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9.2.2. Failure diagnostics of AT - the general information

Refusals of AT most often happen for one of the following five reasons:

a) Decrease in efficiency of return of the engine;
b) Violation of adjustments;
c) Malfunction of hydraulics;
d) Mechanical damages;
e) Failures of the onboard processor / its alarm chain.

Failure diagnostics always has to begin with the simplest checks: estimate the level and a condition of ATF (see the Head Nastroyki and routine maintenance), check adjustment of drives of gear shifting and a butterfly valve. Further, carry out trial runs of the car for the purpose of definition of efficiency of the made corrections. If it was not succeeded to fix a problem, it is necessary to drive away the car on car repair shop for more detailed diagnostics with use of the special equipment. The description of some of symptoms of violations of functioning of AT is provided in the Section devoted to failure diagnostics of knots and systems of the car at the beginning of the present manual.

List of the most typical refusals of AT

See also corresponding subsection in the Section devoted to failure diagnostics of knots and systems of the car in Introduction to the present manual.


Transmission provides the movement of the car forward or back

· Adjustment of drafts of switching is broken;
· The ATF/is underestimated level hydraulic pressure as a result of violation of passability of an oil filter, the wrong installation of valvate assembly, or damage of the reducing valve / managing director of the valve of the converter of rotation fell.

The movement is absent in provisions "D" and "2"

· The forward clutch coupling is faulty

Forward transfers do not function

· The back clutch coupling is faulty;
· The valve of the N-D accumulator is faulty.

The engine becomes deaf when switching transmission from situation "N" in situation "D" or "R"

· The engine does not develop the required power;
· Valvate assembly of AT is incorrectly established;
· The control ball of valvate assembly is jammed;
· The valve of coupling of the converter of rotation, or the valve of the N-D accumulator is faulty.

The box revolves at advance


· The ATF/hydraulic level pressure fell;
· The one-pass clutch coupling is faulty;
· Valvate assembly is faulty;
· The back clutch coupling is excessively worn-out.

The box revolves at inclusion of a reverse


· The ATF/hydraulic level pressure fell;
· The brake contour lowered transfers/reverse is faulty;
· The forward clutch coupling is excessively worn-out;
· Valvate assembly is faulty.

Too weak reception of the car at the movement on the 2nd and 3rd transfers takes place


· The ATF/hydraulic level pressure fell;
· The rotation converter is faulty;
· The back clutch coupling is faulty;
· Faulty/are wrong valvate assembly is established;
· Brake assembly of inclusion of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken.

Efficiency of braking by the engine in the L mode is reduced


· Valvate assembly is faulty;
· Brake assembly of the modes lowered transfers/reverse is faulty.

Turns of a stop of the converter of rotation are excessively underestimated


· The power developed by the engine is insufficient;
· The rotation converter is faulty.

Turns of a stop of the converter of rotation are excessively overestimated


· The ATF/hydraulic level pressure fell;
· The one-pass clutch coupling is faulty;
· The forward clutch coupling is faulty;
· The back clutch coupling is faulty;
· Valvate assembly is faulty.

The car moves at the transmission transferred to situation "N"


· The forward or back clutch coupling is faulty.

Transmission is not transferred to parking situation


· Adjustment of the drive of switching is broken;
· The mechanism of inclusion of situation "P" is faulty.

Discrepancy between the chosen and actually joining modes takes place


· The ATF/hydraulic level pressure fell;
· Valvate assembly is faulty;
· The forward clutch coupling is faulty;
· The brake tape of inclusion of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The operating regulator is faulty.

There is no switching of transmission to a low gear in any of provisions


· Serviceability of functioning of a butterfly valve is broken;
· The valve of switching of 1/2 transfers is faulty;
· The valve of switching of 2/3 transfers is faulty;
· The operating regulator is faulty.

Serviceability of switching of transmission from the 1st transfer on the 2nd is broken


· The ATF/hydraulic level pressure fell;
· Passability of an oil filter is broken;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The forward clutch coupling is faulty;
· The operating regulator is faulty;
· Valvate assembly is faulty.

Serviceability of switching of transmission from the 2nd transfer on the 3rd is broken

· The ATF/hydraulic level pressure fell;
· Passability of an oil filter is broken;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The forward clutch coupling is faulty;
· The operating regulator is faulty;
· Valvate assembly is faulty.

Switching of the 1st transfer to the 2nd and on the 3rd happens to the 2nd too sharply

· Adjustment of a cable of the drive of a butterfly valve is broken;
· Valvate assembly is faulty;
· The operating regulator is faulty;
· The forward clutch coupling is faulty;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken.

Switching of the 3rd transfer to the 2nd and on the 1st happens to the 2nd too sharply

· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The operating regulator is faulty;
· Valvate assembly is faulty.

The rotation converter during the work makes the howling sound

· The oil pump is faulty.

The converter of rotation jingles during the work

· The driving disk burst;
· The bolt of fastening of the converter of rotation to a driving disk weakened.

Primary checks

 PERFORMANCE ORDER

1. During a short trip warm up transmission up to the normal working temperature.
2. Check the ATF level (see the Head Nastroyki and routine maintenance):

a) If liquid is obviously not enough, make the corresponding adjustment, having added necessary quantity ATF is fresher. Be convinced of correctness of the carried-out adjustment according to indications of the measuring probe, then check transmission for existence of signs of external leaks;
b) If level is excessively high, merge surplus of ATF, then check it for existence of the traces of presence of cooling liquid demonstrating violation of tightness of the internal partitions of a radiator separating its heat exchanger from side tanks with ATF;
c) If ATF is made foam, empty transmission and fill it with fresh liquid, - check the merged ATF for existence of traces of presence of cooling liquid.
3. Check installation of turns of idling of the engine (see the Head of the Power supply system and release). In case of need drive away the car on car repair shop for performance of the corresponding adjustments.

If the engine not as it should be, it is not necessary to start performance of primary checks of transmission until the corresponding corrections are made.

4. Make sure of correctness of adjustment and smoothness of the course of a draft/cable of the drive of switching of draft.


Diagnostics of leakages of ATF

General information

The majority of leaks easily come to light at visual check. Repair usually consists in replacement of the corresponding defective epiploon or laying. If it is not possible to reveal a leak source during external survey, act as it is described below.

First of all it is necessary to exclude probability of a mistake in definition of the nature of leak. It is not necessary to confuse ATF to motive oil or brake fluid (transmission liquid usually has dark red color).

For identification of a source of leak make short (several kilometers) a trip, then park the car over the outspread blank sheet of a cardboard. Later a couple of minutes the source of leak can be revealed in the wake of the liquid dripping on a cardboard.

Attentively examine the suspected site and the surface surrounding it, paying special attention to joints of the interfaced pro-masonry surfaces. For the purpose of expansion of a viewing angle use a pocket mirror.

If it is not possible to reveal a leak source still, carefully wipe the surface of the suspected site with the rags moistened with solvent, then dry it.

Make one more short trip, this time often changing the speed of the movement, then again examine the cleaned suspected site.

After identification of a source of leak, it is necessary to define and remove the cause of its development, and only then to pass to performance of necessary recovery work. Replacement of the damaged laying will not result in desirable result if to leave not eliminated the defect of the interfaced surface which led to a sealant exit out of operation. So, the deformed flange needs to be aligned.

In the following subsections the most typical reasons of development of leakages of ATF and a condition which have to be executed that there was no recurrence are listed.

Part cannot be executed from the listed requirements without use of the special equipment. In this case the car should be driven away on car repair shop.


Leaks through pro-masonry surfaces

 PERFORMANCE ORDER

1. Periodically examine the transmission case pallet. Check existence on the places and reliability of tightening of fixing bolts, you watch that on a cover traces of mechanical damages did not appear (deformation of the pallet can lead to failure of the valvate assembly located in transmission).
2. Via the pallet excessively hard tightening of fixing bolts, violation of passability of the ventilating line, mechanical damage of a sealing surface of a case of transmission, laying destruction, and also emergence of cracks or porosity of walls of a case are among the possible reasons of development of leaks. If laying of the pallet or a case of transmission is formed by a sealant pillow, the probability of the wrong choice of type of the last is not excluded. Through laying of the pallet can lead to leaks also overflow of a case transmission liquid, or increase in pressure of ATF.


Leaks through epiploons and cuffs

 PERFORMANCE ORDER

1. The most typical reasons of an exit of epiploons of transmission excessively high ATF level/pressure, violation of passability of a ventilating branch pipe, mechanical damage of walls of a landing nest, damage actually out of operation are among an epiploon, or the wrong installation of the last. Also the probability of damage of a pin of the shaft passed throughout an epiploon, or an excessive side play of the last as a result of wear of bearings is not excluded.
2. Check a state and correctness of landing of a sealing cuff of the directing tube of the measuring probe. Periodically examine on existence of signs of leaks a surface around an arrangement of a driving gear wheel of the speedometer/sensor of the speed (VSS). In case of need you make replacement of a sealing ring.


Leaks through defects in transmission case walls

 PERFORMANCE ORDER

1. Formation of cracks or a time in a transmission case body can be the reason of development of leakages of ATF, - consult at specialists of car service.
2. Check tightness of nipple knots of connection of hoses of a cooler of ATF.


Leaks through сапун and a jellied mouth

 PERFORMANCE ORDER

Leaks through сапун ventilation or a jellied mouth can happen owing to overflow of transmission, hit in ATF of cooling liquid, passability violation сапуна / a ventilating branch pipe or returnable drainage openings.


Check of serviceability of functioning of mechanical subsystems of AT

Check on completely slowed down car (stall test)

 PERFORMANCE ORDER

1. Operability of transmission and the engine is made by measurement of frequency of rotation of a bent shaft in provisions "R" and "D" of AT at completely slowed down car.

ATF has to be heated-up up to the normal working temperature (50 ÷ 80 °C). Duration of each check should not exceed five seconds. Check should be made by forces of two people: one has to watch car wheels, the second makes necessary manipulations in interior of the car.

2. Slow down forward and back wheels of the car.
3. Connect a tachometer to the engine.
4. Completely cock the parking brake.
5. The left leg squeeze out against the stop a pedal of a foot brake.
6. Transfer a control lever the transfer case to situation H2.
7. Start the engine. Transfer the AT selector lever to situation "D", squeeze out against the stop the accelerator pedal and quickly consider indications of a tachometer.

If during check performance back wheels of the car begin to rotate before the frequency of rotation of the engine reaches the required value (2300 ÷ 2600 rpm), release the accelerator pedal and stop check.

8. Make similar check with transfer of transmission to situation "R".
9. If the frequency of rotation of the engine in both cases is identical below demanded, therefore, the engine does not develop full capacity, or the coupling of a free wheeling of the AT hydrotransformer is faulty.

If frequency is lower demanded on 600 rpm, the hydrotransformer is perhaps faulty actually.

10. If the frequency of rotation of the engine is higher than the transmission of "D" demanded in situation, it can demonstrate excessive pressure decrease in the main highway, pro-slipping in the coupling of a free wheeling No. 2, violation of serviceability of functioning of the coupling of a free wheeling of the raising planetary row, or pro-slipping in the coupling of direct transfer of the transfer case.
11. Excess of frequency of rotation of the engine in the provision "R" of transmission demonstrates pressure drop in the main highway, pro-slipping in the coupling of direct transfer, pro-slipping in a brake of the first and back transfers, violation of serviceability of functioning of the coupling of a free wheeling of the raising planetary row, or pro-slipping in the coupling of direct transfer of the transfer case.
12. If turns of the engine are overestimated in both provisions of transmission, so or excessively pressure fell in the main highway, or the ATF level does not correspond to the required value, or serviceability of functioning of the coupling of a free wheeling of the raising planetary row is broken, or pro-slipping in the coupling of direct transfer of the transfer case takes place.


Check of time of delay of switching

 PERFORMANCE ORDER

1. If at the engine working at single turns to transfer the selector lever to one of advance ranges, until a start of motion there has to pass some time. On duration of this delay it is possible to judge serviceability of functioning of blocking couplings of the raising planetary number, the forward course, direct transfer and a brake of the first and back transfers.

Check should be made on the engine which is warmed up up to the normal working temperature. The end result should be received by method of averaging of results of three checks, between each of which there have to pass not less than one minute. It is given detailed descriptions of the course of performance of this check below.

2. Completely cock the parking brake. Transfer a control lever of the transfer case to situation H2.
3. Start the engine and check turns of its idling, - in case of need make the corresponding adjustment.
4. Transfer the selector lever from situation "N" to situation "D" and by means of a stop watch measure delay time, - average value of three consecutive dimensions should not exceed 1.2 seconds.
5. Working in a similar manner, define time of a delay of turning on of the reverse gear which should not exceed 1.5 seconds.
6. Too low pressure in the main highway, violation of serviceability of functioning of the coupling of the forward course, the coupling of a free wheeling of the raising number of planetary assembly, or a brake of the first and back transfers can be the reason of excessive size of a delay of inclusion.


Hydraulic checks

General information

 PERFORMANCE ORDER

Performance of the checks described below will require the help of the assistant.

1. Check the level and a condition of ATF (see the Head Nastroyki and routine maintenance).
2. During a short trip warm up transmission up to the normal working temperature.
3. The car also establish to Poddomkratta it on props, - driving wheels have to be completely torn off from the earth.
4. Working according to instructions of manufacturers of the device, connect a tachometer. Arrange a tachometer so that its indicator was well looked through from the driver's place.
5. Find unions of connection of the manometer on transmission case sidewalls, near the line of its joint with the pallet. Turn out a stopper and connect a transitional nozzle of the measuring instrument to the corresponding union.

Some measurements will require the manometer with a scale to 28 kgfs/cm2 (see Specifications).


6. Perform measurements of hydraulic pressure of AT at various turns of the engine and in various provisions of the lever of the selector. Compare results of measurements to requirements of Specifications. In case of need make the corresponding regulriovka, replace defective components.
7. Having finished measurements tighten traffic jams of unions with the required effort.


The analysis of results of check of pressure in lines

F3A21 transmission

 PERFORMANCE ORDER

1. Excessively low pressure in provisions "D", "L" and "2" at normal indications in situation "R" demonstrates existence of leaks in a contour of a back clutch coupling, or through a sealing ring of the accumulator 1-2.
2. The underestimated pressure in provisions "D" and "R" at norm in situation "L" speaks about leaks in a contour of a forward clutch coupling.
3. The underestimated pressure in provisions "D" and "L" at normal in situation "2" is the evidence of leaks in a contour lowered transfers/reverse.
4. The lowered pressure in all modes can indicate malfunction of the oil pump, weakening of bolts of fastening of valvate assembly, violation of passability of the filter or jamming of the valve of the regulator of pressure.


Transmissions of the F4A20 series (F4A22 and F4A23/33/51)

 PERFORMANCE ORDER

1. The reasons of understating/overestimate of pressure in all lines can be: violation of passability of an oil filter, violation of adjusting parameters of the operating regulator, jammings of the valve of the regulator of pressure, the wrong pressure of dumping of the oil pump, leakage of ATF in valvate assembly.
2. The wrong reducing pressure can demonstrate violation of passability of the reducing filter, jamming of the reducing valve, or development of leaks in valvate assembly.
3. The wrong pressure in the line of a brake contour of the kickdown mode speaks about violation of serviceability of functioning of the servo-driver of the mode, or refusal of functioning of valvate assembly.
4. Can be the reasons of the wrong indication at measurement of pressure of a forward clutch coupling: leakages of ATF in the kickdown mode servo-driver, or valvate assembly, refusal of valvate assembly, leak on the piston or the holder of the coupling.
5. The wrong pressure of the face coupling indicates leakages of ATF on the coupling / to valvate assembly, or violation of serviceability of functioning of the last.
6. The wrong pressure in the brake line lowered transfers/reverse indicates leakages of ATF on the site between valvate assembly and a case of transmission (a sealing ring), refusal of functioning of valvate assembly or leak via the piston or the holder of the corresponding brake assembly.
7. Can be the reasons of the wrong indication at measurement of pressure of the converter of rotation: leakages of ATF in the oil cooler, or lines of a connecting path, violation of serviceability of functioning of the converter, leak through an epiploon of a main shaft, jamming of the electromagnetic valve of coupling of the converter (TCCSV valve), or failure of the valve of management of the converter.


Check of pressure of the operating regulator (F3A21 transmission)

 PERFORMANCE ORDER

1. Need for performance of this check arises only in case of violation of correctness of the moments of switching of transmission. Adjustment of a cable of the drive of a butterfly valve at the same time should not be broken.
2. Connect the manometer to the corresponding union on a transmission case.
3. Consider indications of the measuring instrument in the provision "D" of transmission. Compare results of measurement to requirements of Specifications.
4. At the set speed of the movement of the car jamming of the valve of the operating regulator, or violation of passability of the filter of the regulator can be the reason of deviations of pressure.
5. The operating regulator has to react in due time and smoothly to measurement of speed and come back to the basic pressure (0 ÷ 20 kPa) at a vehicle stop.


Trial runs

Tests have to be made at ATF which is warmed up up to the normal working temperature (50 ÷ 80 °C).


The moments of switching of the modes of the transfer case (H2, H4 and L 4) are various, besides, in the L4 mode inclusion of the 4th transfer and blocking of the hydrotransformer are forbidden.


Check in the range "D" in normal and sports operating modes of AT

 PERFORMANCE ORDER

1. Transfer the AT selector lever to situation "D", squeeze out against the stop the accelerator pedal and hold it in this situation. Check the moments of gear shifting 1-2, 2-3 and 3-4, - compare results of check to requirements of Specifications.
2. Check is made for the normal and sports modes of functioning of AT.
3. Lack of switching 1-2 testifies to an entrance out of operation of the electromagnetic valve No. 2, or sticking of the valve 1-2.
4. The electromagnetic valve No. 1 is responsible for lack of switching 2-3, also the probability of sticking of the valve of switching 2-3 is not excluded.
5. In the absence of switching 3-4 check a condition of the valve 3-4.
6. Violation of serviceability of functioning of a butterfly valve and valves of switching 1-2/2-3/3-4 can appear the reason of failure of the moments of gear shifting.
7. Lack of blocking of the hydrotransformer is explained by failure of the electromagnetic valve No. 3, or sticking the blocking inclusion valve.
8. Estimate smoothness of gear shifting. By the cause of pushes excessively high pressure in the main highway, violation of serviceability of functioning of the hydroaccumulator, or control ball valve can be put.
9. Moving with the blocked hydrotransformer, or on the 4th transfer, estimate intensity of vibrations and a noise background.

Also violation of balancing of the driveshaft can be the cause of vibrations and noise.

10. Accelerate the car before inclusion of the 4th transfer and, braking, define the moments of switching 4-3, 3-2 and 2-1. compare results of check to requirements of Specifications.
11. Estimate smoothness lowering switchings.
12. Check quality of blocking of the hydrotransformer, - at uniform motion on the 4th transfer blocking has to happen at a speed about 75 km/h. Slightly press the accelerator pedal, - turns of the engine should not change considerably, otherwise blocking of the hydrotransformer is broken.


Check in the range "2"

 PERFORMANCE ORDER

1. Transfer the AT selector lever to situation "2", squeeze out against the stop the accelerator pedal and hold it in this situation.
2. Define the moment of switching 1-2, compare result of check to requirements of Specifications.

In this mode of switching 2-3, 3-4 and blocking of the hydrotransformer are forbidden; at the movement with a speed of 100 km/h and above braking by the engine is forbidden.

3. Moving on the 2nd transfer, release the accelerator pedal and estimate efficiency of braking of the car the engine. If braking is absent, therefore, the brake of providing this mode is faulty.


Check in the range of "L"

 PERFORMANCE ORDER

1. At inclusion of the L mode any raising switchings are forbidden, - the car has to move on the first transfer all the time.
2. Release the accelerator pedal and estimate intensity of braking by the engine. If braking is absent, therefore, the brake of inclusion of the first and back transfers is faulty.
3. Estimate noise level and vibrations in the course of braking of the car the engine.


Check in the range of "R"

 PERFORMANCE ORDER

Transfer the AT selector lever to situation "R" and begin the movement in the accelerator pedal which is squeezed out against the stop, - pro-slipping of frictional elements of management has to be absent.


Check in the range "Р"

 PERFORMANCE ORDER

Park the car on a bias not less than 5 ° and transfer the selector lever to situation "P", you do not cock the parking brake, - the car has to remain motionless.