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T-Car Service Training Manual: Automatic Transmission

Instructor Guide

Table of Contents
3.0 General Information: Description ......................................................... 5 General Information: Specification ............................................................ 6 General Information: Application of Transmission ..................................... 7 Control Mode: Control Driving Mode ......................................................... 8 Operation: Function of Components ....................................................... 13 Operation: Operation Chart ..................................................................... 14 Operation: Power Flow (Reverse Gear) .................................................. 15 Power Flow: 1st Gear .............................................................................. 16 Power Flow: 2nd Gear............................................................................. 17 Power Flow: 3rd Gear ............................................................................. 18 Power Flow: 4th Gear.............................................................................. 19 Control System: Control System Feature ................................................ 20 Control System: Schematic of Electrical Control System ........................ 21 Control System: Schematic of Hydraulic Control System........................ 22 Control System: System Control Description .......................................... 23 Control System: Output Speed Sensor ................................................... 24 Control System: Input Speed Sensor ...................................................... 25 Control System: Fluid Temperature Sensor ............................................ 26 Control System: Shift Solenoid................................................................ 27 Control System: Shift Solenoid 1, 2......................................................... 28 Control System: Pressure Control Solenoid ............................................ 29 Control System: Lock-up Solenoid .......................................................... 30 Control System: Timing Solenoid ............................................................ 31 Control System: PNP Switch ................................................................... 32 Control System: Brake Transmission Shift Interlock ............................... 33 Control System: CAN Communication .................................................... 34 Diagnosis: Input/Output Factor of TCM ................................................... 35 Diagnosis: Transmission Control Module (TCM) ..................................... 36 Diagnosis: Hold Lamp ............................................................................. 38 Diagnosis: Diagnostic Trouble Codes (DTCs) ......................................... 39 Diagnosis: Fail safe (Default Action) ....................................................... 41 Diagnosis: General Diagnosis Procedure ............................................... 43 Diagnosis: Fluid Level Check .................................................................. 44 Diagnosis: Time Lag Test........................................................................ 45 Diagnosis: Stall Test ............................................................................... 46 Diagnosis: Line Pressure test.................................................................. 47 Diagnosis: Fluid Pressure Check Port..................................................... 48 Special Tools ........................................................................................... 51 Special Tools ........................................................................................... 52 Automatic Transmission: Lab 1 ............................................................... 54 Automatic Transmission: Lab 2 ............................................................... 55 Automatic Transmission: Lab 3 ............................................................... 56 Automatic Transmission: Lab 4 ............................................................... 57 Automatic Transmission: Test Questions ................................................ 58

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AT-1

3.0 General Information: Description


The AISIN Automatic Transmission (81-40LE) is an electrically controlled four-speed transmission with a lock-up mechanism. It is designed for front wheel drive vehicles with a transversely mounted engine. The 81-40LE AT consists of a torque converter with lock-up clutch, 4 speed with 2 sets of planetary gear units (Ravigneaux-type) that are light and compact. They utilize both hydraulic and electronic control systems. The 81-40LE has the following features: The TCM(Transmission Control Module) controls the clutches and the brakes based on the shift pattern for each driving mode (economy, power, hold, up-hill 1, 2, down-hill and lock-up). During shifting, the engine torque and hydraulic pressure in the transmission are electronically controlled in order to reduce shifting harshness.

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Structure of Automatic Transmission(81-40LE)

AT-2

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General Information: Specification

Application

Specification 81-40 LE(Forward 4th, Reverse 1st) 216 mm (8.5 in) 54 Kg (119 lbs) Economy / Power / Hold/ Up-slop1,2 / Down-slope Engaged At 4th Gear in Economy 2.875 : 1 1.568 : 1 1.000 : 1 0.697 : 1 2.300 : 1 1.019 3.750 : 1(1.5L), 4.052 : 1(1.4 L) P-R-N-D-2-1 Forward clutch Direct clutch Reverse clutch Over Drive(O/D) & 2nd coast brake 2nd brake 1st & Reverse brake One way clutch No.1 One way clutch No.2 ISU Dexron III / JWS-3309(T-IV) Not required 5.6 L (5.9 qt) When Overhaul 2.1 5.6 L (5.9 qt) D : 2240 ~ 2440 RPM

Remarks Electronically controlled

Instructor Guide

Type Torque Converter Diameter Weight Control Mode Lock-up Clutch 1st 2nd 3rd Gear Ratio 4th Reverse Counter Gear Ratio Final Gear Ratio Shift Lever Range C1 Clutch C2 C3 Brake B1 B2 B3 One way clutch Oil type Oil Replacement Oil Capacity Oil Filter Replacement when replace Oil Refill when overhaul Stall RPM F1 F2

Daewoo / AW

General Information: Application of Transmission


Transmission Applications
Area for Auto T/M (Aisin) Model Engine type 1.2L SOHC 1.5L SOHC T-Car 1.4L SOHC 1.4L DOHC 1.6L DOHC Domestic/General AW80-40LE AW81-40LE Not used Not used Not used Europe AW80-40LE Only M/T Only M/T AW81-40LE Not used North America Not used Not used Not used Not used AW81-40LE Remarks

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Identification

AT-3

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Control Mode: Control Driving Mode


Shift Lever Position

AT-4

Driving Mode
Economy/Power mode The Economy mode is used for normal driving conditions. Drivers link is detected using adaptive learning from the accelerator operation. This control changes shift points to economy (low speed) and power (high speed) according to the linking degree.
Range "D" range "2" Range "1" range Economy mode 1234(L) 12 3 12 Power mode 1234 123 1 2 Remarks : Shift up/down : Only shift down (L) : Lock-up

Control Mode: Control Driving Mode


Driving Mode
Hold mode This mode is used as a 3rd gear vehicle start on slippery roads by pushing the hold mode switch.
Range "D" range "2" Range "1" range Hold mode 3rd gear 2 3 1 2 : Only shift down Remarks

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Up-hill mode 1,2 This function detects up-hill conditions and changes the shift mode to avoid constant shifting during up-hill travel or towing. The TCM detects up-hill travel from engine torque and decreasing acceleration, this mode changes shift points in up-hill, 1 and 2 depending on the incline.

Operating condition of Up-slope mode 1) "D", "2","1" range 2) After warm-up(Oil Temp 40C (104F)) 3) Vehicle speed is more than 5 km/h 4) Above all conditions should be satisfied.

Release condition of Up-slope mode 1) "P", "R" "N" range 2) Vehicle stoped 3) Flat road 4) Hold mode 5) Vehicle speed is less than 5 km/h

Down-hill mode This function detects down-hill road conditions and changes the shift map to brake the engine without manually shifting. When the TCM detects down-hill travel from engine torque and increase in acceleration with the accelerator closed, this mode operates engine brake by changing shift points in the down-hill mode.

Operating condition of Down-slope mode 1) "D" range 2) After warm-up(Oil Temp 40C (104F)) 3) Vehicle speed is more than 8 km/h. 4) Above all conditions should be satisfied

Release condition of Down-slope mode 1) Except "D" range 2) Vehicle stopped 3) Flat road 4) Hold mode 5) Vehicle speed is less than 5 km/h

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Control Mode: Control Driving Mode


Driving Mode
Emergency mode If shift-related trouble codes cause the TCM to shut down power to the solenoid valves to protect the transmission the vehicle can still be driven by shifting manually.
Shift lever range Availble gear P P R R N N D 3 2 3 1 3

Shift control and Lock-up control The TCM sends signals to the S1, S2 which operate the on/off shift control according to each shift schedule. The TCM signals are sent after receiving input from the throttle valve signal, vehicle speed signal, shift lever signal and so on.
Gear 1 st gear 2 nd gear 3 rd gear 4 th gear Solenoid (S1) On On Off Off Solenoid (S2) On Off Off On

Lock-up control /Lock-up inhibit The TCM controls the Lock-up solenoid on/off based on vehicle speed and throttle opening in order to optimize driving performance and fuel economy. During the conditions in the chart below, this control cuts Lockup operation at shift down or idle conditions. The Lock-up will disengage to prevent the engine from stalling when the brake pedal is depressed.

Cut off condition of Lock-up operation 1. Except "D" range 2. 4th & Brake switch "On" 3. Transmission oil Temp' is less than - 40C 4. Engine Temp' is less than - 40C

Control Mode: Control Driving Mode


Driving Mode
4th gear cut control at low temperature This eliminates 4th gear when the engine is at low temperature or: The shift lever is in the 2 or 1 range The A/T fluid temperature is less than 15C (59F). The engine temperature is less than -40C (-40F).

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Line pressure learning control When up shifting: This control determines the line pressure for each clutching or braking in order to reduce shift harshness at up-shifting. When 4-3 down shifting: This control determines the line pressure to the C1 clutch in order to reduce shift harshness at 4-3 down shifting. When 3-4 shifting: This control determines the C1 clutch timing from the timing solenoid (ST) operation and then applies that timing to the C1 clutch in order to reduce shift harshness at 3-4 shifting.
1) 50C (122F) A/T oil temperature Line pressure learn control 2) "D" range (Up shifting / 4-3 down shifting) 3) Throttle valve opening 1) 20C (68F) A/T oil temperature 2) "D" range 3) Throttle valve opening 110C (230F)

120C (248F)

3-4 learning control

Adaptation guideline *Note: After replacement of A/T, TCM software (updating), adapted data must be cleared and re-adaptation is required. Warm-up A/T fluid temperature (50C (122F) A/T fluid temperature < 110C (230F)) Up shift adaptation: Up shift 1-2, 2-3, 3-4 gear at each throttle opening (20%, 40%, 60% ,80%, 100%) in D range and repeat 5 times. 3-4 shift adaptation: 3-4 shifting at each throttle opening (20%, 40%, 60%, 80%, 100%) in D range and repeat 5 times. 4-3 shift adaptation: Accelerate to 4th gear in D, 4-3 kick down at each vehicle speed(2055, 55-70, 70-90, 90-125, 125 + km/h (12-34, 34-43, 43-56, 56-78, 78 + mph)) and repeat 5 times.

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Control Mode: Control Driving Mode


Driving Mode
Squat control Improves the shift quality for N-D shifting through 2nd gear before downshifting to 1st gear.
1) 20C (68F) < A/T oil temperature 2) No hold mode 3) Throttle valve opening = 0%

Squat control condition

Torque reduction control Improves shift quality by sending a torque reduction request signal from the TCM to the ECM and cutting engine torque during N-D shift, N-R shift and 1234. If accelerator pedal is depressed rapidly, this control establishes the upper limit value of engine torque and avoids Engine flare at 34. Reverse inhibit control This system is a safety device, If R is selected while the vehicle is moving forward in gear, the TCM controls the timing solenoid preventing reverse gear engaging.

Reverse inhibit control (Not available reverse gear) Release reverse inhibit control (Available reverse gear)

1) Vehicle speed > 11Km/h (6.9 mph) 2) "R" range 1) Vehicle speed < 9 Km/h (5.6 mph) 2) Except "R" range

Operation: Function of Components


Function of Components
Components C1 Forward clutch C2 Direct clutch C3 Reverse clutch Function - Connecting input shaft & Front planetary sun gear - Connecting input shaft & Planetary carrier - Connecting input shaft & Rear planetary sun gear

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B1 O/D & 2nd coast brake - Holding rear planetary sun gear directly B2 2nd brake - Holding rear planetary sun gear with F1 B3 1st & Reverse brake - Holding planetary carrier F1 One way clutch 1 F2 One way clutch 2 - Holding counterclockwise rotation of rear planetary sun gear when B2 operation. - Holding counterclockwise rotation of planetary carrier.

Component Position

AT-5

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Operation: Operation Chart


Operation Chart
One way clutch B3 F1 F2

Shift lever & Gear Position

Solenoid

Clutch

Brake

S1

S2 ON

ST
OFF

C1

C2

C3

B1

B2

ON

Less than 9 Km/h ON (5.6 mph) 9 Km/h (5.6 mph) ON or More

ON

OFF

ON

ON

N
1 st 2 nd

ON ON ON
OFF

ON ON
OFF

OFF

OFF


ON/ OFF


ON/ OFF

OFF

D
3

3 rd

OFF

OFF

4 OFF ON 4 th 1 st
OFF

ON
OFF

ON ON
OFF

ON ON
OFF

OFF

2 nd 3 rd 1 st

OFF

OFF

OFF

ON ON

ON
OFF

OFF

1
2 nd
OFF

Operation: Power Flow (Reverse Gear)


Reverse Gear (Gear Ratio: 2.300)
Solenoid Range S1 S2 ST C1 C2 C3 ON B1 B2 B3 ON F1 F2 Less than 9 Km/h ON ON OFF (5.6 mph) R 9 Km/h (5.6 mph) ON ON ON or More Clutch Brake Freewheel

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Engine Brake

AT-6

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Power Flow: 1st Gear


1st Gear (Gear Ratio 2.300)
Solenoid Range S1 S2 ST C1 C2 C3 B1 B2 B3 F1 F2 ON ON ON ON Clutch Brake Freewheel Engine Brake

D,2 1st gear ON ON OFF ON 1 1st gear ON ON OFF ON

AT-7

Power Flow: 2nd Gear


2nd Gear (Gear Ratio 1.568)
Solenoid Range S1 D 2nd gear 2 2nd gear S2 ST C1 C2 C3 B1 B2 ON ON ON B3 Clutch Brake Freewheel Engine Brake F1 F2 ON ON ON

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ON OFF OFF ON ON OFF OFF

AT-8

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Power Flow: 3rd Gear


3rd Gear (Gear Ratio 1.000)
Solenoid Range S1 D 3 S2 ST C1 C2 C3 B1 B2 ON ON OFF B3 Clutch Brake Freewheel Engine Brake F1 F2

3rd gear OFF OFF OFF ON ON 3rd gear OFF OFF OFF ON ON

AT-9

Power Flow: 4th Gear


4th Gear (Gear Ratio .697)
Solenoid Range S1 D S2 ST C1 C2 ON C3 B1 B2 Clutch Brake Freewheel Engine Brake B3 F1 F2

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4th gear OFF ON OFF

ON ON

AT-10

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Control System: Control System Feature


System Feature (Block Diagram)

AT-11

Control System: Schematic of Electrical Control System


Schematic of Electrical Control System

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Control System: Schematic of Hydraulic Control System


Schematic of Hydraulic Control System

AT-13

Control System: System Control Description


System Control Description
Introduction The hydraulic control system governs the hydraulic pressure to the transmission torque converter, clutches, and brakes depending on driving conditions. There are four solenoid valves in the valve body. The TCM controls gear shifting by switching ON and OFF numbers 1 and 2 solenoid valves. The pressure control solenoid, which is a linear solenoid, controls the hydraulic fluid pressure for clutches and brakes in order to reduce gear shifting harshness. The TCM controls the lock-up solenoid valve to engage or disengage the lock-up clutch of the torque converter. Shifting control Depending on the vehicle speed and the throttle position, the TCM switches the solenoids 1 (S1) and (S2), which control the hydraulic shift valves and change the gear shift position. The TCM is programmed with different shift patterns for each driving mode: (Economy, Power, Hold) Lock-up control Depending on vehicle speed and the throttle position, the TCM controls the lock-up solenoid, which modulates lock-up fluid pressure. The TCM temporarily turns the lock-up OFF during shifting in order to reduce shift harshness. The Lock-up is available only in 4th gear. * Lock-up disable condition Brake light: ON TP: 0% Engine temperature is too cold

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Control System: Output Speed Sensor


Output Speed Sensor
The output speed sensor is a hall effect type sensor which detects vehicle speed from the differential ring gear. It sends 4 pulses per revolution of the ring gear to both the TCM and the speedometer.

AT-14

Control System: Input Speed Sensor


Input Speed Sensor
The input speed sensor is located on top of the transmission and provides the input shaft speed data to TCM. The inductive type sensor measures the speed of the direct clutch (C2) drum generating AC voltage at 16 pulses per revolution. This input speed signal together with the output speed signal is used for shift, fluid pressure and lock-up control strategies.

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Inspection Sensor resistance: 560 ~ 680 ohms at 20C (68F) Insulation resistance: Infinite
AT-15

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Control System: Fluid Temperature Sensor


Fluid Temperature Sensor
The fluid temperature sensor located on the valve body in fluid pan is NTC (Negative Temperature Coefficient) type. This sensors signal is used for line pressure control, up-hill/down hill mode control, shifting time control, lock-up control, and 3-4 shift cut control at low temperature.

TFT -30C (-22F) 10C (50F)

Ohm() 44,0006600 6,445645 24716 1116

AT-16

110C (230F) 145C (293F)

Control System: Shift Solenoid


Shift Solenoid 1, 2
The two shift solenoids are located on the valve body. Depending mainly on the vehicle speed and the throttle position, the TCM switches them ON and OFF, which changes the fluid circuit. The ON and OFF combination of S1 and S2 determines the gears. TCM controls the power supply lines ON and OFF positions and are grounded to the transmission housing. When ECT(engine coolant temperature) is less than -40C (-40F) or transmission fluid temperature is less than 15C (59F), 4th up-shift will not be available.

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Control System: Shift Solenoid 1, 2


Shift Solenoid 1, 2
Gear Solenoid (S1) Solenoid (S2) 1st 2nd 3rd 4th P,R,N ON ON OFF OFF ON ON OFF OFF ON ON

AT-18

Control System: Pressure Control Solenoid


Pressure Control Solenoid
The pressure control solenoid (linear solenoid) is located on the valve body. It regulates the transmission fluid pressure that adjusts line pressure reducing shifting harshness. The TCM controls this solenoid by PWM (Pulse Width Modulation). The line pressure is controlled proportional to throttle angle.

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Resistance (Ohm) Insulation (Ohm) Maximum Current

5.0 - 5.6 Infinite 1A

AT-19

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Control System: Lock-up Solenoid


Lock-up Solenoid
The lock-up solenoid is located on the valve body and controls the lock-up operation. It improves fuel consumption and driving performance at high speed. The solenoid is grounded to the transmission housing, and the TCM controls its ON and OFF power depending on vehicle speed and throttle position. The lock-up can be activated in 4th gear only. The lock-up is disabled when: The brake switch is On The throttle valve is closed. The ECT is too cold The Fluid temperature is too cold
Solenoid ON OFF Lock-up Engaged Released

AT-20
Resistance (Ohm) Insulation (Ohm) 11 ~ 16 Infinite

Control System: Timing Solenoid


Timing Solenoid
The timing solenoid is located on the valve body and controls the forward clutch (C1) supply and exhaust fluid that reduces 3-4 shifting harshness. It also controls operation pressure of the forward clutch (C1) for optimum readiness. It also prevents reverse from engaging at more than 9 km/h.

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Resistance (Ohm) Insulation (Ohm)

11 ~ 16 Infinite

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Control System: PNP Switch


PNP Switch
The PNP safety switch relays the position of the shift lever to the TCM and operates a back-up lamp switch. This safety device prevents unintended engine starting. The TCM uses PNP switch information to control line pressure, lock-up clutch, and shift solenoid operation.

AT-22

Control System: Brake Transmission Shift Interlock


Brake Transmission Shift Interlock
1. The BTSI is a safety device that prevents unintended shift lever movement from the P position into the R or D range unless the brake pedal is depressed . It functions in all ignition switch positions. 2. The TCM unlocks the shift lever when the brake ON signal is received. 3. If the BTSI system malfunctions, the shift lever can be moved by inserting the ignition key into the key slot located in the shift console.

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Control System: CAN Communication


CAN (Controller Area Network) Communication
The ECM and TCM maintain optimum control by exchanging the following information through the CAN lines: 1. Information from ECM to TCM Engine RPM Engine torque control Throttle position sensor signal Engine coolant temperature sensor signal Intake air temperature sensor signal Manifold absolute pressure sensor signal Electronic spark timing A/C On signal

2. Information from TCM to ECM


AT-24

Engine torque reduction control Output (vehicle) speed sensor signal Transmission Fluid temperature sensor signal PNP switch signal Gear state

Diagnosis: Input/Output Factor of TCM


Description of Automatic Transmission

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Diagnosis: Transmission Control Module (TCM)


TCM
The TCM primarily controls shift points and lock-up engagement. It has 52 pins with A, B connectors and is located under the instrument panel on the passenger side. Shifting occurs when two solenoids are actuated by the TCM. The TCM also regulates the pressure control solenoid, the torque converter lock-up solenoid, and the timing control solenoid. If the TCM detects any problem during the operation of the automatic transmission, the hold lamp in instrument panel will blink.

AT-26

Diagnosis: Transmission Control Module (TCM)


TCM

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Pin No A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26

Description TCM ground Pressure control solenoid (-) Not used Pressure control solenoid (+) Lock-up solenoid control Ignition power Not used Not used Not used Not used Oil temperature sensor (-) Oil temperature sensor (+) Not used Timing control solenoid Shift solenoid No.1 (S1) Shift solenoid No.2 (S2) CAN Hi Not used Not used Not used Not used Not used Not used Battery voltage Not used Not used

Pin No B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26

Description Reverse signal (shift lever) Not used Hold mode lamp Hold mode switch Not used Input speed sensor (+) "D" range signal (shift lever) "N" range signal (shift lever) Not used Not used Not used Not used Not used Not used Not used Input speed sensor (-) Not used "1" range signal (shift lever) "2" range signal (shift lever) "P" range signal (shift lever) Not used Brake signal Diagnosis Not used Vehicle speed sensor signal Not used

Note: Always check service manual for circuit pin locations

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Diagnosis: Hold Lamp


Diagnostic Lamp (Hold Lamp)
The TCM constantly monitors operation of sensors, solenoids and other installed electronic parts. If a malfunction occurs with any of these parts, the hold lamp in the IP will blink. When the ignition switch is turned ON, the hold lamp will light for 4 seconds and then go out if there is no malfunction. If the TCM detects any malfunction of the automatic transmission, the hold lamp will blink immediately.

AT-28

Diagnosis: Diagnostic Trouble Codes (DTCs)


DTC
DTC P0562 P0563 P0604 P0705 P0712 P0713 P0717 P0722 P0727 P0741 P0742 Blinkin g code 51 53 64 56 67 68 38 39 42 14 15 29 P0743 36 33 P0748 32 P0751 46 25 P0753 17 P0756 48 28 P0758 26 P1701 P1702 43 44 Description System voltage error (Volatge too low) System voltage error( Voltage too high) Internal TCM RAM error PNP switch circuit malfunction (no signal or short) Oil temperature sensor circuit error (short to ground) Oil temperature sensor circuit error (open circuit) Input speed sensor(ISS) circuit error (no signal) Output speed sensor(OSS) circuit error (no signal) CAN signal error (no RPM signal from ECM) Lock-up solenoid circuit error (SL) (stuck-off) Lock-up solenoid circuit error (SL) (stuck-on) Lock-up solenoid circuit error (SL) (short to battery or open circuit) Lock-up solenoid circuit error (SL) (short to ground) Pressure control solenoid circuit error(SLT) (short to battery) Pressure control solenoid circuit error(SLT) (short to ground or open circuit) Shift solenoid circuit error(S1) (solenoid stuck-on) Shift solenoid circuit error(S1) (short to battery or open circuit) Shift solenoid circuit error(S1) (short to ground) Shift solenoid circuit error(S2) (solenoid stuck-on) Shift solenoid circuit error(S2) (short to battery or open circuit) Shift solenoid circuit error(S2) (short to ground) CAN signal error (ECT signal error from ECM) CAN signal error (engine torque signal error from ECM) Type B B B B C2 C2 B B A B B B B A A B A A B A A D A MIL MIL MIL MIL MIL --MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL MIL -MIL Hold Lamp C2 C2 C2 C2 C2 C2 C2 C2 C1 C2 C2 C2 C2 C1 C1 C2 C1 C1 C2 C1 C1 D C1

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Diagnosis: Diagnostic Trouble Codes (DTCs)


DTC
DTC P1705 P1710 P1790 P1791 U2105 Blinkin g code 45 22 61 21 41 Description CAN error (no signal from ECM) Timing solenoid circuit error (ST) (short to battery/ground or open circuit) Check sum error (TCM internal error) CAN signal error (TPS signal error from ECM) CAN error (no signal from ECM or CAN bus off error) Type A A B A A MIL MIL MIL MIL MIL MIL Hold Lamp C1 C1 C2 C1 C1

Lamp Action According to DTC type


Type A B C1 C2 D Lamp light & DTC code memorized condition 1 driving cycle 2 driving cycle 1 driving cycle 2 driving cycle 1 driving cycle Lamp MIL MIL Hold Hold ___ Lamp off condition 3 driving cycle 3 driving cycle TCM judges normal condition TCM judges normal condition ___ Remarks EOBD EOBD Except EOBD Except EOBD EOBD / WO-OBD

* Description of DTC type Type A: Malfunction is related directly to emissions so that its level exceeds regulations. Upon detection of this type of a malfunction the MIL lights and the malfunction is recorded in the ECM &TCM. Type B: MIL lights, but the malfunction is stored on the second consecutive malfunction. The malfunction affects emission so that its level exceeds the regulation. Type C1: The TCM will request the illumination of the hold lamp and stores the DTC when the TCM detects a failure during the next ignition cycle. Type C2: The TCM will request the illumination of hold lamp and store the DTC when the TCM detects a failure during two consecutive ignition cycles. Type D: The TCM will not request the illumination of hold lamp or MIL lamp, but will store DTC when TCM detects a failure on the first ignition cycle.

Diagnosis: Fail safe (Default Action)


DTC P0562 P0563 P0604 Type B B B No default action No default action No default action 1) Short condition : - TCM judges following priority (D >2>L>R>N>P) - No Lock-up, - No learning 2) No signal condition : - TCM judges all range "D" - No Lock-up, - No learning - TCM set TFT temp' data "200 C" - No Lock-up, No Learning, No 4th gear - No torque reduction - No Lock-up, No Learning, No 4th gear - No torque reduction - No Lock-up, No Learning, No 4th gear - Substitute input signal as a output signal - TCM judge engine speed "0" rpm - No torque reduction - No Lock-up, No Learning, No 4th gear No default action No default action 1) Short to battery condition : - 1st gear under 10km/h - No Lock-up 2) Short to ground : - No Lock-up Default action

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P0705

P0712 P0713 P0717

C2 C2 B

P0722

P0727

P0741 P0742

B B

P0743

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Diagnosis: Fail safe (Default Action)


DTC Type Default action 1) Short to battery condition : - No torque reduction - No Lock-up, No learning, No 4th gear 2) Short to ground or open condition : - Emergency mode No default action 1) Short to battery condition : - No torque reduction - No Lock-up, No learning, No 4th gear 2) Short to ground condition : - Emergency mode No default action 1) Short to battery condition : - No torque reduction - No Lock-up, No learning 2) Short to ground condition : - Emergency mode TCM judges water temp' 90C" when lapse 15 min. - No torque reduction - No Lock-up, No learning, No 4th gear - TCM judges engine speed "0" rpm - No Lock-up, No Learning, No 4th gear - Emergency mode - Emergency mode - No Lock-up, No learning, No 4th gear - TCM judges engine speed "0" rpm - No Lock-up, No Learning, No 4th gear

P0748

P0751

P0753

P0756

P0758

P1701 P1702 P1705 P1710 P1790 P1791 U2105

D A A A B A C1

Emergency Mode
Range "D", "2", "L" "R" Gear 3rd gear reverse Remarks

Diagnosis: General Diagnosis Procedure


General Diagnostic Procedure
For proper diagnoses of problems, it is necessary to understand conditions such as hot or cold coolant temperature, hot or cold ambient temperature, vehicle driving condition, vehicle weight and so on. Automatic transmission system issues can be caused by engine problems as well as transmission mechanical and electrical problems. Troubleshooting must begin in the correct area.

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Diagnosis: Fluid Level Check


Fluid level check
Fluid specification
Oil Replacement Period Oil Capacity Oil Capacity - when oil replace Oil type Not required 5.6 L (5.9 qt) 2.1 L (2.2 qt) ISU Dexron III / JWS-3309(T-IV)

Fluid level checking procedure Because fluid level varies with temperature, it should only be checked at the normal operating temperature (70-80C (158-176F)). The fluid level checking procedure is as follows: 1. Locate the vehicle on the level ground and apply the parking brake. 2. Start the engine, depress the brake pedal and move the shift lever from P through L at idle in one smooth motion. 3. Check the fluid level while in the P position at idle. 4. Pull the fluid level indicator out and wipe it, put the indicator back into in the tube and then pull it out again, visually check the fluid level.
AT-30

5. Normal fluid level should be between the MIN and MAX line of HOT indication.

Fluid condition
Fluid color should be clear red. Color change represents transmission aging or disc and bushing wear or damage.

Diagnosis: Time Lag Test


Test purpose Time lag is the time it takes for the transmission to shift into gear when the shift lever is shifted from N to any D or R position while the engine is idling. The time lag test can confirm the hydraulic, clutch/brake conditions. *Caution Test at normal operating temperature. Have 1 min. interval between tests. Determine average of 3 tests.

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Test procedure 1. Locate the vehicle on the level ground and apply the parking brake. 2. Start the engine and confirm idle RPM. 3. Depress the brake pedal. 4. After selecting D position from N, measure the time you can feel the shift. 5. After selecting R position from N, measure the time you can feel the shift.
N -> D N -> R Less than 0.7 sec Less than 1.2 sec Remarks

Diagnosis
Time Lag Test Result Possible Cause 1. Line pressure is too low. (pressure control solenoid failure, primary regulator valve failure) 2. C1 (Forward Clutch) slipping 3. Timing solenoid malfuction 4. Oil leak for "D" range circuit 1. Line pressure is too low. (Pressure control solenoid failure, primary regulator valve failure) 2. C3 (Reverse Clutch) slipping. 3. B3 (Low and Reverse Brake) slipping. 4. Oil leak for "R" range circuit

1. N -> D Measured time is longer than normal value

2. N -> R Measured time is longer than normal value

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Diagnosis: Stall Test


Test purpose By measuring the highest RPM in the D and R positions, you can check the total performance of the transmission and the engine. * Caution Test at normal operating temperature (50-80C (122-176F)). Switch off A/C, lights and any other accessories. Do not perform this test several times and not for more than 5 sec. Make sure to keep interval for more than 1 min. between stall tests.

Test procedure 1. Locate the vehicle on the level ground and apply the parking brake. 2. Chock the wheels in accordance with Service Manual procedures only. 3. Start the engine and confirm idle RPM. 3. Depress the brake pedal with the left foot and select D position. 4. Depressing the accelerator with the right foot, read the engine RPM. (within 5 sec.) 5. Repeat 1-4 for the R position.

Standard value

2390 150RPM

Diagnosis
Stall Test Result 1. At D / R, the stall speed is lower than the normal value Possible Cause 1. Engine power is low 2. Stator in torque converter is out of order. 1. C1 (Forward Clutch) slipping. 2. Line pressure is too low. (pressure control solenoid failure, primary regulator valve failure) 3. F2 falure 1. Line pressure is too low. (pressure control solenoid failure, primary regulator valve failure) 2. C3 (Reverse Clutch) slipping. 3. B3 (Low and Reverse Brake) slipping. 1. Line pressure is too low. (pressure control solenoid failure, primary regulator valve failure) 2. Oil pump failure 3. Oil strainer failure (clogging) 4. Oil leak for each range circuit.

2. At only D, the stall speed is higher than the normal value

3. At only R, the stall speed is higher than the normal value

4. At D & R, the stall speed is higher than normal value

Diagnosis: Line Pressure test


Test purpose By measuring line pressure at each shift lever position, you can check the fluid pump, each valve and the clutches and brakes. Test procedure 1. Remove the fluid pressure test plug and install the oil pressure gage. 2. Chock the wheels in accordance with Service Manual procedures only. 3. Apply the parking brake. 4. Start the engine and confirm idle RPM. 5. Depress the brake pedal. 4. Measure the line pressure at D and R position. Line pressure specification
Lever position Idle (kg/cm ) Stall (kg/cm )
2 2

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D 3.9 ~ 4.2 (55.5 - 59.7 psi) 11.3 ~ 12.5 (160.7 - 177.8 psi)

R 6.0 ~6.9 (85.3 - 98.1 psi) 18.6 (264.6 psi)

Diagnosis
Test Result 1. At D or R, the pressure is higher than normal Possible Cause 1. Pressure Control Solenoid malfunction 2. 1st Regulator vlave malfunction 1. Pressure Control Solenoid malfunction 2. 1st Regulator vlave malfunction 3. Oil pump malfunction 4. Oil leaking at each range 1. D position oil circuit leak 2. C1(forward clutch) malfunction 1. R position oil circuit leak 2. B3(low & reverse brake) malfunction 3. C3(reverse clutch) malfunction

AT-31

2. At D & R, the pressure is lower than normal 3. At only D, the pressure is lower than normal 4. At only R, the pressure is lower than normal

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Diagnosis: Fluid Pressure Check Port


Transmission Housing Side

AT-32

Diagnosis: Fluid Pressure Check Port


Valve Body Side

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AT-33

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Diagnosis: Fluid Pressure Check Port


Accumulator Side

AT-34

Special Tools
Special Tool

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AT-35

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Special Tools

AT-36

Special Tools

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AT-37

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Automatic Transmission: Lab 1


Objective
Using a Scan Tool and a service manual, correctly read the data from the vehicle speed sensor, PNP switch, and TCM within the allotted time frame following all safety precautions.

Lab Set-Up
Vehicle: 2003 GM/Daewoo T car Recommended instructor/technician ratio 1:12 maximum Instructions 1. Provide each group with a service manual to read and review Scan Tool procedures 2. Break class into groups of 3 3. Provide each group with a vehicle Technician Tools Scan Tool Basic Hand Tools

Expected Technician Path


1. Turns the IGN to run position 2. Connects the Scan Tool to the DLC 3. Read data from transmission using Scan Tool 4. Verifies data results with instructor

Automatic Transmission: Lab 2


Objective
Using a DMM and a training manual correctly perform a resistance/ continuity test on the oil temperature sensor in the allotted time frame following all safety precautions.

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Lab Set-Up
Vehicle: 2003 GM/Daewoo T car Recommended instructor/technician ratio 1:12 maximum Instructions 1. Provide each group with a training manual and to read and review continuity/resistance procedures and values 2. Break class into groups of 3 3. Provide each group with a vehicle Technician Tools DMM

Expected Technician Path


1. Turns the ignition off 2. Connects the DMM 3. Reads the resistance values

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Automatic Transmission: Lab 3


Objective
Using a DMM and a training manual, correctly perform a resistance/ continuity test on solenoids 1 and 2 in the allotted time frame following all safety precautions.

Lab Set-Up
Vehicle: 2003 GM/Daewoo T car Recommended instructor/technician ratio 1:12 maximum Instructions 1. Provide each group with a training manual to read and review continuity/resistance procedures and values 2. Break class into groups of 3 3. Provide each group with a vehicle Technician Tools DMM

Expected Technician Path


1. Turns the ignition off 2. Connects the DMM 3. Reads the resistance values

Automatic Transmission: Lab 4


Objective
Using an appropriate service manual and pressure gage, correctly perform a line pressure test in the allotted time frame following all safety precautions.

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Lab Set-Up
Vehicle: 2003 GM/Daewoo T car Recommended instructor/technician ratio 1:12 maximum Instructions 1. Provide each group with an appropriate service manual and a pressure gage, perform line pressure test procedures 2. Break class into groups of 3 3. Provide each group with a vehicle Technician Tools Pressure Gauge

Expected Technician Path


1. Removes the oil pressure test plug 2. Installs the oil pressure gauge 3. Blocks each wheel with bricks 4. Applies the parking brake 5. Starts the engine 6. Confirms idle RPM 7. Depresses brake pedal 8. Measures the line pressure at D and R positions 9. Uses table in service manual to compare pressure readings and normal ranges

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Automatic Transmission: Test Questions

1. True/False: The function of the C1 forward clutch is to connect the input shaft and front planetary sun gear.

[True. The function of the C1 forward clutch is to connect input shaft and front planetary sun gear.]
2. True/False: The C2 direct clutch connects the input shaft and rear planetary sun gear.

[False. The C2 direct clutch connects the input shaft and planetary carrier.]
3. Which clutch connects the input shaft and rear planetary sun gear? A. C1 B. C2 C. F1 D. C3

[The correct answer is D. The reverse clutch connects the input shaft and rear planetary sun gear.]
4. Which clutch holds the counterclockwise rotation of rear planetary sun gear when B2 operates? A. F1 B. F2 C. C3 D. C1

[The correct answer is A. The F2 one way clutch 1 holds counterclockwise rotation of rear planetary sun gear when B2 operates.]
5. Which clutch holds counterclockwise rotation of the planetary carrier? A. F1 B. F2 C. C3 D. C1

[The correct answer is B. The F2 one way clutch w holds counterclockwise rotation of the planetary carrier.]

6. Which brake directly holds the rear planetary sun gear to the case? A. B3 1st and reverse brake B. B2 2nd brake C. B1 O/D and second coast brake

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[The correct answer is C. The B1 O/D and second coast brake directly holds the rear planetary sun gear.]
7. Which brake holds the rear planetary sun gear with F1 to the case? A. B3 1st and reverse brake B. B2 2nd brake C. B1 O/D and second coast brake

[The correct answer is B. B2 2nd brake holds the rear planetary sun gear with F1.]
8. Which brake holds the planetary carrier to the case? A. B2 2nd brake B. B1 O/D and second coast brake C. B3 1st and reverse brake

[The correct answer is C. The B3 1st and reverse brake holds the planetary carrier.]
9. Which component detects vehicle speed from the differential gear rotations? A. Crankshaft Position Sensor B. C2 Cylinder revolution sensor C. Output speed sensor D. Input speed sensor

[The correct answer is C. The output speed sensor detects vehicle speed from the differential gear rotations.]
10. True/False: The output speed sensor measures the speed of the differential ring gear and sends signals to the speedometer.

[True. The output speed sensor measures the speed of the differential ring gear and sends signals to the speedometer.]

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11. The oil temperature sensor is used to control line pressure, up/down slope mode, shifting time, lock-up, and _____________________.

[The correct answer is 3-4 shift cut at low temperature.]


12. True/False: The oil temperature sensor is located on the oil pump.

[False. The oil temperature sensor is located on the valve body inside the oil pan.]
13. Which of the following solenoids regulates the transmission fluid pressure to adjust line pressure and reduce shifting shock? A. Pressure control B. Lock-up C. Timing D. ST

[The correct answer is A. The pressure control solenoid regulates the transmission fluid pressure to adjust line pressure and reduce shifting shock.]
14. Which of following solenoids improves fuel consumption and driving performance during high speeds? A. ST B. Pressure control C. Timing D. Lock-up

[The correct answer is D. The lock-up solenoid controls the lock-up operation to improve fuel consumption and driving performance during high speeds.]
15. The function of the timing solenoid includes controlling supply or exhaust oil of the forward clutch thereby reducing 3-4 shifting shock, controlling forward clutch operation pressure and _____________________. A. preventing first gear from engaging during park/neutral B. preventing reverse gear from engaging at 9km/h or more C. allowing first gear to engage during park/neutral D. allowing reverse gear to engage at 5km/h or less

[The correct answer is B. The timing solenoid prevents reverse gear from engaging at 9km/h for safety.]

16. The TCM uses information from the PNP switch to control line pressure, lock-up, and ________________. A. shift solenoid operation B. vehicle speed C. selector position D. AC clutch engagement

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[The correct answer is A. The TCM uses information from the PNP switch to control line pressure, lock-up, and shift solenoid operation.]
17. If the shift interlock is inoperative, what can the driver do to bypass it? A. Remove shifting cable B. Attach traction to move the shift lever C. Insert key into keyhole on the shifter console D. Adjust the brake switch

[The correct answer is C. The driver can insert a key into the keyhole to bypass an inoperative shift lock.]
18. What is the primary function of the TCM? A. To actuate the injector drivers B. To control shift points and lock-up C. To adjust emission levels D. To control engine torque

[The correct answer is B. The primary function of the TCM is to control shift points and lock-up.]
19. True/False: Drivers are notified of any automatic transmission problems by a blinking hold lamp in the instrument panel.

[True. Drivers are notified of any automatic transmission problems by a blinking hold lamp in the instrument panel.]
20. True/False: Transmission oil levels need to checked cold.

[False. Oil levels should be checked at normal operating temperatures.]


21. True/False: The purpose of a line pressure test is to inspect the valves and torque converter.

[False. A line pressure test allows you to inspect the oil pump, each valve, clutches, and brakes by measure at each shift lever position.]