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Textbook Module1 AT (Automatic Transmission) Module1 AT (Automatic Transmission) LESSON 1.1 Overview .3 O nl y 1.1.1 Introduction 1.1.2 Model Range 1.1.3 Specification 1.2 Layout 1.3 se 1.2.1 Main Feature 1.2.2 Input & Output Elements Components 1.3.1 Mechanical Components Drive Train 23 na 1.4 lU 1.3.2 Hydraulic Control Components 13 1.3.3 TCU Input Components 16 1.3.4 TCU Output Components 19 1.5 tio 1.4.1 Clutch & Brake Operation 23 1.4.2 Power Flow 24 Maintenance .29 Ed uc a 1.5.1 Oil Level Adjustment 29 1.5.2 TCM Learning 31 1.5.3 Inhibitor Switch Cable Adjustment 33 [Learning Objectives] Fo r ▪ Explain the system mechanism by observing a transmission layout ▪ List the locations, mechanisms and functions of components ▪ Explain the power flow in each gear shift by observing the solenoid valve operation chart ▪ Take necessary actions after a part change and list the cautionary measures required for maintenance Basic Chassis Technology Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1.1 Overview 1.1.1 Introduction The functions of a transmission are as follows ▪ Increased driving force when starting off or driving uphill ▪ Reduced engine rotation speed for increased rotary power ▪ Reversing a vehicle, as an engine cannot reverse-rotate lU ▪ High-speed rotation of wheels during high-speed driving se ▪ No load on the engine at startup O nl y A transmission is a device that changes and transfers engine power (rotary power and speed) to the wheels according to a vehicle's driving state Transmissions come in a manual type and an automatic type A transmission is installed between the clutch and propeller shaft or between the clutch and final gear Fo r Ed uc a tio na An automatic transmission performs automatic clutch and transmission control, which is manually performed with a manual transmission A torque converter, which functions as a clutch, a wet multi-plate clutch, which controls planetary gears, and a brake band make up an automatic transmission Because the engine and power transfer device are connected via a medium in fluid, vibration and shock are absorbed, and gear shift appropriate for engine output can take place at all times Compared to the manual transmission, the automatic transmission consumes approximately 10% more fuel, but many drivers prefer the automatic transmission for its convenience and ride comfort Basic Chassis Technology Module1 AT (Automatic Transmission) Model Range lU se O nl y 1.1.2 Textbook na In order to cope with the specific needs for different vehicles and markets Hyundai uses several different automatic transmissions in the product range, such as: tio ▪ Model: A163 ▪ Model: A4AF3 uc a The A163 model is a 3-speed electronic controlled front wheel driven automatic transaxle produced by AISIN, Japan and there are two divisions as follows A163-A is for 0.8ε Engine (DOM only) A163-B is for 1.0ε Engine, Application: MX (Atos, Visto, Atos Prime) Ed It is the latest development among the alpha automatic transaxles (advanced alpha A/T) It is a 4-speed electronic controlled front wheel driven transaxle produced by HMC Application: X -3, LC (Accent), TB (Getz), LD,C-car The vehicles equipped an alpha engine) ▪ Model: F4A series and F5A series Fo r The F4A51 model is a HIVEC 4-speed electronic controlled front wheel driven automatic transaxle produced by HMC and installed on the vehicle that has the engine volume of 2.0L or more The F5A51 model is a 5-speed electronic controlled front wheel driven automatic transaxle produced by HMC and is based on the speed version Depending on the actual vehicle there are several versions available, such as the A5HF1 for the NF Sonata Also for the speed transmissions several versions are available W4A51 is a kind of F4A51 HIVEC 4-speed A/T with a 4-wheel drive mechanism Application: santa Fe ▪ Model: AW30-40LE The AW30-40LE model is a 4-speed electronic controlled rear wheel driven automatic transmission produced by AISIN, Japan Application: HP (Terracan) Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) ▪ Model: FRA It is a 4-speed electronic controlled front wheel driven automatic transaxle produced by JATCO, Japan Application: MX (Atos, Visto, Atos Prime) ▪ Model: KM175 It is a Kyoto Model 4-speed electronic controlled front wheel driven automatic transaxle produced by HMC and there are two divisions as follows KM175-5 is for 2.0SOHC KM175-6 is for 2.0DOHC Engine Application: Y-3(Sonata), Santamo ▪ Model: F21-450 O nl y It is a 6-speed electronic controlled front wheel driven automatic transaxle produced by AISIN, Japan The TCM is placed on top of the transaxle housing and all sensors are positioned inside the AT assembly Application: EN (Veracruz) ▪ Model: A5SR1/2 se It is a 5-speed electronic controlled rear wheel driven automatic transmission by JATOCO, Japan, produced in Korea by Hyundai Power-Tech Application: H-1 (TQ) CRDi 2.5L, BK (Genesis Coupe) 2.0L ▪ Model: A4CF1/2 lU It is a 4-speed/5-speed electronic controlled front wheel driven automatic transaxle developed by HMC Application: HD (Elantra) 1.6L/2.0L, FD (i30) 1.6L/2.0L na ▪ Model: B400/B600 ▪ Model: 6HP26 tio It is a 6-speed electronic controlled front wheel driven automatic transaxle by AISIN, Japan Application: BH (Genesis) 3.3L/3.8L uc a It is a 6-speed electronic controlled rear wheel driven automatic transmission by ZF, Germany The TCM and input sensors are integrated on the valve body Application: BH (Genesis) 4.6L, BK (Genesis Coupe) 3.8L ▪ Model: A6LFx, A6MFx Ed It is a 6-speed electronic controlled front wheel driven automatic transmission developed by Hyundai Motor Company The speed sensors are integrated on the valve body Application: LM (Tucson, ix35), YF (Sonata) ▪ Model: 6HP19 Fo r It is a 6-speed electronic controlled rear wheel driven automatic transmission by ZF The TCM and input sensors are integrated on the valve body Application: BK (Genesis coupe) 3.8L Basic Chassis Technology Module1 AT (Automatic Transmission) 1.1.3 Textbook Specification A6GF1 A6MF1 Applicable Engines ν-1.8MPI, γ-1.6 MPI Lambda- 3.3, 3/8 Allowed Max Torque (kg.m) 18kgf-m 33.5/45kgf-m Length (mm) 373 387 73 94 1st 4.4 4.651 2nd 2.726 2.833 3rd 1.834 4th 1.392 5th 6th 0.774 O nl y Categories R 3.44 3.39 Clutch Set (OD, 35R) Brake Set (UD, LR, 26) OWC Set 0.722 Set (OD, 35R) Set (UD, LR, 26) Set Fo r Ed uc a tio na Component 1.387 se Gear Ratio 1.842 lU Weight (kg) Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) Layout 1.2.1 Main Feature uc a tio na lU se O nl y 1.2 Ed An automatic transmission is made up of a torque converter, which transfers engine power, a gear device, which converts power transferred from the torque converter, a hydraulic system, which changes the shift ratio by changing the gear device configuration, and an electronic control system, which controls the overall function of an automatic transmission Fo r An automatic transmission receives signals from various sensors and switches and controls the solenoid valve, clutch and brakes for converting power received from the torque converter into planetary gear output appropriate for different gear shifts Basic Chassis Technology Module1 AT (Automatic Transmission) Input & Output Elements na lU se O nl y 1.2.2 Textbook uc a tio TCU processes signals received from sensors for optimal gear shifts, smoother shifts and improved fuel efficiency The input section receives various sensor signals, the control section determines the optimal gear selection based on sensor signals and controls the hydraulic pressure and the damper clutch, and the output section executes controls based on TCM commands TCM functions as follows ▪ Determines the optimal gear selection using sensor data ▪ Executes gear shift if the current gear is not the optimal gear (prevent gear shift shock) Ed ▪ Determines the damper clutch activation – activates and deactivates accordingly ▪ Regulates the line pressure based on current torque level Fo r ▪ Performs automatic transaxle diagnosis Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1.3 Components 1.3.1 Mechanical Components 1) Torque Convertor O nl y Functions and Roles na lU se A torque converter transfers engine power to a transmission and is made up of an impeller, turbine and stator Its functions are as follows tio • Power transfer: Transfers engine power to the transmission • Torque increase: Torque is increased by a stator to exceed engine-shaft torque • Oil pump: Rotates the oil pump driver gear to pump oil uc a • Improved fuel efficiency: Engine RPM (power) is transferred to a transmission by a damper clutch Mechanism • Torque multiplication Fo r Ed Due to the application of the stator the engine torque can be multiplied The torque multiplication is possible because the stator redirects the backflow stream so that it reaches the impeller vanes having the same direction that the impeller has and works as follows: during starting off the impeller turns with engine speed and the turbine is on halt The fluid driven by the impeller reaches the turbine and transfers the energy (engine torque) to it Basic Chassis Technology Module1 AT (Automatic Transmission) Textbook • Fluid clutch operation When leaving the turbine again the fluid flow is redirected by the stator, so that the fluid stream becomes the same direction then the impeller (engine) is turning This creates a force which tries to turn the stator against the impeller (engine) turn direction Due to the one way clutch this movement is restricted Therefore the oil flow is redirected into the engine turn direction This sharp change in direction causes a backblock of the fluid The force created by this acts as additional force on the turbine (within turning direction), so that its output torque is increased Another positive effect is that the fluid which is returned to the impeller reaches it in turning direction and nearly free of vortices O nl y 2) Damper Clutch Functions and Roles tio na lU se Due to the fact that a fluid coupling needs a minimum speed difference between the impeller and the turbine (slippage) resulting in higher fuel consumption, modern torque converters incorporate additionally a so called lock up clutch or damper clutch The lock up clutch avoids any slippage in the torque converter during cruising by locking the turbine against the impeller (front cover), so that they turn together Fo r Ed uc a Mechanism Figure 1-1 Damper Clutch Applied (left) / Damper Clutch Released (right) 10 Basic Chassis Technology Module1 AT (Automatic Transmission) Textbook Mechanism Solenoid Valve Control • Normal high type VFS solenoid valves lU se O nl y The solenoid valve induces magnetic force created according to TCM control signals to move the plunger maintained inside the product by springs and hydraulic pressure, opening ports and creating control pressure The amperage is cancelled when the solenoid valve is not controlled As a result, the spool is moved to the left via spring force, as shown in the below figure, and the oil pressure is transferred from supply to control When the solenoid valve is controlled, the amperage is applied The plunger is moved to the right via magnetic force together with the spool The valve closes the supply side, forces the pressure out through the exhaust, and reduces the line pressure tio na UD, OD, 35R and line pressure control solenoid valve are normal high type As the solenoid valve is energized, the corresponding clutch or brake will be disengaged In the current data of scanner, it shows 50mA when it turns off and 850mA when it turns on respectively However, due to the different capacity, note that the line pressure solenoid valve differs from others even those are same normal high type, therefore the line pressure solenoid is not interchangeable with others • Normal low type VFS solenoid valves uc a Torque converter clutch and 26 brake solenoid valve are normal low type As the solenoid valve is energized, the corresponding clutch or brake will be engaged In the current data of scanner, it shows 50mA when it turns off and 850mA when it turns on respectively • Normal low type On-Off solenoid valves Fo r Ed Shift solenoid A and B are normal low type Shift solenoid A operates to control LB brake pressure together with OD VFS solenoid, and shift solenoid B operates to control 35R clutch together with 35R VFS solenoid It shows just on or off in the scanner depending on the current status 20 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) Solenoid Valve Operation Table 1–2 Solenoid Valve Operation Table P/N R UD/B D/S ○ ○ ○ ○ ○ OD/C ○ 26/B ○ LR/B ○ ○ 1ST OWC OFF ON OFF OFF SS-A ON OFF OFF T/CON 0 LP 0 35R/C 852 852 26/B 0 OD/C 852 UD/B 852 ○ ○ ○ ○ ON OFF ON OFF OFF OFF OFF OFF OFF 0 0 852 0 0 852 852 852 se SS-B 852 0 852 852 852 852 0 0 0 852 852 na Solenoid Valve Operation ○ O nl y ○ 35R/C lU Element tio Owing to the fact that the name of clutch and brake was made from the gear position that the corresponding clutch and brake are engaged, e.g., 26 brake, 35R clutch, we can easily assume that ‘in which gear those elements are engaged uc a That is, 26 brake functions at 2nd and 6th speed gear and 35R clutch functions at 3rd, 5th and Reverse gear Only LR brake is engaged at Parking and Neutral range that the power is not transferred to the output gear Therefore, the hydraulic pressure is lower than driving ranges Also the operating elements at 1st gear differs depending on the range (D or Sports mode) as follows Ed D-1st: Upon the output shaft speed is over 100rpm (vehicle speed is 8kph), LR brake is disengaged and OWC will function Oppositely if the speed is lower than 6kph, LR brake is engaged again Fo r The under drive brake is engaged as long the gear ratio is lower than by and that is the reason why it is named as ‘Under’ drive in forward range Over drive clutch is engaged from the 4th speed to 6th speed, high speed gear range Basic Chassis Technology 21 Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) 22 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1.4 Drive Train 1.4.1 Clutch & Brake Operation Table 1–3 Clutch & Brake Operation Table Brake ▲ NC ▲ R ● ▲ 1ST ● ● D 1ST ●→X ● 2ND ● 3RD ● 4TH ● OWC ● ● ● ● ● ● ● tio ▪ ●: Hydraulic pressure is applied 35R ● na 5TH 6TH O/D ● S D/S 26 O nl y P/N UD se LR Clutch lU Range Fo r Ed uc a ▪ ▲: Hydraulic pressure is applied but no power is transmitted Basic Chassis Technology 23 Module1 AT (Automatic Transmission) 1.4.2 Textbook Power Flow lU se O nl y 1) Gear, Clutch and Brakes Ed uc a tio na 2) 1st Gear Fo r Power transmission path Turbine → Input shaft → Rear sun gear → annulus gear → 24 → Rear annulus gear → Front → Out (T/F DRV GEAR) Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) se O nl y 3) 2nd Gear Power transmission path Turbine → Input shaft → Rear sun gear → Rear annulus gear → Front annulus gear → lU → Out → Middle annulus gear → Out na Rear planet carrier → Middle planet carrier → Fo r Ed uc a tio 4) 3rd Gear Power transmission path Turbine → Input shaft → Rear sun gear → Rear annulus gear → Front annulus gear → → Out Input shaft → → Middle sun gear → Middle planet carrier → Middle annulus gear → Front planet carrier → Out Basic Chassis Technology 25 Module1 AT (Automatic Transmission) Textbook se O nl y 5) 4th Gear Power transmission path Turbine → Input shaft → lU → Rear annulus gear → Front annulus gear → → Out Fo r Ed uc a tio na 6) 5th Gear Power transmission path Turbine → Input shaft → → Rear planet carrier → Middle planet carrier → → Middle annulus gear → Front planet carrier → Out 26 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) se O nl y 7) 6th Gear Power transmission path → Rear planet carrier → Middle planet carrier → lU Turbine → Input shaft → → Middle annulus gear → Front planet carrier → Out Fo r Ed uc a tio na 8) 5th Gear Power transmission path Turbine → Input shaft → Rear sun gear → → Middle planet carrier → → Middle annulus gear (reverse) → Out Basic Chassis Technology 27 Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) 28 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1.5 Maintenance 1.5.1 Oil Level Adjustment 1) ATF (Automatic Transmission Fluid) Overview O nl y Transmits power within the torque converter and functions as the hydraulic fluid of hydraulic devices (valves, clutch, brakes) Also lubricates and cools rotating parts An ATF shortage causes an influx, which creates abnormal pressure within the oil pressure circuit, resulting in delayed gear shifts, clutch/brake disk abrasion or ATF deterioration Conversely, an ATF excess causes gear rotation to cause bubbles, which ultimately causes the same issue as an ATF shortage se 2) ATF Inspection ▪ Color lU ATF contains red dye for distinction from other transmission oils and engine oil Having a transparent red color at first, ATF gradually turns maroonish as mileage increases and eventually becomes a light brown color na ▪ Type & Volume ▪ Replacement Timing tio ATF SP-Ⅳ(A6LF1/2/3: Approx 7.8 liters, A6MF1/2: Approx 7.1 liters) Fo r Ed 3) Procedure uc a Change ATF if it turns dark brown or black, smells burnt or if ground metal is present on the oil level gauge when checking the oil level Change ATF after traveling more than 100,000km Open the ATF filler cap and add 700cc Start the engine (after starting the engine and while raising the ATF temperature, not operate in stall state) With the engine idling, use a scanner to check that the automatic transmission’s oil temperature sensor reads 55℃ in the P position With the engine running, step on the brakes and shift the lever through P → R → N → D → N → R P twice and then put the gear into P (stay more than seconds at each position) Raise the vehicle with a lift and remove the oil level plug located at the bottom of the AT valve body cover Basic Chassis Technology 29 Module1 AT (Automatic Transmission) Textbook If a small amount of oil leaks out, the oil level is normal If the leaked oil is more than 900cc (50 60℃) for minutes, this means that the oil level is too high Check for the aforementioned small leak and then replace the oil level plug (check torque rating) If there is no oil leak, it means that the oil is insufficient Restart from step If replacing all ATF, remove the magnet plug, drain the oil, replace the plug, add liters of oil, and then follow steps through If oil was totally drained, pour 5ℓ and then perform the above procedure Fo r Ed uc a tio na lU se O nl y NOTE 30 Basic Chassis Technology Textbook 1.5.2 Module1 AT (Automatic Transmission) TCM Learning 1) Purpose TCM learning minimizes the influence of mass production deviation for smoother gear shifts, consistency in the feeling of gear shifts and prevention of durability loss from increased mileage It can be understood as "breaking in" an automatic transmission Perform TCM learning in the following instances ▪ Upon TCM replacement Do an auto T/A reset in GDS at the same time NOTE 2) Procedure N→D 26/B 1→2 35R/C 2→3 OD/C 3→4 ▪ Learning for UD brake Engine speed < 700RPM Stay in N for more than2 sec Repeat lU UD/B Conditions - times na Shift APS = 10 - 30% (15 - 20% recommended) Common Conditions Oil Temp = 40 - 90℃ There must be no APS change during shifts (within 3%) tio Category se ▪ Upon TCM upgrading O nl y ▪ Upon transmission replacement Ed uc a When the shift lever is moved from N to D range, the under drive brake is engaged Many technicians may forget to this learning even if the procedure is simple Keep to stay N range for more than 2sec and move to D range And then return back to N range after 2sec at least You have to repeat or 4times to complete Upon doing this learning, TCM will learn the basic control factor for UD brake and it will be utilized and compensated whenever the UD brake engagement is required in other shift activities ▪ Learning for 26 brake Fo r As you may know, 26 brake is engaged for the first time when the gear is up-shifted from 1st to 2nd speed When the shift is performed under normal driving condition, the basic hydraulic control factor for 26 brake is memorized so that it will be transferred and utilized for other shift control ▪ Learning for 35R clutch As you may know, 35R clutch is engaged for the first time when the gear is up-shifted from 2nd to 3rd speed When the shift is performed under normal driving condition, the basic hydraulic control factor for 35R clutch is memorized so that it will be transferred and utilized for other shift control Basic Chassis Technology 31 Module1 AT (Automatic Transmission) Textbook ▪ Learning for OD clutch As you may know, OD clutch is engaged for the first time when the gear is up-shifted from 3rd to 4th speed When the shift is performed under normal driving condition, the basic hydraulic control factor for OD clutch is memorized so that it will be transferred and utilized for other shift control Fo r Ed uc a tio na lU se O nl y Upon learning above items, it is transferred to all other shift control whenever those elements are engaged or disengaged, that is the reason why it is not necessary to up-shift to max speed (6th speed) for TCM learning 32 Basic Chassis Technology Textbook 1.5.3 Module1 AT (Automatic Transmission) Inhibitor Switch Cable Adjustment 1) Purpose If an inhibitor switch DTC is generated or if start-up failure in P or N occurs intermittently, suspect a defective cable rather than a faulty component Inspect the shift cable bracket and adjust the shift cable in the correct manner lU se O nl y 2) Procedure Figure 1-12 Switch Body Set the selector lever to the “N” position na Loosen the control lever coupling nut so that the control cable and lever are free Set the manual control lever to the neutral position tio Loosen the inhibitor switch mounting bolts and turn the inhibitor switch body so that the hole in the end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle range switch body flange are aligned uc a Tighten the transaxle range switch body mounting bolts to the specified torque Be careful at this time that the position of the switch body is not changed Gently pull the transmission control cable in the direction of front side of vehicle in order to eliminate to much free play, and then tighten the adjusting nut Ed Re-check that the selector lever is in the “N” position Fo r Check that each range on the transmission side operates and functions correctly for each position of the selector lever Basic Chassis Technology 33 Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) 34 Basic Chassis Technology ... lU se O nl y Module1 AT (Automatic Transmission) 28 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1. 5 Maintenance 1. 5 .1 Oil Level Adjustment 1) ATF (Automatic Transmission...Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1. 1 Overview 1. 1 .1 Introduction The functions of a... Technology 21 Textbook Fo r Ed uc a tio na lU se O nl y Module1 AT (Automatic Transmission) 22 Basic Chassis Technology Textbook Module1 AT (Automatic Transmission) 1. 4 Drive Train 1. 4 .1 Clutch