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39
AUTOMATIC TRANSMISSIONS
AND TRANSAXLES
CHAPTER OVERVIEW
This chapter discusses automatic transmission and transaxle theory, components, and
operation.

CHAPTER OBJECTIVES
Explain the basic design and operation of standard and lockup torque converters.
Describe the design and operation of a simple planetary gearset and Simpson gear
train.
Name the major types of planetary gear controls used on automatic transmissions
and explain their basic operating principles.
Describe the construction and operation of common Simpson gear train-based
transmissions and transaxles.
Describe the construction and operation of common Ravigneaux gear train-based
transmissions and transaxles.
Describe the construction and operation of transaxles that use planetary gearsets in
tandem.
Describe the construction and operation of automatic transmissions that use helical
gears in constant mesh.
Describe the construction and operation of CVTs
Describe the design and operation of the hydraulic controls and valves used in
modern transmissions and transaxles.
Explain the role of the following components of the transmission control system:
pressure regulator valve, throttle valve, governor assembly, manual valve, shift
valves, and kickdown valve.
Identify the various pressures in the transmission, state their purpose, and tell how
they influence the operation of the transmission.
Explain the advantages of using electronic controls for transmission shifting.
Briefly describe what determines the shift characteristics of each selector lever
position.
Identify the input and output devices in a typical electronic control system and
briefly describe the function of each.

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INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Torque Converter
A. Design
B. Components
C. Basic Operation
D. Types of Oil Flow
E. Overrunning Clutch
Hint: Use a cutaway converter to show the students its internal components.
Demonstrate the stator overrunning clutch operation. Point out the path of
the oil during vortex and rotary flow. Show how the torque converter clutch is
applied and released.
II. Lockup Torque Converter
A. Lockup Piston Clutch
III. Planetary Gears
A. How Planetary Gears Work
1. Maximum Forward Reduction
2. Minimum Forward Reduction
3. Maximum Overdrive
4. Slow Overdrive
5. Slow Reverse
6. Fast Reverse
7. Direct Drive
8. Neutral Operation
Hint: Pass around a simple planetary gearset to help the students become
more familiar with it. Practice producing the common ratios by manually
manipulating the gears.
IV. Compound Planetary Gearsets
A. Simpson Gear Train
B. Ravigneaux Gear Train
C. Planetary Gearsets in Tandem
V. Hondas Nonplanetary-Based Transmission
VI. Continuously Variable Transmissions (CVT)
Hint: Display a Simpson, a Ravigneaux, and a tandem gearset. Students should
be encouraged to disassemble and reassemble them until they are very familiar
with them.
VII. Planetary Gear Controls
A. Transmission Bands
B. Transmission Servos
1. Simple Servo
2. Compound Servo
Hint: Display single- and double-wrapped styles of bands.
VIII. Transmission Clutches
A. Overrunning Clutches
Hint: Show a roller clutch and a sprag clutch and explain the difference.
B. Multiple-Disc Clutches
Hint: Show smooth and waffle-cut clutch discs. Explain the importance of
using the correct style and the correct type of friction facing. Show how
easily the friction material is damaged by scratching it with a fingernail to
emphasize the importance of maintaining adequate fluid pressures in the
transmission.

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C. Planetary Control Terminology

IX. Bearings, Bushings, and Thrust Washers
X. Snap Rings
XI. Gaskets and Seals
A. Gaskets
B. Seals
1. O-rings
2. Lip Seals
3. Square-cut Seal
C. Metal Sealing Rings
D. Teflon Seals
XII. Final Drives and Differentials
A. Final Drive Assemblies
XIII. Hydraulic System
A. Hydraulic Principles
XIV. Applications of Hydraulics in Transmissions
A. Functions of ATF
B. Reservoir
C. Venting
D. Transmission Coolers
E. Valve Body
1. Check Ball Valve
2. Poppet Valve
3. Spool Valve
F. Oil Pump
G. Pressure Regulator Valve
H. Governor Assembly
XV. Pressure Boosts
A. MAP Sensor
B. Kickdown Valve
XVI. Shift Quality
A. Shift Timing
XVII. Hydraulic Circuits
Hint: Display a valve body containing spool valves, check valves, and solenoids.
Describe their function.
A. Line Pressure
B. Throttle Pressure
C. Governor Pressure
D. Converter Pressure
E. Torque Converter Controls and Pressure
F. Lockup Clutch Engagement
XVIII. Electronic Controls
Hint: Display some input and some output devices. Show the differences and
have the students try to match them to a list of names.
A. Transmission Control Module
B. Inputs
1. On-Off Switches
2. Transmission Fluid Temperature (TFT) Sensor
3. Transmission Pressure Switches
4. Voltage-Generating Sensors

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C. Adaptive Controls
D. Outputs
1. Electronic Pressure Control (EPC) Solenoid
2. Variable Force Solenoid (VFS)
3. Torque Converter Clutch (TCC) Solenoid
E. Operational Modes
F. Manual Shifting
1. BMWs Steptronic
2. Chrysler Autostick
3. Hondas Sequential Sportshift
4. Triptronic
5. Toyota/Lexus Systems
G. CVT Controls

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Rotary flow of oil in the torque converter is the flow of oil around the circumference
of the converter as it rotates around its axis. Rotary flow begins to occur when the
speed of the turbine is near the speed of the impeller, or near coupling speed. Vortex
flow is the flow of oil from the impeller to the turbine and back to the impeller, at a
90-degree angle to engine rotation. The oil from the turbine to the impeller is redirected by the stator during torque multiplication. Maximum vortex flow occurs during maximum torque multiplication and is described as spiraling its way around the
converter.
2. The overrunning clutch is responsible for allowing the stator to rotate in only one
direction.
3. When two planetary gearsets are used in tandem, there are two simple planetary
units connected in series, as compared to a compound planetary gearset that shares
components.
4. The four common configurations used as the final drives on FWD vehicles are the
helical gear, planetary gear, bevel gear, and hypoid gear.
5. Three major types or rubber seals are used in automatic transmissions: the O-ring,
the lip, and the square-cut seal.
6. Shift timing decisions are based not only on sensor input, but also on a predetermined
schedule and on adaptive control strategies.
7. c. When the carrier is the input, the planetary gearset produces overdrive. When the
carrier is the input and the ring gear is held, maximum, not minimum (slow) overdrive is achieved.
8. a. When the carrier is held, a planetary gearset produces reverse.
9. c. Overrunning clutches are used to either hold a planetary gear member stationary
or to drive one.
10. d. Neither technician is correct. Shift timing is determined by comparing input from
a variety of sensors
11. c. Modulated shift solenoids and modulated converter clutch solenoids are used in
some transmissions.
12. a. Shift solenoids direct the flow of oil to apply and release various apply devices;
they do not mechanically apply a band or clutch assembly.
13. b. Technician B is correct. The EPC solenoid controls pressures throughout the
transmission.

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14. b. In order for lockup to occur, the lockup solenoid must be energized and the switch
valve must be held down by line pressure.
15. The three types of sealing rings used in automatic transmissions are the cast iron,
nylon, and Teflon seals.
16. b. An axial load is controlled by thrust washers.
17. a. Rotary flow is correctly described. Centrifugal lockup converters are not commonly
used.
18. False. The vent is designed to allow the exhaust of built-up air pressure that develops from heat and the moving internal components.
19. c. Both technicians are correct.
20. c. Both technicians are correct.
Chapters 39 and 40 are combined in the Tech Manual. The Tech Manual Procedures,
Additional Teaching Hints, and answers to the Tech Manual Review Questions for both
chapters are at the end of Chapter 40.

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40
AUTOMATIC TRANSMISSION
AND TRANSAXLE SERVICE

CHAPTER OVERVIEW
This chapter describes how to perform service and maintenance of automatic transmissions and transaxles. Diagnosis and the replacement of the necessary parts to restore service are included.

CHAPTER OBJECTIVES
Listen to the drivers complaint, road test the vehicle, then determine the needed
repairs.
Diagnose unusual fluid usage, level, and condition problems.
Replace automatic transmission fluid and filters.
Diagnose electronic control systems and determine needed repairs.
Conduct preliminary checks on EAT systems and determine needed repairs or
service.
Perform converter clutch system tests and determine needed repairs and service.
Inspect, test, and replace electrical/electronic sensors
Inspect, test, bypass, and replace actuators.
Diagnose noise and vibration problems.
Diagnose hydraulic and vacuum control problems.
Perform oil pressure tests and determine needed repairs.
Inspect and adjust external linkages.
Describe the basic steps for overhauling a transmission.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Identification
II. Diagnostics
A. Fluid Check
B. Recommended Applications
C. Fluid Changes
D. Parking Pawl

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Chapter 40

III. Fluid Leaks

A. Oil Pan
B. Torque Converter
C. Extension Housing
D. Speedometer Drive
E. Electrical Connections
F. Checking Transmission and Transaxle Mounts
G. Transmission Cooler Line Inspection
IV. Basic EAT Testing
A. Guidelines for Diagnosing EATs
B. Converter Clutch Control Diagnostics
V. Preliminary EAT Checks
A. Basic System Checks
B. Diagnostic Trouble Codes
C. Basic Diagnostics of Non-OBD-II Systems
D. Basic Diagnostics of OBD-II Systems
E. Electronic Defaults
Hint: Display some printouts of fault codes. Discuss the information
conveyed and how it is used by technicians to service transmissions. Have the
students practice retrieving DTCs.
VI. Detailed Testing of Inputs
A. Testing Switches
B. Throttle Position Sensor
C. Mass Airflow Sensor
D. Temperature Sensors
E. Speed Sensors
Hint: Demonstrate testing input sensors. Provide some known good and
some failed sensors for the students to practice with.
VII. Detailed Testing of Actuators
A. Testing Actuators with a Lab Scope
B. Testing Actuators with an Ohmmeter
Hint: Demonstrate testing actuators. Provide some known good and some
failed actuators for the students to practice with. If possible, provide a
solenoid that is electrically good but is restricted or seized to demonstrate the
importance of checking not only the electrical circuit, but also the hydraulic
circuit.
VIII. Road Testing the Vehicle
A. Diagnosis of Noise and Vibration Problems
B. Torque Converter
IX. Testing Converter Clutches
A. Engagement Quality
B. TC-Related Cooler Problems
X. Diagnosing Hydraulic and Vacuum Control Systems
A. Pressure Tests
XI. Common Problems
A. Valve Body
B. Servo Assemblies
XII. Linkages
A. Gear Selector Linkage
B. Throttle Valve Linkages

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C. Kickdown Switch Adjustment

D. Band Adjustment
XIII. Rebuilding a Transmission
Hint: Arrange for a trip to a transmission rebuilding facility so that students can
see what is required. Describe the type of work performed and the working
environment of technicians with this skill.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. A low fluid level usually indicates an external fluid leak.
2. Transmission fluid with a milky appearance indicates that engine coolant is contaminating the transmission fluid from a faulty transmission cooler.
3. When there are gum or varnish deposits on the transmission dipstick, the transmission fluid needs to be changed.
4. Typically, during a pressure test the pressure should not drop more than 15 psi
(103 kPa) between shifts.
5. Pressure switches can be tested by applying air pressure to the area of the switch that
would normally be exposed to hydraulic pressure and checking the switch for leaks.
6. When servicing a valve body, ensure that each valve moves freely in its bore. If it does
not move freely, clean the valve and the bore and retest. If the valve cannot be cleaned
enough to move freely in its bore, it is usually replaced.
7. False. The same procedure is used.
8. a. When a shudder occurs during engagement of the torque converter clutch, the
problem is typically in the converter.
9. c. Check the transmission fluid level at operating temperature with the engine
running.
10. a. Effective diagnosis and testing depends on understanding which planetary controls
are applied in each particular gear range. Not all slipping conditions are due to a leaking hydraulic circuit; other factors such as worn, glazed, or incorrect friction elements
can also cause slippage.
11. d. All of the above
12. c. Both technicians are correct.
13. b. When there is slippage in any (all) forward gears, a faulty forward clutch is suspected. A delayed upshift would not be related to the forward clutch, but would more
likely be due to the governor or the throttle valve.
14. d. Neither technician is correct. Using the shape of the transmission pan to identify
the type of transmission is only one method; additional information such as make,
model, and assembly date are available using the transmission identification number.
15. a. A faulty TP sensor can cause delayed upshifts. An open shift solenoid would cause
some of the shifts to be missing or the transmission to operate in limp-in mode.
16. b. Delayed shifting may be the result of sticking spool valves or slow application of
clutches due to leaking hydraulic circuits. Worn planetary gearset members would
more likely result in noise.
17. c. Both technicians are correct.
18. d. Neither technician is correct. The problems described would be indicated by lower,
not higher, pressure.
19. a. Many computer controlled solenoids are ground side switched; hydraulic pressure
does not apply a solenoid.
20. c. Both technicians are correct.

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TECH MANUAL
The following procedures are included in Chapters 39/40 of the Tech Manual:
1.
2.
3.
4.
5.
6.
7.

Visually inspecting an automatic transmission

Road testing a vehicle to check the operation of a lockup torque converter clutch.
Road testing a vehicle to check the operation of an automatic transmission.
Conducting a stall test.
Pressure testing a automatic transmission.
Servicing a valve body.
Overhauling a multiple-disc clutch assembly.

ADDITIONAL TEACHING HINTS FROM CHAPTERS 39/40

Demonstrate how to reseal a leaky transmission using the pump seal, o-ring, gasket,
tail shaft seal, and pan gasket on a removed transmission.
Demonstrate how to properly install cooling lines.
Demonstrate how to measure the pump for reuse.
Many students will be working in general repair shops and will be handling
components like automobile transmissions as one unit. All technicians, however,
can expect at some time to repair leaky or broken hydraulic fittings.
Have your students assemble fittings, hoses, and tubing, depending on what is
available, so they can learn how to make proper cuts and flanges and how to select
the proper hardware.
In conjunction with the preceding exercise, you can have each students project
start and end with a certain fitting, so that in the end they can all be connected
together and put under fluid pressure. (This might give the students a sense of
teamwork and show how important the individuals contribution is to the group; it
may also show how just one component can make an entire system fail.)
Take the students through changing the filter in an automatic transmission. Stress
work area cleanliness and proper gasket installation.
Make sure the students can restore the automatic transmission fluid to its proper
level.
Demonstrate the procedure for protecting components and open lines from
contamination while the system is open.

ANSWERS TO TECH MANUAL QUESTIONS FOR

CHAPTERS 39/40
1. Stall testing of the automatic transmission is not widely accepted by vehicle manufacturers because damage to the torque converter is very possible. As a general rule,
if the service manual does not give specifications for stall testing, then the manufacturer does not recommend this task.
2. True
3. To eliminate other parts
4. c

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5. a. Ravigneaux
b. Simpson and tandem
6. d
7. c
8. Servos and clutches
9. It links the throttle valve of the transmission with the throttle pate of the engines
throttle-body assembly. The motion of the throttle plate is transferred to the throttle
valve.
10. Oil pump, governor, and throttle circuits.
11. c
12. It will decrease the life of ATF by 50%.
13. True
14. Adaptive learning allows the computer to compensate for wear and other events that
might occur and cause the normal shift programming to be inefficient.
15. d

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41
FOUR- AND
ALL-WHEEL DRIVE
CHAPTER OVERVIEW
This chapter presents a general explanation of the design and servicing of four- and allwheel-drive systems. These systems are very popular and, therefore, the need for service
and repair is increasing.

CHAPTER OBJECTIVES
Identify the advantages of four- and all-wheel drive.
Name the major components of a conventional four-wheel-drive system.
Name the components of a transfer case.
State the difference between the transfer, open, and limited slip differentials.
State the major purpose of locking/unlocking hubs.
Name the five shift lever positions on a typical 4WD vehicle.
Understand the difference between four- and all-wheel drive.
Know the purpose of a viscous clutch in all-wheel drive.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Four-Wheel Drive Versus All-Wheel Drive
II. Four-Wheel-Drive Systems
III. Transfer Case
A. Interaxle Differentials
IV. Locking/Unlocking Hubs
A. Axle Disconnects
V. Conventional Four-Wheel-Drive Operating Modes
VI. Four-Wheel-Drive Passenger Cars
A. Limited-Slip and Open Differentials
VII. Servicing Four-Wheel-Drive Vehicles
A. Servicing the Transfer Case
VIII. All-Wheel-Drive Systems
A. Viscous Clutch
B. Center Differential All-Wheel Drive
C. Haldex Clutch

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ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. All-wheel drive provides improved traction and handling.
2. A four-wheel drive has (1) a transfer case, (2) a front drive shaft, and (3) a front
drive axle.
3. A viscous clutch transfers power to drive the axle with low traction, replacing the center differential in an all-wheel-drive application.
4. An interaxle differential dissipates driveline windup, allowing the front and rear axles
to operate at different speeds.
5. False. Two drive shafts are more common.
6. c. Tractive effort is the driving force exerted by the wheels against the road surface.
7. When the plates of a viscous coupling (clutch) rotate at different speeds, the plates
shear, or cut through, the fluid.
8. d. None of the above.
9. A viscous clutch operates on a principle similar to the operation of a viscous fan
clutch. When used in an all-wheel-drive application, it takes the place of a center differential in the transfer case. Each axle is allowed to operate at different speeds during conditions such as cornering, but when one axle has less traction, the difference
in rotating speeds causes the clutch to lock up and transfer more torque to the axle
with better traction. This is useful in all-wheel-drive applications because driveline
windup is eliminated while traction and handling are improved.
10. b. This condition would result in severe driveline windup.
11. a. Full time, four-wheel drive divides torque equally among the wheels during normal operating conditions.
12. d. Neither technician is correct. Neither of these components is electronically
controlled.
13. d. The transfer clutch functions as an interaxle differential.
14. c. A computer-controlled duty cycle solenoid operates the transfer clutch.
15. c. Both technicians are correct.
16. d. The fluid in a viscous clutch stiffens as it becomes heated.
17. b. Not all transfer cases have either of these components.
18. d. None of the above
19. b. The purpose of the viscous clutch is to improve traction and mobility.
20. a. All-wheel-drive (AWD) vehicles must have a center differential, while most 4WD
vehicles do not.

TECH MANUAL
The following procedures are included in Chapter 41 of the Tech Manual:
1. Inspecting the fluid level in a transfer case.
2. Road testing a transfer case.
3. Replacing a transfer case output shaft bushing and seal.

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ADDITIONAL TEACHING HINTS

Examine and discuss CV joints and U-joints.
Discuss the advantages and disadvantages of limited slip differentials in 4/AWD
systems.
Examine and discuss locking/unlocking hubs.

ANSWERS TO TECH MANUAL QUESTIONS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Four-wheel drive
True
True
False
4WD passenger cars are typically based on front-wheel-drive models, 4WD trucks are
normally based on rear-wheel-drive models.
The limited-slip differential can be used to dissipate driveline windup. Also, this system provides greater traction than one with an open differential.
b
The viscous clutch transfers torque to the axle with more traction. It also dissipates
driveline windup.
c
d

SECTION 6
Answers to ASE Prep Test Questions
1.
2.
3.
4.
5.

b
c
a
b
c

6.
7.
8.
9.
10.

c
b
a
a
b

11.
12.
13.
14.
15.

a
b
c
b
a

16.
17.
18.
19.
20.

d
a
d
c
b