AUT233 Automatic Transmission II
Fall 2007
|
Course Number |
AUT233 |
Credit Hours |
3 |
|
Section Number Class Times Class Days |
34227, 2nd 8 wks; 11:45am-2:30pm
MTWTh |
Instructor |
|
|
E-mail |
dhanan@eicc.edu |
Phone |
563-441-4228 |
|
Office Hours |
3:00pm-4:00pm |
Office |
3116BB |
|
Room |
3119 |
Website |
Text
Automatic Transmissions and
Transaxles, 3rd Ed. – Birch and Rockwood
Automatic Transmisions II Student Activity Manual 2007 Ed. Hanan
Course Description
This
course is designed to provide advanced knowledge in the diagnosis and repair of
automatic transmissions and transaxles. The student will develop skills in
reading transmission hydraulic control circuit schematics. The student will
develop the skills necessary to perform diagnosis of electronically controlled
automatic transmissions and transaxles. The student will dis-assemble and
re-assemble an automatic overdrive transaxle. The use of pressure gauges, scan
tools and other test equipment will be practiced.
Major Topics Covered
Knowledge
of transmission hydraulic circuits
Knowledge
of sensor inputs
Knowledge
of control outputs
Knowledge
of TCM functions
Use of service
information and troubleshooting procedures
Prerequisites
AT131
Attendance/Participation
See Below
Evaluation
Final
grade will be based on six areas:
Final
Test......................................10%
Quiz
scores..................................25%
Case
Studies………………………………10%
Lab
work........................................30%
Employee
Characteristics……….15%
Lab
Log...........................................10%
Final
Grading Scale:
A
> 90 - 100%
B
> 80 - 89%
C
> 70 - 79%
D
> 60 - 69%
F
> 59% or below
No
unit tests will be given in this course.
QUIZZES:
A quiz may be given every other day. A missed quiz cannot be made up. Each
student may be required to write 5 quiz questions as part of their quiz score.
These are due before the quiz and will not be accepted late. The lowest quiz
score will be dropped.
LAB WORK: Work
performance will be evaluated based on lab worksheets. Worksheets will be
collected weekly as the work is completed. All worksheets must be turned in as
required. Worksheets MUST be initialed by the instructor as they are
completed or they will not be accepted!
CASE
STUDIES: Small groups will be assigned transmission diagnostic case studies. The
group will be required to work together to answer questions concerning the case
study. The group will earn a grade for the case study assignment. The grade
earned will be based on the thoroughness of the group’s answers to the
questions. The grade each individual
receives for the case study will be based on that individual’s participation in
the process and the grade earned by the group for the case study.
The
individual grade will be earned based on a peer assessment. Each member of the
group will rate the other members as to the level of effort in participation on
a scale of 1 to 10. The instructor will average the rating for each student.
The average will be divided by 10 to determine the Participation Factor. (The
instructor reserves the right to adjust the average the rating as he deems
fit.) The group case study grade will then be multiplied by the Participation Factor
to determine the individual’s case study grade.
Examples:
Group grade » 85 out of 100
Individual Rating Average » 8.2
÷ 10 = .82 Participation Factor
85 X .82 = 69.7 Case Study grade
Group grade » 95 out of 100
Individual Rating Average » 9.5 ÷ 10 = .95 Participation Factor
95 X .95 = 90.2 Case Study grade
LAB
LOGS: A weekly lab log will be kept by each student. The student will record
his/her lab activity for each day. The weekly lab grade will be determined from
the student’s log. Any lab sheets will be turned in with the log. The log must
be turned in every Monday. A log not turned in will result in a zero for
the weekly lab grade.
The log entry must
include the following: Name, Day & Date, Description of the lab activity
(minimum of five sentences),
Five things learned that Week, Difficulties experienced that week
and Description of the best part of the week.
EMPLOYEE CHARACTERISTICS: Students will receive a
weekly grade based on their demonstration of basic employee characteristics
expected by employers. These include Dependability, Punctuality, Productivity, Teamwork,
Communication, Safety, and Cleanup. The instructor will rate each
characteristic weekly on the following scale:
0 – Unacceptable,
does not meet minimum requirements
2 - Consistently
meets minimum requirements
3 - Occasionally
exceeds minimum requirements
4 - Consistently
exceeds minimum requirements
FINAL
TEST: All students are expected to take the final test. Failing to do so will
adversely affect your final grade.
Exam Make-up policy
See Above
Late Assignment Policy
See Above
Assessment
See Above
Cell phone policy
See Below
The following are non-negotiable
expectations of classroom and lab conduct.
- Class members will attend class on time.
The instructor reserves the right to refuse admittance to anyone who
arrives late for class! (Ten minutes grace for students and instructor on
rare occasions.)
- Class members will refrain from
negative comments about others in the class.
- Class members will refrain from
disrupting the learning of others by theirs words and behavior.
- Class members will adhere to all
safety policies.
- Cell phones will not ring or be used
for conversation during classroom or lab sessions.
- Class members will refrain from using
tobacco products during classroom or lab sessions.
- Class members will refrain from
sleeping in class. Sleep at home, be alert in class!
- Class members will endeavor to conduct
themselves in a professional manner.
POLICIES ON ACADEMIC DISHONESTY CAN BE FOUND IN THE EICCD STUDENT CODE
OF CONDUCT PUBLISHED IN THE STUDENT HANDBOOK.
Benefits of taking this class
Students who
successfully complete this course will have increased their understanding of
how automatic transmissions and their computer control systems function. They
will also learn how to test the components of the electronic system.
Study Tips
To be successful
students must complete the assignments given them. Working in small groups of
two will increase the learning in the lab.
Semester
Schedule
Event
|
Date
|
|
Start date |
10/22/07 |
|
Midterm |
NA |
|
Advising Day |
11-14-07 |
|
Staff Development Day |
NA |
|
College Closed |
11-22 & 23-07 |
|
Last date to drop with “W” |
12-12-07 |
|
End date |
12/19/07 |
Academic Accommodation
Anyone who feels
they may need an academic accommodation based on the impact of a documented
disability should contact Jan Weis at the
Class Cancellation
Students may go to
the web site at http://www.eicc.edu/students to check if class has been cancelled. Once
there, click on academics and again on class cancellations. You may also call
the college at 563-441-4001.
Course Schedule
Automatic
Transmission II
Approximate
Lesson Sequence
Reading
Assignment Topics
1 Intro
and Review 3,
4, 5, 6, 7 & 9
2 Inspection
and Overhaul Procedures 16,
17 & 18
3 Electronic Control Devices 8
& 13
4 Sensor
and Actuator Testing 13
5 Hydraulic Circuits GM
4T65-E Handouts
6 Torque Converter Testing and
12.6,
12.7, 12.9 & 13.6.2
Transmission
Pressure Testing
7 Case Studies
8 Case Studies
Course Competencies/Outcomes for Automatic Transmission II
Upon the completion of this course, the students will be able
to:
1. Identify and interpret transmission/transaxle concern; assure proper
engine operation; determine
necessary action. P-1
2. Diagnose fluid loss and condition concerns; check fluid level on
transmissions with and without dip-
stick;
determine necessary action. P-1
3. Perform pressure tests; determine necessary action. P-1
4. Perform stall test; determine necessary action. P-3
5. Perform lock-up converter system tests; determine necessary action. P-3
6. Diagnose mechanical and vacuum control system concerns; determine
necessary action. P-2
7. Diagnose noise and vibration concerns; determine necessary action. P-2
8. Diagnose electrical/electronical concerns
using principles of electricity (Ohm’s Law). P-2
9. Diagnose electronic transmission control systems using a scan tool; determine
necessary action. P-1
10. Measure torque converter endplay and check for interference; check
stator clutch. P-2
11. Inspect transaxle drive, link chains, sprockets, gears, bearings, and
bushings; perform necessary
action. P-2
12. Inspect, measure, repair, adjust or replace transaxle final drive
components. P-2
Note: P-1, P-2, & P-3 indicate the NATEF task
priority level.
Lesson 1
Transmission Component Inspection
- Before
teardown
-Input shaft end-play
-indicates need for thrust washer or shim change
- During
Teardown
- Oil pump & Torque Converter
- bushing for torque converter
- stator support
- pumping components slide clearance
- scoring
- Governor
- drive gear
- “apple coring”
- springs
- valve
- Drive Chain and Sprockets
- deflection or stretch
- wear
- bearings and bushings
- Drums and bands
- clutch pistons
- return springs
- check balls
- scoring
- deglaze with 600 grit crocus
cloth,
smooth
on a lathe
- friction material
- sealing ring areas
- struts and anchors
- Thrust washers, bushings and bearings
- wear and scoring
- thickness
- Planetary members
- Pinion gear wear
- Pinion end-play
- replaceable
thrust washers
- Pinion gear bearing smoothness
- Spline fit
- Ring and sun gear wear
- bushings and thrust washers
- Shafts
- splines
- bearing surfaces
- sealing ring lands, 0.003" clearance
- end bushings
- Servos and Accumulators
- piston
- pin
- length of servo pin, if selective fit
- springs
- Case
- Accumulator and servo bores
- Bushings
- Warpage across valve body surface, 0.002" max.
Bolt in center support if applicable
- thread condition
- splines
Valve body
- sticking or scored valves,
- broken springs
- warpage
- separator plate damage
- Over-running Clutches
- rollers or sprags
- races
- springs
- rotation direction
During
Reassembly
- Clutch pack clearance:
min. 0.010" per friction disc
- Air check clutches
- Servo pin length
- Band adjustment
- End-play of input shaft
Lesson 2
Electronic
Transmission Control Devices
What automatic transmission functions maybe controlled electronically?
Shift timing, shift quality, line pressure, TCC
TCM/PCM Inputs
The TCM uses a variety of inputs to determine the actions
necessary to maintain proper transmission operation.
· Torque
load –
o
Throttle position or manifold vacuum input
§ Throttle
position sensor
§ Manifold
absolute pressure sensor
o
Replaces throttle valve or modulator
· Vehicle speed –
o
Vehicle speed sensor
o
Output shaft speed sensor
o
Replaces governor
· Manual
valve position –
o
Transmission range sensor
o
May be a potentiometer or a set of pressure switches
on the valve body
· Transmission
temperature –
o
Transmission fluid temp. sensor
· Input
shaft speed –
o
Input shaft or
turbine speed sensor – ISS or TSS sensor
· Impeller
speed –
o
Crankshaft position sensor
The TCM uses the TSS and CKP to determine the torque
converter slip ratio.
The TCM uses the TSS and
· Brake
application –
o
Brake light switch input
· Engine
temperature –
o
Engine coolant temperature sensor
The TCM uses the TPS, VSS, brake light switch input and ECT
to determine when to lock and unlock the torque converter.
TCM/PCM outputs
The TCM uses a few electromagnetic actuators to affect
hydraulic pressures in the transmission and provide optimum transmission
function.
Transmission Solenoid Control
Two methods are used to control transmission solenoids:
· Saturation-
the TCM driver is ON or OFF. The solenoid resistance limits the current. (Solenoid resistance > 10 ohms)
· Pulse
Width Modulated- The TCM controls the current level by pulsing the solenoid ON
and OFF rapidly. The ON time varies to vary the current. (Solenoid resistance < 10 ohms)
Solenoid Functions
· Shift
solenoid –
o
Controls fluid flow to an apply device directly
§ This type
may be pulsed initially to control the quality of the shift
OR
o
Controls fluid pressure on a shift valve
§ This type
is usually “On” or “Off”, not pulsed
· TCC
solenoid –
o
Controls fluid pressure at one end of the TCC apply
valve which locks and unlocks the torque converter
· TCC
modulation solenoid –
o
A pulsed solenoid that is used to gradually “ramp up”
the TCC apply pressure
o
Controls the converter clutch regulator valve
o
Sometimes referred to as the PWM solenoid
· Electronic
Pressure Control (EPC) Solenoid or Force Motor
o
The EPC is used to control the main line pressure
§ The EPC
creates and varies a torque signal pressure based on the torque load
§ The torque
signal pressure acts on the main pressure regulator valve to control the line
pressure (similar to T.V. or modulator pressure)
o
The average current through the EPC is varied by the
TCM using pulse width modulation
§ A low
average current results in a higher torque signal pressure and higher line
pressure
§ A high
average current results in a lower torque signal pressure and lower line
pressure
See page 212
o
Some EPC are pulsed fully every 10 seconds to prevent
contamination by small metal particles
· Governor
Pressure
o
The TCM uses vehicle speed input to control the
governor pressure solenoid and create governor pressure. The TCM controls shift
points using the governor pressure solenoid.
o
The TCM will lock up the TCC to cool the transmission
if it is overheating
TCM Strategies
· Reduced
engine torque during shifts
o
The PCM retards spark timing and/or reduces fuel
delivery during the shift
o
Shift quality is improved and transmission wear is decreased
· Regulate
transmission temperature with torque converter clutch
o
The PCM will wait longer to lock up the TCC when the
unit is cold to lessen the time required to reach operating temperature
· Limp-In
o
Occurs when power is lost to the TCM or transmission
and when a major electrical or mechanical problem has been detected
o
All solenoids are de-energized
o
No up shifts or down shifts
o
The transmission is stuck in 2nd or 3rd
gear
o
Reverse is still available
· Adaptive
Learn
o
The TCM learns that a particular shift is slipping or
a slip is occurring after a shift
· GM – Shift
and Steady State Adapts
· Chrysler
FWD – Clutch Volume Index (CVI)
o
It attempts to correct the problem by increasing line
pressure during the shift
· Most
electronically shifted transmissions must have their adaptive learn reset after
a major repair. Reset or relearn procedures vary depending on the transmission
model. Always refer to the proper service information.
Some TCM’s learn
and adapt to a driver’s style (fuzzy logic).
Lesson 3
Transmission
Hydraulic Circuits
On the following pages you will find hydraulic schematics for a GM 4T65-E transmission. We will study the pressure circuits for a variety of the transmission’s ranges.
Following the schematics will be a series of discussion
questions to help with circuit study and understanding.
4T65E
- Park Fluid Flow
When
the gear selector lever is in the PARK (P) position and the engine is running,
fluid is drawn into the oil pump and line pressure is then directed to the
following control devices:
Pressure Regulator Valve (313)
Regulates pump output (line pressure) in response to torque signal fluid
pressure acting on the boost valve, spring force and line pressure acting on
the end of the valve. Line pressure is directed to the manual valve, 3
accumulator valves, torque signal regulator valve, pressure relief valve, TCC
regulator valve, #10 ball check valve and 2-3 shift valve, 3-2 manual downshift
valve, 3-4 shift valve, 2-3 shift solenoid valve, #3 ball check valve and input
clutch, and actuator feed limit valve.
Actuator Feed Limit Valve (414)
Line pressure is routed to the valve and limited to a maximum pressure as it
passes through the valve and enters the actuator feed circuit. Actuator feed is
then routed to the pressure control solenoid valve and into the 1-2, 3-4 shift
solenoid valve.
Pressure Control (PC) Solenoid Valve (322)
Controlled by the PCM, the PC solenoid valve regulates filtered actuator feed
pressure entering the torque signal circuit. Torque signal fluid is then routed
to the pressure regulator valve, the 1-2, 2-3 and 3-4 accumulator valves.
Torque Signal Regulator Valve (321)
Regulates line pressure into the torque signal fluid circuit. This regulation
is controlled by filtered actuator feed fluid pressure from the PC solenoid
valve.
Line Pressure Relief Valve (324)
Exhausts line pressure above 1,690 - 2,480 kPa (450 - 360 psi).
Manual Valve (404)
The manual valve is moved to the NEUTRAL position and
blocks line pressure from entering the Reverse fluid circuit. The reverse fluid
circuit is opened to an exhaust at the manual valve.
Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly (34)
The Transmission Fluid Pressure (TFP) manual valve position switch assembly is
a device containing five hydraulically activated (normally open) pressure
switches which are monitored by the Powertrain Control Module (PCM) . The
switches close or open electrical circuits when hydraulic fluid acts on the
diaphragm inside the sw