GEARBOX PRESENTATION : AL AUTOACTIVE AUTOMATIC GEARBOX 4 —Goneral 2~ Identification 3~ Summary of operated components, 4 Position : needle thrust bearings, friction washers, adjusting shims, 5 ~ Description : clutcn assemblies E1 and E2, brake Fi 6 Presentation : special too!s PRECAUTIONS TO BE TAKEN : AL4 AUTOACTIVE AUTOMATIC GEARBOX 1 General 2 Transporting and storing the gearbox '3— Components to be systematically changed FITTING : AUTOMATIC GEARBOX ON REPAIR BENCH 1— Recommended tools 2. Fitting the support to the gearbox DISMANTLING ; CONVERTER HOUSING SIDE 1 Recommended tools 2 Removing DISMANTLING — RE-ASSEMBLY : OIL PUMP 1 — Dismantling 2—Re-assembly REMOVE ~ REFIT ; DIFFERENTIAL AND SECONDARY LINE BEARINGS 11— Recommended toots 2 Secondary line bearings 3 = Differential bearings DISMANTLING : REAR HOUSING SIDE 1 = Recommended tools 2- Removing DISMANTLING — RE-ASSEMBLY : CLUTCH ASSEMBLIES E1 AND E2 4 — Recommended toots 2-Dismantiing 3—Re-assembly 4 = Clearance checks. 2 13 14 15 15 20 22 22 25 28 28 a” 31 34 37 39,REMOVE ~ REFIT : INTERNAL SELECTOR CONTROL 1 — Recommended tools 2—Removing 3 — Refitting DISMANTLING ~ RE-ASSEMBLY : EPICYCLIC GEAR TRAINS 1 Recommended tools 2— Dismantling 3—Refittng REFITTING ; REAR HOUSING SIDE 1 — Recommended tools 2 Refiting 3~ Checking the clearance of the input shaft REFITTING : CONVERTER HOUSING SIDE 4 — Recommended tools 2 Refitiing OVERHAUL : HYDRAULIC VALVE BLOCK 1 — Presentation 2 Cross sections 3 - Spring identification 4 — Removing the hydraulic valve block 5 Dismantling the hydraulic valve block 6 — Reassombling the hydraulic vaive biock 7 — Rofitting the hydraulic valve block 8 ~ Adjusting the internal selector control (roller blade) 42 43 a.s 47 a7 48 51 52 59 59 63. 4 66 63 69PRESENTATION : AL4 AUTOACTIVE AUTOMATIC GEARBOX 4-GENERAL (1) torque converter. (2) olt pump. (3) double epicyclic gear train. (4) primary shaft (6) output shaft (6) cifterentia (7) clutch Et (8) cluten £2 (9) disc brake F1 (10) band brake F2. (11) band brake F3. (12) supply hub. The AL4 automatic gearbox weighs approximately : = 70 kg with oll and converter + 57 kg without ol and without converter maar 42— IDENTIFICATION 2.1 — ALA automatic gearbox ‘The gearbox can be identified by an engraving on the rear housing, a’ component number. *b* serial number. moe 2 od e2.3 — Hydraulic valve block ‘The identification number of the hydraulic valve block Is engraved on the left hand side of the main distributor ‘yf bench assembly number (1 bench with 2 assemblies). “year of manufacture, "P day of the year of manufacture. ‘my bench number. “at repair number (1” = + repair) i part number.3 - SUMMARY OF OPERATED COMPONENTS ‘The AL4 automatic gearbox changes gears using the following components + 2 duiches (Et and E2) + 3 brakes (F1 disc brakes F2 and F3 band brakes) = 2 double epicyclic gear tain ear Drivin ce¢ Clutches: Brakes: Postion ote geariover | Gea, | Diving | tacked | Gee ae i P "BT = x R ® cae x x N n er = x t 7T x x 2 [anes x) x x ° 3 [nese | [XO] x 4 *ca-pat | PT XP) xp x] 7 mT PE x x 5 2 [pose | pe | REY XT x Slice - xe | x | x i >r er x px 2 2 “eapET | ee | XC) x x a 7 “er x x Indox +X ectivated component (¢) :the lock-up cluteh may be activated (depending on the driving conditions) "C1r— erown wheel with internal teeth 1 "C2" crown wheel with internal teeth 2 "P51" planet wheel carrier + "PS2"~ planet wheel camer 2 “pt” —sunwheo! 1 2 "P2"—sunwnee! 2 2 +C2-PS1” the planet whee! carrier "PS1" Is mechanically connected to the crown wheel "C2" 1 'G1-PS2"— the planet wheel carriar "PS2" is mechanically connected to the crown wheel "C1" © "P= lock-up clutch = "ET" clutch E1 = 7E2"— clutch E2 2 1F1" — brake Ft 2 7F2"— brake F2 2 7FS"— brake F3 DPS - ALYCaches ery Per Pee X 2 presa baton" ores program falocton Index + X : activated component Comvercesiosrevanes EVES | BSE | ESS * (7): the lock-up clutch may be activated (depending on the driving conditions) =P" ~ lock-up cluten *7E1" — clutch E1 = 1E2" — clutch £2 "Ft" — brake Ft FZ" brake F2 "FS" — brake F3 = "EVS" — sequence electrovaive (EVS1 to EVS6) De - ACH "ASE4— POSITION : NEEDLE THRUST BEARINGS, FRICTION WASHERS, ADJUSTING SHIMS (13) and (14) friction washers. (16) to (20) need thrust bearing. (21) adjusting shim. NOTE ; The black surfaces of the stops always face the converter side, NOTE : The needle thrust bearing (18) cannot be removed. oo 75 - DESCRIPTION : CLUTCH ASSEMBLIES E1 AND E2, BRAKE F1 Recaiver ~~] Operating clearance in mm Number of diac = A=tt0 14 6 TER B=2024 4 eT =_ 6 e2 Et NOTE : The discs are lined on one side and smooth fon the other, with alternating internal and extemal fasteners, Brakes F3 and F2 are band brakes, a S6 — PRESENTATION : SPECIAL TOOLS 6.1 ~ Peripheral ropair kit (-}.0338, M2! Ni S N2| P {A locating post (-) 0338 A. [8] handles for removing-refiting the converter (~).0338 B. {C] ight hand driveshaft seal extractor (-).0338 C. [D] converter retaining stop (~).0338 D. [E] bal joint extractor (~).0338 E [F converter seal refiting tool (-).0338 F IG] converter lip seal removal hook (—).0336 G. [H1] lofthand driveshaft seal fting drift (-).0338 H1 {12} left hand driveshaft seal fiting guide (-) 0338 H2 [U1] right hand driveshaft seal fiting dit (-).0398 Jt [02] right hand criveshaft seal fting guide (~).0338 J2. {K_ selection shaft seal fiting ott (-).0398 K. {U interface harness for checking the AL automatic gsorbox (-).0938 L [Mt] adjusting screw for the internal selection contro (~).0998 Mt {12} adjusting shim for the intemal selection control (-).0838 M2. [N11] gear selector shatt sao! oxtractor(-).0938 Nt IN2} gear selector shaft seal extractor (-).0338 N2 [P| socket for removing the gearbox mounting shatt (0938 P. nae 9 =6.2 — Repair kit (~).0342 A | B [A] too! for extracting the large differential bearing (-).0342 A. [B] pin of the too! for fiting the cage of the srrall differential bearing (-).0342 B. [C] too! for fiting the left hand driveshaft deflector seal (-).0342 C. [0] too! for adjusting the ball blade (~).0342 D. [E] too! for supporting the input shaft (-).0342 E (iveaded rod, L = 150 mm, @ 8 x 1,26, fo be made in the workshop). [FI too! for fiting the small differential bearing (~).0342 F. [G] tool for fiting the cage of the small differential bearing (-).0342 6. (HI 100! for iting the large differential bearing (~).0342 H. [i] tool for fing the secondary line bearings (-).0242 J [k} too! for extracting secondary line bearings (-).0342 K. [LJ end piece for removing the cage of the large differential bearing (—).0342 L. [MJ tool for extracting the cage of the large differential bearing (~).0342 M. [N] too! for removing-refitting the epicyclic gear train nut (~).0342 N. are 40 =[AA] too! for preforming the piston of brake F1 (-).0342 AA. [AB] too! for pretorming the elutch E1 counter piston (-).0342 AB. [AC] too! for preforming the piston of clutch E1 (-).0942 AC. [AO] too! for preforming the piston of clutch E2 (~).0342 AD. [AE] too! for removing the clutch E2 counter piston (-).0342 AE, [AF] too! for removing the clutch E1 counter piston (~).0342 AF, [AG] too! for ting the clutch piston 2 (-).0342 AG. [AH] tool for guiding the inner lip ofthe clutch £2 counter piston (~),0342 AH. [AJ] too for guiding the outer lip of the clutch E2 counter piston (-).0342 As. TAK] too! for fiting circlips of clutch E1 and £2 housing assembly (~).0342 AK, TAL} too! for fting the cage of the large differential bearing (-).0342 AL, Tana 1PRECAUTIONS TO BE TAKEN : GEARBOX - GENERAL Do not use tichiorethyiane and paint thinner s0 as to avoid splashes or contact with the seals. Clean the parts using an ultrasonic device in a hot anti-corrosion detergent bath, Do not clean the following components + the friction dises + non removable parts (wipe with a chamois leather) ‘When cleaning, and when not completely dismantling the gearbox, blank the driveshaft output orifices. WARNING : Using cloths may cause fluff to enter the hydraulic circuits Wiping parts : = use special int free workshop paper or a chamois, leather + carefully blow the components clean with compressed air Blow thoroughly with compressed air into all hydraulic supply and component lubricating channels, During reassembly * lubricate all rubber seals (mbsture of vaseline and gearbox oil) ++ oll new friction discs wth the recommended oil When dismanting a goarbox, when the ol is burnt, full of metal particles or bits of lining, the following operations must be performed ‘* drain and rinse the converter and heat exchanger carefully. Do not add any other fluid than the oil recommended + dismantlo and clean the hydraulic distrbutor carefully : ell the valves must move freely without tight spots (see section on hydraulic distributor) AL4 AUTOACTIVE AUTOMATIC. 2 TRANSPORTING AND STORING THE GEARBOX ‘The converter support bracket must be fitted when handling to avoid breaking the input shaft segment (Gismantiing the converter). “The gearbox should always be stored filed with oil, both boforo and after repairs (6 litres of the recommenced oil). 12