chap103 pps Automotive technology at University of Cambridge

start Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 OBJECTIVES: After studying Chapter 103, the reader should be able to: • • • • Discuss how to disassemble an automatic transmission/transaxle Explain how to properly install and check clutch packs Describe how to flush the cooler Explain how to properly reassemble an automatic transmission/transaxle Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 OBJECTIVES: After studying Chapter 103, the reader should be able to: • • • List the steps necessary to follow when removing an automatic transmission/transaxle assembly Describe how to properly remove and install an aluminum pump in an automatic transmission/transaxle Explain how to flush an automatic transmission fluid cooler Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 KEY TERMS: Assembly lube OSHA air nozzle Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 REMOVING THE AUTOMATIC TRANSMISSION/ TRANSAXLE FOR SERVICE Removing an automatic transmission/transaxle from a vehicle includes many steps to avoid doing damage to the vehicle or harm to yourself Most procedures include the following: Step #1 Disconnect the negative (-) battery cable from the battery Step #2 Disconnect the driveshaft or drive axle shafts Step #3 Disconnect all cooler lines, linkage, and electrical connections Be sure to label each to ensure proper reinstallation Step #4 Disconnect the torque converter from the flex (drive) plate of the engine Step #5 Support the engine before disconnecting the automatic transmission/transaxle, as shown in Figure 103–1 Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Figure 103–1 (a) A tall safety stand with a block of wood on top being used to support the engine to permit the removal of the automatic transmission without doing harm to the engine or its accessories Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Figure 103–1 (b) A chain and holding fixture being used on this front-wheel-drive vehicle to support the engine when the transaxle is removed Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Step #7 Support the transmission/transaxle on a jack and remove the attaching bolts at the bell housing of the engine, as shown below Remove the transmission/transaxle from the vehicle Figure 103–2 (a) A typical transmission jack The top portion of the jack can be raised by pumping the lever on the side Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Figure 103–2 (b) A transmission jack in position during the removal of the transaxle assembly Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 The Chain Trick If two slide hammers are not available to remove a cast iron pump from anautomatic transmission, try using a length of chain Attach each end of a chain to the pump and jerk the chain The pump should come out CAUTION: Do not attempt this procedure with an aluminum pump or damage could result Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 See the chart on Page 1327 of your textbook Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Dyno Testing the Automatic Transmission/Transaxle A rebuilt automatic transmission/transaxle can be tested on a dynamometer powered by an electric motor as shown below, or by a gasoline engine as shown in Figure 103–22 Most dynamometers are equipped with pressure gauges as well as provide a load so the operation of the unit can be checked before being installed in the vehicle Figure 103–21 A motor-driven dynamometer being used to check the operation of a 41TE transaxle Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Figure 103–22 A gasoline engine-powered dynamometer being set up to test a rear-wheel-drive transmission Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 REINSTALLING THE AUTOMATIC TRANSMISSION/TRANSAXLE After the unit has been reassembled and all end play checks indicate that the unit is properly assembled, reinstall the automatic transmission/transaxle in the vehicle Many experts recommend that new transmission/transaxle mounts be installed to assure proper driveshaft/drive axle shaft angles NOTE: New mounts are particularly important if the unit was leaking automatic transmission fluid (ATF) The ATF can soften and deteriorate the rubber used in the mounts Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Before installing the unit into the vehicle, flush the torque converter with clean ATF Carefully install the torque converter onto the input shaft being sure to fully engage the pump gear Carefully install the unit and use a torque wrench to torque the bolts to the bell housing Attach the torque converter to the flex (drive) plate Reattach all electrical connections Lower the vehicle and add enough ATF to properly fill the unit Consult factory information for the recommended amount to avoid under-or overfilling Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Avoid Using Red Assembly Lube Assembly lube is used during the reassembly of automatic transmissions If red assembly lube is used on seals, it may look like an automatic transmission fluid leak when the transmission gets hot and the lube melts If you use blue, green, brown, or clear lube, the color will immediately identify it as assembly lube Many transmissions have been disassembled because the tech thought the red liquid dripping from parts of the transmission was automatic transmission fluid, while in fact it was just assembly lube that melted and ran when the transmission reached normal operating temperature Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman Figure 103–23 Blue assembly lube ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 ROAD TEST Start the engine and check the level of the ATF Carefully testdrive the vehicle checking for proper operation and shift points Hoist the vehicle and check for any possible ATF leaks before returning the vehicle to the customer Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 Install a Transmission Cooler An auxiliary transmission fluid cooler is recommended by most experts to help keep the temperature from becoming excessive, especially when towing or performing other heavy-duty vehicle operation Most experts recommend that the cooler be connected so that the hot fluids travel through the auxiliary cooler and then through the factory cooler and return to the transmission/transaxle Using this method of plumbing allows the radiator to warm the transmission fluid in cold weather as well as provide additional cooling of the fluid when the fluid temperature is high Figure 103–24 An auxiliary transmission cooler installed on a Chevrolet tow vehicle Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 PHOTO SEQUENCE 6T70 Transaxle Service Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 PHOTO SEQUENCE 6T70 Transaxle Service (cont.) Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 PHOTO SEQUENCE 6T70 Transaxle Service (cont.) Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 PHOTO SEQUENCE 6T70 Transaxle Service Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman (cont.) ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 SUMMARY The transmission pan should be carefully inspected for evidence of excessive wear material Use a magnet to check for any particles of steel that could be the result of serious internal damage such as a defective planetary gear set The engine should be properly supported before the automatic transmission/transaxle is removed from the vehicle When reassembling an automatic transmission/transaxle, the clutch pack clearances should be checked with a feeler gauge and air checked End play should be checked according to the vehicle manufacturer’s recommendations This check is also used as a double check for the service technician that the unit was properly assembled Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 SUMMARY (cont.) All vehicle manufacturers recommend that the automatic transmission fluid cooler be flushed when rebuilding or replacing an automatic transmission/transaxle Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 PowerPoint transcription by TAB Publishing Services end Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc Inc Pearson PearsonPrentice PrenticeHall Hall- -Upper UpperSaddle SaddleRiver, River,NJ NJ07458 07458 ... should be avoided The water may contaminate the new fluid when the cooler lines are reattached and the ATF flows through the cooler NOTE: At least two quarts (liters) of ATF should flow through... their exact location There will be vacant spring seats in some applications This allows the manufacturer to use the same piston but vary the number and location of springs to precisely match spring... reinstallation of the clutch pack easier Continued Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition By James D Halderman ©©2008 2009Pearson PearsonEducation, Education,Inc