Technical Service Information

AS6 / AS68RC
PRELIMINARY INFORMATION

The following information is for the AS6 / AS68RC six speed Medium Duty Truck transmission. It is found
in the Mitsubishi Fuso starting in 2005, 07 and up Isuzu cab over, and 07 and up Dodge incomplete chassis.
There is information on both versions in the following pages. The operational characteristics displayed are
for the Dodge, which are similar to the Isuzu. The Valve Body information and specifications are from an
Isuzu application, and are very similar to the Dodge.

AS6 / AS68RC
ISUZU AND DODGE TRUCKS

QEE1F
6B0052

TJS04560052

3
9
5
5
3
1

AISIN SEIKI CO., LTD

MADE IN JAPAN
SERIAL NO.

6B - 0051

Copyright © 2011 ATSG

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

GENERAL DESCRIPTION
Beginning in model year 2007 Daimler-Chrysler AS 6 8 R C
introduced a new rear drive transmission that is
= Commercial Applications
manufactured by Aisin Seiki in Japan and referred to = Rear Wheel Drive
as the AS68RC by Chrysler. It is a six speed, rear = Relative Torque Capacity
wheel drive (RWD) automatic transmission and = Six Forward Speeds
found in Dodge 3500, 4500, and 5500 chassis, with = Aisin Seiki (Manufacturer)
the Cummins 6.7L diesel engine. Refer to Figure 1
for the definitions of AS68RC.
Primary reason was to assist Dodge's re-entry into Figure 1
the commercial truck market with its 26,000 lb
GCVW rating. This is accomplished through the use
of a multi-plate torque converter clutch and heavy
duty gear train housed in a conventional transmission
50 60 70
case assembly, as shown in Figure 3. 40 80
100
The primary mechanical components of the AS68RC 30 60
80 120
140
90
are as follows: 20 40 160 100
Three Driving Clutch Packs. 10
20
180 110
Two Brake Clutch Packs. MPH km/h 200 120
0
One One-Way Sprag Clutch.
Three Planetary Gear Sets. P R N D 3 2 1
Torque Converter Multi-Disc Lock-up Clutch door

Fuel efficiency is provided by clutch to clutch

shifting, an on-demand torque converter clutch, and
Instrument Panel
the use of two overdrive ratios. Refer to Figure 3 for (Speedometer)
component locations and identification of each
Copyright © 2011 ATSG
component. The AS68RC provides six forward and
one reverse range. With the selective lever in D Figure 2
(Drive), all forward ranges are available when the
O/D and Tow/Haul features are Off. AS68RC Shift Quadrant
Fully electronic shift and torque converter clutch The AS68RC shift quadrant indicator is located in
controls optimize transmission operation, fuel the speedometer housing, as shown in Figure 2 and is
economy, and towing capability. The Transmission equipped with a column shift lever. Shift lever
Control Module (TCM) has the capability to alter positions are as follows:
shift schedules, line pressure, and the apply and P When the Park position is selected, there is no
release of the torque converter clutch. The TCM powerflow through the transaxle. The parking pawl
receives information from several electronic sensors is engaged which locks the output shaft to the case.
and based on that information will output to the The engine can be started and the ignition key can be
following solenoids located on the valve body. removed.
Four Linear (PWM) Solenoids.
Four On/Off Shift Solenoids. R When the Reverse position is selected, the vehicle
The TCM also communicates with the Engine can be operated in a rearward direction at a reduced
Control Module (ECM) and the Totally Integrated gear ratio.
Power Module (TIPM) via the CAN-C bus. The N When the Neutral position is selected, there is no
TCM is a stand alone module located located under powerflow through the transaxle. The output shaft is
driver side dash next to the steering shaft. free to rotate and the engine can be started. This
The AS68RC can also accommodate a variety of position can also be selected while the vehicle is
Power Take Off (PTO) accessories and is available in moving to restart the engine, if necessary.
2WD and 4WD versions.
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
AS68RC INTERNAL COMPONENT IDENTIFICATION AND LOCATION
Torque Converter K-2
Clutch Clutch
K-1 K-3 B-1 B-2 F-1
Clutch Clutch Clutch Clutch Sprag

COMPONENT APPLICATION CHART

K-1 K-2 K-3 B-1 B-2 F-1 Torq Conv Gear
RANGE Clutch Clutch Clutch Clutch Clutch Sprag Clutch Ratio
Park On
Reverse On On 3.54
Neutral On
"D"-1st On On Hold 3.74
"D"-2nd On On Applied* 2.00
"D"-3rd On On Applied* 1.34
"D"-4th On On Applied* 1.00
"D"-5th On On Applied* 0.77
"D"-6th On On Applied* 0.63

* TCC is available in 2nd thru 6th gear, based on throttle position, fluid temp and vehicle speed.

Copyright © 2011 ATSG

Figure 3
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

AS68RC Shift Quadrant (Cont'd)

D The Drive position is the normal position for most 1 Manual "1" position prevents transmission from
forward gear operations. The Drive position provides shifting above 1st gear, and provides maximum
automatic upshifts and downshifts, apply and release engine braking. Manual 1 can be selected at any
of the converter clutch, and maximum fuel economy vehicle speed, but will not downshift until vehicle
during normal operation. Drive range allows the speed calibrated into the TCM has been reached, to
transmission to operate in each of the six forward gear prevent engine over-speed.
ratios, with the O/D and Tow/Haul in Off position.
Downshifts are available for safe passing, by AS68RC Tow/Haul and O/D Off
depressing the accelerator. The "Tow/Haul" and "O/D Off" button is located on
the end of the manual selector lever, as shown in
3 Manual "3" position prevents transmission from Figure 4. Pressing the button once enables the
shifting above 3rd gear, and adds more performance Tow/Haul mode and the "Tow/Haul" lamp will be
and engine braking for hilly terrain. Manual 3 can be illuminated. In Tow/Haul mode 6th gear is disabled
selected at any vehicle speed, but will not downshift and all upshifts will be delayed. Closed throttle
until vehicle speed calibrated into the TCM has been downshifts, for improved engine braking, may occur
reached, to prevent engine over-speed. during steady braking conditions.
Pressing the button a second time enables the O/D-
Off mode, where all 5th and 6th gear operation is
2 Manual "2" position prevents transmission from inhibited (No overdrive ratios), and the O/D Off lamp
shifting above 2nd gear, and provides engine braking
will be illuminated. Tow/Haul and O/D Off lamps are
for hilly terrain. Manual 2 can be selected at any
located just to the right of the temperature gauge, as
vehicle speed, but will not downshift until vehicle
shown in Figure 4.
speed calibrated into the TCM has been reached, to
Pressing the button a third time will restore normal
prevent engine over-speed.
operation. Normal operation is the default on start-
up, the switch must be pressed after each key start if
Tow/Haul mode is desired.

AS68RC SHIFT QUADRANT

"TOW/HAUL" AND "O/D OFF" LAMPS
TOW
HAUL

140 245 O/D

OFF

"TOW/HAUL" AND
PRND321 "O/D OFF" BUTTON

AUL
TOW/H
F
OD/OF

Copyright © 2011 ATSG

Figure 4
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

IDENTIFICATION TAG LOCATION

Transmission identification numbers are included in
the bar code label located on the torque converter
housing. There is also a stamped steel identification
tag riveted to the left side of the transmission case, as
shown in Figure 5. This tag also includes build date
information. This information is necessary when any
replacement parts are needed.

IDENTIFICATION TAG LOCATION

QEE1F
6B0052

TJS04560052

3
9
5
5
3
1

AISIN SEIKI CO., LTD

MADE IN JAPAN
SERIAL NO.

6B - 0051

QEE1F
6B0052 AISIN SEIKI CO., LTD
MADE IN JAPAN
TJS04560052 SERIAL NO.
{

{
{
{

Serial Number 6B - 0051

Build Year
{
{

Build Day
Component Code Serial Number
Traceability Production Month
Production Year (6=2006)

A B C D E F G H I J K L
Jan Feb Mar April May June July Aug Sept Oct Nov Dec

Copyright © 2011 ATSG

Figure 5
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

EXTREMELY VERSATILE TRANSMISSION

The Aisin Seiki 6 Speed transmission, at the time of and adapter in the extension housing, as shown in
this printing, is found in the Isuzu NPR, Daimler- Figure 6. The Daimler-Chrysler version uses a mount
Chrysler 3500, 4500, 5500, and possibly replacing the on the bottom of the extension housing and a cross
AW450-43LE unit in Mitsubishi Fuso, and the member. The Isuzu NPR uses the mounting holes on
Tiltmaster trucks. the top left and right sides of the extension housing, as
The Aisin Seiki TR80 transmission can be adapted to shown in Figure 6 and 7.
virtually any type vehicle that is in need of the 26000 There are also at least two different dip stick tube
GCVW torque capacity rating. The TR80 locations, as shown in Figure 6.
transmission is equipped with a bolt-on converter The turbine shaft speed sensor has two different
housing that makes it adaptable to any engine size. locations, as shown in Figure 7. The Isuzu NPR
The case is cast so that it can accommodate a variety mounts on the top center of the case, and the Daimler-
of Power Take Off (PTO) accessories, with PTO Chrysler models is located on the driver side of the
openings available on either side, or on both sides. transmission, within the area of the unfinished casting
The bolt-on extension housing has several different for an additional PTO. Notice also that the
mounting options available on the side and bottom of transmission vent exhausts to the inside of the
the housing and comes in 2WD and 4WD versions. converter housing (See Figure 7).
Some models also use a speedometer gear

Daimler-Crysler
Applications

QEE1F
6B0052

TJS04560052

3
9
5
5
3
1

AISIN SEIKI CO., LTD

MADE IN JAPAN
SERIAL NO.

6B - 0051

Isuzu NPR
Applications
Speedometer Adapter
(Some Models Only)
Copyright © 2011 ATSG

Figure 6
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

Isuzu NPR Vent

Turbine Speed Sensor
Location

Daimler-Chrysler
Turbine Speed Sensor
Location
NOTE: Daimler-Chrysler Turbine Speed Sensor is located on the driver side as the active PTO window is
located on the right hand side of the transmission.

Figure 7

EXTERNAL ELECTRONIC COMPONENTS

Input (Turbine) Speed Sensor
The Input Speed Sensor (ISS) is a magneto resistive INPUT (TURBINE) SPEED SENSOR
speed sensor that generates a DC square wave signal
that the TCM interprets as rotational speed. The ISS
measures the speed of the sun gear for the P1
planetary. The P1 sun gear and the PTO drive gear are
an assembly. The PTO drive gear serves as the tone
wheel for the ISS. The ISS generates 69 pulses per
revolution.
The ISS is primarily used by the TCM to monitor
torque converter clutch application and slippage, and
is the primary input for converter clutch pressure
regulation.
The TCM also uses ISS signal with the Output Speed
Sensor (OSS) signal to determine actual gear ratio.
Both speed sensors share a common 8 volt supply
from the TCM. The ISS is illustrated in Figure 8.
Copyright © 2011 ATSG

Figure 8 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

EXTERNAL ELECTRONIC COMPONENTS (CONT'D) OUTPUT SPEED SENSOR

Output Speed Sensor
The Output Speed Sensor (OSS) is located on the
driver side of the transmission and located in the
extension housing, as shown in Figure 10. The OSS is
a magneto-resistive speed sensor that generates a DC
square wave signal that the TCM interprets as
rotational speed. The OSS measures the speed of the
parking gear teeth attached to the output shaft,
providing the vehicle speed signal. The ABS system
provides back-up vehicle speed should the OSS fail.
The OSS generates 16 pulses per revolution.
The TCM uses the OSS signal to constantly monitor
output shaft speed. It is used with the ISS signal to Copyright © 2011 ATSG
determine actual gear ratio. The OSS signal is Figure 9
compared to the vehicle speed signal from ABS to
validate vehicle speed. Both speed sensors share a
common 8 volt supply from the TCM. The OSS is
illustrated in Figure 9.

10-Way Solenoid
Harness "A"
Connector

QEE1F
6B0052

TJS04560052

3
9
5
5
3
1

AISIN SEIKI CO., LTD

MADE IN JAPAN
SERIAL NO.

6B - 0051

Output Speed
Sensor

12-Way Solenoid
Transmission Harness "B"
Range Switch Connector
Copyright © 2011 ATSG

Figure 10
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TCM CONNECTOR AND TERMINAL IDENTIFICATION

1 6 1 7 1 9

7 12 8 16 10 21

13 17 17 24 22 31

TCM TCM TCM

Connector "A" Connector "B" Connector "C"
Copyright © 2011 ATSG

Figure 11

EXTERNAL ELECTRONIC COMPONENTS (CONT'D) Transmission Range Switch

Transmission Case Connectors On the Aisin Seiki AS68RC (Chrysler) models a
The Aisin Seiki AS68RC uses two transmission case Transmission Range Switch (TRS) is used that has
connectors with an internal wire harness for each, as seven detent positions (P R N D 3 2 1), as shown in
shown in Figure 13. One of them is a 10 terminal Figure 14. Although the charts in Figure 14 are used
connector referred to as "Solenoid A Harness" and the to check the integrity of the switch's range selection,
other is a 12 terminal connector referred to as using an ohmmeter, the best method is to check the
"Solenoid B Harness". switch in the vehicle with a voltmeter.
Refer to Figure 12 for a solenoid resistance chart for By looking at the chart in Figure 14, it can be seen
each of the eight solenoids used in this unit. that terminal 4 is the common terminal for all range
selections. This is the voltage supply into the switch.
Terminals 6 and 10 are used for starting purposes
Solenoid Resistance Chart only. With the ignition switch "ON" there must be
Solenoid Resistance battery voltage at terminal 4. If there is not, this must
Linear Solenoid "A" 5.5 - 7.5 Ohms be repaired first. If voltage is present, it should exit the
assigned terminal for each range selection.
Linear Solenoid "B" 5.5 - 7.5 Ohms The TRS switch can also be checked for shorts. With
Linear Solenoid "C" 5.5 - 7.5 Ohms the ignition switch "OFF", using an ohmmeter at the
Linear Solenoid "D" 5.5 - 7.5 Ohms same terminals shown in the Figure 14 chart, the
reading should be less than 2 ohms resistance.
On/Off Shift Solenoid 1 14 - 16 Ohms A complete wiring schematic from transmission to
On/Off Shift Solenoid 2 14 - 16 Ohms the TCM is shown in Figure 15 and 16. TCM
connector identification is shown in Figure 11.
On/Off Shift Solenoid 3 14 - 16 Ohms
On/Off Shift Solenoid 4 14 - 16 Ohms

Figure 12

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

SOLENOID CONNECTOR AND TERMINAL IDENTIFICATION

5 1 1 5
10 6 6 10

10-Way Solenoid
Harness "A" 10-Way
Vehicle Harness
All Connector
Views are
"Face View"
6 1 1 6
12 7 7 12

12-Way Solenoid
Harness "B" 12-Way
Vehicle Harness

10-Way Solenoid Connector "A"

TCM Conn. Outside Inside
Terminal Function Number Wire Color Wire Color
1 Pressure Switch Number 7 (1/4" NPT) C10 Dk Green/Violet White
2 Pressure Switch Number 5 (1/8" NPT) A11 Yellow/Dk Blue Lt Green
3 TFT Sensor Voltage Signal B15 Dk Green/Orange Pink
4 Power Voltage for Linear Solenoid "C" C5 Yellow/Brown Dk Blue
5 Ground for Linear Solenoid "A" C7 Dk Green/Lt Green Black
6 Pressure Switch Number 8 (1/8" NPT) C26 Dk Green/White Black
7 Pressure Switch Number 4 (1/8" NPT) A5 Dk Green/Brown Orange
8 TFT Sensor Return C28 Yellow/White Tan
9 Ground for Linear Solenoid "C" C15 Yellow/Pink White
10 Power Voltage for Linear Solenoid "A" C6 Dk Green/Tan Yellow

12-Way Solenoid Connector "B"

TCM Conn. Outside Inside
Terminal Function Number Wire Color Wire Color
1 Pressure Switch Number 1 (1/4" NPT) A6 Dk Green/Brown Tan
2 Pressure Switch Number 6 (1/8" NPT) A16 Dk Green/Orange Yellow
3 On/Off Shift Solenoid 2 Power C22 Dk Green/Yellow Black
4 On/Off Shift Solenoid 4 Power B19 Dk Green/Lt Blue Orange
5 Power Voltage for Linear Solenoid "D" C30 Yellow/Gray Dk Blue
6 Ground for Linear Solenoid "B" C8 Yellow/Red Tan
7 Pressure Switch Number 2 (1/4" NPT) A17 Dk Green/Red Pink
8 Pressure Switch Number 3 (1/8" NPT) A12 Dk Green/Pink Black
9 On/Off Shift Solenoid 3 Power C3 Dk Green/Dk Blue Yellow
10 On/Off Shift Solenoid 1 Power C1 Dk Green/Gray Lt Green
11 Ground for Linear Solenoid "D" C31 Yellow/Pink White
12 Power Voltage for Linear Solenoid "B" C9 Yellow/Brown Pink
Copyright © 2011 ATSG
Figure 13
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TRANSMISSION RANGE SWITCH TERMINAL IDENTIFICATION

6 10 All Connector 1 5
Views are
1 5 6 10
"Face View"

Transmission Range Transmission Range

Switch Connector Switch Vehicle
Harness Connector

TRS 10-Way Connector

Range 4 5 9 1 8 2 7 3 10 6
P
3
R
9
5
5
1
3
N
D
3
2
1

10-Way Transmission Range Switch Connector

TCM Conn. Outside
Terminal Function Number Wire Color
1 Transmission Range Switch "Neutral" C29 Dk Green/Dk Blue
2 Transmission Range Switch "3" C18 Dk Green/Dk Blue
3 Transmission Range Switch "1" C16 Dk Green/Dk Blue
4 Power In From Integrated Power Module (IPM) (IPM) B1 Pink/White
5 Transmission Range Switch "Park" C20 Yellow/Dk Blue
6 To Ground At "G100" Black/Lt Green
7 Transmission Range Switch "2" C17 Dk Green/Yellow
8 Transmission Range Switch "Drive" C19 Dk Green/Lt Blue
9 Transmission Range Switch "Reverse" C21 Dk Green/Dk Blue
10 Park/Neutral Switch Input To Integrated Power Module (IPM) (IPM) B2 Yellow/Dk Blue
Copyright © 2011 ATSG

Figure 14 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TYPICAL AS68RC SOLENOID AND PRESSURE SWITCH WIRE SCHEMATIC

(IN "TO COOLER" LINE)

Yellow/Violet
TCC
Fluid Temp
1
Sensor 2
Yellow/White TCM
LOCATED UNDER DRIVER
SIDE DASH TO LEFT OF
STEERING COLUMN
Transmission Sol "A"
10-Way
Internal 2-Way Conn Yellow/Violet
White Conn B16 TFT SIGNAL +
Black Tan Yellow/White Yellow/White
Sump
TFT
8 C28 SENSOR(S) RETURN
Black Pink Dk Green/Orange Dk Green/Orange
Sensor 3 B15 TFT SIGNAL +
Internal 2-Way
White Conn
Orange Orange Dk Green/Brown
PS 4 (1/8" NPT) 7 A5 PRESSURE SWITCH 4
Lt Green Lt Green Yellow/Dk Blue
PS 5 (1/8" NPT) 2 A11 PRESSURE SWITCH 5

White Dk Green/Violet
PS 7 (1/4" NPT) 1 C10 PRESSURE SWITCH 7
Black Dk Green/White
PS 8 (1/8"NPT) 6 C26 PRESSURE SWITCH 8
Twisted
Dk Blue Yellow/Brown Pair Yellow/Brown
4 C5 LINEAR SOLENOID C +
Linear
Solenoid "C" White Yellow/Pink Yellow/Pink
9 Twisted
C15 LINEAR SOLENOID C -
Yellow Dk Green/Tan Pair Dk Green/Tan
10 C6 LINEAR SOLENOID A +
Linear
Solenoid "A" Black Dk Green/Lt Green Dk Green/Lt Green
5 C7 LINEAR SOLENOID A -

Sol "B" Dk Green/Orange

12-Way
Conn
Twisted
Pink Yellow/Brown Pair Yellow/Brown
12 C9 LINEAR SOLENOID B +
Linear
Solenoid "B" Tan Yellow/Red Yellow/Red
6 C8 LINEAR SOLENOID B -
Twisted
Dk Blue Yellow/Gray Pair Yellow/Gray
5 C30 LINEAR SOLENOID D +
Linear
Solenoid "D" White Yellow/Pink Yellow/Pink
11 C31 LINEAR SOLENOID D -

Tan Dk Green/Brown
PS 1 (1/4" NPT) 1 A6 PRESSURE SWITCH 1
Pink Dk Green/Red
PS 2 (1/4" NPT) 7 A17 PRESSURE SWITCH 2
Black Dk Green/Pink
PS 3 (1/8" NPT) 8 A12 PRESSURE SWITCH 3
Yellow Dk Green/Orange
PS 6 (1/8" NPT) 2 A16 PRESSURE SWITCH 6

On/Off Shift
Solenoid 1 Lt Green Dk Green/Gray
10 C1 SHIFT SOLENOID 1 +

On/Off Shift
Solenoid 2 Black Dk Green/Yellow
3 C22 SHIFT SOLENOID 2 +

On/Off Shift
Solenoid 3 Yellow Dk Green/Dk Blue
9 C3 SHIFT SOLENOID 3 +

On/Off Shift
Solenoid 4 Orange Dk Green/Lt Blue
4 B19 SHIFT SOLENOID 4 +

Transmission TCM
Note: Wire Colors May Vary Copyright © 2011 ATSG

Figure 15 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TYPICAL AS68RC RANGE SWITCH WIRE SCHEMATIC

Yellow/Dk Blue
TCM 5 R
P

LOCATED UNDER DRIVER See Figure 11 For N

D
SIDE DASH TO LEFT OF TCM Connector Views
3
STEERING COLUMN 16 PULSES 2
1
PER REV.
Dk Green/Dk Blue P
Dk Green/Brown Dk Green/Brown
OUTPUT SPEED B2 1 OUTPUT 9 N
R

Yellow/Dk Blue 2 SPEED D

Yellow/Dk Blue
SUPPLY 8V + B1 Yellow/Dk Blue
3
2
2 TURBINE 1

Dk Green/Orange Dk Green/Orange SPEED

INPUT SPEED A1 1 R
P
Dk Green/Dk Blue
69 PULSES 1 N

PER REV. D
3
2
1

P
R
N
Dk Green/Lt Blue
8 D
3
2
Dk Green Lt Blue/Black
0.D. SWITCH INPUT B14 1

P
R
N
D
Dk Green/Dk Blue
2 3
2
1

P
Yellow/Dk Blue
TRANS RANGE SWIT "P" C20 N
R

Dk Green/Dk Blue
TRANS RANGE SWIT "R" C21 D
3
Dk Green/Dk Blue Dk Green/Yellow
TRANS RANGE SWIT "N" C29 7 2
1
Dk Green/Lt Blue
TRANS RANGE SWIT "D" C19 P
Dk Green/Dk Blue R
TRANS RANGE SWIT "3" C18 N

Dk Green/Yellow D
TRANS RANGE SWIT "2" C17 3
Dk Green/Dk Blue Dk Green/Dk Blue 2
TRANS RANGE SWIT "1" C16 3 1

P
R
Black/Lt Green
6 N
D

Yellow/Red 3
TCM POWER IN C3 2
1
White/Lt Green Yellow/Dk Blue
CAN C HIGH (+) B20 10
White/Lt Blue Pink/White
CAN C LOW (-) B21 4
TCM

White/Lt Green
CAN C HIGH (+) B1
White/Lt Blue
CAN C LOW (-) B21

White/Lt Blue
CAN C LOW (-) C9
CAN C HIGH (+) White/Lt Green
C1
Yellow/Red
TCM BATTERY FEED L5
Yellow/Dk Blue
P/N SWITCH INPUT B2
PCM Pink/White
IGNITION (HOT RUN/START) B1
(6.7L Diesel)

IPM/TIPM
Integrated Power Module
Totally Integrated Power Module Note: Wire Colors May Vary Copyright © 2011 ATSG

Figure 16 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

EXTERNAL ELECTRONIC COMPONENTS (CONT'D)

Converter Out Fluid Temperature Sensor SOLENOID BRACKET

The torque converter out thermistor is mounted

externally on the passenger side of the transmission,
in the "To Cooler" fitting, as shown in Figure 18.
Torque converter out temperature sensor monitors
torque converter fluid temperature, which is typically
much hotter than sump fluid temperature and
determines appropriate TCC lock-up strategy.
SUMP TEMP SENSOR
INTERNAL ELECTRONIC COMPONENTS
Sump Fluid Temperature Sensor
The sump thermistor is located on the valve body "O" RING

under the linear solenoid bracket, as shown in Figure Copyright © 2010 ATSG
17. Temperatures above and below normal operating Figure 17
range result in modified shift points until normal
operating temperatures are resumed.
Both temperature sensors are Negative Thermal
Coefficient (NTC) sensor, which means an increase in
temperature results in a decrease in sensor resistance.

Torque Converter
Temperature Sensor Copyright © 2011 ATSG

Figure 18 11-25
Page 14 of 42
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

INTERNAL ELECTRONIC COMPONENTS

Control and Shift Solenoid Operation Linear (PWM) Solenoids "A", "C", "D"
There are a total of eight solenoids located on the These three solenoids operate in the same manner,
valve body in the locations shown in Figure 19, along as shown in Figure 20, based on commands from the
with the wire colors that are connected to each of the TCM. All three of these linear solenoids are
solenoids. The sump fluid temperature sensor "Normally-Vented".
location is also shown under the linear solenoid Linear (PWM) Solenoid "A"controls clutch
bracket. pressures to the B1, K1 and K2 clutches.
There are four linear solenoids (PWM) and four Linear (PWM) Solenoid "C" is a multi-tasking
On/Off Shift solenoids, as shown in Figure 19. The solenoid, it controls Forward and Reverse
TCM uses the APP and OSS sensor signals as the engagements and torque converter clutch apply
primary influences on shift control. Based on a pressure.
predetermined shift map, On/Off solenoids and Linear (PWM) Solenoid "D" controls the main line
Linear (PWM) solenoids are activated as needed to pressure.
provide the appropriate gear. Refer to Figure 20 for operational checks.
All shifts are performed by means of clutch to clutch
control where one clutch is engaged as another is
disengaged (No double-swap shifts).

SOLENOID IDENTIFICATION
600

Linear
* Solenoid "D"
(DK BLUE AND WHITE)

On/Off
31010

Solenoid "3"
(YELLOW)
T1

On/Off
Linear Solenoid "2"
Solenoid "C" * (BLACK)
(DK BLUE AND WHITE)

Linear
Solenoid "A"
(YELLOW AND BLACK)
Sump Temp
31010 Sensor
Linear (PINK & TAN)
Solenoid "B"
(TAN AND PINK)
T1

On/Off On/Off
Solenoid "1" Solenoid "4"
(LT GREEN) (ORANGE)

Currently The Solenoids "Are Not" Serviced Separately! Copyright © 2011 ATSG

Figure 19 11-25
Page 15 of 42
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

Linear (PWM) Solenoid "A", "C", and "D", Linear (PWM) Solenoid "A", "C", and "D",
Normally Vented Normally Vented

Solenoid "OFF" Solenoid "ON"

ORANGE ORANGE
"O" RING Exhaust Open "O" RING
Exhaust Closed
Based On Needs

SNOUT DIAMETER SNOUT DIAMETER

16.94 MM (.667") 16.94 MM (.667")

5.5 - 7.5 Ohms Solenoid Feed Solenoid Feed

Resistance Copyright © 2011 ATSG

Figure 20

INTERNAL ELECTRONIC COMPONENTS (CONT'D)

Linear (PWM) Solenoid "B", Linear (PWM) Solenoid "B" controls the clutch
Linear (PWM) Solenoid "B" operates exactly the pressure to B2 and K3 clutches, based on the
opposite of the other linear solenoids, in that it is commands from the TCM.
"Normally Applied", as shown in Figure 21 The Refer to Figure 21 for operational checks on Linear
solenoid snout is also smaller in diameter than the (PWM) Solenoid "B".
other three and requires a different color "O" ring.
Continued on next Page

Linear (PWM) Solenoid "B", Linear (PWM) Solenoid "B",

Normally Applied Normally Applied

Solenoid "OFF" Solenoid "ON"

TAN TAN
"O" RING Exhaust Closed "O" RING
Exhaust Open
Based On Needs

SNOUT DIAMETER SNOUT DIAMETER

16.43 MM (.647") 16.43 MM (.647")

5.5 - 7.5 Ohms Solenoid Feed Solenoid Feed

Resistance Copyright © 2011 ATSG

Figure 21 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

On/Off Shift Solenoid 1, 2, 3, 4, On/Off Shift Solenoid 1, 2, 3, 4,

Normally Closed Normally Closed

Solenoid "OFF" Solenoid "ON"

Out To Control
Closed Valves

14 - 16 Ohms Solenoid Feed Solenoid Feed

Resistance Copyright © 2011 ATSG

Figure 22

INTERNAL ELECTRONIC COMPONENTS (CONT'D)

On/Off Shift Solenoids 1, 2, 3, 4,
These solenoids all operate in exactly the same
manner, as shown in Figure 22, based on commands
from the TCM. All four of the On/Off solenoids are
"Normally Closed".
These four solenoids operate in conjunction with the
linear (PWM) solenoids to provide the proper gear
ratio for the current road conditions.
Refer to Figure 22 for operational checks.

11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

INTERNAL ELECTRONIC COMPONENTS (CONT'D)

Pressure Switches
The AS68RC transmission is equipped with eight Notice that three of the switches are 1/4" NPT and
"Normally Open” pressure switches that are mounted five of the switches are 1/8" NPT. NPT stands for
in the valve body. These pressure switches monitor National Pipe Thread.
various hydraulic circuits to verify proper valve Daimler/Chrysler part numbers are as follows:
operation. Refer to Figure 23 for their various 1/8" NPT pressure switch is 68019699AA (5 Req.).
locations, identification, and wire color that belongs 1/4" NPT pressure switch is 68019700AA (3 Req.).
on the switch, as well as testing procedures, for proper
function of the switches.
PRESSURE SWITCH IDENTIFICATION
Pressure
1/8" NPT Pressure Switch = 68019699AA
Switch 5
(1/8" NPT) 1/4" NPT Pressure Switch = 68019700AA
(LT GREEN)

600

31010
T1

Pressure
Switch 8
(1/8" NPT)
White
Connector To
(BLACK)
Upper Switches *
(ORANGE AND LT GREEN)
Pressure
Switch 6
(1/8" NPT)
(YELLOW)

31010
Pressure
Switch 4 Pressure
(1/8" NPT) Switch 2
T1
(1/4" NPT)
(ORANGE) (PINK)

Positive lead

Normally Open 1/8" NPT Pressure Switch

Closes at 45-50 psi (meter reads continuity)
Pressure
Apply Air Negative lead White
Switch 3
Here Pressure Connector To
Positive lead (1/8" NPT) Pressure
(BLACK) Switch 7 Switch 1 TFT Sensor
Normally Open 1/4" NPT Pressure Switch (1/4" NPT) (1/4" NPT) (PINK AND TAN)
Closes at 65-70 psi (meter reads continuity) (WHITE) (TAN)

Apply Air Negative lead Copyright © 2011 ATSG

Here

Figure 23 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

AS68RC SHIFT SOLENOID APPLICATION CHART

On/Off Solenoids (1) Linear (PWM) Solenoids (2) Pressure Switches (3)
RANGE S1 S2 S3 S4 "A" "B" "C" "D" PS-1 PS-2 PS-3 PS-4 PS-5 PS-6 PS-7 PS-8

Park Off On On On Low High Low High O O O C C C O O

Reverse (HT) On Off On On Low Low Low Low O C C O C C O O
Reverse On On On On Low Low High Low O C C C C C C O
Neutral Off On On On Low High Low High O O O C C C O O
Neut/Dr (T) Off On On On
Dr-1st (Stop) Off On On On Low High High Low O O O C C C C C
Dr-1st Off Off On On Low High Low Low O O O O C C O C
Dr/1-2 (T) Off Off On On
Dr-2nd Off Off Off Off High High Low High C O O O O O O C
Dr/2-3 (T) Off Off Off On
Dr-3rd On Off Off Off Low Low Low High O C C O O O O C
Dr/3-4 (T) On Off Off On
Dr-4th TCC On On Off Off High High High High C O C C O O O C
Dr/4-5 (T) On On Off On
Dr-5th TCC Off On Off On Low Low High High O C O C O O O C
Dr/5-6 (T) Off On Off On
Dr-6th TCC Off On Off On High High High High C O O C O O O C
Man-1st Off Off On On Low Low Low Low O C O O C C O C

(T) = Transition.
(HT) = High Torque Copyright © 2011 ATSG
(1) All On/Off solenoids are normally closed and allow no fluid through the solenoid.
(2) Linear (PWM) solenoids "A", "C", and "D" are Normally-Vented. Linear (PWM) solenoid "B" is Normally-Applied.
(Low and High refer to PWM Duty Cycle).
(3) All pressure switches are normally open and closed when oil pressure is applied, C = Closed (Grounded), O = Open (12V).

Figure 24
Default "Limp-In" Mode
The "Limp-In" gear ranges available in the AS68RC
are 5th gear, 3rd gear and reverse.
If the fault occurs when in 4th, 5th or 6th gear, the
transmission will default to 5th gear and remain there
until it is safe enough to downshift to 3rd.
If the fault occurs when in 1st, 2nd or 3rd gear, the
transmission will default to 3rd gear and will not upshift
to any higher gear.
Reverse is available in either default range. Default
operation is indicated by the MIL lamp being
illuminated and the transmission will have extremely
harsh garage shifts, Park to Reverse & Park to Drive.
11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
PRESSURE TAP LOCATIONS

Lube Line
Pressure Pressure

QEE1F
6B0052

TJS04560052

3
9
5
5
3
1

AISIN SEIKI CO., LTD

MADE IN JAPAN
SERIAL NO.

6B - 0051

Converter In
Pressure

Line Pressure Specifications

Line K1 K2 K3 B1 B2* TCC On
Park 110-250 0 0 0 0 70 0
Reverse 250 0 0 85-250 0 110-250 0
Neutral 115-250 0 0 0 0 70 0
First 250 75-250 0 0 0 110-250 0
Second 115 115 0 0 115 0 0
Third 115 115 0 115 0 0 115
Fourth 115 115 115 0 0 0 115
Fifth 115 0 115 115 0 0 115
Sixth 115 0 115 0 115 0 115
Checked at 1500 RPM
* Need OSS signal in Manual L - Raise rear wheels or Transfer Case in Neutral.

Copyright © 2011 ATSG

Figure 25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

PRESSURE TAP LOCATIONS

"To Cooler"
Pressure
Converter
TCC Apply Return
& Release Pressure
Pressure
B1 Clutch
Pressure

B2 Clutch
Pressure
"From Cooler"
K1 Clutch Pressure
K3 Clutch K2 Clutch
Pressure Pressure Pressure

Copyright © 2011 ATSG

Figure 26 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
AISIN SEIKI 6 SPEED ACCUMULATOR IDENTIFICATION A
C B

C B
No Machined Machined
Step On Step On
Inside Inside
Diameter Diameter

Notice that accumulator "B" piston has a CASE ACCUMULATOR SPRING SPECIFICATIONS
machined step on the inside diameter and requires ACCUMULATOR "A" ACCUMULATOR "A"
the long blue spring. Accumulator "C" piston Free Length = 1.720" Piston Height = 1.471"
Spring Diameter = .433" Piston Diameter = .630"
does not have the machined step and requires the Wire Diameter = .075"
shorter yellow spring. Approx Coils = 13 (PURPLE)
The bore in the case for accumulator "B" is
ACCUMULATOR "B" ACCUMULATOR "B"
deeper than the bore for accumulator "C". When Free Length = 2.590" Piston Height = 1.460"
the accumulators are installed correctly, Spring Diameter = .598" Piston Diameter = .786"
accumulator piston "B" will stick out of case Wire Diameter = .060" Machined Step Inside
Approx Coils = 12 (BLUE)
approximately 3/4" and accumulator piston "C"
will be almost flush with the case. Note: these two ACCUMULATOR "C" ACCUMULATOR "C"
Free Length = 1.987" Piston Height = 1.500"
accumulators are used for Forward and Reverse Spring Diameter = .598" Piston Diameter = .786"
engagements and are connected in the same oil Wire Diameter = .103" NO Machined Step Inside
circuit. Approx Coils = 12 (YELLOW)
Note: These are Isuzu calibrations. Chrysler
Copyright © 2011 ATSG
calibrations may be different.
Figure 27
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
AIR CHECKS AND CASE PASSAGE IDENTIFICATION, VALVE BODY SIDE

K-1 K-2
Clutch Clutch

11
10 8 7 1 2 3
9 6 4
12

5
13

14

15

16

K-3 B-1
Clutch Clutch

17 18 19

B-2
Clutch

20

1 PUMP INLET (SUCTION). 11 "FROM" COOLER.

2 PUMP OUTLET (LINE). 12 SECONDARY REG. PRESSURE TO LOCK-UP CONTROL VALVE.
3 CONVERTER IN. 13 "TO" COOLER.
4 PRESSURE CONTROL SOLENOID TO P.R. VALVE. 14 NEUTRAL TO DRIVE AND REVERSE ACCUMULATOR.
5 PRESSURE CONTROL SOLENOID DAMPER PISTON. 15 NEUTRAL TO DRIVE AND REVERSE ACCUMULATOR.
6 K-2 CLUTCH. 16 LUBE.
7 LUBE TO PLANETARY PISTONS. 17 K-3 CLUTCH.
8 CONVERTER CLUTCH APPLY AND RELEASE. 18 LUBE.
9 CONVERTER RETURN. 19 B-1 CLUTCH.
10 K-1 CLUTCH. 20 B-2 CLUTCH. Copyright © 2011 ATSG

Figure 28
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

2
CASE PASSAGE I.D.
FRONT OF CASE

2
8

12
10
9
8 3
7 2
6 1

1 PUMP INLET (SUCTION).

2 PUMP OUTLET (LINE).
3 CONVERTER IN.
4 PRESSURE CONTROL SOLENOID TO P.R. VALVE.
5 N/A
6 K-2 CLUTCH.
7 LUBE TO PLANETARY PINIONS / CANCEL PRESSURE.
8 TCC APPLY AND RELEASE.
9 CONVERTER RETURN.
10 K-1 CLUTCH.
9 11 N/A
2 12 SECONDARY REG. FEED TO LOCK-UP CONTROL VALVE.

PUMP PASSAGE I.D.

AT
2

2 REAR OF PUMP
8
5 0

12
10
9
3 8
2 7
1 6

Copyright © 2011 ATSG

Figure 29
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

PARTIAL PUMP PASSAGE I.D.

12
7

2-A

9
2 12
4

2 2

2
1
8

12
10 1 2

9 2

8
7 1 PUMP INLET (SUCTION).
2 PUMP OUTLET (LINE).
3 CONVERTER IN.
4 PRESSURE CONTROL SOLENOID TO P.R. VALVE.
5 N/A
6 K-2 CLUTCH.
7 LUBE TO PLANETARY PINIONS / CANCEL PRESSURE.
12 8 TCC APPLY AND RELEASE.
7 9 CONVERTER RETURN.
10 K-1 CLUTCH.
11 N/A
7
12 SECONDARY REGULATOR PRESSURE.
2
12
7 2-A LINE PRESSURE TO PRESSURE REG. BALANCE ORIFICE
9
2
4

12

8
1

12
10
2 1 9
8
7

Copyright © 2011 ATSG

Figure 30
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

VALVE BODY ASSEMBLY

The valve body is retained to the transmission case
with 19 bolts of six different lengths, as shown in
Figure 31. An additional bolt that fastens the detent
spring must also be removed to relieve the tension on
the inside detent lever for easier removal and
installation.
There are a total of 19 different lengths of valve body
bolts throughout the valve body. Refer to Figure 32,
33 and 34 for their lengths and locations. Illustration
numbers, (example: 980), are referring to the
exploded views in figures 31, 35 and 39.

VALVE BODY RETAINING BOLTS EXPLODED VIEW

982 983

985
981
984

981

981
981

980

981
1
T
0
01

981
31
31

T
1
01
0

986
986
0
60

Copyright © 2011 ATSG

Figure 31
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
VALVE BODY RETAINING BOLTS
2 7 3 2
4
2

*
31010
6 T1

T1
31010
600

2 2
6 Copyright © 2010 ATSG
Reference Head
Number Quantity Size Appearance Length

58.0 mm (2.284")
(1) 1 With Flange
ILLUSTRATION NO. 980
10 mm

(2) 6 31.2 mm (1.228")

With Flange
10 mm ILLUSTRATION NO. 981

43.0 mm (1.692")
(3) 1 With Flange
ILLUSTRATION NO. 982
10 mm

50.0 mm (1.968")
(4) 1 With Flange
ILLUSTRATION NO. 983
10 mm

41.2 mm (1.622")
(5) 1 With Flange
10 mm ILLUSTRATION NO. 984

56.2 mm (2.212")
(6) 9 With Flange
10 mm ILLUSTRATION NO. 985 Copyright © 2011 ATSG

41.5 mm (1.634")
(7) 1 With Wave Washer
8 mm ILLUSTRATION NO. 986

Figure 32 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LOWER VALVE BODY BOLTS 10 8 9 15 13 9

*
31010
T1

12 14

T1
31010
600

13 10 11 10 9
Copyright © 2010 ATSG

Reference Head
Number Quantity Size Appearance Length

(8) 1 41.7 mm (1.642")

With Flange
10 mm ILLUSTRATION NO. 987

12.4 mm (.490")
(9) 3 With Flange
10 mm ILLUSTRATION NO. 988

(10) 3 25.0 mm (.984")

With Flange
10 mm ILLUSTRATION NO. 989

58.0 mm (2.284")
(11) 1 With Flange
10 mm ILLUSTRATION NO. 990

21.3 mm (.840")
(12) 2 With Washer
8 mm ILLUSTRATION NO. 991

55.0 mm (2.165")
With Washer
(13) 14 (13 In Cover, 1 In TFT Brkt)
8 mm ILLUSTRATION NO. 992

37.6 mm (1.480")
(14) 1 With Washer
ILLUSTRATION NO. 993 Copyright © 2011 ATSG
8 mm

(15) 2 29.4 mm (1.157")

With Washer
8 mm ILLUSTRATION NO. 994

Figure 33 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

UPPER VALVE BODY BOLTS

17 20 19

28

04
1
20

9
31010 20
T1
18 20

20

16

20 20
20 Copyright © 2010 ATSG

Reference Head
Number Quantity Size Appearance Length

24.5 mm (.965")
(16) 1 With Washer
ILLUSTRATION NO. 995
8 mm

42.3 mm (1.665")
(17) 3 With Washer
ILLUSTRATION NO. 996
8 mm

(18) 1 40.0 mm (1.575")

With Wave Washer
ILLUSTRATION NO. 997
8 mm

37.0 mm (1.457")
(19) 1 With Wave Washer
ILLUSTRATION NO. 998
8 mm

37.5 mm (1.476")
(20) 13 With Washer
ILLUSTRATION NO. 999
8 mm

Copyright © 2011 ATSG

Figure 34
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LOWER VALVE BODY EXPLODED VIEW
992

991 992

Refer to Figure 36 for Legend

991

318

990
989
317

31

T
1
01
0

316 989
319

315

314
0
60

988 320

989
980
986 313
321

322

323 324
310
311
988
987 325
308
307 309 312

988
306
305

326
1
T

304
328
0
01

303
3 1

330
302

301

303 332
327
302
329
CBC-2 301
Torque Converter 331
Check Valve
CBC-1 300
Cooler
Check Valve
Copyright © 2011 ATSG
Figure 35
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

Figure 35 and 38 Legend

300 LOWER VALVE BODY CASTING.
301 LARGE CHECK BALL CAPSULE (2 REQUIRED).
302 LARGE CHECK BALL CAPSULE SPRING (2 REQUIRED) (WHITE).
303 LARGE CHECK BALL, 11 MM (.499") DIAMETER (2 REQUIRED).
304 LINEAR SOLENOID "D" "O" RING (ORANGE).
305 LINEAR SOLENOID "D", LINE PRESSURE, (SNOUT DIAMETER = .667").
306 ON/OFF SHIFT SOLENOID 3 (NO "O" RING USED).
307 ON/OFF SHIFT SOLENOID 2 (NO "O" RING USED).
308 LINEAR SOLENOID "D" RETAINING BRACKET.
309 PRESSURE SWITCH EIGHT (1/8" NPT).
310 DETENT SPRING COVER PLATE.
311 DETENT SPRING.
312 PRESSURE SWITCH SIX (1/8" NPT).
313 ON/OFF SHIFT SOLENOID 4 (NO "O" RING USED).
314 COVER PLATE SPACER TO LOWER VALVE BODY GASKET.
315 COVER PLATE SPACER PLATE.
316 COVER PLATE SPACER TO COVER PLATE GASKET.
317 COVER PLATE.
318 RETAINING PLATE (LOCK-UP CONTROL RETAINER).
319 LINEAR SOLENOID "B", "A", & "C" RETAINING BRACKET.
320 SUMP TEMPERATURE SENSOR & BRACKET ASSEMBLY.
321 SUMP TEMPERATURE SENSOR "O" RING.
322 PRESSURE SWITCH ONE (1/4" NPT).
323 PRESSURE SWITCH TWO (1/4" NPT).
324 PRESSURE SWITCH SEVEN (1/4" NPT).
325 PRESSURE SWITCH THREE (1/8" NPT).
326 ON/OFF SHIFT SOLENOID 1 (NO "O" RING USED).
327 LINEAR SOLENOID "B", SHIFT PRESSURE, (SNOUT DIAMETER = .647").
328 LINEAR SOLENOID "B" "O" RING (BROWN).
329 LINEAR SOLENOID "A", SHIFT PRESSURE, (SNOUT DIAMETER = .667").
330 LINEAR SOLENOID "A" "O" RING (ORANGE).
331 LINEAR SOLENOID "C", MULTIPLE TASK, (SNOUT DIAMETER = .667").
332 LINEAR SOLENOID "C" "O" RING (ORANGE).
349 SMALL CHECK BALL CAPSULE.
350 SMALL CHECK BALL SPRING (ORANGE).
351 SMALL CHECK BALL, 10 MM (.393").
352 ACCUMULATOR VALVE SPRING, 3 REQUIRED (RED).
353 ACCUMULATOR VALVES, LONG WITH DIMPLE, (.471" DIAMETER).
354 ACCUMULATOR VALVE SPRING, 2 REQUIRED (LT. GREEN).
355 ACCUMULATOR VALVES, SHORT WITH DIMPLE, (.491" DIAMETER).
356 LOWER VALVE BODY TO SPACER PLATE GASKET.
357 MAIN VALVE BODY SPACER PLATE.
358 SPACER PLATE TO UPPER VALVE BODY GASKET.
980 LINEAR SOLENOID "D" RETAINING BOLT (SEE BOLT CHART).
987 ON/OFF SHIFT SOLENOID 3 RETAINING BOLT (SEE BOLT CHART).
988 ON/OFF SHIFT SOLENOID RETAINING BOLT (SEE BOLT CHART).
989 LINEAR SOLENOID RETAINING BRACKET BOLT (SEE BOLT CHART).
990 LINEAR SOLENOID RETAINING BRACKET BOLT (SEE BOLT CHART).
991 COVER PLATE BOLTS (SEE BOLT CHART).
992 COVER PLATE BOLTS (SEE BOLT CHART.

Figure 36

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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LOWER VALVE BODY EXPLODED VIEW

1
T
0
01
31
343
300
343 }
342

}
342
348

346 345
343
347
}342 345

344

341
339

340
336
338
334 333
337
335
337

333

300 LOWER VALVE BODY CASTING.

333 VALVE TRAIN BORE PLUG (2 REQUIRED).
334 LOCK-UP CONTROL VALVE BORE PLUG RETAINER. LOWER VALVE BODY SPRING SPECIFICATIONS
335 LOCK-UP CONTROL VALVE.
336 LOCK-UP CONTROL VALVE SPRING (PINK). SPRING NUMBER 336 SPRING NUMBER 343 (3)
337 BORE PLUG RETAINERS (2 REQUIRED). Free Length = 1.230" Free Length = 1.334"
338 SHIFT VALVE NUMBER 4 SPRING (BLUE). Spring Diameter = .319" Spring Diameter = .361"
339 SHIFT VALVE NUMBER 4. Wire Diameter = .030" Wire Diameter = .033"
340 CONTROL VALVE NUMBER 3 BORE PLUG. Approx Coils = 12 (PINK) Approx Coils = 11 (YELLOW)
341 CONTROL VALVE NUMBER 3, K1 AND K3, (LARGE DIA. = .440").
342 CONTROL VALVE CLIPS (CALIBRATES SPRING PRESSURE). SPRING NUMBER 338 SPRING NUMBER 345 (2)
343 CONTROL VALVE SPRING (3 REQUIRED) (YELLOW). Free Length = 1.585" Free Length = .925"
344 CONTROL VALVE NUMBER 1 PLUNGER (LARGE DIA. = .668"). Spring Diameter = .434" Spring Diameter = .582"
345 CONTROL VALVE PLUNGER SPRING (2 REQUIRED) (BLUE). Wire Diameter = .034" Wire Diameter = .037"
346 CONTROL VALVE NUMBER 1, K1, K2 AND B3, (LARGE DIA. = .471").
Approx Coils = 9 (BLUE) Approx Coils = 5 (BLUE)
347 CONTROL VALVE NUMBER 2 PLUNGER (LARGE DIA. = .648").
348 CONTROL VALVE NUMBER 2, K3 AND B2, (LARGE DIA. = .431").

Copyright © 2011 ATSG

Figure 37
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LOWER VALVE BODY EXPLODED VIEW

358

357

356

ACCV-7

ACCV-5
353
ACCV-6 ACCV-4
Refer to Figure 36 for Legend 353
352
355 ACCV-3
353
352
351 352 355
CBC-3 354
"D" Ranges 350
Orifice Ball 354
349

300
ACCV-3 = Linear "A" Solenoid Output Accumulator To PSW-1.
ACCV-4 = Linear "B" Solenoid Output Accumulator To PSW-2.
ACCV-5 = Linear "C" Solenoid Feed Accumulator.
ACCV-6 = Linear "A" Solenoid Feed Accumulator.
ACCV-7 = Linear "B" Solenoid Feed Accumulator.

Copyright © 2011 ATSG

Figure 38 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

There are a couple of things to be aware of when Also, valves 375 and 381 are both the same diameter
assembling the upper valve body and are shown in and will install, but cannot be interchanged because of
Figure 40. Notice the bore plug retainer for valve the valve land configuration. Install them as shown in
number 372. Even though it is the same as all the other Figure 40.
retainers, it installs laying on its side, as shown in Figure
40. Installed like you think it should go, it will protrude
past the valve body surface.

UPPER VALVE BODY EXPLODED VIEW

996

996

998

363
364 999
996

362
04
9
28

3
1

1
0
1
0

T
1

361

359
997

995

360

359 MANUAL VALVE.

360 UPPER VALVE BODY CASTING.
361 PRESSURE SWITCH FIVE (1/8" NPT).
362 PRESSURE SWITCH FOUR (1/8" NPT).
363 PRESSURE SWITCH HARNESS AND DRAIN BALL RETAINING BRACKET.
364 DRAIN BALL, 27 MM (1.062") DIAMETER.
995 VALVE BODY BOLT (SEE BOLT CHART).
996 RETAINING BRACKET BOLTS (SEE BOLT CHART).
997 VALVE BODY BOLT (SEE BOLT CHART).
998 VALVE BODY BOLT (SEE BOLT CHART).
999 VALVE BODY BOLTS (SEE BOLT CHART).

Copyright © 2011 ATSG

Figure 39 11-25
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
UPPER VALVE BODY EXPLODED VIEW
CORRECT INCORRECT

337 337

373
370

372
369
371

368

337

367

366
365

BALL SIZE
11.00 MM (.433")
VALVE 375 & 381
BOTH .471" DIAMETER
374

375
377
337

378
380
360 337

379 376
381

UPPER VALVE BODY SPRING SPECIFICATIONS 383

337
SPRING NUMBER 366 SPRING NUMBER 377
Free Length = 1.922" Free Length = 1.555" 384 382
Spring Diameter = .484" Spring Diameter = .483" 337
Wire Diameter = .090" Wire Diameter = .039" 385
Approx Coils = 13 (WHITE) Approx Coils = 10 (LT BLUE)

SPRING NUMBER 368 SPRING NUMBER 380

Free Length = 1.645" Free Length = 1.585"
Spring Diameter = .395" Spring Diameter = .433"
Wire Diameter = .032" Wire Diameter = .035"
Approx Coils = 11 (RED) Approx Coils = 9 (BLUE)

SPRING NUMBER 371 SPRING NUMBER 384

Free Length = 1.500" Free Length = 2.265" Refer to Figure 41 for Legend
Spring Diameter = .348" Spring Diameter = .528"
Wire Diameter = .023" Wire Diameter = .055"
Approx Coils = 17 (DK BLUE) Approx Coils = 12 (PINK)

SPRING NUMBER 374

Free Length = 1.560"
Spring Diameter = .435"
Wire Diameter = .039"
Approx Coils = 10 (LT GREEN) Copyright © 2011 ATSG

Figure 40
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AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
UPPER VALVE BODY EXPLODED VIEW

ACCV-1 = Cooler Blow-Off.

ACCV-2 = Solenoid Modulating Pressure Blow-Off. ACCV-1

393
CBC-5
"R" Range 389 ACCV-2 CBC-4
389 B2 Clutch Apply
Orifice Ball
388 Orifice Ball
391 392 388
387 387
386
390

360

337 BORE PLUG RETAINERS (7 REQUIRED). 379 SHIFT VALVE NUMBER 2 BORE PLUG.
360 UPPER VALVE BODY CASTING. 380 SHIFT VALVE NUMBER 3 SPRING (BLUE).
365 LINE PRESSURE BLOW-OFF BALL, 11 MM (.433") DIAMETER. 381 SHIFT VALVE NUMBER 3.
366 LINE PRESSURE BLOW-OFF BALL SPRING (WHITE). 382 SHIFT VALVE NUMBER 3 BORE PLUG.
367 LINE PRESSURE BLOW-OFF BORE PLUG. 383 MODULATOR VALVE.
368 GAIN CHANGE VALVE SPRING (RED). 384 MODULATOR VALVE SPRING (PINK).
369 GAIN CHANGE VALVE. 385 MODULATOR VALVE BORE PLUG.
370 GAIN CHANGE VALVE BORE PLUG. 386 PLASTIC SCREEN.
371 COMBINED DRAIN VALVE SPRING (DK BLUE). 387 SMALL CHECK BALL CAPSULE (2 REQUIRED).
372 COMBINED DRAIN VALVE. 388 SMALL CHECK BALL SPRING, 2 REQUIRED, (ORANGE).
373 COMBINED DRAIN VALVE BORE PLUG (NOTE RETAINER DIRECTION). 389 SMALL CHECK BALL, 10 MM (.393") DIAMETER (2 REQUIRED).
374 SHIFT VALVE NUMBER 1 SPRING (LT GREEN). 390 ACCUMULATOR VALVE SPRING (WHITE).
375 SHIFT VALVE NUMBER 1. 391 ACCUMULATOR VALVE, SHORT W/O DIMPLE, .470" DIAMETER.
376 SHIFT VALVE NUMBER 1 BORE PLUG. 392 ACCUMULATOR VALVE SPRING (LT BLUE).
377 SHIFT VALVE NUMBER 2 SPRING (LT BLUE). 393 ACCUMULATOR VALVE, LONG W/O DIMPLE, .510" DIAMETER.
378 SHIFT VALVE NUMBER 2.
Copyright © 2011 ATSG

Figure 41
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 Technical Service Information

LOWER VALVE BODY FILTER SIDE

Torque
Converter
Check Valve

31010
T1
Cooler
Check Valve

T1
31010
600

Check Ball And Capsule

CHECK BALL DIAMETER = .499"
CAPSULE DIAMETER = .667"
SPRING FREE LENGTH = .758" (WHITE PAINT)
SPRING WIRE DIAMETER = .019" (WHITE PAINT)
SPRING APPROX. COILS = 8 (WHITE PAINT)

Copyright © 2011 ATSG

Figure 42 11-25
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 Technical Service Information

LOWER VALVE BODY SPACER PLATE SIDE

ACCV-3 = Linear "A" Solenoid Output Accumulator To PSW-1. ACCV-5 ACCV-6 ACCV-7
ACCV-4 = Linear "B" Solenoid Output Accumulator To PSW-2. Long With Long With Long With
ACCV-5 = Linear "C" Solenoid Feed Accumulator. Dimple Dimple Dimple
ACCV-6 = Linear "A" Solenoid Feed Accumulator.
ACCV-7 = Linear "B" Solenoid Feed Accumulator.

ACCV-3 ACCV-4
Short With Short With
CBC-3 Dimple Dimple
"D" Ranges
Orifice Ball

"Long" Accumulator Piston (With Dimple) "Short" Accumulator Piston (With Dimple)
PISTON DIAMETER = .471" PISTON DIAMETER = .491"
PISTON OVERALL LENGTH = .996" PISTON OVERALL LENGTH = .785"
SPRING FREE LENGTH = 1.140" (RED PAINT) SPRING FREE LENGTH = .895" (LT GREEN PAINT)
SPRING WIRE DIAMETER = .049" (RED PAINT) SPRING WIRE DIAMETER = .063" (LT GREEN PAINT)
SPRING APPROX. COILS = 10 (RED PAINT) SPRING APPROX. COILS = 9 (LT GREEN PAINT)

Check Ball And Capsule

CHECK BALL DIAMETER = .393"
CAPSULE DIAMETER = .526"
SPRING FREE LENGTH = .502" (ORANGE PAINT)
SPRING WIRE DIAMETER = .014" (ORANGE PAINT)
SPRING APPROX. COILS = 7 (ORANGE PAINT)
Copyright © 2011 ATSG
Figure 43 11-25
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 Technical Service Information

UPPER VALVE BODY SPACER PLATE SIDE

ACCV-1 = Cooler Blow-Off.
ACCV-2 = Solenoid Modulating Pressure Blow-Off.

ACCV-2
ACCV-1
Long Without
Short Without
Dimple
Dimple
Screen

CBC-5 CBC-4
"R" Range B2 Clutch Apply
Orifice Ball Orifice Ball

"Long" Accumulator Piston (Without Dimple) "Short" Accumulator Piston (Without Dimple)
PISTON DIAMETER = .510" PISTON DIAMETER = .470"
PISTON OVERALL LENGTH = .913" PISTON OVERALL LENGTH = .650"
SPRING FREE LENGTH = 1.325" (LT BLUE PAINT) SPRING FREE LENGTH = .932" (WHITE PAINT)
SPRING WIRE DIAMETER = .054" (LT BLUE PAINT) SPRING WIRE DIAMETER = .047" (WHITE PAINT)
SPRING APPROX. COILS = 13 (LT BLUE PAINT) SPRING APPROX. COILS = 11 (WHITE PAINT)

Check Ball And Capsule

CHECK BALL DIAMETER = .393"
CAPSULE DIAMETER = .526"
SPRING FREE LENGTH = .502" (ORANGE PAINT)
SPRING WIRE DIAMETER = .014" (ORANGE PAINT)
SPRING APPROX. COILS = 7 (ORANGE PAINT)
Copyright © 2011 ATSG

Figure 44 11-25
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 Technical Service Information
OIL PUMP COVER EXPLODED VIEW

PRIMARY REG
SPRING FREE LENGTH = 3.575"
SPRING DIAMETER = .885"
WIRE DIAMETER = .115"
APPROX. COILS = 13 (BLUE)

Pressure Regulator
CONVERTER REG Valve Retainer
SPRING FREE LENGTH = 1.520"
SPRING DIAMETER = .555"
WIRE DIAMETER = .078"
APPROX. COILS = 9 (WHITE)
TA
2
50

Secondary Regulator
Valve Retainer
Copyright © 2011 ATSG

Figure 45 11-25
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Technical Service Information

OIL PUMP BODY EXPLODED VIEW

Inner Gerotor

Outer Gerotor

Copyright © 2011 ATSG

Figure 46

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 Technical Service Information
DAIMLER/CHRYSLER AS68RC DIAGNOSTIC TROUBLE CODES
DTC DESCRIPTION
P0560 System Voltage Malfunction
P0613 Transmission Control Module (TCM)
P0702 Transmission Control System Electrical
P0706 Transmission Range Switch Rationality and Pressure Switch N0. 8
P0707 Transmission Range Switch Circuit Low
P0708 Transmission Range Switch Circuit High
P0711 Transmission Fluid Temperature Sensor A (Sump), Circuit Performance
P0712 Transmission Fluid Temperature Sensor A (Sump), Circuit Low
P0713 Transmission Fluid Temperature Sensor A (Sump), Circuit High
P0717 Input Speed Sensor Circuit, No Signal
P0722 Output Speed Sensor Circuit, No Signal
P0730 Incorrect Gear Ratio
P0745 Line Pressure Solenoid (Linear Solenoid "D" ) Electrical
P0746 Clutch Pressure Control Solenoid (Linear Solenoid "A" ) Performance or Stuck Off
P0748 Clutch Pressure Control Solenoid (Linear Solenoid "A" ) Electrical
P0751 On/Off Shift Solenoid 1 (A), Performance or Stuck Off
P0756 On/Off Shift Solenoid 2 (B), Performance or Stuck Off
P0761 On/Off Shift Solenoid 3 (C), Performance or Stuck Off
P0766 On/Off Shift Solenoid 4 (D), Performance or Stuck Off
P0776 Clutch Pressure Control Solenoid (Linear Solenoid "B" ) Performance or Stuck Off
P0778 Clutch Pressure Control Solenoid (Linear Solenoid "B" ) Electrical
P0796 Clutch Pressure Control Solenoid (Linear Solenoid "C" ) Performance or Stuck Off
P0798 Clutch Pressure Control Solenoid (Linear Solenoid "C" ) Electrical
P0973 On/Off Shift Solenoid 1 (A), Control Circuit Low
P0974 On/Off Shift Solenoid 1 (A), Control Circuit High
P0976 On/Off Shift Solenoid 2 (B), Control Circuit Low
P0977 On/Off Shift Solenoid 2 (B), Control Circuit High
P0979 On/Off Shift Solenoid 3 (C), Control Circuit Low
P0980 On/Off Shift Solenoid 3 (C), Control Circuit High
P0982 On/Off Shift Solenoid 4 (D), Control Circuit Low
P0983 On/Off Shift Solenoid 4 (D), Control Circuit High
P1679 TCU Not Calibrated
P1720 Loss Of Output Speed
P2741 Transmission Fluid Temperature Sensor B (Torque Converter Out), Circuit Performance
P2742 Transmission Fluid Temperature Sensor B (Torque Converter Out), Circuit Low
P2743 Transmission Fluid Temperature Sensor B (Torque Converter Out), Circuit High
P2757 TCC Pressure Control Solenoid (Linear Solenoid "C" ) Performance or Stuck Off
U0001 High Speed (CAN) Communication Bus
U0100 Lost Communication with TCM/ECM
U0121 Lost Communication with Anti-Lock Brake System (ABS) Control Module
U0141 Lost Communication with Totally Integrated Power Module (TIPM)
U01400 Implausible TPS Signal Received
U01401 Implausible Engine Speed Signal Received
U140D Implausible Wheel Speed Signal Received
C1400 Implausible Wheel Speed Signal Received

Copyright © 2011 ATSG

Figure 48
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AUTOMATIC TRANSMISSION SERVICE GROUP