CHANGE:
Beginning at Start Of Production for 1994, all THM 4T60-E transaxles have a re-designed Vehicle Wiring Harness, a re-designed Internal Transaxle Wiring Harness, and the pins in the 7-way case connector DO NOT have the same function as the previous models. There is also one 1993 pull-ahead model, 3BHW, used in the Oldsmobile Cutlass Supreme with the 3.1L engine, that uses the re-designed wiring.

REASON:
The addition of the temperature sensor in the 1994 model transaxles created the need for the wiring to be totally re-designed. Since the temperature sensor required two pins on the case connector and only one was available, it became necessary to combine the 12V power source on one pin "E", instead of the previous two pins "A" & "E".

PARTS AFFECTED:
(1) VEHICLE WIRING HARNESS - Cavity function changes to accommodate the new design wiring, as shown in Figure 1, which includes both previous and the new design electrical schematics.
(2) INTERNAL TRANSAXLE WIRING HARNESS - Cavity function changes to accommodate the re-designed wiring. Refer to Figures 2, which will depend on the model you are working on.
(3) TEMPERATURE SENSOR - Added internally to the transaxle to give the PCM transaxle temperature information. There are 2 different types of the temperature sensor. One sensor is screwed into the channel plate near the TCC accumulator bore and monitors cooler fluid temperature. The other type sensor is incorporated into the wiring harness and clips to the valve body spacer plate, as shown in Figure .2. Regardless of which type temperature sensor you have, the wires will will go through terminals 'IF" & "G" in the new case connector.

INTERCHANGEABILITY:
NONE OF THE PARTS LISTED ABOVE ARE INTERCHANGEABLE WITH ANY OF THE PREVIOUS DESIGN LEVEL PARTS, AS DAMAGE TO ELECTRICAL SYSTEM AND COMPONENTS CAN OCCUR.Some hot car tools like usb kkl vag-com 409.1 and usb kkl vag-com 409.1 maybe are useful.

WARNING: NONE OF THE BREAK-OUT BOXES CURRENTLY AVAILABLE FROM THE AFTERMARKET SOURCES AND USED TO SHIFT THE TRANSAXLE THRU THE SHIFT PATTERN, ARE COMPATIBLE WITH 1994 MODEL 4T60-E DAMAGE TO THE ELECTRICAL COMPONENTS AND/OR BREAK-OUT BOX MAY OCCUR,

 

 

Figure 1

 

 

 

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LAUNCH ICARD Parameters:
Voltage Input: 8 ~ 32V
Working temperature: 0~ 50
Storage temperature: -20~ 70
Dimensions: 51*24*36mm(L*W*H)
Weight: <100g
Power: <0.9W

LAUNCH ICARD Functions:
Read vehicle trouble codes info
Clear vehicle trouble codes
Read vehicle data stream info
Read vehicle freeze frame data
Read vehicle VIN code
Readiness test

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COMPLAINT:
1. AWD LOCK - indicator will remain on, but differential will not lock.
2. ANTI-LOOK - indicator will remain on, and ABS operation would be disabled.

CAUSE:
The cause may be an inoperative and/or intermittent Center Differential Locking Switch (See Figure 1) due to moisture entry during the manufacturing process.

CORRECTION:
Replace the Center Differential Tacking Switch with a new one, now available under OEM part number 8665329.More tools such as sbb v33 key programmer and CarProg Full V4.1 maybe can help you.

Figure 1:http://flic.kr/p/eaCcvr

COMPLAINT:
After flywheel replacement, Ford Taurus/Sable vehicles equipped with the 3.0L, 12 Valve Vulcan engine, may return with an engine rear main oil seal leak. The vehicle did not have this leak after the road test leak check.

CAUSE:
The cause may be over tightening of the flywheel to crankshaft bolts, as the 3.0 Liter, 12 valve Vulcan engine can very easily have the crankshaft pulled out of round by over tightening.

CORRECTION:
When replacing the flywheel, be sure to install flywheel with the stiffener plate towards the transmission and torque the flywheel to crankshaft bolts to 54-64 Ft. Lbs. in a cris-cross pattern.Refer to Figure 1.

Figure 1:http://flic.kr/p/e9Yk1d

COMPLAINT:
Vehicles equipped with the 50-40LE or the 50-42LE transaxle may exhibit a No Reverse No 1st and No 4th condition before and/or after overhaul.

CAUSE:
The cause may be,
1.While cleaning and servicing the valve body, the solenoid screens were installed upside down blocking solenoid feed to the shift solenoids and shift valves as shown in Figure 2.
2.The Shift solenoids are not functioning mechanically.

CORRECTION:
Follow the corrections listed below:
1.Assemble the solenoid screens as shown in Figure 3.
2.Check the Shift Solenoids mechanically as shown in Figure 4 and replace as necessary.

SERVICE INFORMATION:
SOLENOID 1 & 2 (Volvo Part Number)................................6843783

 

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Figure 1:http://flic.kr/p/e5Sv8a
Figure 2:http://flic.kr/p/e5Y9pY
Figure 3:http://flic.kr/p/e5Y9ph
Figure 4:http://flic.kr/p/e5Y9qE

During tear-down, it is very difficult if not impossible to remove the front carrier to output shaft snap ring. Even if only an inspection service is being performed, the tail housing and parking gear to output shaft snap ring must be removed first. See figure 1. This will allow the output shaft to be pushed far enough forward to remove the front carrier to output shaft snap ring without damaging it. See figure 2,

Figure 1:http://flic.kr/p/e4PYsg
Figure 2:http://flic.kr/p/e4VAVd

 

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During tear-down, it is very difficult if not impossible to remove the front carrier to output shaft snap ring. Even if only an inspection service is being performed, the tail housing and parking gear to output shaft snap ring must be removed first. See figure 1. This will allow the output shaft to be pushed far enough forward to remove the front carrier to output shaft snap ring without damaging it. See figure 2,

Figure 1:http://flic.kr/p/e4PYsg
Figure 2:http://flic.kr/p/e4VAVd

 

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1.EARLY 1991 ONLY: USES 5 CHECKBALLS IN THE LOCATIONS SHOWN IN FIGURE 1.

2.LATE 1991 ONLY: THE B12 CHECKBALL THAT SEPARATED TV/L234 WAS ELIMINATED, AS SHOWN IN FIGURE 2. THIS REQUIRED A SPACER PLATE CHANGE.You can get more car tools CAT ET Adapter 3 and  CAS1 7series ID7944 -315LP MHZ for help.

 

3.1992 MODEL ONLY: THE B13 CHECKBALL WAS ELIMINATED, ALLOWING FORWARD CLUTCH OIL TO EXHAUST UNORIFICED IN OVERDRIVE.
THE B2 CHECKBALL WAS ADDED FORCING FORWARD CLUTCH OIL THRU
THE "K" ORIFICE. REFER TO FIGURE 3.

Figure 1:http://flic.kr/p/e48JBN
Figure 2:http://flic.kr/p/e436QM
Figure 3:http://flic.kr/p/e436S6

VALVE BODY NUMBER ONE:
Valve Body Number One and the auxiliary valve body that goes with it, are illustrated in Figure 1, and were used in 1982-1983 models.Most models used only the two terminal 3rd clutch switch and it was not used in all models.Refer to Figure 8 for 3rd clutch switch usage by model.Some of these models also used a governor switch screwed into the auxiliary valve body to control the converter clutch application, which requires a governor pressure passage drilled in the main valve body and the auxiliary valve body.This model auxiliary valve body also used an orificed cup plug in the channel behind the lock-up solenoid, to orifice line pressure down to a value that the solenoid could exhaust.This auxiliary valve body also has shift TV oil routed to the converter clutch regulator valve, which requires a shift TV pressure passage drilled in the main valve body.This valve body and auxiliary valve body combination is recommended for use only on 1982-1983 model vehicles.Refer to Figure One.

VALVE BODY NUMBER TWO:
Valve Body Number Two and the auxiliary valve body that goes with it, are illustrated in Figure 2, and were used in 1984-1986 and partial 1987 models.Most models used only the two terminal 3rd clutch switch and it was not used in all models.Refer to Figure 8 for 3rd clutch switch usage by model.Some of these models also used a governor switch screwed into the auxiliary valve body to control the converter clutch application,which requires a governor pressure passage drilled into the main valve body and the auxiliary valve body.The only difference between this valve body and auxiliary valve body combination, and the 1982-1983 version, is the orificed cup plug was removed from behind the lock-up solenoid.This combination requires a different auxiliary valve body cover gasket with a slot to orifice the oil to the solenoid.This valve body and auxiliary valve body combination can be used on 1982-1986 models and any 1987 model that still has the converter clutch regulator valve line-up and shift TV oil fed to the auxiliary valve body.Refer to Figure Two.

VALVE BODY NUMBER THREE:
Valve Body Number Three and the auxiliary valve body that goes with it, are illustrated in Figure 3, and were used in 1988-1989 models and partial 1987 models.Notice that the auxiliary valve body worm track configuration changes drastically, as the previous converter clutch regulator valve was removed and in its place goes a 3-2 Orifice Control Valve line-up.Notice also that the governor passage is now gone in both the main valve body and auxiliary valve body, and in its place is 2nd clutch oil to accommodate the addition of a 2nd clutch switch on some models.These models can use any one of three different 3rd clutch switches.Refer to Figure 8 for 3rd clutch switch and 2nd clutch switch usage by model, and Figures 10 and 11 for switch identification.This combination also requires a different auxiliary valve body cover gasket than number 1 or number 2.Notice also that this was the first year for the screen in the auxiliary valve body for the lock-up solenoid.1988 was also the first year for a different case connector.Some models used a round case connector instead of the square one.Refer to Figure 8 for case connector usage by model and Figure 12 for case connector identification.This valve body and auxiliary valve body combination can be used on 1988-1989 models and any 1987 model that uses the 3-2 orifice control valve line-up and 2nd clutch pressure fed to the auxiliary valve body.Refer to Figure Three.You can get more car tools VAG DASH K+CAN and  VAG Drive Box for help.

 

VALVE BODY NUMBER FOUR:
Valve Body Number Four and the auxiliary valve body that goes with it, are illustrated in Figure 4, and used in 1988-1989 models and partial 1987 models.The only difference between this combination and valve body number 3 is the orifice cup plug installed in the 2nd clutch oil passage in the main valve body, as shown in Figure 4.This valve body and auxiliary valve body combination should interchange with valve body number 3 without any functional problems.Refer to Figure Four.

VALVE BODY NUMBER FIVE:
Valve Body Number Five and the auxiliary valve body that goes with it, are illustrated in Figure 5, and used in 1990-1993 models.These models use a "Push-In" 3rd clutch switch instead of the screw-in and is a single terminal normally closed switch, which requires a different auxiliary valve body to accommodate the new 3rd clutch switch.Also notice that the auxiliary valve body has an extra passage drilled that the other 1990-Up auxiliary valve bodies that use the screw-in 3rd clutch switch do not have, directly above the round 3rd clutch feed passage.Even with these differences, the 1990-Up valve bodies and auxiliary valve bodies will interchange as long as the correct 3rd clutch switch and 2nd clutch switch are used for the model you are working on.Refer to Figures 8 and 9 for 2nd and 3rd clutch switch usage by model and Figures 10 and 11 for switch identification.Refer to Figures 8 and 9 for case connector usage and Figure 12 for case connector identification.This valve body and auxiliary valve body combination can be used on 1990-Up models as long as proper switch configurations are met.Refer to Figure Five.

VALVE BODY NUMBER SIX:
Valve Body Number Six and the auxiliary valve body that goes with it, are illustrated in Figure 6, and used in 1990-Up models.These models use a "Screw-In" 3rd clutch switch and 2nd clutch switch that are model sensitive.Refer to Figures 8 and 9 for 2nd and 3rd clutch switch usage by model and Figures 10 and 11 for switch identification.This valve body and auxiliary valve body combination can be used on 1990-Up models as long as proper switch configurations are met.  Refer to Figure Six.

VALVE BODY NUMBER SEVEN:
Valve Body Number Seven and the auxiliary valve body that goes with it, are illustrated in Figure 7, and used in 1990-Up models.These models use a "Screw-In" 3rd clutch switch and 2nd clutch switch that are model sensitive.Also notice that the passage next to the 2nd clutch passage in the main valve body that normally carries 3rd clutch oil has not been drilled into the direct clutch passage, however we still have 3rd clutch oil fed to the auxiliary valve body through the small round hole.Refer to Figures 8 and 9 for 2nd and 3rd clutch switch usage by model and Figures 10 and 11 for switch identification.This valve body and auxiliary valve body combination can be used on 1990-Up models as long as proper switch configurations are met.Refer to Figure Seven.

Figure 1:http://flic.kr/p/e33rN8
Figure 2:http://flic.kr/p/e33rNn
Figure 3:http://flic.kr/p/e3998S
Figure 4:http://flic.kr/p/e33rPF
Figure 5:http://flic.kr/p/e399aS
Figure 6:http://flic.kr/p/e33rRt
Figure 7:http://flic.kr/p/e33rSM
Figure 8:http://flic.kr/p/e399fd
Figure 9:http://flic.kr/p/e33rVV
Figure 10:http://flic.kr/p/e33rXa
Figure 11:http://flic.kr/p/e33sbV
Figure 12:http://flic.kr/p/e33sdv
Figure 13:http://flic.kr/p/e33sf2