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5L40E (A5S 360R) BMW 98 on & Cadillac 03 on

5 SPEED RWD (Full Electronic Control)

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Revision 07/2007
 A
5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)

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 A
5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)

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 A
5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)

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5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)
ILL ILL
NO. DESCRIPTION YEARS QTY PART NO NO. DESCRIPTION YEARS QTY PART NO
KITS MOULDED PISTONS Cont...
Kit Overhaul Kit Without Pistons 174F Piston Overdrive Brake
(Transtec).................................. 98-ON 1 5L40E.OHK01 (BMW AWD).............................. 98-ON 1 5L40E.PIS10
Kit Overhaul Kit Without Pistons 178H Piston Second Coast Brake
(Precision)................................. 98-ON 1 5L40E.OHK51 (BMW AWD).............................. 98-ON 1 5L40E.PIS10
Kit Overhaul Kit With Pistons
(Precision)................................. 98-ON 1 5L40E.OHK03 Please Note: Due to changes in piston design made by the OEM at
various points, it is quite possible that the above kits may not
be entirely compatible with all the pistons in your unit

GASKETS SEALING RINGS

100K Oil Pan (Rubber) ....................... 98-ON 1 5L40E.GAS01 Kit Sealing Ring Kit ........................ 99-ON 1 5L40E.SRK01
101K Pump (Bonded)......................... 98-ON 1 5L40E.GAS02
102K Extension Housing (Bonded) .... 98-ON 1 5L40E.GAS03

FRICTION PLATES
RUBBER COMPONENTS Kit Friction Plate Kit........................ 99-ON 1 5L40E.FRK01
Kit Friction Plate Kit (Alto) .............. 99-ON 1 5L40E.FRK51
120B Pump Outer 'O' Ring ................. 98-ON 1 5L40E.OR01 250B Direct Clutch (Internal Spline)
(173mm OD x 1.60mm x 36T) .. 99-ON 4 5L40E.FRP01
250B Direct Clutch (Internal Spline)
(173mm OD x 1.60mm x 36T)
METAL CLAD SEALS (BMW X5 3.0Ltr Diesel) ............ 99-ON 5 5L40E.FRP01
251B Direct Clutch (External Spline)
150A Pump ........................................ 98-ON 1 5L40E.MCS01
(180mm OD x 1.60mm x 36T) .. 99-ON 4 5L40E.FRP02
151K Extension Housing
251B Direct Clutch (External Spline)
(62mm x 43mm x 7mm) ............ 98-ON 1 5L40E.MCS02
(180mm OD x 1.60mm x 36T)
152K Tube Kit, Valve Body to Case ... 98-ON 1 5L40E.TU01
(BMW X5 3.0Ltr Diesel) ............ 99-ON 5 5L40E.FRP02
NI 4WD Output Seal (BMW X5) .... 98-ON 1 4L30E.MCS02
252B Reverse Clutch (Internal Spline)
NI Manual Lever ............................ 98-ON 1-2 4L30E.MCS04
(180mm OD x 1.60mm x 36T) .. 99-ON 2 5L40E.FRP05
252B Reverse Clutch (Internal Spline)
(180mm OD x 1.60mm x 36T)
MOULDED PISTONS (BMW X5 3.0Ltr Diesel) ............ 99-ON 3 5L40E.FRP05
253B Reverse Clutch (External Spline)
Kit Piston Kit (9 Pistons) (OEM) ..... 02-ON 1 5L40E.PISKIT01 (186mm OD x 1.60mm x 36T) .. 99-ON 2 5L40E.FRP06
Kit Piston Kit (3 Pistons) (OEM) 253B Reverse Clutch (External Spline)
(Used until 2002 only, use in addition to (186mm OD x 1.60mm x 36T)
5L40E.PISKIT01 to cover early applications, (BMW X5 3.0Ltr Diesel) ............ 99-ON 3 5L40E.FRP06
which are used in GM & mainly BMW) 254C Coast Clutch (Internal Spline)
.................................................. 98-02 1 5L40E.PISKIT04 (124mm OD x 1.60mm x 24T) .. 99-ON 3 5L40E.FRP03
Kit Piston Kit (RWD) (Precision) 254C Coast Clutch (Internal Spline)
(11 Pistons, Contains Direct, Reverse, Coast, Overdrive (2WD), (124mm OD x 1.60mm x 24T)
Intermediate, Low/Rev (Except Cadillac), Low/Rev (Cadillac), (BMW X5 3.0Ltr Diesel) ............ 99-ON 4 5L40E.FRP03
Second Coast (2WD), Second (BMW 2WD), Second(Cadillac) & 255C Coast Clutch (External Spline)
Forward Clutch Pistons) (131mm OD x 1.60mm x 12T) .. 99-ON 3 5L40E.FRP04
(Does not contain, Second (AWD), Second Coast (AWD) & 255C Coast Clutch (External Spline)
Overdrive (AWD) Clutch Pistons) (131mm OD x 1.60mm x 12T)
.................................................. 98-ON 1 5L40E.PISKIT52 (BMW X5 3.0Ltr Diesel) ............ 99-ON 4 5L40E.FRP04
Kit Piston Kit (BMW AWD) (Precision) 256C Forward Clutch (Internal Spline)
(7 Pistons, Contains Direct, Reverse, Coast, Intermediate, (130mm OD x 1.60mm x 24T) .. 99-ON 4 5L40E.FRP07
Low/Reverse (Except Cadillac), Forward & Second,Clutch (AWD) 257C Forward Clutch (External Spline)
Pistons) (137mm OD x 1.60mm x 24T) .. 99-ON 4 5L40E.FRP08
(Does not contain, Overdrive (2WD), Low/Reverse Cadillac), 258F Overdrive Brake (Internal Spline)
Second Coast (2WD), Second Clutch (BMW 2WD) or Second (180mm OD x 1.60mm x 36T) .. 99-ON 2 5L40E.FRP05
(Cadillac) Clutch Pistons). 259F Overdrive Brake (External Spline)
(Needs, Second Coast, & Overdrive (AWD) Clutch Pistons, (186mm OD x 1.60mm x 36T) .. 99-ON 2 5L40E.FRP06
5L40E.PIS10 x 2 to Complete Kit) 260F Intermediate Brake (Internal Splines)
................................................. 98-ON 1 5L40E.PISKIT51 (135mm OD x 1.60mm x 24T) .. 99-ON 3 5L40E.FRP11
Kit Piston Kit (Combi Kit) (Precision) 261F Intermediate Brake (External Spline)
(12 Pistons, Contains Direct, Reverse, Coast, Overdrive (141mm OD x 1.60mm x 24T) .. 99-ON 3 5L40E.FRP12
Intermediate, Low/Rev (Except Cadillac), Low/Rev (Cadillac), 262H Low/Reverse Brake (Internal Spline)
Second Coast (2WD), Second (BMW 2WD), Second (Cadillac), (173mm OD x 1.60mm x 36T) .. 99-ON 5 5L40E.FRP01
Second (AWD) & Forward Clutch Pistons) 262H Low/Reverse Brake (Internal Spline)
(Does not contain, Second (AWD), Second Coast (AWD) & (173mm OD x 1.60mm x 36T)
Overdrive (AWD) Clutch Pistons) (BMW X5 3.0Ltr Diesel) ............ 99-ON 6 5L40E.FRP01
(Needs Second Coast (AWD) & Overdrive (AWD) 263H Low/Reverse Brake (External Spline)
5L40E.PIS10 to Complete Kit) (180mm OD x 1.60mm x 29T) .. 99-ON 5 5L40E.FRP14
.................................................. 98-ON 1 5L40E.PISKIT53

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 5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)
ILL ILL
NO. DESCRIPTION YEARS QTY PART NO NO. DESCRIPTION YEARS QTY PART NO
FRICTION PLATES Cont... THRUST WASHERS & BEARINGS
263H Low/Reverse Brake (External Spline)
(180mm OD x 1.60mm x 29T)
(BMW X5 3.0Ltr Diesel) ............ 99-ON 6 5L40E.FRP14
264H Second Brake (Internal Splines)
(130mm OD x 1.60mm x 24T) .. 99-ON 5 5L40E.FRP15
264H Second Brake (Internal Splines)
(130mm OD x 1.60mm x 24T)
(BMW X5 3.0Ltr Diesel) ............ 99-ON 6 5L40E.FRP15
264H Second Brake (Internal Splines)
(138mm OD x 1.60mm x 24T) .. 99-ON 5 5L40E.FRP19**
265H Second Brake (External Splines) ELECTRICAL COMPONENTS
(136mm OD x 1.60mm x 24T) .. 99-ON 5 5L40E.FRP16 700K EPC Solenoid (OEM) ................ 99-03 1 4T40E.SOL11
265H Second Brake (External Splines) 700K EPC Solenoid ........................... 99-03 1 4T40E.SOL01
(136mm OD x 1.60mm x 24T) 700K EPC Solenoid ........................... 04-ON 1 4T40E.SOL05
(BMW X5 3.0Ltr Diesel) ............ 99-ON 6 5L40E.FRP16 701K TCC/PWM Solenoid.................. 99-ON 1 4L60E.SOL01
265H Second Brake (External Splines) 702K 1-2 Shift Solenoid ..................... 99-ON 1 5L40E.SOL04
(144mm OD x 1.60mm x 24T) .. 99-ON 5 5L40E.FRP20** 703K 2-3 Shift Solenoid ..................... 99-ON 1 5L40E.SOL04
266H Second Coast Brake (Internal Spline) 704K 4-5 Shift Solenoid ..................... 99-ON 1 5L40E.SOL04
(173mm OD x 1.60mm x 36T) .. 99-ON 3 5L40E.FRP01 705K Input Speed Sensor .................. 99-ON 1 5L40E.ELE03
266H Second Coast Brake (Internal Spline) 706K Output Speed Sensor ............... 99-ON 1 5L40E.ELE03
(176mm OD x 1.60mm x 36T) .. 99-ON 3 5L40E.FRP21** NI PRNDL Switch (BMW) .............. 99-ON 1 5L40E.ELE02
267H Second Coast Brake (External Spline)
(180mm OD x 1.60mm x 36T) .. 99-ON 3 5L40E.FRP02
267H Second Coast Brake (External Spline)
(183mm OD x 1.60mm x 6T) .... 99-ON 3 5L40E.FRP22**

** Alternative Sizes VALVE BODY PARTS

PRESSURE PLATES 750K Valve Body Assy (Remanufactured)
.................................................. 99-ON 1 5L40E.VB01
403C Forward Clutch Kit Boost Valve & Spacer Kit
(5.00mm Thick) ......................... 99-ON AR 5L40E.PP01 (Sonnax™)................................ 99-ON 1 5L40E.VA01
(5.50mm Thick) ......................... 99-ON AR 5L40E.PP02 Kit TCC Regulator Valve & Sleeve (Sonnax)
404F Overdrive Brake (Requires Tool Kit 5L40E.VA03)
(5.00mm Thick) ......................... 99-ON 1 5L40E.PP03 Click Here for Information...... 99-ON 1 5L40E.VA02
406H Low/Reverse Brake Kit Tool Kit for 5L40E.VA02 (Sonnax)
(5.00mm Thick) ......................... 99-ON 1 5L40E.PP04 (Reamer Jig, Guide Pin & Reamer)
.................................................. 99-ON 1 5L40E.VA03
Kit Actuator Feed Limit Valve & Sleeve (Sonnax®)
(Requires Tool Kit 5L40E.VA05)
SPRINGS & CIRCLIPS Click Here for Information...... 99-ON 1 5L40E.VA04
Kit Tool Kit for 5L40E.VA04 (Sonnax®)
(Two Reamers & Guide Pin) ..... 99-ON 1 5L40E.VA05

FILTERS
HARD PARTS
450K Pan Filter (BMW Except X5)
(Spacer hight 17mm & 34mm, Tube has 800A Bell Housing (Remanufactured)
white spacer & two brown seals) .................................................. 99-ON 1 5L40E.CAS01
.................................................. 99-ON 1 5L40E.FIL01 801A Pump Assembly ........................ 99-ON 1 5L40E.PUM01
450K Pan Filter 801A Pump Assembly
(4WD BMW X5 & Range Rover) (Remaufactured) ....................... 99-ON 1 5L40E.PUM02
.................................................. 00-ON 1 5L40E.FIL02 803A Rotor Kit, 13 Vane (17.955mm)
450K Pan Filter (Cadillac 2003-Up & BMW Except X5) (w/o Slide) ................................. 99-ON 1 4L60E.PUM02
(Spacer hight 7mm & 27mm, 816D Forward Sprag .......................... 99-ON 1 5L40E.OWC01
Tube only has two brown seals) 819E Intermediate Sprag ................... 99-ON 1 5L40E.OWC01
.................................................. 03-ON 1 5L40E.FIL03 822F Inermediate Drum (Used) ......... 99-ON 1 5L40E.DRU02
826G Low Clutch Sprag ..................... 99-ON 1 5L40E.OWC02
NI Filter Kit (OEM BMW X5) .......... 00-ON 1 5L40E.FIL12 835J Second Clutch Sprag ................ 99-ON 1 5L40E.OWC03

BUSHINGS
550A Bell Housing (Sonnax™) .......... 99-ON 1 TH700.BUS03
554C Forward Clutch Drum................ 99-ON 1 5L40E.BUS02

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5L40E (A5S 360R) BMW 98 on & Cadillac 03 on
5 SPEED RWD (Full Electronic Control)
ILL ILL
NO. DESCRIPTION YEARS QTY PART NO NO. DESCRIPTION YEARS QTY PART NO
SPECIAL ITEMS

TOOLS & MANUALS

NI ATSG Rebuild Manual
(4L40E/5L40E).......................... 99-ON 5L40E.MAN01
Kit Tool Kit for 5L40E.VA02 (Sonnax)
(Reamer Jig, Guide Pin & Reamer)
.................................................. 99-ON 1 5L40E.VA03
Kit Piston Installer Kit (11 Piece) .... 99-ON 5L40E.TOOL01

Note: If not using the piston installer kit, we recommend the use
of Seal-E-Zee Original and Extreme for the installation of these
pistons, details listed below.

NI Seal-E-Zee Original (400ml) ..... TOOL.109

NI Seal-E-Zee Extreme
(Use with Original) (300ml) ....... TOOL.136
NI Seal-E-Zee Original & Extreme Kit TOOL.122
NI Snap Ring Pliers, for removal & Instalation
of large eared case snap ring.
.................................................. 99-ON TOOL.131
NI Replacement Tips for TOOL..131 TOOL.138

238
 Back
5L40E.VA02 & VA03
D i s t r i b u t o r
D a t a S h e e t 5L40-E
PART NUMBERS 55211-04K, F-55211-TL4

COMPLAINT
SECONDARY COMPLAINTs
TCC slip and ratio codes
• Transmission and converter overheat • Delayed or no reverse • Reverse lockout valve sticking

Cause
Wear at the TCC regulator valve bore
reduces apply pressure or TCC solenoid
is damaged from valve contact.

COrrection TCC Regulator

Retaining Clip
This kit includes a wear-resistant Valve Spring
sleeve, modified valve and spring to re-
establish proper apply pressure to the
torque converter clutch, and prevents
TCC Regulator Sleeve
damage to the TCC PWM solenoid.

TCC Regulator
Valve & Sleeve Reamer Jig
TCC Regulator
Valve
Kit
TCC PWM
Soleniod Valve
Spacer
55211-04K TOOL

1 Sleeve R Guide Pin

D

EQ
U IRE
1 Valve
2 Retaining Clips
1 Spring
1 Spacer
Reamer Solenoid Valve
Retainer
F-55211-TL4
1 Reamer Jig
1 Guide Pin
1 Reamer Sonnax Part Summary
When the TCC PWM solenoid is energized and TCC signal fluid pressure is present, it strokes
the TCC regulator valve and regulates line pressure into the converter clutch apply passage. Due
to the pulse width modulation of the solenoid, the regulator valve is continuously oscillating.
Excessive wear at the large spool diameter can prevent proper valve movement, causing no TCC,
slips or soft apply. Excessive wear at the balance end of the bore can lead to harsh apply.
Additionally, the OEM valve stops against the TCC PWM solenoid screen, resulting in damage
or breakage. Debris from the broken screen can lodge at the reverse lockout valve, resulting in no
reverse. The Sonnax TCC regulator valve and sleeve kit includes a highly wear-resistant sleeve,
modified valve and spring to restore proper converter clutch apply pressure. A protective spacer is
also included to eliminate damage to the solenoid screen. The valve bore must be reamed to
accommodate the sleeve.

Features & Benefits

• Highly wear resistant sleeve provides significantly more valve support to reduce leakage and
prevent wear.
• Anodized aluminum valve resists wear to prevent leakage.
• Modified replacement spring restores proper pressure with the undersized valve.
• Protective spacer eliminates solenoid screen damage.

©2007 Sonnax Industries, Inc. 55211-04K Rev:-, 55211-04K 04-30-07

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • info@sonnax.com 1
 5L40E.VA04 & VA05 Back
D i s t r i b u t o r
D a t a S h e e t 5L40-E
PART NUMBER 55211-01K

COMPLAINT
SECONDARY COMPLAINTs
Reduced line pressure, gear ratio slip codes
• 2nd gear starts • Loss of 4th, 5th gear • TCC slippage • Forward, overdrive or coast clutch distress

Cause Valve Body

Wear at the AFL bore reduces line rise

and solenoid pressure.

COrrection Valve

This kit includes a wear-resistant sleeve,

modified valve and spring to re-establish
feed limit control. Retaining Clip Sleeve

AFL Valve
& Sleeve Kit Spring
Reamer Jig

55211-01K TOOL

1 Sleeve R
D

EQ
UIRE
1 Valve Guide Pin
1 Retaining Clip
1 Spring
Roughing Reamer

F-55211-TL Clip
1 Reamer Jig Finish Reamer
1 Guide Pin
1 Roughing Reamer
1 Finish Reamer Part Summary:
Actuator pressure is supplied to the EPC force motor and shift solenoids. At the force motor it is
Also available TOOL controlled to react on the boost valve, which is used to control clutch and TCC slippage. AFL
pressure is also supplied to the shift solenoids and positions the shift valve accordingly. When AFL
55211-04K R
pressure is too high, solenoids are flooded and line pressure can be excessive, causing piston or
D

EQ
UIRE

TCC Regulator Valve & Sleeve Kit housing fatigue. When AFL is too low, clutches slip and shift valves do not completely stroke. In
D ranges, low solenoid pressure can cause the coast clutch to release and distress the forward
clutch. In OD 5th range, reduced AFL pressure allows the overdrive clutch to come off or causes 2nd
F-55211-TL4 gear starts. If reduced feed limit pressure is supplied to the safety mode valve, it could remain in the
Tool Kit for 55211-04K released position, which will make the vehicle operate in 5th gear only. The Sonnax AFL valve &
sleeve kit 55211-01K includes a highly wear-resistant sleeve, modified valve and spring to restore
proper feed limit pressure control. The valve bore must be reamed to accommodate the sleeve.

Features & Benefits:

• Highly wear-resistant sleeve provides significantly more valve support to reduce leakage and
prevent wear.
• Anodized aluminum valve resists wear to prevent leakage.
• Contoured valve stem significantly decreases fluid flow influence over limiting pressure.
• Annular grooves added to the valve properly center it within the sleeve, preventing wear due
to side loading.
• Replacement spring limits feed limit pressure to 115 psi for proper pressure control.

©2007 Sonnax Industries, Inc. 55211-01K Rev:-, 55211-01K 05-30-07

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • info@sonnax.com 1