As-T-T026 4FA4 Automatic Transmission Chery Tigo

Welcome to the Chery Automobile

Automatic Transmission F4A4

PDF created with pdfFactory Pro trial version www.pdffactory.com

http://www.pdffactory.com


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.




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.




Overview of transmission drive axleComponent identification and functionPower mechanical transmission circuit diagramHydraulic power system operationElectrical program control system




概述概述




♦♦ 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




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




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




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.




Output shaft sensor

Electromagnetic valve switch connector

Input shaft sensor

Gear switch




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




Low speed clutch clip (MD759666) (Shown as #11 in the figure)

15 types of dimension at choice.

0.1mm difference for each level,

Min dimension at 1.6 mm as max dimension at 3.0 mm




Overview of Transmission Drive AxleComponent Identification and EffectsPower Mechanical Transmission Circuit DiagramHydraulic Power System OperationElectrical Program Control System




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




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




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




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




Low Speed ClutchLow Speed Clutch





Output PinionOutput Pinion






Overdrive Overdrive Planetary Planetary GearGear

Reverse Sun GearReverse Sun Gear


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.




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




Reverse Gear Clutch/Overdrive ClutchReverse Gear Clutch/Overdrive Clutch

Overdrive ClutchOverdrive Clutch





Simulation DiagramSimulation DiagramOverdrive ClutchOverdrive Clutch

Gear 2 BrakeGear 2 Brake











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.




Overdrive Overdrive ClutchClutch

Output Planet Output Planet CarrierCarrier

Reverse Gear Reverse Gear Sun GearSun Gear


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

Simulation DiagramSimulation DiagramGear 2 BrakeGear 2 Brake






Overdrive PinionOverdrive Pinion


Low/Reverse Gear BrakeLow/Reverse Gear Brake




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




Gear 2 BrakeGear 2 Brake




Simulation Diagram

Overdrive ClutchOverdrive Clutch Gear 2 BrakeGear 2 Brake

Output Planetary GearOutput Planetary Gear










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.




Low/Reverse Low/Reverse Gear BrakeGear Brake




Simulation Diagram








Overdrive Overdrive PinionPinion




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.




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





OneOne--way Clutchway Clutch






Overdrive Overdrive Planetary GearPlanetary Gear





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.





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


Low/Reverse Gear Brake Piston

Central Support




安全方向


Safety Direction




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




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




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




Unit Identification Test

AA BB CC DD EEFF

GG

HH

IIJJKK

LL

MM

NN




Overdrive Clutch

Gear 2 BrakeGear 2 BrakeOutput PinionOutput Pinion

Low Speed Low Speed ClutchClutch

Input Shaft


Low Speed Sun Low Speed Sun GearGear

Ring Gear for Ring Gear for Low/Reverse Low/Reverse GearGear

Output Ring Output Ring GearGear




Low/Reverse Gear Low/Reverse Gear BrakeBrake


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





Component

Gearshift Lever

Position

Gear Ratio

Engine Start

Parking Mechanism







P Parking - OK X - - - X - - R Reverse

Gear 2.480 - - - X - X - -

N Neutral Gear

- OK - - - - X - -


D


3






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








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




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





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.




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





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





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


Front Ring Gear

Rear Sun Gear Rear Ring Gear

l/R


Torque Converter

Output Ring Gear

Output Planet Carrier

Output Shaft




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


Front Ring Gear

Rear Sun Gear Rear Ring Gear

L/R


Torque Converter

Input Shaft

Output Ring Gear




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




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




Working Status of Various Gear Units.


Component

Gearshift Lever

Position

Gear Ratio

Engine Start

Parking Mechanism







P Parking - Enabled X - - - X - - R Reverse

Gear 2.480 - - - X - X - -

N Neutral Gear

- Enabled - - - - X - -


D


3










•• 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.




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




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




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.




Sub Inner Valve Body and Outer Valve Body




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




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


2档Electromagnetic 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




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




Manual Control Valve

Manual Control Manual Control Gearshift LeverGearshift Lever




• 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.




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




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


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.




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



Pressure Pressure Regulating ValveRegulating Valve

DDAA

BB

CC

From Gear 2 BrakeFrom Gear 2 Brake

4455 333366




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




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


Electromagnetic Electromagnetic Valve turns onValve turns on


From From Hydraulic Hydraulic Torque Torque Converter Converter Pressure Pressure Control ValveControl Valve


212177

EngagementEngagement




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




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


AA

BB


To LR Brake through To LR Brake through Failure Protection Valve AFailure Protection Valve A




Conversion Valve Conversion Valve –– Gear 3 and Gear 4Gear 3 and Gear 4


To Pressure To Pressure Regulating ValveRegulating Valve






Reverse Gear

Clutch

LR Brake

Gear 2Brake

UD Clutch

OD Clutch

Failure Protecti

on A

Conversion

Valve

LRValve


Gear 2Valve

Gear 2Electromagnetic Valve

UDValve


ODValve

OD Electromagnetic Valve

Manual Valve

Failure Protecti

onB

Failure Protection ValveFailure Protection Valve




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




Accumulator (Pressure Reservoir)Accumulator (Pressure Reservoir)

Accumulator Accumulator SpringSpring

Accumulator PistonAccumulator PistonSeal RingSeal Ring

Accumulator Accumulator SpringSpring




No. Name

1 For Low/Reverse Gear Brake

2 For Low Speed Clutch

3 For Gear 2 Brake

4 For Overdrive Clutch




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




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




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




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




Steel Ball ValveSteel Ball Valve

Check ValveCheck Valve




Master Oil FilterMaster Oil Filter

Master Oil FilterMaster Oil Filter




Clutch Clutch drumdrum

PistonPiston

Balancing Oil Balancing Oil CavityCavity

Pressure Pressure ChamberChamber

Return Spring HubReturn Spring Hub

Balancing Oil CavityBalancing Oil Cavity




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





Parking and Neutral GearParking and Neutral Gear

Input Input ShaftShaft



Low/Reverse Gear Low/Reverse Gear BrakeBrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear

ClutchClutchOverdrive Overdrive ClutchClutch

Overdrive Overdrive Planet CarrierPlanet Carrier



Ring Gear for Ring Gear for Low/Reverse GearLow/Reverse Gear







Gear 1Gear 1

Damper clutch


Accumulator



Pipeline pressure Failure protecti

on valve A


Conversion valve









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


Oil pump Oil filter

Oil pan

Safety valve

Off Off






Gear 1Gear 1

Input Input ShaftShaft



Low/Reverse Gear Low/Reverse Gear BrakeBrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear

ClutchClutchOverdrive Overdrive ClutchClutch











Gear 2Gear 2

OD electromagn

etic valve

Damper clutch


Accumulator




on valve A


Conversion valve









DCC electromagn

etic valve LR


LR electromagn

etic valve

Gear 2 electromagn

etic valve

UD electromagn

etic valve

Off Running Running

Regulating valve


Oil pump Oil filter

Oil pan

Safety valve






Gear 2Gear 2



Output PinionOutput PinionLow/Reverse Gear Low/Reverse Gear BrakeBrake

Gear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive Overdrive

ClutchClutch











Gear 3Gear 3Damper clutch


Accumulator




on valve A


Conversion valve









DCC electromagn

etic valve LR


LR electromagn

etic valve

Gear 2 electromagn

etic valve

UD electromagn

etic valve

OD electromagn

etic valve

Off Running Running

Regulating valve


Oil pump Oil filter

Oil pan

Safety valve


Running Off





Gear 3Gear 3




Low/Reverse Gear BrakeLow/Reverse Gear BrakeGear 2 BrakeGear 2 BrakeReverse Gear Reverse Gear ClutchClutchOverdrive ClutchOverdrive Clutch





Overdrive PinionOverdrive Pinion





Damper clutch


Accumulator




on valve A


Conversion valve









DCC electromagn

etic valve LR


LR electromagn

etic valve

Gear 2 electromagn

etic valve

UD electromagn

etic valve

OD electromagn

etic valve

Off Running Running

Regulating valve


Oil pump Oil filter

Oil pan

Safety valve


Running Off

Gear 4Gear 4





Gear 4Gear 4


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











Reverse GearReverse Gear

LR electromagn

etic valve

Damper clutch


Accumulator

Gear 2 brake UD clutch OD clutch One-way ball valve

Accumulator Accumulator Accumulator


on valve A


Conversion valve









DCC electromagn

etic valve LR


Gear 2 electromagn

etic valve

UD electromagn

etic valve

OD electromagn

etic valve

Running

Regulating valve


Oil pump Oil filter

Oil pan

Safety valve


Running Off Running Running





Reverse GearReverse Gear


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











Failure Protection Mode (All Electromagnetic Valves Turn Off)Failure Protection Mode (All Electromagnetic Valves Turn Off)

Damper clutch


Accumulator




on valve A



Conversion valve









DCC electromagne

tic valve LR


LR electromagne

tic valve

Gear 2 electromagn

etic valve

UD electromagn

etic valve

OD electromagn

etic valve

Regulating valve


Oil pump Oil filter

Oil pan

Safety valve


Off Off Off Off Off




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


Accumulator




on valve A


Conversion valve




lD pressure control valve




DCC electroma

gnetic valve

LR electromagne

tic valve

LR electromagnetic valve



Regulating valve


Oil pump Oil filter

Oil pan Safety valve


Off Off Running Running Running

Gear 2 electromagnetic valve






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




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




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.




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)




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




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.




ATFATF




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.




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.




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




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





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)





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

Key: cPDF created with pdfFactory Pro trial version www.pdffactory.com




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

Key: cPDF created with pdfFactory Pro trial version www.pdffactory.com







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)




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




Ignition SwitchIgnition Switch

A/TA/T--ECUECU

Ignition SwitchIgnition Switch

Power SupplyPower Supply




Output Shaft Sensor

Electromagnetic Valve Switch Connector

Input Shaft Sensor

Gear Switch

InputInput\\Output Shaft SensorOutput Shaft Sensor




Input Shaft/Output Shaft Speed SensorInput Shaft/Output Shaft Speed Sensor

ConnectorConnector

Hall UnitHall Unit




#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




Crankshaft Position SensorCrankshaft Position Sensor

Crankshaft Crankshaft Position SensorPosition Sensor




Crankshaft Position SensorCrankshaft Position Sensor-- System CircuitSystem Circuit

Crankshaft Position Sensor

Grounding J/C




Throttle Position SensorThrottle Position Sensor





Throttle Position Sensor Throttle Position Sensor -- System CircuitSystem Circuit

Grounding J/C

Engine-ECU

Engine Control System


Throttle Position SensorIdling Position Switch




#6-12

A/T Temperature SensorA/T Temperature Sensor

A/T Temperature A/T Temperature SensorSensor




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)




A/T Temperature SensorA/T Temperature Sensor-- System CircuitSystem Circuit

A/TA/T--ECUECU

A/T Oil Temperature Sensor




Control SwitchControl Switch

Control SwitchControl Switch




Control Switch Control Switch -- FunctionFunction

Motion Mode A/TMotion Mode A/T




Control Switch Control Switch -- System CircuitSystem Circuit

A/TA/T--ECUECU

General Fuse

Manual Gearshift Proof Switch




Control Switch Checking

Gear Position

Terminal Number




Dual Pressure SwitchDual Pressure Switch

Dual Pressure SwitchDual Pressure Switch




#6-23

Dual Pressure Switch Dual Pressure Switch -- System CircuitSystem Circuit

A/TA/T--ECUECU

Dual Pressure Switch




#6-24

Idling Position SwitchIdling Position Switch





Idling Position SwitchIdling Position Switch ––System CircuitSystem Circuit

Grounding J/C

Engine -ECU



Throttle Position SensorIdling

Position Switch




#6-26

Parking Lamp SwitchParking Lamp Switch


Brake PedalBrake Pedal




#6-27

Parking Lamp Switch Parking Lamp Switch -- System CircuitSystem Circuit

A/TA/T--ECUECU

Parking Lamp Switch

Fuse




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




Gear Selector Switch Gear Selector Switch and Gearshift Switchand Gearshift Switch

Gearshift Gearshift SwitchSwitch

Gear Selector Gear Selector SwitchSwitch




#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




#6-32

Actuator Actuator -- A/T Control RelayA/T Control Relay

A/T Control Relay




#6-33

A/T Control Relay A/T Control Relay –– System CircuitSystem Circuit

A/TA/T--ECUECU

Battery

Special Fuse

Control Relay




#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


Low/Reverse Low/Reverse GearElectromagnetGearElectromagnetic Valveic Valve




#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




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


Low/Reverse Low/Reverse GearElectromagnetic GearElectromagnetic ValveValve

#6-36




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




#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




#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




UpshiftUpshiftControlControl




#6-41 & 42

Throttle Open ExtentThrottle Open Extent

Vehicle SpeedVehicle Speed


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




#6-44 & 45

Learning Control Learning Control SystemSystem




#6-47

Learning Control System and Feedback ControlLearning Control System and Feedback Control




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.





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

Key: cKey: cPDF created with pdfFactory Pro trial version www.pdffactory.com




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





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





DCC electromagnetic valve is:DCC electromagnetic valve is:

a.a. Normal Open TypeNormal Open Typeb.b. Normal Close TypeNormal Close Type

Key: aKey: a





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




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




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




Basic Checking of Automatic Transmission




Learning Objective

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




Checking of Oil Quality and Oil LevelStalling TestTime Lag TestOil Pressure Test

Learning Contents

Adjustment of Control Cable




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.




(5) The dipstick of B11 automatic transmission has HOT marking and the ATF temperature of automatic transmission is at 70－80 。

2. Checking of automatic transmission oil quality: Drop the transmission oil of the dipstick onto the clean white paper and check the oil color and scent.




Stalling 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.




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.




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.




• 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.




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.





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.


1) The pressure of overdrive clutch should be at 590－690 kpa.2) The pressure of secondary brake should be at 590－690 kpa.




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.




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




(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



Control Switch

Hole inside Flange

Hole End of Section A-A




(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





Documents

As-T-T026 4FA4 Automatic Transmission Chery Tigo