10.9. Repair of the automatic transmission

Automatic transmission

1 – torque converter;
2 – shaft of the oil pump;
3 – pipe of the index of level and filling of oil;
4 – the rotation frequency sensor on entrances / turbines;
5 – transmission range switch;
6 – selector cable arm;
7 – arm;
8 - sensor of provision of a bent shaft;

9 - sensor of speed and gear wheel of the drive of a speedometer;
10 – entrance pipe;
11 – output pipe;
12 – oil pallet;
13 – laying (to replace);
14 – case of the block of valves;
15 – oil pump

Automatic transmission

1 – lock ring;
2 – coupling forward / backing;
3 – small solar gear wheel and coupling No. 1;
4 – brake films 2-oy/of the 4th of transfers;
5 – anchor rack and pin;
6 – lock ring;
7 – coupling No. 2 and planetary block;

8 – holder of the servo-driver;
9 – servo-driver piston;
10 – piston rod;
11 – lock ring;
12 – internal gear wheel;
13 – coupling 3-ey/the 4th transfers

Automatic transmission
1 – turbine shaft;
2 – exit case;
3 – nuts;
4 – washer;
5 – plate;
6 – shaft;
7 – bolt; 		8 – holder of the lever;
9 – parking lever;
10 – lock lever;
11 – returnable spring;
12 – bolts;
13 – modulator support;
14 – transmission case

Automatic transmission
1 – differential;
2 – (to replace) a cylindrical pin;
3 – case of bearings;
4 – intermediate gear wheel;
5 – output gear wheel;
6 – bearing cover;
 7 – (to replace) external rings of bearings;
8 – adjusting laying (to replace);
9 – (to replace) an oil sealing ring;
10 – (to replace) sealing rings;
11 – converter case

General recommendations

You carry out dismantling of the automatic transmission in the place protected from dust for an exception of pollution of details of the transmission. When dismantling check a condition of details of the transmission for lack of wear and damages.

For division of parts of a case use only plastic hammers.

Do not use rags when dismantling the transmission: fibers of rags can fill canals for liquid. Some details are similar at each other therefore when dismantling arrange them so that not to mix them. Remove the block of valves of management and completely clear it if coupling or a brake tape burned slightly or quality of liquid in the automatic transmission worsened.

Cleaning

PERFORMANCE ORDER
1. Before dismantling clear the external surface of the transmission a cleaner or solvent.
2. Clear the removed details solvent and dry up compressed air. Clear all channels and openings compressed air, and check that in them there are no barriers.
Prevention

When cleaning details with compressed air, put on glasses.
Be careful not to spill liquid at removal of the converter of torque.

Dismantling

PERFORMANCE ORDER
1. Remove the torque converter from a converter case.
2. Manually remove a shaft of the oil pump.
3. Remove a pipe of the index of level and filling of oil.
4. Shoot the rotation frequency sensor with entrances / turbines.
5. Remove the transmission range switch.
6. Remove a selector cable arm.
7. Remove an arm.
8. Remove the sensor of provision of a bent shaft.
9. Remove the sensor of speed and a gear wheel of the drive of a speedometer.

10. Remove an entrance pipe.

11. Remove an output pipe.
12. Collect special OK130 990 007 adaptation with the holder of OK130 175 011A
Prevention

Do not incline the transmission in one party in the course of dismantling as it can suddenly turn over and put a trauma.
Prevention

Before a transmission turning, remove the oil pallet. It guarantees that all foreign inclusions and particles will remain in the pallet.
13. Turn out nineteen bolts and remove the oil pallet:
a. investigate all foreign inclusions and particles found in the pallet and on a magnet to define a condition of details of the transmission. Existence of particles of wear of coupling testifies to wear of a plate of the drive or brake tapes. Steel particles on a magnet testify to wear of bearings, gear wheels or plates of the drive. Existence of aluminum particles testifies to wear of plugs or a case of the transmission;
b. in the presence of a large number of foreign inclusions and particles, replace the converter of torque and carefully check a condition of details of the transmission.
14. Remove a clip (one bolt).
15. Disconnect electromagnetic valves.
16. Turn out three bolts and remove the mesh filter.
17. Turn out bolts of A, B and C and remove arms.

Length of bolts (measured from the head basis):
А: 30 mm
В: 50 mm
С: 14 mm
18. Remove the case of the block of valves of management.
19. Remove a shaft and a plate:
      – weaken nuts, and extend a shaft;
      - turn out nuts, remove a washer and a plate.
20. Turn out a bolt and remove the holder of the lever of the parking.
21. Turn out two bolts the holder of the lever of the parking.
22. Remove the lock lever and a returnable spring.
23. Remove a modulator support.
24. Turn out ten bolts and remove the oil pump.

25. Remove coupling forward / a backing:

a. remove a lock ring of a shaft of the turbine;
b. lift assembled coupling forward / a backing and remove it from the transmission.
26. Remove a small solar gear wheel and coupling No. 1.
Prevention

Use a wire piece for fastening of a brake tape so that it was not damaged at a pulling.
27. Shoot brake films 2-4.
28. Remove a pin, at the same time support an anchor rack.
29. Remove an anchor rack.
30. Remove the servo-driver:
a. squeeze the piston of the servo-driver and remove a lock ring;
b. remove the holder of the servo-driver, the piston and a spring.
31. Remove unilateral coupling No. 2 and planetary assembly:
a. remove a lock ring;
b. remove unilateral coupling No. 2 together with planetary assembly;
c. remove a frictional plate.
32. Remove an internal gear wheel:
a. remove a lock ring;
b. remove an internal gear wheel of their case of an exit.
33. Remove the block of coupling 3–4:
a. remove a sealing ring from a turbine shaft sideways of the converter;
b. remove a turbine shaft to remove the block of coupling 3–4;
c. remove the block of coupling 3–4 of a turbine shaft.
34. Turn out bolts (from the converter - eight bolts and from a transmission case - seven bolts) and remove a transmission case, striking it with the plastic hammer.
35. Remove the exit case from an output gear wheel.
36. Remove differential.
37. Remove the case of bearings:
a. the hammer and a round drift beat out a cylindrical pin;
b. turn out eleven bolts of fastening of the case of bearings;
c. remove the case of bearings, striking it with the plastic hammer.
38. Remove the block of an intermediate gear wheel and knot of an output gear wheel, beating out them from the torque converter.
39. Uncover bearings:
a. turn out bolts of fastening of a cover of bearings;
b. special OK130 175 011A adaptation remove the converter case;
c. squeeze out a cover of bearings from the converter case.
Prevention

Establish earlier removed external ring of the bearing during repeated assembly to adjust a preliminary tightness of bearings.
40. Special OK130 170 012 adaptation remove an external ring of the bearing.

Assembly

Prevention

If the plate of the drive or a brake tape are replaced new, before installation impregnate a new detail in liquid for the automatic transmission during, at least two hours.

Before assembly, grease with liquid for the automatic transmission all oil sealing rings, the rotating details, sealing rings of round section, and mobile details.

All sealing rings of round section, oil sealing rings, and laying have to be replaced with new.

At repeated assembly use technical vaseline, but do not grease with jellied lubricant.

 When it is necessary to replace the plug, replace a detail (knot) the plug supporting the same.

 After putting sealant assembly needs to be made within 10 minutes and to sustain 30 minutes before filling with liquid for the automatic transmission.

PERFORMANCE ORDER
1. Combine a cover of bearings with the directing bolts and press it, as shown in the drawing.

Inhaling moment: 10,8-13,7 N of m

2. Tapping with the plastic hammer, establish assembled an intermediate gear wheel and an output gear wheel.

3. Install the bearing case:
a. install the bearing case on a converter casing;
b. combine deepening on intermediate to a shaft with a tag on the bearing case;
c. establish by the hammer and a thin drift a cylindrical pin;
d. screw eleven bolts.

Inhaling moment: 19–25 N • m
4. Establish a parking stopper:
a. establish a stopper of the parking and a shaft;
b. establish a spring and a lock ring.
c. manually move a shaft and be convinced that the stopper of the parking works.
5. Establish a support of the modulator and fix by new bolts.

Inhaling moment: 15–17 N • m
6. Install the lever of a clamp and a returnable spring.
7. Install the parking lever.

8. Establish the holder of the lever and a bolt.

Inhaling moment: 7,9–10,7 N • m

9. Establish a plate and a shaft:
a. establish a plate a washer and nuts;
b. tighten nuts the required moment.

Inhaling moment: 42–54 N • m
10. Establish differential in a converter casing. Install special OK201 270 014 adaptation.
11. Install a new oil sealing ring on the block of an output gear wheel.

12. Install the case of an exit to an output gear wheel and install a bearing ring on the exit case.

Outer diameter of the bearing: 72,1 mm
13. Apply a thin film of the TB-1217B silicone sealant on the interfaced surfaces of a casing of the converter and a case of the transmission.
14. Establish new sealing rings on a converter casing.
Prevention

Check that sealant will not be squeezed out to canals for lubricant, at installation of a case of the transmission.
15. Fix a transmission case to a converter casing.

Inhaling moment: 38-51 N of m

16. For support of a shaft of the turbine install special OK201 190 019 adaptation.
17. Establish a shaft of the turbine and the block of coupling 3–4:
a. collect a shaft of the turbine and the block of coupling 3–4;
b. check that the axial bearing is installed properly;
c. establish a shaft of the turbine and the block of coupling 3-4 in a transmission case as assembly.
18. Establish an internal gear wheel:
a. install an internal gear wheel in the exit case;
b. establish a spring lock ring.
19. Establish planetary assembly:
a. check that the axial bearing and the surface of swing of the bearing are installed properly;
b. one hand hold a turbine shaft from a provorachivaniye;
c. establish planetary assembly and the clutch drum 3-4, turning it.
20. Establish brake tapes of the lowest transfers, transfers of a backing and a plate of the drive.
21. Establish a fastening plate.
22. Establish a spring lock ring.
23. To establish a frictional disk.
24. To establish unilateral coupling No. 2:
a. you hold unilateral coupling No. 2 horizontally;
b. establish it, turning planetary assembly counterclockwise;
c. establish a spring lock ring.
25. Establish an anchor rack and a shaft.
Prevention

The lock of the brake film 2-4 and anchor rack are held apart, as shown in the drawing.
26. Establish the brake film 2-4 in a transmission case so that the tape was completely free.
27. Establish a small solar gear wheel and unilateral couplings No. 1:
and. check that the axial bearing and the surface of swing of the bearing are installed in the correct situation;
b. turning, establish a small solar gear wheel and unilateral couplings No. 1.
28. Establish coupling forward / a backing:
a. check that the axial bearing is installed in the correct situation;
b. turning, establish coupling forward / a backing.
Prevention

Height of installation of coupling forward / a backing in relation to a flange of a case of the transmission is various.
Maximum height: 0,9 mm
29. Establish a spring lock ring in deepening of a shaft of the turbine.

30. Measure a gap between a flange and an end face of the rolling bearing as follows:
a. install the bearing on coupling forward / a backing;
b. remove previously established surface of swing and laying;
c. install the thickest laying (2,2 mm) on the oil pump;
d. install the oil pump on coupling assembly, without establishing laying of the oil pump;
e. measure a gap And between a case of the transmission and the oil pump;
f. according to the measured gap choose laying of a certain thickness
Gap And, mm
Thickness of laying, mm
0,091 – 1,01
1,2
0,71 – 0,90
1,4
0,51 – 0,70
1,6
0,31 – 0,50
1,8
0,11 – 0,30
2,0
0 – 0,10
2,2
31. Remove the oil pump, and then install the surface of swing of the bearing and new laying on the oil pump.
32. Install the oil pump on the transmission.

Inhaling moment: 19-25 N • m
33. Check adjustment of brake films 2-4 as follows:
a. install the servo-driver piston on OK201 190 021 adaptation;
b. establish a sealing ring of round section on the holder of the servo-driver with OK201 190 021 adaptation;
c. grease a sealing ring of round section with liquid for automatic transmissions and establish assembly of a tape of the servo-driver with adaptation in a case of the transmission and fix by a spring lock ring.
d. establish a measuring tip of the indicator of hour type in a piston core end face;
e. give compressed air via the channel of supply of liquid, with an air nozzle condensed with rubber and measure the core course;

Air pressure: at most 392 kPa
Core course: 1,0-7,0 mm
f. if the course of a core does not correspond to demanded, choose the corresponding core;

Piston core length mm: 95,0, 95,5, 96,0, 96,5, 97,0, 97,5, 98,0, 98,5, 99,0
g. remove assembly of a tape of the servo-driver with adaptation.
Prevention

At removal do not damage a spring lock ring.
34. Install the servo-driver in a transmission case:
a. establish a spring of the servo-driver and assembly of the servo-driver.
b. establish a spring lock ring.
c. establish the brake film 2-4 on a piston servo-driver core.
35. Combine the mechanical valve with a pin on a plate and install the case of the adjusting valve.

Inhaling moment: 7,9-10,7 N • m
Length of bolts (measured from the head basis):
А: 30 mm
В: 50 mm
С: 14 mm
36. Connect the electromagnetic valve and the socket of the sensor of temperature of liquid in the automatic transmission.
37. Connect the socket of the electromagnetic valve.
Prevention

Install magnets in the oil pallet in the places shown in the drawing.
38. Establish new laying and the oil pallet, and fix it by nineteen bolts.

Inhaling moment: 8,4-10,7 N of m

39. Establish an entrance and output pipe.
40. Install the sensor of speed and the mechanism of the drive of a speedometer.
41. Install the sensor of an angle of rotation of a bent shaft.

42. Establish an arm.

43. Install the transmission range switch:
a. manually turn a shaft in a position N;
b. to install the transmission range switch;
c. tighten bolts of fastening of the switch of range of the transmission;

Inhaling moment: 7,9–10,7 N • m
d. check that position of the lever of the selector and indicator of the chosen position coincide.

44. Remove the transmission from special adaptation 130 990 007/OK130 175 011A.

45. To establish a new sealing ring and a pipe of the index of level and filling of oil.

Inhaling moment: 7,9–10,7 N • m

46. To install the rotation frequency sensor on a turbine entrance.

Inhaling moment: 7,9–10,7 N • m
47. Establish a shaft of the oil pump.
48. Establish a sealing ring on a turbine shaft.
49. Fill the converter with liquid for automatic transmissions.

Liquid type for the automatic transmission: M-lll or dexron III
Prevention

When filling with liquid you keep the converter in vertical position. Do not pour liquid. If the converter is not installed easily, do not apply to it great efforts: establish carefully.
50. Install the converter in a converter casing, turn it for combination of grooves.

51. Check correctness of installation of the converter, measuring distance And between an end face of the converter and a transmission case flange.

A distance: 13.6 mm