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Technical Service Information
FORD 4R100
"PWM" AND "NON-PWM"
PUMP DIFFERENCES
CHANGE: Beginning at the start of production in 1999, the 4R100 transmission was offered with two
different torque converter clutch application strategies. A "PWM" (Pulse Width Modulated)
version, was added in V-10 gas powered vehicles and all diesel, and a "NON-PWM" version,
offered in all other gas powered vehicles. This required two different solenoid packs as well as two
different pump assemblies.
REASON: For smooth converter apply on V-10 gas and diesel engine models.
PARTS AFFECTED:
(1) PUMP ASSEMBLY:
• The pump cover assembly had the rear of the Converter Clutch Valve bore enlarged approximately
.070" to acommodate the enlarged land of the Converter Clutch Valve as shown in Figure 3.
A .036" orifice and an air bleed were added to the TCC Solenoid signal passage as shown in Figure
• 2.
The Converter Clutch Control Valve's rear spool was enlarged approximately .070." There was
• also a bushing and valve added to the end of the valve train as shown in Figure 3.
A hole was added to the pump cover to connect the Converter Clutch Control Valve Bushing to
• Converter Regulator Valve oil, as shown in Figure 2.
The Converter release orifice in the NON-PWM pump cover, as shown in Figure 1, was removed
• from the PWM pump cover as shown in Figure 2.
Refer to Figure 4 for the NON-PWM pump hydraulic circuit.
Refer to Figure 5 for the PWM pump hydraulic circuit with all of the hydraulic changes shown.
THE SOLENOID PACK:
The PWM solenoid pack requires a Pulse Width Modulated torque converter clutch solenoid and
(2) the NON-PWM solenoid pack requires an on-off torque converter clutch solenoid. Refer to
• Figure 6 to identify the differences between the two solenoid packs.
INTERCHANGABILITY:
None of the parts listed above are interchangable from model to model.
SERVICE INFORMATION:
"NON-PWM" Pump assy. (with "Cast Iron" coast clutch drum).................F81Z-7A103-AA
"NON-PWM" Pump assy. (with "Stamped Steel" coast clutch drum)..........F81Z-7A103-BA
"PWM" Pump assy. (with "Stamped Steel" coast clutch drum)....................F81Z-7A103-CA
"NON-PWM" Solenoid Pack...........................................................................F81Z-7G391-BA
"PWM" Solenoid Pack.....................................................................................F81Z-7G391-AB
Copyright © 2000 ATSG
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Technical Service Information
4R100 "NON-PWM" PUMP
COVER ASSEMBLY
CONVERTER REGULATOR
VALVE
CONVERTER CLUTCH
CONTROL VALVE PRESSURE REGULATOR
VALVE
CONVERTER RELEASE
ORIFICE .070"
RETAINER
LUBE ORIFICE
.090"
Copyright © 2000 ATSG
Figure 1 00-30
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Technical Service Information
4R100 "PWM" PUMP
COVER ASSEMBLY
CONVERTER CLUTCH
CONTROL VALVE CONVERTER REGULATOR
VALVE
HOLE ADDED TO
CONNECT TO HOLE IN
CONTROL VALVE BUSHING PRESSURE REGULATOR
VALVE
CONVERTER RELEASE
ORIFICE OMITTED
RETAINER
LUBE ORIFICE
.090" ADDED AIR
ADDED ORIFICE IN BLEED
TCC PWM SOLENOID
SIGNAL PASSAGE
.036" Copyright © 2000 ATSG
Figure 2
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CONVERTER CLUTCH CONTROL VALVE
"NON-PWM" "PWM"
.530" .600"
.485" .545"
THE DIAMETER AND THE LENGTH OF THE SPOOL ON THE VALVE LAND SHOWN ABOVE,
WERE INCREASED ON PWM VERSIONS. THE BORE IN THE PUMP WAS ALSO ENLARGED
APPROXIMATELY .070" TO ACOMMODATE THE CHANGES IN THE DIAMETER OF THE VALVE
Copyright © 2000 ATSG
Figure 3
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Technical Service Information
4R100 "NON-PWM" PUMP
HYDRAULIC CIRCUIT
CONVERTER
AIR BLEED REGULATOR VALVE
CONVERTER CLUTCH
CONTROL VALVE MAIN REGULATOR
VALVE
BALANCE
TCC EXHAUST ORIFICE .030"
ORIFICE .070"
LUBE
LUBE
ORIFICE .090"
BALANCE
ORIFICE .030"
EPC
SIGNAL
REVERSE
MAIN LINE
TCC SOLENOID
SIGNAL TO COAST
CLUTCH
TO SUMP
Copyright © 2000 ATSG
Figure 4
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Technical Service Information
4R100 "PWM" PUMP
HYDRAULIC CIRCUIT
.062" ORIFICE CONVERTER
IN SLEEVE AIR BLEED REGULATOR VALVE
CONVERTER CLUTCH MAIN REGULATOR
CONTROL VALVE VALVE
BALANCE
TCC EXHAUST ORIFICE .030"
ORIFICE OMITTED
CONVERTER REG.
OIL CONNECTION
LUBE
LUBE
ORIFICE .090" ADDED
AIR BLEED BALANCE
EPC ORIFICE .030"
SIGNAL
REVERSE
MAIN LINE
TCC PWM
TO COAST
SOLENOID
CLUTCH
SIGNAL ADDED TO SUMP
.036" ORIFICE
IN TCC PWM
SOLENOID SIGNAL
Copyright © 2000 ATSG
Figure 5
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Technical Service Information
FORD 4R100
SOLENOID RESISTANCE CHARTS
Solenoid Resistance Chart
Solenoid Body
Solenoid Pin Numbers Resistance
Shift Solenoid "B" (2) 1 and 2 20-30 Ohms
Shift Solenoid "A" (1) 1 and 3 20-30 Ohms
TCC Solenoid, On-Off (NON-PWM) 1 and 4 20-30 Ohms
TCC Solenoid, Diesel & V10 (PWM) 1 and 4 10-20 Ohms
Coast Clutch Solenoid 1 and 5 20-30 Ohms
Electronic Pressure Control Solenoid 11 and 12 3.0-5.0 Ohms
Transmission Fluid Temp Sensor 7 and 8 Variable
SOLENOID BODY
CONNECTOR
7 8 11 12
6 5 4 3 2 1
SOLENOID ASSEMBLY
"NON-PWM" versions - Part Number = F81Z-7G391-BA
"PWM" versions ----- Part Number = F81Z-7G391-AB
Copyright © 2000 ATSG
Figure 6
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