4L80-E Automatic Transmission

^ Tools Required
- J35944-A Cooler Flushing Tool
- J35944-20 Biodegradable Flushing Solution

PREPARATION
Flush the transmission oil cooler whenever the transmission is removed for service. It is essential to flush the oil cooler after transmission installation, after a major overhaul, if oil contamination is suspected, or in any case of pump or torque converter replacement.
Perform the flush procedure after the overhaul or replacement assembly has been reinstalled in the vehicle to ensure the complete transmission system service.
1. Do not reconnect the oil cooler lines after installing the overhauled or service replacement transmission.
2. Remove the fill cap on J35944-A.
3. Fill the can with 0.6L (20 - 21 ounces) of flushing solution. Do not overfill the tool or the tool will need to be recharged with air before the backflush. Follow the manufacturer's suggested procedures for proper handling of the solution.

NOTICE: Do not substitute with any other solution. The flushing tool is designed to use only this concentrate. Use of any other solution can result in damage to. the tool, cooler components, or improper flushing of the cooler.

4. Secure the fill cap.
5. Pressurize the flusher can with shop air to 550 - 700 kPa (80 - 100 psi).

CAUTION: Air supply must be equipped with a water and oil filter. This air supply must not exceed 825 kPa (120 psi). Excess air pressure may rupture the flushing cooler, causing personal injury.

6. Connect the discharge hose to the transmission end of the oil cooler lines that goes to the top fitting at the radiator.
7. Clip the discharge hose onto the oil drain container.
8. Secure the flushing tool to the undercarriage of the vehicle with the hook provided.
9. Connect the hose from the flushing tool to the remaining oil cooler lines.
10. Switch the water valve on the tool to the OFF position.
11. Connect the water hose from the water supply to the tool.
12. Turn on the water supply at the faucet.

INITIAL FLUSH

CAUTION: If water does not flow through the oil cooler (system is completely plugged), do not continue flushing procedure. Turn the water off immediately and inspect the lines and cooler for restrictions and repair, or personal injury could result.

1. Switch the water valve on the tool to the ON position.
2. Allow the water to flow through the oil cooler for 10 seconds in order to remove the supply of transmission fluid in the system.
3. Switch the water valve on the tool to the OFF position.
4. Clip the discharge hose onto a 5 gallon pail.
5. Secure a lid on the pail or position a shop towel over the end of the discharge hose in order to prevent a splash. The discharge will foam vigorously when the solution is introduced in the water stream.
6. Switch the water valve on the tool to the ON position.
7. Depress the trigger to mix the flushing solution in the water flow. Use the bale clip provided on the handle to hold the trigger down.
8. Attach the air supply to the air valve located on the plumbing of the tool for 3-5 seconds at the end of every 15-20 second interval, in order to create a surging action.
9. Flush the oil cooler with water and solution for 2 minutes.
10. Release the trigger.
11. Switch the water valve on the tool to the OFF position.
12. Disconnect both hoses from the oil cooler lines.

BACKFLUSH
1. Connect the hoses to the oil cooler lines in the opposite order from the initial flush procedures to perform a backflush.
2. Switch the water valve on the tool to the ON position.
3. Depress the trigger to mix the flushing solution in the water flow. Use the bale clip provided on the handle to hold the trigger down.
4. Attach the air supply to the air valve located on the plumbing of the tool for 3-5 seconds at the end of every 15-20 second interval, in order to create a surging action.
5. Flush the oil cooler with water and solution for 2 minutes.
6. Release the trigger and allow only water to rinse the oil cooler for 1 minute.
7. Switch the water valve on the tool to the OFF position.
8. Turn the water supply off at the faucet.
9. Attach the air supply to the air valve located on the plumbing of the tool.
10. Dry the system out with air for at least 2 minutes.

NOTICE: Excessive residual moisture can cause corrosion in the oil cooler or cooler lines and can damage the transmission. If steps 9-15 cannot be completed at this time, rinse the oil cooler and cooler lines with transmission fluid. Complete steps 9-15 after reinstallation of the transmission.

11. Continue drying out the system if moisture is visibly exiting from the oil cooler line discharge hose. Use an air chuck clip in order to secure the air chuck onto the air valve for ease of operation.
12. Connect the cooler feed line to the transmission bottom connector.
13. Attach the discharge hose to the cooler return line (top connector), if not already connected.
14. Place the other end of the discharge hose into an appropriate drain container.
15. Fill the transmission with automatic transmission fluid.
16. Start the engine and let it run for 30 seconds.
The procedure mentioned above will ensure the following:
^ Removal of any residual moisture from the oil cooler and cooler lines
^ Protection of all components from corrosion

17. Check the flow rate through the cooler. A minimum of 2.0 L (2 quarts) must be obtained during this 30 second run.
18. Check the fluid flow out of the transmission if fluid flow is insufficient by using the following procedure:
18.1. Disconnect the oil cooler feed line at the radiator
18.2. Restart the engine

19. Perform the following procedures according to the flow rate:
19.1. Inspect the oil cooler pipes and fittings for restrictions or leaks.
19.2. Repeat the check of fluid flow out of the return line.
19.3. Replace the oil cooler if the flow is still inhibited.

^ Inspect the transmission for the cause of insufficient feed flow.
^ For sufficient feed flow, perform the following:

20. Remove the discharge hose.
21. Reconnect the cooler return line to the transmission.
22. Refill the transmission with fluid to the proper level.

CLEANING PROCEDURE
The tools should be cleaned after every third use.
1. Disconnect the water supply hose from the tool.
2. Bleed the air pressure from the can.
3. Remove the fill cap.
4. Return any unused solution to the container.
5. Rinse the can out with water. Do not store the tool with the solution in the tank.
6. Loosen the large coupling nut in order to remove the plumbing from the tank.
7. Remove the screen from the plumbing.
8. Wash the screen with water.
9. Remove any material in the solution orifice by using the cleaning pin.
The orifice is located in the plumbing below the screen.
10. Reconnect the plumbing.
11. Fill half of the can with water.
12. Secure the fill cap.
13. Pressurize the can to 550 - 700 kPa (80 - 100 psi).
14. Aim the tool into the 5 gallon pail or floor drain.
15. Depress the trigger for 30 seconds in order to allow the water from the can to flow through the solution orifice. This will ensure proper cleaning.
16. Bleed the air pressure from the can.
17. Remove the fill cap.
18. Empty the can.
19. Reconnect the fill cap to the flushing tool.