R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Grinding, replacing, filling and more in here

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scheherazade
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R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:46 pm

I will provide a rough overview of :

(transmission in car)
- ACM solenoid cleaning

(transmission out of car)
- Rear subframe removal
- Dodson mechanical retainer install (rear retainers + front wheel drive retainer)
- Dodson line pressure sensor install
- Clutch basket upgrade
- E-TS unit shim install
- ACM valve body cleaning
- FCM valve body cleaning



This is not a post for detailed instructions (I will look up links to other posts that I made reference to when I did this, and post them [later])

I want to share pictures in a structured manner, so that if anyone else does this in the future, they can take a look around and get an idea of what the various bits look like and feel familiar before digging in.

--- Do not reply ---

-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 4:55 am, edited 1 time in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:47 pm

Rear subframe removal :

https://imgur.com/a/LwFe2

- Disconnect brake calipers
- Remove under panels
- Remove exhaust
- Remove heat shield in front of transmission
- Disconnect rear e-brake lines
- Disconnect shifter cable from the external lever
- Disconnect shifter cable from the retaining bracket near the external lever
- Disconnect ground wire at rear of subframe
- Disconnect small harness at rear of subframe
- Disconnect vent hose at rear of subframe
- Disconnect main harness connectors on side of transmission, near oil pan
- Disconnect ancillary harness connector on side of transmission
- Remove transmission support brace (large aluminum piece)
- Mark drive shafts (necessary?)
- Unbolt drive shafts from trans
- Drain oil
- Remove heat exchanger from front of trans
- Remove oil pan (and pickup)
- Disconnect connector at front left of oil pan area, with wire headed to the front interior of the transmission
- Replace oil pan (finger tight)
- Support the transmission with transmission jack
- Loosen the 6 main nuts holding the subframe to the chassis.
*** DO NOT LOWER THE TRANSMISSION ALL THE WAY DOWN ***
- Lower the transmission a few inches
- Unhook the shifter cable from its detent on the top side of the transmission (previously not reachable).
- Verify that all connections are undone
- Verify that all harness cables are not entagled within the subframe
- Now lower the transmission all the way down.

-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 12:00 am, edited 1 time in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:48 pm

FCM access

https://imgur.com/a/ulun8

- Disconnect harness from front of transmission (This is the E-TS connection)
- Unbolt front of transmission
- Slide front of transmission off of the mid section

*Front section contains : (https://imgur.com/WPSakd0)
FCM (L shaped assembly with electronics and oil pump (dark item on bottom left))
Clutches (large round center piece)
E-TS (cylinder on right)

- Unbolt the FCM unit

If you are replacing line pressure sensors, feel free to remove them now. (https://imgur.com/JJCczca)

-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 12:15 am, edited 5 times in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:48 pm

Clutch basket upgrade

https://imgur.com/a/veXhl

This one is a basic swap

- Undo the circlip that keeps the clutch assembly in place
- Slide the clutch assemble off of the front section
- Mark the clutch assembly components with registration marks (it's somewhat important to disassemble and reassemble with as little alteration as possible)
- Remove the massive circlip that runs the perimeter of the clutch assembly
- Pull the top off of the assembly (has the sprocket)
- Remove the interior (Clutch backets and clutch plates)
- Slide off the clutch plates (don't mix them up)
- Swap large round flat bearings from old baskets to new baskets (sit around the center barrel of clutch baskets, https://imgur.com/K7nxPD9 -> https://imgur.com/abafrVd)
- Slide the clutch plates onto the new clutch baskets (mind registration marks)
- Slide the new clutch baskets back in to the assembly (mind registration marks)
- Place the top w/ sprocket back on (mind registration marks)
- Replace perimeter circlip
- Slide clutch assembly back into the transmission front section
- Install new circlip


-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 12:34 am, edited 6 times in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:48 pm

Mechanical Retainer Install

https://imgur.com/a/Qugxk

- Remove mid section of transmission



On rear of mid section :
- Remove circlips
- Remove the circular shim on the right shaft (note that one mechanical circlip has an extrusion that takes the place of the shim)

Attach the left mechanical retainer : The halves WITHOUT the extrusion.
- Take each half of the mechanical retainer and attach them to the shaft. They are stiff, so press them in with channel lock pliers.

Attach the right mechanical retainer : The halves WITH the extrusion.
- Take each half of the mechanical retainer and attach them to the shaft. They are stiff, so press them in with channel lock pliers.

Pitfall : The force to press them into place from the sides is significant. If you attempt to use the small screws to torque the two pieces together and into place, you are likely to stretch the screws and still not fully seat each half. Take the time to press each half into place before applying the screws.

- Apply the screws to the halves, with red loctite. Refer to a torque chart.



On the front mid section :
- Pop out the cap from the interior of the output shaft
- Prepare the Dodson FWD retainer by tapping in the tapered back piece into the large front piece. Thread in the screw.
- Torque the bolt such that it spreads out the retainer body just enough that it snugly fits into the interior of the shaft.
- Slide the mechanical retainer into the shaft
- Hold the retainer with channel locks, put a mini vice on the channel locks to squeeze them very tight
- Using the channel locks, hold the mechanical retainer in place, and torque the bolt so that the mechanical retainer wedges into place.
- Loosen the bolt, and apply red loctite
- Reapply the bolt and torque it to 30 lb ft

Note : I used a dremel to texture the interior of the shaft, and the outer bore of the mechanical retainer, such that they interlock with more friction. (have the shaft already stuffed with an oily rag, and pull it out to clean off any dust)

-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 2:33 am, edited 1 time in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:48 pm

E-TS unit shim

https://imgur.com/a/kVxRO

E-TS removal :
- Unbolt the E-TS cable bracket from the front section of the transmission
- Unclip the harness connector retainer at the front of the transmission (exterior)
- Bolt a bar to the front wheel drive shaft flange (exterior side of the E-TS unit)
- Holding the bar in place, undo the nut that holds the E-TS unit to the flange
- Slide off the flange, and extract the E-TS unit
*Note that the E-TS unit has a cone washer where it engages the FWD output shaft, and the taper faces rearward

E-TS disassembly :
- Place the E-TS unit pointed downwards in a vice, clamping the cast iron cross assembly on the front of the E-TS unit
- Apply registration marks to the E-TS housing and the locking collar
- Tap the locking collar counter clockwise until it loosens
- Unscrew the locking collar, counting the number of turns
*Refer to images to see the puller tool used to extract the drive motor from the E-TS
- Remove the circlip that retains the drive electric motor
- Pull the drive electric motor from the E-TS
*Refer to images to see the turning tool used to unscrew the cap from the E-TS
- Place a registration mark on the E-TS cap
- Unscrew the E-TS cap, counting the number of turns
- Remove the top pressure plate
- Remove the 6 balls
- Drain the fluid
- Remove the bottom pressure plate
- Remove the clutch stack
- Rearrange the clutch stack to line up the holes (for better circulation)
- Replace the clutch stack
- Re-fill the E-TS unit with fluid just up to the top clutch plate
- Replace the bottom pressure plate
- Replace the 6 balls
- Insert the shim
- Replace the top pressure plate
- Replace the E-TS cap, turning it the previous amount of turns, and lining up the registration marks
- Press the motor unit back into the E-TS unit
- Replace the circlip that retains the motor
- Replace the locking collar, turning it the previous amount of turns, and lining up the registration marks

- Reinstall into the front of the transmission

-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 3:14 am, edited 2 times in total.

scheherazade
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:48 pm

FCM and ACM cleaning



ACM cleaning
https://imgur.com/a/7P07e

(NOTE : More details are available in the "ACM Solenoid cleaning" section, which overlaps with 'disassembly' within this section)

- Remove oil pan from the transmission mid section
- Unscrew the oil filter cap
- Remove oil filter
- Unscrew the ACM from the transmission
- Remove the circuit board
- Remove the solenoids
- Unscrew the two halves
- Remove the 6 micro filters
*Clean
*Reassemble
- Install a new filter

This unit has no check valves or funny business.

Pitfall : When re-assembling, ensure that the gear selector pistons are lined up with the position sensors, such that the magnets inside the pistons are facing the sensors.

After you re-assemble, there are 4 pin holes inside the valve body through which you can insert a wire that will pass through a hole in the pistons, locking the pistons into proper position for re-insertion into the transmission.





FCM cleaning
https://imgur.com/a/i17ZG

- Remove the circuit board
- Remove the 4 solenoids
- Place a Torx bit into both sides of the oil pump
- Using a long breaker bar on each side, turn the bolt that holds the drive gear CLOCKWISE to loosen (righty-loosey)
- Remove the bolts holding the valve body together. You should have 3 parts, and 2 gaskets
- Remove the 2 micro filters
* Clean
* Reassemble

Pitfall : There are 3 balls in this assembly. 2 light colored balls that free-float. 1 metallic ball that is spring loaded. When separating the halves, do it slowly over a plastic bin, so that you can collect any parts that fall out. Take care to note the holes that the balls fell from (there are multiple that they can fit into).

Note : The micro filters can clog and rupture (An already cleaned example : https://imgur.com/LiMZy0n)


-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 3:51 am, edited 4 times in total.

scheherazade
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Posts: 726
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:49 pm

In-car : ACM solenoid cleaning : Step 1 : Oil pan removal

https://imgur.com/a/irvgL

- Remove undertray
- Remove drain plug
- Remove overflow tube
- Let drain
- Locate Fuller plug and loosen/remove it
- Unbolt the oil pan



-scheherazade
Last edited by scheherazade on Thu Nov 16, 2017 4:50 am, edited 1 time in total.

scheherazade
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Posts: 726
Joined: Wed Dec 05, 2007 11:19 am
Location: nova

Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:49 pm

In-car : ACM solenoid cleaning : Step 2 : ACM removal

https://imgur.com/a/O9BaT

- Remove oil pickup
- Remove harness shield
- Unplug harness
- Remove clips that hold the internal harness connector in place
- Pop harness connectors into the interior of the transmission
- Disconnect each connector inside the transmission from the ACM unit
- Insert wires into the 4 ACM piston retention holes
- Remove the bolts holding the ACM in place
- Slide out the ACM , downwards. You may need to jiggle it to make it release.

-scheherazade
Last edited by scheherazade on Sat Nov 18, 2017 6:31 pm, edited 3 times in total.

scheherazade
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Posts: 726
Joined: Wed Dec 05, 2007 11:19 am
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Re: R35 GTR GR6 FCM/ACM mainenance DIY (solenoids/sensors/retaineers)

Postby scheherazade » Wed Nov 15, 2017 11:49 pm

Placeholder : In-car : ACM Piston and Solenoid cleaning : step 3 : cleaning

https://imgur.com/a/eP6NC

Cleaning Pistons :
- Remove the wires retaining the pistons
- Remove circlips limiting the pistons from sliding out
- Remove the piston caps
- Slide out the pistons (*Keep them arranged in the same order/orientation they were in the ACM)
*Clean
- Re-insert pistons
- Rotate the pistons to align the piston magnets with the position sensors
- Insert the wires to retain the pistons
- Install piston caps
- Install circlips


Cleaning Solenoids :
- Unbolt solenoid
- Take care to not lose the spring loaded ball+plate+spring assembly underneath the solenoid.
- Warm up the tabs around the perimeter of the solenoid
- Bend up the tabs (use something thin to wedge in and pull up the tabs - do gradual bends, not sharp)
- Disassemble the solenoid, separating housing+piston+coil (https://imgur.com/QHxwv0m)
*Clean
- Reassemble (channel locks are good for bending the tabs back down)

-scheherazade


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