Automatic Transmissions And Transaxles

by Birch, Thomas S.; Rockwood, Chuck

• ISBN13: 9780131197299
• ISBN10: 0131197290
• Edition: 3rd
• Format: Paperback w/CD
• Copyright: 2006-01-01
• Publisher: Prentice Hall

Summary

Automotive Transmissions and Transaxles presents comprehensive coverage of the operating principles as well as the service and repair procedures for modern automatic transmissions and transaxles. Its complete and up-to-date coverage provides readers with all the information needed to understand the latest automotive technology. Illustrations provided by some of the 48 vehicle and other manufacturers associated with MVAC, a Spanish language glossary, Real World Fixes case studies, and Service Tips all provide readers with support material, visuals, and tools to reinforce concepts and deepen understanding. The up-to-date content begins with operating theory and progresses from service and maintenance operations to problem diagnosis and repair procedures. Features information on evolving automobile technology and modern transmissionsincluding electronically controlled models. Covers transmission and power train advancese.g., continuously variable transmissions, hybrid drive systems, and 6-speed transmissions. For modern automotive technicians.

Table of Contents

Service Information, Fasteners, Tools, and Safety	1	(25)
Learning Objectives	1	(1)
Vehicle Identification	1	(2)
VECI Label	2	(1)
Calibration Codes	2	(1)
Casting Numbers	3	(1)
Service Information	3	(1)
Service Manuals	3	(1)
Electronic Service Information	3	(1)
Technical Service Bulletins	4	(1)
Internet	4	(1)
Steel Classification	4	(1)
Steel Classification Examples	5	(1)
Threaded Fasteners	5	(3)
Metric Bolts	6	(1)
Bolt Grade	6	(1)
Nuts	6	(2)
Washers	8	(1)
Basic Tool List	8	(5)
Tool Sets and Accessories	11	(1)
Brand Name versus Proper Term	12	(1)
Safety Tips for Using Hand Tools	13	(1)
Measuring Tools	13	(2)
Micrometer	13	(1)
Telescopic Gauge	14	(1)
Vernier Dial Caliper	14	(1)
Dial Indicator	15	(1)
Safety Tips for Technicians	15	(5)
Vehicle Lifting (Hoisting) Safety	18	(2)
Electrical Cord Safety	20	(1)
Fire Extinguishers	20	(6)
Types of Fire Extinguishers	20	(4)
Review Questions	24	(1)
Chapter Quiz	24	(2)
Environmental and Hazardous Materials	26	(13)
Learning Objectives	26	(1)
Introduction	26	(1)
Occupational Safety and Health Act	26	(1)
Health Care Rights	27	(1)
Hazardous Waste	27	(1)
Resource Conservation and Recovery Act (RCRA)	27	(1)
Clean Air Act	28	(1)
Material Safety Data Sheets (MSDS)	28	(1)
Asbestos Exposure Hazard	28	(2)
OSHA Asbestos Standards	29	(1)
EPA Asbestos Regulations	29	(1)
Asbestos Handling Guidelines	29	(1)
Proper Disposal	30	(9)
Used Brake Fluid	30	(1)
Used Oil	30	(1)
Solvents	31	(2)
Coolant Disposal	33	(1)
Lead-Acid Battery Waste	34	(1)
Fuel Safety and Storage	35	(1)
Air Bag Handling	35	(1)
Used Tire Disposal	36	(1)
Air Conditioning Refrigerant Oil Disposal	36	(1)
Review Questions	37	(1)
Chapter Quiz	37	(2)
Introduction to Transmissions	39	(30)
Learning Objectives	39	(1)
Transmissions: Their Purpose	39	(2)
Torque and Horsepower	41	(1)
Gear Ratios	42	(3)
Tractive Force	45	(1)
Standard Transmission and Clutch	46	(3)
Simple Planetary Gearsets	49	(2)
Compound Planetary Gearsets	51	(3)
Control Devices	54	(1)
Transmission Hydraulics	55	(2)
Torque Converters	57	(1)
Transaxle Final Drive and Differential	58	(1)
Four Wheel Drive	59	(2)
Nonplanetary Gear Automatic Transmissions	61	(1)
Hybrid Drive System	62	(7)
Review Questions	66	(1)
Chapter Quiz	67	(2)
Apply Devices: Clutches and Bands	69	(19)
Learning Objectives	69	(1)
Introduction	69	(1)
Driving Devices	69	(1)
Multiple-Disc Driving Clutches	70	(7)
Clutch Plates	72	(2)
Clutch Operation	74	(3)
One-Way Driving Clutches	77	(2)
Clutch Operation	79	(1)
Holding/Reaction Devices	79	(1)
Multiple-Disc Holding Clutches	79	(1)
One-Way Holding Clutches	79	(1)
Bands	80	(2)
Band Operation	81	(1)
Shift Quality	82	(6)
Shifts Involving One-Way Clutches	84	(1)
Deceleration with One-Way Clutches	84	(1)
Review Questions	85	(1)
Chapter Quiz	85	(3)
Power Flow Through Transmission Gearsets	88	(43)
Learning Objectives	88	(1)
Rules of Power Transfer	88	(4)
Planetary Gear Ratios	90	(2)
Transaxles	92	(2)
Park	94	(1)
Transmission Schematics	94	(1)
Simpson Gear Train Transmissions	95	(7)
Neutral	98	(1)
First Gear	98	(1)
Second Gear	99	(1)
Third Gear	100	(1)
Reverse	100	(2)
Shift Timing	102	(1)
Simpson Gear Train Plus an Additional Gearset	103	(3)
Overdrive	103	(3)
Ravigneaux Gearsets	106	(9)
Two-Speed Ravigneaux Arrangement and Operation	106	(2)
Three-Speed Ravigneaux Arrangement and Operation: First Version	108	(2)
Three-Speed Ravigneaux Arrangement and Operation: Second Version	110	(2)
Four-Speed Ravigneaux Arrangement and Operation	112	(1)
Four-Speed Ravigneaux Arrangement and Operation: Second Version	113	(1)
Lepelletier gear train	113	(2)
Four-Speed Overdrive Gearset	115	(9)
Power Flow: 4T60E	116	(1)
Four-Speed Overdrive Gearset: Second Version	117	(3)
Four-Speed Overdrive Gearset: Variation of Second Version	120	(3)
Four-Speed Overdrive Gearset: Variation Two	123	(1)
Nonplanetary Gearsets	124	(7)
Helical Gear Types	124	(1)
CVT Types	124	(3)
Review Questions	127	(1)
Chapter Quiz	128	(3)
Hydraulic System Theory	131	(31)
Learning Objectives	131	(1)
Introduction	131	(1)
Hydraulic Principles	132	(2)
Simple Hydraulic Systems	134	(1)
Basic Automatic Transmission Hydraulics	135	(1)
Producing Fluid Flow and Pressure	135	(3)
Providing Clean Fluid	138	(2)
Controlling Fluid Flows	140	(6)
Valve Hydraulic Forces	144	(2)
Controlling Fluid Pressure	146	(3)
Sealing Fluid Pressure	149	(3)
Special Notes on Elastomers	151	(1)
Applying Fluid Pressure	152	(2)
Determining Piston Force	154	(1)
Modifying Flow and Pressure	154	(1)
Automatic Transmission Fluid	155	(7)
Review Questions	159	(1)
Chapter Quiz	160	(2)
Hydraulic Shift Control	162	(26)
Learning Objectives	162	(1)
Introduction	162	(2)
Pressure Development and Control	164	(2)
Torque Converter, Oil Cooler, and Lubrication Circuit	166	(6)
Torque Converter Pressure Control	166	(2)
Torque Converter Clutch Control	168	(1)
Cooler Flow	168	(2)
Lubrication Flow	170	(2)
Throttle Pressure	172	(5)
Mechanical Throttle Valves	174	(1)
Vacuum Throttle Valves	175	(2)
Wide-Open Throttle Kickdown Valve	177	(1)
Manual Value	177	(2)
Governor Valve	179	(2)
Shift Valves	181	(7)
Shift Overlap	182	(1)
Shift Modifiers	183	(1)
Downshifts	184	(1)
Review Questions	185	(1)
Chapter Quiz	185	(3)
Electronic Transmission Controls	188	(28)
Learning Objectives	188	(1)
Introduction	188	(2)
Basic Electricity	190	(7)
System Components	193	(4)
Basic Electronics	197	(19)
Sensors	197	(6)
Electronic Transmission Shift Controls	203	(5)
Actuators	208	(5)
Review Questions	213	(1)
Chapter Quiz	214	(2)
Torque Converters	216	(12)
Learning Objectives	216	(1)
Introduction	216	(1)
Construction	216	(3)
Operation	219	(2)
Torque Multiplication	219	(1)
Coupling Phase	220	(1)
Torque Converter Clutches	221	(2)
Controlled TCC Capacity	222	(1)
Viscous Converter Clutch	223	(1)
Stall Speed	223	(2)
Stall Factors	224	(1)
Planetary Gear Torque Converters	225	(3)
Review Questions	226	(1)
Chapter Quiz	226	(2)
Transmission Descriptions	228	(40)
Learning Objectives	228	(1)
Introduction	228	(2)
Transaxles	229	(1)
Chrysler Corporation	230	(7)
DaimlerChrysler Rear Wheel Drive Transmissions	232	(4)
DaimlerChrysler Transaxles	236	(1)
Ford Motor Company	237	(10)
Ford Motor Company Rear Wheel Drive Transmissions	238	(4)
Ford Motor Company Transaxles	242	(5)
General Motors Corporation	247	(6)
General Motors Rear Wheel Drive Transmissions	247	(5)
General Motors Transaxles	252	(1)
Saturn Transaxle	253	(1)
Import Transmissions/Transaxles	253	(3)
Honda/Acura	256	(3)
Honda Three-Speed Transaxles	256	(1)
Honda Four-Speed Transaxles	257	(1)
Longitudinal Designs	258	(1)
Nissan	259	(1)
RWD Transmissions	259	(1)
FWD Transaxles	259	(1)
Toyota	259	(9)
RWD Transmissions	260	(2)
FWD Transaxles	262	(4)
Review Questions	266	(1)
Chapter Quiz	266	(2)
Transmission Service and Maintenance	268	(24)
Learning Objectives	268	(1)
Introduction	268	(1)
Fluid Checks	269	(3)
Transaxle Final Drives and Differentials	271	(1)
Fluid Condition	271	(1)
Fluid Changes	272	(8)
Fluid Changing, Dropping the Pan	274	(4)
Fluid Changing, Fluid Evacuator	278	(1)
Fluid Exchange and Flush Units	279	(1)
Manual Linkage Checks	280	(4)
Manual Linkage Adjustment	282	(2)
Throttle Linkage Checks	284	(4)
Throttle Linkage Adjustments	286	(2)
Band Adjustments	288	(4)
Review Questions	289	(1)
Chapter Quiz	290	(2)
Mechanical Problem Solving and Diagnosis	292	(40)
Learning Objectives	292	(1)
Introduction	292	(1)
Problem-Solving Procedures	293	(1)
Diagnostic Procedure	294	(2)
Visual Inspection	296	(1)
Road Test	296	(4)
Torque Converter Clutch Tests	300	(3)
Converter Clutch Hydraulic Checks	301	(1)
Cooler Circuit Flow Check	302	(1)
Hydraulic System Pressure Tests	303	(6)
Interpreting Pressure Readings	306	(1)
Fluid Flow Diagrams	307	(2)
Checking Governor Pressure	309	(1)
Modulator Checks	309	(3)
Modulator Diaphragm Leakage	309	(1)
Modulator Vacuum Supply	310	(1)
Modulator Stem Alignment	311	(1)
Modulator Spring Pressure	311	(1)
Stall Tests	312	(3)
Interpreting Stall Test Readings	314	(1)
Oil Pan Debris Check	315	(1)
Air Testing	315	(5)
Wet Air Checks	318	(1)
Isolating Valve Body Problems	318	(2)
Oil Leak Tests	320	(2)
Noise, Vibration, and Harshness (NVH)	322	(5)
Noise Checks	323	(3)
Vibration Checks	326	(1)
Troubleshooting Charts	327	(5)
Review Questions	327	(3)
Chapter Quiz	330	(2)
Electronic Transmission Problem Solving and Diagnosis	332	(41)
Learning Objectives	332	(1)
Electronic Transmission Diagnosis	332	(1)
Electrical Circuit Problems	333	(2)
Open Circuits	333	(1)
High-Resistance Circuits	334	(1)
Shorted Circuits	334	(1)
Grounded Circuits	334	(1)
Measuring Electrical Values	335	(13)
Measuring Voltage	338	(3)
Measuring Resistance	341	(1)
Measuring Amperage	342	(2)
Measuring Duty Cycle	344	(1)
Scan Tools	345	(2)
Oscilloscopes	347	(1)
Interpreting Measurements	347	(1)
Electrical/Electronic System Repair	348	(4)
Electronic Control System Checks	352	(8)
Recalibration	352	(3)
Electronic Control System Cautions	355	(1)
Diagnostic Trouble Codes (DTCs)	355	(4)
Signal Monitor	359	(1)
Forcing Shifts Electrically	359	(1)
Clutch Volume Index	359	(1)
EMI Electronic Problems	360	(1)
Electronic Component and Circuit Checks	360	(9)
TCM Power Checks	360	(3)
TCC Checks	363	(1)
Solenoid Checks	363	(3)
Switch Checks	366	(1)
Speed Sensor Checks	367	(1)
Throttle Position Sensor Checks	368	(1)
Temperature Sensor Checks	369	(1)
Electronic Repair Job Completion	369	(4)
Review Questions	369	(1)
Chapter Quiz	370	(3)
In-Vehicle Transmission Repair	373	(27)
Learning Objectives	373	(1)
Introduction	373	(1)
Manual Shift Linkage, Interlock, and Seal	374	(1)
Lip Seal Replacement	375	(1)
TV Linkage and Seal	376	(1)
Vacuum Modulator Removal and Replacement	377	(1)
Aluminum Thread Repair	378	(2)
Electrical Component Removal, Repair, and Replacement	380	(1)
Cooler Line and Fitting Repair	380	(3)
Valve Body Removal and Replacement	383	(3)
Servo and Accumulator Piston, Cover, and Seal Service	386	(2)
Remove, Replace, and Align Power Train Mounts	388	(1)
Extension Housing Seal and Bushing Service	388	(2)
Extension Housing Removal, RWD Transmission	390	(3)
Speedometer Gear Replacement	392	(1)
Park Gear and Pawl Service	393	(1)
Governor Service	393	(7)
Governor Disassembly	395	(2)
Review Questions	397	(1)
Chapter Quiz	398	(2)
Transmission/Transaxle Removal and Replacement	400	(18)
Learning Objectives	400	(1)
Introduction	400	(1)
Transmission Removal	401	(3)
Transaxle Removal	404	(2)
Drive Shaft Removal and Replacement	406	(6)
RWD Drive Shaft Removal and Replacement	407	(1)
FWD Drive Shaft Removal and Replacement	407	(5)
Transmission Installation	412	(2)
Transaxle Installation	414	(4)
Review Questions	416	(1)
Chapter Quiz	416	(2)
Transmission Overhaul: Disassembly and Reassembly	418	(34)
Learning Objectives	418	(1)
Introduction	418	(4)
Overhauled Transmissions	418	(1)
Remanufactured Transmissions	419	(1)
Transmission Parts	420	(1)
Overhaul Procedure	420	(2)
Transmission Disassembly	422	(1)
Predisassembly Cleanup	422	(1)
Torque Converter Removal	423	(1)
Disassembly Fixtures	423	(1)
Preliminary Disassembly	423	(6)
End Play Check	427	(2)
Other Predisassembly Checks	429	(1)
Pump Removal	429	(4)
Transaxles Using Input Chain Drive	431	(2)
Major Disassembly	433	(3)
Transmission Assembly	436	(16)
Pump Installation and End Play Adjustment	443	(4)
Torque Converter Installation	447	(3)
Review Questions	450	(1)
Chapter Quiz	450	(2)
Transmission Overhaul Procedures	452	(21)
Learning Objectives	452	(1)
Introduction	452	(1)
Component Cleaning	452	(2)
Bushing, Bearing, and Thrust Washer Service	454	(5)
Bushing Removal	456	(1)
Bushing Installation	457	(2)
Tapered Roller Bearing Service	459	(1)
Friction Material Service	459	(4)
Lined Plate Service	460	(1)
Steel Plate Service	461	(1)
Band Service	462	(1)
New Friction Material Preparation	463	(1)
Internal Seal Service	463	(10)
Fitting Rubber Seals	465	(1)
Installing Pistons with Lip Seals	466	(3)
Fitting Sealing Rings	469	(1)
Installing Teflon Sealing Rings	469	(2)
Review Questions	471	(1)
Chapter Quiz	471	(2)
Subassembly Repair	473	(36)
Learning Objectives	473	(1)
Subassembly Repair	473	(1)
Case Inspection	473	(5)
Pump Service	478	(5)
Clutch Assembly Service	483	(9)
One-Way Clutch Service	492	(1)
Gearset Service	492	(3)
Valve Body Service	495	(10)
Solenoids and Switches	505	(1)
Differential Service	506	(3)
Review Questions	507	(1)
Chapter Quiz	508	(1)
Torque Converter Service	509	(18)
Learning Objectives	509	(1)
Introduction	509	(1)
Torque Converter Checks	510	(7)
Visual Checks	510	(1)
Stator One-Way Clutch Check	511	(1)
End Play Check	512	(1)
Internal Interference Checks	513	(1)
Torque Converter Clutch Checks	514	(1)
Leak Checks	515	(2)
Torque Converter Cleaning	517	(3)
Drilling a Torque Converter	517	(1)
Cooler Cleaning	518	(2)
Torque Converter Rebuilding	520	(7)
Disassembling a Torque Converter	520	(1)
Cleaning	520	(1)
Subassembly Repair	521	(1)
Torque Converter Reassembly	522	(2)
Postassembly Checks	524	(1)
Review Questions	525	(1)
Chapter Quiz	525	(2)
Automatic Transmission Modifications	527	(18)
Learning Objectives	527	(1)
Introduction	527	(2)
Shift Quality	528	(1)
Shift Improver Kits	529	(5)
Orifice Changes	529	(2)
Accumulator Changes	531	(1)
Programming Changes, Electronic-Controlled Transmissions	531	(1)
Programming Changes, Nonelectronic-Controlled Transmissions	532	(2)
Clutch Packs	534	(3)
Increasing Pack Size	534	(2)
Drilling a Hub or Drum	536	(1)
Floater Springs	537	(1)
Band Changes	537	(1)
Improving Lubrication	537	(2)
Gear Train Changes	539	(1)
Competition Transmissions: Strengthening and Lightening Changes	540	(1)
Manual Shift Valve Bodies	540	(1)
High-Stall Converters	541	(1)
Direct Couplers	542	(1)
Conclusion	542	(3)
Appendix A ASE Certification	545	(4)
Appendix B Automatic Transmission Models	549	(16)
Appendix C ATF Specification Comparison	565	(6)
Appendix D OBD-II Transmission Diagnostic Trouble Codes	571	(2)
Appendix E J1930 Transmission Term Acronyms	573	(2)
Appendix F Shift Signal Monitor	575	(2)
Appendix G English-Metric-English Conversion Table	577	(2)
Appendix H ATTS and NATEF	579	(4)
English Glossary	583	(4)
Spanish Glossary	587	(8)
Index	595