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   General information
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   Checks and adjustments of components of a control system of AT
   Checks and adjustments of a mekhaniko-hydraulic part
   Check and adjustment of a driving cable of AT
   Removal and installation of the lever of the AT selector
   Removal and AT installation
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Kia Sportage>> Automatic transmission>> Checks and adjustments of a mekhaniko-hydraulic part

Checks and adjustments of a mekhaniko-hydraulic part

Stall-Test

General information

Some automobile companies consider that performance of this check is interfaced to risk of an exit of transmission out of operation owing to emergence of the raised loads of its working elements!

Stall-Test is applied to check of serviceability of functioning of the converter of rotation (hydrotransformer) and an assessment of holding ability of brake assemblies and friction clutches of transmission assembly.

One of defining conditions of performance of check is serviceability of a condition and correctness of setup of the power unit, - check levels of cooling liquid, impellent oil and ATF

Check is made at working, heated-up to normal working temperature, the engine and AT put on transfer, - do not forget to cock the parking brake and to prop up wheels protivootkatny boots.

For carrying out check of Stall-Test the good tachometer and the spetsifikatsionny card of turns of the engine is required. Connection of a tachometer should be made strictly according to instructions of manufacturers of the device, - try to place a measuring instrument so that its dial was well looked through from a driver's place.

Over the dial it will be reasonable to put labels of limiting admissible turns, - the minimum and maximum value of turns Stall-Test-and are usually provided in the spetsifikatsionny map.

The main lack of described check is potential possibility of an overheat of transmission. For this reason not all manufacturers publish spetsifikatsionny cards of turns of Stall-Test. Nevertheless, Stall-Test uses wide popularity among the experts who are engaged in regenerative repair of automatic transmissions for whom producers of AT can issue the special bulletins made on the basis of carrying out intra branch research works.

Order of performance of procedure

 PERFORMANCE ORDER

  1. Cock the parking brake and prop up car wheels protivootkatny boots.
  2. Warm up the engine and transmission, - the temperature of ATF should be in limits of a range of 70 ÷ 80 °C.
  3. Connect to the engine a tachometer.
  4. At the cocked parking brake check turns of idling of the engine (see. Head the Current leaving and service) in the position "R" of the lever of the selector.
  5. Transfer the selector lever to the situation "R".
  6. The left foot firmly squeeze out a pedal of a foot brake, right accurately squeeze out to a floor a gas pedal, - after turns of the engine are stabilized, consider the indication of a tachometer and at once release a gas pedal.

In order to avoid damage of the AT internal components the pedal of gas should not keep pressed more than within 5 seconds!

  1. Transfer the selector lever to the situation "N" and let's to the engine work on single turns within at least one minute for the purpose of prevention of irreversible change of structure of ATF as a result of an overheat.
  2. Repeat procedure for AT modes "D", "D-HOLD" and "L".
  3. By the card given below determine a condition of internal knots of transmission assembly, in case of need make the corresponding corrections.

The analysis of results of check of Stall-Test, operations procedure on elimination of malfunctions

Result of check

Possible reason

Operations procedure on malfunction elimination

Only a few indications are underestimated for all AT modes
  • The obgonny coupling in the hydrotransformer revolves
  • The managing director, or the executive valve of inclusion switching off of blocking of the hydrotransformer is faulty Ý/m
  • The engine does not develop the demanded capacity
  • Replace the hydrotransformer
  • Check a condition of valves, execute necessary corrections
  • Execute setup of the engine (see. Introduction and Heads Current leaving and service and Engine)
Indications for modes "D" and "R" are overestimated
  • Demanded main pressure does not develop
  • Serviceability of functioning of the obgonny O/D coupling is broken
  • O/D friction clutch revolves
  • Check the main pressure
  • Check a coupling condition
  • Check a friction clutch condition
Indications for a mode "D" are overestimated
  • Demanded main pressure does not develop
  • The friction clutch of forward transfers revolves
  • Serviceability of functioning of the obgonny coupling No. 2 is broken
  • Check the main pressure
  • Check a friction clutch condition
  • Check a coupling condition
Indications for the mode "R" are overestimated
  • Demanded main pressure does not develop
  • The friction clutch of direct perception revolves
  • The brake of the R and L modes revolves
  • Check the main pressure
  • Check a friction clutch condition
  • Check a condition of brake assembly
Indications for the D-HOLD mode are overestimated
  • Demanded main pressure does not develop
  • The brake of transfers from the 2nd and above revolves
  • The mode "2" brake revolves
  • Check the main pressure
  • Check a condition of brake assembly
  • Check a condition of brake assembly
Indications for a mode "L" are overestimated
  • Demanded main pressure does not develop
  • The brake of the R and L modes revolves
  • Check the main pressure
  • Check a condition of brake assembly

Check of a delay of a response (Time-Lag-Test)

 PERFORMANCE ORDER

  1. The response of transmission to switchings of the lever of the selector at the engine working at single turns occurs with defined times oh a delay.
  2. During this check the size of a delay of a response of AT on «N-D» and «N-R» switchings is estimated.
  3. Execute the preparatory procedures similar to Stall-Test described above for check.
  4. Connect to the engine a tachometer (act according to instructions of manufacturers of the device) and at the cocked parking brake check idling turns in the position "R" of the lever of the selector (see. Head Current leaving and service).
  5. Transfer the lever to the situation "N".
  6. Prepare a stop watch and measure time of a delay of a response of transmission for lever switching in situation "D".
  7. Return the lever to the situation "N" and let's to the engine work within at least one minute on single turns.
  8. Operating in a similar manner, measure size of a delay of a response of AT on «N-R» switching
  9. Repeat check for each switching three times, then calculate the sensor switch arithmetic-mean values and compare them to nominal size of a delay, for transmissions of the AW372LE type of making 1.2 seconds.
  10. Being verified with table data, make the analysis of results of check, execute necessary corrections.

The analysis of results of check of Time-Lag-Test, operations procedure on elimination of malfunctions

Result of check

Possible reason

Operations procedure on malfunction elimination

The delay of a response of switching of "N-D" is excessive
  • Demanded main pressure does not develop
  • The friction clutch of forward transfers revolves
  • The obgonny O/D coupling revolves
  • Check the main pressure
  • Check a friction clutch condition
  • Check a coupling condition
The delay of a response of switching of "N-R" is excessive
  • Demanded main pressure does not develop
  • The friction clutch of direct perception revolves
  • The brake of modes "L" and "R" revolves
  • Check the main pressure
  • Check a friction clutch condition
  • Check a condition of brake assembly

Check of the main pressure

 PERFORMANCE ORDER

  1. Execute the preparatory procedures similar to Stall-Test described above for check.
  2. Connect to the engine a tachometer (act according to instructions of manufacturers of the device) and at the cocked parking brake check idling turns in the position "R" of the lever of the selector (see. Head Current leaving and service).
  3. Through a special transitional nozzle connect to the service union of check of the main pressure of transmission a manometer.
  4. The left foot firmly squeeze out a pedal of a foot brake, transfer the selector lever to situation "D" and consider the manometer indication for single turns of the engine.
  5. Holding a brake pressed, the right foot accurately squeeze out to a floor a pedal of gas and when turns of the engine are stabilized (turns Stall-Test-and), consider the indication of a manometer and at once release gas.

In order to avoid damage of the AT internal components the pedal of gas should not keep pressed more than within 5 seconds!

  1. Transfer the selector lever to the situation "N" and let's to the engine work on single turns within at least one minute for the purpose of prevention of irreversible change of structure of ATF as a result of an overheat.
  2. Operating in a similar manner, make measurements of the main pressure for the transmission R, D-HOLD and L modes.
  3. Having finished check, remove a manometer and muffle the service union the NEW stopper, having tightened it with effort of 14.7 ÷ 17.6 Nanometers.
  4. Compare results of the executed measurements to nominal rates.

Nominal rates of the main pressure

Main pressure, kgf/cm2 (kPa)

Mode

Engine turns

Idling

Turns Stall-Test-and

"D", "D-HOLD", "L" 3.7 ÷ 4.1 (363 ÷ 402) 9.5 ÷ 11.0 (932 ÷ 1079)
"R" 5.5 ÷ 6.1 (540 ÷ 598) 13.2 ÷ 15.7 (1295 ÷ 1540)
  1. By the card given below determine a condition of internal knots of transmission assembly, in case of need make the corresponding corrections.

The analysis of results of check of the main pressure, operations procedure on elimination of malfunctions

Result of check

Possible reason

Operations procedure on malfunction elimination

Indications for modes "D" and "R" are overestimated
  • The throttle valve is jammed
  • The primary valve regulator is jammed
  • Adjustment of a driving cable of AT is broken
Indications for modes "D" and "R" are underestimated
  • The throttle valve is jammed
  • The primary valve regulator is jammed
  • Pump assembly is worn-out
  • Adjustment of a driving cable of AT is broken
  • Leak in a hydraulic contour of a friction clutch of O/D takes place
Indications for a mode "D" are underestimated
  • Leak in a hydraulic contour of the 1st transfer of a mode "D" takes place
  • Leak in a hydraulic contour of a friction clutch of forward transfers takes place
  • Check a condition of the corresponding valves and components
  • Check a condition of the friction clutch, the corresponding valves and components
Indications for the mode "R" are underestimated
  • Leak in a hydraulic contour of the mode "R" takes place
  • Leak in a hydraulic contour of a friction clutch of direct perception takes place
  • Leak in a hydraulic contour of a brake of modes "L" and "R" takes place
  • Check a condition of the corresponding valves and components
  • Check a condition of the corresponding valves and components
  • Check a condition of the brake assembly, the corresponding valves and components

Trial runs

If AT is suspected of violation of serviceability of functioning, first of all always it is necessary to try to decide on representation of nature of refusal.

At firm car repair shops it is usually possible to order the card of switchings of AT where the moments of switching of transmission provided by standards are specified at various operational parameters (speed, loading, vehicle type, the switching direction). In the most detailed maps such additional parameters, as standard installations on operating pressure of a drive of friction clutches and brake assemblies can be specified. Besides, here explanations on interpretation of violations revealed during trial runs can be provided. Comparison of parameters of the actual switchings which were taking place at trial runs, with the corresponding card will help to localize possible sources of malfunctions.

There are two ways of carrying out trial runs. In the first case at a wheel of a vehicle there should be personally an owner of the car that will allow checking to make sure of adequacy of skills of its driving to requirements of the card of switchings. In the second case test arrival is made in free from traffic a safe place, - the skilled mechanic-driver with the assistant make detailed verification of parameters of functioning of transmission with the card of switchings. During test operation of units of transmission, the engine and systems of their management is checked. Normal work of AT depends, in many respects, on serviceability of functioning of the engine in this connection, this unit during tests is given not less attention, than AT.

At definition of the moments of switching of transmission correctness of ratios of operating pressure of a throttle and a centrifugal regulator is actually checked at various loads of the engine. One more factor to which it should be paid special attention during tests, absence of stress of switchings of transmission is. Switchings can occur in strict accordance with card requirements, however violation of their smoothness, or an excessive lag effect will be powerful arguments in favor of need of performance of check of a condition of hydroaccumulators.

During test arrival all possible high-speed and loading modes should be checked, - completeness of collected information is guarantee of correctness of conclusions. It is necessary to give special attention to behavior of a vehicle under the conditions described by the owner when violations took place, - accuracy of definition of conditions of refusal is a fundamental factor at identification of its source.

In case of detection of the insignificant malfunctions expressed in violation of external adjustments or failure of elements which replacement does not demand transmission dismantle from the car, the corresponding procedures are made on a place. If malfunction has serious character, performance of major maintenance of transmission is offered to the client.

During tests transmission should be heated-up to normal working temperature (70 ÷ 80 ° C).

Make sure of serviceability of activation of switching of kickdown in a mode "D", - switchings should take place in all provided combinations: O/D ® 3, O/D ® 2, O/D ® 1, 3 ® 2, 3 ® 1 and 2 ® 1.

In case of identification of unusual noise or vibrations try to define the nature of their emergence. The most probable sources of noise and vibrating backgrounds are the hydrotransformer, driving / driveshafts and differentials. It is necessary to trace dependence of emergence of noise/vibrations on initial parameters at car movement in a mode "D": O/D with blocking of the hydrotransformer, O/D without hydrotransformer blocking, the 3rd transfer (at the included special HOLD mode).

Compare results of supervision to the card of violations given below.

The analysis of results of trial runs, operations procedure on elimination of malfunctions

Result of check

Possible reason

Operations procedure on malfunction elimination

There is no raising, or a lowering switching in a range of the first or second of transfers (1-2 or 2-1)
  • It is jammed Ý/m the valve switch B
  • The valve of switching 1-2 is jammed
  • Check a valve switch condition
  • Check a valve condition
There is no raising, or a lowering switching in a range of the second or third transfers (2-3 or 3-2)
  • It is jammed Ý/m the valve switch A
  • The valve of switching 2-3 is jammed
  • Check a valve switch condition
  • Check a valve condition
There is no raising, or a lowering switching in a range of the third or fourth transfers (3-O/D or O/D-3)
  • It is jammed Ý/m the valve switch A or B
  • The valve of switching 3-4 is jammed
  • Check a condition of valves switches
  • Check a valve condition
Hydrotransformer blocking does not work
  • The managing director or the executive valve of inclusion of blocking is jammed Ý/m
  • Check a condition of valves
The gear shifting schedule is broken
  • Adjustment of a driving cable of AT is broken
  • Switching valves are jammed
Absence of stress of switchings is broken, or pro-slippings take place
  • Hydroaccumulators are jammed
  • It is jammed, or the control ball of klapanny assembly is lost
  • Friction clutches, brake assemblies or obgonny couplings are worn-out
  • Check a condition gidroak-
    kumulyator
  • Check existence and serviceability of functioning of control balls
  • Check a condition of the corresponding components
There is no effect of braking by the engine
  • Friction clutches, brake assemblies or obgonny couplings are worn-out
  • Check a condition of the corresponding components