Aisin Aw 03 II - 30 40LE

AUTOMATIC TRANSAXLE for HP-CAR
AW 03-II AW 30-40LE
INTRODUCTION
Main points To control the line pressure, the pressure control solenoid valve was adopted instead of throttle cable. A/T lamp was installed so as to be turned on when the temperature of ATF is higher than the specified level to protect transmission. was eliminated.) For the smooth shift feeling, various signals between engine ECM and TCM is being communicated. (Torque reduction request, water temperature and so on.) In case of 4 wheel drive low or high ATF temperature, the shift pattern is changed. 4 solenoid valves were adopted to control each gear, line pressure and lock up operation. Chonan TSTC If there are trouble or failure on the sensor or system, A/T lamp is blinked. (Hold mode and its lamp
INTRODUCTION
General specifications
TYPE GENERAL MODEL GEAR RATIO
1ST 2ND 3RD 4TH R FINAL GEAR RATIO
AUTOMATIC 2.5 TCI 2.9 TCI 3.5 V6 4-Speed Transmission with Floor Shift AISIN 30-40LEi AISIN 03-II 2.826 2.804 1.493 1.531 1.000 1.000 0.688 0.705 2.703 2.393 4.875 4.222 4.625
Chonan TSTC
INTRODUCTION
General specifications
TYPE Maximum torque Weight (kg) T/C Stall torque ratio Torque converter (DIA) Stall RPM ATF ATF CAPA. (LITER)
2.5 TCI 24kgfm 72 2.1 241mm
8.73 (L)
AUTOMATIC 2.9 TCI 3.5 V6 35kgfm 79.8 2.02 254mm 2,630 2,520 DEXRON II 9.2 (L)
Chonan TSTC
INTRODUCTION
Variation of AISIN AW Automatic transaxle on HMC vehicles
Model 03-72L 03-72LE 03-II 30-43LE 30-40LEi
Application Galloper, H-100 Bus H-100 Truck, H-1 (N/A) HP (2.5 Tci) H-1(Tci), SR HP (2.9C/rail, 3.5 V6)
Remarks Hydraulic type
ECT
Chonan TSTC
ATOMATIC TRANSMISSION
- AISIN AW 03-II (for 4D56 TCi) - AISIN AW 30-40LEi (for 2.9TCi / 3.5 V6)
Chonan TSTC
MECHANICAL (03-II)
Section view
C0 B0 B3 F0 C1 C2 B1 B2 F1 F2
T/C V/B
Chonan TSTC
MECHANICAL (03-II)
Components
COMPONENT C0 C1 C2 B0 B1 B2 B3 F0 F1 F2 O /D D IR E C T C L U T C H FO RW ARD CLUTCH D IR E C T C L U T C H O /D B R A K E 2ND COAST BRAKE 2ND BRAKE 1ST & REVERSE BRAKE O /D O N E -W A Y C L U T C H N O .1 O N E -W A Y C L U T C H N O .2 O N E -W A Y C L U T C H F U N C T IO N C o n n e c t O /D S U N G E A R a n d O /D C A R IE R C o n n e c t IN P U T S H A F T a n d IN P U T S H A F T C o n n e c t IN P U T S H A F T a n d F r/R r P L A N E T A R Y SUN GEAR L o c k O /D S U N G E A R L o c k F r/R r P L A N E T A R Y S U N G E A R L o c k c o u n te rc lo c k w is e ro ta tio n o f F r/R r P L A N E T A R Y S U N G E A R (L o c k O U T E R R A C E o f F 1 ) L o c k F r P L A N E T A R Y C A R IE R C o n n e c t O /D S U N G E A R a n d O /D C A R IE R , w h e n O /D S U N G E A R ro ta te s ra p id m o re th a n O /D C A R IE R L o c k c o u n te rc lo c k w is e ro ta tio n o f F r/R r P L A N E T A R Y S U N G E A R , w h e n B 2 o p e ra tio n s L o c k c o u n te rc lo c k w is e ro ta tio n o f F r P L A N E T A R Y C A R IE R
Chonan TSTC
MECHANICAL (03-II)
Operating elements
POSITION SOLENOID S1 S2 SL C0 CLUTCH C1
I.P.
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
P R N 1st D 2nd 3rd 4th 1st 2 2nd 3rd L 1st 2nd
ON ON ON ON ON OFF
OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF ON
ON ON ON ON ON ON OFF ON ON ON ON ON
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON ON ON
OFF OFF OFF OFF
OFF OFF OFF ON=>OFF OFF OFF OFF ON=>OFF OFF OFF ON OFF
2.703 2.825 1.493 1.000 0.730 2.825 1.493 1.000 2.825 1.493
OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF ON OFF ON ON ON OFF OFF OFF OFF ON
ON ON=>OFF ON OFF OFF OFF ON OFF OFF ON
OFF OFF ON ON OFF ON ON
OFF OFF OFF ON ON ON ON ON
OFF OFF ON ON OFF OFF
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON
OFF OFF
OFF OFF ON OFF
OFF OFF OFF OFF OFF OFF OFF OFF ON ON
OFF OFF
Chonan TSTC
MECHANICAL (30-40LEi)
Components
10
1 3 4
Chonan TSTC
Components
7 8
11
Chonan TSTC
Components
No. 1 2 3 4 5 6 7 8 9 TR switch Cooler OUT Cooler IN Breather hose OTS Input speed sensor Outer lever T/M wire Parts Output speed sensor Function To detect the output shaft speed To detect selected or driving range From oil cooler to transmission From transmission to oil cooler For the air bleeding inside of transmission To detect the ATF temperature To detect the input shaft speed Connected to control cable to operate driving range Solenoid valve connector
12
Chonan TSTC
Section view
O/D brake Direct clutch Forward clutch 2nd coast brake 2nd brake L&R brake
13
O/D clutch
O/D OWC
No.1 OWC
No.2 OWC
Chonan TSTC
Components
COMPONENT C0 C1 C2 B0 B1 B2 B3 F0 F1 F2 O /D D IR E C T C L U T C H FO RW ARD CLUTCH D IR E C T C L U T C H O /D B R A K E 2ND COAST BRAKE 2ND BRAKE 1ST & REVERSE BRAKE O /D O N E -W A Y C L U T C H N O .1 O N E -W A Y C L U T C H N O .2 O N E -W A Y C L U T C H F U N C T IO N C o n n e c t O /D S U N G E A R a n d O /D C A R IE R C o n n e c t IN P U T S H A F T a n d IN P U T S H A F T C o n n e c t IN P U T S H A F T a n d F r/R r P L A N E T A R Y SUN GEAR L o c k O /D S U N G E A R L o c k F r/R r P L A N E T A R Y S U N G E A R L o c k c o u n te rc lo c k w is e ro ta tio n o f F r/R r P L A N E T A R Y S U N G E A R (L o c k O U T E R R A C E o f F 1 ) L o c k F r P L A N E T A R Y C A R IE R C o n n e c t O /D S U N G E A R a n d O /D C A R IE R , w h e n O /D S U N G E A R ro ta te s ra p id m o re th a n O /D C A R IE R L o c k c o u n te rc lo c k w is e ro ta tio n o f F r/R r P L A N E T A R Y S U N G E A R , w h e n B 2 o p e ra tio n s L o c k c o u n te rc lo c k w is e ro ta tio n o f F r P L A N E T A R Y C A R IE R
14
Chonan TSTC
Operating elements
POSITION P R(V<7) R(V>=7) N 1st D 2nd 3rd 4th 1st 2 L 2nd 3rd 1st 2nd SOLENOID S1 ON ON ON ON ON ON
OFF OFF
15
CLUTCH C0
ON ON
BRAKE B0 ~ OFF ~ OFF

OFF
O.W.C. B3
OFF
GEAR F2 RATIO
~ ~ OFF OFF OFF
S2
OFF OFF ON OFF OFF ON ON
SL ~OFF ~OFF
OFF
C1 OFF OFF
OFF
C2
OFF ON
B1
OFF OFF
B2
OFF OFF OFF OFF OFF ON ~
F0 ~OFF
ON ON
F1
OFF OFF ~ OFF ~ OFF OFF ~
~ ~ ~ ~ ~ ~ ~
ON ~
OFF OFF OFF OFF OFF
393 ~
~ON
ON ON
OFF OFF OFF
~OFF
OFF
~ ~ ~
~OFF ~OFF
OFF
OFF ON
ON ON
~ OFF
OFF
~OFF
ON ON ON
~ ~
OFF
~OFF
OFF OFF OFF
ON-> OFF
804 ~ 531 ~ 000 ~ ~ 705 ~ 804 ~ 531 000 ~ 804 ~ 531
~ON
ON OFF ON
OFF ON ON OFF
OFF ~ OFF
ON
ON-> OFF
OFF OFF OFF ON-> OFF
ON
ON ~
ON ON OFF
OFF~
OFF OFF ~
~ OFF
OFF ON ON
ON ~ ON
ON
OFF OFF OFF OFF
OFF ON ON ON ON
ON ON
OFF
~OFF
OFF OFF
OFF
~OFF
ON OFF
~ON
ON ON
OFF ON OFF
OFF ~
OFF OFF
ON ~ ON ~ OFF ON ~
ON ~
OFF OFF ~
OFF
ON ON
ON
OFF ON OFF
ON ON
OFF ON
~OFF
OFF
~OFF
ON
ON ~
OFF
~ON
OFF
OFF ~
ON
ON ~
Chonan TSTC
MECHANICAL
Principle of each range 1ST, 2ND 3RD
16
Direct coupling
Speed reduction
Direct coupling
4TH
Rev.
Speed increase
Direct coupling
Direct coupling
Reversed rotation
Chonan TSTC
MECHANICAL
The usages of friction plate
17
Elements Engine C-0 B-0 C-1 C-2 B-1 B-2 B-3
03-II 4D56 Tci

n=1 n=3 n=5 n=3 n=2 n=3 n=5
Friction plate 30-40LEi KJ2.9 3.5 V6

n=2 n=4 n=6 n=4 Band n=5 n=7 n=2 n=4 n=6 n=4 Band n=5 n=6
Chonan TSTC
MECHANICAL (03-II)
D 1st GEAR
I.P.
18
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
1st
ON
OFF OFF
bO
ON
ON
OFF OFF OFF OFF OFF OFF OFF
ON
OFF
ON=>OFF
2.825
bP
eO
eQ
O/D f d`PLANETARY q tmh s
n^ c ok `qx `mds
e ok `qx `mds FR f d`PLANETARY q tmh s
q RR f dok`mds`qx PLANETARY ` q tmh s
Chonan TSTC
MECHANICAL (03-II)
D 2nd GEAR
I.P.
19
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
2nd
ON
ON
OFF
bO
ON
ON
OFF OFF OFF OFF

aQ bP
ON
OFF OFF
ON ON=>OFF
OFF
1.493
eO
eP
n^ cok O/Dfd`q tmh `mds`qx s PLANETARY
e ok `mds `qx FR PLANETARY fd`q tmh s
q ok `mds `qx RR PLANETARY fd`q tmh s
Chonan TSTC
MECHANICAL (03-II)
D 3rd GEAR
I.P.
20
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
3rd
OFF
ON
OFF
ON
ON
OFF
ON
OFF OFF
ON
OFF OFF
ON
OFF
OFF
1.000
bO
bP
bQ
eO
O/Dfd`q tmh PLANETARY s
n^ cok
`mds
`qx
ok `mds `qx FRe PLANETARY fd`q tmh s
RR PLANETARY fd`q tmh s
ok
`mds
`qx
Chonan TSTC
MECHANICAL (03-II)
D 4th GEAR
I.P.
21
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
4th
OFF OFF
ON
aO
OFF
ON
OFF
ON
ON
OFF
ON
OFF OFF OFF
OFF
OFF
0.730
bP
bQ
O/Dfd`qPLANETARY tmh s
n^ cok
`mds
`qx
Chonan TSTC
MECHANICAL (03-II)
R Reverse
I.P.
22
BRAKE C2
O.P.
O.W.C. B3
I.P. O.P.
GEAR F2 RATIO
B0
B1
B2
F0
F1
ON
OFF OFF
ON
OFF
ON
ON
OFF OFF OFF

aR
ON
ON
ON
OFF
OFF
2.703
bQ bO
eO
n^ cok O/D fd`q tmh `mds s`qx PLANETARY
Chonan TSTC
P, N range - O/D clutch, O/D OWC are engaged.
O/D clutch
O/D OWC
Chonan TSTC
R range - O/D clutch, O/D OWC, Direct clutch, L&R brake are engaged. L&R brake
Direct clutch O/D clutch
O/D OWC
Chonan TSTC
D range 1st gear - O/D clutch, O/D OWC, Forward clutch, No.2 OWC are engaged.
O/D clutch Forward clutch
25
No.2 OWC
O/D OWC
* No.2 OWC is operated during vehicle acceleration. No.2 OWC is not operated during vehicle deceleration.
Chonan TSTC
D range 2nd gear - O/D clutch, O/D OWC, Forward clutch, 2nd brake, No.1 OWC are engaged.
O/D clutch Forward clutch 2nd brake
26
No.1 OWC
O/D OWC
* No.1 OWC is operated during vehicle acceleration. No.1 OWC is not operated during vehicle deceleration.
Chonan TSTC
D range 3rd gear - O/D clutch, O/D OWC, Forward clutch, Direct clutch, 2nd brake are engaged.
O/D clutch Forward clutch Direct clutch 2nd brake
27
O/D OWC
Chonan TSTC
D range 4th gear - Forward clutch, Direct clutch, O/D brake, 2nd brake are engaged.
O/D brake 2nd brake Direct clutch Forward clutch
28
Chonan TSTC
2 or L range 2nd gear - O/D clutch, O/D OWC, Forward clutch, 2nd brake, 2nd coast brake, No.1 OWC are engaged.
O/D clutch Forward clutch 2nd coast brake 2nd brake
29
No.1 OWC
O/D OWC
* No.1 OWC is always hold due to the 2nd coast brake regardless of vehicle acceleration or deceleration. Engine brake is not available.
Chonan TSTC
MECHANICAL (03-II)
Line Pressure MPa (kgf/cm2)
IDLE D R 0.32-0.38 (3.5-4.2) 0.47-0.56 (5.2-6.2) STALL 1.15-1.31 (12.7-14.5) 1.48-1.78 (16.3-19.6)
30
Line pressure check port
Chonan TSTC
CONTROL SYSTEM
Control diagram
31
ENGINE
PLANETARY GEAR
SHIFT V.
THROTTLE POSITION SENSOR
(THROTTLE PRESSURE)
SPEED SENSOR
The vehicle speed signal detect ed by speed sensor and the thro ttle opening signal detected by E CM are sent to TCM. Then, TC M sends the electronic signal (O N/OFF) to each solenoid for gea rs shifting of 1st, 2nd, 3rd and 4t h and proper L-up timing. Also, TCM sends the electronic signal to SLT in accordance with the throttle opening to produce o il pressure (throttle pressure).
SLT ECM
(THROTTLE OPENING SIGNAL)
SHIFT Sol. (SPEED SIGNAL)
TCM
ACCERELATOR
SENSOR
Chonan TSTC
HYDRAULIC CONTROL SYSTEM

System
TCM Voltage Sol. Shift valve Control valve Line pressure Lubrication Oil cooler Operation Oil pump pressure Planetary gear
32
Torque converter
Send oil
Regulator valve Modulator valve
Based on the hydraulic pressure created by the oil pump, TCM sends signals to solenoid and hydraulic control syste m governs the hydraulic pressure acting on the torque converter, planetary gear, clutches and brakes in accordance with the vehicle driving conditions.
Oil pump Clutch Brake
Oil pan
Chonan TSTC
ELECTRIC PARTS
Input speed sensor
Input Speed Sensor detects A/T input speed from rotation number of C0(Over drive clutch) drum, and they transmit to TCM as a signal.
33
NC0
NC0G
Chonan TSTC
ELECTRIC PARTS
Input speed sensor
(1) Make sure to inspect resistance again at 20 degree C when resistance differ from standards except 20 degree C. (2) It might become infinity ohm when inspect resistance at higher temperature.
34
1100 1000 Resistance / ohm 900 800 700 600 (520) 500 400
(428)
(1027)
560 680 ohm (20 degree C)
(846)
680
560
-40
0 40 80 120 150 Temperature / degree C
Chonan TSTC
ELECTRIC PARTS
Output speed sensor
Output Speed Sensor detects a turn number of magnet of rotor sensor installed in output sh aft, and communicates to TCM as a signal.
35
SP
SPG
Chonan TSTC
ELECTRIC PARTS
Output speed sensor
36
750 Resistance / ohm 650
(715)
(584)
380 480 ohm (20 degree C)
550 450
480
(362)
350 250
(295)
380
-40
Chonan TSTC
ELECTRIC PARTS
Oil temperature sensor
The Oil Temperature Sensor concerts ATF temperature variation into electronic signals to tra nsmit to TCM. This information is necessary for shift control and L-up control, etc.
37
OT
OT-G
0 degree C 160 degree C
1,884 - 2,290 ohm 19.2 - 22.2 k ohm
Chonan TSTC
ELECTRIC PARTS
Chonan TSTC
ELECTRIC PARTS
Solenoid valves
39
Shift Solenoid No.1/2 is each, and it is installed VALVE BODY of A/T directly. And Shift Solen oid No.1/2 does the operation of ON / OFF by the control signal from TCM, and changes a po sition of shift valve by a combination with Shift Solenoid No.1/2, and changes gear. 11 15 ohm (20 degree C)
24 Resistance / ohm 20
(16.6) (22.6)
Normal close type
16 12 8
15
Shift solenoid No.1 No.2 (S1, S2) L-up Solenoid
(11.5) (8.4)
11
-40
Chonan TSTC
ELECTRIC PARTS
Solenoid valves
(1) Make sure to inspect resistance again at 20 degree C when resistance differ from standards except 20 degree C. (2) It might become infinity ohm when inspect resistance at higher temperature. Normal open type: No connect battery Connect battery
40
No leak air Leak air
Chonan TSTC
ELECTRIC PARTS
Line pressure control solenoid valve
SLT controls linear throttle pressure by control signal from TCM and line pressure for clutche d and brakes to reduce shift shock.
Low <= Oil Pressure => High
41
Low <= Current => High
Chonan TSTC
ELECTRIC PARTS
Line pressure control solenoid valve
5.0 5.6 ohm (20 degree C)
9 8 Resistance/ Resistance/ohm 7 6 5 4 3 -40 40 80 120 Temperature/ Temperature/degree C 0
42
(8.5)
(7.6) 5.6
(4.3) (3.8)
5.0
Chonan TSTC
ELECTRIC PARTS
Lock-up solenoid valve
43
Lock-up solenoid valve operates of ON/OFF by the control signal from TCM and L-up clutch in side T/C. Normal open type
According to each L-up shift schedule, TCM sends signals to the Lock-up solenoid valve which operates ON/OFF control L-up control on the basis of the vehicle speed and the throttle ope ning.
Chonan TSTC
ELECTRIC PARTS
Lock-up solenoid valve
44
Normal open type: No connect battery Connect battery Leak air No leak air
Chonan TSTC
ELECTRIC PARTS
Wire to solenoid valves
Wire To Solenoid puts wiring of Shift Solenoid No.1, No.2, L-up Solenoid and SLT together in one connector, and it is installed to A/T case.
45
S1 S2 SL
SLT
SLTG
Chonan TSTC
ELECTRIC PARTS
TCM terminals
1 S1 12 +B IG 33 2 S2 SL GND 34 14 SLT 15 --35 16 --36 17 SLTG BK 37 18 -3 -DGC 38 4 -OT 39 5 WT --40 6 TH TC KL 41 7 NC0 8 SP -42 25 --43 26 --44 27 L4 28 -DG1 45 29 --46 9 OD OIL-L 10 P N 2 47
03A711
46
11 R D L 48 32
NC0G SPG
GND OTG
1: Shift solenoid No.1 2: Shift solenoid No.2 3: Open 4: Open 5: Water temperature signal 6: Throttle opening signal 7: Input speed sensor (+) 8: Output speed sensor (+) 9: O/D off switch 10: Position switch P 11: Position switch R 12: Battery (+)
25: Open 26: Open 27: L4 switch 28: Open 29: Open 30: Oil lamp 31: Position switch N 32: Position switch D 33: Ignition switch 34: Ground (-) 35: Open 36: Open
Chonan TSTC
ELECTRIC PARTS
TCM terminals
1 S1 12 +B IG 33 2 S2 SL GND 34 14 SLT 15 --35 16 --36 17 SLTG BK 37 18 -3 -DGC 38 4 -OT 39 5 WT --40 6 TH TC KL 41 7 NC0 8 SP -42 25 --43 26 --44 27 L4 28 -DG1 45 29 --46 9 OD OIL-L 10 P N 2 47
03A711
47
11 R D L 48 32
NC0G SPG
GND OTG
13: L-up control solenoid (+) 14: Line pressure control solenoid (+) 15: Open 16: Open 17: Line pressure control solenoid (-) 18: Open 19: Diagnosis terminal 20: Oil temperature sensor (+) 21: Open 22: Torque control signal 23: Input speed sensor (-) 24: Output speed sensor (-)
37: Brake switch 38: Ground (-) 39: Oil temperature (-) 40: Open 41: Diagnosis signal (K-LINE) 42: Open 43: Open 44: Open 45: Diagnosis terminal 46: Open 47: Position switch 2 48: Position switch L
Chonan TSTC
ELECTRIC PARTS
Inhibitor switch (Transaxle range switch)
48
TR switch transmits the information which range includes shift lever of A/T to TCM by combi nation of a position circuit terminal. 1) It is possible for TR switch to start an engine in only P and N. (Prevention of reckless driving) 2) It is used for TR switch to shift control.
5 9 4 8 3 7 2 6 1 4 10 9 3 8 2 7 6 1 5
For 4D56 TCi
For 2.9 Tci / 3.5V6
N
ST(+)
2 L
C D
ST(-)
Chonan TSTC
ELECTRIC PARTS
Connector of vehicle harness (TCM)
TR switch
N
ST(+)
49
Solenoid
P
2 L
C D
S1 S2 SL
SLT
SLT G
ST(-)
Input speed
Output speed
SP SPG
NC0
NC0G
OTS
OT OT-G
Chonan TSTC
ELECTRONIC CONTROL
INPUT
A/T range switch Input speed signal Output speed signal
50
OUTPUT
Shift solenoid-1 Shift solenoid-2 Pressure control solenoid Lock up control solenoid OTS lamp K-Line
MicroProcessor
O/D off signal
Oil Temp. signal Brake signal
ROM
L4 signal RAM ECM
Chonan TSTC
ELECTRONIC CONTROL
Shift control schedule
51
In accordance with the vehicle speed and the throttle opening, the TCM sends signal to the shi ft solenoids (No.1 and No.2) which operate the shift valves. Gear 1st 2nd 3rd 4th No.1 ON ON OFF OFF No.2 OFF ON ON OFF
Chonan TSTC
ELECTRONIC CONTROL
L4 SWITCH BRAKE SWITCH DIAGNOSIS
52
#1 TR SWITCH #2 OUTPUT SPEED SENSOR (SP) #3 INPUT SPEED SENSOR
THROTTLE OPENING SIGNAL
O/D OFF SWITCH TCM
ECM
WATER TEMPERATURE SIGNAL TORQUE CONTROL SIGNAL
OIL TEMPERATURE (C0) LAMP
#4 SPEED METER DRIVEN GEAR (SPM) #5 OIL TEMPERATURE SENSOR (OT) #6 SHIFT SORENOID NO.1 NO.2 (S1, S2)
#3 #2 #5 #1
#7 LINE PRESSURE CONTROL SOLENOID (SLT) #8 LOCK UP SOLENOID (SL)
ENGINE
V/B
#6 #7 #8
Chonan TSTC
ELECTRONIC CONTROL
Lock-up cut control
When the following 3 conditions give approval by 1, TCM cancels L-up. (1) Brake switch ON (2) Accelerator opening is full closed. (Engine Rev. is idle speed) (3) Engine water temperature is low.
53
Over drive cut control

When the following condition, TCM cancels 4th gear. (1) Engine water temperature is low. (2) L4 S/W ON (3) O/D switch OFF
Chonan TSTC
ELECTRONIC CONTROL
Driving control
HP/2.5 TCI D 2 L 1 <=> 2 <=> 3 <=> 4(L) 1 <=> 2 <= 3 1 <= 2
54
<=>: Shift up/down, <=: Only shift down, (L): L-up operation
Chonan TSTC
ELECTRONIC CONTROL
High ATF temperature control
55
When ATF temperature abnormally rises (more than 140 degree C), TCM changes shift pat tern automatically. As a result, A/T can get bigger driving low gear range, and the rise of ATF temperature by torque converter slip can be prevented. Also, a warning lamp will brink if the oil temperature rises to more than 147 degree C.
ATF temperature > 140
Mode 1
High ATF temperature shift pattern A/T lamp on
ATF temperature > 147
Mode 2
ATF temperature < 127
A/T lamp off
Chonan TSTC
ELECTRONIC CONTROL
Torque reduction control and line pressure control
Torque reduction control improves the shift quality due to sending torque reduction request signal from TCM to ECM and reducing engine torque increase of shift at N-D, N-R shift and 1 <=> 2 <=> 3 <=> 4. Line pressure control improves the shift quality due to controllable line pressure at N-D, NR shift, and 1 <=> 2 <=> 3 <=> 4.
56
Chonan TSTC
ELECTRONIC CONTROL
Squat control
When the shift lever is shifted from N to D, the Squat control operation which temporarily shifts to 3rd gear reduce shifting shock and squatting vehicle. N=>D
57
3rd. 1st. 1st.
Chonan TSTC
ELECTRONIC CONTROL
Coast down control
To prevent the frequent gear shift during short time in the condition of low TPS opening ratio and to improve the shift quality such as 2->1, 3->2 at the coast down road, a special shift pattern was adopted to be operated in case of specified vehicle condition.
Throttle (%) Normal Shift Pattern
58
2->1
1->2
3->2
2->3
CD2->1 CD1->2 CD3->2 CD2->3
idle
0
A
Output speed (rpm)
Chonan TSTC
ELECTRONIC CONTROL
Coast down control start condition
1) Brake switch is N (When the foot brake is depressed) 2) Engine is idle (When the accelerator pedal is not depressed)
59
Coast down control cancellation condition

1) After 1 second since the brake switch is OFF (To prevent hysteresis) 2) TPS > 0% (When the accelerator pedal is depressed) Comparing with previous shift pattern, the width A was enlarged so as to prohibit the shift busy.
Chonan TSTC
ELECTRONIC CONTROL
Pin to pin communication
Items Torque control Engine rpm MIL VSS* WTS** 4D56 Tci O X X X O J3-2.9 Tci (C/Rail) O O X X O 3.5 V6 (Euro-III) O O O O O
60
VSS*
ECM TCM
WTS**
4D56, 3.5 V6 On/Off switch from ECM to TCM J3-2.9 C/rail PWM from ECM to TCM
VSS
Chonan TSTC
ELECTRONIC CONTROL
Engine RPM (ECM->TCM) : Except 4D56TCi
The E_REV is a rectangular signal with 50% +/-10% duty cycle. The number of pulses is 4 pulse per 1 crankshaft revolution.
one crank revolution
61
t T
t / T 100% = 50
+/- 10
Chonan TSTC
ELECTRONIC CONTROL
Accelerator position (ECM->TCM)
The frequency of PWM(Pulse-Width Modulation) signal is 100 Hz.
62
f = 100 Hz +/- 1% T_PWM = 10 ms +/- 0.1ms

t T_PWM
APS = duty cycle [%] =
t [ms ] * 100 % T _ PWM [ms ]
Specification of duty cycles : 0 % duty-cycle < 5 % 5 % duty-cycle < 10 % 10 % duty-cycle 83 % 83 % < duty-cycle 94 % 94 % < duty-cycle 100 %
0.0 ms t < 0.5 ms 0.5 ms t < 1.0 ms 1.0 ms t 8.3 ms 8.3 ms < t 9.4 ms 9.4 ms < t 10.0 ms
failure of APS signal 0 % APS valid (0 % APS - 100 % APS) 100 % APS failure of APS signal
The APS information is always transferred when IG key is ON even during cranking. If accel pedal sensor is fail, ECM should transfer 100% PWM.
Chonan TSTC
ELECTRONIC CONTROL
PWM THROTTLE SIGNAL
Duty vs Throttle openings
WOT (100%)
63
TPS (%) 0%TPS signal
(0%)
0 5 10 83
Duty ratio ( t / T ) (%)
94
100
Fail
Fail
Chonan TSTC
ELECTRONIC CONTROL
Water temperature (ECM->TCM) for KJ2.9TCi (C/Rail)
The frequency of PWM(Pulse-Width Modulation) signal is 100 Hz.
64
f = 100 Hz +/- 1% T_PWM = 10 ms +/- 0.1ms

t T_PWM
WT = duty cycle[%] = (
t[ms] / T_PWM[ms] ) * 100%
Specification of duty cycles : 0 % duty-cycle < 5 % 5 % duty-cycle < 10 % 10 % duty-cycle 90 % 90 % < duty-cycle 95 % 95 % < duty-cycle 100 %
0.0 ms t < 0.5 ms failure of WT signal 0.5 ms t < 1.0 ms -50degC WT 1.0 ms t 9.0 ms valid ( -50degC WT 150degC WT) 9.0 ms < t 9.5 ms 150degC WT 9.5 ms < t 10.0 ms failure of WT signal
The WT information should be always transferred when IG key is ON even during cranking. If water temperature sensor is fail, ECM should transfer 100% PWM
Chonan TSTC
ELECTRONIC CONTROL
Water temperature signal for 4D56TCi, 3.5 V6
WATER TEMPERATURE SWITCH
CIRCUIT
TCU
65
IG
ECU
Io
WT 5
1.8K
0.01 or less
Io Leak resistance Chattering time Signal logic
: 10mA max. (at IG = 16V) : 100Kmin. : 10msec. Max. : Active low at low temperature. 0V (ECT<37 ), 12V (ECT>40 )
Chonan TSTC
ELECTRONIC CONTROL
Torque reduction request (ECM<-TCM)
66
The torque request signal is transmitted by the TCM and is used by ECM to reduce the engine torque during gear shift. The active signal is a low state.
f = 100 Hz +/- 1% T_PWM = 10 ms +/- 0.1ms

t T_PWM
DT _ PWM = duty cycle [%] =
t [ms ] * 100 % T _ PWM [ms ]
Chonan TSTC
ELECTRONIC CONTROL
Torque reduction request (ECM<-TCM)
67
Specification of duty cycles : TCM will monitor continuously the hardware output line for the presence of error so that a `stuck high` or `stuck low` of output can be detected. constant high signal when no gear shifting No reduction required 0 % < duty-cycle < 10 % 0.0 ms < t < 1.0 ms ECM ignores this request(invalid signal) 10 % duty-cycle < 14 % 1.0 ms t < 1.4 ms Maximum torque reduction requested 14 % duty-cycle 96 % 1.4 ms t 9.6 ms Valid signal 96 % < duty-cycle 98 % 9.6 ms < t 9.8 ms No reduction requested 98 % < duty-cycle < 100 % 9.8 ms < t < 10.0 ms ECM ignores this request(invalid signal) constant low signal Failure of T_RED signal TCM have no information of real (current) engine torque, but through the calibration work at each condition in the actual vehicle for up- and down-shifts, the TCM determines the value by how much the engine torque has to be reduced.
Chonan TSTC
ELECTRONIC CONTROL
MIL request (TCM->ECM) Only for 3.5 V6 with OBD-II or E-OBD
By the MIL-line the TCM demands of the ECM to switch on or off the malfunction indication lamp (MIL). Specification of MIL_REQuest signal:
Ts1 Ts2 TL TH
68
Initialize
MIL off
MIL on
Ts1 TCM ECM 0.3 sec
Ts2 2.0sec
TL 90ms
TH 1660ms
1500<TL+TH<2000msec
Chonan TSTC
DIAGNOSIS
A/T(Automatic Transmission) oil temperature warning light
69
The A/T oil temperature warning light comes on (No blinking) when the automatic transmission oil temperature goes up to the temperature that may result in serious damage of automatic transmission. If the A/T oil temperature warning light comes on while driving, park your vehicle in at a safe place as soon as possible and with the selector lever is shifted into "P" position, and allow the engine to idle until the warning light goes off. And when the warning light goes off, the vehicle can be driven normally.
Chonan TSTC
DIAGNOSIS
Diagnostic Specification for HP (Except EU & N/A)
CODE P0705 P0722 P0743 P0753 P0758 P1121 P0710 P0715 P0748 P1780 Description Transmission Range Sensor Circuit Malfunction(OPEN/SHORT) Output speed Sensor Circuit(No signal) Torque converter Clutch Circuit(SL) Electrical(HIGH/LOW Voltage) Shift Solenoid A(S1) Electrical(HIGH/LOW Voltage) Shift Solenoid B(S2) Electrical(HIGH/LOW Voltage) Throttle sensor Signal Malfunction(PWM Type) Transmission Fluid Temperature Sensor Circuit Malfunction(OPEN/SHORT) Input speed Sensor Circuit(No signal) Pressure Solenoid(Sth) Electrical(HIGH/LOW Voltage) Torque reduction signal malfunction(LOW Voltage) 03-II C B C A A B C B A B 4D56TCI C B C A A B C B A B
70
30LEi
3.5D
Type A : Failure store DTC on the 1st driving cycle. Type B : Oil-lamp blinking on the 2nd. consecutive driving cycle with a fail store DTC. Type C : Oil-lamp not blinking, store DTC on 2nd consecutive driving cycle with a fail.
Chonan TSTC
DIAGNOSIS
2nd. consecutive driving cycle
2 Driving cycle detection: How to duplicate DTC. DTC duplicates in case failures are detected at least 2 provided IG OFF => ON
Symptom simulation test [TR-4] 1 Symptom simulation
71
test
PXXXX 2
Tester detects one failure Tester detects the 1 failure (1 driving cycle) (One driving cycle)
IG OFF => ON
AC C ON AC C ON
OFF
IG OFF => ON
OFF
IG OFF
ON
Perform the symptom Implement symptom simulation test again [TR-4] simulation test again again (Two driving cycle)
Tester failure (2 driving cycle) 5 At the 2 detects failure
Chonan TSTC
DIAGNOSIS
How to check the Fail-code by means of DGI/DGC
1) Let the PIN No. 11 of DLC ground. 2) Fail-code will be flashed on Oil-lamp after several seconds of Oil-Lamp turned on. 3) For the clear of Fail-code, let the PIN No. 3 of DLC ground over than 5seconds.
72
DTC clear switch Data Link Connector

1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16
K-line
Diagnosis switch
Chonan TSTC
DIAGNOSIS
MIL & Oil lamp flush
Caution that MIL and Oil-lamp flashing are not installed simultaneously in a vehicle.
73
EU & N/A
MIL A/T lamp
DTC warning ATF temp. high only
General
A/T lamp
DTC warning
+
ATF temp. high only
Chonan TSTC
DIAGNOSIS
How to count the Oil-lamp blinking
For example : P1783 / P0604
74
A C A C A C A C A C A C A
A C A C A C A C A C A C A C A
A C A C A
A C A C A C A C A C A
A C A C A C A
A : 0.5sec.
B : 1.5sec.
C : 0.3sec.
D : 1.5sec.
Chonan TSTC
DIAGNOSIS
DTC
DTC
0753
75
Detection item Shift solenoid No.1 Shift solenoid No.2 L-up solenoid
Detection condition Open circuit GND short cir cuit Open circuit GND short cir cuit Open circuit GND short cir cuit Open circuit GND short cir cuit
Lamp OFF
FAILE SAFE
Cancel condition
Emergency 2 OFF
After IG OFF=> ON
0758
0743
OFF
No L-up
Gear shifting After IG OFF=> ON, TCM judge normal
0748
Line pressure solenoid
OFF
Emergency 2
Chonan TSTC
DIAGNOSIS
DTC
DTC Detection item Input speed sensor Detection condition Lamp FAILE SAFE
No L-up, No line pressure control, No torque reduction control No change 4th gear, No L-up, No squat control, No line pressure control, No torque reduction control, As for vehicle speed, substitute C0 rotate. Full line pressure, Throttle opening =0% fixed No line pressure control, No torque, reduction control, No squat control
76
Cancel condition
After TCM judge normal, 0km/h is detected
0715
No signal
ON
0722
Output speed sensor
No signal
ON
1121
Throttle position sensor
No signal
ON
Chonan TSTC
DIAGNOSIS
DTC
DTC Detection item Transaxle Range switch Detection condition Open circuit OFF GND short cir cuit Open circuit OFF GND short cir cuit No signal ON Lamp FAILE SAFE Open: All range D , GND short: TCM judge following priority D>2>L>R>N>P High oil temperature mode No L-up, No squat control, No line pressure control No torque reduction control Cancel condition TCM Judge normal
77
0705
0710
After TCM judge normal, 0km/h is detected TCM Judge normal
1780
Torque Control signal
Chonan TSTC
DIAGNOSIS
DTC
Emergency mode 2 + Gear shifting is available by turning all the solenoid OFF and manual shift each gear range.
78
D Gear range Failure 1st 2nd 4th 3rd 4th 1st
2 2nd 3rd 3rd 1st
L 2nd 1st
Chonan TSTC
DIAGNOSIS
Hi-scan
2.5 TCI with EST Chonan TSTC
DIAGNOSIS
Hi-scan
DIAGNOSIS
Hi-scan
DIAGNOSIS
Hi-scan
DIAGNOSIS
Troubleshooting
P0750, P0753 P0755, P0758 P0740, P0743 Solenoid No.1 (S1) Open, Ground short Solenoid No.2 (S2) Open, Ground short L-up solenoid (SL) Open, Ground short
83
DTC DETECTION CONDITION Ground short: DTC decides a failure in case any trouble is detected at the other gears at 8 times after a trouble detection at a gear for 0.3 sec.. Open: DTC decides a failure in case any trouble is detected at the other gears at 8 times after a trouble detection at a gear for 0.5 sec.. And 2 driving cycles detect.
CAUSE OF FAILURE
1. Harness or connector between each shift solenoid and TCM 2. Each shift solenoid 3. TCM
Chonan TSTC
DIAGNOSIS
Troubleshooting
P0748 Pressure control solenoid Open, Ground short
84
DTC DETECTION CONDITION
CAUSE OF FAILURE 1. Harness or connector between pressure control solenoid and TCM. 2. Pressure control solenoid 3. TCM
Open, GND short: When detected detection condition that the electric current value of less than 20 mA has been detected in 12.5 seconds normal value is output from TCM, DTC is decided. (+B) Ground short: When detected detection condition that the output of more than 1.36 A in 0.5 seconds is detected, DTC is decided.
Chonan TSTC
DIAGNOSIS
Troubleshooting
P0715 P0720, P0722 Input speed sensor No signal Output speed sensor No signal CAUSE OF FAILURE
85
DTC DETECTION CONDITION No C0 signal: When detected detection condition that no pulse of C0 signals is detected during 12 pulses of SP signals detected, failure is 1 time. When detected more than 1000 times continuously, a temporary failure is decided. When it is detected again after IG OFF => ON, the total of failures become 2 times and DTC is decided. No SP signal : When detected detection condition that no pulse of SP signals is detected during 45 pulses of C0 signals detected, failure is 1 time. When detected more than 500 times continuously, a temporary failure is failure is decided. When it is detected again after IG OFF=>ON, the total of failures become 2 times and DTC is decided.
1. Harness or connector between each speed sensor and TCM. 2. Each speed sensor 3. TCM
Chonan TSTC
DIAGNOSIS
Troubleshooting
P0705 TR switch No signal, Open CAUSE OF FAILURE
86
DTC DETECTION CONDITION
No signal: DTC decides a temporary failure in case no signal is transmitted more than 30 sec. at 1130 rpm. When any trouble is detected again after IG OFF =>ON, the number of problems total 2 and DTC decides a failure. Open: DTC decides a temporary failure in case detected 2 or more signals for more than 10 sec. When any trouble is detected again after IG OFF =>ON, the number of problems total 2 and D TC decides a failure.
1. Harness or connector between TR switch and TCM. 2. TR switch 3. TCM
Chonan TSTC
DIAGNOSIS
Troubleshooting
P0710 Oil temperature (OT) Open, Ground short CAUSE OF FAILURE
87
DTC DETECTION CONDITION Open: When detected detection condition that the abnormal condition of oil temperature after 15 mimutes has passed since IG ON, a temporary failure is decided. When it is detected again after IG OFF => ON, the total of failures become 2 times and DTC is decided. Ground short: When detected detection condition that the abnormal condition for 5 minutes since IG ON, a temporary failure is decided. When it is detected again after IG is OFF => ON, the total of failures become 2 times and DTC is decided.
1. Harness or connector between oil temperature sensor and TCM. 2. Oil temperature sensor 3. TCM
Chonan TSTC
TCM SIGNALS
Standard sheet for TCM signals (3.5V6)
No 1 A1 Items SCSV 1 Condition Type IDLE Hz Signals Level Vbatt 0V Description 1st/2nd : 13.6V/13.2V 3rd/4th : 0V Remarks Current : 0.95A
88
A2
SCSV 2
IDLE
Hz
Vbatt 0V
2nd/3rd : 13V/13.1V 1st/4th : 0V
Current : 0.95A
B1
W/TEMP SIG (FROM ECU)
40 37
or more or less
DC PWM
Vbatt-2V ~ Vbatt VGND-0.3 ~ 1.5V HI : Vbatt-2V ~ Vbatt LO : VGND-0.3 ~ 1.5V FREQ. : 100Hz DUTY(-) : C.T - 10% W.O.T - 83%
11.5V 0V HI : 7.24V LO : 0V FREQ. : 100Hz DUTY(-) : C.T - 10.4% W.O.T - 82% VHI VLOW Vp-p : 5.68V (IDLE) HI : 5.24V LO : -0.44V FREQ. : 91Hz 3000rpm : Vp-p : 18.1V HI:11.4V/LO:-6.7V FREQ. : 398Hz
B2
TPS SIG(PWM)
ACCEL C.T & W.O.T
B3
Input speed sensor signal
IDLE
PULSE
16PULSE/CO CYLINDER REV.
Chonan TSTC
TCM SIGNALS
Standard sheet for TCM signals(3.5V6)
No 8 Items Condition Type B4 Output speed sensor signal Driving PULSE Signals Level VHI VLOW 12PULSE/TM REV. Description Vp-p : 4.24V(30KPH) HI : 4.58V LO : 0.34V FREQ. : 199Hz 9 B5 O/D OFF SW OFF SW OFF OFF SW ON DC DC DC Hz 10 B6 INHIBITOR SW(P) P R/N/D/2/L 11 B7 INHIBITOR SW(R) R P/N/D/2/L 12 A5 BATT IGN OFF IGN ON 13 A6 LOCK-UP SOL Driving DC VGND-0.3 ~ 1V Vbatt-2V ~ Vbatt Vbatt 0.8V or less Vbatt 0.8V or less Vbatt Vbatt Vbatt 0V Io : 1.9A MAX 14 A7 PCSV IDLE PULSE Vbatt 00.5V HI : 13.1V(IHI : 0.94A) LO : 0V(ILO : 0.65A) FREQ. : 299Hz(-DUTY:44.4%) 3000rpm : -DUTY : 53.2% FREQ. : 300Hz OFF SW OFF : 0V OFF SW ON : 13.5V 13.5V 0V 12.5V 0V 12.3V 12.3V HI : 13.1V(IHI : 1.84A) LO : 0V(ILO : 1.15A) Remarks 60KPH : Vp-p : 6.12V HI:5.44V/LO:-0.68V FREQ. : 403Hz
89
Io : 1A MAX
Chonan TSTC
TCM SIGNALS
Standard sheet for TCM signals(3.5V6)
No Items Condition Type 17 A10 EARTH FOR PCSV 19 A12 DTC CLEAR SW IGN OFF IGN ON DC PULSE 20 A13 OIL TEMP SNSR IGN OFF IDLE 22 B9 TORQUE CONTROL Driving DC VGND-0.3 ~ 2V Vbatt 0V 0 5V 4V MIN 1.5V MAX FREQ. : 100Hz 23 B10 EARTH FOR CO CYLINDER 24 B11 EARTH FOR VSS 25 B12 ENG. REVOLUTION IDLE FROM ECU PULSE 4.0V MIN VGND-0.3 ~ 1V FREQ. : ABOUT 28Hz(850rpm) 27 B14 L4 SW SW OFF SW ON DC 30 B17 OTS LAMP LAMP OFF LAMP ON DC VGND-0.3 ~ 1V Vbatt-2V ~ Vbatt Vbatt 1.5V MAX SW OFF : 5.8V SW ON : 0V 12.1V 0V(3.15sec ON) G/LVL 0V 10.4V 0V 1.15V(After WARM UP) HI : 4.2V LO : 0V FREQ. : 100Hz(-DUTY:20%) G/LVL Signals Level Description G/LVL DTC CLR : GND Remarks
90
Chonan TSTC
TCM SIGNALS
No Items N P/R/D/2/L DC DC 32 B19 INHIBITOR SW(D) D P/R/N/2/L 33 A14 POWER(IGN 1) IGN OFF IGN ON 34 A15 EARTH FOR POWER 37 A18 BRAKE SW SW OFF SW ON 38 A19 EARTH FOR POWER 39 A20 EARTH FOR OTS 41 B21 K-LINE In comm. (10.4Kbps) 44 B24 SPEEDMETER Driving Hz PULSE LOGIC "0" : Vbatt 20% or less LOGIC "1" : Vbatt 80% or more Vbatt VGND-0.3 ~ 1V FREQ. : 42.5Hz(60KPH) 0V 12.1V HI : 11.4V LO : 0V FREQ. : 12Hz(20KPH) G/LVL DC VGND-0.3 ~ 2V Vbatt-2.0 ~ Vbatt 0V 13V Condition Type 31 B18 INHIBITOR SW(N) DC Vbatt 0.8V or less Vbatt 0.8V or less 0V 9V ~ 16V Signals Level 12.9V 0V 13.4V 0V 0V 12V Description Remarks OFF SURGE : -40.4V
91
Chonan TSTC
TCM SIGNALS
No Items Condition Type 45 B25 DIAG. SW IGN OFF IGN ON DC DC 47 B27 INHIBITOR SW(2) 2 P/R/N/D/L 48 B28 INHIBITOR SW(L) L P/R/N/D/2 DC 0V Vbatt Vbatt 0.8V or less Vbatt 0.8V or less Signals Level 0V 10.7V 13V 0V 13.1V 0V Description Remarks
DTC CODE OUTPUT : GND(VGND-0.3 ~ 1V)
92
Chonan TSTC
WIRING DIAGRAM
Electrical wiring diagram
93
Chonan TSTC
SHIFT PATTERN
TPS(%) 100
94
HP 2.5 DSL NORMAL SHIFT PATTERN
90
80
70
60
50
40
30
20
10
0 0 20 40 60 VSS (KPH) (KPH) 80 100 120
Chonan TSTC
SHIFT PATTERN
TPS(%) 100
95
43 34
21
HP 2.5 DSL HIGH ATF SHIFT PATTERN

12 D3 D3 D/C D/C OFF ON 32
90
D2 D/C OFF
23 D4 D/C OFF
80
D4 D/C ON
70
60
50
40
30
20
D2 D/C ON
10
0 0 20 40
VSS 60 (KPH) (KPH)
80
100
120
Chonan TSTC
SHIFT PATTERN
HP 2.5 DSL D RANGE 4LOW MODE
100
2 1
1 2
3 2
2 3
75 TPS (%)
50
25
1000
2000 Output speed (rpm)
3000
4000
Chonan TSTC
SHIFT PATTERN
HP 2.5 DSL 2 RANGE 4LOW MODE
100
2 1 1 2
3 2
75 TPS (%)
50
25
1000
3000
4000
Chonan TSTC
SHIFT PATTERN
HP 2.5 DSL L RANGE 4LOW MODE
100
2 1
75 TPS (%)
50
25
1000
3000
4000
Chonan TSTC
SHIFT PATTERN
TPS(%) 100
99 3->4
HP -3.5 GSL NORMAL SHIFT PATTERN
2->1
90
1->2
3->2
2->3
D3 D/C OFF
80
70
60
4->3
50
D4 D/C ON
40
30
D3 D/C ON : 3->4 Up-shift D4 D/C OFF : 4->3 Down-shift
20
10
0 0 20 40 60 80 VSS (KPH) 100 120 140 160 180
Chonan TSTC
SHIFT PATTERN
TPS(%) 100
100
HP -3.5 GSL HIGH ATF SHIFT PATTERN

12 32 23 43 34
90
80
21
70
60
D3 D/C ON
50
40
D3 D/C OFF
30
20
10
D2 D/C OFF
D2 D/C ON
D4 D/C OFF
D4 D/C ON
0 0 20 40 60 80 VSS (KPH) 100 120 140 160 180
Chonan TSTC
SHIFT PATTERN
HP 3.5 GSL D RANGE 4LOW MODE
100
2 1 1 2
3 2 2 3
75 TPS (%)
50
25
1000
2000 3000 Output speed (rpm)
4000
5000
6000
Chonan TSTC
SHIFT PATTERN
HP 3.5 GSL 2 RANGE 4LOW MODE
100
2 1 1 2
3 2
75 TPS (%)
50
25
1000
4000
5000
6000
Chonan TSTC
SHIFT PATTERN
HP 3.5 GSL L RANGE 4LOW MODE
100
2 1
75 TPS (%)
50
25
1000
4000
5000
6000
Chonan TSTC
Hydraulic pressure circuit diagram - Reverse range
AW30-40LEi
104
Hydraulic pressure circuit diagram - D range 1st gear
AW30-40LEi
105
Hydraulic pressure circuit diagram - D range 2nd gear
AW30-40LEi
106
Hydraulic pressure circuit diagram - D range 3rd gear
AW30-40LEi
107
Hydraulic pressure circuit diagram - D range 4th gear
AW30-40LEi
108
Hydraulic pressure circuit diagram - 2 range 1st gear
AW30-40LEi
109
Hydraulic pressure circuit diagram - 2 range 2nd gear
AW30-40LEi
110
Hydraulic pressure circuit diagram - 2 range 3rd gear
AW30-40LEi
111
Hydraulic pressure circuit diagram - L range 1st gear
AW30-40LEi
112

Aisin Aw 03 II - 30 40LE

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Aisin Aw 03 II - 30 40LE

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AUTOMATIC TRANSAXLE for HP-CAR

TYPE GENERAL MODEL GEAR RATIO

1ST 2ND 3RD 4TH R FINAL GEAR RATIO

2.5 TCI 24kgfm 72 2.1 241mm

Model 03-72L 03-72LE 03-II 30-43LE 30-40LEi

Remarks Hydraulic type

P R N 1st D 2nd 3rd 4th 1st 2 2nd 3rd L 1st 2nd

OFF OFF OFF OFF

ON ON=>OFF ON OFF OFF OFF ON OFF OFF ON

OFF OFF ON ON OFF ON ON

OFF OFF OFF ON ON ON ON ON

OFF OFF ON ON OFF OFF

OFF OFF ON OFF

OFF OFF OFF OFF OFF OFF OFF OFF ON ON

BRAKE B0 ~ OFF ~ OFF

OFF OFF OFF

804 ~ 531 ~ 000 ~ ~ 705 ~ 804 ~ 531 000 ~ 804 ~ 531

OFF OFF OFF ON-> OFF

OFF OFF OFF OFF

Elements Engine C-0 B-0 C-1 C-2 B-1 B-2 B-3

03-II 4D56 Tci

Friction plate 30-40LEi KJ2.9 3.5 V6

OFF OFF OFF OFF OFF OFF OFF

O/D f d`PLANETARY q tmh s

e ok `qx `mds FR f d`PLANETARY q tmh s

q RR f dok`mds`qx PLANETARY ` q tmh s

OFF OFF OFF OFF

n^ cok O/Dfd`q tmh `mds`qx s PLANETARY

e ok `mds `qx FR PLANETARY fd`q tmh s

q ok `mds `qx RR PLANETARY fd`q tmh s

O/Dfd`q tmh PLANETARY s

ok `mds `qx FRe PLANETARY fd`q tmh s

RR PLANETARY fd`q tmh s

OFF OFF OFF

ok `mds `qx FRe PLANETARY fd`q tmh s

q ok `mds `qx RR PLANETARY fd`q tmh s

OFF OFF OFF

n^ cok O/D fd`q tmh `mds s`qx PLANETARY

ok `mds `qx FRe PLANETARY fd`q tmh s

q ok `mds `qx RR PLANETARY fd`q tmh s

Line pressure check port

THROTTLE POSITION SENSOR

SHIFT Sol. (SPEED SIGNAL)

HYDRAULIC CONTROL SYSTEM

Regulator valve Modulator valve

Oil pump Clutch Brake

560 680 ohm (20 degree C)

0 40 80 120 150 Temperature / degree C

750 Resistance / ohm 650

380 480 ohm (20 degree C)

0 40 80 120 150 Temperature / degree C

0 degree C 160 degree C

1,884 - 2,290 ohm 19.2 - 22.2 k ohm

Normal close type

Shift solenoid No.1 No.2 (S1, S2) L-up Solenoid

0 40 80 120 150 Temperature / degree C

No leak air Leak air

Low <= Current => High

For 4D56 TCi

For 2.9 Tci / 3.5V6

O/D off signal

Oil Temp. signal Brake signal