NAG 1/W5A580 Auto Transmission Diagnosis and Repair

MODULE 1 TRANSMISSION AND FLUID IDENTIFICATION

Figure 1 NAG 1 Automatic Transmission Clutch Layout

The New Automatic Gearbox Version 1 (NAG 1) automatic transmission is an
electronically controlled, five-speed transmission equipped with a variably engaged
torque converter clutch. As with most automatic transmissions, the NAG 1
transmission uses hydraulically applied clutches to shift a planetary gear train.
The NAG 1 automatic transmission has three planetary gear sets. Fifth gear is an
overdrive range. The planetary gear set is actuated by application of hydraulic
clutches (B1, K1, K2, B3, K3 and B2) via shift valves and electric solenoids in the
valve body. The NAG 1 also uses two overrunning clutches (F1 and F2). The
Transmission Control Module (TCM) electronically actuates the solenoids. The
electronic control system enables application of fluid pressures for adaptation to the
current operating conditions such as vehicle speed and engine output during a shift
phase, thus providing quality shifts.
The system performs its functions based on continuous sensor and switch feedback
information. In addition, the TCM receives information from the engine management,
body control and chassis control systems over the CAN bus.

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

The TCM controls fluid pressures to the operating clutches during the shift phase by
looking at two input speed sensors (N3 and N2) (calculated input shaft speed) and
ABS wheel speed sensors (calculated output shaft speed) along with other various
inputs. TCM control provides quality transmission shifting. Having more precise
control over the hydraulic system provides the advantage of flexible adaptation to
various vehicle and engine combinations.
The NAG 1 automatic transmission provides:
• Five forward gears
• Adaptive mode
• Close ratios (1st through 5th)
• Fill-for-life fluid (some versions have lengthy fluid change intervals)
• Two reverse gears

TRANSMISSION RANGES

Figure 2 Crossfire Shift Lever Assembly Shown

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

The shift lever can be moved into various positions. The shift lever position and gear
selections are:
Table 1 Transmission Ranges
SHIFT
LEVER GEAR
POSITION SELECTION DESCRIPTION
P Parking and starting position.
R Reverse gear (standard and winter mode).
N Neutral and starting position. No transmission of power
takes place. The vehicle can be moved freely. Allows
starting engine with vehicle in motion.
D All five forward gears are available.
4 Upshifting only to 4th gear range. Provides engine
braking. Inhibits overdrive.
3 Upshifting only to 3rd gear range. Provides engine
braking.
2 Upshifting only to 2nd gear range. Provides engine
braking.
1 Driving possible only in 1st gear range. Provides
maximum engine braking.
Table 2 Gear Range Ratios
RATIO (W5A580,
W5J400 AND
GEAR RANGE W5A380) RATIO (W5A330)
1st 3.59 3.95
2nd 2.19 2.423
3rd 1.41 1.486
4th 1.00 1.00
5th 0.83 0.833
Reverse 3.16 3.147
Reverse 1 1.93 1.93
(4WD/AWD position on LX and WK)
(Winter Mode Crossfire Only)

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

A Winter/Standard (W/S) switch is incorporated into the shift lever assembly on

Crossfire vehicles. With the W/S switch in the “S” position, lower gear ratios are
provided in first and reverse gears. With the W/S switch in the “W” position, higher
ratios are provided in first and reverse gears.

NAG 1 TRANSMISSION MODEL DESIGNATION AND APPLICATION

The following illustration provides an example explanation of the NAG 1 transmission
model designation.

W Hydraulic Torque Converter A or Automatic or Jeep Four Wheel

J Drive
5 Number of Forward Gears 580, Maximum Input Torque (N•m)
380 or
330
Figure 3 Model Designation Explanation

722. Automatic Transmission for 81 Version of Transmission for Vehicle

Passenger Cars Application Matched to Engine
(Digits Vary with Application)
6. Sales Designation (W5AXXX)
Figure 4 Model Designation Explanation (Sprinter/Crossfire)

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

The NAG 1 family of five-speed automatic transmissions includes the W5A580, the
W5J400, the W5A380 and the W5A330 versions. The acronym NAG comes from the
German words for new automatic transmission. The “1” refers to the first iteration of
the transmission.
Table 3 Family of NAG 1 Transmissions
ENGINE
MODEL VEHICLE APPLICATION TRANSMISSION SALES CODE
YEAR MARKET FAMILY SALES CODE SALES CODE DESCRIPTION
BUX Grand 2.7L 5-Cyl. DGJ Five-Speed
Cherokee Diesel (ENF) Auto
(WG) Transmission
(W5J400)
2003
U.S. Sprinter 2.7L 5-Cyl. DGJ Five-Speed
(VA) Diesel (EX9) Auto
Transmission
(W5A380)
U.S. Sprinter 2.7L 5-Cyl. DGJ Five-Speed
(VA) Diesel (EX9) Auto
Transmission
(W5A380)
2004
U.S., Crossfire 3.2L 6-Cyl. DGU Five-Speed
Canada, (ZH) Gas (EGX) Auto
Mexico Transmission
and BUX (W5A330)
U.S. Sprinter 2.7L 5-Cyl. DGJ Five-Speed
(VA) Diesel (EX9) Auto
Transmission
(W5A380)
U.S., Chrysler 5.7L 8-Cyl. DGJ Five-Speed
Canada, 300C and Gas (EZB) Auto
Mexico Dodge Transmission
and BUX Magnum (W5A580)
(LX)
U.S., Grand 3.7L 6-Cyl. DGJ Five-Speed
Canada Cherokee Gas (EKG) Auto
2005
and (WK) Transmission
Mexico (W5A580)
BUX Grand 3.7L 6-Cyl. DGJ Five-Speed
Cherokee Gas (EKG) or Auto
(WH) 3.0L 6-Cyl. Transmission
Diesel (EXL) (W5A580 or
W5J400)
U.S., Crossfire 3.2L 6-Cyl. DGU Five-Speed
Canada, (ZH) Gas (EGX) Auto
Mexico Transmission
and BUX (W5A330)

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

TRANSMISSION FLUID
Transmission fluid serves a number of purposes including application of hydraulics,
lubrication, cooling, cleaning and seal conditioning. Transmission shift quality, heat
dissipation and Transmission Control Module (TCM) calibration all dictate the type of
transmission fluid that is used. Transmission fluids are similar but have different
characteristics such as viscosity and the additives in the fluid, which is why there
will be different fluids used in Crossfire, Sprinter and 300C. Drain and refill the
transmission fluid at the recommended service intervals.
The transmission has varying capacities depending on vehicle application.
Transmission fluid capacity includes the transmission, the torque converter and the
transmission fluid cooler. The transmission is supplied from the plant with the
proper amount of fluid.
The fill tube in Sprinter and Crossfire vehicles is sealed from the factory and requires
a special service dipstick tool (#8863A) to check fluid level and a special cap is used
for sealing the transmission dipstick tube. A special funnel (#8908) which has a
filter, is required in Europe to fill the transmission. This allows reusing the
transmission fluid after being filtered through the funnel. The 300C (LX) requires
special service dipstick tool (9336). Grand Cherokee (WK) comes equipped with a
dipstick.

1 Locking Pin 3 Fill Tube

2 Fill Tube Cap
Figure 5 Fill Tube Cap (Sprinter/Crossfire)
The transmission fluid can be checked in either Park or Neutral. Refer to the
appropriate Owner’s Manual and service information for fluid level checking, service
intervals, fill procedures, fluid capacity, fluid application and type.

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

Oil Level Control

LTD407a
1 Float 2 Oil Return Path
Figure 6 Oil Level Control Float on Valve Body
The oil level control float closes the opening between the oil pan (sump) and the
planetary gear set chamber so that the gear sets do not become overfilled and churn
in the oil. As the oil level rises due to normal operating temperature increase, the oil
forces a float on the valve body to rise against an opening in the housing that leads to
the gear set chamber. The float prevents the oil from entering the transmission gears
which can cause oil foaming (aeration). Instead, the oil in the sump rises up around
the outside of the gear set chamber. Cast drain ports in the gear set chamber area
allow for excess oil return to the sump (oil pan).

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

TRANSMISSION ID STAMP LOCATION

1 Transmission Bar Code 2 Pin Stamp Pad

Identification Label
Figure 7 Transmission Bar Code Label and Pin Stamp Pad Location

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NAG 1/W5A580 Auto Transmission Diagnosis and Repair

1 Traceability 7 Build Sequence

2 Supplier Code 8 Last Three Part Number Digits
3 Component Code 9 Revision Level
4 Build Day (Julian Date) 10 Transmission Part Number
5 Build Year 11 Part Number Prefix
6 Line/Shift Code
Figure 8 Example Transmission Bar Code Label Interpretation

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 NAG 1/W5A580 Auto Transmission Diagnosis and Repair

Notes:

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