Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Automatic Transmissions
Self-Study Program
Course Number 951903
Audi of America, Inc.
Service Training
Printed in U.S.A.
Printed in 6/2000
Course Number 951903
Table of Contents:
OBJECTIVES ................................................................................................................................II
INTRODUCTION .........................................................................................................................1
SUMMARY .................................................................................................................................72
TELETEST ...................................................................................................................................73
i
OBJECTIVES
Objectives:
ii
INTRODUCTION TO THE 01V AND 01L AUTOMATIC TRANSMISSIONS
01V Application
All-wheel drive A8
4.2 Liter A6.
1
INTRODUCTION TO THE 01V AND 01L AUTOMATIC TRANSMISSIONS
2
INTRODUCTION TO THE 01V AND 01L AUTOMATIC TRANSMISSIONS
3
BASIC AUTOMATIC TRANSMISSION OPERATION
Objectives:
4
BASIC AUTOMATIC TRANSMISSION OPERATION
Torque Conversion
Impeller, or Pump
Turbine
Stator.
5
BASIC AUTOMATIC TRANSMISSION OPERATION
The TCC is inactive during the Open phase. This TCC Active
is normally in the lower gears under high load.
6
BASIC AUTOMATIC TRANSMISSION OPERATION
Planetary Gearsets
The power transferred through the torque con- The 01V transmission uses both a Ravigneaux
verter is passed on to the planetary gearsets. gearset and a Simpson gearset. The 01L trans-
mission uses three Simpson gearsets in an ar-
Planetary gearsets consist of a central, or sun rangement called a Wilson gearset.
gear, with planet gears that run on the sun gear
and ring gear. These planet gears are attached The function of the planetary gearsets is to create
to the planet carrier. different gear ratios. These ratios are created by
holding and driving different parts of the plan-
A Simpson gearset is composed of: etary gearset.
1 Sun Gear
1 Planet Carrier with 3 Planetary Gears
1 Ring Gear.
7
BASIC AUTOMATIC TRANSMISSION OPERATION
After the power is transferred from the torque Clutches can either turn or hold a geartrain
converter, the clutches determine what parts of component. If the clutch pack sits inside of a
the planetary gears spin and which are held in clutch drum, it turns a component.
place.
If the clutch pack splines to the transmission case,
Clutches are a series of friction plates and steel its a holding clutch because it holds a compo-
plates alternately splined between two compo- nent to the case. Audi refers to holding clutches
nents. When a clutch piston squeezes these as brakes.
plates together, the two components will lock
together. Some manufacturers use a type of brake called a
band. A band wraps around the outside of a
The type of clutches Audi uses are multi-plate wet clutch drum or geartrain component to hold it in
clutches. This assembly usually consists of 4 or 5 place. Current Audi transmissions do not use
clutch discs. bands.
8
BASIC AUTOMATIC TRANSMISSION OPERATION
Freewheeling Clutches
Locked
9
BASIC AUTOMATIC TRANSMISSION OPERATION
Oil Pump
Oil Pump
10
BASIC AUTOMATIC TRANSMISSION OPERATION
Computer Controls
The Transmission Control Module (TCM) receives The main external sensor the TCM receives
signals from many sensors and uses these signals information from is the Electronic Control Module
to control when the transmission shifts and how (ECM). The ECM supplies signals such as throttle
the shifts feel. position, engine speed and engine load. How-
ever, the TCM also supplies the ECM with signals.
Some of the internal transmission sensors are the
transmission temperature sensor, the transmission For example, the TCM can tell the ECM when it is
input speed sensor and the transmission vehicle planning to shift. The ECM will reduce engine
speed sensor. power slightly as the transmission is shifting. As a
result, the driver feels a smooth and seamless
shift, because the ECM and TCM are working
together.
TCM
ABS/ASR
Control Module
Motor
Intervention
Signal
ECM
11
BASIC AUTOMATIC TRANSMISSION OPERATION
Sensors Actuators
Sensors are components that tell the Transmission The actuators do the work. These are the com-
Control Module (TCM) what is happening. These ponents that move when commanded. These
components relay the transmission fluid tempera- components are valve body solenoids, pressure
ture, the transmission input speed, the transmis- control valves, shift lock solenoids and many other
sion output speed and many other signals. components.
This information is then relayed to the TCM. The The actuators close the loop that the sensors
TCM interprets this information and uses it to start. As a result, the central computer knows
control the actuators. what is happening inside of the transmission and
how to keep everything operating smoothly.
12
BASIC AUTOMATIC TRANSMISSION OPERATION
Audi transmissions have functions called emer- This section has shown the basics of transmission
gency running modes. There are two possible operation.
emergency running modes, the default functions
and the emergency running mode. Power is transferred from the engine to the trans-
mission through a torque converter. This torque
These modes alter the way the transmission converter is filled with fluid, so there is no direct
operates when a failure has occurred. These contact between the engine and the transmission.
modes are designed to try and eliminate heat
production in the transmission, and to allow the The torque converter clutch creates direct contact
vehicle to be driven to safety. between the engine and the transmission to help
achieve better fuel economy and to cool the
transmission fluid.
13
01V POWERFLOW
Objectives:
14
01V POWERFLOW
1 Sun Gear
1 Planet Carrier with 3 Planetary Gears
1 Ring Gear. Ravigneaux Gearset Simpson Gearset
15
01V POWERFLOW
Powerflow Overview
Sun
Gear
Ring
Gears
Planetary Gears
180-
180-
Input Shaft Small Sun Large Sun Brake D Brake G Clutch F Output
Gear Gear Shaft
16
01V POWERFLOW
1st gear
Clutch A
Brake G Engaged
Disengaged
Stops the Simpson sun gear FL1 = Freewheeling Clutch
The ring gear drives the Simpson gearset
The planetary gears rotate around the sun
gear
The Simpson planetary housing drives the
driveshaft.
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
17
01V POWERFLOW
2nd gear
Clutch A
Brake C
Brake G
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
18
01V POWERFLOW
3rd gear
Clutch A
Brake C
Clutch F
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
19
01V POWERFLOW
4th gear
Clutch A
Clutch E
Clutch F Engaged
Disengaged
Locks the Simpson ring gear, driven by the FL1 = Freewheeling Clutch
Ravigneaux gear set, to the Simpson sun gear
The Simpson gear ratio is 1:1
The Simpson planet carrier drives the output
shaft
Transfer from input shaft to output shaft is 1:1.
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
20
01V POWERFLOW
5th gear
Clutch E
Brake C
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
21
01V POWERFLOW
Reverse
Clutch B
Brake D
Ring Gear
Black Arrows = Power Transfer
White Arrows = No Power Transfer
Small Planet Gear (freewheeling)
22
01V POWERFLOW
The clutch logic chart tells you what is applied in For example, if a vehicle comes in that will not
each gear, similar to the pages you just went shift from 1st gear to 2nd gear, you can look at
through. the chart and see what is applied.
This chart can be very helpful during the diagno- The only difference between 1st and 2nd gears is
sis of the transmission. the application of brake C. The symptom would
indicate that Brake C is not applying.
01V / 5 HP 19
CLUTCH LOG IC
R = REVERSE X X X
N = NEUTR AL X- X-
D, 1ST GEAR X X X
D, 2ND GEAR X X X
D, 3RD GEAR X* X X
D, 4TH GEAR X X X
D, 5TH GEAR X X X
2, 2-1 DOWNSHIFT X X X X
Torque Converter
Clutch
X = Component active
- = Component inactive
(X) = Component active depending on vehicle status (overlapping)
23
01V POWERFLOW
Summary
24
01L POWERFLOW
Objectives:
25
01L POWERFLOW
Planetary 3
26
01L POWERFLOW
1st Gear
Clutch A
E B F
C D A
27
01L POWERFLOW
2nd Gear
Clutch A
Brake E
E B F
C D A
28
01L POWERFLOW
3rd Gear
Clutch A Brake D
Drives the 2/3 sun gear Holds the 1st sun gear
The 2/3 sun gear drives the 2nd planetary This causes the 1st planetary gears to spin
gears around the 1st sun gear in the same
The 2nd planetary gears drive the 2nd ring direction as the engine rotation and drive the
gear 1st ring gear
Since the 2nd ring gear and 1st planetary The 1st ring gear drives the 2nd planetary
carrier are tied together, the 1st planetary carrier and the 3rd ring gear, since they are
carrier is driven. all tied together
The 3rd planet carrier transfers this power to
the output shaft.
E B F
C D A
29
01L POWERFLOW
4th Gear
Clutch A Clutch B
Drives the 2/3 sun gear. Drives the 2nd planet carrier
This attempts to apply two gears at the same
time. All three planetary assemblies lock and
spin as one. Input speed equals output
speed, 1:1.
E B F
C D A
30
01L POWERFLOW
5th Gear
Clutch B Brake D
Drives the 2nd planet carrier, the 1st ring gear Holds the 1st sun gear. As a result, the 1st
and the 3rd ring gear at engine speed planet carrier turns in the direction of engine
The 2nd planet carrier drives the 2nd ring rotation
gear and the 2/3 sun gear This causes the 1st planetary gears to spin
The 2nd ring gear is connected to the 1st around the 1st sun gear in the same
planet carrier. The 1st planet carrier drives the direction as the engine rotation
1st planetary gears around the held sun gear, This results in higher rpm at the 2nd planetary
causing a gear reduction gears. The 2nd planetary gears transfer this
The 2/3 sun gear drives the 3rd planet carrier faster speed over to the 3rd planet carrier.
at the speed difference between the 3rd ring
and sun gears
The difference in speed between the 2/3 sun
gear and the 3rd ring gear causes the planet
carrier to turn at higher than input speed.
E B F
C D A
31
01L POWERFLOW
Reverse
Clutch C Brake F
Drives the 1st sun gear Holds the 1st and 3rd ring gears as well as
The 1st sun gear drives the 1st planet carrier the 2nd planet carrier
because the 1st ring gear is being held. The 2nd ring gear is driven by the 1st
planetary carrier and turns in the direction of
engine rotation
The 2nd ring gear transfers this power
through the 2nd planetary gears and to the
2/3 sun gear
Although the 2nd planetary gears are turning
in the direction of engine rotation, they turn
the 2/3 sun gear in the opposite direction of
engine rotation because the 2nd carrier is
held
From the 2/3 sun gear, the 3rd planet carrier
is driven against the stationary 3rd ring gear
The 3rd planet carrier transfers this power to
the output shaft in the opposite direction of
engine rotation.
E B F
C D A
32
01L POWERFLOW
The clutch logic chart tells you what is applied in The only difference between 2nd and 3rd gears is
each gear, similar to the pages you just went the application of brake D and the release of
through. brake E. If the transmission operates fine in 5th
gear (brake D applied), the problem is most likely
This chart can be very helpful during the diagno- with brake E.
sis of the transmission. For example, if a vehicle
comes in that will not shift from 2nd gear to 3rd
gear, you can look at the chart and see what is
applied.
01L / 5 HP 24
CLUTCH LOG IC
R = REVERSE X X
N = NEUTR AL X
D, 1ST GEAR X X
D, 2ND GEAR X X
D, 3RD GEAR X X
D, 4TH GEAR X X
D, 5TH GEAR X X
2, 2-1 DOWNSHIFT X X X
Torque Converter
Clutch
X = Component active
- = Component inactive
(X) = Component active depending on vehicle status (overlapping)
33
01L POWERFLOW
Summary
34
TORSEN DIFFERENTIAL
Objectives:
35
TORSEN DIFFERENTIAL
Torsen Differential
Transmission Output
Shaft
To Rear Axle
To Front Axle
36
TORSEN DIFFERENTIAL
The Torsen differential is composed of the follow- The teeth on each of the planet gears mesh with
ing components: the teeth of one side gear.
Differential Housing
Hollow Shaft
Planet Gears
37
TORSEN DIFFERENTIAL
When an axle loses traction, the planet gears, The maximum amount of power that can be sent
through the spur gears, are responsible for the to the axle with better traction is determined by
power transfer. the Torque Bias Ratio (TBR). TBR is determined by
the angle and shape of the teeth on the side and
The interlocked planet gears will apply even force planet gears. The TBR of the Torsen differential is
to each side gear. Only the planet gear meshed about 2:1. This means that about two-thirds of
to the side gear that has traction can apply this the torque, or about 67%, can be sent to the axle
force. The other planet gear is simply following with better traction. The remaining third is sent to
along. the other axle.
Planet Gear
Side Gear
38
TORSEN DIFFERENTIAL
Summary
39
40
ELECTRONIC OPERATION
Electronic Operation
Objectives:
41
ELECTRONIC OPERATION
Sensors
ECM
Multifunction Transmission
Range (TR) Switch F125
ABS
/ASR
ABS/ASR Electronic Control
Module
42
ELECTRONIC OPERATION
Actuators
Solenoid Valves
Transmission Control
Module J217
ECM
Gear Indicator
Automatic Transmission
Relay
43
ELECTRONIC OPERATION
Sensors
Clutch B Housing
G182 Transmission
Input Sensor (Hall type)
44
ELECTRONIC OPERATION
Sensors
Poor Signal
2 V/Div. 10 ms/Div.
T
0
Signal Application
45
ELECTRONIC OPERATION
Sensors
G38 is an inductive sensor that records trans- The sensor on the 01V front-wheel drive and all-
mission output RPM. wheel drive uses a trigger wheel on the output
shaft for a signal.
The ECM calculates the vehicle speed from the
transmission output RPM. The sensor for the 01L all-wheel drive uses a
trigger wheel on the the Torsen differential for a
Shielding for the signal wires prevents outside signal.
electric interference.
01L 01V
Signal Application
46
ELECTRONIC OPERATION
Sensors
Kick-down Switch F8
Signal Application
Kick-down Switch F8
Short to Ground/Electrical Malfunction in
Circuit
47
ELECTRONIC OPERATION
Sensors
Signal Application
48
ELECTRONIC OPERATION
Sensors
With the exception of the A8, no other Audi When the driver pushes the throttle pedal to this
vehicles with ME7 have a throttle switch to point, the internal components of the accelera-
provide kick-down information. Automatic tor position sensor will exceed the full-load
voltage normally sent to the ECM. The ECM
transmission vehicles have a pressure element interprets this excessive voltage level as a kick-
in place of the accelerator pedal stop. This down action and will transfer this information
pressure element generates a mechanical to the TCM.
pressure point which gives the driver a kick-
down feeling. The kick-down switching point can only be tested
using diagnostic testers.
Kick-down Range
Accelerator Pedal Travel
5,0
G79
Signal Voltage (V)
G185
0
20 % 40 % 60 % 80 % 100 %
49
ELECTRONIC OPERATION
Sensors
Signal Application
50
ELECTRONIC OPERATION
Sensors
Signal Application
When in drive, moving the selector lever to-
wards the passenger side will enable Tiptronic
operation.
51
ELECTRONIC OPERATION
Sensors
Signal Application
52
ELECTRONIC OPERATION
Sensors
Signal Application
53
ELECTRONIC OPERATION
Sensors
Fuel Injector
TCM
ECM
Throttle Position Sensor G69
Signal Application
54
ELECTRONIC OPERATION
Sensors
The Engine Speed Sensor, G28, sends the The fuel consumption signal is calculated from
engine speed signal to the ECM. The ECM also the injector timing by the ECM.
sends this signal to the TCM.
The TCM recognizes this signal as the instanta-
neous torque of the engine. The TCM will
calculate shift points according to the signal
received.
Signal Application
If the ECM does not receive an engine RPM Effect of Signal Failure
signal, the motor will die.
A replacement value is calculated from the
If this signal is not received by the TCM, the throttle position sensor and RPM signals, then
transmission will go into Emergency Mode. sent to the TCM.
55
ELECTRONIC OPERATION
Sensors
Signal Application
56
ELECTRONIC OPERATION
Sensors
TCM
ABS/ASR
Control Module
Motor
Intervention
Signal
ECM
57
ELECTRONIC OPERATION
Sensors
If the TCM receives a signal from the ABS/ASR The transmission informs the engine when it
ECM, the TCM supports automatic traction wants to shift. The ECM adapts injection
control in that: quantity and timing to reduce engine torque.
58
ELECTRONIC OPERATION
Actuators
N90
N89
N88
59
ELECTRONIC OPERATION
Actuators
60
ELECTRONIC OPERATION
01V / 5 HP 19
SOLENOID LOG IC
R = REVERSE X - - X - X -
N = NEUTR AL X X - X - X -
D, 1ST GEAR X X - X - X -
D, 2ND GEAR X X - X X X -
2, 2-1 DOWNSHIFT X - - X - X -
D, 5-4 DOWNSHIFT X - X X X - X
Torque Converter
- - - - - - X
Clutch
X = Component active
- = Component inactive
X - X = Component active depending on vehicle status (overlapping)
61
ELECTRONIC OPERATION
Actuators
The solenoid valves open or close the oil Self-Diagnosis Failure Message
canals to the clutches or the brakes when the
TCM activates them. Solenoid Valve 1,2 or 3
(N88, N89, N90)
Keep in mind, even if the solenoid valve is
working properly, the valve in the valve body Short to Ground
may be stuck and causing shifting concerns. Short to Positive
Electrical Malfunction
62
ELECTRONIC OPERATION
Actuators
63
ELECTRONIC OPERATION
01 L / 5 HP 24
SOLENOID LOG IC
R = REVERSE - X - X X- X - X-
N = NEUTR AL X - X X -X X - -X
D, 1ST GEAR X - - X X- X - X-
2, 2-1 DOWNSHIFT X - - X X X - X
D, 5-4 DOWNSHIFT - X - X - X - -
Torque Converter
- - - - - - X -
Clutch
X = Component active
- = Component inactive
- X - = Component active depending on vehicle status (overlapping)
64
ELECTRONIC OPERATION
Actuators
Signal Application
The TCM (J217) will wait for a signal from the
Brake Switch before disengaging the shift lock
solenoid.
65
ELECTRONIC OPERATION
Actuators
N No gears engaged.
66
ELECTRONIC OPERATION
Actuators
No Output
67
ELECTRONIC OPERATION
Switches
Signal Application
No Output
68
ELECTRONIC OPERATION
The Dynamic Shift Program (DSP) was introduced In addition to the adaptive functions that lead
in 1992 for the 01F and 01K transmissions. It to driving program changes over longer drive
was a joint development project between ZF time periods, short term functions provide an
and Bosch. increase in the spontaneity of the transmission
to special driving situations.
Earlier DSP systems had two driver adaptation
modes, the current DSP has 240 possible driver Examples:
adaptation modes. Many of these 240 different
driver adaptation modes are grouped. Rapid changes in pedal position can cause
the transmission to shift down by 1 to 3
For example, modes 0-60 may all be in the driving ranges depending on vehicle speed.
same group and cause the transmission to act This activates rapid downshifting that is
the same way. Modes 61-80 might be grouped independent of the kick-down switch input
as well. And so on.
When the pressure on the accelerator pedal
The current mode, or DSP number, can be is rapidly reduced, upshifts are not carried
viewed through the VAG 1551/1552 or VAS 5051 out. This prevents upshifts before curves.
Scan Tool. The cold driving mode will appear This function is cancelled as soon as the
as 241 and the Tiptronic mode will appear as driver accelerates again
243. Otherwise, the DSP number will be vari-
able. The higher the number is, the harsher the The transmission temperature signal is used
shift will be. to trigger the cold driving mode.
The DSP processes the following inputs to Cold Driving Mode
determine the type of driver style:
During the cold driving mode, 241, the engine
The throttle valve position and the speed at will not upshift until a higher rpm. Depending
which the throttle valve changes position on year or model, this is calculated from either
Vehicle speed acceleration and decelera- engine coolant, transmission oil temperature or
tion time.
ATF temperature
Selector lever position. After about 40 seconds, the engine DSP number
will shift out of 241 and into a regular number.
The DSP looks at the following when plotting The cold running procedure is designed to help
shift adaptation modes: the catalytic converters heat up quicker.
The driver behavior Mountain Recognition Mode
The driving route profile recognition
Other spontaneous influences. Mountain recognition takes place mainly through
the calculation of actual acceleration vs. the
The type of driving route will be recognized over engine torque and the vehicle speed. This is
the basic driver classification. compared with a set measurement taken on
level ground.
69
ELECTRONIC OPERATION
If the signal of a sensor fails, the TCM tries to If no replacement signal can be obtained
establish a substitute-signal from the signals during the default function, the TCM will switch
of other sensors. If a substitute-signal can be the transmission into Emergency Mode.
established, the Transmission function for the
most part will be retained. Emergency Mode has two possibilities:
With many default functions, the transmission Mechanical Emergency Running Mode with
alters its operation in the following ways: operational TCM
70
ELECTRONIC OPERATION
Summary
71
SUMMARY
72
Knowledge Assessment
Knowledge Assessment
An on-line Knowledge Assessment (exam) is available for this SSP.
The Knowledge Assessment may or may not be required for Certification.
You can find this Knowledge Assessment at:
www.accessaudi.com
From the accessaudi.com homepage:
iii
WSP-521-951-93