韓國現(xiàn)代santamoMPV汽車自動變速器維修手冊(英文版).ppt

1、Chonan TSTC,- KM(Kyoto Model) - Alpha, Beta series,Application vehicle : SLC, Santamo J-1, Y-2,3 X-2,3 RD (Before 2000MY),2,Identification number is stamped as 2 rows of 6 digits each as below on the transaxle case.,Identification number , Product Serial No.,1. Identification No. for , Series,MODEL

2、LINE UP Torque converter,4,2. Identification No. for KM Series,MODEL LINE UP Damper spring - *1 ; Domestic or export (except NAS) - *2 ;NAS - T/Con ; Torque converter,MODEL LINE UP it is composed of a kickdown band, drum, kickdown servo, switch and anchor. When the 2nd pressure is admitted to the ap

3、ply side chamber of kickdown servo cylinder, the kickdown piston and rod moves toward the left, tightening the brake band to hold the kickdown drum. As a result, the reverse sun gear (interlocked,with the kickdown drum) is held. This brake brake functions during 2nd gear and during overdrive. The ki

4、ckdown servo switch detects the position of the kickdown piston just before the brake is applied, and sends the signal to the transaxle control module. Using this signal, the transaxle control module controls,COMPONENTS,31,the 2nd pressure both before, and during application of the brake. In the ini

5、tial control stage or until just before the kickdown brake is applied, a higher 2nd pressure is supplied to the kickdown servo so that the kickdown piston con move quickly for faster response to the kickdown condition that has been initiated. In the second control stage or while the brake is being a

6、pplied, the 2nd pressure is regulated at an optimum level so that the band is tightened on the drum the proper amount for good kickdown “feeling”.,Movement of K/D servo,Kickdown drum,Kickdown band,Kickdown servo rod,A4 A3 A2 A1,A1 : K/D servo is fully released, that is, K/D drum rotates freely. A2 :

7、 K/D servo starts to move to engage the K/D band. A3 : K/D drum starts to stop. A4 : K/D drum stops completely.,COMPONENTS,32,When K/D drum engaged 1. K/D servo moves fast from A1 to A2 point with high pressure. 2. To reduce the shock, K/D servo slides from A2 to A3 point with relatively low pressur

8、e 3. K/D servo moves very fast to fasten the K/D drum with high pressure.,Movement of K/D servo,Service Point,COMPONENTS,33,1. Completely remove all dirt and other contaminating materials adhered around the kickdown adjust screw. 2. Loosen the lock nut. 3. Loosen and tighten the adjust screw two tim

9、es by torque of 5Nm (3.6lb.ft). 4. Again loosen the adjust screw 3 to 3-1/3 turns. 5. Tighten the lock nut to the specified torque. Lock nut : 15-25Nm (150-250kg.cm, 11-18lb.ft),NOTE : Kickdown servo adjustment,Before assembly, apply sealant (DC780) to center portion of the adjust screw.,COMPONENTS,

10、34,5. Low-Reverse brake,Center support,Piston,Hydraulic pressure,Return spring,Rear side,Brake plate,Brake disc,Pressure plate (selective),Brake reaction plate,COMPONENTS,35,Low-reverse brake is of the multiple disc type and is composed of a center support, disc plates and a piston. The brake operat

11、es when the shift is in 1st gear in the “L” range or back gear. It fastens the carrier in the planetary gearing set. That is, the shafts of the long and short pinions are fastened.,Inspection,* Install the snap ring. * Note that align the opening end of the snap ring with the pulse generator A insta

12、lling hole.,COMPONENTS,Installation hole of pulse generator A (before 94MY),36,Service Point,“N”R” shift (C1,B2) t(sec),B2 actuation point moved,C1 actuation point (delayed proper endplay),B2 actuation point (delayed:wave spring+proper end play),COMPONENTS,: Analysis ,37,6. One-way Clutch (O.W.C),Fr

13、ee,Lock,Sprag,Outer race (Planetary gear carrier),Inner race (Center support),Forward sun gear,Reverse sun gear,Annulus gear,Short pinion,Long pinion,Carrier,COMPONENTS,38,One-way clutch is of the sprag type and is incorporated between the pinion carrier and the center support. In 1st gear(D or 2 ra

14、nge), the long pinion rotates clockwise. This reduces a force which has the tendency to cause the carrier is blocked from rotating in that direction by the one-way clutch. As a result, the long pinion transmits its force to the annulus gear. The carrier, which is coupled with the one-way clutch oute

15、r race, is free to turn in clockwise direction. In an engine braking condition under which the annulus gear is turned first, the carrier turns clockwise freely and, therefore, the engine braking effect is not obtained.,Service Point,COMPONENTS,39,7. Planetary Gear,Forward sun gear,Reverse sun gear,A

16、nnulus gear,Short pinion,Long pinion,Carrier,Parking sprag,Outer race,One-way clutch,Low-reverse brakes hub,COMPONENTS,40,The planetary gear set incorporated in this transaxle consists of a forward sun gear, a reverse sun gear, a short pinion, a carrier to support both pinions, and an annulus gear.

17、The reverse sun gear is connected to the front clutch retainer via the kickdown drum, while the forward sun gear is connected to the rear clutch hub. The carrier is built in one unit with the low reverse brakes hub and the outer race of the one-way clutch. The carrier is connected to the end clutch

18、via the end clutch shaft. The annulus gear, to which the output flange is connected conveys driving force to the transfer drive gear installed on the output flange. And the parking sprag is provided on the outer circumference of the annulus gear.,COMPONENTS,41,8. Parking Mechanism,Parking sprag (Ann

19、ulus gear),Parking pawl,Parking sprag rod,Cam,Support,Support,Parking sprag rod,Detent ball (From 97My : Roller type),Detent plate (Manual control shaft),COMPONENTS,42,When the shaft is in the “P” range, the parking pawl engages with the parking sprag provided on outer circumference of the annulus g

20、ear to fasten the output shaft, to prevent the wheels from rotating. In other words, when the select lever is set to the “P” range, the detent plate and the parking sprag rod move in the direction of arrow, causing the cam on the parking sprag rod to push up the parking pawl to engage with the sprag

21、. In case the parking pawl collides against a crest of the sprag, only the rod moves because the parking pawl cannot be moved upward, and the cam, while pressing the spring, collides with the parking pawl and the support, and is withheld in this condition. If the car is moved even slightly in this c

22、ondition, the turning of wheels causes the annulus gear to turn as well. Since the cam is pressed in the direction of arrow, the parking pawl is pushed up as a bottom of the sprag aligns with the parking sprag to engage with the sprag. In this way, the parking mechanism eliminates any chances of the

23、 vehicle from being idly moved.,COMPONENTS,43,Service Point,COMPONENTS,44,1st Gear (“D” and “2” range),Operating elements : * Rear clutch * One-way clutch,Short pinion,Carrier,Forward sun gear,Transfer drive gear,Idler gear,Transfer driven gear,Rear clutch,One-way clutch,Long pinion,Annulus gear,POW

24、ER FLOW,45,1st Gear (“L” range),Operating elements : * Rear clutch * Low-reverse brake,Short pinion,Carrier,Forward sun gear,Rear clutch,Long pinion,Annulus gear,Low-reverse brake,POWER FLOW,46,2nd Gear,Operating elements : * Rear clutch * Kickdown brake,Short pinion,Forward sun gear,Kickdown brake,

25、Annulus gear,Rear clutch,Long pinion,POWER FLOW,47,3rd Gear,Operating elements : * Front clutch * Rear clutch * End clutch,Forward sun gear,Carrier,End clutch,Annulus gear,Reverse sun gear,Rear clutch,Front clutch,POWER FLOW,48,4th Gear (Overdrive),Operating elements : * Kickdown brake * End clutch,

26、Kickdown brake,End clutch,Long pinion,Carrier,Annulus gear,Reverse sun gear,POWER FLOW,49,Reverse,Operating elements : * Front clutch * Low-reverse brake,Low-reverse brake,Front clutch,Reverse sun gear,Carrier,Annulus gear,Long pinion,POWER FLOW,: , . ,50,1. Oil Pump 2. Valve Body 3. Operation of Ea

27、ch Valve 4. Adjustment of Hydraulic Pressure,CONTENTS,HYDRAULIC CONTROL SYSTEM,: ,51,The hydraulic control system consists of an oil pump which generates hydraulic pressure for the auto T/M. It also has valves and solenoid valves that control the hydraulic pressure for switch the oil passages. The v

28、alves and solenoid valves are built into the valve body.,Oil seal,Housing,Drive gear,O-ring,Seal ring,Snap ring,Steel ball,Driven gear,Reaction shaft support,Bolt,Seal ring,OIL PUMP,52,Oil pump generates pressure for supplying oil to the torque converter, for lubricating frictional parts of the plan

29、etary gearing set and the overrunning clutch, etc., and for activating the hydraulic control system. The pump is one of the inner-teeth engaging trochoid type. It always generates the oil pressure when the engine is running since the drive gear is driven by 2 pawls of the pump drive hub welded at th

30、e center of the torque converter shell.,Service Point,OIL PUMP,53,Upper Valve Body,N-D control valve,N-D control sleeve,Manual valve,Shift control valve,Shift control plug B,Rear clutch exhaust valve B,1-2 shift valve,2-3/4-3 shift valve,Rear clutch exhaust valve A,Shift control plug A,Adjusting scr

31、ew,Regulator valve,Pressure control valve,Torque converter control valve,VALVE BODY,54,Lower Valve Body,End clutch valve,End clutch plug,Stopper,Damper clutch control valve,Reducing valve,Adjusting screw,N-R control/accumulator valve,VALVE BODY,55,Valve body Mounting bolts,- KM176-5 - KM175-5 - KM17

32、5-6 - F4A33, The circles gray indicate “Mounting Bolts”,VALVE BODY,56,Lower Valve body Installing bolts,- KM176-5 - KM175-5 - KM175-6 - F4A33, Numbers which points the circles are “Bolt length”,VALVE BODY,57,Upper Valve body Installing bolts,- KM176-5 - KM175-5 - KM175-6 - F4A33, Numbers which point

33、s the circles are “Bolt length”,VALVE BODY,58,Valve body Mounting bolts,- A4AF1, The circles gray indicate “Mounting Bolts”,VALVE BODY,59,Lower Valve body Installing bolts, Numbers which points the circles are “Bolt length”,- A4AF1,VALVE BODY,60,Upper Valve body Installing bolts, Numbers which point

34、s the circles are “Bolt length”,- A4AF1,VALVE BODY,61,Manual Valve,P R N D 2 L,Manual valve,To torque converter,To shift control valve,To pressure control valve,To N-R control valve,Oil pump,Oil filter,Oil pan,Ex Ex,Ex,OPERATION OF EACH VALVE,: MANUAL VALVE ,62,Manual Valve,The manual valve moves in

35、 conjunction with the selector lever in the drivers compartment, providing each valve and control element with the pressure.,Regulator Valve,This valve regulates the line pressure generated by the oil pump. The valve corresponds with every driving condition.,Selector lever in “N”,”D”,”2” or “L”,The

36、hydraulic pressure from the oil pump is directed to the regulator valve through the No.1 line. After passing through the regulator valve, hydraulic pressure is then directed to the torque converter via the torque converter control valve. At the same time, the pressure from the No.1 line is directed

37、to the manual valve and then to the chamber (A) at the right end of the regulator valve through the No.4 port. The pressure directed to the chamber (A) acts on the regulator valve against the regulator valve spring force and shifts the valve to regulate the,OPERATION OF EACH VALVE,63,Line pressure.

38、When the engine speeds up, the oil pumps speed becomes greater, and the hydraulic pressure increases. This also increases the hydraulic pressure directed to the chamber (A). The increased chamber (A) pressure forces the regulator valve toward the left, overcoming the spring force. At this point the

39、No.3 port leading to the torque converter opens wide, which allows more fluid to flow to the torque converter.,Selector lever in “N”,”D”,”2” or “L”,Regulator valve,If the hydraulic pressure increases even more, the regulator valve is forced further leftward and the No.2 port opens. In this state, th

40、e fluid flows through,To torque converter control valve,Ex,Line pressure (from oil pump),Pump suction,1,2,A,4a,9a,3,9,Line pressure,OPERATION OF EACH VALVE,64,the port toward the suction side of the pump and the line pressure is released. When the line pressure drops, the chamber (A) pressure also d

41、rops, and the regulator valve is forced back toward the right by the spring force, closing the No.2 port. Through this cyclical operation of the regulator valve, the line pressure is maintained at a constant level. The line relief valve provided in the No.1 line opens if the line pressure becomes so

42、 high that the regulator valve cannot deal with it. In this way, the hydraulic circuit is protected.,Selector lever in “N”,”D”,”2” or “L”,Selector lever in “R”,When the manual valve is shifted to the “R” range position, the No.4 port that was open is closed. The No.9 port is opened instead. This all

43、ows the line pressure to be directed to the #4 land of the regulator valve. As this pressure works on the area equivalent to the difference between the diameter D4 of the #4 land and the diameter D5 of the #5 land, the force pushing the regulator valve toward the left side is relatively weak as,OPER

44、ATION OF EACH VALVE,65,compared to the force generated when applied to the other portion of the valve. Therefore, a pressure higher than that of previously described forward drive ranges is required to open the No.2 port. The higher pressure thus serves to move the elements in the reverse range. The

45、 operation of the regulator valve driven by the higher pressure is the same as that of the aforementioned forward drive ranges.,Selector lever in “R”,P R N D 2 L,To torque converter control valve,Ex Ex,Regulator valve,Ex,Manual valve,To N-D control valve,1,Line pressure (from oil pump),9,2,1,4,5,9,3

46、,D4 D5,Orifice,OPERATION OF EACH VALVE,66,Selector lever in “P”,When the manual valve is shifted to the “P” range position, the manual valve exhaust port communicates with the line pressure port, and the line pressure is relieved. In this situation, no pressure is directed to the No.4 and No.9 ports

47、. This causes the regulator valve to be held at its extreme tight position by the spring force, and the No.3 port to be closed. Therefore only fluid that passes through the orifice is directed to the torque converter.,P R N D 2 L,To torque converter control valve,Ex Ex,Regulator valve,Ex,Manual valv

48、e,To N-D control valve,1,Line pressure (from oil pump),9,2,1,4,5,9,3,Orifice,To Shift control valve,OPERATION OF EACH VALVE,67,Torque Converter Control Valve,This valve maintains the torque converter pressure and lubricant pressure at a constant level. If the pressure from the regulator valve become

49、s too high, the pressure inside chamber (B) pressure increases to a level that overcomes the spring force, the torque converter control valve is forced toward the left. The leftward movement of the valve opens the No.2 port, and through this port the fluid returns to the suction side of the pump. As

50、 a result, the line pressure drops. If the line pressure drops, the chamber (B) pressure also,Torque converter control valve,Regulator valve,Ex,Ex,Ex,3,3,2,1,2,4,9,To manual valve,Chamber B,Small hole,3,To Torque converter,OPERATION OF EACH VALVE,68,Torque Converter Control Valve,drops, and the valv

51、e is shifted back toward the right by the spring force, thus closing the No.2 port. Repetition of the above mentioned cycle regulates the torque converter pressure and maintains it at a constant level.,Damper Clutch Control Valve,The damper clutch valve is incorporated in the lower valve body. It ch

52、anges the hydraulic oil pressure used to control the damper clutch.,Service Point,OPERATION OF EACH VALVE,69,Damper Clutch Control Valve,From reducing valve,Line pressure,Ex,To DCCSV,To torque converter (when damper clutch is released),To torque converter (when damper clutch is engaged),Ex,From redu

53、cing valve,From torque converter control valve,To oil cooler,OPERATION OF EACH VALVE,70,N-D Control Valve,P R N D 2 L,Ex Ex,Manual valve,1,9,4,5,9,Ex,N-D Control valve,Transaxle Control Module,Ex,Ex,Ex,Ex,OFF,Pressure Control valve,Pressure Control Solenoid valve,N-R Control valve,To rear clutch,#1,

54、#2,#3,#4,OPERATION OF EACH VALVE,71,N-D Control Valve,The purpose of this valve is to prevent shock from occurring when shifting from “N” to “D”. The valve supplies the rear clutch with oil pressure regulated by the pressure control valve only when the N-D shifting is being performed. After the shif

55、ting is completed, the valve is switched over to allow the line pressure to the rear clutch.,Reducing Valve,The reducing valve is installed at the lower valve body ; it functions to produce a constant pressure which is always lower than the line pressure. With this pressure as the hydraulic pressure

56、 source, the control pressure is produced by the pressure control solenoid valve, thus activating the pressure control valve.,OPERATION OF EACH VALVE,72,Reducing Valve,Transaxle Control Module,Ex,Ex,Ex,Ex,OFF,Pressure Control valve,Pressure Control Solenoid valve,N-R Control valve,Reducing valve,Adj

57、usting screw,Ex,Ex,Line pressure,1,23,9,16,23b,23,10,5,OPERATION OF EACH VALVE,73,Shift Control Valve and Solenoid Valves,Plug,Line pressure,#2,#1,Plug,Shift control valve,4th pressure,Ex,Shift control solenoid valve “B”,Shift control solenoid valve “A”,TCM,OPERATION OF EACH VALVE,74,Shift Control Valve and Solenoid Valves,The line pressure acting upon the shift control valve is controlled by the two shift cont