As-T-T026 4FA4 Automatic Transmission Chery Tigo

Welcome to the Chery Automobile

Automatic Transmission F4A4

Learning Objective • •

•

• •

Identify all components and their functions Describe the power flow and hydraulic circuit for all gears. Understand the position and functions for all sensors and actuators. Promote the efficiency of trouble -shooting. Correct disassembling and assembling of Eastar AT transmission.

Learning Contents •

Theory Unit

The command of all system or component operations is the necessa ry premise for effective diagnosis of system trouble. •

Skill and Diagnosis Unit

To provide you with w ith the practical experience and deepen the memo ry on the basis of theory and diagnosis technology learnt before.

Overview of transmission drive axle Component identification and function Power mechanical transmission circuit diagram Hydraulic power system operation Electrical program control system

概述

Characteristics of Transmission Drive Axle ♦ 2 – two-wheel design

¯ Silencer device ¯ transverse engine installation layout

♦ Gear ratio realization through

following components:

¯ 2 planetary gear set ¯ 3 multiple disc clutches (input) ¯ 2 multiple disc brakes (lock)

Model Code Transmission Number

Transmission number: 2.0L

F4A4BK1-N1Z

2.4 L

F4A4BK2-N1Z

Model F4A42 F = Front wheel drive 4 = 4 forward gears A = Automatic 4 = Low horsepower application 2 = Heavy duty Model

Automatic Transmission Drive Axle Housing

Rear Cover Transmission Housing

Torque Converter Housing

Bearing Retainer

Valve Body Cover Oil Filter

Function

4 Gears (P, R, N, and D) Plus Manual Gearshift (+/ -)

§ The manual gearshift mode can be

Gear Selector Rod Position: P = Parking R = Reverse Gear N = Neutral Gear D = Forward Gear Manual Gearshift Mode: + = Upshift - = Downs Downshif hiftt

shifted to only when the gear selector rod is at position D. § Under the manual gearshift mode,

pull the gear selector rod towards the + mark to upshift the transmission transmission to the next higher gear; pull the gearshift selector rod towards the – mark to downshift the transmission to the next lower gear. § Under manual mode, the upshift

can be performed under any vehicle speed; however, the downshift can be shifted only when the vehicle speed is lowered to allowable scope.

Output shaft sensor

Input shaft sensor

Electromagnetic valve switch connector

Gear switch

Eastar East ar AT Control Control Wor Workin king g Theor Theory y Electromagnetic valve

Sensor

E C U

T C

Gearshift control rod

Pressure control valve

Engine power

Hydraulic torque converter

U

Actuator

Planet transmission mechanism

Differential Diagnosis communication interface

Output

Low speed clutch clip (MD759666) (Shown as #11 in the figure) 15 types of dimension at choice. 0.1mm difference for each level, Min dimension at 1.6 mm as max dimension at 3.0 mm

Overview of Transmission Drive Axle Component Identification and Effects Power Mechanical Transmission Circuit Diagram Hydraulic Power System Operation Electrical Program Control System

Internal Component Identification and Effects

The gear transmission transmission train is comprised of two rows of planetary gear set, one oneway clutch and five actuators (three composite disc clutches and two composite disc brakes

Planet Gear Set -

CR-CR” Type

“

Features: The ring gear of front planet row is the planet carrier of the rear planet row.

Planet Carrier 行星架

The ring gear of rear planet row is the planet carrier of front planet row. Ring齿圈 Gear

太阳齿轮 Sun Gear

Simulation Diagram Overdrive Clutch

Overdrive Carrier

Reverse Gear Clutch

Gear 2 Brake

Low /Reverse Gear Brake Output Planetary Gear Low Speed Clutch

Planet

Input Shaft

Reverse Gear Sun Gear Overdrive Planetary gear Output Ring Gear

Output Planet Carrier

Ring Gear for Low/Reverse Gear

Low Speed Sun Gear

Gear Transmission Train – Planet Planet Gear Set

Low Speed Sun Gear 低速太阳齿轮 Snap Ring Snap Ring 弹簧卡环

Output Planet Carrier 输出行星架

超速行星架 Overdrive Planet Carrier

Snap Ring

弹簧卡环

Locating Disc 定位盘

Overdrive Overdrive Drum #4 Thrust 号止推轴承 washer 超速行星架

号止推轴承 #3 #3 Thrust washer

One-way Clutch 单向离合器

Low Speed Clutch


Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Output Pinion Low Speed Clutch

Overdrive Carrier

Planet Input Shaft Shaft

Reverse Sun Gear

Overdrive Planetary Gear


Output Ring Gear


Low Speed Sun Gear

The low speed clutch will engage at Gear 1, Gear 2 and Gear 3, with the purpose of transmitting the power of input shaft to the low speed sun gear.

Spring Retainer

D-Ring D-环 Snap Ring Spring 弹簧卡环 Retainer 弹簧架回位弹簧 D-Ring Spring D-环Return

Low Speed Clutch piston 低速离合器活塞 D-RingD-环 Low Speed 低速离合器释放 Clutch drum

Snap Ring 弹簧卡环 Clutch 离合器反作用盘 Reaction Disc

Input Shaft 输入轴 Clutch 离合器片

Plate

密封圈 Seal Ring

离合器盘 Clutch

Disc

弹簧卡环 Snap Ring

Reverse Gear Clutch/Overdrive Clutch

Overdrive Clutch

Reverse Gear Clutch


Reverse Gear Clutch

Gear 2 Brake


Overdrive Carrier

Planet

Input Shaft

Reverse Gear Sun Gear Overdrive Planetary Gear


Output Ring Gear


Low Speed Sun Gear

The overdrive clutch will engage at Gear 3 and Gear 4. The overdrive clutch will transmit the power from input shaft to the overdrive planet carrier and the ring gear for Low/Reverse gear.

Simulation Diagram Overdrive Clutch Overdrive Carrier

Reverse Gear Clutch

Gear 2 Brake


Planet

Input Shaft

Reverse Gear Sun Gear Overdrive Pinion

Output Carrier Carrier Output Ring Gear


Planet

Low Speed Sun Gear

The reverse gear clutch will engage only when the reverse gear is shifted to. The reverse gear clutch will transmit the power from input shaft to the reverse gear sun gear.

Reverse Gear Clutch drum 倒档离合器保持架

超速离合器毂 Overdrive Clutch drum Reverse Sun Gear 倒档太阳齿轮

超速离合器 Overdrive Clutch Piston 活塞

From Input Shaft 来自输入轴 Return Spring回位弹簧架 retainer

Reverse Gear Clutch drum 倒档离合器毂

Reverse Gear Clutch Piston 倒档离合器活塞

Gear 2 Brake


Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Output Planetary Gear Low Speed Clutch

Overdrive Carrier

Planet Input Shaft

Reverse Gear Sun Gear

Overdrive Planetary Gear

Output Planet Carrier Output Ring Gear


Low Speed Sun Gear

Gear 2 brake will engage only when at Gear 2 and Gear 4. Gear 2 brake lock the reverse gear sun gear gear and the transmission housing together. together.

Low/Reverse Gear Brake

Simulation Diagram

Overdrive Clutch

Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Output Output Pinion Low Speed Clutch

Overdrive Carrier

Planet Input Shaft Shaft

Reverse Gear Sun Gear Overdrive Pinion Pinion


Output Ring Gear


Low Speed Sun Gear

The Low/Reverse gear brake will engage when at parking, neutral gear, gear 1 and reverse gear. The Low/Reverse gear brake will lock together the ring gear for Low/Reverse gear as well as overdrive planet carrier and transmisson transmisson housing. The engagement of Low/Reverse gear brake at parking and neutral gear is for the purpose of reducing the shift time to gear 1 and reverse gear. At that moment, it’s applied with low hydraulic pressure that make the gear engagement looser to facilitate the gearshift.

Low/Reverse Gear Brake – Gear 2 Brake Gear 2 Brake

Reaction Disc

Low/Reverse Brake

Gear

Low/Reverse Piston

Gear 2 Brake Piston

Gear

Brake

One-way Clutch Overdrive Clutch

Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake One-way Clutch OneLow Speed Clutch

Overdrive Carrier

Planet Input Shaft

Reverse Gear Sun Gear Overdrive Planetary Gear

Output Output Planet Carrier

Output Ring Gear


Low Speed Sun Gear

The effects of one-way clutch are to avoid the rotation of overdrive planet carrier and ring gear for Low/Reverse gear gear towards the direction direction opposite to the engine direction.

One-way Clutch Outer Ring of One-way 单向离合器外圈 Clutch

Low Speed Sun Gear 低速太阳齿轮 One-way Clutch 单向离合器 Snap弹簧卡环 Ring

Overdrive 超速行星架 Planet Carrier

Low/Reverse Gear 低倒档齿圈 Ring Gear Outer Planet 外行星架 Carrier Central Support 中央支架

低倒档制动 Low/Reverse Gear Brake 器活塞 Piston

Inner Ring of One-way 单向离合器内圈 Clutch

One-way Clutch

Safety Direction 安全方向

Output Shaft/Transfer Case Driven Gear

Transfer Case Driven Gear 分动器从动齿轮

Lock Nut 锁紧螺母

Left Hand Thread

Shaft Hex Lock Hole 轴六角锁定孔

Actuator Identification and Function

Actuator Name

Marking

Function

Low Speed Clutch

UD

Connect input shaft and low speed sun gear

Reverse Gear Clutch

REV

Connect input shaft and reverse gear sun gear

Overdrive Clutch

OD

Connect input shaft and overdrive planet carrier


LR

Fix the ring gear for Low/Reverse gear and overdrive planet carrier

Gear 2 Brake

2ND

Fix the reverse sun gear

One-way Clutch

OWC

Restrict the rotation direction of ring gear for low/reverse gear

Related Operating Components

Related Operating Component

Gear Ratio

Engine Start

Parking Mechani sm

Drive Low Speed Clutch (UD)

Reverse Gear Clutch (REV)

Overspe ed Clutch (OD)

2.480

Enabled -

X -

-

X

-

Enabled

-

-

-

2.842 1.529 1.000 0.712 2.842 1.529 1.000 2.842 1.529 2.842

-

-

X X X X X X X X X

-

Gearshift Lever

Gear 2 Brake (2ND)

Unidirec tional Clutch (OWC)

-

Lock Low Gear/Re verse Gear Brake (LR) X X

-

-

-

X

-

-

Position P R N D

Parking Reverse Gear Neutral Gear Gear 1 Gear 2 Gear 3 Gear 4 Gear 1 Gear 2 Gear 3 Gear 1 Gear 2 Gear 1

X X 3 X 2 L * Low gear/reverse gear is applied when vehicle speed is lower than 10km/h.

X* X X X* X X* X X X：Operating Components

X X X -

Unit Identification Test B

A

C

D

E

N

F G

M L

H K

J

I

Taking Taking advantage advantage of following following figure, figure, fill fill in the components that met with the following description: c

Connect input shaft and overdrive planet planet carrier. Lock reverse gear sun gear. e Connect input shaft and low speed sun a gear. Lock ring gear for Low/Reverse gear d overdrive planet carrier and gear. b

Connect input shaft and reverse gear sun Overdrive Clutch

a. b. c. d. e.

Low speed clutch Reverse gear clutch Overdrive clutch Low/Reverse gear brake Gear 3 brake

Reverse Gear Clutch Clutch

Low/Reverse Low/Reverse Gear Gear 2 Brake Brake Output Pinion Low Speed Clutch Clutch

Overdrive Planet Carrier

Input Sha

Reverse Gear Sun Gear Gear Overdrive Pinion



Low Speed Sun Gear

Drive Related Operating Component

Lock

Gear Ratio

Engine Start

Parking Mechani sm

Low Speed Clutch (UD)






2.480

OK -

X -

-

X

-

X X

-

-

-

OK

-

-

-

-

X

-

-

2.842 1.529 1.000 0.712 2.842 1.529 1.000 2.842 1.529 2.842

-

-

X X X X X X X X X

-

X X X -

X* X* X* X

X X X X -

X X X -

Gearshift Lever Position

P R N D

3

2 L


* Low gear/reverse gear is applied when vehicle speed is lower than 10km/h.

X：Operating Components

Taking advantage of above figure, fill in the components that me t with the following description:

b d a e c

Only operate at reverse gear. Only operate at gear 1 and reverse reverse gear. gear. Only operate at gear 1, gear 2 and gear 3. Only operate at gear 2 and gear 4. Only operate at gear 3 and gear 4. a. b. c. d. e.

UD REV OD LR 2ND


Power Transmission Circuit for All Gears

Output Front Planet Carrier

Rear Planet Carrier

Input Shaft Front Sun Rear Sun Rear Ring Gear Front Ring Gear Gear Gear

Gear 1 Transmission Circuit (UD ( UD and L/R participating operation) The power from input shaft will transmit to front row (low speed) sun gear through the UD c lutch. The front row (low speed) sun gear drive the front row (Low/Reverse gear) ring gear to rotate counterclockwise through the output pinion. At the same time, the front row (output) planet carrier can rotate clockwise through the output pinion. Since the L/R locked the front row (Low/Reverse gear) ring gear, then the front row (output) planet carrier will decelerate the output.

Engine

Torque Converter

Output

Rear Planet Carrier Front Planet Carrier

Input Shaft Rear Sun Gear Rear ring gear Front ring gear

Front Sun Gear

Input Shaft

(At that moment L/R lock front row ring gear)

Gear

Differential Differential

Transmission Transmission Shaft

UD

Front Row Planet Carrier

Wheel

Front Row Sun Gear

Output

Key Point •

When above 10km/h at gear 1, the LR is not connected with oil pressure and the one-way clutch is locked to avoid the clockwise rotation of overdrive planet carrier.

•

The one-way clutch is used to promote the upshift upshift quality quality from gear gear 1 to gear 2 and and facilitate the smooth sliding downshift.

Gear II Transmission Circuit (UD and 2ND Participating Operation) The front row (LR) ring gear can rotate freely after the release of LR brake. The rear row (reverse gear) sun gear is locked when the gear 2 brake is engaged. The power transmitted through the front row (LR) ring gear will drive the overdrive planetary gear to rotate around the front row (low speed) sun gear and drive the rear row planet carrier to rotate clockwise. Since the rear row planet carrier is connected with LR ring gear, the LR ring gear will rotate c lockwise. lockwise. The rotation of LR ring gear and the rotation of output planet carrier at gear 1 can achieve the gear 2 gear ratio. 。

Engine

Torque Converter

L/R


Rear Planet Carrier

Input Shaft Rear Sun Gear

Front Sun Gear

Front Ring Gear

Input Shaft

Front Row (Low/Reverse Gear) Ring Gear

UD

Rear Ring Gear

Front Row (Low Speed) Rear Row (Overdrive) Planet Carrier

Sun Gear Front Row (Output) Planet Carrier

Output Gear

Differential Differentia l

Transmission Shaft

Gear III Transmission Circuit (UD and OD Participating Operation) The UD clutch will transmit the power to the front row (UD) sun gear. Front Planet Carrier

When the LR ring gear and UD sun gear rotate in same speed, the planetary gear set will rotate like one independent locked device.

Input Shaft Front Sun Gear Front Ring Gear

Gear ratio: 1:1。 UD Engine

l/R

Output

The rear row (OD) clutch will transmit the power to the rear row (OD) planet carrier and front row (LR) ring gear.

Rear Planet Carrier

Rear Sun Gear Rear Ring Gear

Front Row Sun Gear

Input Shaft

Output

OD

Rear Row Planet Carrier

Front Row Ring Gear

Gear IV Transmission Circuit (UD and OD Participating Operation) The OD clutch will transmit the power to the rear row (OD) planet carrier.

Rear Planet Carrier Front Planet Carrier

Since the rear row (reverse gear) sun gear is locked by gear 2 brake, the rear row (OD) pinion will rotate clockwise around the rear row (reverse gear) sun gear. When the rear row (OD) pinion rotates clockwise and the reverse gear sun gear is fixed, the speed output of output ring gear is the overdrive. Engine

Torque Converter Output Ring Gear

l/R

Output

Input Shaft Front Sun Gear Front Ring Gear

Input Shaft Output Planet Carrier


Overdrive Clutch Output Shaft


Reverse Gear Transmission Circuit (REV and L/R Participating Operation)

The reverse gear clutch will transmit the power to the rear row (reverse gear) sun gear.

L/R


Since the LR brake is engaged and rear row (OD) planet carrier is locked, the output ring gear will rotate counterclockwise.

Input Shaft Front Sun Gear


Front Ring Gear

Engine Output Ring Gear

Rear Planet Carrier

Torque Converter Output Gear

Input Shaft

REV

Differential

Reverse Gear Sun Gear Transmission Shaft

Gear P Brake Working Theory (1)

驻车滚杆 Parking

Parking Wedge 驻车滚杆支架驻车楔块 Parking Rolling

Rolling Rod

Rod Bracket

Manual Control Rod 手动控制杆

Latch Spring 掣子弹簧

Gear P Brake Working Theory (2)

Parking Rolling Rod 驻车滚杆 Parking Wedge 驻车楔块 Parking Gear 驻车齿轮

Control 抑制开关 Switch

Parking 驻车滚杆支撑件 Rolling Rod Support

Working Status of Various Gear Units.

Drive Related Operating Component

Gear Ratio

Engine Start

Parking Mechani sm







2.480

Enabled -

X -

-

X

-

X X

-

-

-

Enabled

-

-

-

-

X

-

-

2.842 1.529 1.000 0.712 2.842 1.529 1.000 2.842 1.529 2.842

-

-

X X X X X X X X X

-

X X X -

X* X* X* X

X X X X -

X X X -

Gearshift Lever Position P R N D

3

2 L


Lock

* Low gear/reverse gear is applied when vehicle speed is lower than 10km/h.

X ：Operating Components


•

•

•

•

The power from engine will be transmitted to the wheel through the transmission and the final deceleration gear. 4 electromagnetic valves controlled by A/T -ECU for gearshift. The fluid flow will be stocked when the gearshift electromagnetic electromagnetic valve is started and the fluid flow will pass through when such valve is turned off. A/T-ECU also operates one deceleration deceleration clutch to control the electromagnetic electromagnetic valve and the fluid flow will pass through when the A/T -ECU is turned off.

Reverse Gear Clutch

Gear 2 Brake

LR Brake

UD Clutch

OD Clutch One-way Ball Valve

Accumulator

Accumulator

Accumulator

Accumulator

Damper Clutch

Failure Protection Valve A

Failure Protection Valve B

Damper Clutch Control Valve

Conversio n Valve DCC Electrom agnetic Valve

Hydraulic Torque Converter Pressure Control Valve

LR Pressur e Control Valve

Oil Pan

Gear 2 Electromagn etic Valve

UD Pressure Control Valve

UD Electrom agnetic Valve

Pressure Regulating Valve

Manual Valve

Oil Pump Oil Filter

LR Electroma gnetic Valve

Gear 2 Pressure Control Valve

Safety Valve

OD Pressure Control Valve

OD Electroma gnetic Valve

Oil Pump After installed on the hydraulic torque converter, the oil pump is driven directly by the hydraulic torque converter through the flywheel to provide the hydraulic oil with certain pressure to the operation of hydraulic torque converter, hydraulic control system and the gearshift actuator. Tooth Size of Drive Gear

11

Tooth Size of Driven Gear

13

Max Oil Pressure kPa

1,520

Output Volume cm3 /rev

14.5

Valve Body Assembly

The valve body assembly is installed to perpendicular to the left side of transmission drive axle housing so as to reduce the th e entire height of the transmission. The valve body is installed with w ith 11 pressure valves and 5 electromagnetic valves.

Sub Inner Valve Body and Outer Valve Body

Control Electromagnetic Valve

Marking

Electromagnetic Valve Na me

#1

Low Speed Electromagnetic Valve

#2

Gear 2 Electromagnetic Valve

#3

Damper Clutch Control Electromagnetic Valve

#4

overdrive Valve

#5

Low/Reverse Electromagnetic Valve

Electromagnetic G e ar

Operation Component and Function •

Reverse Gear Clutch

Gear 2 Brake

LR Brake Accumulator

OD Clutch

UD Clutch

Accumulator

Accumulator

One-way Ball Valve

Accumulator

Damper Clutch Failu re Prote ction Valve A


Damper Clutch Control Valve Conversion Valve

DCC Electroma gnetic Valve


LR Pressure Control Valve

Oil Pan

2 Electrom agnetic Valve

UD Pressure Control Valve

OD Pressure Control Valve

UD Electroma gnetic Valve


Manual Valve

Oil Pump Oil Filter

LR Electrom agnetic Valve

Gear 2 Pressure Control Valve

Safety Valve

OD Electroma gnetic Valve

The effects of 5 pressure control valves are to control the hydraulic pressure applied on the clutch and brake based on the hydraulic pressure from the electromagnetic valve

From Manual Valve



Pipeline Pressure (From Oil Pump)

Pipeline Pressure (From Oil Pump)

Pipeline Pressure (kPa)

Oil Opening Affected by Pipeline Pressure

340

1A, 5A, 33A

Gear 1 and Gear 2

1,030

1A, 5A

Gear 3 and Gear 4

640

1A, 5A, 18A

1,520

1A

Gear Position Parking and Neutral Gear

Reverse Gear

Manual Control Valve

Manual Control Gearshift Lever

•

All the clutches are at release status when at parking and neutral gear. In order to achieve the rapid shift s hift to gear 1 or reverse gear, the LR brake is engaged. When at parking and neutral gear, the manual valve will lead the hydraulic pressure to the pressure regulating valve so as to reduce the pipeline pressure. Since all the clutches are at release status, the power from input shaft shaft will not be transm transmitted itted to the planetar planetary y gear. gear.

Manual Control Valve – N and P Position Oil pressure is transmitted through #5 and #33 oil opening to the regulating valve, which will regulate the pipeline pressure 340kPa

To LR Brake

Failure Protection Valve A at

。


A D

B

C

6

5

4

33

Manual Control Valve Pipeline Pressure (from Oil Pump)

When the manual manual control valve valve is at D position the #4 and #5 oil opening opening

Manual Control Valve will open to apply the pipeline pipeline pressure on on the Gear 2 brake, UD clutch, D Position OD clutch, electromagnetic valve and the related pressure control valve. Since the oil pressure at #33 oil opening is relieved, the pipeline pressure regulated by the pressure regulating valve is increased.

To Actuator Failure Protection Valve A

A D

5

B

Pressure Regulating Valve C

4

33

Manual Control Valve Pipeline Pressure (from Oil Pump)

Manual Control ValveReverse Gear – R Position Clutch

From Gear 2 Brake


A D

Pressure Pressure Regulating Valve

B

C

6

5

4

33

Manual Control Valve Pipeline Pressure (From Oil Pump)

Hydraulic Torque Converter Pressure Control Valve To Damper Clutch Control Valve

3

To Damper Clutch Control Valve

3A

3

3A

Cavity 2

3

2

From Pressure Regulating Valve

To Oil Pump

3

From Pressure Regulating Valve

Damper Clutch Control Valve and Electroma Electromagnetic gnetic Electromagnet ic Valve Engagement

isengagement

20

21 7

7

21

Electromagnetic Valve Turns off

Pipeline Pressure

From Hydraulic Torque Converter Pressure Control Valve

Pipeline Pressure

Electromagnetic Valve turns on

Pipeline From Pressure Pressure Hydraulic Torque Converter Pressure Control Valve

Pipeline Pressure Pressure

Conversion Valve – Gear 1 and Reverse Gear (Restrain LR Brake during Failure Protection Process) To LR Brake through Failure Pipeline Pressure Protection Valve A

C A

B

From LR Pressure Control Valve

Conversion Valve – Failure Protection To LR Brake through Failure Protection Valve A

Pipeline Pressure from OD Control Control Valve

Pipeline Pressure

C A

B

To Pressure Regulating Valve From LR Pressure Control Valve

Conversion Valve – Gear 3 and Gear 4 Pipeline Pressure

Pipeline Pressure

To Pressure Regulating Valve From LR Pressure Control Valve

Failure Protection Valve Reverse Gear Clutch

LR Brake

Gear 2 Brake

Failure Protecti on A

Failure Protecti onB

UD Clutch

OD Clutch

Convers ion Valve LR Valve

LR Electro magneti c Valve

Gear 2 Valve

Gear 2 Electro magneti c Valve

Manual Valve

UD Valve

UD Electro magneti c Valve

OD Valve

OD Electro magneti c Valve

Failure Protection Function u Major Fault – – Electromagnetic valve turns off and only Gear 3 is

operational. u The indicator of Gear N will flash in following frequency: ¯1 Hz for failure protection ¯2 Hz if ATF is overheated. u Under normal operations, the gears of reverse gear can not enga ge

when the vehicle forwarding speed is at or higher than 7km/h.

Accumulator (Pressure Reservoir)

Accumulator Spring

Accumulator Spring

Seal Ring Accumulator Piston

No.

Name

1

For Low/Reverse Gear Brake

2

For Low Speed Clutch

3

For Gear 2 Brake

4

For Overdrive Clutch

Electromagnetic Valve Overdrive Electromagnetic Valve Low/Reverse Gear Electromagnetic Valve


Gear 2Electromagneti c Valve

Hydraulic Torque Converter Damper Clutch Electromagnetic Valve

Electromagnetic Valve Characteristic = Normal Open Type

Turn On Turn Off

Oil Cut Oil Thru

Pressure Control Valve and Electromagnetic Valve OD Clutch

OD Clutch

Disengagement

Engagement Pressure Control Valve Electromagn etic Valve Turns Off

Electromagnetic Valve Turns On

Pipeline Pressure

Pipeline Pressure

The effects of 5 pressure control valves are to control the hydraulic pressure applied on the clutch and brake based on the hydraulic pressure from electromagnetic valve.

Electromagnetic Valve Application Sheet

Electromagnetic Valve Gear Position

LR

2ND

UD

OD

DCC (Ref.)

Gear 1

Off

On

Off

On

Off

Gear 2

On

Off

Off

On

On

Gear 3

On

On

Off

Off

On

Gear 4

On

Off

On

Off

On

Reverse Gear

Off

On

On

On

Off

Neutral Gear/Parking

Off

On

On

On

Off

Check Valve Steel Ball Valve

Master Oil Filter Master Oil Filter

Balancing Oil Cavity Clutch drum

Piston

Return Spring Hub

Balancing Oil Cavity Pressure Chamber

Parking and Reverse Gear Reverse gear clutch

LR clutch

Accumulator

Damper clutch

UD clutch

Gear 2 brake

Accumulator

OD clutch

Accumulator

One-way ball valve Accumulator

Pipeline pressure

Failure protection valve B

Failure protect ion valve A

Hydraulic torque Pipeline pressure

converter hydraulic pressure and lubricating pressure

Damper clutch control valve

Conversion valve

DCC electromag netic valve

Off

LR electro magne tic valve

LR electromag netic valve

Off

Gear 2 pressure control valve

UD pressure control valve

Gear 2 electromag netic valve

UD electromag netic valve

Running

OD pressure control valve

Damper clutch pressure

Running

OD electromag netic valve

Running

Regulating valve Manual control valve

Oil pump Oil filter Oil pan

Safety valve

Oil pump suction pressure

Damper clutch control electromagnetic valve pressure

Parking and Neutral Gear

Overdrive Clutch

Reverse Gear Clutch

Low/Reverse Gear Gear 2 Brake Brake Output Pinion Low Speed Clutch


Input Shaft




Low Speed Sun Gear

Gear 1

Reverse gear clutch

LR clutch

Gear 2 brake

UD clutch

OD clutch


Damper clutch

Accumulator Accumulator


Accumulator

Pipeline pressure


Failure protecti on valve A

Hydraulic torque converter hydraulic pressure and lubricating pressure


Conversion valve Gear 2 pressure control valve DCC electromagn etic valve

Off



OD pressure control valve Damper clutch pressure

LR electro magneti c valve

LR electromagn etic valve

Off

Gear 2 electromagn etic valve

Running

UD electromagn etic valve

Off

OD electromagn etic valve

Running



Safety valve


Gear 1 Overdrive Clutch

Reverse Gear Clutch

Gear 2 Brake



Input Shaft




Low Speed Sun Gear

Gear 2

Reverse gear clutch

LR clutch

Gear 2 brake

UD clutch

OD clutch One-way ball valve

Accumulator



Accumulator

Damper clutch

Pipeline pressure








Off


Running



Damper clutch pressure UD electromagn etic valve


Running



Safety valve



Gear 2

Overdrive Clutch

Reverse Gear Clutch

Gear 2 Brake



Input Shaft




Low Speed Sun Gear

Gear 3

Reverse gear clutch

LR clutch

Gear 2 brake

Accumulator

UD clutch

Accumulator

OD clutch

Accumulator


Damper clutch Failure protection valve B


Pipeline pressure




Running



Running



Running



Off


Off



Safety valve





Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Output Output Pinion Low Speed Clutch


Input Shaft

Reverse Gear Sun Gear Overdrive Pinion Output Planet Carrier Output Ring Gear


Low Speed Sun Gear

Gear 4

Reverse gear clutch

LR clutch

Gear 2 brake

Accumulator

UD clutch

Accumulator

OD clutch

Accumulator




Pipeline pressure




Running



Running


Off




Running


Off



Safety valve





Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Low Speed Clutch Low Speed Clutch

Overdrive Planet Carrier Input Shaft




Low Speed Sun Gear

Reverse Gear

Reverse gear clutch

LR clutch

Gear 2 brake

Accumulator

UD clutch

Accumulator

OD clutch

Accumulator




Pipeline pressure



Conversion valve Gear 2 pressure control valve




Damper clutch pressure DCC electromagn etic valve

Running


LR electro magneti c valve Off


Running


Running


Running



Safety valve


Reverse Gear Overdrive Clutch

Reverse Gear Clutch

Gear 2 Brake

Low/Reverse Gear Brake Low Speed Clutch Low Speed Clutch

Overdrive Planet Carrier Input Shaft




Low Speed Sun Gear

Failure Protection Mode (All Electromagnetic Valves Turn Off) Reverse gear clutch

LR clutch

Gear 2 brake

Accumulator

UD clutch

Accumulator

OD clutch

Accumulator

Damper clutch




Pipeline pressure



Conversion valve Gear 2 pressure control valve




Damper clutch pressure DCC electromagne tic valve

Off

LR electromagne tic valve

LR electro magneti c valve Off


Off


Off


Off



Safety valve


Using the following hydraulic figure, answer following questions :

Knowledge Test

1. 2. 3.

UD Clutch OD Clutch UD Electromagnetic Valve, OD Electromagnetic Valve Gear 3

List participat ed in the operation. operation. List all the friction friction component componentss that participated components participated List the the turn turn-off electromagnetic electromagnetic lectromagnetic valves. Which gear is the automatic transmission axle at for operati on?

Reverse gear clutch

LR clutch

Gear 2 brake

UD clutch

OD clutch One-way ball valve

Accumulator

Accumulator

Accumulator Accumulator Accumulator

Damper clutch Failure protecti on valve A


Pipeline pressure Hydraulic torque converter hydraulic pressure and lubricating pressure


Conversion valve

DCC electroma gnetic valve

Running

Gear 2 pressure control valve

lD pressu pressure re control valve


OD pressure control valve Oil pump suction pressure

LR electro magne tic valve

LR electromag netic valve

Running

Gear 2 electromag netic valve

Running

UD electromag netic valve

Off

UD electrom agnetic valve

Off



Safety valve


Knowledge Test Link the each component and its function of of the the main main valve valve body body with the corresponding sentence with correct correct description: description:

a b

To apply pipeline pressure on proper valves. To maintain the hydraulic pressure pressure from oil pump below certain pressure.

d f

To convert the electric signal from A/T-ECU into hydraulic pressure.

To apply and relieve relieve the pressure pressure applied on the friction friction compon ents and to relieve the pressure applied on LR brake under failure f ailure protection status.

g

a. b. c. d.

To reliever the Gear 2 brake pressure under failure protection status.

Manual Valve Pressure Regulating Valve Pressure Control Valve Electromagnetic Valve

e. f. g.

Conversion Valve Failure Protection Valve A Failure Protection Valve B

Pressure Measurement Hole Position

2nd =

Gear 2 Brake

UD =

Low Speed Clutch

LR =


RV =

Reverse Gear Clutch

OD =

Overdrive Clutch

DA =

Damper Clutch Engagement

DR =

Damper Clutch Disengagement

Hydraulic Test:

• • •

•

•

(1) Preheat the oil from engine to transmission to 80-100 ºC. (2) Lift the vehicle until the wheels can rotate freely. (3) Connect the special oil pressure gage onto the oil pressure measurement hole. (4) In accordance with the shown status of standard oil pressure measurement table, measure the oil pressure of each measurement hole. The measurement of each hole should be within the standard range. (5) If some measurement values is beyond the standard range, please refer to the oil pressure measurement and diagnosis table for causes.

S t a n d a r d O i l P r e s s u r e T e s t ( .2

4

Measurement Status

Gear Lever Positi on

Gear Posit ion

Engine Speed (rpm)

P

-

R

Rever se Gear

N

Standard Oil Pressure kPa (psi)

Deceleratio n Clutch Pressure

Reverse Gear Clutch Pressure

Overdrive Clutch Pressure

2500

-

-

-

2500

-

1,270-1,770 (185-256)

-2500

-

Gear 1

2,500

1010-1050 (146-152)

Gear 2

2500

Gear 3

2500

Gear 4

2,500

Neutr al Gear

Low Gear /Reverse Gear Clutch Pressure

Secondary Brake Pressure

Torque Converter Pressure

310-390 (45-56)

-

250-350 (36-56)

-

1,270-1,770 (185-256)

-

500-700 (73-101)

-

-

310-390 (45-56)

-

250-390 (36-56)

-

-

* 10101010-105 1050 0 (146-152)

-

500-700 (73-101)

-

-

-

1010-1050 (146-152)

500-700 (73-101)

590-690 (85-100)

-

590-690 (85-100)

-

-

450-650 (65-94)

-

-

590-690 (85-100)

-

590-690 (85-100)

450-650 (65-94)

D

L

)

I. Basic Checking and Adjustment

1. Checking: (1) Drive the vehicle, till the AFT reached working temperature (70-80 ºC). (2) Park the vehicle on level ground. (3) Shift the gear selector lever to all gear positions once, then shift to gear “N”. (4) Clean and check the outside of dipstick and withdraw the dipstick to check the oil level. Notice: The burn scent of ATF oil indicated that the transmission oil is polluted. The tiny particles in the oil pan indicated that the transmission is worn out and it ’s necessary to overhaul the transmission. (5) Check if the transmission oil level is within the HOT marking of the dipstick. If lower lower than HOT marking, refill refill the ART till the oil level is above the HOT marking. ATF Model: DEXRON-III Refilling Standard: 6.5L

2. ATF Replacement

• • •

• •

• • • • •

• • •

•

(1) Disassemble the hose connector between the transmission and the cooler (2) Start the engine to drain the oil (At Gear “N”, engine under idling status). Note: The engine must be stopped after started for one minute, because the transmission oil will be fully drained. (3) Remove the drain plug at the bottom of the transmission to drain the oil. (4) Refit the drain plug through washer and tighten to the specified torque. Specified torque: 32Nm. (5) Fill in new ATF from the refilling tubing. (6) Repeat step (2) Note: Check the pollution pollution conditions conditions of ATF. Repeat step (5) and (6) if necessary. necessary. (7) Fill in new ATF from the refilling tubing. (8) Refit the hose connector disassembled in step 1 and refit the dipstick (Please clean the dipstick before refit) (9) Start the engine and maintain idling run for 1~2 min. (10) Shift the gear selector lever to each gear position and then shift to gear “N”. (12) Drive the vehicle till the ATF reached working temperature (70-80 ºC) and re-check the oil level. The oil level must be within the HOT range of dipstick. (13) Refit the checking dipstick of transmission.

ATF

Stalling Test:

•

•

•

• • • • • • •

When the gear is at “D” or “R” position, measure the max engine speed under the torque converter stalling status and measure the working conditions of torque converter one-way clutch and transmission clutch and brake. Notice: Keep any persons away from the front or rear of the vehicle during test so as to avoid any danger. A. Checking of transmission oil level and temperature and engine coolant temperature. Oil Level: Within HOT range of dipstick. Oil Temperature: 80-100ºC Engine Coolant Temperature: Temperature: 80-100ºC B. Checking of four of four wheels C. Pull up the handbrake and step down the brake pedal to the end. D. Start the engine. E. Shift the gear selector lever to “D” position, step down the accelerator pedal to the end, and read the engine speed at that moment.

Result Analysis of Torque Converter Test: (1) Stalling speed is excessive high at “D” and “R” position. Excessive low working oil pressure. • Low/Reverse Low/Reverse gear brake has skid. • (2) Stalling speed is excessive high at “D” position. Deceleration clutch has skid. • (3) Stalling speed is excessive high at “R” position. Reverse gear clutch has skid. • (4) Stalling speed is excessive low at “D” and “R” position. Fault of torque converter. • Engine power output is insufficient. •

Summary u Pressure measurement hole

– –

Stamped Name

u Major Trouble Failure Protection

– –

Only Gear 3 is operational

u Manual Valve

–

Three operation positions

u Effects of each valve body

–

Including individual valve

u Damper Clutch

–

Partially locked at Gear 2

–

u Oil Pump u ATF

Fully locked at Gear 3 & Gear 4.

– –

Unrepairable

Knowledge Test - 1 In order to facilitate facilitate the measurement of hydraulic pressure, the names of hydraulic measurement holes are stamped on the transmission housing.

Right

/

Wrong

Knowledge Test - 2 List the three operation positions of manual valve: a.

R

b.

N

c.

D(D

P 3

2

1)

Knowledge Test - 3 Technician “A” said that the electromagnetic valve controlled by the TCU controls the operation operation of of damper clutch. Technician “B” said that it will be partially locked at Gear 2 and it will be partially or fully locked at Gear 3 and Gear 4. Who’s right?

a.

Technician A

b.

Technician B

c.

Both A and B

d.

None of A and B

Key: c

Knowledge Test - 4 For oil pump, which one of following descriptions descriptions is right? a. The oil pump can’t be disassembled, since the incorrect adjustment during refit will result the failure of oil pump. b. Oil pump must be replaced as assembly since it’s unrepairable. c.

Both a and b

d.

None of a and b

Key: c


Reading – Sensor

Judgment – Transmission Control Device

Transmission Control Device (A/T-ECU)

Ignition Switch Input Shaft Speed Sensor Output Shaft Speed Sensor

Gearshift Mode Control

Crankshaft Position Sensor (MPI)

Execution — Actuator Auto Transmission Control Relay Damper Clutch Control Electromagnetic Valve (DCC)

Low/Reverse Gear (LR) Electromagnetic Electromagnetic Valve Gear 2 Valve

Gearshift Hydraulic Control

Throttle Position Sensor Auto Transmission Oil Temperature Sensor

Control Switch

(2nd)

Electromagnetic

Low Speed (UD) Electromagnetic Valve Overdrive (OD) Electromagnetic Valve

Damper Clutch Control Failure Protection Mode (Trouble Indicator Flashes)

Dual Pressure Switch Trouble Indicator Control

Idling Position Switch (MPI)

Diagnosis Trouble Code Output (Diagnosis Indicator Flashes)

Parking Lamp Switch (MPI) Constant Speed Device (MPI)

Cruise

Control

Gear Selector Switch (Motion Mode) Movement – Actuator Gearshift Switch (Motion Mode)

Engine ECU

Diagnosis Instrument

Sensor Name

Function

Input shaft speed sensor

To detect input shaft speed (turbine speed) on the UD clutch holder.

Output shaft speed sensor

To detect output shaft speed (transfer case drive gear speed) on the transfer case driven gear.

Crankshaft position sensor (MPI)

To detect engine speed on crankshaft chain wheel.

Parking lamp switch (MPI) Throttle position sensor

To detect if the brake is working by using contact switch on brake pedal To detect descendant extent of accelera tor pedal by using potentiometer.

Auto transmission oil temperature sensor Control switch

To detect ATF ATF temperat ure by using potentio meter.

Vehicle speed sensor

To detect vehicle speed based on the odometer gear.

Dual pressure switch

To detect if A/C is working by using dual pressure switch.

Idling position switch (MPI) Constant speed cruise control device (MPI) Gear selector switch (motion mode) Gearshift switch (motion mode)

To detect gearshift lever position by using contact switch.

To detect the fully-enclosed throttle position by using the contact switch on the TPS. Constant speed cruise control device issue one overspeed cancellation signal. To detect A/T gearshift lever position (motion mode or automatic mode) by using contact switch. To detect the upshift code or downshift code when the driver uses contact switch for gear selection.

Ignition Switch

Ignition Switch

Power Supply

A/T-ECU

Input \ Output Output Shaft Sensor Output Shaft Sensor

Input Shaft Sensor

Electroma gnetic Valve Switch Connector

Gear Switch

Input Shaft/Output Shaft Speed Sensor

Connector

Hall Unit

Input Shaft/Output Shaft Speed Sensor –

System Circuit Ignition Switch

Input Shaft Speed Sensor

Output Shaft Speed Sensor

A/T-ECU #6-7

Crankshaft Position Sensor


Crankshaft Position Sensor - System Circuit


Grounding J/C

Throttle Position Sensor


Throttle Position Sensor - System Circuit

Grounding J/C

Engine-ECU

Engine Control System


Idling Position Switch


A/T Temperature Sensor

A/T Temperature Sensor

#6-12

A/T Temperature Sensor - Function

温 Te度 mperature

电 R阻 esis(k taΩn)ce (k Ω)

0°C

16.7 – 20.5

20°C

7.3 – 8.9

40°C

3.4 – 4.2

60°C

1.9 – 2.1

80°C

1.0 – 1.2

100°C

0.57 – 0.69

A/T Temperature Sensor - System Circuit

A/T Oil Temperature Sensor

A/T-ECU

Control Switch

Control Switch

Control Switch - Function

Motion Mode A/T

Control Switch - System Circuit General Fuse

Manual Gearshift Proof Switch

A/T-ECU A/T-

Control Switch Checking

Gear Position

Terminal Number

Dual Pressure Switch Dual Pressure Switch

Dual Pressure Switch - System Circuit

Dual Pressure Switch

A/T-ECU

#6-23



#6-24

Idling Position Switch – – System Circuit

Grounding J/C

Engine -ECU





Parking Lamp Switch

Parking Lamp Switch

Brake Pedal

#6-26

Parking Lamp Switch - System Circuit Fuse

Parking Lamp Switch

A/T-ECU A/T-

#6-27

Constant Speed Cruise Control

System Circuit A/T-ECU

Constant Speed Cruise Control Device

Automatic Constant Speed Driving-ECU

#6-2 #6 -28 8 & 29 29

Gear Selector Switch and Gearshift Switch

Gearshift Switch

Gear Selector Switch

Gear Selector Switch and Gearshift Switch – System Circuit J/B General Fuse

Manual Gearshift Proof Switch

Gearshift Switch

Motion

Automatic

Vehicle Mode

Mode

Selector Lever

Gearshift Switch Assembly

#631

Actuator - A/T Control Relay

A/T Control Relay

#6-32

A/T Control Relay – System Circuit Battery

Special Fuse

Control Relay

A/T-ECU #6-33

Damper Clutch Control (DCC) Electromagnetic Valve Overdrive Electromagnetic Valve Low/Reverse GearElectromagnet ic Valve

Low Speed Electromagneti c Valve



#6-35

Damper Clutch Control (DCC) Electromagnetic Valve – System Circuit A/T Control Relay

A/T-ECU #6-35

LR, UD, Gear 2 and OD Electromagnetic Valve Overdrive Electromagnetic Valve Low/Reverse GearElectromagnetic Valve




#6-36

LR, UD, Gear 2 and OD Electromagnetic Valve – System Circuit A/T Control Relay

A/T-ECU #6-37

Gearshift Control

Electromagnetic Valve Gear Position

LR

Gear 2

UD

OD

DCC (Ref.)

Gear 1

Off

On

Off

On

Off

Gear 2

On

Off

Off

On

On

Gear 3

On

On

Off

Off

On

Gear 4

On

Off

On

Off

On

Reverse Gear

Off

On

On

On

Off

Neutral Gear/Parking

Off

On

On

On

Off

#6-39

Upshift Control

T h r o t t l e O p e n E x t e n t

2-3 Shift Gear Range 3-4 Shift Gear Range Range

Output Shaft Speed Vehicle Speed

Downshift Control T h r o t t l e O p e n E x t e n t

2-3 Shift Gear Range

3-4 Shift Gear Range Range

Output Shaft Speed Vehicle Speed

#6-40 & 41

INVECS-II Throttle Open Extent

Best Overall Control Pre-programmed PreManual Gearshift Data

Vehicle Speed

Parking Parking Lamp Switch

Steering Wheel Direction

Decision Making

Best Gear Gear Selection Selection

Road Conditions Conditions and Driver Input

Learning Control System Engine Input

Wheel Load

Parking Lamp switch

Evaluation of Driver’s Characteristics Characteris tics and Characteristics Habits

Gearshift Best Adapting to Driver

Steering Wheel

#6-4 #6 -41 1 & 42 42

Learning Control System

#6-44 & 45

Learning Control System and Feedback Control

#6-47

Knowledge Test - 1 Link the following sensors sensors with with the options that best described its function.

F

To detect ATF temperature.

a. Ignition Switch

k

To detect engine idling.

b. Input Shaft Speed Speed Sensor Sensor

b

To detect turbine speed.

c. Output Shaft Speed Speed Sensor Sensor

d

To detect engine speed.

d. Crankshaft Position Sensor

j

To detect the vehicle A/C turn-on/turn-off status. e. Throttle Position Sensor Temperature Sensor To detect the descendant angle of the t he accelerator f. A/T Oil Temperature

e pedal c h g

g. Control Switch To detect the drive gear speed of transfer case.

h. Parking Lamp Switch

To detect the brake turn-on/turn-off status.

j. Dual Pressure Switch

To detect the gearshift lever position.

k. Turned-off Throttle Switch

To issue signal to A/T-ECU to provide working a voltage.

Knowledge Test - 2

Which component supplies electromagnetic valve? a.

A/T-ECU

b.

Engine ECU

c.

A/T Control Relay

d.

None of Above

power

to

the

Key: c

Knowledge Test - 3 Which component controls the hydraulic pressure of damper clutch control valve?

a. A/T-ECU b. Damper Clutch Control Electromagnetic Valve Valve c. Pressure Regulating Valve d. None of Above

Key: b

Knowledge Test - 4 LR, Gear 2, UD and OD electromagnetic valve are: a.

Normal Open Type

b.

Normal Close Type

Key: a

Knowledge Test - 5 DCC electromagnetic valve is: a.

Normal Open Type

b.

Normal Close Type

Key: a

Knowledge Test - 6 Gear N indicator will display which of the following items? a.

ATF Temperature Alarm

b. c. d. e.

Failure Protection Operation Operati on Operatio n Reading Diagnosis Code All of Above None of Above

Key: d

Knowledge Test 7 Technician “A” said that the INVECS -II can make the gear selection adapt to the needs of the common drivers on various road conditions. Technician “B” said that the INVECS -II can change the gearshift moment to meet with the habits and modified input of the drivers. Which description of the technicians is right? a. b. c. d.

Technician “A” Technician “B” Both None of Above Key: c

CE BOX/C/18

器 A/T继电 Relay

TCU/2/5 CE BOX/C/2 TCU/2/1 C/2 Gear Switch 档位开关

左A/B/11 Left A/B/11

转速输入 Speed Input

Speed Output 转速输出

Oil Temperature 油温传感器 Sensor

Electromagne 电磁阀 tic Valve

F/13

TCU/2/14

Reverse Gear Signal

倒档信号

Left 左A/C/6 A/A/6

TCU/1/15

左A/C/6 Left A/C/6

TCU/2/9

到 To ECU 89#

To 到 ECU 24#

到 To ECU 86#

TCU/1/4 TCU/2/4

TCU/1/3 TCU/1/2

到仪表B1 To Instrument B1 到仪表B2 To Instrument B2 到仪 B3 To表 Instrument B3 到仪表B4 To Instrument B4

TCU/1/5

TCU/2/6

TCU/1/6

TCU/1/1

TCU/2/13 TCU/1/11

TCU/1/12

TCU/1/13

TCU/1/14

Left A/C/16 左A/C/16

到 To ECU 84#

到 To ECU 59#

到 To ECU 7#

TCU/2/3

诊断口 Terminal 3# Diagnosis

到 To

到 To

ECU 80#

ECU 56#

T o D 到 i a g 诊 n o s 断 i s T 口 e r m 7# i n a l 7 #

B r

a 刹 k e 车 S i g 信 n a l 号

T o 到 I n s 仪 t r u m 表 e n B8 t B 8

T o到 I n s 仪 t r u m 表 e n B7 t B 7

T o 到 I n s 仪 t r u m 表 e n B6 t B 6

T o到 I n s 仪 t r u m 表 e nB5 t B 5

Basic Checking of Automatic Transmission

Learning Objective Through the detailed learning and understanding of basic checking items, to master the operation performance of series F4A4 automatic transmission used in Chery B11 vehicles, master how to determine the transmission status, and master the special checking flow and operation procedure of automatic transmission.

Learning Contents

Checking of Oil Quality and Oil Level Stalling Test Time Lag Test Oil Pressure Test Adjustment of Control Cable

Checking of Oil Quality and Oil Level •

• • •

•

The checking of automatic automatic transmission oil oil quality and oil level is the most basic checking checking item of automatic transmission transmission and also is one of the important foundations foundations that determines if the automatic transmission is needed for disassembling check. 1. Oil Level Checking C hecking (1) Park the vehicle on the level ground and pull up the handbrake. (2) Run the engine in idling speed. (3) Step down and hold the brake pedal, shift the gear selector lever to Gear P, R, N, and D respectively, hold the gear selector lever at each gear gear for several seconds seconds so as to fill the hydraulic hydraulic torque converter and all gearshift actuators with automatic transmission transmission oil, and at last shift shift the gear selector lever to the parking gear “P”. (4) At pressure measure the oil level.

(5) The dipstick of B11 automatic transmission has HOT marking and the ATF temperature of automatic transmission is at 70 －80 ℃。 2. Checking of automatic transmission oil quality: Drop the transmission oil of the dipstick onto the clean white paper and check the oil color and scent.

Stalling Test lThe stalling test is to measure the max engine speed under stalling test when at Gear

“D” or “R”, of which the measurement is to check the working status of torque converter one-way clutch and the clutch and brake of transmission. l1. Checking: lCondition: Engine Coolant Temperature: 80 －100 ℃; transmission oil temperature: 80 －100 ℃ with oil level within HOT range of dipstick. The brake and handbrake should function well on level ground. lStep: A. Support the four wheels with triangular woods. B. Pull up the handbrake and step down the brake pedal to the end. l C. Start the engine, shift to Gear D, step down the accelerator pedal to the end, and then l read the engine speed. lNotice: l A. The duration of stepping down the accelerator pedal to the end should not exceed 8s. l B. When need multi times of test, shift the gear to the Gear N and maintain the engine speed at 1,000r/min. l C. Keep any persons away from the front or rear of the vehicle during test so as to avoid any danger.

2. Standard Valve: At Gear D: 2,000 －2,900 r/min At Gear R: 2,000－2,900 r/min 3. Test Analysis: (1) When the engine engine speed is too high and the oil pressure pressure is too low at Gear D/R, the L/R brake has skid. (2) When the the engine engine speed is too high high at Gear D, the UD UD clutch has skid. (3) When the the engine speed is too high high at Gear R, the reverse gear clutch has skid. (4) When the engine speed is too low at Gear R and Gear R, the torque converter has fault.

Time Lag Test •

•

When shift the gear selector lever from neutral gear to forward gear or reverse gear under the condition that the engine is running in idling speed, one short period of time lag or time delay is required for the automatic transmission to to achieve the gearshift. gearshift. This short period of time is referred as the time lag of the automatic automatic transmission. transmission. The time lag test test is to measure the gearshift time lag of the automatic transmission so as to determine if the master oil line pressure and the gearshift units function well depending on the duration of time lag. Time Lag Test Measurement: Evidence Instruction: Instruction: the excessive N-D time lag indicated the excessive low master oil line pressure, excessive excessive worn-out of low speed clutch or Low/Reverse gear brake; the excessive N-R time lag indicated the excessive low reverse gear oil line pressure, excessive worn-out of Low/Reverse gear clutch, excessive worn-out of Low/Reverse gear clutch and individual clutch damage.

• •

• •

•

•

•

Checking Steps: (1) The temperature of engine and transmission reach normal temperature temperature (50－90 ℃). (2) Park the vehicle on level ground and pull up the handbrake. (3) Shift the gear selector lever to Gear N and Gear D respectively respectively to check the idling status. The idling status at Gear D should be slightly lower than the one at Gear N. (4) Shift the automatic transmission gear selector lever from Gear N to Gear D and measure the vibration time with sopwatch. The vibration time should be the N-D time lag. (5) Shift the gear selector lever to Gear N and run the engine in idling speed for the same test. Take the average value of three times of test results as the N-D time lag. (6) In accordance with above test method, shift the gear selector lever from Gear N to Gear R and measure the N-R time lag.

Oil Pressure Test Checking of Oil Pressure:

•

Before test, drive the vehicle till the engine temperature and the automatic transmission temperature reach normal working working temperature. temperature. Park the vehicle vehicle on level ground and check if the engine idling and transmission oil level meet with the requirements. Wedge the triangular wood before and after the wheels. 1. Shift the gear to the gear 1 position position of manual gear and step down the accelerator to increase increase the engine engine speed to 2,500 r/min. At that moment, observe the oil pressure of following two components: co mponents: 1) The pressure of the low speed clutch should be at 1,010 －1,050 kpa. 2) The pressure pressure of Low/Reverse gear gear clutch should be at 1,010 －1,050 kpa. 2. Shift the gear to the gear 2 position position of manual gear and step down the accelerator to increase increase the engine engine speed to 2,500 r/min. At that moment, observe the oil pressure of following two components: co mponents: 1) The pressure of gear gear 2 brake should should be at 1,010 －1,050 kpa. 2) The pressure of low speed clutch should be at 1,010 －1,050 kpa.

3. Shift the gear to the gear 3 position of manual gear and step down the accelerator to increase the engine speed to 2,500 r/min. At that moment, observe the oil pressure of following two components: 1) The pressu pressure re of overdr overdrive ive clutch clutch should should be be at 590 590 －690 kpa. 2) The pressure of low speed clutch should be at 590 －690 kpa. 4. Shift the gear to the gear 4 position of manual gear and step down the accelerator to increase the engine speed to 2,500 r/min. At that moment, observe the oil pressure of following two components: 1) The pressure pressure of overdrive overdrive clutch clutch should be be at 590 －690 kpa. 2) The pressure of secondary brake should be at 590 －690 kpa.

5. Shift the gear to the reverse reverse gear and step down down the accelerator accelerator to increase the engine speed to 2,500 r/min. At that moment, observe the oil pressure of following two components: 1). The pressure of reverse gear clutch should be at 1,270 －1,770 kpa. 2) The pressure of Low/Reverse gear clutch should be at 1,270 － 1,770 kpa. 6. When at Gear P and Gear N, only the Low/Reverse gear clutch effect the function with the purpose of facilitating facilitati ng the shift to reverse gear and Gear D. At that moment, the oil pressure of Low/Reverse Low/Reverse gear clutch should should be at 310-390 310-390 kpa when the engine engine speed is increased to 2,500 r/min.

Control Cable Adjustment (1) Shift the test gear selector lever to gear “N”. (2) Loosen the nut between bet ween the control cable and the manual control lever to let the control cable and manual control lever under free status. Shift the manual control lever to gear “N”.

Adjustment Nut Transmission Control Cable

Manual Control Lever

(3) Loosen the transmission gear switch installation screws and then rotate the gear switch till the flange of manual control lever is aligned with the one of gear switch. (4) Tighten the bolts of transmission gear switch to the standard torque specification and make sure that the position of gear switch is correct without any movement.

Installation Bolt


Hole End of Section A-A Manual Control Lever Hole inside Flange Control Switch

Adjustment Bolt


(5) Pull tight the transmission control cable slightly towards the arrow direction and then tighten the adjustment nut. (6) Check if the gear selector lever is at gear “N”. (7) Check if the operation at each position of transmission side and the function of each position of gear selector lever are all normal.

As-T-T026 4FA4 Automatic Transmission Chery Tigo

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