AW50 40 maintenance .pdf

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AW 50-40, 50-42, 50-42LE:
AF 14, 20, 22

Transmission Identification Plate
1208
818

50-42

Example:
50-42LE = Transmission designation
1208818 = Volvo P/N
95 = Year of manufacture
F = Manufactured in June (A=January and so on.
NOTE! The letter I is not used.)
W = Transmission 50-42LE*
8 = Transmission manufactured for Volvo
1243 = Manufacturing number, starting with 0001 each month.

95

F

W

8

1243

POSITION

Applied Elements
B2 = Intermediate Clutch
B3 = Low & Reverse Clutch
B4 = Underdrive Brake Band
C1 = Forward Clutch
C2 = Direct Clutch
C3 = Underdrive Clutch

P

Parking

R

Reverse

N

Neutral

*) LE indicates that the transmisson has the lock-up function and
is electronically controlled.
This transmission is an AW50-42, manufactured in June 1995.

S1 S2

C1

C2 C3

B1

B2

B3 B4

F1 F2

F3

1st
2nd
D
3rd
4th

F1 = Intermediate Sprag
F2 = Low Sprag
F3 = Underdrive Sprag

1st
3

2nd
3rd

S1 = Shift Solenoid A
S2 = Shift Solenoid B
L

1st
2nd

94659

Caution: This kit contains a Duraprene valve body cover gasket. This gasket is intended to be used on covers that are not used in
conjunction with a transmission mount. The torsional loads placed on the gasket surfaces will result in a leak on this application. It
is recommended to use a sealer in place of the gasket.

Clutch Clearances
Overrun Clutch

.023" - .057"

Intermediate Clutch

.045" - .073"

Low/Reverse Clutch

.074" - .095"

Forward Clutch

Direct Clutch

Underdrive Clutch
Underdrive Brake Band

End Play = .015" - .035"

.060" - .074"

with 4 plates

.045" - .058"

with 3 plates

.060" - .074"

with 4 plates

.045" - .058"

with 3 plates

.060" - .074"

with 4 plates

.045" - .058"

with 3 plates

.216" - .276"

Line Pressures
At idle (800 -850 rpm): 60 - 85 psi at idle.
Line pressures for all engine models.
At stall: 170 - 256 psi.
Notes: Stall speeds vary with engine model.
All pressure readings taken in Drive
or Reverse.

Underdrive Brake Band Procedure:
Install piston in reverse order of disassembly. Measure
length of piston stem protruding from case. Apply air
to servo and re-measure length of piston stem. The
difference is the piston stroke length. Specification is
.216" - .276". Adjust as needed.

Resistance for Components
Component

Remarks

Resistance ( )

Engine Speed RPM Sensor
Solenoid A
Solenoid B

300 - 600
Resistance between the solenoid
pin and the solenoid cover/
transmission housing

Solenoid Lock-up
Solenoid - Pressure Control

Oil Temperature Sensor

10 - 15
10 - 15
10 - 15

Resistance between the solenoid pins

Temperature
°C (°F)

-2-

2-6

0 (32)

1700 - 2300

20 (68)

765 - 1035

40 (104)

340 - 460

80 (176)

107 - 143

100 (212)

64 - 86

150 (302)

23 - 31

Checking System Pressure

Checking Kickdown Switch Resistance

Depress brake pedal.
Move gear selector into the various positions
and record system pressure.

The ohmmeter should read approx. 0 Ω with the
accelarator pedal (AP) fully depressed and infinite
resistance in all other positions.

Table, AW TCM 50-42 System Pressure
Engine

Idling Speed Gear Position Line Pressure
(rpm)
(MPa) (psi)

B5202

850

D/R

0.4 / 0.6
(85 / 57)

B5204S

800

D/R

0.4 / 0.6
(85 / 57)

B5254S1

8501

D/R

0.4 / 0.6
(85 / 57)

B5252S

850

D/R

0.4 / 0.6
(85 / 57)

B5234S

850

D/R

0.4 / 0.6
(85 / 57)

B5234T

1)

850

D/R

Checking Oil Temperature Sensor Resistance
Connect an ohmmeter between the transmission connector terminals 12 and 13 (transmission side).

0.4 / 0.6
(85 / 57)

800 rpm, model years 1992-1993

Correct Installation
Lead In Chamfer

Pump Seal Installation
Some, but not all, Toyota pumps
feature a deep lead-in chamfer on
the pump seal bore. To ensure
proper contact between the seal
and the seal bore, the seal should
be pressed in until it bottoms in
the bore. This should be standard
procedure on all seals that use a
nose gasket for bore sealing. This
may result in the seal being
installed below the top of the
pump bore face.

Full Contact Between
Metal Case and
Pump Bore

Pump Body

Rubber Nose on Seal

Incorrect Installation
Lead In Chamfer

Full Contact Between
Rubber Nose and
bottom of Bore

Poor Contact Between Metal
Case and Pump Body
Pump Body

Rubber Nose on Seal

-3-

No Contact Between
Rubber Nose and
bottom of Bore

Volvo/Saab AW50-42LE
"Rear" Valve Body, "Rear" Side

Speed Sensors

Pressure Relief
Valve and
Spring
Check Valve
and Spring

Volvo/Saab AW50-42LE
"Center" Valve Body, "Front" Side
Large
Filter
Screen

Requires Four Rubber Checkballs
5.0mm (.197" In Diameter

4 Small
Filter
Screens

Copyright © 1998 ATSG

Copyright © 1998 ATSG

-4-

Volvo/Saab AW50-42LE "Center" Valve Body, "Rear" Side

Check Valve
Assembly

Bypass Valve
and Spring

If the spacer plate has only one small hole over either
location DO NOT install a checkball

This checkball can go in
either location indicated by
the arrows.

Check Valve
and Spring

If the spacer plate has one large and one small
hole over location INSTALL a checkball.

Requires Four Rubber Checkballs
5.0mm (.197" In Diameter

Copyright © 1998 ATSG

-5-

Rear Valve Body Accumulator Pistons

Underdrive
Accumulator
Piston
Solenoid B

Direct Clutch
Accumulator
Piston

Note: Illustration for reference only.
Valves and springs may vary between
makes and models

Intermediate
Accumulator
Piston

Front Valve Body Solenoid Location
Lock-Up
Solenoid

Pressure Control Solenoid

Shift Solenoid A

Shift
Solenoid B

-6-

Air Check Passages

Sprag Rotation

Low Sprag

Freewheel Counterclockwise; Lock Clockwise
Outer Hub
Held
Overrun
Clutch

Intermediate Sprag

Intermediate
Clutch

Intermediate
Hub

Direct Clutch
Forward
Clutch

Overrun Hub

With Intermediate Hub Held, Overrun
Hub Freewheels Clockwise; Locks
Counterclockwise

Low/Reverse
Clutch

Held

Freewheels Counterclockwise;
Locks Clockwise

7

Forward
Accumulator

2nd Brake
Clutch

Underdrive
Clutch

Low
Sprag

Direct
Clutch
Underdrive
Brake

Intermediate
Sprag

Forward
Clutch

Underdrive
Brake
Accumulator

Overrun
Clutch

Underdrive
Sprag

SOME OF THE INFORMATION IN THIS BOOKLET MAY HAVE BEEN PROVIDED
OR APPROVED BY THE AUTOMATIC TRANSMISSION SERVICE GROUP AND/OR
THE AUTOMATIC TRANSMISSION REBUILDERS ASSOCIATION. THE INFORMATION CONTAINED HEREIN IS ACCURATE TO THE BEST OF OUR KNOWLEDGE.
WE ARE NOT RESPONSIBLE FOR ANY INACCURACIES OR WARRANTY CLAIMS
WHICH MAY RESULT FROM THE USE OF THIS INFORMATION.



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