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Manual de mantenimiento y reparacion de camioneta china , Chery Tigo.
Citation preview
Welcome to the Chery Automobile
Automatic Transmission F4A4
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Learning Objective
•• Identify all components and their functionsIdentify all components and their functions•• Describe the power flow and hydraulic Describe the power flow and hydraulic
circuit for all gears.circuit for all gears.•• Understand the position and functions for Understand the position and functions for
all sensors and actuators.all sensors and actuators.•• Promote the efficiency of troublePromote the efficiency of trouble--shooting.shooting.•• Correct disassembling and assembling of Correct disassembling and assembling of
EastarEastar AT transmission.AT transmission.
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Learning ContentsLearning Contents
•• Theory UnitTheory UnitThe command of all system or component operations is the necessaThe command of all system or component operations is the necessary ry premise for effective diagnosis of system trouble.premise for effective diagnosis of system trouble.
•• Skill and Diagnosis UnitSkill and Diagnosis UnitTo provide you with the practical experience and deepen the memoTo provide you with the practical experience and deepen the memory ry on the basis of theory and diagnosis technology learnt before.on the basis of theory and diagnosis technology learnt before.
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Overview of transmission drive axleComponent identification and functionPower mechanical transmission circuit diagramHydraulic power system operationElectrical program control system
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概述概述
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♦♦ 2 2 –– twotwo--wheel designwheel design¯ Silencer deviceSilencer device
¯ transverse engine installation layouttransverse engine installation layout
♦♦ Gear ratio realization through following components:Gear ratio realization through following components:¯ 2 planetary gear set2 planetary gear set¯ 3 multiple disc clutches (input)3 multiple disc clutches (input)¯ 2 multiple disc brakes (lock)2 multiple disc brakes (lock)
Characteristics of Transmission Drive AxleCharacteristics of Transmission Drive Axle
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Model F4A42F = Front wheel driveF = Front wheel drive4 = 4 forward gears4 = 4 forward gearsA = AutomaticA = Automatic4 = Low horsepower 4 = Low horsepower applicationapplication2 = Heavy duty2 = Heavy duty
Model CodeModel Code
Transmission number:
2.0L F4A4BK1-N1Z
2.4 L F4A4BK2-N1Z
Transmission Number
Model
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Automatic Transmission Automatic Transmission Drive Axle HousingDrive Axle Housing
Torque Converter Torque Converter HousingHousing
Bearing Bearing RetainerRetainer
Oil FilterOil Filter
Valve Body Valve Body CoverCover
Transmission Transmission HousingHousing
Rear CoverRear Cover
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FunctionFunction
Gear Selector Rod Position:P = ParkingR = Reverse GearN = Neutral GearD = Forward GearManual Gearshift Mode:+ = Upshift- = Downshift
4 Gears (P, R, N, and D) Plus Manual Gearshift (+/4 Gears (P, R, N, and D) Plus Manual Gearshift (+/--))
§ The manual gearshift mode can be 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 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 upshiftcan be performed under any vehicle speed; however, the downshift can be shifted only when the vehicle speed is lowered to allowable scope.
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Output shaft sensor
Electromagnetic valve switch connector
Input shaft sensor
Gear switch
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Eastar AT Control Working Theory
T
C
UECU
Electromagnetic valve
Actuator
Planet transmission mechanism
Differential
Engine power Hydraulic torque converter
Sensor
OutputDiagnosis communication interface
Pressure control valve
Gearshift control rod
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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
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Overview of Transmission Drive AxleComponent Identification and EffectsPower Mechanical Transmission Circuit DiagramHydraulic Power System OperationElectrical Program Control System
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Internal Component Internal Component Identification and Identification and EffectsEffects
The gear transmission train is comprised of two rows of planetary gear set, one one-way clutch and five actuators (three composite disc clutches and two composite disc brakes
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行星架 太阳齿轮
齿圈
Planet Gear Set Planet Gear Set -- ““CRCR--CRCR”” TypeType
Features:
The ring gear of front planet row is the planet carrier of the rear planet row.
The ring gear of rear planet row is the planet carrier of front planet row.
Planet Carrier Sun Gear
Ring Gear
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Simulation Diagram
Overdrive ClutchOverdrive ClutchGear 2 BrakeGear 2 Brake
Output Planetary GearOutput Planetary GearLow Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive Planetary Planetary geargear
Reverse Gear Sun Reverse Gear Sun GearGear
Overdrive Planet Overdrive Planet CarrierCarrier
Low /Reverse Gear Low /Reverse Gear BrakeBrake
Reverse Gear Reverse Gear ClutchClutch
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弹簧卡环
输出行星架
低速太阳齿轮
定位盘
单向离合器
#3号止推轴承
#4号止推轴承 超速行星架
超速行星架
弹簧卡环
Gear Transmission Train Gear Transmission Train ––Planet Gear SetPlanet Gear Set
Low Speed Sun Gear
Snap Ring
Snap RingOutput Planet Carrier
Overdrive Planet Carrier
One-way Clutch
Locating Disc
Snap Ring
#3 Thrust washer
#4 Thrust washer Overdrive Drum
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Low Speed ClutchLow Speed Clutch
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Overdrive ClutchOverdrive ClutchGear 2 BrakeGear 2 Brake
Output PinionOutput Pinion
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive Planetary Planetary GearGear
Reverse Sun GearReverse Sun Gear
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear BrakeReverse Gear Reverse Gear ClutchClutch
Simulation DiagramSimulation Diagram
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.
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Spring Retainer
密封圈
输入轴
低速离合器释放
离合器盘
低速离合器活塞
D-环 回位弹簧
弹簧架
D-环
弹簧卡环
弹簧卡环
离合器反作用盘 弹簧卡环
D-环
离合器片
Input Shaft
Seal Ring
Low Speed Clutch drum
D-Ring
Low Speed Clutch piston
Snap RingSnap Ring
Clutch Disc
Clutch Plate
Clutch Reaction Disc
D-Ring
D-Ring
Return Spring
Spring Retainer
Snap Ring
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Reverse Gear Clutch/Overdrive ClutchReverse Gear Clutch/Overdrive Clutch
Overdrive ClutchOverdrive Clutch
Reverse Gear Reverse Gear ClutchClutch
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Simulation DiagramSimulation DiagramOverdrive ClutchOverdrive Clutch
Gear 2 BrakeGear 2 Brake
Output PinionOutput Pinion
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive Planetary Planetary GearGear
Reverse Gear Sun Reverse Gear Sun GearGear
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear BrakeReverse Gear Reverse Gear ClutchClutch
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.
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Overdrive Overdrive ClutchClutch
Output Planet Output Planet CarrierCarrier
Reverse Gear Reverse Gear Sun GearSun Gear
Reverse Gear Reverse Gear ClutchClutch
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.
Simulation DiagramSimulation DiagramGear 2 BrakeGear 2 Brake
Output PinionOutput Pinion
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive PinionOverdrive Pinion
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear Brake
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倒档离合器保持架
超速离合器 活塞
回位弹簧架
倒档离合器活塞
倒档离合器毂
超速离合器毂
倒档太阳齿轮
来自输入轴
Reverse Sun Gear
From Input Shaft
Reverse Gear Clutch drum
Return Spring retainer
Reverse Gear Clutch Piston
Overdrive Clutch drum
Reverse Gear Clutch drum
Overdrive Clutch Piston
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Gear 2 BrakeGear 2 Brake
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Simulation Diagram
Overdrive ClutchOverdrive Clutch Gear 2 BrakeGear 2 Brake
Output Planetary GearOutput Planetary Gear
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive Planetary Planetary GearGear
Reverse Gear Sun Reverse Gear Sun GearGear
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear BrakeReverse Gear Reverse Gear ClutchClutch
Gear 2 brake will engage only when at Gear 2 and Gear 4. Gear 2 brake lock the reverse gear sun gear and the transmission housing together.
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Low/Reverse Low/Reverse Gear BrakeGear Brake
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Simulation Diagram
Overdrive ClutchOverdrive ClutchGear 2 BrakeGear 2 Brake
Output PinionOutput Pinion
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive PinionPinion
Reverse Gear Sun Reverse Gear Sun GearGear
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear BrakeReverse Gear Reverse Gear ClutchClutch
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 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 andreverse gear. At that moment, it’s applied with low hydraulic pressure that make the gear engagement looser to facilitate the gearshift.
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Low/Reverse Gear Brake Low/Reverse Gear Brake –– Gear Gear 2 Brake2 Brake
Low/Reverse Gear Brake Low/Reverse Gear Brake PistonPiston
Gear 2 Brake PistonGear 2 Brake Piston
Reaction Reaction DiscDisc
Low/Reverse Gear Low/Reverse Gear BrakeBrake
Gear Gear 22 BrakeBrake
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Overdrive ClutchOverdrive ClutchGear 2 BrakeGear 2 Brake
OneOne--way Clutchway Clutch
Low Speed ClutchLow Speed Clutch
Input ShaftInput Shaft
Output Planet CarrierOutput Planet Carrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive Overdrive Planetary GearPlanetary Gear
Reverse Gear Sun Reverse Gear Sun GearGear
Overdrive Planet Overdrive Planet CarrierCarrier
Low/Reverse Gear BrakeLow/Reverse Gear BrakeReverse Gear Reverse Gear ClutchClutch
OneOne--way Clutchway Clutch
The effects of one-way clutch are to avoid the rotation of overdrive planet carrier and ring gear for Low/Reverse gear towards the direction opposite to the engine direction.
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OneOne--way Clutchway Clutch
单向离合器外圈
低速太阳齿轮
超速行星架
单向离合器
低倒档齿圈
弹簧卡环
外行星架
中央支架
低倒档制动
器活塞
单向离合器内圈
One-way ClutchSnap Ring
Outer Planet Carrier
Low/Reverse Gear Ring Gear
Inner Ring of One-way Clutch
Low Speed Sun Gear
Outer Ring of One-way Clutch
Overdrive Planet Carrier
Low/Reverse Gear Brake Piston
Central Support
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安全方向
OneOne--way Clutchway Clutch
Safety Direction
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分动器从动齿轮 轴六角锁定孔
锁紧螺母
Output Shaft/Transfer Case Driven GearOutput Shaft/Transfer Case Driven Gear
Left Hand ThreadLeft Hand Thread
Transfer Case Driven Gear
Lock Nut
Shaft Hex Lock Hole
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Actuator Identification and Function
Restrict the rotation direction of ring gear for low/reverse gear
OWCOne-way Clutch
Fix the reverse sun gear2NDGear 2 Brake
Fix the ring gear for Low/Reverse gear and overdrive planet carrier
LRLow/Reverse Gear Brake
Connect input shaft and overdrive planet carrierODOverdrive Clutch
Connect input shaft and reverse gear sun gearREVReverse Gear Clutch
Connect input shaft and low speed sun gearUDLow Speed Clutch
FunctionMarkingActuator Name
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Drive Lock Related Operating
Component
Gearshift Lever
Position
Gear Ratio
Engine Start
Parking Mechanism
Low Speed Clutch (UD)
Reverse Gear Clutch (REV)
Overspeed Clutch (OD)
Low Gear/Reverse Gear Brake (LR)
Gear 2 Brake (2ND)
Unidirectional Clutch (OWC)
P Parking - Enabled X - - - X - - R Reverse
Gear 2.480 - - - X - X - -
N Neutral Gear
- Enabled - - - - X - -
Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X - Gear 3 1.000 - - X - X - - -
D
Gear 4 0.712 - - - - X - X - Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X -
3
Gear 3 1.000 - - X - X - - - Gear 1 2.842 - - X - - X* - X 2 Gear 2 1.529 - - X - - - X -
L Gear 1 2.842 - - X - - X - * Low gear/reverse gear is applied when vehicle speed is lower than 10km/h. X:Operating Components
Related Operating ComponentsRelated Operating Components
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Unit Identification Test
AA BB CC DD EEFF
GG
HH
IIJJKK
LL
MM
NN
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Overdrive Clutch
Gear 2 BrakeGear 2 BrakeOutput PinionOutput Pinion
Low Speed Low Speed ClutchClutch
Input Shaft
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse Low/Reverse GearGear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
Overdrive Planet Carrier
Low/Reverse Gear Low/Reverse Gear BrakeBrake
Reverse Gear Reverse Gear ClutchClutch
Taking advantage of following figure, fill in Taking advantage of following figure, fill in the components that met with the following the components that met with the following description:description:
Connect input shaft and overdrive Connect input shaft and overdrive planet carrier.planet carrier.
Lock reverse gear sun gear.Lock reverse gear sun gear.Connect input shaft and low speed sun Connect input shaft and low speed sun
gear.gear.Lock ring gear for Low/Reverse gear Lock ring gear for Low/Reverse gear
and overdrive planet carrierand overdrive planet carrier。。Connect input shaft and reverse gear sun Connect input shaft and reverse gear sun
gear.gear.
a.a. Low speed clutchLow speed clutchb.b. Reverse gear clutchReverse gear clutchc.c. Overdrive clutchOverdrive clutchd.d. Low/Reverse gear brakeLow/Reverse gear brakee.e. Gear 3 brakeGear 3 brake
cc
eeaa
dd
bb
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Drive Lock Related Operating
Component
Gearshift Lever
Position
Gear Ratio
Engine Start
Parking Mechanism
Low Speed Clutch (UD)
Reverse Gear Clutch (REV)
Overspeed Clutch (OD)
Low Speed Clutch (UD)
Reverse Gear Clutch (REV)
Overspeed Clutch (OD)
P Parking - OK X - - - X - - R Reverse
Gear 2.480 - - - X - X - -
N Neutral Gear
- OK - - - - X - -
Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X - Gear 3 1.000 - - X - X - - -
D
Gear 4 0.712 - - - - X - X - Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X -
3
Gear 3 1.000 - - X - X - - - Gear 1 2.842 - - X - - X* - X 2 Gear 2 1.529 - - X - - - X -
L Gear 1 2.842 - - X - - X - * Low gear/reverse gear is applied when vehicle speed is lower than 10km/h. X:Operating Components
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Taking advantage of above figure, fill in the components that meTaking advantage of above figure, fill in the components that met with the t with the following description:following description:
Only operate at reverse gear.Only operate at reverse gear.Only operate at gear 1 and reverse gear.Only operate at gear 1 and reverse gear.Only operate at gear 1, gear 2 and gear 3.Only operate at gear 1, gear 2 and gear 3.Only operate at gear 2 and gear 4.Only operate at gear 2 and gear 4.Only operate at gear 3 and gear 4.Only operate at gear 3 and gear 4.
bdaec
a. UDb. REVc. ODd. LRe. 2ND
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Overview of Transmission Drive AxleComponent Identification and EffectsPower Mechanical Transmission Circuit DiagramHydraulic Power System OperationElectrical Program Control System
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Power Transmission Circuit for All Gears
Output
Input ShaftFront Sun
Gear Front Ring Gear
Rear Sun Gear Rear Ring
Gear
Rear Planet CarrierFront Planet Carrier
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Engine Torque Converter Input Shaft UD Front Row Sun Gear
(At that moment L/R lock front row ring gear) Front Row Planet Carrier Output
Gear Differential Transmission Shaft Wheel
Gear 1 Transmission Circuit (UD and L/R participating operation)
The power from input shaft will transmit to front row (low speed) sun gear through the UD clutch.
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.
Output
Input Shaft
Front Sun GearFront ring gear
Rear Sun Gear
Rear ring gear
Rear Planet CarrierFront Planet Carrier
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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 quality from gear 1 to gear 2 and facilitate the smooth sliding downshift.
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Gear II Transmission Circuit (UD and 2ND Participating Operation)
Engine Torque Converter Input Shaft UD Front Row (Low Speed)
Front Row (Low/Reverse Gear) Ring Gear Rear Row (Overdrive) Planet Carrier
Sun Gear
Front Row (Output) Planet Carrier Output Gear Differential Transmission Shaft
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 clockwise.
The rotation of LR ring gear and the rotation of output planet carrier at gear 1 can achieve the gear 2 gear ratio. 。
Output
Input Shaft
Front Sun GearFront Ring Gear
Rear Sun Gear
Rear Ring Gear
L/R
Rear Planet CarrierFront Planet Carrier
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Gear III Transmission Circuit (UD and OD Participating Operation)
UD Front Row Sun Gear
Engine Input Shaft Output
OD Rear Row Planet Carrier Front Row Ring Gear
The UD clutch will transmit the power to the front row (UD) sun gear.
The rear row (OD) clutch will transmit the power to the rear row (OD) planet carrier and front row (LR) ring gear.
When the LR ring gear and UD sun gear rotate in same speed, the planetary gear set will rotate like one independent locked device.
Gear ratio: 1:1。
Output
Input ShaftFront Sun Gear
Front Ring Gear
Rear Sun Gear
Rear Ring Gear
l/R
Rear Planet CarrierFront Planet Carrier
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Gear IV Transmission Circuit (UD and OD Participating Operation)
Engine Input Shaft Overdrive Clutch Overdrive Planet Carrier
The OD clutch will transmit the power to the rear row (OD) 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.
Output
Input ShaftFront Sun Gear
Front Ring Gear
Rear Sun Gear Rear Ring Gear
l/R
Rear Planet CarrierFront Planet Carrier
Torque Converter
Output Ring Gear
Output Planet Carrier
Output Shaft
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Reverse Gear Transmission Circuit (REV and L/R Participating Operation)
Engine REV Reverse Gear Sun Gear
Output Gear Differential Transmission Shaft
The reverse gear clutch will transmit the power to the rear row (reverse gear) sun gear.
Since the LR brake is engaged and rear row (OD) planet carrier is locked, the output ring gear will rotate counterclockwise.
Output
Input ShaftFront Sun Gear
Front Ring Gear
Rear Sun Gear Rear Ring Gear
L/R
Rear Planet CarrierFront Planet Carrier
Torque Converter
Input Shaft
Output Ring Gear
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掣子弹簧
手动控制杆
驻车滚杆 驻车滚杆支架 驻车楔块
Gear P Brake Working Theory (1)
Latch Spring
Manual Control Rod
Parking WedgeParking Rolling Rod
Parking Rolling Rod Bracket
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Gear P Brake Working Theory (2)
驻车滚杆
驻车楔块
驻车齿轮
驻车滚杆支撑件
抑制开关Control Switch
Parking Rolling Rod
Parking Rolling Rod Support
Parking Wedge
Parking Gear
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Working Status of Various Gear Units.
Drive Lock Related Operating
Component
Gearshift Lever
Position
Gear Ratio
Engine Start
Parking Mechanism
Low Speed Clutch (UD)
Reverse Gear Clutch (REV)
Overspeed Clutch (OD)
Low Speed Clutch (UD)
Reverse Gear Clutch (REV)
Overspeed Clutch (OD)
P Parking - Enabled X - - - X - - R Reverse
Gear 2.480 - - - X - X - -
N Neutral Gear
- Enabled - - - - X - -
Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X - Gear 3 1.000 - - X - X - - -
D
Gear 4 0.712 - - - - X - X - Gear 1 2.842 - - X - - X* - X Gear 2 1.529 - - X - - - X -
3
Gear 3 1.000 - - X - X - - - Gear 1 2.842 - - X - - X* - X 2 Gear 2 1.529 - - X - - - X -
L Gear 1 2.842 - - X - - X - * Low gear/reverse gear is applied when vehicle speed is lower than 10km/h. X:Operating Components
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Overview of Transmission Drive AxleComponent Identification and EffectsPower Mechanical Transmission Circuit DiagramHydraulic Power System OperationElectrical Program Control System
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•• The power from engine will be transmitted to the The power from engine will be transmitted to the wheel through the transmission and the final wheel through the transmission and the final deceleration gear. deceleration gear.
•• 4 electromagnetic valves controlled by A/T4 electromagnetic valves controlled by A/T--ECU ECU for gearshift.for gearshift.
•• The fluid flow will be stocked when the gearshift The fluid flow will be stocked when the gearshift electromagnetic valve is started and the fluid flow electromagnetic valve is started and the fluid flow will pass through when such valve is turned off.will pass through when such valve is turned off.
•• A/TA/T--ECU also operates one deceleration clutch to ECU also operates one deceleration clutch to control the electromagnetic valve and the fluid control the electromagnetic valve and the fluid flow will pass through when the A/Tflow will pass through when the A/T--ECU is ECU is turned off.turned off.
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Reverse Gear Clutch LR Brake Gear 2 Brake UD Clutch OD Clutch
AccumulatorAccumulatorAccumulatorAccumulator
Failure Protection Valve A
Failure Protection Valve B
One-way Ball Valve
Damper Clutch Control Valve
Damper Clutch
DCCElectromagnetic Valve
Hydraulic Torque ConverterPressure Control Valve
Oil Pan
Oil Filter
Oil Pump
Pressure Regulating Valve
Safety Valve
Manual Valve
LRElectromagnetic Valve
Gear 2Electromagn
etic Valve
UDElectromagnetic Valve
ODElectromagnetic Valve
ODPressure Control Valve
UDPressure Control Valve
Gear 2Pressure Control Valve
LRPressureControlValve
Conversion Valve
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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.
14.5Output Volume cm3/rev
1,520Max Oil Pressure kPa
13Tooth Size of Driven Gear
11Tooth Size of Drive Gear
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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 entire height of the transmission. The valve body is installed with 11 pressure valves and 5 electromagnetic valves.
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Sub Inner Valve Body and Outer Valve Body
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Marking Electromagnetic Valve Name
#1 Low Speed Electromagnetic Valve
#2 Gear 2 Electromagnetic Valve
#3 Damper Clutch Control Electromagnetic Valve
#4 overdrive Electromagnetic Valve
#5 Low/Reverse Gear Electromagnetic Valve
Control Electromagnetic Valve
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Reverse Gear Clutch
LR Brake Gear 2 Brake UD Clutch OD Clutch
AccumulatorAccumulatorAccumulatorAccumulator
Failure Protection Valve A
Failure Protection Valve B
One-way Ball Valve
Damper Clutch Control Valve
Damper Clutch
DCCElectromagnetic Valve
Hydraulic Torque ConverterPressure Control Valve
Oil Pan
Oil Filter
Oil Pump
Pressure Regulating Valve
Safety Valve
Manual Valve
LRElectromagnetic Valve
2档Electromagnetic Valve
UDElectromagnetic Valve
ODElectromagnetic Valve
ODPressure Control Valve
UDPressure Control Valve
Gear 2Pressure Control Valve
LRPressureControl Valve
Conversion Valve
•• Operation Operation Component and Component and FunctionFunction
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
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Pressure Pressure Regulating Regulating ValveValve
From Manual ValveFrom Manual Valve
Pipeline Pressure Pipeline Pressure (From Oil Pump)(From Oil Pump)
Hydraulic Torque Hydraulic Torque Converter Pressure Converter Pressure
Control ValveControl Valve Pipeline Pressure Pipeline Pressure (From Oil Pump)(From Oil Pump)
1A1,520Reverse Gear
1A, 5A, 18A640Gear 3 and Gear 4
1A, 5A1,030Gear 1 and Gear 2
1A, 5A, 33A340Parking and Neutral Gear
Oil Opening Affected by Pipeline PressurePipeline Pressure (kPa)Gear Position
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Manual Control Valve
Manual Control Manual Control Gearshift LeverGearshift Lever
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• All the clutches are at release status when at parking and neutral gear. In order to achieve the rapid shift 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 will not be transmitted to the planetary gear.
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Failure Protection Failure Protection Valve AValve A
Pipeline Pressure (from Oil Pipeline Pressure (from Oil Pump)Pump)
Manual Manual Control ValveControl Valve
To LR BrakeTo LR Brake
Pressure Pressure Regulating Regulating
ValveValve DDAA
BB
CC
333355 46
Oil pressure is transmitted through #5 and #33 oil opening to the regulating valve, which will regulate the pipeline pressure at 340kPa。
Manual Control Valve Manual Control Valve –– N and P PositionN and P Position
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Manual Control Valve Manual Control Valve --D PositionD Position
Failure Protection Failure Protection Valve AValve A
Pipeline Pressure (from Oil Pump)Pipeline Pressure (from Oil Pump)
To ActuatorTo Actuator
Manual Manual Control ValveControl Valve
Pressure Pressure Regulating Regulating ValveValve
DDAA
BB
CC
4455 3333
When the manual control valve is at D position the #4 and #5 oil opening will open to apply the pipeline pressure on the Gear 2 brake, UD clutch, 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.
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Manual Manual Control Valve Control Valve ––R PositionR Position
Pipeline Pressure (From Oil Pipeline Pressure (From Oil Pump)Pump)
Failure Protection Failure Protection Valve BValve B
Reverse Gear Reverse Gear ClutchClutch
Manual Manual Control ValveControl Valve
Pressure Pressure Regulating ValveRegulating Valve
DDAA
BB
CC
From Gear 2 BrakeFrom Gear 2 Brake
4455 333366
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Hydraulic Torque Converter Hydraulic Torque Converter Pressure Control ValvePressure Control Valve
CavityCavity
To Damper Clutch Control ValveTo Damper Clutch Control Valve To Damper Clutch Control ValveTo Damper Clutch Control Valve
From Pressure From Pressure Regulating Regulating ValveValve
From Pressure From Pressure Regulating Regulating ValveValve
To Oil PumpTo Oil Pump
22 33
33 3A3A3A3A
22 33
33
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Damper Clutch Control Valve and Electromagnetic ValveDamper Clutch Control Valve and Electromagnetic Valve
Electromagnetic Electromagnetic Valve Turns offValve Turns off
DisengagementDisengagement
2020
77
2121
Pipeline Pipeline PressurePressure
From From Hydraulic Hydraulic Torque Torque Converter Converter Pressure Pressure Control Control ValveValve
Pipeline Pipeline PressurePressure
Electromagnetic Electromagnetic Valve turns onValve turns on
Pipeline Pipeline PressurePressure
From From Hydraulic Hydraulic Torque Torque Converter Converter Pressure Pressure Control ValveControl Valve
Pipeline Pipeline PressurePressure
212177
EngagementEngagement
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Conversion Valve Conversion Valve –– Gear 1 and Reverse Gear (Restrain LR Gear 1 and Reverse Gear (Restrain LR Brake during Failure Protection Process)Brake during Failure Protection Process)
To LR Brake through Failure To LR Brake through Failure Protection Valve AProtection Valve A
Pipeline PressurePipeline Pressure
AA
From LR Pressure Control ValveFrom LR Pressure Control Valve
BB
CC
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Conversion Valve Conversion Valve –– Failure Failure ProtectionProtection
Pipeline Pipeline Pressure Pressure from OD from OD Control Control ValveValve CC
To Pressure To Pressure Regulating ValveRegulating Valve
Pipeline PressurePipeline Pressure
AA
BB
From LR Pressure Control ValveFrom LR Pressure Control Valve
To LR Brake through To LR Brake through Failure Protection Valve AFailure Protection Valve A
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Conversion Valve Conversion Valve –– Gear 3 and Gear 4Gear 3 and Gear 4
Pipeline Pipeline PressurePressure
To Pressure To Pressure Regulating ValveRegulating Valve
Pipeline PressurePipeline Pressure
From LR Pressure Control ValveFrom LR Pressure Control Valve
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Reverse Gear
Clutch
LR Brake
Gear 2Brake
UD Clutch
OD Clutch
Failure Protecti
on A
Conversion
Valve
LRValve
LRElectromagnetic Valve
Gear 2Valve
Gear 2Electromagnetic Valve
UDValve
UDElectromagnetic Valve
ODValve
OD Electromagnetic Valve
Manual Valve
Failure Protecti
onB
Failure Protection ValveFailure Protection Valve
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uuMajor FaultMajor Fault –– Electromagnetic Electromagnetic vvalvealve turns off and only Gear 3 is turns off and only Gear 3 is
operational.operational.
uu The indicator of Gear N will flash in following frequency:The indicator of Gear N will flash in following frequency:
¯1 1 Hz for failure protectionHz for failure protection
¯2 2 Hz if ATF is overheated.Hz if ATF is overheated.
uu Under normal operations, the gears of reverse gear can not engaUnder normal operations, the gears of reverse gear can not engage ge
when the vehicle forwarding speed is at or higher than when the vehicle forwarding speed is at or higher than 77km/h.km/h.
Failure Protection FunctionFailure Protection Function
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Accumulator (Pressure Reservoir)Accumulator (Pressure Reservoir)
Accumulator Accumulator SpringSpring
Accumulator PistonAccumulator PistonSeal RingSeal Ring
Accumulator Accumulator SpringSpring
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No. Name
1 For Low/Reverse Gear Brake
2 For Low Speed Clutch
3 For Gear 2 Brake
4 For Overdrive Clutch
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Electromagnetic ValveElectromagnetic Valve
Overdrive Overdrive Electromagnetic Electromagnetic ValveValve
Low/Reverse Gear Low/Reverse Gear Electromagnetic Electromagnetic ValveValve
Low Speed Low Speed Electromagnetic Electromagnetic ValveValve
Gear Gear 2Electromagneti2Electromagnetic Valvec Valve
Hydraulic Hydraulic Torque Torque Converter Converter Damper Clutch Damper Clutch Electromagnetic Electromagnetic ValveValve
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Electromagnetic Valve Characteristic = Electromagnetic Valve Characteristic = Normal Open TypeNormal Open Type
Turn On Oil CutTurn On Oil Cut
Turn Off Oil ThruTurn Off Oil Thru
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Pressure Control Valve and Pressure Control Valve and Electromagnetic ValveElectromagnetic Valve
Electromagnetic Electromagnetic Valve Valve Turns OnTurns On
ElectromagnElectromagnetic Valve etic Valve Turns OffTurns Off
Pipeline PressurePipeline Pressure Pipeline PressurePipeline Pressure
OD ClutchOD ClutchOD ClutchOD Clutch
DisengagementDisengagement EngagementEngagement
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.
Pressure Pressure Control ValveControl Valve
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Electromagnetic Valve Application SheetElectromagnetic Valve Application Sheet
OffOnOnOnOffReverse Gear
OffOnOnOnOffNeutral Gear/Parking
OnOffOnOffOnGear 4
OnOffOffOnOnGear 3
OnOnOffOffOnGear 2
OffOnOffOnOffGear 1
DCC (Ref.)ODUD2NDLR
Electromagnetic ValveGear Position
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Steel Ball ValveSteel Ball Valve
Check ValveCheck Valve
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Master Oil FilterMaster Oil Filter
Master Oil FilterMaster Oil Filter
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Clutch Clutch drumdrum
PistonPiston
Balancing Oil Balancing Oil CavityCavity
Pressure Pressure ChamberChamber
Return Spring HubReturn Spring Hub
Balancing Oil CavityBalancing Oil Cavity
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Parking and Reverse GearParking and Reverse Gear
Pipeline pressure
OD pressure control valve
Off
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch
One-way ball valve Accumulator Accumulator Accumulator
Pipeline pressure Failure protect
ion valve
A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagnetic valve LR
electromagne
tic valve
LR electromagnetic valve
Gear 2 electromagnetic valve
UD electromagnetic valve
OD electromagnetic valve
Off Running Running Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
Damper clutch control valve
OD pressure control valve
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Parking and Neutral GearParking and Neutral Gear
Input Input ShaftShaft
Low Speed Low Speed ClutchClutch
Output PinionOutput Pinion
Low/Reverse Gear Low/Reverse Gear BrakeBrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear
ClutchClutchOverdrive Overdrive ClutchClutch
Overdrive Overdrive Planet CarrierPlanet Carrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
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Gear 1Gear 1
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch
One-way ball valve Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagn
etic valve LR
electromagnetic valve
LR electromagn
etic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
OD electromagn
etic valve
Off Running Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
Off Off
OD pressure control valve
Damper clutch control valve
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Gear 1Gear 1
Input Input ShaftShaft
Low Speed Low Speed ClutchClutch
Output PinionOutput Pinion
Low/Reverse Gear Low/Reverse Gear BrakeBrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear
ClutchClutchOverdrive Overdrive ClutchClutch
Overdrive Overdrive Planet CarrierPlanet Carrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
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Gear 2Gear 2
OD electromagn
etic valve
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch
One-way ball valve Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagn
etic valve LR
electromagnetic valve
LR electromagn
etic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
Off Running Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
OD pressure control valve
Damper clutch control valve
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Gear 2Gear 2
Input ShaftInput Shaft
Low Speed Low Speed ClutchClutch
Output PinionOutput PinionLow/Reverse Gear Low/Reverse Gear BrakeBrake
Gear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive Overdrive
ClutchClutch
Overdrive Overdrive Planet CarrierPlanet Carrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
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Gear 3Gear 3Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch
One-way ball valve Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagn
etic valve LR
electromagnetic valve
LR electromagn
etic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
OD electromagn
etic valve
Off Running Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
OD pressure control valve
Running Off
Damper clutch control valve
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Gear 3Gear 3
Input ShaftInput Shaft
Low Speed Low Speed ClutchClutch
Output PinionOutput Pinion
Low/Reverse Gear BrakeLow/Reverse Gear BrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive ClutchOverdrive Clutch
Overdrive Planet Overdrive Planet CarrierCarrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun GearLow Speed Sun GearRing Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring GearOutput Ring Gear
Overdrive PinionOverdrive Pinion
Reverse Gear Sun Reverse Gear Sun GearGear
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Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch
One-way ball valve Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagn
etic valve LR
electromagnetic valve
LR electromagn
etic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
OD electromagn
etic valve
Off Running Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
OD pressure control valve
Running Off
Gear 4Gear 4
Damper clutch control valve
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Gear 4Gear 4
Input ShaftInput Shaft
Low Speed ClutchLow Speed ClutchLow Speed ClutchLow Speed Clutch
Low/Reverse Gear BrakeLow/Reverse Gear BrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive Overdrive
ClutchClutch
Overdrive Overdrive Planet CarrierPlanet Carrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
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Reverse GearReverse Gear
LR electromagn
etic valve
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch One-way ball valve
Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagn
etic valve LR
electromagnetic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
OD electromagn
etic valve
Running
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
OD pressure control valve
Running Off Running Running
Damper clutch control valve
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Reverse GearReverse Gear
Input ShaftInput Shaft
Low Speed ClutchLow Speed ClutchLow Speed ClutchLow Speed Clutch
Low/Reverse Gear BrakeLow/Reverse Gear BrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive Overdrive
ClutchClutch
Overdrive Overdrive Planet CarrierPlanet Carrier
Output Planet Output Planet CarrierCarrier
Low Speed Sun Low Speed Sun GearGear
Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear
Output Ring Output Ring GearGear
Overdrive Overdrive PinionPinion
Reverse Gear Reverse Gear Sun GearSun Gear
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Failure Protection Mode (All Electromagnetic Valves Turn Off)Failure Protection Mode (All Electromagnetic Valves Turn Off)
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch One-way ball valve
Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Failure protection valve B
Damper clutch control valve
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
UD pressure control valve
Oil pump suction pressure
Damper clutch pressure
Damper clutch control
electromagnetic valve pressure
DCC electromagne
tic valve LR
electromagnetic valve
LR electromagne
tic valve
Gear 2 electromagn
etic valve
UD electromagn
etic valve
OD electromagn
etic valve
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan
Safety valve
OD pressure control valve
Off Off Off Off Off
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Knowledge Knowledge TestTest
Using the following hydraulic figure, answer following questionsUsing the following hydraulic figure, answer following questions::
1. List all the friction components that participated in the op1. List all the friction components that participated in the operation.eration.2. List the turn2. List the turn--off eoff electromagnetic valves.lectromagnetic valves.3. Which gear is the automatic transmission axle at for operati3. Which gear is the automatic transmission axle at for operation?on?
UD ClutchUD Clutch,,OD ClutchOD ClutchUD Electromagnetic Valve, UD Electromagnetic Valve, OD Electromagnetic ValveOD Electromagnetic ValveGear 3Gear 3
Damper clutch
Reverse gear clutch LR clutch
Accumulator
Gear 2 brake UD clutch OD clutch One-way ball valve
Accumulator Accumulator Accumulator
Pipeline pressure Failure protecti
on valve A
Damper clutch control valve
Conversion valve
Hydraulic torque converter hydraulic
pressure and lubricating pressure
Gear 2 pressure control valve
lD pressure control valve
Oil pump suction pressure
Damper clutch control
electromagnetic valve pressure
DCC electroma
gnetic valve
LR electromagne
tic valve
LR electromagnetic valve
UD electromagnetic valve
UD electromagnetic valve
Regulating valve
Manual control valve
Oil pump Oil filter
Oil pan Safety valve
OD pressure control valve
Off Off Running Running Running
Gear 2 electromagnetic valve
Failure protection valve B
Oil pump suction pressure
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Knowledge TestKnowledge Test
Link the each component and its function of the main valve body Link the each component and its function of the main valve body with with the corresponding sentence with correct description:the corresponding sentence with correct description:
To apply pipeline pressure on proper valves. To apply pipeline pressure on proper valves. To maintain the hydraulic pressure from oil pump below certain To maintain the hydraulic pressure from oil pump below certain
pressure. pressure.
To convert the electric signal from A/TTo convert the electric signal from A/T--ECU into hydraulic pressure.ECU into hydraulic pressure.
To apply and relieve the pressure applied on the friction componTo apply and relieve the pressure applied on the friction components and ents and to relieve the pressure applied on LR brake under failure protecto relieve the pressure applied on LR brake under failure protection status.tion status.
To reliever the Gear 2 brake pressure under failure protection sTo reliever the Gear 2 brake pressure under failure protection status. tatus.
a. a. Manual Valve Manual Valve b. b. Pressure Regulating ValvePressure Regulating Valvec.c. Pressure Control ValvePressure Control Valved. d. Electromagnetic ValveElectromagnetic Valve
e.e. Conversion ValveConversion Valvef. f. Failure Protection Valve AFailure Protection Valve Ag. g. Failure Protection Valve BFailure Protection Valve B
aabb
ddff
gg
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2nd = 2nd = Gear 2 Brake Gear 2 Brake UD = UD = Low Speed ClutchLow Speed ClutchLR = LR = Low/Reverse Gear BrakeLow/Reverse Gear BrakeRV = RV = Reverse Gear Clutch Reverse Gear Clutch OD = OD = Overdrive ClutchOverdrive ClutchDA = DA = Damper Clutch EngagementDamper Clutch EngagementDR = DR = Damper Clutch DisengagementDamper Clutch Disengagement
Pressure Measurement Pressure Measurement Hole PositionHole Position
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Hydraulic Test:
• (1) Preheat the oil from engine to transmission to 80-100ºC. • (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 standardrange.
• (5) If some measurement values is beyond the standard range, please refer to the oil pressure measurement and diagnosis table for causes.
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Measurement Status Standard Oil Pressure kPa (psi)
Gear Lever Position
Gear Position
Engine Speed (rpm)
Deceleration Clutch Pressure
Reverse Gear Clutch Pressure
Overdrive Clutch Pressure
Low Gear /Reverse Gear Clutch Pressure
Secondary Brake Pressure
Torque Converter Pressure
P - 2500 - - - 310-390(45-56) - 250-350
(36-56)
RReverse Gear
2500 - 1,270-1,770(185-256) - 1,270-1,770
(185-256) - 500-700(73-101)
N Neutral Gear
-2500 - - - 310-390(45-56) - 250-390
(36-56)
D
Gear 1 2,500 1010-1050
(146-152) - - * 1010-1050(146-152) - 500-700
(73-101)
Gear 2 2500 - - - 1010-1050
(146-152)500-700(73-101)
Gear 3 2500 590-690
(85-100) - 590-690(85-100) - - 450-650
(65-94)
Gear 4 2,500 - - 590-690
(85-100) - 590-690(85-100)
450-650(65-94)
Standard Oil Pressure Test (
2.
4L)
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I. Basic Checking and Adjustment
1. Checking:(1) Drive the vehicle, till the AFT reached working temperature (70-80ºC).(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 than HOT marking, refill the ART till the oil level is above the HOT marking.ATF Model: DEXRON-III Refilling Standard: 6.5L
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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 conditions of ATF. Repeat step (5) and (6) if 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 (70-80ºC) and re-check the
oil level. The oil level must be within the HOT range of dipstick. • (13) Refit the checking dipstick of transmission.
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ATFATF
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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: 80-100ºC• B. Checking 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.
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Result Analysis of Torque Converter Test:
(1) Stalling speed is excessive high at “D” and “R” position.• Excessive low working oil pressure.• 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.
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SummarySummary
uu Pressure measurement holePressure measurement hole –– Stamped NameStamped Name
uu Major Trouble Failure ProtectionMajor Trouble Failure Protection –– Only Gear 3 is operationalOnly Gear 3 is operational
uu Manual Valve Manual Valve –– Three operation positionsThree operation positions
uu Effects of each valve body Effects of each valve body –– Including individual valveIncluding individual valve
uu Damper Damper Clutch Clutch –– Partially locked at Partially locked at Gear 2Gear 2–– Fully locked at Gear 3 & Gear 4.Fully locked at Gear 3 & Gear 4.
uu Oil PumpOil Pump –– UnrepairableUnrepairable
uu ATFATF
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Knowledge Test Knowledge Test -- 11
In order to facilitate the measurement of hydraulic In order to facilitate the measurement of hydraulic pressure, the names of hydraulic measurement holes pressure, the names of hydraulic measurement holes are stamped on the transmission housing.are stamped on the transmission housing.
Right Right // WrongWrong
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Knowledge Test Knowledge Test -- 22
List the three operation positions of manual List the three operation positions of manual
valve:valve:
a. a.
b. b.
c. c.
R
N,P
D(D,3,2,1)
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Knowledge Test Knowledge Test -- 33
Technician Technician ““AA”” said that the electromagnetic valve controlled said that the electromagnetic valve controlled by the TCU controls the operation of damper clutch.by the TCU controls the operation of damper clutch.Technician Technician ““BB”” said that it will be partially locked at Gear 2 said that it will be partially locked at Gear 2 and it will be partially or fully locked at Gear 3 and Gear 4.and it will be partially or fully locked at Gear 3 and Gear 4.WhoWho’’s right? s right?
a.a. Technician Technician AAb. b. Technician Technician BBc. c. Both Both AA and and BBd.d. None of None of AA and and BB
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Knowledge Test Knowledge Test -- 44
For oil pump, which one of following descriptions is For oil pump, which one of following descriptions is right?right?
a. a. The oil pump canThe oil pump can’’t be disassembled, since the t be disassembled, since the incorrect adjustment during refit will result the failure of oilincorrect adjustment during refit will result the failure of oilpump.pump.b.b. Oil pump must be replaced as assembly since itOil pump must be replaced as assembly since it’’s s unrepairableunrepairable..c.c. Both a and bBoth a and bd.d. None of a and bNone of a and b
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Overview of Transmission Drive AxleComponent Identification and EffectsPower Mechanical Transmission Circuit DiagramHydraulic Power System OperationElectrical Program Control System
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Reading – Sensor Judgment – Transmission Control Device Execution — Actuator
Movement – Actuator
Ignition Switch
Input Shaft Speed Sensor
Auto Transmission Control RelayTransmission Control Device
(A/T-ECU)
Output Shaft Speed Sensor
Crankshaft Position Sensor (MPI)
Throttle Position Sensor
Auto Transmission Oil Temperature Sensor
Control Switch
Dual Pressure Switch
Idling Position Switch (MPI)
Parking Lamp Switch (MPI)
Constant Speed Cruise Control Device (MPI)
Gear Selector Switch (Motion Mode)
Gearshift Switch (Motion Mode)
Damper Clutch Control Electromagnetic Valve (DCC)
Low/Reverse Gear (LR) Electromagnetic ValveGear 2 (2nd) Electromagnetic ValveLow Speed (UD) Electromagnetic Valve
Overdrive (OD) Electromagnetic Valve
Engine ECU Diagnosis Instrument
Gearshift Mode Control
Gearshift Hydraulic Control
Damper Clutch Control
Trouble Indicator Control
Failure Protection Mode (Trouble Indicator Flashes)
Diagnosis Trouble Code Output (Diagnosis Indicator Flashes)
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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) To detect if the brake is working by using contact switch on brake pedal Throttle position sensor To detect descendant extent of accelerator pedal by using potentiometer.
Auto transmission oil temperature sensor
To detect ATF temperature by using potentiometer.
Control switch To detect gearshift lever position by using contact switch.
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) To detect the fully-enclosed throttle position by using the contact switch on the TPS. Constant speed cruise control device (MPI) Constant speed cruise control device issue one overspeed cancellation signal.
Gear selector switch (motion mode) To detect A/T gearshift lever position (motion mode or automatic mode) by using contact switch. Gearshift switch (motion mode) To detect the upshift code or downshift code when the driver uses contact switch for gear
selection.
SensorSensor
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Ignition SwitchIgnition Switch
A/TA/T--ECUECU
Ignition SwitchIgnition Switch
Power SupplyPower Supply
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Output Shaft Sensor
Electromagnetic Valve Switch Connector
Input Shaft Sensor
Gear Switch
InputInput\\Output Shaft SensorOutput Shaft Sensor
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Input Shaft/Output Shaft Speed SensorInput Shaft/Output Shaft Speed Sensor
ConnectorConnector
Hall UnitHall Unit
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#6-7
Input Shaft/Output Shaft Speed Sensor Input Shaft/Output Shaft Speed Sensor –– System CircuitSystem Circuit
A/TA/T--ECUECU
Ignition Switch
Output Shaft Speed Sensor
Input Shaft Speed Sensor
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Crankshaft Position SensorCrankshaft Position Sensor
Crankshaft Crankshaft Position SensorPosition Sensor
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Crankshaft Position SensorCrankshaft Position Sensor-- System CircuitSystem Circuit
Crankshaft Position Sensor
Grounding J/C
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Throttle Position SensorThrottle Position Sensor
Throttle Position Sensor
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Throttle Position Sensor Throttle Position Sensor -- System CircuitSystem Circuit
Grounding J/C
Engine-ECU
Engine Control System
Engine Control System
Throttle Position SensorIdling Position Switch
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#6-12
A/T Temperature SensorA/T Temperature Sensor
A/T Temperature A/T Temperature SensorSensor
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A/T Temperature Sensor A/T Temperature Sensor -- FunctionFunction
温度 电阻 (kΩ)
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
Temperature Resistance (kΩ)
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A/T Temperature SensorA/T Temperature Sensor-- System CircuitSystem Circuit
A/TA/T--ECUECU
A/T Oil Temperature Sensor
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Control SwitchControl Switch
Control SwitchControl Switch
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Control Switch Control Switch -- FunctionFunction
Motion Mode A/TMotion Mode A/T
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Control Switch Control Switch -- System CircuitSystem Circuit
A/TA/T--ECUECU
General Fuse
Manual Gearshift Proof Switch
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Control Switch Checking
Gear Position
Terminal Number
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Dual Pressure SwitchDual Pressure Switch
Dual Pressure SwitchDual Pressure Switch
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#6-23
Dual Pressure Switch Dual Pressure Switch -- System CircuitSystem Circuit
A/TA/T--ECUECU
Dual Pressure Switch
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#6-24
Idling Position SwitchIdling Position Switch
Throttle Position Sensor
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Idling Position SwitchIdling Position Switch ––System CircuitSystem Circuit
Grounding J/C
Engine -ECU
Engine Control System
Engine Control System
Throttle Position SensorIdling
Position Switch
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#6-26
Parking Lamp SwitchParking Lamp Switch
Parking Lamp SwitchParking Lamp Switch
Brake PedalBrake Pedal
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#6-27
Parking Lamp Switch Parking Lamp Switch -- System CircuitSystem Circuit
A/TA/T--ECUECU
Parking Lamp Switch
Fuse
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Constant Speed Constant Speed Cruise ControlCruise Control
#6-28 & 29
Constant Speed Cruise Constant Speed Cruise Control DeviceControl Device
System CircuitSystem Circuit
A/TA/T--ECUECU
Automatic Constant Speed Driving-ECU
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Gear Selector Switch Gear Selector Switch and Gearshift Switchand Gearshift Switch
Gearshift Gearshift SwitchSwitch
Gear Selector Gear Selector SwitchSwitch
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#6-31
Gear Selector Switch and Gearshift Switch Gear Selector Switch and Gearshift Switch ––System CircuitSystem Circuit J/B
General Fuse
Manual Gearshift Proof Switch
Selector Lever
Gearshift Switch Assembly
Gearshift Switch Motion
Vehicle Mode
Automatic
Mode
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#6-32
Actuator Actuator -- A/T Control RelayA/T Control Relay
A/T Control Relay
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#6-33
A/T Control Relay A/T Control Relay –– System CircuitSystem Circuit
A/TA/T--ECUECU
Battery
Special Fuse
Control Relay
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#6-35
Damper Clutch Control (DCC) Damper Clutch Control (DCC) Electromagnetic ValveElectromagnetic Valve
Low Speed Low Speed ElectromagnetiElectromagnetic Valvec Valve
Gear 2 Gear 2 Electromagnetic Electromagnetic ValveValve
Damper Clutch Damper Clutch Control Control Electromagnetic Electromagnetic ValveValve
Overdrive Overdrive Electromagnetic Electromagnetic ValveValve
Low/Reverse Low/Reverse GearElectromagnetGearElectromagnetic Valveic Valve
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#6-35
Damper Clutch Control (DCC) Electromagnetic Valve Damper Clutch Control (DCC) Electromagnetic Valve –– System CircuitSystem Circuit
A/T Control RelayA/T Control Relay
A/TA/T--ECUECU
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LR, UD, Gear 2 and OD Electromagnetic ValveLR, UD, Gear 2 and OD Electromagnetic Valve
Low Speed Low Speed Electromagnetic Electromagnetic ValveValve
Gear 2 Gear 2 Electromagnetic Electromagnetic ValveValve
Damper Clutch Damper Clutch Control Control Electromagnetic Electromagnetic ValveValve
Overdrive Overdrive Electromagnetic Electromagnetic ValveValve
Low/Reverse Low/Reverse GearElectromagnetic GearElectromagnetic ValveValve
#6-36
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A/T Control RelayA/T Control Relay
A/TA/T--ECUECU
#6-37
LR, UD, Gear 2 and OD Electromagnetic Valve LR, UD, Gear 2 and OD Electromagnetic Valve –– System CircuitSystem Circuit
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#6-39
Gearshift ControlGearshift Control
OffOnOnOnOffReverse Gear
OffOnOnOnOffNeutral Gear/Parking
OnOffOnOffOnGear 4
OnOffOffOnOnGear 3
OnOnOffOffOnGear 2
OffOnOffOnOffGear 1
DCC (Ref.)ODUDGear 2LR
Electromagnetic ValveGear Position
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#6-40 & 41
Throttle O
pen Extent
Throttle O
pen Extent
Throttle O
pen Extent
Throttle O
pen Extent
Vehicle Vehicle SpeedSpeed
Vehicle Vehicle SpeedSpeed
Downshift Downshift ControlControl
Output Shaft Output Shaft SpeedSpeed
Output Shaft Output Shaft SpeedSpeed
33--4 Shift 4 Shift Gear Gear RangeRange
33--4 Shift 4 Shift Gear Gear RangeRange
22--3 Shift 3 Shift Gear Gear RangeRange
22--3 Shift 3 Shift Gear Gear RangeRange
UpshiftUpshiftControlControl
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#6-41 & 42
Throttle Open ExtentThrottle Open Extent
Vehicle SpeedVehicle Speed
Parking Lamp SwitchParking Lamp Switch
Steering Wheel Steering Wheel DirectionDirection
PrePre--programmed programmed Manual Gearshift DataManual Gearshift Data
Road Conditions and Road Conditions and Driver InputDriver Input
Best Gear SelectionBest Gear Selection
Learning Control SystemLearning Control System
Decision Decision MakingMaking
Engine InputEngine Input
Wheel LoadWheel Load
Parking Lamp switchParking Lamp switch
Steering WheelSteering Wheel
Evaluation of DriverEvaluation of Driver’’s s Characteristics and Characteristics and HabitsHabits
Gearshift Best Gearshift Best Adapting to DriverAdapting to Driver
INVECSINVECS--II Best Overall ControlII Best Overall Control
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#6-44 & 45
Learning Control Learning Control SystemSystem
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#6-47
Learning Control System and Feedback ControlLearning Control System and Feedback Control
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Knowledge Test Knowledge Test -- 11Link the following sensors with the options that best described Link the following sensors with the options that best described its function.its function.
FFkkbbddjjee
cchhggaa
a. Ignition Switchb. Input Shaft Speed Sensorc. Output Shaft Speed Sensord. Crankshaft Position Sensore. Throttle Position Sensorf. A/T Oil Temperature Sensorg. Control Switchh. Parking Lamp Switchj. Dual Pressure Switchk. Turned-off Throttle Switch
To detect ATF temperature.To detect engine idling.To detect turbine speed.To detect engine speed.To detect the vehicle A/C turn-on/turn-off status.To detect the descendant angle of the accelerator
pedalTo detect the drive gear speed of transfer case.To detect the brake turn-on/turn-off status.To detect the gearshift lever position.To issue signal to A/T-ECU to provide working
voltage.
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Knowledge Test Knowledge Test -- 22
Which component supplies power to the Which component supplies power to the electromagnetic valve?electromagnetic valve?
a.a. A/TA/T--ECUECUb.b. Engine ECUEngine ECUc.c. A/T Control RelayA/T Control Relayd.d. None of AboveNone of Above
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Knowledge Test Knowledge Test -- 33
Which component controls the hydraulic pressure of Which component controls the hydraulic pressure of damper clutch control valve? damper clutch control valve?
a.a. A/TA/T--ECUECUb. Damper Clutch Control Electromagnetic Valveb. Damper Clutch Control Electromagnetic Valvec.c. Pressure Regulating ValvePressure Regulating Valved.d. None of AboveNone of Above
Key: bKey: b
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Knowledge Test Knowledge Test -- 44
LR, Gear 2, UD and OD electromagnetic LR, Gear 2, UD and OD electromagnetic valve are:valve are:
a.a. Normal Open TypeNormal Open Typeb.b. Normal Close TypeNormal Close Type
Key: aKey: a
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Knowledge Test Knowledge Test -- 55
DCC electromagnetic valve is:DCC electromagnetic valve is:
a.a. Normal Open TypeNormal Open Typeb.b. Normal Close TypeNormal Close Type
Key: aKey: a
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Knowledge Test Knowledge Test -- 66
Gear N indicator will display which of the Gear N indicator will display which of the following items?following items?
a.a. ATF Temperature AlarmATF Temperature Alarmb.b. Failure Protection OperationFailure Protection Operationc.c. Reading Diagnosis CodeReading Diagnosis Coded.d. All of AboveAll of Abovee.e. None of AboveNone of Above
Key: dKey: d
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Knowledge Test Knowledge Test 77
Technician Technician ““AA”” said that the INVECSsaid that the INVECS--II can make the gear II can make the gear selection adapt to the needs of the common drivers on various selection adapt to the needs of the common drivers on various road conditions.road conditions.Technician Technician ““BB”” said that the INVECSsaid that the INVECS--II can change the II can change the gearshift moment to meet with the habits and modified input gearshift moment to meet with the habits and modified input of the drivers. of the drivers. Which description of the technicians is right?Which description of the technicians is right?
a.a. Technician Technician ““AA””b.b. Technician Technician ““BB””c.c. BothBothd.d. None of AboveNone of Above
Key: cKey: c
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TCU/1/5 TCU/1/6 TCU/1/1
TCU/1/15
TCU/2/3
F/13
左A/A/6
TCU/2/9
C/2
左A/B/11
TCU/2/4
TCU/2/5
CE BOX/C/18
CE BOX/C/2
TCU/2/1
TCU/1/4
TCU/1/3
TCU/1/2
到仪表B1
到仪表B2
到仪表B4
到仪表B3
TCU/1/11 TCU/1/12 TCU/1/13 TCU/1/14
TCU/2/13
左A/C/16
TCU/2/6
到ECU80#
到
诊
断口7#
到ECU56#
到ECU7#
到ECU59#
到ECU84#
到ECU89#
到ECU24#
到ECU86#
TCU/2/14
左A/C/6
3# 诊断口
档位开关
转速输出转速输入
A/T继电器
电磁阀
油温传感器
到
仪
表B8
到
仪
表B7
到
仪
表B6
到
仪
表B5刹
车
信
号
倒档信号
To To To
Speed Input Speed OutputOil
Temperature Sensor
Electromagnetic Valve
Gear Switch
Reverse Gear Signal
To Instrument B1
To Instrument B2
To Instrument B3
To Instrument B4
To Instrument B
5
To Instrument B
6
To Instrument B
7
To Instrument B
8
Brake Signal
To Diagnosis Term
inal 7#
ToTo
ToToTo
Diagnosis Terminal
A/T Relay
Left A/C/16
Left A/C/6Left A/C/6
Left A/B/11
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Basic Checking of Automatic Transmission
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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.
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Checking of Oil Quality and Oil LevelStalling TestTime Lag TestOil Pressure Test
Learning Contents
Adjustment of Control Cable
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Checking of Oil Quality and Oil Level
• The checking of automatic transmission oil quality and oil level is the most basic checking item of automatic transmission and also is one of the important foundations that determines if the automatic transmission is needed for disassembling check. 1. Oil Level Checking
• (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 for several seconds so as to fill the hydraulic torque converter and all gearshift actuators with automatic transmission oil, and at last shift the gear selector lever to the parking gear “P”.
• (4) At pressure measure the oil level.
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(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.
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Stalling TestlThe 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.l 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 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.
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2. Standard Valve: At Gear D: 2,000-2,900 r/minAt Gear R: 2,000-2,900 r/min
3. Test Analysis:(1) When the engine speed is too high and the oil pressure is too low at Gear D/R, the L/R brake has skid.(2) When the engine speed is too high at Gear D, the UD clutch has skid.(3) When the engine speed is too 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.
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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 achieve the gearshift. This short period of time is referred as the time lag of the automatic transmission. The time lag 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: the excessive N-D time lag indicated the excessive low master oil line pressure, 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.
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• Checking Steps:• (1) The temperature of engine and transmission reach normal 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 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.
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Oil Pressure Test•Checking of Oil Pressure:Before test, drive the vehicle till the engine temperature and the automatic transmission temperature reach normal working temperature. Park the 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 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 of the low speed clutch should be at 1,010-1,050 kpa.2) The pressure of Low/Reverse gear clutch should be at 1,010-1,050 kpa.
2. Shift the gear to the gear 2 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 of gear 2 brake should be at 1,010-1,050 kpa.2) The pressure of low speed clutch should be at 1,010-1,050 kpa.
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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 pressure of overdrive clutch should be at 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 of overdrive clutch should be at 590-690 kpa.2) The pressure of secondary brake should be at 590-690 kpa.
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5. Shift the gear to the reverse 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 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 the shift to reverse gear and Gear D. At that moment, the oil pressure of Low/Reverse gear clutch should be at 310-390 kpa when the engine speed is increased to 2,500 r/min.
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Control Cable Adjustment
(1) Shift the test gear selector lever to gear “N”.(2) Loosen the nut between 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 NutTransmission Control Cable
Manual Control Lever
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(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
Manual Control Lever
Manual Control Lever
Control Switch
Hole inside Flange
Hole End of Section A-A
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(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.
Adjustment Bolt
Manual Control Lever
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