Holden studies indicate that plugged or restricted transmission oil coolers
and pipes cause insufficient transmission lubrication and elevated operating temperatures
which can lead to premature transmission failure. Many repeat repair cases may have
been prevented by following published procedures for transmission oil cooler flushing
and flow checking. This procedure includes flow checking and flushing the auxiliary
transmission oil cooler, if equipped.
Important: Use the
J 45096
or equivalent to flush and flow test the transmission oil cooler and
the oil cooler pipes after the transaxle is removed for repairs.
Only DEXRON®VI automatic transmission fluid should be used when doing a
repair on a Holden transmission.
Time allowance for performing the cooler flow checking and flushing procedure
has been included in the appropriate labor time guide operations since the 1987 model
year. The service procedure steps for oil cooler flushing and flow testing are as
follows:
Cooler Flow Check and Flushing Steps
- Machine Set-up
- Determine Minimum Flow Rate
- Back Flush
- Forward Flush
- Flow Test
- Code Recording Procedure
- Clean-up
Tools Required
• | J 45096
Transmission
Oil Cooling System Flush and Flow Test Tool |
• | Shop air supply with water/oil filters, regulator and pressure gage --
minimum 90 psi |
Machine Set-up
- Verify that the main power switch (1)
is in the OFF position.
- Place the main function switch (2) in the IDLE position.
- Connect
J 45096
to the vehicle 12V DC power source by connecting the red battery
clip to the positive, +, battery post on the vehicle and connect the negative lead
to a known good chassis ground.
- Turn the main power switch to the ON position.
Notice: Do not overfill the supply vessel. Damage to the unit may result. To
verify the fluid level, view the LCD screen display while filling the unit,
to ensure the fluid level does not exceed 30 L (32 qt).
- Fill the supply tank with Dexron®VI/Mercon®, or equivalent, through
the fill port.
- Reinstall and tighten the fill cap.
- Connect a shop air supply hose to the quick-disconnect
on the rear panel marked SUPPLY AIR.
Determine Minimum Flow Rate
- From the machine display, identify the temperature
of the automatic transmission fluid that is stored in the supply vessel of
J 45096
.
- Determine whether the transmission oil cooler
is steel or aluminum by using a magnet (1) at the cooler flange (2)
at the radiator.
- Refer to the table below. Using the temperature from step 1, locate
on either the Steel MINIMUM Flow Rate table or the Aluminium MINIMUM Flow Rate table
the minimum flow rate in gallons per minutes (GPM). Record the minimum flow rate in
GPMs and the supply fluid temperature for further reference.
Example:
• | Fluid temperature: 75°F |
| The MINIMUM flow rate for this example
is 0.8 GPM. |
- Inspect transmission oil cooler lines for damage or kinks that may cause
restricted oil flow. Repair as needed and refer to the appropriate Holden service
manual procedures.
Minimum Flow Rate in Litres Per Minute (LPM)
Temperature Range
| Steel
| Aluminium
|
65 - 66°F
| 2.3 lpm
| 1.9 lpm
|
67 - 70°F
| 2.7 lpm
| 2.7 lpm
|
71 - 75°F
| 3.0 lpm
| 3.0 lpm
|
76 - 80°F
| 3.4 lpm
| 3.4 lpm
|
81 - 84°F
| 3.8 lpm
| 3.8 lpm
|
85 - 89°F
| 4.2 lpm
| 4.2 lpm
|
90 - 94°F
| 4.5 lpm
| 4.5 lpm
|
95 - 98°F
| 4.9 lpm
| 4.9 lpm
|
99 - 103°F
| 5.3 lpm
| 5.3 lpm
|
104 - 108°F
| 5.7 lpm
| 5.7 lpm
|
109 - 112°F
| 5.7 lpm
| 5.7 lpm
|
113 - 117°F
| 5.7 lpm
| 6.0 lpm
|
118 - 120°F
| 6.8 lpm
| 6.4 lpm
|
Back Flush Procedure
- Connect
the
J 45096
adapters (1)
to the vehicle's transmission oil cooler supply and return lines at the transmission
using
J 45806
(2).
- Connect the black supply hose (1) to the return line, top connector of
the transmission, and the clear waste hose (2) to the feed line, bottom connector
of the transmission, to the vehicle cooler lines. This is the reverse flow -
backflush direction.
- Turn the main function switch to the FLUSH
position. Allow the machine to operate for 30 seconds.
- Turn the main function switch to the IDLE
position and allow the supply vessel pressure to dissipate.
Forward Flush
- Disconnect the supply and waste hoses from the vehicle cooler lines. Reverse
the supply and waste hoses to provide a normal flow direction.
- Turn the main function switch to the FLUSH
position and allow machine to operate for 30 seconds.
Flow Test
Important: If the flow rate is less than 0.5 gpm,
the LCD displays an error message. Refer to the Troubleshooting section of the operation
manual.
- Turn the main function switch to the FLOW position and allow the oil to flow
for 15 seconds. Observe and note the flow rate; this is the TESTED flow rate.
- Compare the TESTED flow rate to the MINIMUM flow rate information previously
recorded.
• | If the TESTED flow rate is equal to or greater than the MINIMUM flow rate
recorded, the oil cooling system is functioning properly. Perform Code Recording Procedure. |
• | If the TESTED flow rate is less than the MINIMUM flow rate previously
recorded, repeat the back flush and forward flush procedures. |
- If the TESTED flow rate is less than the MINIMUM flow rate after the second
test, perform Code Recording Procedure.
3.1. | Replace the transmission oil cooler. |
3.2. | Reconnect supply and waste hoses to the cooler lines in the normal flow
direction. Perform Flow Test. |
3.3. | Perform Code Recording Procedure. |
Code Recording Procedure
- Turn the main function switch to the CODE
position.
Important:
• | If power is interrupted prior to the recording of the seven-character
code, the code will be lost and the flow rate test will need to be repeated. |
• | The flow test must run for a minimum of 8-10 seconds and be above
0.5 gpm for a code to be generated. |
- Record TESTED flow rate, temperature, cycle and seven-character flow
code information on repair order.
Clean-up
- Turn the main function switch (2)
to the IDLE position and allow the supply vessel pressure to dissipate.
- Turn the main power switch (1) to the OFF position.
- Disconnect the supply and waste hoses and the 12-volt power source
from the vehicle.
Note: A small amount of water may drain from the bottom
of the unit when the air supply is disconnected. This is a normal operation of the
built-in water separator.
- Disconnect the air supply hose from
J 45096
.
- Dispose of the waste Automatic transmissionF in accordance with all applicable
federal, state, and local requirements.