Automatic Transmissions and Transaxles Book

 1. Service Information, Fasteners, Tools, and Safety.

Learning Objectives.

Vehicle Identification.

Service Information.

Steel Classification.

Threaded Fasteners.

Basic Tool List.

Measuring Tools.

Safety Tips for Technicians.

Electrical Cord Safety.

Fire Extinguishers.

Review Questions.

Chapter Quiz.

 

 2. Environmental and Hazardous Materials.

Learning Objectives.

Introduction.

Occupational Safety and Health Act (OSHA).

Hazardous Waste.

Resource Conservation and Recovery Act (RCRA).

Clean Air Act.

Material Safety Data Sheets (MSDS).

Asbestos Exposure Hazard.

Proper Disposal.

Review Questions.

Chapter Quiz.

 

 3. Introduction to Transmissions.

Transmissions: Their Purpose.

Torque and Horsepower.

Gear Ratios.

Tractive Force.

Standard Transmission and Clutch.

Simple Planetary Gearsets.

Compound Planetary Gearsets.

Control Devices.

Transmission Hydraulics.

Torque Converters.

Transaxle Final Drive and Differential.

Four Wheel Drive.

Nonplanetary Gear Automatic Transmissions.

Hybrid Drive System.

 

 4. Apply Devices: Clutches and Bands.

Introduction.

Driving Devices.

Multiple-Disc Driving Clutches.

Clutch Plates.

Clutch Operation.

One-Way Driving Clutches.

Clutch Operation.

Holding/Reaction Devices.

Multiple-Disc Holding Clutches.

One-Way Holding Clutches.

Bands.

Band Operation.

Shift Quality.

Shifts Involving One-Way Clutches.

Deceleration with One-Way Clutches.

 

 5. Power Flow Through Transmission Gearsets.

Rules of Power Transfer.

Planetary GearRatios.

Transaxles.

Park.

Transmission Schematics.

Simpson Gear Train Transmissions.

Neutral.

First Gear.

Second Gear.

Third Gear.

Reverse.

Shift Timing.

Simpson Gear Train Plus and Additional Gearset.

Overdrive.

Ravigneaux Gearsets.

Two-Speed Arrangement and Operation.

Three-Speed Arrangement and Operation: First Version.

Three-Speed Arrangement and Operation: Second Version.

Four-Speed Arrangement and Operation: First Version.

Four-Speed Arrangement and Operation: Second Version.

Four-Speed Overdrive Gearset.

Four-Speed Overdrive Geafset: Second Version.

Four-Speed Overdrive Gearset: Variation of Second Version.

Four-Speed Overdrive: Variation Two.

Nonplanetary Gearsets.

Helical Gear Types.

CVT Types.

 

 6. Hydraulic System Theory.

Introduction.

Hydraulic Principles.

Simple Hydraulic Systems.

Basic Automatic Transmission Hydraulics.

Producing Fluid Flow and Pressure.

Providing Clean Fluid.

Controlling Fluid Flows.

Valve Hydraulic Forces.

Controlling Fluid Pressure.

Sealing Fluid Pressure.

Special Notes on Elastomers.

Applying Fluid Pressure.

Determining Piston Forces.

Modifying Flow and Pressure.

Automatic Transmission Fluid.

 

 7. Hydraulic Shift Control.

Introduction.

Pressure Development and Control.

Torque Converter, Oil Cooler, and Lubrication Circuit.

Torque Converter Pressure Control.

Torque Converter Clutch Control.

Cooler Flow.

Lubrication Flow.

Throttle Pressure.

Mechanical Throttle Valves.

Vacuum Throttle Valves.

Wide-Open Throttle Kickdown Valve.

Manual Valve.

Governor Valve.

Shift Valves.

Shift Overlap.

Shift Modifies.

Downshifts.

 

 8. Electronic Transmission Controls.

Introduction.

Basic Electricity.

System Components.

Basic Electronics.

Sensors.

Electronic Transmission Shift Controls.

Accuators.

 

 9. Torque Converters.

Introduction.

Construction.

Operation.

Torque Multiplication.

Coupling Phase.

Torque Converter Clutches.

Viscous Converter Clutch.

Stall Speed.

Stall Factors.

Planetary Gear Torque Converters.

 

10. Transmission Descriptions.

Introduction.

Transaxles.

Chrysler Corporation.

DailmerChrysler Rear Wheel Drive Transmissions.

DaimlerChrysler Front Wheel Drive Transaxles.

Ford Motor Company.

Ford Motor Company Rear Wheel Drive Transmissions.

Ford Motor Company Front Wheel Drive Transaxles.

General Motors Corporation.

General Motors Rear Wheel Drive Transmissions.

General Motors Front Wheel Drive Transaxles.

Saturn Transaxle.

Import Transmissions/Transaxles.

Honda/Acura.

Honda Three-Speed Transaxles.

Honda Four-Speed Transaxles.

Longitudinal Designs.

Nissan.

RWD Transmissions.

FWD Transaxles.

Toyota.

RWD Transmissions.

FWD Transaxles.

 

11. Transmission Service and Maintenance.

Introduction.

Fluid Checks.

Transaxle Final Drives and  Differentials.

Fluid Condition.

Fluid Changes.

Fluid Exchange and Flush Units.

Manual Linkage Checks.

Manual Linkage Adjustment.

Throttle Linkage Checks.

Throttle Linkage Adjustments.

Band Adjustments.

 

12. Mechanical Problem Solving and Diagnosis.

Introduction.

Problem-Solving Procedures.

Diagnostic Procedure.

Visual Inspection.

Road Test.

Torque Converter Clutch Tests.

Converter Clutch Hydraulic Checks.

Cooler Circuit Flow Check.

Hydraulic System Pressure Tests.

Interpreting Pressure Readings.

Fluid Flow Diagrams.

Checking Governor Pressure.

Modulator Checks.

Modulator Diaphragm Leakage.

Modulator Vacuum Supply.

Modulator Stem Alignment.

Modulator Spring Pressure.

Stall Tests.

Interpreting Stall Test Readings.

Oil Pan Debris Check.

Air Tests.

Wet Air Checks.

Isolating Valve Body Problems.

Oil Leak Tests.

Noise, Vibration, and Harshness (NVH).

Noise Checks.

Vibration Checks.

Troubleshooting Charts.

 

13. Electronic Transmission Problem Solving and Diagnosis.

Electronic Transmission Diagnosis.

Electrical Circuit Problems.

Open Circuits.

High Resistance Circuits.

Shorted Circuits.

Grounded Circuits.

Measuring Electrical Values.

Measuring Voltage.

Measuring Resistance.

Measuring Amperage.

Scan Tools.

Oscilloscopes.

Interpreting Measurements.

Electrical/Electronic System Repair.

Electronic Control System Checks.

Recalibration.

Codes.

Signal Monitor.

Forcing Shifts Electrically.

Clutch Volume Index.

EMI Electronic Problems.

Electronic Component and Circuit Checks.

ECM Power Checks.

TCC Checks.

Solenoid Checks.

Switch Checks.

Speed Sensor Checks.

Throttle Position Sensor Checks.

Temperature Sensor Checks.

Electronic Repair Job Completion.

 

14. In-Vehicle Transmission Repair.

Introduction.

Manual Shift Linkage, Interlock, and Seal.

Lip Seal Replacement.

TV Linkage and Seal.

Vacuum Modulator Removal and Replacement.

Aluminum Thread Repair.

Electrical Component Removal, Repair, and Replacement.

Cooler Line and Fitting Repair.

Valve Body Removal and Replacement.

Servo and Accumulator Piston, Cover, and Seal Service.

Extension Housing Seal and Bushing Service.

Extension Housing Removal, RWD Transmission.

Speedometer Gear Replacement.

Park Gear and Pawl Service.

Governor Service.

Governor Disassembly.

 

15. Transmission/Transaxle Remove and Replace.

Introduction.

Transmission Removal.

Transaxle Removal.

Drive Shaft Removal and Replacement.

RWD Drive Shaft Removal and  Replacement.

FWD Drive Shaft Removal and Replacement.

Transmission Installation.

Transaxle Installation.

 

16. Transmission Overhaul: Disassembly and Reassembly.

Introduction.

Overhauled Transmissions.

Remanufactured Transmissions.

Transmission Parts.

Overhaul Procedure.

Transmission Disassembly.

Predisassembly Cleanup.

Torque Converter Removal.

Disassembly Fixtures.

Preliminary Disassembly.

End Play Check.

Other Predisassembly Checks.

Pump Removal.

Transaxles Using Input Chain Drive.

Major Disassembly.

Transmission Assembly.

Pump Installation and End Play Adjustment.

Torque Converter Installation.

 

17. Transmission Overhaul Procedures.

Introduction.

Component Cleaning.

Bushing, Bearing, and Thrust Washer Service.

Bushing Removal.

Bushing Installation.

Tapered Roller Bearing Service.

Friction Material Service.

Lined Plate Service.

Steel Plate Service.

Band Service.

New Friction Material Preparation.

Internal Seal Service.

Fitting Rubber Seals.

Installing Pistons with Lip Seals.

Fitting Sealing Rings.

Installing Teflon Sealing Rings.

 

18. Subassembly Repair.

Subassembly Repair.

Case Inspection.

Pump Service.

Clutch Assembly Service.

Gearset Service.

Valve Body Service.

Solenoids and Switches.

Differential Service.

 

19. Torque Converter Service.

Introduction.

Torque Converter Checks.

Visual Checks.

Stator One-Way Clutch Check.

End Play Check.

Internal Interference Checks.

Torque Converter Clutch Checks.

Leak Checks.

Torque Converter Cleaning.

Drilling a Torque Converter.

Cooler Cleaning.

Torque Converter Rebuilding.

Disassembling a Torque Converter.

Cleaning.

Subassembly Repair.

Torque Converter Reassembly.

Postassembly Checks.

 

20. Automatic Transmission Modifications.

Introduction.

Shift Quality.

Shift Kits.

Orifice Changes.

Accumulator Changes.

Programming Changes, Electronic Controlled Transmissions.

Programming Changes, Nonelectronic -Controlled Transmissions.

Clutch Packs.

Increasing Pack Size.

Drilling a Hub or Drum.

Floater Springs.

Band Changes.

Improving Lubrication.

Gear Train Changes.

Competition Transmissions: Strengthening  and Lightening Changes.

Manual Shift Valve Bodies.

High-Stall Converters.

Direct Couplers.

Conclusion.

 

Appendix A: ASE Certification.

 

 

Appendix B: Automatic Transmission Models.

 

 

Appendix C: ATF Specification Comparison.

 

 

Appendix D: OBD II Diagnostic Trouble Codes.

 

 

Appendix E: J 1930 Transmission Term Acronyms.

 

 

Appendix F: Shift Signal Monitor.

 

 

Appendix G: English-Metric-English Conversion Table.

 

 

Appendix H: CATTS and NATEF.

 

 

Glossary.

 

 

Index.