Automatic Transmissions and Transaxles

by Birch, Tom; Rockwood, Chuck

• ISBN13: 9780130846945
• ISBN10: 0130846945
• Edition: 2nd
• Format: Paperback
• Copyright: 2002-01-01
• Publisher: PRENTICE HALL

Summary

Undergraduate level courses in Automatic Transmissions Theory or Service. Automotive Transmissions and Transaxles is a comprehensive text that covers the operating principles as well as the service and repair procedures for modern automatic transmissions and transaxles. It is the most complete and up-to-date text on the subject, with hundreds of illustrations and thorough coverage of modern automatic transmissions. The readable format begins with operating theory and progresses from service and maintenance operations to problem diagnosis and repair procedures.

Table of Contents

Introduction to Transmissions	1	(30)
Transmissions: Their Purpose	1	(2)
Torque and Horsepower	3	(1)
Gear Ratios	4	(3)
Tractive Force	7	(2)
Standard Transmission and Clutch	9	(2)
Simple Planetary Gearsets	11	(4)
Compound Planetary Gearsets	15	(1)
Control Devices	15	(2)
Transmission Hydraulics	17	(2)
Torque Converters	19	(1)
Transaxle Final Drive and Differential	20	(3)
Four Wheel Drive	23	(2)
Nonplanetary Gear Automatic Transmissions	25	(1)
Hybrid Drive System	25	(6)
Apply Devices: Clutches and Bands	31	(20)
Introduction	31	(1)
Driving Devices	31	(1)
Multiple-Disc Driving Clutches	32	(7)
Clutch Plates	35	(2)
Clutch Operation	37	(2)
One-Way Driving Clutches	39	(2)
Clutch Operation	40	(1)
Holding/Reaction Devices	41	(1)
Multiple-Disc Holding Clutches	42	(1)
One-Way Holding Clutches	42	(1)
Bands	42	(3)
Band Operation	44	(1)
Shift Quality	45	(6)
Shifts Involving One-Way Clutches	47	(1)
Deceleration with One-Way Clutches	47	(4)
Power Flow Through Transmission Gearsets	51	(46)
Rules of Power Transfer	51	(3)
Planetary Gear Ratios	52	(2)
Transaxles	54	(1)
Park	55	(2)
Transmission Schematics	57	(2)
Simpson Gear Train Transmissions	59	(7)
Neutral	61	(1)
First Gear	61	(1)
Second Gear	62	(1)
Third Gear	63	(1)
Reverse	64	(2)
Shift Timing	66	(1)
Simpson Gear Train Plus and Additional Gearset	67	(4)
Overdrive	67	(4)
Ravigneaux Gearsets	71	(9)
Two-Speed Arrangement and Operation	72	(1)
Three-Speed Arrangement and Operation: First Version	72	(2)
Three-Speed Arrangement and Operation: Second Version	74	(1)
Four-Speed Arrangement and Operation: First Version	74	(5)
Four-Speed Arrangement and Operation: Second Version	79	(1)
Four-Speed Overdrive Gearset	80	(10)
Four-Speed Overdrive Gearset: Second Version	80	(7)
Four-Speed Overdrive Gearset: Variation of Second Version	87	(3)
Four-Speed Overdrive: Variation Two	90	(1)
Nonplanetary Gearsets	90	(7)
Helical Gear Types	90	(1)
CVT Types	90	(7)
Hydraulic System Theory	97	(32)
Introduction	97	(1)
Hydraulic Principles	97	(3)
Simple Hydraulic Systems	100	(1)
Basic Automatic Transmission Hydraulics	101	(1)
Producing Fluid Flow and Pressure	101	(5)
Providing Clean Fluid	106	(2)
Controlling Fluid Flows	108	(6)
Valve Hydraulic Forces	113	(1)
Controlling Fluid Pressure	114	(1)
Sealing Fluid Pressure	115	(5)
Special Notes on Elastomers	118	(2)
Applying Fluid Pressure	120	(1)
Determining Piston Forces	121	(1)
Modifying Flow and Pressure	121	(2)
Automatic Transmission Fluid	123	(6)
Hydraulic Shift Control	129	(30)
Introduction	129	(2)
Pressure Development and Control	131	(2)
Torque Converter, Oil Cooler, and Lubrication Circuit	133	(7)
Torque Converter Pressure Control	134	(2)
Torque Converter Clutch Control	136	(1)
Cooler Flow	137	(2)
Lubrication Flow	139	(1)
Throttle Pressure	140	(5)
Mechanical Throttle Valves	141	(1)
Vacuum Throttle Valves	142	(1)
Wide-Open Throttle Kickdown Valve	143	(2)
Manual Valve	145	(1)
Governor Valve	145	(5)
Shift Valves	150	(9)
Shift Overlap	151	(1)
Shift Modifiers	152	(3)
Downshifts	155	(4)
Electronic Transmission Controls	159	(28)
Introduction	159	(2)
Basic Electricity	161	(6)
System Components	164	(3)
Basic Electronic	167	(20)
Sensors	167	(7)
Electronic Transmission Shift Controls	174	(3)
Accuators	177	(10)
Torque Converters	187	(14)
Introduction	187	(1)
Construction	187	(2)
Operation	189	(3)
Torque Multiplication	191	(1)
Coupling Phase	192	(1)
Torque Converter Clutches	192	(3)
Viscous Converter Clutch	195	(1)
Stall Speed	195	(2)
Stall Factors	195	(2)
Planetary Gear Torque Converters	197	(4)
Transmission Descriptions	201	(40)
Introduction	201	(2)
Transaxles	202	(1)
Chrysler Corporation	203	(6)
DailmerChrysler Rear Wheel Drive Transmissions	204	(3)
DaimlerChrysler Front Wheel Drive Transaxles	207	(2)
Ford Motor Company	209	(12)
Ford Motor Company Rear Wheel Drive Transmissions	211	(4)
Ford Motor Company Front Wheel Drive Transaxles	215	(6)
General Motors Corporation	221	(9)
General Motors Rear Wheel Drive Transmissions	221	(5)
General Motors Front Wheel Drive Transaxles	226	(4)
Saturn Transaxle	230	(1)
Import Transmissions/Transaxles	230	(1)
Honda/Acura	230	(3)
Honda Three-Speed Transaxles	230	(1)
Honda Four-Speed Transaxles	231	(1)
Longitudinal Designs	232	(1)
Nissan	233	(1)
RWD Transmissions	233	(1)
FWD Transaxles	233	(1)
Toyota	233	(8)
RWD Transmissions	235	(1)
FWD Transaxles	236	(5)
Transmission Service and Maintenance	241	(22)
Introduction	241	(1)
Fluid Checks	241	(3)
Transaxle Final Drives and Differentials	243	(1)
Fluid Condition	243	(1)
Fluid Changes	244	(7)
Fluid Exchange and Flush Units	250	(1)
Manual Linkage Checks	251	(2)
Manual Linkage Adjustment	253	(1)
Throttle Linkage Checks	253	(6)
Throttle Linkage Adjustments	257	(2)
Band Adjustments	259	(4)
Mechanical Problem Solving and Diagnosis	263	(36)
Introduction	263	(1)
Problem-Solving Procedures	264	(1)
Diagnostic Procedure	265	(1)
Visual Inspection	266	(1)
Road Test	266	(4)
Torque Converter Clutch Tests	270	(3)
Converter Clutch Hydraulic Checks	271	(1)
Cooler Circuit Flow Check	272	(1)
Hydraulic System Pressure Tests	273	(6)
Interpreting Pressure Readings	275	(2)
Fluid Flow Diagrams	277	(1)
Checking Governor Pressure	277	(2)
Modulator Checks	279	(3)
Modulator Diaphragm Leakage	279	(1)
Modulator Vacuum Supply	280	(1)
Modulator Stem Alignment	280	(1)
Modulator Spring Pressure	281	(1)
Stall Tests	282	(3)
Interpreting Stall Test Readings	284	(1)
Oil Pan Debris Check	285	(1)
Air Tests	285	(3)
Wet Air Checks	288	(1)
Isolating Valve Body Problems	288	(1)
Oil Leak Tests	288	(2)
Noise, Vibration, and Harshness (NVH)	290	(4)
Noise Checks	291	(2)
Vibration Checks	293	(1)
Troubleshooting Charts	294	(5)
Electronic Transmission Problem Solving and Diagnosis	299	(36)
Electronic Transmission Diagnosis	299	(1)
Electrical Circuit Problems	300	(2)
Open Circuits	301	(1)
High Resistance Circuits	301	(1)
Shorted Circuits	301	(1)
Grounded Circuits	301	(1)
Measuring Electrical Values	302	(9)
Measuring Voltage	304	(2)
Measuring Resistance	306	(1)
Measuring Amperage	307	(1)
Scan Tools	307	(3)
Oscilloscopes	310	(1)
Interpreting Measurements	311	(1)
Electrical/Electronic System Repair	311	(4)
Electronic Control System Checks	315	(7)
Recalibration	316	(2)
Electrostatic Discharge	318	(1)
Codes	318	(3)
Signal Monitor	321	(1)
Forcing Shifts Electrically	321	(1)
Clutch Volume Index	321	(1)
EMI Electronic Problems	322	(1)
Electronic Component and Circuit Checks	322	(8)
ECM Power Checks	322	(3)
TCC Checks	325	(1)
Solenoid Checks	325	(2)
Switch Checks	327	(2)
Speed Sensor Checks	329	(1)
Throttle Position Sensor Checks	330	(1)
Temperature Sensor Checks	330	(1)
Electronic Repair Job Completion	330	(5)
In-Vehicle Transmission Repair	335	(24)
Introduction	335	(1)
Manual Shift Linkage, Interlock, and Seal	336	(1)
Lip Seal Replacement	337	(1)
TV Linkage and Seal	338	(1)
Vacuum Modulator Removal and Replacement	339	(1)
Aluminum Thread Repair	340	(2)
Electrical Component Removal, Repair, and Replacement	342	(1)
Cooler Line and Fitting Repair	342	(2)
Value Body Removal and Replacement	344	(3)
Servo and Accumulator Piston, Cover, and Seal Service	347	(1)
Extension Housing Seal and Bushing Service	348	(3)
Extension Housing Removal, RWD Transmission	351	(2)
Speedometer Gear Replacement	352	(1)
Park Gear and Pawl Service	353	(1)
Governor Service	353	(6)
Governor Disassembly	354	(5)
Transmission/Transaxle Removal and Replacement	359	(18)
Introduction	359	(1)
Transmission Removal	360	(2)
Transaxle Removal	362	(3)
Drive Shaft Removal and Replacement	365	(7)
RWD Drive Shaft Removal and Replacement	365	(1)
FWD Drive Shaft Removal and Replacement	366	(6)
Transmission Installation	372	(2)
Transaxle Installation	374	(3)
Transmission Overhaul: Disassembly and Reassembly	377	(34)
Introduction	377	(3)
Overhauled Transmissions	377	(1)
Remanufactured Transmissions	378	(1)
Transmission Parts	378	(1)
Overhaul Procedure	379	(1)
Transmission Disassembly	380	(3)
Predisassembly Cleanup	380	(1)
Torque Converter Removal	380	(1)
Disassembly Fixtures	380	(3)
Preliminary Disassembly	383	(7)
End Play Check	387	(2)
Other Predisassembly Checks	389	(1)
Pump Removal	390	(3)
Transaxles Using Input Chain Drive	392	(1)
Major Disassembly	393	(5)
Transmission Assembly	398	(13)
Pump Installation and End Play Adjustment	403	(3)
Torque Converter Installation	406	(5)
Transmission Overhaul Procedures	411	(22)
Introduction	411	(1)
Component Cleaning	411	(2)
Bushing, Bearing, and Thrust Washer Service	413	(5)
Bushing Removal	413	(4)
Bushing Installation	417	(1)
Tapered Roller Bearing Service	418	(1)
Friction Material Service	418	(4)
Lined Plate Service	420	(1)
Steel Plate Service	420	(2)
Band Service	422	(1)
New Friction Material Preparation	422	(1)
Internal Seal Service	422	(11)
Fitting Rubber Seals	425	(1)
Installing Pistons with Lip Seals	426	(2)
Fitting Sealing Rings	428	(1)
Installing Teflon Sealing Rings	429	(4)
Subassembly Repair	433	(34)
Subassembly Repair	433	(1)
Case Inspection	433	(4)
Pump Service	437	(6)
Clutch Assembly Service	443	(8)
Gearset Service	451	(1)
Valve Body Service	452	(10)
Solenoids and Switches	462	(1)
Differential Service	462	(5)
Torque Converter Service	467	(18)
Introduction	467	(1)
Torque Converter Checks	468	(6)
Visual Checks	468	(1)
Stator One-Way Clutch Check	468	(2)
End Play Check	470	(1)
Internal Interference Checks	471	(1)
Torque Converter Clutch Checks	472	(1)
Leak Checks	473	(1)
Torque Converter Cleaning	474	(3)
Drilling a Torque Converter	475	(1)
Cooler Cleaning	475	(2)
Torque Converter Rebuilding	477	(8)
Disassembling a Torque Converter	478	(1)
Cleaning	478	(1)
Subassembly Repair	479	(1)
Torque Converter Reassembly	480	(1)
Postassembly Checks	480	(5)
Automatic Transmission Modifications	485	(18)
Introduction	485	(2)
Shift Quality	486	(1)
Shift Kits	487	(5)
Orifice Changes	487	(2)
Accumulator Changes	489	(1)
Programming Changes, Electronic-Controlled Transmissions	490	(1)
Programming Changes, Nonelectronic-Controlled Transmissions	490	(2)
Clutch Packs	492	(3)
Increasing Pack Size	493	(1)
Drilling a Hub or Drum	494	(1)
Floater Springs	495	(1)
Band Changes	495	(1)
Improving Lubrication	495	(2)
Gear Train Changes	497	(1)
Competition Transmissions: Strengthening and Lightening Changes	498	(1)
Manual Shift Valve Bodies	499	(1)
High-Stall Converters	499	(1)
Direct Couplers	500	(1)
Conclusion	500	(3)
Appendix A ASE Certification	503	(4)
Appendix B Automatic Transmission Models	507	(14)
Appendix C ATF Specification Comparison	521	(6)
Appendix D OBD-II Transmission Diagnostic Trouble Codes	527	(2)
Appendix E J1930 Transmission Term Acronyms	529	(2)
Appendix F Shift Signal Monitor	531	(2)
Appendix G English-Metric-English Conversion Table	533	(2)
Appendix H CATTS and NATEF	535	(2)
Glossary	537	(4)
Index	541