NMWR 9-2520-582 (4L80E--4L85E TRANS 2014).pdf

NATIONAL MAINTENANCE WORK REQUIREMENT

INCLUDING

REPAIR PARTS AND SPECIAL TOOLS LIST

CONTAINING

NATIONAL OVERHAUL STANDARDS

FOR

4L80-E/4L85-E TRANSMISSION

HMMWV FOV

(NSN 2520-01-489-0849) P/N 57K4407

(NSN 2520-01-489-0850) P/N 57K6204

(NSN 2520-01-625-7876) P/N 57K6233

This publication is not available through St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-IM/TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*NMWR 9-2520-582, dated 4 April 2014, supersedes NMWR 9-2520-582, dated 17 February 2006, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

WARREN, MICHIGAN 48397-5000

4 APRIL 2014

*NMWR 9-2520-582

WARNING SUMMARY

• This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in serious injury or death to personnel. Refer to FM 4-25.11 for first aid instructions.

• Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Always use protective goggles or face shield and avoid repeated and prolonged skin contact by wearing rubber or solvent resistant gloves. If contact with eyes occurs, flush eyes with water and seek medical attention. Wash hands and skin immediately after exposure with soap and water and use a lanolin-based skin cream to prevent skin drying. Remove contaminated clothing as soon as possible.

Store, handle, and dispose of contaminated cloths and clothing according to local procedures and plans.

• Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use. Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may cause injury to personnel. Seek medical attention in the event of an injury.

• Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Use caution when handling heavy parts. Provide adequate support and use assistance during procedure.

Transmission weight is 252 lbs (114 kg). Ensure lifting device is in good operating condition and of suitable load capacity. Failure to comply may result in death or injury to personnel. Seek medical attention in the event of an injury.

• All personnel must stand clear during lifting operations. A swinging or shifting load may result in death or injury to personnel. Seek medical attention in the event of an injury.

• Torque converter must be supported by retaining straps at all times to prevent torque converter from falling out. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• When steam-cleaning, wear protective clothing. Failure to comply may result in serious injury to personnel.

Seek medical attention in the event of an injury.

• Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

• Air pressure must not exceed 70 psi (483 kPa) when air-checking direct/forward clutch piston operation.

Failure to comply may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

NMWR 9-2520-582

a

WARNING SUMMARY - CONTINUED

• Use compressed air only with effective chip guarding and personal protective equipment (goggles/shield.

gloves, etc.). Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Air pressure must not exceed 15 psi (103 kPa) when air checking intermediate clutch piston operation.

Failure to comply may result in injury to personnel and/or damage to equipment. Seek medical attention in the event of an injury.

b

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: NMWR 9-2520-582, dated 4 April 2014, supersedes NMWR 9-2520-582, dated 17 February 2006, including all changes. Zero in the “Change No.” column indicates an original page or work package.

Date of issue for the original NMWR is:

Original: 4 APRIL 2014

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 26 AND

TOTAL NUMBER OF WORK PACKAGES IS 49,

CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front cover Blank Warning Summary (2 pgs) i - viii (8 pgs) Chapter 1 title page (2 pgs) WP 0001 (4 pgs) WP 0002 (4 pgs) Chapter 2 title page (2 pgs) WP 0003 (4 pgs) Chapter 3 title page (2 pgs) WP 0004 (8 pgs) WP 0005 (2 pgs) WP 0006 (2 pgs) WP 0007 (24 pgs) WP 0008 (16 pgs) WP 0009 (6 pgs) WP 0010 (4 pgs) WP 0011 (4 pgs) WP 0012 (8 pgs) WP 0013 (12 pgs) WP 0014 (6 pgs) WP 0015 (8 pgs) WP 0016 (8 pgs) WP 0017 (10 pgs) WP 0018 (10 pgs) WP 0019 (4 pgs) WP 0020 (28 pgs) WP 0021 (8 pgs) WP 0022 (2 pgs) WP 0023 (12 pgs)

Page/WP No. Change No.

WP 0024 (2 pgs) WP 0025 (2 pgs) WP 0026 (2 pgs) WP 0027 (2 pgs) WP 0028 (8 pgs) Chapter 4 title page (2 pgs) WP 0029 (8 pgs) WP 0030 (4 pgs) WP 0031 (4 pgs) WP 0032 (4 pgs) WP 0033 (4 pgs) WP 0034 (4 pgs) WP 0035 (4 pgs) WP 0036 (4 pgs) WP 0037 (4 pgs) WP 0038 (4 pgs) WP 0039 (4 pgs) WP 0040 (4 pgs) WP 0041 (4 pgs) WP 0042 (4 pgs) WP 0043 (6 pgs) WP 0044 (4 pgs) WP 0045 (6 pgs) Chapter 5 title page (2 pgs) WP 0046 (2 pgs) WP 0047 (2 pgs) WP 0048 (4 pgs) WP 0049 (2 pgs) Back cover

A/B blank

U.S. ARMY TACOM LIFE CYCLE

MANAGEMENT COMMAND

4 APRIL 2014

NATIONAL MAINTENANCE WORK REQUIREMENT

INCLUDING

REPAIR PARTS AND SPECIAL TOOLS LIST

CONTAINING

NATIONAL OVERHAUL STANDARDS

FOR

4L80-E/4L85-E TRANSMISSION

HMMWV FOV

(NSN 2520-01-489-0849) 57K4407

(NSN 2520-01-489-0850) 57K6204

(NSN 2520-01-625-7876) 57K6233

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and blank forms) through the Internet, on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-IM/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397–5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786–1856 or commercial (586) 282–1856.

A reply will be furnished to you.

*NMWR 9-2520-582

i

This publication is not available through St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-IM/TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*NMWR 9-2520-582, dated 4 April 2014, supersedes NMWR 9-2520-582, dated 17 February 2006, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

WP Sequence No./Page No.

CHAPTER 1 - GENERAL INFORMATION AND EQUIPMENT DESCRIPTION AND DATA

General Information ......................................................................................................................... WP 0001

Equipment Description and Data .................................................................................................... WP 0002

Figure 1. Transmission. ............................................................................................................... WP 0002-1

Table 1. 4L85-E Parts. ................................................................................................................ WP 0002-2

Table 2. Equipment Configuration Data. .................................................................................... WP 0002-3

Table 3. Gear Range Information. .............................................................................................. WP 0002-3

CHAPTER 2 - NMWR TROUBLESHOOTING PROCEDURES

Preshop Analysis .............................................................................................................................. WP 0003

Table 1. Preshop Analysis Cover Sheet. .................................................................................... WP 0003-2

Table 2. Preshop Analysis Checksheet. ...................................................................................... WP 0003-3

Figure 1. Transmission Assembly Preshop Analysis. ................................................................ WP 0003-3

Figure 2. Component Checklist. ................................................................................................. WP 0003-4

CHAPTER 3 - MAINTENANCE INSTRUCTIONS

General Maintenance Instructions ................................................................................................... WP 0004

Table 1. Cleaning Guidelines. ..................................................................................................... WP 0004-4

Table 2. General Inspection Guidelines. .................................................................................... WP 0004-5

Table 3. Repairable Defects. ....................................................................................................... WP 0004-7

Removing Transmission from Shipping Container ........................................................................ WP 0005

Mounting Transmission on Holding Fixture .................................................................................. WP 0006

Figure 1. Transmission and Torque Converter Assembly. ........................................................ WP 0006-1

Figure 2. Transmission Mounted in Holding Fixture. ............................................................... WP 0006-2

Transmission Disassembly into Subassemblies .............................................................................. WP 0007

Figure 1. Transmission Speed Sensors. ...................................................................................... WP 0007-1

Figure 2. Transmission Oil Pan and Filter. ................................................................................ WP 0007-2

Figure 3. Transmission Solenoid Wiring Harness. .................................................................... WP 0007-3

Figure 4. Wiring Harness Removal. ........................................................................................... WP 0007-4

Figure 5. Transmission Pressure Switch and Spring and Roller Assembly. ............................. WP 0007-5

Figure 6. Screen Filter Location. ................................................................................................ WP 0007-6

Figure 7. Checkball Locations. ................................................................................................... WP 0007-7

Figure 8. Front Servo Piston. ...................................................................................................... WP 0007-8

Figure 9. Rear Servo Piston. ....................................................................................................... WP 0007-9

Figure 10. Parking System Operational Check. ......................................................................... WP 0007-10

Figure 11. Parking Lock Pawl and Actuator Assembly Removal. ........................................... WP 0007-11

Figure 12. Front End Play. ......................................................................................................... WP 0007-12

Figure 13. Rear End Play. ........................................................................................................... WP 0007-13

Figure 14. Turbine Shaft Seal Removal. .................................................................................... WP 0007-14

Figure 15. Oil Pump Remover/Installer Installation. ................................................................. WP 0007-14

Figure 16. Oil Pump Removal. ................................................................................................... WP 0007-15

Figure 17. Turbine Shaft Removal. ............................................................................................ WP 0007-16

Figure 18. Fourth Clutch Housing Removal. ............................................................................. WP 0007-16

Figure 19. Forward Clutch Assembly Removal. ........................................................................ WP 0007-17

Figure 20. Direct Clutch and Front Band Assembly Removal. ................................................ WP 0007-18

Figure 21. Intermediate Clutch Assembly Removal. ................................................................. WP 0007-19

Figure 22. Oil Cooler Adapters Removal. ................................................................................. WP 0007-20 ii

TABLE OF CONTENTS - CONTINUED

CHAPTER 3 - MAINTENANCE INSTRUCTIONS - Continued

Figure 23. Center Support Bolt Removal. .................................................................................. WP 0007-20

Figure 24. Rear Drum Removal. ................................................................................................ WP 0007-21

Figure 25. Rear Band Removal. ................................................................................................. WP 0007-22

Figure 26. Center Support Assembly. ........................................................................................ WP 0007-23

Accumulator Housing and Control Valve ...................................................................................... WP 0008

Figure 1. Accumulator Housing. ................................................................................................. WP 0008-2

Figure 2. Accumulator Housing Disassembly. ........................................................................... WP 0008-3

Figure 3. Control Valve Disassembly. ....................................................................................... WP 0008-5

Figure 4. Control Valve Cleaning and Inspection. .................................................................... WP 0008-7

Figure 5. Control Valve Assembly. ............................................................................................ WP 0008-9

Figure 6. Accumulator Housing Cleaning and Inspection. ........................................................ WP 0008-11

Figure 7. Accumulator Housing Tightening Sequence. ............................................................. WP 0008-13

Table 1. Solenoid Resistance Chart. ........................................................................................... WP 0008-14

Figure 8. Connector End View. .................................................................................................. WP 0008-15

Transmission Case Repair ............................................................................................................... WP 0009

Figure 1. Retaining Ring and Seal Removal. ............................................................................. WP 0009-1

Figure 2. Transmission Mounted in Holding Fixture. ............................................................... WP 0009-3

Figure 3. Transmission Case Inspection. .................................................................................... WP 0009-4

Figure 4. Parking Pawl and Actuator Assembly Inspection. ..................................................... WP 0009-5

Figure 5. Seal and Retaining Ring Installation. ......................................................................... WP 0009-6

Front Servo Repair .......................................................................................................................... WP 0010

Figure 1. Front Servo Disassembly. ........................................................................................... WP 0010-1

Figure 2. Front Servo/Spring Inspection. ................................................................................... WP 0010-2

Figure 3. Front Servo Assembly. ................................................................................................ WP 0010-3

Rear Servo Repair ............................................................................................................................ WP 0011

Figure 1. Rear Servo Disassembly. ............................................................................................ WP 0011-1

Figure 2. Rear Servo Inspection. ................................................................................................ WP 0011-3

Figure 3. Rear Servo Assembly. ................................................................................................. WP 0011-4

Oil Pump Repair .............................................................................................................................. WP 0012

Figure 1. Oil Pump Disassembly. ............................................................................................... WP 0012-1

Figure 2. Oil Pump O-Rings Removal. ...................................................................................... WP 0012-2

Figure 3. Oil Pump Gears. .......................................................................................................... WP 0012-3

Figure 4. Oil Pump Measurement. ............................................................................................. WP 0012-3

Figure 5. Oil Pump Valve Inspection. ........................................................................................ WP 0012-4

Figure 6. Oil Pump Seal Installation. ......................................................................................... WP 0012-5

Figure 7. Oil Pump Gear Installation. ........................................................................................ WP 0012-5

Figure 8. Oil Pump Assembly. ................................................................................................... WP 0012-6

Figure 9. Oil Pump O-Rings Installation. .................................................................................. WP 0012-7

Turbine Shaft and Overrun Clutch Repair ...................................................................................... WP 0013

Figure 1. Turbine Shaft Assembly Disassembly. ....................................................................... WP 0013-1

Figure 2. Overrun Clutch Disassembly. ..................................................................................... WP 0013-2

Figure 3. Turbine Shaft Checkball Inspection. .......................................................................... WP 0013-3 iii

CHAPTER 3 - MAINTENANCE INSTRUCTIONS - Continued

Figure 4. Turbine Shaft/Overrun Clutch Inspection. ................................................................. WP 0013-4

Figure 5. High-Speed and High-Torque Parts Identification. .................................................... WP 0013-5

Figure 6. Overrun Clutch Assembly. .......................................................................................... WP 0013-6

Figure 7. Overrun Clutch Clearance Check. .............................................................................. WP 0013-7

Figure 8. Turbine Shaft Seal Installation. .................................................................................. WP 0013-9

Figure 9. Turbine Shaft Seal Installation. .................................................................................. WP 0013-10

Figure 10. Roller Clutch Installation. ......................................................................................... WP 0013-11

Figure 11. Overdrive Unit Assembly. ........................................................................................ WP 0013-11

Fourth Clutch Repair ....................................................................................................................... WP 0014

Figure 1. Fourth Clutch Disassembly. ........................................................................................ WP 0014-1

Figure 2. Fourth Clutch Cleaning and Inspection. ..................................................................... WP 0014-3

Figure 3. Fourth Clutch Assembly. ............................................................................................ WP 0014-5

Figure 4. Fourth Clutch Measurement. ....................................................................................... WP 0014-6

Forward Clutch Repair .................................................................................................................... WP 0015

Figure 1. Forward Clutch Disassembly. ..................................................................................... WP 0015-1

Figure 2. Forward Clutch Piston Disassembly. .......................................................................... WP 0015-2

Figure 3. Forward Clutch. ........................................................................................................... WP 0015-3

Figure 4. Center Sleeve Seal Installation. .................................................................................. WP 0015-4

Figure 5. Seal Installers. ............................................................................................................. WP 0015-4

Figure 6. Spring Compressor. ..................................................................................................... WP 0015-5

Figure 7. Forward Clutch Assembly. ......................................................................................... WP 0015-6

Figure 8. Forward Clutch Measurement. .................................................................................... WP 0015-7

Figure 9. Forward Clutch. ........................................................................................................... WP 0015-8

Direct Clutch Repair ........................................................................................................................ WP 0016

Figure 1. Direct Clutch Sprag Disassembly. .............................................................................. WP 0016-1

Figure 2. Direct Clutch Disassembly. ......................................................................................... WP 0016-2

Figure 3. Direct Clutch Piston Disassembly. ............................................................................. WP 0016-3

Figure 4. Direct Clutch Inspection. ............................................................................................ WP 0016-4

Figure 5. Direct Clutch Piston Assembly. .................................................................................. WP 0016-5

Figure 6. Direct Clutch Sprag Installation. ................................................................................ WP 0016-6

Figure 7. Direct Clutch Assembly. ............................................................................................. WP 0016-7

Gear Unit and Output Shaft Repair ................................................................................................ WP 0017

Figure 1. Gear Unit. .................................................................................................................... WP 0017-1

Figure 2. Internal Gear. ............................................................................................................... WP 0017-2

Figure 3. Main Shaft. .................................................................................................................. WP 0017-3

Figure 4. Output Carrier. ............................................................................................................. WP 0017-4

Figure 5. Sun Gear. ..................................................................................................................... WP 0017-4

Figure 6. Reaction Drum. ........................................................................................................... WP 0017-5

Figure 7. Roller Clutch. .............................................................................................................. WP 0017-5

Figure 8. Retaining Ring and Washers. ..................................................................................... WP 0017-6

Figure 9. Sun Gear Shaft. ........................................................................................................... WP 0017-6

Figure 10. Output Shaft. ............................................................................................................. WP 0017-7 iv

CHAPTER 3 - MAINTENANCE INSTRUCTIONS - Continued

Figure 11. Bearing Inspection. .................................................................................................... WP 0017-7

Figure 12. Output Shaft Assembly. ............................................................................................ WP 0017-8

Figure 13. Output Drum Assembly. ........................................................................................... WP 0017-9

Figure 14. Gear Unit Assembly. ................................................................................................. WP 0017-10

Center Support Repair ..................................................................................................................... WP 0018

Figure 1. Center Support Packing Retainers. ............................................................................. WP 0018-1

Figure 2. Center Support Disassembly. ...................................................................................... WP 0018-2

Figure 3. Center Support Inspection. .......................................................................................... WP 0018-3

Figure 4. Gauge Pin. ................................................................................................................... WP 0018-4

Figure 5. Springs/Clutch. ............................................................................................................ WP 0018-5

Figure 6. Drive Plate Rings. ....................................................................................................... WP 0018-5

Figure 7. Center Support Bushing Inspection. ........................................................................... WP 0018-6

Figure 8. Center Support Piston Installation. ............................................................................. WP 0018-7

Figure 9. Center Support Spring Assembly. .............................................................................. WP 0018-8

Figure 10. Center Support Packing Retainer Installation. ......................................................... WP 0018-9

Figure 11. Oil Cooler Fitting Seal. ............................................................................................. WP 0018-10

Direct Clutch Piston Movement Measurement ............................................................................... WP 0019

Figure 1. Direct Clutch Measurement. ....................................................................................... WP 0019-3

Transmission Assembly ................................................................................................................... WP 0020

Figure 1. Transmission Parking Lock Pawl. .............................................................................. WP 0020-3

Figure 2. Center Support Assembly. .......................................................................................... WP 0020-4

Figure 3. Rear Band Installation. ................................................................................................ WP 0020-5

Figure 4. Center Support Installation. ........................................................................................ WP 0020-6

Table 1. Rear Selective Washer Thickness. ............................................................................... WP 0020-7

Figure 5. Transmission End Play Check. ................................................................................... WP 0020-7

Figure 6. Center Support Bolt Installation. ................................................................................ WP 0020-8

Figure 7. Oil Cooler Adapter Identification. .............................................................................. WP 0020-9

Figure 8. Oil Cooler Adapter Installation. ................................................................................. WP 0020-10

Figure 9. Intermediate Clutch Assembly. ................................................................................... WP 0020-11

Figure 10. Direct Clutch Assembly. ........................................................................................... WP 0020-12

Figure 11. Forward Clutch Installation. ..................................................................................... WP 0020-13

Figure 12. Fourth Clutch Housing. ............................................................................................. WP 0020-14

Figure 13. Overrun Clutch Housing Installation. ....................................................................... WP 0020-14

Figure 14. Oil Pump Installation. ............................................................................................... WP 0020-15

Table 2. Front Selective Washer Thickness. .............................................................................. WP 0020-16

Figure 15. End Play Check. ........................................................................................................ WP 0020-16

Figure 16. Seal Installation. ........................................................................................................ WP 0020-17

Figure 17. Front Servo Installation. ............................................................................................ WP 0020-17

Table 3. Apply Pin Selection. ..................................................................................................... WP 0020-18

Figure 18. Band Apply Pin. ........................................................................................................ WP 0020-19

Figure 19. Rear Servo Installation. ............................................................................................. WP 0020-20

Figure 20. Checkball Location. ................................................................................................... WP 0020-21 v

CHAPTER 3 - MAINTENANCE INSTRUCTIONS - Continued

Figure 21. Control Valve Installation. ........................................................................................ WP 0020-21

Figure 22. Spring and Roller Installation. .................................................................................. WP 0020-22

Figure 23. Lube Tube and Wire Harness Installation. ............................................................... WP 0020-23

Figure 24. Wire Harness Installation. ......................................................................................... WP 0020-24

Figure 25. Torque Sequence. ...................................................................................................... WP 0020-24

Figure 26. Filter Installation. ...................................................................................................... WP 0020-25

Figure 27. Speed Sensor Installation. ......................................................................................... WP 0020-26

Figure 28. Torque Converter Installation. .................................................................................. WP 0020-27

Figure 29. Transmission Holding Fixture. ................................................................................. WP 0020-28

Transmission Testing and Test Reports .......................................................................................... WP 0021

Table 1. Power and Line Pressure Test Specifications. ............................................................. WP 0021-4

Table 2. Solenoid Resistance Chart (Warm). ............................................................................. WP 0021-5

Table 3. Pressure Control Solenoid Test (Cold). ....................................................................... WP 0021-5

Table 4. Stall Test. ...................................................................................................................... WP 0021-5

Table 5. Power and Line Pressure Test. ..................................................................................... WP 0021-6

Table 6. Pressure Control Solenoid Test (Warm). ..................................................................... WP 0021-6

Table 7. Final Inspection. ........................................................................................................... WP 0021-7

Preservation, Packaging, and Marking ............................................................................................ WP 0022

Preparation for Storage or Shipment .............................................................................................. WP 0023

Figure 1. Transmission IUID Tag Label Location. ................................................................... WP 0023-4

Figure 2. Transmission IUID Tag Label Location. ................................................................... WP 0023-5

Figure 3. Transmission IUID Tag Label Location. ................................................................... WP 0023-7

Figure 4. Transmission IUID Tag Label Location. ................................................................... WP 0023-8

Figure 5. Transmission IUID Tag Label Location. ................................................................... WP 0023-9

Figure 6. Transmission IUID Tag Label Location. ................................................................... WP 0023-10

Table 1. Final Inspection Report (FIR). ..................................................................................... WP 0023-11

Wear Limits ..................................................................................................................................... WP 0024

Table 1. Wear Limits. ................................................................................................................. WP 0024-2

Quality Assurance Requirements .................................................................................................... WP 0025

Illustrated List of Manufactured Items Introduction ...................................................................... WP 0026

Table 1. Manufactured Items Part Number Table of Contents. ................................................ WP 0026-1

Illustrated List of Manufactured Items ........................................................................................... WP 0027

Figure 1. Guide Pin. .................................................................................................................... WP 0027-1

Table 1. Materials. ....................................................................................................................... WP 0027-1

Torque Limits .................................................................................................................................. WP 0028

Figure 1. Measuring Screw Diameter. ........................................................................................ WP 0028-1

Figure 2. Capscrew Head Markings. .......................................................................................... WP 0028-1

Figure 3. Measuring Screw. ........................................................................................................ WP 0028-2

Table 1. Torque Limits for Dry Fasteners. ................................................................................ WP 0028-3

Table 2. Torque Limits for Wet Fasteners. ................................................................................ WP 0028-4

Table 3. Torque Limits for Dry Metric Fasteners. .................................................................... WP 0028-5

Table 4. Torque Limits for Wet Metric Fasteners. .................................................................... WP 0028-6 vi

CHAPTER 3 - MAINTENANCE INSTRUCTIONS - Continued

Table 5. Torque Specifications for Transmission. ..................................................................... WP 0028-8

Chapter 4 - PARTS INFORMATION

Repair Parts and Special Tools List (RPSTL) Introduction ........................................................... WP 0029

Table 1. SMR Code Explanation. ............................................................................................... WP 0029-1

Transmission Shift Lever ................................................................................................................ WP 0030

Figure 1. Transmission Shift Lever. ........................................................................................... WP 0030-2

Torque Converter ............................................................................................................................. WP 0031

Figure 2. Torque Converter. ....................................................................................................... WP 0031-2

Transmission Assembly ................................................................................................................... WP 0032

Figure 3. Transmission Assembly. ............................................................................................. WP 0032-2

Parking Lock System ....................................................................................................................... WP 0033

Figure 4. Parking Lock System. ................................................................................................. WP 0033-2

Planetary Gear Carrier ..................................................................................................................... WP 0034

Figure 5. Planetary Gear Carrier. ............................................................................................... WP 0034-2

Overrun, Overdrive, and Fourth Clutch Assembly ......................................................................... WP 0035

Figure 6. Overrun, Overdrive, and Fourth Clutch Assembly. ................................................... WP 0035-2

Forward Clutch ................................................................................................................................ WP 0036

Figure 7. Forward Clutch. ........................................................................................................... WP 0036-2

Direct Clutch Assembly .................................................................................................................. WP 0037

Figure 8. Direct Clutch Assembly. ............................................................................................. WP 0037-2

Intermediate Clutch and Center Support Assembly ....................................................................... WP 0038

Figure 9. Intermediate Clutch and Center Support Assembly. .................................................. WP 0038-2

Control Valve and Related Parts ..................................................................................................... WP 0039

Figure 10. Control Valve and Related Parts. ............................................................................. WP 0039-2

Control Valve, Accumulator, and Related Parts ............................................................................. WP 0040

Figure 11. Control Valve, Accumulator, and Related Parts. ..................................................... WP 0040-1

Front Servo, Rear Servo, and Governor Assembly ........................................................................ WP 0041

Figure 12. Front Servo, Rear Servo, and Governor Assembly. ................................................ WP 0041-2

Transmission Oil Pump ................................................................................................................... WP 0042

Figure 13. Transmission Oil Pump. ............................................................................................ WP 0042-2

Kits ................................................................................................................................................... WP 0043

National Stock Number Index ......................................................................................................... WP 0044

Part Number Index .......................................................................................................................... WP 0045

Chapter 5 - SUPPORTING INFORMATION

References ........................................................................................................................................ WP 0046

Expendable and Durable Items List ................................................................................................ WP 0047

Table 1. Expendable and Durable Items List. ............................................................................ WP 0047-2

Tool Identification List .................................................................................................................... WP 0048

Table 1. Tool Identification List. ................................................................................................ WP 0048-2

Mandatory Replacement Part List ................................................................................................... WP 0049

Table 1. Mandatory Replacement Part List. ............................................................................... WP 0049-1 vii/viii blank

CHAPTER 1

GENERAL INFORMATION AND EQUIPMENT

DESCRIPTION AND DATA

FOR

4L80-E/4L85-E TRANSMISSION

HMMWV FOV

SUSTAINMENT MAINTENANCE

GENERAL INFORMATION

SCOPE

This NMWR is for use by maintenance technicians at certified repair sites. The instructions in this NMWR apply to model-year 2000 and newer 4L80-E/4L85-E transmissions (HMMWV FOV). If information conflicts, the data contained in this NMWR shall take precedence. The condition of the transmission after rebuild shall be that utility and performance are returned to a near-zero-time/near-zero-miles or like-new condition.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards. Components that are worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

Before performing any rebuild activity, the maintenance technician shall become familiar with all procedures in this NMWR.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual;

DA PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your 4L80-E/4L85-E transmission needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion prevention and control of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. The term “corrosion” means the deterioration of a material or its properties due to a reaction of that material with its chemical environment. An example is the rusting of iron.

Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade (also considered to be corrosion based on the above definition of corrosion). Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically ultraviolet) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. The U.S. Army has defined the following nine (9) forms of corrosion used to evaluate the deterioration of metals. These shall be used when evaluating and documenting corrosion.

UNIFORM (or general attack): Affects a large area of exposed metal surface, like rust on steel or tarnish on silver. It gradually reduces the thickness of the metal until it fails.

CREVICE: Occurs in crevices created by rubber seals, gaskets, bolt heads, lap joints, dirt or other surface deposits. It will develop anywhere moisture or other corrosive agents are trapped and unable to drain or evaporate.

SELECTIVE LEACHING: One element, usually the anodic element of an alloy, corrodes away, leaving the cathodic element. This can create holes in metal.

INTERGRANULAR: Metal deterioration caused by corrosion on the bonds between or across the grain boundaries of the metal. The metal will appear to be peeling off in sheets, flaking, or being pushed apart by

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CORROSION PREVENTION AND CONTROL (CPC) - CONTINUED

layers. A particular type of intergranular corrosion is exfoliation.

PITTING: This can result from conditions similar to those for crevice corrosion. Pits can develop on various materials due to their composition. Rifle boxes are big victims of pitting.

EROSION: Results when a moving fluid (liquid or gas) flows across a metal surface, particularly when solid particles are present in the fluid. Corrosion actually occurs on the surface of the metal, but the moving fluid washes away the corrosion and exposes a new metal surface, which also corrodes.

FRETTING: Occurs as a result of small, repetitive movements (e.g., vibration) between two surfaces in contact with each other. It’s usually identified by a black powder corrosion product or pits on the surface.

GALVANIC: Occurs when two different types of metal come in contact with each other, like steel bolts on aluminum, for example. This is a common problem on aircraft because of their mix of metals.

STRESS: Term used to describe corrosion cracking and corrosion fatigue. Where an item is not ready/available due to one of these forms of corrosion, it shall be recorded as a corrosion failure in the inspection record and the appropriate code (170) for corrosion shall be used when requesting/performing maintenance.

SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

ARMY PETROLEUM, OIL, AND LUBRICANTS (POL)

Proper disposal of hazardous waste material is vital to protecting the environment and providing a safe work environment. Materials such as batteries, oils, and antifreeze must be disposed of in a safe and efficient manner.

DO NOT overfill any fluid reservoir. If fluid flows out of reservoir, stop IMMEDIATELY to avoid spillage.

Immediately clean up spilled fluid before proceeding with any task.

Refer to local procedures and plans for preventing and responding to fluid spills or leaks. Comply with local regulations when disposing of clean up material and fluids.

The following references are provided to ensure that proper disposal methods are followed:

Waste Disposal Instructions (MEIS/MIDI CD ROM) National Environmental Policy Act of 1969 (NEPA) Clean Air Act (CAA) Resource Conservation…