Next day delivery to
KS OK NE SD MN IL IA MO AR www.erikssonindustries.com
on orders called in by 4pm. 146B Elm St., Old Saybrook, CT 06475

**COMPUTERS**
Transmission Control Module
ECM & TCM
Mitsubishi-Honda-Hyundai-GEO Heated Cooler
Kia-Mazda-Nissan-Suzuki-Toyota Line Flusher
BOSCH ECM
GM - Ford - Chrysler - Dodge 800-725-6499
Next Day Air Shipping Available 417-725-6400
One Year Warranty
Best Customer SVC&Return Policy Transmission
Ford *GM * Chrysler off vehicle Dyno/CV
ECM reprogramming available Tester
888-217-4072
Autocomp Technologies, Inc.
8515 N. Freeway, Houston, Texas www.g-tec.com
E Call and
Foreign Make ON

Find it All!
or
Do estic
m

!Automatic Soft Parts

!Rebuilt Standards !Transfer Cases
!Clutches !Bearing Kits
!NEW & USED PARTS
Dyn
o
Tes
ted
Reb
uilt
Unit
800-578-8726
s
Sanford, FL
866-798-8726 800-773-8726
Tallahassee, FL Saucier, MS

GEARS October 2007 121

 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed

SHOPPER CLASSIFIED ADS

elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.
For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

BMW Mercedes-Benz Audi Driveline Specialists

Remanufactured to Transmissions
Perfection and
Hundreds of Transmissions in-stock.
Immediate installation available. Axles
2 year limited warranty.
Over 1,000 in stock
Dyno-tested. New, Quality Rebuilt
Remanufactured torque converter included. Kits available to rebuild your
Parts Specialists own: Bearings/Gears/Hard Parts
Toll free 800 - 372 - TRANS
Toll Free: 800-8 2 2 - 2 3 7 5
1331 Rollins Road Burlingame, CA 94010
tel 650 - 348 - 3990 fax 650 - 348 - 3019 www.partsbyweller.com

WWWQUALITYGEARCOM

GEARS
GEARS_QG_May07.indd 1 5/1/07 10:36:42 AM

For The transmission Rebuilding Industry

This could be
your ad!
call
(805) 604-2000
and find out how!

122 GEARS October 2007

 ProfitBoost Software

by far the easiest

& best RO writing
software I have ever
used, says Ray Kunz
ESI Consultant
Sacramento, CA
x Easy to Learn RO Writing
x Reliable and Secure
x Future Proof
x Free Demo Available

Visit www.ProfitBoost.com
or call 888-274-3776

INSTA-CLEAN
800-331-6405

PARTS WASHERS

INSTA-CLEAN www.instaclean.com
PARTS WASHERS

INSTA-CLEAN
PARTS WASHERS
800-331-6405

INSTA-CLEAN
PARTS WASHERS

INSTA-CLEAN
PARTS WASHERS

30 Years Same
Area
C E D ES National
M ER Employment
> Reman Transmissions Headquarters
w/converters for the transmission industry

> 722.6 Electronic We make it easy to relocate

Transmissions Employees and shop owners

call
Dodge Sprinters
and all other 1-888-412-TEAM
or visit our website
DaimlerChrysler Nag 1's
www.transteam.com
www.silverstartransmission.com

Silver Star Transmission

24 7 SUPPLIER
MEMBER

Hours Days
800-369-6601 or fax 405-330-9446

GEARS October 2007 123

 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed

SHOPPER CLASSIFIED ADS

elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.
For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

Automatic Hard Parts Warehouse

lizing Se Hab
Specia la
in Late Espao
l
Models

1.877.888.5160
Local 614.444.5160 Fax 614.444.5165
www.transmissionhardparts.com
Columbus, OH
We Strip 350+ Transmissions a day

ATRA is much
more than just
a HelpLine...
Nationwide Inter-shop Warranty
ATRA Online's Tech Center
Technical Seminars
Testing & Certification
GEARS Magazine
Customer Referral Services
Bankcard Services
Check Verification Services
Consumer Financing Services
Point of Sale Support
Consumer Complaint Arbitration
Health Insurance Services HA
RD
PARTS G
UA
R
C
Garage Liability Services
AN
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(866) GO-4-ATRA Call For Prices

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124 GEARS October 2007

 STE
Traction Control Technology

6QEBUFE
XJUI






























WANTED: *OEVTUSZ
$PNQPOFOUT
Automatic Transmission Cores
4IJGU
,JU
7BMWF
#PEJFT
Torque Converter Cores
6OQBSBMMFMFE
1SPEVDU
4VQQPSU
ALL TYPES!

.POUI
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8BSSBOUZ
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$%30.
DBUBMPH
Early Foreign New Venture 149, 249

)VOESFET
PG
7BMWF
#PEJFT
3FBEZ
UP
4IJQ Borg Warner 44-04, 44-72, 13-72
Late Domestic
Rebuilt NV247 Clutch Pack
Late Foreign
More Models Available
REMAN INDUSTRIES Call for Info
1551 Pratt Blvd.
Elkgrove Village IL 60007 1304

Contact Dave
1-800-729-8726 ask for Dino! &NBJM
TBMFT!WBMWFCPEZQSPDPN (800) 883-6188
email: dcardone@remanindustries.com XXXWBMWFCPEZQSPDPN djhanger@earthlink.net

A Division of Truck Parts Specialists

YOUR ONE SOURCE FOR

DRIVETRAIN PARTS
FOR CARS & TRUCKS The only,
Standard Transmission
Bearing Kits
Transfercase
Chains
original,
Hard Parts
Soft Parts
Hard Parts
Soft Parts
patented,
Exchange Units Exchange Units in-shop fix
Differential Conponents WE BUILD & REPAIR for worn
cases.
Ring & Pinions
Diff. Cases DRIVESHAFTS
Internal Kits &
Axle Shafts
Posi Units PTOS

Ask For Eddie Light Duty Specialists

1-800-282-0525 Northland Transmission Inc.

LOCAL (813) 623-1531 FAX (813) 626-0729
1221 U.S. HWY 301 NORTH TAMPA, FL 33619 Phone: 715-458-2617 Fax: 715-458-2611
THE RIGHT SOURCE. FOR THE RIGHT PRICE. RIGHT NOW www.servobore.com

HARD PARTS FOR

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AUTOMATIC TRANSMISSIONS
TORQUE CONVERTERS
TRANSFER CASES

WE HAVE OVER 500,000 PARTS IN STOCK

CALL 602-971-0477
getithardparts.com
WE SHIP UPS DAILY

GEARS October 2007 125

 SHOPPER CLASSIFIED
GEARS classified advertising cost $95.00 for up to 50 words for a one time insertion. ATRA members are eligible to receive up to three (3) FREE classified
advertisements in GEARS annually (per 9 issues). Members wishing to place ads once their three FREE ads have been placed may do so at the cost listed above.
Ads exceeding the maximum word count will cost $1.50 for each additional word (not including phone number and address).
Tech at T he
Speed of Life
RatioTek
Automatic Trans
Repair & Tech Info.
DVD Computer Disk
New 3rd Edition now shipping.
It's HOT - Over 125 trannys
Get the RatioTek computer pro-
gram with all the Steve Younger
books, super fixes, videos &
common complaints.
Takes 5 seconds to look up
VB check balls not minutes.
Inexpensive lease plans are avail-
able under $30.00 month.
ATRA, ASA & ATSG members
receive 25% off on the leasing
programs and discounts on full
purchase programs.
Visit the web site and view a full
color sample book. Navigate the
menus and get a feel for the books
and their contents. This program
installs easily and can be installed
on multiple computers. Visit
info@ratiotek.com or call to receive
lease and purchase information.
Note: New Address & Phones
Transcel Inc.
15902A Halliburton # 272
City Of Industry, CA 91745
626-968-2754 Fax 626-961-8563
www.ratiotek.com
BUSINESS FOR SALE: Fantastic lo-
cation in Central New Jersey located
on US Highway 1. Primarily transmis-
sions but also doing general repair. In
business for 30 years under same
ownership. Shop features 8 lifts (7-
9000# plus 1-12500# Mohawk lifts), air
conditioned rebuilding area and office
and 5500 sq. ft. Excellent customer
base both retail and commercial. Parts
washer, flywheel grinder, welding
equipment, new Robinare A/C equip-
ment, tire changer & balancer, lathe, 50
ton press, inventory, plus much more.
Walk in and make a good living--owner
126 GEARS
October 2007
SM
WE STOCK:
*NEW* AX4N VALVE BODIES
*NEW* 4F27E VALVE BODIES
We offer a complete machine shop
for ALL of your rebuilding needs!
USED, NEW AND REBUILT
FOREIGN AND DOMESTIC
RETAIL AND WHOLESALE
ONE CALL DOES IT ALL!
800-461-5396
retiring. Call Gary 732-236-7523 for
details. ATRA Mbr
BUSINESS FOR SALE: Desert Trans-
mission Shop & Equipment Well es-
tablished business since 1961, located
in Phoenix, Arizona, historic art district.
Block building, 2345 sq. ft., land .22
acres, equipment and parts. Can be
sold separately; transmission equip-
ment $150,000; block building and land
priced at $795,000. Owner retiring. A
lot of potential. For information call:
Roni Russell (480) 897-7446 or Bernie
Kilroy (480) 251-5353. ATRA Mbr
BUSINESS FOR SALE: Just listed
Kens Transmission Shop Owner
retiring. This shop has been continu-
ally operating since 1975 and features
an excellent location with great visibil-
ity near the Lamb-Weston RDO plant.
Set on a prime commercial corner on
Highway #71, this property can be pur-
chased with just the building and land
for $179,000. The buyer can also pur-
chase necessary equipment for either
a general repair shop or transmission
shop for an additional $70,000. Call
Rich at (800) 248-4032 for more infor-
mation. ATRA Mbr
BUSINESS FOR SALE: Beautiful Tex-
as Hill Country A very clean Cottman
Transmission Center located between
San Antonio and Austin just off busy I-
H 35. Turn-key operation, owner relo-
cation forces sale of center. 95K Firm!
Serious inquiries only! Call Dan at (830)
629-6600.
BUSINESS FOR SALE: Transmission
shop with general repair capabilities
Over 32 years continuous ownership
Easy access and visibility from four
lane US HWY 151 in Beaver Dam, WI
100x100x22 Foot building on two acres
with warehouse and dock Five lifts in-
cluding heavy truck Includes tools and
equipment, large inventory, library, new-
er computers and ProfitBoost software
Current U-Haul dealer, recent top 100
dealer award www.doncigelsketrans.
com, click on Business Opportunity
Contact Don at (920) 210-3325.
ATRA Mbr
BUSINESS FOR SALE: Florida
Transmission parts business for sale
in Broward, Florida. Specialized in soft
parts and converters, three years in
business with customer base, property
also available for sale. Please contact
JC at: (305) 490-4390.
BUSINESS FOR SALE: Arizona Only
driveline and rear end shop in booming
North Phoenix, Arizona. Base of good
shops, dealers and customers working
with us for over 21 years. Reputation
built on doing every job as promised
110% no matter what. 2000 square
foot auto shop, 1680 square foot ma-
chine shop, office, customer reception,
spacious outside parking and storage.
Maximum inventory, two lifts, driveline
balancer, parts washer, welding equip-
ment and more. Training available, sell-
ing due to health, call Ed at (623) 869-
0510.
EQUIPMENT FOR SALE: Torque Con-
verter Rebuilding Equipment TCRS
horizontal torque weld aligner (US$)
$7500.00, TCRS conveyer parts wash-
er $2400.00, Jones and Lamson turret
lathe $2000.00. Prices are FOB Toron-
to and all the equipment is in working
condition, Please call Bruce (800) 668-
6232.
October 2007
EQUIPMENT FOR SALE: (1)Trans-
mission Dyno-Mark-3R Dynadrome
serial# 3103, new condition with oper-
ators manual and adaptors, cost $50.
K asking $13.5 or best offer. (2) Flow
Test Flush operation SPX Kent-Moore
model-J45096, asking $1000.00 (3)
Kent-Moore planetary carrier rebuilding
set (J-25587-70) asking $500.00. Call
Lee at (613) 925-3007.
FREE TRIAL: SuperFRED powered
by Management Feedback Systems,
Inc. is easy to use automotive shop
management software. MFS has pro-
vided management software for over
24 years to automotive repair profes-
sionals like you. Call now to receive
your FREE 90-day version of Super-
FRED. Outstanding technical support
is included, try before you buy. (888)
637-3733 (888-MFS-FRED), on the
internet: www.mfsfred.com or email:
sales@mfsfred.com. ATRA Mbr
HELP WANTED: Illinois Transmis-
sion parts supplier is looking for a
sales rep who would be responsible
for parts sales within the entire eastern
half of the US. Salary plus commission
and full benefits. Send resume to: KB
Cores, 288 South Tec Drive, Kankakee,
IL 60901 Attention: Debbie Hubert.
ATRA Mbr
HELP WANTED: D&E Automotive
Products, Inc., St. Louis, MO, seeks
a highly motivated sales professional.
Extensive transmission parts sales
experience required. This key position
requires someone who is dynamic, reli-
able, sharp and tenacious, with strong
communication and people skills. We
are an equal opportunity employer of-
fering great benefits. Fax resume to:
248-731-9928. ATRA Mbr
HELP WANTED: Transmission rebuild-
ers needed for production facility in
Klamath Falls, Oregon. Excellent work-
ing conditions, pay and benefits. Great
place to live with lots of hunting, fishing,
camping and water sports. Also need-
ed is a standard transmission special-
ist and experienced torque converter
builder. Call Dave at 1-800-409-1540
Monday through Friday, 8 am to 5 pm.
Or contact us at valleytransmission-
manufacturing.com, Email: aap@fire-
serve.net, Fax: 541-850-0398, Direct
Phone: 541-850-0203.
HELP WANTED: Looking for an experi-
enced R&I technician for all makes and
models. Wages based on experience.
Benefits offered. Please fax resume
to (780) 455-7213 or email at protech-
transmissions@shaw.ca. If you prefer
call Rob at (780) 453-3300. ATRA Mbr
HELP WANTED: One of the largest
remanufactures of torque converters
and transmission hard parts is seek-
ing knowledgeable individuals to join
our aggressive sales team. Relocated
or work from your home. TCRA, ATRA
Member. Send all inquires to: Email
address: dcardone@remanindustries.
com. ATRA Mbr
HELP WANTED: TransTeam Employ-
ment USA, The National Employment
Headquarters for the transmission in-
dustry wants you! We offer a low cost
internet recruiting service for our reg-
istered transmission shop owners and
deliver nationwide job opportunities to
our registered employees. Always a
free service to all industry employees.
Visit our web site www.transteam.com
24 hours a day, 7 days a week to see
how it works or call (888) 412-TEAM
w
(8326). We make it easy to relocate!
ATRA Mbr

Subscribe Today!
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X I want my very own subscription to the next 9 issues of GEARS.

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City

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Phone

Signature

Please enclose check or money order in U.S. funds and send to:
GEARS 2400 LATIGO AVENUE OXNARD, CALIFORNIA 93030
or call: (805)604-2000
U.S. $30 ~ Canada $45 ~ Other Areas $65

GEARS October 2007 127

 ADVERTISERS
Name Page Name Page

A & Reds Transmission Parts.............................................. 79 Mitchell 1.............................................................................. 33

www.areds.com www.mitchell1.com
Allomatic Products Co.......................................................... 11 Newco Autoline - GmbH....................................................... 53
www.allomatic.com www.newco-autoline.de
Amorim Industrial Solutions........................................... 63, 81 North American Bancard...................................................... 51
www.amorimsolutions.com www.nynab.com
ATI Performance Products................................................... 48 Power Pusher By Nu-Star, Inc....................................... 45, 99
www.atiperformanceproducts.com www.powerpusher.com
ATRA.................................................................................... 69 Precision International.......................................................... 39
www.atraonline.com www.transmissionkits.com
Borg-Warner Automotive................................................ 47, 83 ProfitBoost LLC.................................................................. 101
BorgWarner Morse TEC....................................................... 37 www.profitBoost.com
www.morsetec.com Raybestos Powertrain.................................................... 3, 103
California Transmission Products-CALTRANS..................... 87 www.raybestospowertrain.com
www.cal-trans.com Reman Industries Inc......................................................... 105
Canada-Wide Parts Distributors Ltd..................................... 85 www.remanindustries.com
www.canadawideparts.com Seal Aftermarket Products-
Consolidated Transmission Parts, Inc.................................. 89 Parker Hannifin Corporation............................................. 59
www.consolidatedtrans.com www.parker.com
Converter Man Ltd............................................................... 91 Slauson Transmission Parts................................................. 49
www.converterman.com www.slauson.com
DACCO Inc........................................................................... 73 Sonnax Industries...........................................................28, 29
www.daccoinc.com www.sonnax.com
Drivetrain Solutions.............................................................. 44 SuperFlow Technologies Group........................................... 57
www.drivetrain-solutions.com www.superflow.com
Educational Seminars Institute - ESi.................................... 45 Superior Transmission Parts.............................41, 107, Insert
www.esiseminars.com www.superior-transmission.com
Elite, The Success Tool Company....................................... 44 Teckpak-Fitzall (Trans-A-Matic)............................................ 35
www.thesuccesstoolcompany.com www.teckpak-fitzall.com
European Exchange, Inc...................................................... 93 Tool Exchange Inc.- Profit Tool............................................. 36
www.europeanexchange.com www.profittoolplan.com
Ford Customer Service Division......................................... IFC Transgo......................................................................5, 31, 67
GM Parts.............................................................................. 61 www.transgo.com
www.goodwrench.com Transmission Specialties.............................................. 50, 109
Hecat Inc.............................................................................. 95 www.transmission-specialties.com
www.hecatinc.com Hardparts for Transmissions................................................ 42
Heffernan Group................................................................... 75 www.wesellhardparts.com
www.heffgroup.com Transtar Industries, Inc..................................... 64, 65, 77, 111
Mopar................................................................................... 43 www.transtarindustries.com
Jasper Engines & Transmissions....................................... IBC TransTec.........................................................................15, 55
www.jasperengines.com www.transtec.com
Life Automotive Products Inc.................................................. 7 VBX - ValveBody Xpress, Inc............................................. 113
www.smartblend.com www.valvebodyxpress.com
LUBEGARD By International lubricants, Inc. Whatever It Takes Transmission Parts, Inc.................... 9, 115
.....................................................................OBC, Rider, 97 www.wittrans.com
www.lubegard.com ZF Sales and Service NA, LLC............................................ 13
www.zf-group.com

CALENDAR
ATRA Technical Seminar Schedule
2007

10/6/07 Portland, OR 11/3/07 New York, NY

10/11/07 ATRA's Powertrain Expo, NV 11/10/07 Baltimore, MD
10/20/07 Chicago, IL

128 GEARS October 2007

jasper ad.indd IBC2 12/29/06 3:35:02 PM