Aygo Mmt Ops

CH

CHASSIS – MULTI-MODE MANUAL TRANSMISSION SYSTEM

293CH19

Shift Stroke SensorShift & Select Actuator

Select Motor

Shift Motor

Lever to rotate shift& select lever shaft

Select MotorShaft Shift Motor

Shaft (Gear)

Shift Motor

Select StrokeSensor

Shift & SelectLever Shaft

Shift & Select Lever

Ring GearSelect Motor

Shift & SelectLever Shaft Shift & Select Lever

Shift Fork Shaft Lever

Shift & Select Lever

Shift Fork Shaft Lever

RShift4

2

Select

5

3

1

ShiftShift ForkShaft Lever

SelectShift ForkShaft Lever

A

View of shift and selectoperation as seen from “A”

CH-15

�CONSTRUCTION AND OPERATION

1. Shift & Select Actuator

General

� The shift & select actuator consists of a shift motor, select motor, shift stroke sensor, select stroke sensor,and shift & select mechanism (shift & select lever, shift & select lever shaft, shift motor shaft, select motorshaft, ring gear, and a lever to rotate the shift & select lever shaft). This actuator cannot be disassembled.

� The rotation of the shift motor is transmitted to the reduction gears and the shift & select lever shaft andcauses the shift & select lever to rotate.

� The rotation of the select motor is transmitted to the rack & pinion gear and the shift & select lever shaftand causes the shift & select lever to slide.

� The movement of the shift & select lever is transmitted to the shift fork shaft via the shift fork shaft lever.As a result, the gear position changes.


244CH10

244CH32

Shift Motor Shaft (Gear) Ring Gear Lever to rotate shift & select lever shaft

Shift MotorShift & Select Lever


Shift Motor Shift MotorShaft (Gear) Ring Gear

Shift & SelectLever


Lever to rotateshift & selectlever shaft

244CH11

244CH33

Select Motor Select Motor Shaft

Shift & Select LeverShift & SelectLever Shaft

Select Motor Select MotorShaft


Shift & SelectLever

CH-16

� Shift Operation �

� Select Operation �

CH


Service Tip

Make sure that the gear is in the neutral position before removing the shift & select actuator. If thegear cannot be shifted to the neutral position due to malfunctions in the actuator and/or transaxle gear,remove the plug from the shift & select actuator and confirm the slit is in the neutral position. If not,use a screwdriver to set it in the neutral position.

Neutral

1st, 3rd, 5th

2nd, 4th, Rev293CH06

CH-17


293CH20

244CH07

Hall ICs

Magnetic Yoke

Sensor Vane

55�

0�

–55�

Sensor Vane

4.5

2.5

0.5

–49.6 0

OutputVoltage

49.6Sensor Shaft Rotation Angle (�)

1st, 3rd, 5th 2nd, 4th, Rev.

5th, Rev. 1st, 2nd

For Shift

For Select

(V)

244CH09

Hall IC(Main)

Hall IC(Sub)

Magnet

VCS1, VCL1

VSS1, VSL1

E2S1, E2L1

VCS2, VCL2

VSS2, VSL2

E2S2, E2L2

M-MT ECU

Shift and Select Stroke Sensors

Sensor Vane

MagneticYoke

Magnet

CH-18

Shift and Select Stroke Sensors

� The shift and select stroke sensors consist of 2 Hall ICs and a magnetic yoke that rotates in unison withthe shift & select lever shaft movement. The shift and select stroke sensors convert the changes in themagnetic flux that are caused by the rotation of the shift motor and the selector motor (hence, the rotationof the magnetic yoke) into electric signals, and output them to the M-MT ECU. The M-MT ECUdetermines the extent of the shift stroke and the select stroke from these electric signals in order todetermine the present gear position.

� The main and sub circuits in the shift stroke sensor and the select stroke sensor exhibit the same outputcharacteristics.

� System Diagram �

CH


293CH12

Clutch Release Lever Clutch Stroke Sensor

Clutch Motor Clutch Actuator

Release Engage

Push RodFulcrum

Worm Wheel

Sensor Arm Worm ShaftAssist Spring

CH-19

2. Clutch Actuator

General

� The clutch actuator consists of clutch motor, clutch stroke sensor, worm shaft, worm wheel, push rod andassist spring. This actuator cannot be disassembled.

� The rotation of the clutch motor travels to the reduction gears of the worm shaft and the worm wheel,thus causing the worm wheel to rotate. This movement causes the push rod to move via a fulcrumprovided on the worm wheel, actuating the clutch release lever.

� The worm wheel is provided with an assist spring, which provides a force to assist the movement of thepush rod when the clutch is being operated. This reduces the load on the clutch motor at the time the clutchis being released.


293CH21

244CH07

Hall ICs

Magnetic YokeSensor Vane

–55�

0�

55�

Sensor Vane

4.5

2.5

0.5

–49.6 0 49.6

OutputVoltage

Clutch Engage

Sensor Shaft Rotation Angle (�)

Clutch Release

(V)

244CH09

Clutch Stroke Sensor

Sensor Vane

MagneticYoke

Magnet

Hall IC(Main)

Hall IC(Sub)

Magnet

VCR1

VSR1

E2R1

VCR2

VSR2

E2R2

M-MT ECU

CH-20

Clutch Stroke Sensor

� Same as the shift and select stroke sensors, the clutch stroke sensor consists primarily of 2 Hall ICs (mainand sub), and a magnetic yoke that rotates in unison with the rotation of the worm wheel.

� The 2 Hall ICs convert the changes in the magnetic flux that are caused by the rotation of the clutch motor(hence, the rotation of the magnetic yoke) into electric signals, and output them to the M-MT ECU. TheM-MT ECU determines the extent of the clutch stroke from these electric signals.

� The main and sub circuits in the clutch stroke sensor exhibit the same output characteristics.

� The basic construction and operation of the shift and select stroke sensors are the same as for the clutchstroke sensor.


CH


266NF38

266NF39

Diaphragm Spring

LCC Mechanism

DiaphragmSpring Height

Lower Pressure Plate

PressurePlateHeight

Upper Pressure Plate

Diaphragm Spring Pinion

Lower Pressure Plate

Adjust Wedge Lower Rack

CH-21

3. LCC (Load Controlled Clutch cover) Mechanism

General

� To minimize the increase in the clutch operating load that results from the change in the pressure plateheight with the wear of the clutch disc facing, the LCC (Load Controlled Clutch cover) mechanismmechanically adjusts the pressure plate height to a predetermined position.

� The LCC mechanism is provided in the clutch cover and consists of a pinion, which is located on theupper pressure plate, and a lower rack, upper rack, adjustment wedge, and spring, which are located onthe lower pressure plate.

� Upon determining an increase in the clutch operating load through the load (clutch motor amperage) thatis applied to the clutch motor, the M-MT ECU operates the clutch actuator in order to move thediaphragm spring to the operating range of the LCC mechanism. This enables the LCC mechanism tooperate and mechanically adjust the pressure plate height to a predetermined position.


266NF40

Compress Force Pinion

Upper Pressure Plate Upper Rack

Disengage

266NF41

Spring Force

Spring

266NF42

One Pitch

CH-22

Operation

If the M-MT ECU determines that the clutch operating load is more than normal based on the clutch motoramperage, it activates the clutch actuator to operate the LCC mechanism after the ignition switch is turnedOFF with the vehicle stopped. The M-MT ECU starts this operation prior to the parking control (see pageCH-35) that is performed when the ignition switch is turned OFF.

� The diaphragm spring is compressed to the LCC operation range by the clutch actuator, allowing theupper pressure plate and the pinion to move upward more than normal. As result, the pinion and the upperrack become disengaged.

� When the pinion and the upper rack aredisengaged, the spring force causes the upperrack to move diagonally to the right along theteeth of the lower rack. As a result, the toothposition of the upper rack and the pinion shiftsby 1 pitch, as compared to before theoperation of the LCC mechanism.

� The M-MT ECU stops the clutch actuatorbased on signals from the clutch stroke sensor.Then the tooth position between the pinionand the upper rack is shifted 1 pitch, ascompared to before the operation of the LCCmechanism. As a result, the pinion and theupper pressure plate move together to the leftand engage with lower rack.

CH


266NF43

Diaphragm Spring Height

Adjustment WedgeUpper Pressure Plate Height

Diaphragm Spring Height: Height Before � Height AfterUpper Pressure Plate Height: Height Before � Height After

CH-23

� At this time, the upper pressure plate also moves via the adjustment wedge, causing the position of theupper pressure plate to become higher than before. Additionally, the diaphragm spring moves via thefulcrum, causing the position of the diaphragm spring to become lower than before.


293CH11

Shift Lever Subassembly

Shift Lever Position Sensor

Transmission Shift Main Switch

Shift Lock Solenoid

CH-24

4. Shift Lever Assembly

General

� The shift lever mainly consists of the shift position sensor, transmission shift main switch, shift locksolenoid and shift lever sub-assembly.

� The multi-mode manual transmission system uses a shift-by-wire system in which the M-MT ECUchanges the gear position via actuators in accordance with the shift lever position that has been detectedthrough the shift lever position sensor and the transmission shift main switch.

� An electrical shift lock mechanism that uses a shift lock solenoid to restrict the movement of the shiftlever has been adopted.

CH


244CH15

+ � –

Link 2

Link 1

R � N � E, M

Shift Lever Position Sensor

CH-25

Shift Position Sensor and Transmission Shift Main Switch

� The shift lever position sensor consists of a Link 1 circuit that detects the R, N, E, and M positions ofthe shift lever, and a Link 2 circuit that detects the “+” and “–” positions. The circuits are connected tothe shift lever via the respective links. The contact switches (6-contact switches for Link 1, and 2-contactswitches for Link 2) of the circuits turn ON and OFF in accordance with the fore-aft movement of theshift lever. The M-MT ECU determines the present shift lever position in accordance with the ON/OFFstatus of these contact switches.

� The transmission shift main switch detects the side-to-side movement of the shift lever. It turns OFFwhen the shift lever is in the R, N, or E position, and ON in the M, +, or – position.


293CH07

Contact Point

Link 2 Link 1

Contact Point for LSWR, LSSC, LSNC and LSW–

Contact Point for LSRC, LSWS, LSWN and LSW+

Contact Point Plate

Contact Point Plate

CH-26

� The shift lever position sensor and the transmission shift main switch convert the shift lever position intoelectric signals and output them to the M-MT ECU. The M-MT ECU determines the present shift leverposition from these signals and operates the actuators to change the gear position.

� Shift Lever Position Sensor Cross Section �

Contact PointShift Lever Position

Contact PointR N E M – +

LSRC OFF ON ON ON ON ON

LSWR ON OFF OFF OFF OFF OFF

Link 1LSSC ON ON OFF OFF OFF OFF

Link 1LSWS OFF OFF ON ON ON ON

LSNC ON OFF ON ON ON ON

LSWN OFF ON OFF OFF OFF OFF

Link 2LSW– OFF OFF OFF OFF ON OFF

Link 2LSW+ OFF OFF OFF OFF OFF ON

Transmission ShiftMain Switch

OFF OFF OFF ON ON ON

CH


244CH30

Stop Light Switch

Ignition Switch

Combination Meter� Vehicle Speed Signal

M-MT ECU

� Shift Lock Solenoid� Shift Lever Position Sensor� Transmission Shift Main Switch

CH-27

Shift Lock Mechanism

� The shift lock mechanism activates under the conditions listed below.

– Activates when the ignition switch is turned from ON to OFF, and locks the shift lever in the position(R, N, E and M) in which the ignition switch has been turned OFF. Thus, it disables the operation ofthe shift lever with the ignition switch OFF (when the shift & select actuator is inactive). As a result,it prevents the shift position selected at the shift lever and the actual shift position in the transaxle frombeing mismatched, thus preventing the unintended operation of the shift lever.

– When the brake pedal is not depressed for a minimum of 2 seconds while the following threeconditions are satisfied, the shift lock mechanism activates to lock the shift lever in the neutralposition:

� Shift lever is in the neutral position

� The vehicle speed is approximately 9 km/h (6 mph) or less

� Engine is running

Thus, it prevents the unintended operation of the shift lever, which prevents the vehicle from movingsuddenly.

� The shift lock mechanism becomes deactivated when the ignition switch is turned OFF to ON and thebrake pedal is depressed, thus allowing the driver to operate the shift lever.

� A shift lock release button that can manually cancel the shift lock mechanism has been provided.


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Aygo Mmt Ops