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

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1、Chonan TSTC - KM(Kyoto Model) - Alpha, Beta series Application vehicle : SLC, Santamo J-1, Y-2,3 X-2,3 RD (Before 2000MY) Chonan TSTC 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 , Ser

2、ies 2nd. M/Year 5th. T/Con 6th. Spare Remarks P 4.029 Erect A SLC Y 4.310 Erect A SLC X-3 1.5 DOHC X-3 1.5 SOHC B X-3 1.3 SOHC RD 1.5 SOHC RD 1.5 DOHC F RD 1.5 DOHC WAGON Q 4.381 G RD 1.5 DOHC COUPE 4th. Vehicle G A4AF1 K A4AF2 3.656 1st. Digit A/T Type 3rd. F/Gear ratio SEDAN J : 1988 K : 1989 L :

3、1990 M : 1991 N : 1992 P : 1993 R : 1994 S : 1995 E4.041N CL MODEL LINE UP Torque converter Chonan TSTC 4 2. Identification No. for KM Series 2nd. M/Year 5th. T/Con 6th. Spare Remarks A 3.600 Erect A X-1 1.5 FBC D A D D D D D D D D Slant Slant B X-2 1.5 FBC J-1 1.6 DOHC J-1 1.5C 4th. Vehicle 1st. Di

4、git A/T Type 3rd. F/Gear ratio A KM171-5 E 3.600 Slant A X-2 1.5 FBC B KM176-5 G 4.367 F 4.062 J : 1988 K : 1989 L : 1990 M : 1991 N : 1992 P : 1993 R : 1994 S : 1995 T : 1996 V : 1997 W : 1998 X : 1999 Y : 2000 1 : 2001 A SLC 1.5 B J-1 1.6 DOHC C KM175-5 B C 4.007 Erect A Y-2 2.0 MFI B Y-2 1.8 MFI

5、4.350 Erect A L-1 2.0 MFI 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 apply side chamber of kickdown servo cy

6、linder, 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 To TCM Kickdown servo S/W Adjust rod with the kickdown drum) is held. This brake brake functions during 2nd gear and during overdrive. The ki

7、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 Chonan TSTC 31 the 2nd pressure both before, and during application of the brake

8、. In the initial 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 brak

9、e is being applied, 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

10、freely. A2 : 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 Chonan TSTC 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 wit

11、h relatively low pressure 3. K/D servo moves very fast to fasten the K/D drum with high pressure. Movement of K/D servo Service Point No. Cause Symptom Analysis Remedy Remarks 1 Looseness of K/D band Engine RPM sharply increase (Run-up) F/C is released prior to K/D band engaged. (1st gear state) Adj

12、ust K/D servo rod See note 2 Air exhaust plug cap separated - Shock when shift from 1st to 2nd and from 3rd to 4th gear - 3rd gear hold K/D piston cant move forward. (K/D band slippage) Replace air exhaust plug cap Checking method : repeated shifting from 3rd to 4th or opposite (O/D sw ON-OFF) COMPO

13、NENTS Chonan TSTC 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 times by torque of 5Nm (3.6lb.ft). 4. Again loosen the adjust screw 3 to 3-1/3 turns. 5. Tighten the lock

14、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 Chonan TSTC 34 5. Low-Reverse brake Center support Piston Hydraulic pressure Return spring Rear side Br

15、ake plate Brake disc Pressure plate (selective) Brake reaction plate COMPONENTS Chonan TSTC 35 Low-reverse brake is of the multiple disc type and is composed of a center support, disc plates and a piston. The brake operates when the shift is in 1st gear in the “L” range or back gear. It fastens the

16、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 installing hole. COMPONENTS Installation hole of pulse generator A (before 94MY) Cho

17、nan TSTC 36 Service Point No. Cause Symptom Analysis Remedy Remarks 1 Pressure plate misselected Shock generated during L or R shift - Reverse drive impossible - Stall RPM too high (Clutch slippage) Select the proper pressure plate “N” ”R” shift (C1,B2) t(sec) B2 actuation point moved C1 actuation p

18、oint (delayed proper endplay) B2 actuation point (delayed:wave spring+proper end play) COMPONENTS : Analysis Chonan TSTC 37 6. One-way Clutch (O.W.C) Free Lock Sprag Outer race (Planetary gear carrier) Inner race (Center support) Forward sun gear Reverse sun gear Annulus gear Short pinion Long pinio

19、n Carrier COMPONENTS Chonan TSTC 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 range), the long pinion rotates clockwise. This reduces a force which has the tendency to cause the carrier is blocked from rotating in th

20、at 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 outer race, is free to turn in clockwise direction. In an engine braking condition under which the annulus gear is turned first, the carrier

21、 turns clockwise freely and, therefore, the engine braking effect is not obtained. Service Point No. Cause Symptom Analysis Remedy Remarks 1 O.W.C wear or damaged Forward drive impossible Planetary carrier rotates reverse Replace O.W.C Checking method : Drive is possible at L range COMPONENTS Chonan

22、 TSTC 39 7. Planetary Gear Forward sun gear Reverse sun gear Annulus gear Short pinion Long pinion Carrier Parking sprag Outer race One-way clutch Low-reverse brakes hub COMPONENTS Chonan TSTC 40 The planetary gear set incorporated in this transaxle consists of a forward sun gear, a reverse sun gear

23、, a short pinion, a carrier to support both pinions, and an annulus gear. 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 out

24、er race of the one-way clutch. The carrier is connected to the end clutch 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

25、of the annulus gear. COMPONENTS Chonan TSTC 41 8. Parking Mechanism Parking sprag (Annulus gear) Parking pawl Parking sprag rod Cam Support Support Parking sprag rod Detent ball (From 97My : Roller type) Detent plate (Manual control shaft) COMPONENTS Chonan TSTC 42 When the shaft is in the “P” range

26、, the parking pawl engages with the parking sprag provided on outer circumference of the annulus gear 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 ar

27、row, causing the cam on the parking sprag rod to push up the parking pawl to engage with the sprag. 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 pa

28、wl and the support, and is withheld in this condition. If the car is moved even slightly in this condition, 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 parkin

29、g sprag to engage with the sprag. In this way, the parking mechanism eliminates any chances of the vehicle from being idly moved. COMPONENTS Chonan TSTC 43 Service Point No. Cause Symptom Analysis Remedy Remarks 1 Calking due to cam broken Forward and/or reverse drive impossible intermmittently Park

30、ing sprag locks the annulus gear due to drifted cam Replace parking sprag rod 2 Detent ball separated Looseness of manual lever Detent plate not fixed properly Install detent ball COMPONENTS Chonan TSTC 44 1st Gear (“D” and “2” range) Operating elements : * Rear clutch * One-way clutch Short pinion

31、Carrier Forward sun gear Transfer drive gear Idler gear Transfer driven gear Rear clutch One-way clutch Long pinion Annulus gear POWER FLOW Chonan TSTC 45 1st Gear (“L” range) Operating elements : * Rear clutch * Low-reverse brake Short pinion Carrier Forward sun gear Rear clutch Long pinion Annulus

32、 gear Low-reverse brake POWER FLOW Chonan TSTC 46 2nd Gear Operating elements : * Rear clutch * Kickdown brake Short pinion Forward sun gear Kickdown brake Annulus gear Rear clutch Long pinion POWER FLOW Chonan TSTC 47 3rd Gear Operating elements : * Front clutch * Rear clutch * End clutch Forward s

33、un gear Carrier End clutch Annulus gear Reverse sun gear Rear clutch Front clutch POWER FLOW Chonan TSTC 48 4th Gear (Overdrive) Operating elements : * Kickdown brake * End clutch Kickdown brake End clutch Long pinion Carrier Annulus gear Reverse sun gear POWER FLOW Chonan TSTC 49 Reverse Operating

34、elements : * Front clutch * Low-reverse brake Low-reverse brake Front clutch Reverse sun gear Carrier Annulus gear Long pinion POWER FLOW : , . Chonan TSTC 50 1. Oil Pump 2. Valve Body 3. Operation of Each Valve 4. Adjustment of Hydraulic Pressure CONTENTS HYDRAULIC CONTROL SYSTEM : Chonan TSTC 51 T

35、he 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 valves and solenoid valves are built into the valve body. Oil seal Housing Drive gear O

36、-ring Seal ring Snap ring Steel ball Driven gear Reaction shaft support Bolt Seal ring OIL PUMP Chonan TSTC 52 Oil pump generates pressure for supplying oil to the torque converter, for lubricating frictional parts of the planetary gearing set and the overrunning clutch, etc., and for activating the

37、 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 the center of the torque converter shell. Service Point No. Cause Symptom An

38、alysis Remedy Remarks 1 Foreign material stuck in check valve - Forward drive impossible - Abnormal shock felt when forward drive Rear clutch slippage clean oil pump and reinstall steel ball 2 Improper oil pump gear clearance (side clearance) - Forward drive impossible - Abnormal shock felt when for

39、ward drive Oil pump gear broken Replace oil pump drive it functions to produce a constant pressure which is always lower than the line pressure. With this pressure as the hydraulic pressure source, the control pressure is produced by the pressure control solenoid valve, thus activating the pressure

40、control valve. OPERATION OF EACH VALVE Chonan TSTC 72 Reducing Valve Transaxle Control Module Ex Ex Ex Ex OFF Pressure Control valve Pressure Control Solenoid valve N-R Control valve Reducing valve Adjusting screw Ex Ex Line pressure 1 23 9 16 23b 23 10 5 OPERATION OF EACH VALVE Chonan TSTC 73 Shift

41、 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 Chonan TSTC 74 Shift Control Valve and Solenoid Valves The line pressure acting upon the shift control va

42、lve is controlled by the two shift control solenoid valves (which are switch ON and OFF according to the shifting gear by the transaxle control module command), and the shift control valve is activated according to the shifting gear, thus switching the oil passages. The relationship of the shifting

43、gear and the ON-OFF switch of shift control solenoid valve “A” and “B” is shown in the table below. A B 1st gear ON ON 2nd gear OFF ON 3rd gear OFF OFF 4th gear ON OFF Shift control solenoid valve Operation Position OPERATION OF EACH VALVE Chonan TSTC 75 Shift Control Valve and Solenoid Valves The s

44、hift control solenoid valve “A” controls the line pressure that acts on the plugs, while the solenoid valve “B” controls the pressure that acts on the left end of the shift control valve #1 land. As the #1 land diameter is lager than that of the #2 land, the direction of movement of the shift contro

45、l solenoid valve caused by application of pressure between these lands is to the left. If the pressure is also directed to the left end of the #1 land through the No.5b port, pressure acting on its right end is cancelled by this pressure and the shift control valve is forced to the right by the pres

46、sure applied to the #2 land. OPERATION OF EACH VALVE Chonan TSTC 76 Pressure Control Valve, Solenoid Valve and N-R Control Valve Pressure Control Valve This valve regulates the pressure supplied to each clutch under the control of the pressure control solenoid valve to eliminate shock at the time of

47、 shifting. Pressure Control Solenoid Valve This valve has its duty controlled by the transaxle control module command. It changes an electric command to corresponding hydraulic pressure. No. Cause Symptom Analysis Remedy Remarks 1 Foreign material attached to PCV Shock generated when shift Electroni

48、c pulse by TCM is not transmitted to PCV Clean or replace PCV 2 Foreign material attached to jet in valve body Abrupt increasement of engine rpm Decreasement of reducing pressure (Occurs run-up) Clean valve body Service Point OPERATION OF EACH VALVE Chonan TSTC 77 Pressure Control Valve, Solenoid Va

49、lve and N-R Control Valve Note : Actuator test for PCSV SA Pressure Standard value : 2.53.1 kg/cm2 50% Duty (%) OPERATION OF EACH VALVE Chonan TSTC 78 N-R Control Valve Transaxle Control Module Ex Ex Ex Ex ON Pressure Control valve Pressure Control Solenoid valve N-R Control valve 9 16 23b 23 10 5 P

50、 R N D 2 L Ex Ex Manual valve 1 9 4 5 9 Ex To front clutch Line pressure Reducing pressure To low-reverse brake Check ball Reducing pressure OPERATION OF EACH VALVE Chonan TSTC 79 N-R Control Valve This valve prevents shock from occurring when the select lever is shifted from “N” to “R” (or from “P”

51、 to “R”) by controlling the oil pressure applied to the low-reverse brake. When the manual valve is shifted to the “R” range position, the pressure control solenoid valve functions under duty control from the transaxle control module to reduce the reducing pressure in the No.23b line and to create a

52、nother control pressure in this line. The balance of forces established between the control pressure and the N-R control valve spring determines the degree in which the No.9 line port will be open. The line pressure from the No.9 line is regulated by passing through the port whose opening has been a

53、djusted and then directed to the low-reverse brake. Through this pressure control, the shocks that would occur while shifting to reverse are minimized. Once the low-reverse brake is engaged, the pressure control solenoid valve is deenergized and normal reducing pressure is reestablished in the No.23

54、b line. Since the reestablished OPERATION OF EACH VALVE Chonan TSTC 80 N-R Control Valve reducing pressure moves the N-R control valve toward the left, the line pressure passing through the No.9 port applies directly to the low-reverse brake through the No.16 port and engages the brake with a strong

55、 pressure force. No. Cause Symptom Analysis Remedy Remarks 1 - Foreign material attached to N-R control valve or defective - Foreign material attached to check valve Shock generated when shift N or R range Line pressure is applied to low- reverse brake without duty control Clean valve body or replac

56、e defective part Service Point OPERATION OF EACH VALVE Chonan TSTC 81 R range fail safe function Transaxle Control Module Ex Ex Ex Ex ON Pressure Control valve Pressure Control Solenoid valve N-R Control valve 9 16 23b 23 10 5 P R N D 2 L Ex Ex Manual valve 1 9 4 5 9 Ex To front clutch Line pressure

57、 Reducing pressure To low-reverse brake Check ball Reducing pressure OPERATION OF EACH VALVE Chonan TSTC 82 R range fail safe function The hydraulic control system incorporates a “fail safe feature” which prevents the gear shift from going into reverse, should the driver inadvertently shift the sele

58、ctor lever from a forward drive range to the reverse range while driving. This function is activated when the vehicle is running at a speed of 7 km/h (4.3mph) or higher. If the selector lever is shifted into the “R” position, the transaxle control module activates the pressure control solenoid valve

59、 to release the reducing pressure. Once the reducing pressure drops, the N-D control valve is moved toward the right by the spring force. This closes the No.9 port and causes the pressure in passage 16 to be released. When the pressure in passage 16 is released, the check ball is forced against the

60、right-hand port opening, and shuttle off the line pressure. As a result, the low-reverse brake is released. Although the front clutch is engaged in this situation, the transaxle cannot transmit the reverse driving power unless the low-reverse brake is applied. OPERATION OF EACH VALVE Chonan TSTC 83

61、R range fail safe function Therefore, when the transaxle is placed under the above mentioned condition, it is the same as when it is neutral. 1-2Shift Valve This valve is activated by the line pressure that has been regulated by the shift control valve to change the line pressure flow when shifting

62、is performed between 1st and 2nd gears. It also controls the hydraulic pressure passage to the low-reverse brake when in the R(reverse) gear. 2-3/4-3 Shift Valve The 2-3/4-3 shift valve operates in response to line pressure (3rd to 4th pressure) from the shift control valve, and controls the pressur

63、e acting on the front and rear clutches, and also the kickdown servo release pressure. OPERATION OF EACH VALVE Chonan TSTC 84 1-2 Shift Valve Line pressure 5b Shift control valve 2nd pressure Ex Ex SCSV “B” ON Ex SCSV “A” ON 5b 5a 5b 5a 5a 5 5a 6 7 8 6 16 10 Ex 17 11 To Low-reverse brake 1-2 shift v

64、alve From pressure control valve First speed (at “L” range) OPERATION OF EACH VALVE Chonan TSTC 85 1-2 Shift Valve Line pressure 5b Shift control valve 2nd pressure Ex Ex Ex 5b 5a 5b 5a 5a 5 5a 6 7 8 6 16 10 Ex 17 11 To kickdown servo apply side 1-2 shift valve From pressure control valve Second spe

65、ed SCSV “B” ON SCSV “A” OFF OPERATION OF EACH VALVE Chonan TSTC 86 2-3/4-3 Shift Valve Line pressure 5b Shift control valve Ex Ex Ex 5b 5a 5b 5a 5a 5 5a 6 7 8 6 16 10 Ex 17 11 1-2 shift valve From pressure control valve SCSV “B” SCSV “A” OPERATION OF EACH VALVE Rear clutch exhaust valve 2-3/4-3 shif

66、t valve To end clutch valve Kickdown servo apply side Kickdown servo release side Rear clutch Front clutch From N-D control valve Chonan TSTC 87 Rear Clutch Exhaust Valve OPERATION OF EACH VALVE A To front clutch To rear clutch To kickdown servo release side B Rear clutch exhaust valve 2-3/4-3 shift valve From 1-2 shift valve Shift control solenoid valve-A Ex Shift control solenoid valve-B Ex Ex Chonan TSTC 88 Rear Clutch Exhaust Valve This valve is actuated by the line pressure controlled by th