NAG 1/W5A580 Automatic Transmission Diagnosis and Repair Student Workbook DAIMLERCHRYSLER ACADEMY School of Technical Training School of Technical Training NAG 1/W5A580 Auto Transmission Diagnosis and Repair TABLE OF CONTENTS INTRODUCTION...................................................................................................... 1 STUDENT LEARNING OBJECTIVES ....................................................................... 2 ACRONYMS............................................................................................................. 3 MODULE 1 TRANSMISSION AND FLUID IDENTIFICATION .................................. 5 TRANSMISSION RANGES.................................................................................. 6 NAG 1 TRANSMISSION MODEL DESIGNATION AND APPLICATION .................. 8 TRANSMISSION FLUID ....................................................................................10 Oil Level Control .......................................................................................11 TRANSMISSION ID STAMP LOCATION .............................................................12 MODULE 2 TRANSMISSION MECHANICAL COMPONENTS, DIAGNOSIS, EVALUATION AND DISASSEMBLY ........................................................................15 TRANSMISSION DESCRIPTION ........................................................................15 TRANSMISSION HOUSING...............................................................................16 VALVE BODY...................................................................................................17 MECHANICAL COMPONENT OVERVIEW .........................................................18 Planetary Gear Sets ..................................................................................18 Lubrication of Mechanical Components.....................................................19 Clutch Operation and Gear Ratios.............................................................20 BRAKES (HOLDING CLUTCHES)......................................................................20 B1 Brake ..................................................................................................20 B2 Brake ..................................................................................................22 B3 Brake ..................................................................................................23 B2 and B3 Brake ......................................................................................24 INPUT CLUTCHES ...........................................................................................25 K1 Clutch .................................................................................................25 K2 Clutch .................................................................................................27 K3 Clutch .................................................................................................29 OVERRUNNING CLUTCHES.............................................................................31 PARK LOCK .....................................................................................................33 OIL PUMP ASSEMBLY......................................................................................34 PRELIMINARY DIAGNOSIS...............................................................................35 TRANSMISSION OIL LEAK DIAGNOSIS ............................................................37 Bell Housing and Torque Converter Leak Points ........................................37 Transmission Case Leak Detection Using Dye ...........................................37 GEAR TRAIN END PLAY...................................................................................38 FLUID AND FILTER MAINTENANCE.................................................................38 i NAG 1/W5A580 Auto Transmission Diagnosis and Repair TRANSMISSION FILTER AND VALVE BODY REMOVAL REQUIREMENTS........ 39 FLUID AND FILTER ANALYSIS ........................................................................ 39 Fluid Type ................................................................................................ 40 TRANSMISSION HOUSING .............................................................................. 41 VALVE BODY .................................................................................................. 42 Valve, Check Ball and Strainers ............................................................... 43 Solenoid Valves ........................................................................................ 44 AIR PRESSURE TESTING ................................................................................ 45 TORQUE CONVERTER .................................................................................... 47 BRAKE (HOLDING) CLUTCHES ....................................................................... 48 B2 and B3 Brake Clutches ....................................................................... 48 B1 Brake Clutch....................................................................................... 49 INPUT CLUTCHES........................................................................................... 50 K1, K2 and K3 Input Driving Clutches...................................................... 50 OVERRUNNING CLUTCHES ............................................................................ 51 OIL PUMP ....................................................................................................... 52 PARK LOCK GEAR .......................................................................................... 53 PLANETARY GEARS IDENTIFICATION AND EVALUATION ............................... 54 Pinion, Gears and Carriers ....................................................................... 54 MODULE 3 TRANSMISSION POWERFLOW .......................................................... 57 GEAR RATIOS AND CLUTCH APPLICATION..................................................... 57 FIRST GEAR.................................................................................................... 58 First Gear Powerflow ................................................................................ 59 SECOND GEAR ............................................................................................... 60 Second Gear Powerflow ............................................................................ 61 THIRD GEAR................................................................................................... 62 Third Gear Powerflow ............................................................................... 63 FOURTH GEAR (DIRECT DRIVE) ..................................................................... 64 Fourth Gear Powerflow ............................................................................. 65 FIFTH GEAR (OVERDRIVE) ............................................................................. 66 Fifth Gear Powerflow ................................................................................ 67 REVERSE (NORMAL/STANDARD MODE) ........................................................ 68 Normal Reverse Gear Powerflow................................................................ 69 REVERSE 1 (4X4 LOW OR WINTER MODE)..................................................... 70 Reverse 1 Gear Powerflow......................................................................... 71 NEUTRAL (STANDARD MODE) ........................................................................ 72 Neutral (Standard Mode) .......................................................................... 72 ii NAG 1/W5A580 Auto Transmission Diagnosis and Repair NEUTRAL (DEFAULT MODE) ...........................................................................73 Neutral (Default Mode) ..............................................................................74 MODULE 4 MAJOR COMPONENT SERVICE.........................................................77 OIL PUMP ........................................................................................................77 VALVE BODY...................................................................................................80 Solenoid Valve Testing ..............................................................................81 Valve Identification ...................................................................................82 Valve, Check Ball and Strainers ................................................................82 INPUT CLUTCHES ...........................................................................................83 K1 Input Clutch........................................................................................83 K2 Input Clutch........................................................................................84 K3 Input Clutch........................................................................................85 BRAKE (HOLDING) CLUTCHES........................................................................86 B2 and B3 Brake Clutches........................................................................86 B1 Brake Clutch .......................................................................................88 OVERRUNNING CLUTCHES.............................................................................89 MODULE 5 TRANSMISSION REASSEMBLY..........................................................91 REASSEMBLY..................................................................................................91 B2