TITLE: Perform automatic transmission service SPECIFIC OUTCOMES: Upon completion the task, students should be able to:

1) Execute automatic transmission on road test 2) Execute automatic gear oil flushing 3) Change automatic transmission oil 4) Execute transmission oil level check 5) Execute automatic gear changing test 6) Execute automatic transmission pressure test TOOLS & EQUIPMENTS: No Component 1 Spanar set 2 Screwdriver set 3 Special tool a. MD998316 dial gauge support

Quantity 1 set 1 set 1 unit

COMPONENTS: No 1 Component Quantity Automatic transmission gearbox

1 unit

SAFETY PRECAUTIONS: 1. Understand the safety procedures specified by the lecturer. 2. Always aware, any machine or tool used in the practical task. 3. Do your task in an organized manner as this can minimize the risk of accident occur. 4. Read and follow the experimental method and check with the lecturer if any problem occur. THEORY : An automatic transmission contains more heat-generating parts than a manual transmission. When an automatic transmission has warmed up after some distance of normal driving, the temperature of the ATF in the oil pan is as high as 80C. When the vehicle has been driven up a long slope or the engine has run at high speeds, the temperature may even be 100C or higher. At extremely high temperatures, the ATF and the friction materials used in transmission components generally start deteriorating. For this reason, a variety of measures are incorporated in the automatic transmission to minimize heat resulting from operation under demanding conditions. The cooling system is based on circulation of the ATF through an oil cooler, which is itself cooled by air or water. The oil cooler is generally incorporated into the radiator and is connected to the automatic transmission by two oilcooler tubes; one for outflow fluid and the other for inflow fluid. Heated ATF in the torque converter is directed to the oil cooler and after being cooled by the oil cooler, is directed to various transmission components to lubricate them. After being used as lubricant, the ATF

collects in the oil pan. Automatic transmission fluid (ATF) contains several types of additive. The additives optimize the ATFs frictional characteristics, maintain adequate and consistent viscosity from high to low temperatures, and suppress formation of bubbles. The additives, however, are not immune to deterioration. They, and in turn the ATF, deteriorate over time (more quickly if the vehicle is used under severe conditions). When ATF deteriorates badly, increased shock is felt during gearshifts and operational reliability of the clutches and brakes can be affected. ATF that has deteriorated must be replaced. To determine whether ATF is good or no good on the basis of its colour, recommendation is to use a test tube or a small-size beaker.

ATF is used for multiple purposes including lubrication and hydraulic actuation, so the ATF level must be carefully controlled. If the level is too low, the oil pump may suck air together with ATF, leading to insufficient control-valve pressure and inaccurate movement of valve elements. Also, insufficient pressure can make the clutches and brakes slip, making satisfactory gearshifts impossible. Other problems caused by a low ATF level include poor lubrication and cooling. If the ATF level is too high, the clutch retainer and other rotating parts may agitate the fluid. As the ATF gets hot when it is agitated by these rotating elements, the life of the fluid may be shortened. Bubbles generated by agitation may also give rise to problems. The total quantity of ATF in the automatic transmission is as much as 6-8 liters. Most of the ATF is contained in the torque converter and hydraulic circuit. One-third or one-fourth of the total quantity of the ATF is in the oil pan during operation of the automatic transmission. When the engine is shut down and the automatic transmission stops operating, the ATF level in the oil pan rises greatly as some of the ATF in the torque converter and hydraulic circuits drains into the oil pan. Since the ATF level in the oil pan is not always the same, measuring the level when the engine is not running is pointless. Ones must measure the level using the specified method when the ATF is in the specified temperature range.

PROCEDURE (ON ROAD TEST): DIAGRAM PROCEDURE 1) Engine should be started in P (Park) position where engine power is not transmitted by transmission. Depress the brake pedal. 2) Push the button and move the lever from P (Park) to R (Reverse). Reverse gear will engage and vehicle will start moving backward. 3) Push the button and move the lever to N (Neutral) position. Gear will be free from engagement. 4) Move lever to D (Drive) position. 1st will engages and vehicle starts to move forward. Gear will increase to 2nd, 3rd and 4th if fuel pedal is depressed. 5) Move lever to 3 (3rd speed) position. Gear will not increase higher than 3rd gear.
C

4 6) Move lever to 2 (2nd speed) position. Gear will not increase higher than 2nd gear. 7) Move lever to L (Low) position. Gear will be fixed at 1st gear. 8) Reverse step 6 to 1.

PROCEDURE (CHANGE TRANSMISSION OIL): 1) Park the vehicle on a flat surface. 2) Warm up the car to normal operating temperature (70C to 80C). 3) With the engine off, position the drain pan under the transmission pan and drain the fluid by loosening the pan bolts. Loosen one corner more than the rest to direct the flow into the drain pan. 4) Finish removing the transmission pan bolts, and lower the transmission pan down carefully (Some fluid is still in the transmission pan). 5) Remove the old filter and discard. Make sure filter O-rings or seals are discarded with the filter. 6) Install the new filter by using the same bolts or clips and use a new O-ring or seal. 7) Inspect the pan before cleaning. A small amount of fine gray clutch dust is normal. However if find metal shavings, there could be a mechanical malfunction or transmission damage. 8) Clean the transmission pan thoroughly with solvent and wipe dry so there is no harmful residue. Clean the transmission and transmission pan mating surfaces of all gasket material being careful not to damage the surfaces. 9) Position the transmission pan gasket on the pan. 10)Hand-tighten the transmission bolts in a crisscross pattern until snug. Use a torque wrench to tighten the bolts to 11 Nm. 11) Refill the transmission through the dipstick fill hole. 12)With the vehicle on level ground recheck the fluid level. Check the transmission and lines for leaks. PROCEDURE (OIL LEVEL CHECK): DIAGRAM PROCEDURE

1) Park the vehicle on a flat surface. 2) Raise the ATF temperature to 70C to 80C. 3) Let the engine run at idle. 4) Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the N position. 5) Pull the dipstick and check the level of transmission fluid. 6) ATF should be in hot range.

PROCEDURE (GEAR CHANGING TEST): 1) Start the engine. 2) Depress the brake pedal and move gear selector to D (Drive). 3) Rotate the gear selector knob on the ECT Analyzer to the 1-2 position. The transmission will shift to second gear. 4) Press and hold the first gear button. The transmission will shift to first gear. 5) Release the parking brake. 6) Accelerate to 10 mph (16km/h). 7) Release the first gear button. The transmission should shift to second gear. 8) Accelerate to 20 mph (32km/h). 9) Rotate the selector knob to the number 3 position. The transmission should shift into third gear. 10) Accelerate to 25 mph (40km/h). 11) Rotate the selector knob to the number 4 position. The transmission should shift into fourth gear. 12) Release the accelerator and coast. 13) Rotate the selector knob to the number 3 position. The transmission should downshift into third gear. 14) Apply the brakes, and stop the vehicle. Testing is complete. PROCEDURE (HYDRAULIC PRESSURE TEST):

DIAGRAM

PROCEDURE 1) Warm up the engine until the automatic transmission fluid temperature is 80C 100C. 2) Jack up the vehicle so that the wheels are free to turn. 3) Connect the special tools (2,942 kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900] to each pressure discharge port. 4) Measure the hydraulic at each port under the conditions given in the standard hydraulic pressure table and check that the measured values are within the standard value ranges. 5) If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.

RESULT (GEAR CHANGING):

RESULT (HYDRAULIC PRESSURE):

DISCUSSION & CONCLUSION: 1) Describe the functions of automatic transmission fluid. 2) Why we need to change automatic transmission fluid periodically? 3) Automatic transmission dipstick contains 2 levels (H and C) which are different with engine oil dipstick (high and low). What does H and C means? How does it function?

REFERENCES: 1) Automatic Transmission F4A41, F4A42, F4A51 Service Manual (Mitsubishi Motors Corporation), May 2002 2) Automatic Transmission Training Textbook (Proton Holdings Bhd) 3) Automatic Transmission Inspection Sheet (Proton Holdings Bhd)