Transmission Automatic Gear Management en 2011 07

Automatic transmission control

Work document 1 987 727 652
Name : ............................................
Date: from ............... to ..............
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This training material serves as information for study purposes. It shall not be used for corrective maintenance of
of vehicles. Corrective maintenance should be carried out as per the respective and applicable workshop manuals.
All values specified here are application-dependent and therefore not generally applicable.
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Table of contents
• OVERVIEW OF THE AT- • Parking lock
TRANSMISSION
• AUTOMATIC TRANSMISSION (AT) • Maintenance / Diagnosis
• Overview / Design • Summary
• Torque converter • DUAL CLUTCH GEARBOX
• Oil pump • Overview / Design
• Planetary gear • Clutch systems
• Switching elements • Gearbox unit
• Mechatronics module • Oil circuit
Table of contents
• Mechatronics module • Clutch adjustment
• Maintenance / Diagnosis • Maintenance
• Summary • Summary
• AUTOMATED SHIFT • CONTINOUSLY VARIABLE

TRANSMISSION (AST) TRANSMISSION (CVT)
• Overview / Design • Overview / Design
• Clutch actuator • Components
• Selecting and engaging a gear • Maintenance
• Transmission sensors • Summary
Table of contents
TRANSMISSION
• AUTOMATIC TRANSMISSION (AT) • Maintenance / Diagnosis
• Torque converter • DUAL CLUTCH TRANSMISSION
Overview of the automatic transmission
Double clutch Automatic Continuously

Automatic manual transmission
(ASG or AMT) transmission variable transmission
(DKG or DCT) transmission (AT)
(CVT)
Actuators ECU Actuators Sensors Variator with belt
Clutch actuator with Electro-hydraulics Electronics Hydraulics

the K-ECU module module module
Table of contents
TRANSMISSION
• AUTOMATIC TRANSMISSION (AT) • Maintenance / diagnosis
Automatic transmission (AT)
ZF 6-speed 6HP26 (BMW) since 2003

GM AF40 Gen 2 (Opel Insignia) since 2010 Aisin 6-speed 09G; 09K; 09M (VW) since 2004
Mercedes 7-speed Tronic Mercedes 7-speed Tronic Plus

since 2003 since 2010 AisinWarner 8-speed (Lexus) since 2007
Automatic transmission (AT) - Characteristics
 Hydrodynamic converter as drive-off element

 Immense further development works took place in the last 10 years in
power density
(number of gears, spreading, efficiency)
 Optimization potential in:
 Agility
 Driving pleasure
 Consumption
Advantage
 Excellent switching quality
Automatic transmission (AT)  Today possible up to 8 driving stages (in Lexus)
 Spreading up to 6.7 (Porsche 4.3 and 5 driving stages of DC)
 Less interruption in traction force while switching
 High torque transmission up to (1000 Nm)
Disadvantage
 Complicated and costly technology
Structure of a modern automatic transmission (AT)

1 2 3 4 5 6 7
1. Gear output to drive shaft
2. Planetary wheel-set
3. Multi-disk clutches
4. Converter
5. Turbine
6. Converter clutch
7. Gear input
8. Module for transmission
control
1. Name the parts of the torque converter!

Pump, turbine, guide wheel on freewheeling mechanism and oil.
2. Which type of planetary gears are used in the range of automatic transmission (AT)?
Wheel set concepts: Simpson, Ravigneaux, Simpson and Lepelletier.
Torque converter - Functional principle
The ventilator is switched on and rotating (left). If

1. Pump wheel
another ventilator is placed on the opposite side, then
the air flow will rotate the blade of the second 2. Guide wheel
ventilator. 3. Turbine wheel
4. Housing cover
Basic function
2 3
4 1
2 3
1
ATF flow direction in the converter
Structure
housing
Torque converter - Structure and function

1
1 2 1. Turbine
1 3
2. Pump
3 1
2 3. Guide wheel
8
3 2 4. Converter clutch
9
5. Torsional damper
6. Friction lining
4
7. Drive
10
7 8. Free wheel
5
9. Support for guide wheel
6
10.Output
1. Name the main parts of the torque converter!

Pump (is welded to the converter housing), turbine (it is connected with the transmission
shaft), guide wheel, converter clutch.
Torque converter - converter clutch

3 1. Torque converter
4
2 2. Converter clutch
5 6 7
3. Turbine
1
4. Pump
5. Guide wheel
6. Lubricating valve
7. Non-return valve
8 8. ATF cooler
9. Converter clutch valve
10.Converter pressure valve
11.Pressure control valve
11 9
1. What is the function of the converter clutch?
The converter clutch is used for eliminating the slip
during the torque transmission. The slip between the
10 pump and the turbine is locked up by activating the
converter clutch and thus, the efficiency is improved.
Oil supply / converter clutch closed
Oil pump
Oil pump transmission-side
2 3 4
1. Pressure side
1
2. Crescent moon
3. Inner toothed wheel
4. Suction side
5. External toothed wheel, driven
by the engine
6. Driving tabs
Oil pump engine side
5 6
1. Which type of the oil pump is used in the range of AT transmission?

Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP; Aisin etc.)
and double vane pump ZF 8HP.
2. What should be taken care of while repairing the torque converter?
The driver of the oil pump shall engage itself in the grooves of the converter hub.
Planetary gear - Basic principle
In case of Simpson-set, the planet wheel carrier of one of the set is connected to the
hollow wheel of the other.
Simpson-Planetary wheel set
The long planetary wheels are engaged in the Ravigneaux-set with the big sun
wheel and the planetary wheels of the small sun wheel simultaneously. Special
feature of this set is the common planet carrier due to which a compact design is
possible.
Ravigneaux-planetary wheel set

The system is based on a simple planetary wheel set and a downstream double planetary
wheel set as per Ravigneaux. The basic principle is to operate the sun wheels and the
planet carriers of the double planetary wheel set with different speeds.
Lepelletier-planetary wheel set
Planetary gear – Ravigneaux-planetary wheel set (7-speed Tronic)

Ravigneaux-wheel set Front wheel set Rear wheel set
5 6 23 24
7 14
25
1 8 9 15
19
2 3 20
16
10
17 21
11 12
4
22
13 18
1. Converter-lock-up clutch 7. Large hollow wheel 13. Sun wheel 20. Planet wheel carrier
2. Turbine wheel 8. Short planetary wheels 14. Multi-disk clutch 2 21. Planetary wheels
3. Pump wheel 9. Small hollow wheel 15. Hollow wheel 22. Sun wheel
4. Guide wheel 10. Double planet wheel 16. Planet wheel carrier 23. Multi-disk brake BR
5. Multi-disk brake B1 carriers 17. Planetary wheels 24. Multi-disk brake B2
6. Multi-disk brake B3 11. Multi-disk clutch 1 18. Sun wheel 25. Multi-disk clutch 3
12. Long planetary wheels 19. Hollow wheel
Planetary wheel set – Mercedes 7-speed Tronic
1. Short planetary wheel

2. Long planetary wheel
1
5 3. Planet wheel carrier
2
4. Sun wheel
5. Planetary wheel
3 6 6. Planet wheel carrier
7. Hollow wheel
4
Ravigneaux-wheel set Simple wheel set
Switching elements – multi-disk clutch

1 2
1. Oil feed input
2. Internal disk
5
3. Disk carrier
4. Back-pressure spring
3 5. Outer disk
4
6. Multi-disk clutch 1
5
1. What is the function of the multi-disk clutches?
8 The multi-disk clutches connect different elements of
6 7 2
single wheel sets to each other and thus, enable a
torque transmission as also speed conversion.
2. How are they controlled?
The clutches are closed hydraulically. For this, a
piston is impacted with oil pressure such that it presses
the laminated disk packs together.
Mercedes 7-speed Tronic

Switching elements – Brakes

1
1. Outer disk
5 6
2. Internal disk
4 3. Multi-disk brake 1
3 2
4. Multi-disk brake 2
7. Drum-rotation direction
8. Brake band
9. AT-housing
Multi-disk brake (Mercedes 7-speed Tronic) 10. Piston linkage
11. Piston
1. Which types of brakes are used?

7 Multi-disk - band brakes hold the
components firmly in the
planetary gear and is used for
selecting the gear.
8
9 10 11 12 Drum-brake (Toyota)
Mechatronics module
4
3 1. Variable magnet valve brake 2
2 8
1
7 2. Variable magnet valve clutch 2
5 6
3. Variable magnet valve working pressure
4. Variable magnet valve converter-
15
9 lock-up clutch
16
10 1. Variable magnet valve clutch 3
17 2. Variable magnet valve brake 3
11
3. Variable magnet valve brake 1
18
4. Variable magnet valve clutch 1
19
12 5. Float 1
6. Plug-in coupling
13 7. Electronic Control Unit
8. Valve housing
14 9. Intermediate metal sheet
10.Valve housing
11.Turbine speed sensor
1. What are the functions of the floats? 12.Internal speed sensor
13.Output speed sensor
The floats 1 and 2 close the openings between the oil chamber
and the wheel set space if the oil level increases. 14.Float 2
15.Electrical control unit
Electronic unit
2 3 4 5 10.Output speed sensor
11.Control solenoid valve working pressure
6
1 12.Control solenoid valve clutch 1
13.Control solenoid valve clutch 2
14
7
14.Control solenoid valve clutch 3
15.Control solenoid valve brake 1
13 16.Control solenoid valve brake 2
8 17.Control solenoid valve brake 3
12
18.Control solenoid valve
converter-lockup clutch
9 10. Diagnosis
11
11. Plug-in coupling
12. Connection sensor
10 13. Internal speed sensor
14. Turbine speed sensor
1. Where is the transmission control unit built?

The transmission control unit is built in the transmission housing (below) along with the
electronic module.
Selector lever module

3 4 5 1. Leaf springs of the switch lock
2 2. Locking lever
4
1
3. R/P blocking magnet
4. Selector lever control unit
5. One-touch module +/-
6. Connection for control cable ignition lock
7. Return spring R/P blocking magnet
8
8. Return spring
6
7 9. Selector lever control unit with Tiptronic
switch
10.Functional unit
6
1. What is the function of the blocking magnet?

The blocking magnet R/P is controlled via an
electronic selector level module. The R/P-blocking
magnet releases the selector lever and thus,
enables a switching from the selector lever
position P.
3
10
Parking lock
4
1. Resting plate
3 2. Spring
2 3. Cone
1 4. Parking lock wheel
5. Parking ratchet
5 6. Guide bushing
Mercedes
1. What is the function of the parking lock?
4
The parking lock secures the vehicle against rolling
away.
2. How is it actuated?
It is actuated by the selector lever via Bowden wire
(mechanically) or with the help of the blocking
magnet (electrically).
5 VW-Group
Maintenance / diagnosis - General information
Towing:
The selector lever should be set in position "N". The towing speed should not exceed 50km/h and a distance of 50 km. Vehicles with
all-wheel drive may not be towed with raised front- or rear axle.
The oil pump is not operated while towing due to which the lubrication of the rotating components fails.
Transmission oil (ATF):

No ATF-change is provided within the maintenance intervals (Lifetime filling). Always read the technical documents while re-
filling.
Final test:
Delete error memory and carry out the test drive. Prerequisites:
- The transmission oil level of the automatic transmission is OK.
- The transmission oil level of the torque converter is OK.
The final test has to be carried out mandatorily after repairing the transmission control. It consists of following tests:
- Test drive:
- Leakage test: After completing all the necessary operations on the transmission control and its components, leakage tests
must be carried out.
- Diagnosis tester (self-diagnosis): After a test drive, read the error memory again.
Maintenance / diagnosis – Transmission oil level check

3
1 2 1. Overflow pipe
2. ATF oil
3. Oil pan
4. Locking screw
42
Test pre-requisites (always refer the service manual):
1. The transmission oil temperature using the diagnosis tester
2. Transmission oil temperature: 35...45 °C
3. Engine is running in idle condition
4. Selector lever position P. 1. Where can you find information on the
5. Unscrew the locking screw [4].
6. If the automatic transmission is correctly filled, approx. 1 drop drips maintenance of automatic transmission?
every second from the overflow pipe. ESI[tronic] C and M.
7. Screw the locking screw with a new sealing.
Maintenance / diagnosis – Adjustment

The Adjustments function can be understood as learning of different components and functions about the automatic transmission
control unit. Following adjustments can be carried out:
Reset adaptation values.
Note(s):
- The function 'Reset adaptation values' enables the deletion of internal adaptation parameters of the automatic transmission control
unit.
-After exchanging or renewing one or many components, it is recommended to execute the function 'Reset adaptation values'.
When should the adjustment be made?
– after changing the transmission

– after replacing the transmission control unit
– after changing the ATF
– after repairing the transmission (e.g. changing the slide-valve
gear-box, repairing the clutches)
– after replacing the position of the acceleration pedal-sensor
– in case of complaints regarding the switching comfort
– possible engine exchange or replacing the ECU
It is recommended to carry out an adaptation drive after the adjustment!

(See technical information)
Summary
1. Name the parts of the torque converter!

Pump, turbine, guide wheel on free run and oil.
2. Which type of oil pumps are used in the area of the AT transmission?
Internal gear pump (crescent pump for Mercedes 7-speed Tronic; ZF 6HP; Aisin
etc.) and double vane pump ZF 8HP.
3. What is the function of the blocking magnet?
The blocking magnet R/P is controlled via electronic selector lever module.
The R/P-blocking magnet releases the selector lever and thus, enables a
switching from the selector lever position P.
4. Where can you find information on the maintenance of automatic transmission?
ESI[tronic] C and M.
5. What is the function of the parking lock?
The parking lock protects the vehicle from rolling away.
Table of contents
TRANSMISSION
• AUTOMATIC TRANSMISSION (AT) • Maintenance / diagnosis
Table of contents
• Maintenance / diagnosis • Maintenance

Dual clutch transmission (DCT or DKG)

Dual clutch
Four-speed
transmission
Diagram from the patent specification by Rudolf Franke

1940 Ford/Volvo since 2008
Powershift 6DCT450 6-speed
VW DSG 6-speed since 2003 VW DSG 7-speed since 2007

BMW SMG 7-speed since 2008
Dual clutch transmission - Functional principle

 Basic design similar to shift transmission
 Two clutches
 Toothed wheels supported on three shafts
 Pre-selection of the gears by two counter shafts
 Automatic actuation of clutches and switching elements by the ECU and the actuators
Partial transmission 1
1 3 5
Clutch 1
Clutch 2
2 4 6
Partial transmission 2
Dual clutch transmission (DCT or DKG)
Dual clutch transmission - Characteristics
Advantage
Comfort same as stepped transmission
High efficiency
Individual transmission selection
Lower fuel consumption against automated shift transmission
No interruption in traction force while switching (possible up to 7 gears)
Torque transmission up to (500 Nm)
Disadvantage
Larger installation space than ASG
High bearing forces
Massive design
Complex construction (multi-shaft transmission, sensor, switching mechanism)
6-speed Ford PowerShift 6DCT450
1 2
1. Clutch 1
2. Clutch 2
3. Input shaft (hollow shaft)
3
4. Claw toothing
5. Input shaft (core shaft)
4
1. How does the dual clutch system work?

Two gears can always be engaged at the same time. One of the
clutches operates the odd gears (1,3,5 and R) while the other
clutch operates the even gears (2,4,6).
6-speed VW DSG Type: 02E

2 1. Clutch 1
1
2. Outer disk carrier clutch 1
20 3. Clutch 2
3
19 4. Outer disk carrier Clutch 2
4 5. Main hub
5 6. Drive shaft 2
18
7. Drive shaft for ATF pump
17 6 8. Drive shaft 1
8. Rotary unions
7
9. Pressure compensating room Clutch 1
16
10. Oil pressure room Clutch 1
8 11. Piston 1
15
12. Oil pressure room Clutch 2
9
14 13. Piston 2
10 14. Pressure compensating room Clutch 2
13 11
12 15. Input hub with driver disc
16. Inner disc carrier Clutch 2
1. How does this system work? 17. Inner disc carrier Clutch 1
Functionality is similar to the Ford-System. Two multi-disc- 18. Housing cover
wet-clutches for which a gear is shifted and a gear is pre- 19. Driver disc
selected.
Pressure compensation
1. Clutch 1 7. Main hub with rotary unions
1
2. Piston 1 8. Pressure chamber 2
2 3. Pressure compensating 9. Piston 2
room 1 10. Pressure compensating room 2
3
4. Pressure chamber 1 11. Clutch 2
4 5. Pressure oil feed Clutch 1
5 6. Cooling oil feed
6
1. What is the function of the pressure compensating

rooms?
8 It enables a defined closing and opening of the
clutches 1 and 2. A dynamic pressure compensation
9 takes place when the engine speed is increased.
2. May the dual clutches be dismantled?
10 No! Laminated disc packs are pre-defined by the
factory.
11
Clutch 1 in the upper half and clutch 2 in the lower half are
displayed as force-closed.
7-speed VW DSG Type: 0AM

Engaging system 1. Tie rod
1 2. Pressure plate Clutch 1
15 2 3. Dual-mass flywheel (ZMS)
4. Clutch disc Clutch 1
14
1 5. Crankshaft
3
13
Dual clutch 6. Drive shaft 1
12 4
7. Support bearing
Dual- 8. Central plate
5
mass 9. Disc spring Clutch 1
flywhe
el 10.Clutch disc Clutch 2
11.Drive shaft 2
11
12.Ball cam Clutch 1
10
13.Ball cam Clutch 2
6
9 14. Disc spring Clutch 2
7 15.Pressure plate Clutch 2
1. What type of clutch is used here?

The dual clutch consists of two conventional dry clutches which are combined to one
dual clutch.
Multi-disk clutch VW DSG Type: 02E (7-speed)
Even gears Odd gears
2 5
The pressing movement of the large shift lever [1] is reversed The small shift lever [4] presses the
by re-routing points in a pulling movement. pressure plate 2 [5] against the clutch
The pressing plate 1 [2] is drawn in the direction of the central 2 [green] and closes the clutch 2 .
plate and thus, closes the clutch 1 [blue].
Dual-mass flywheel and engaging system

1
1. Primary mass with bow springs
2. Flange with internal tooth for supporting the driver rim of the
dual clutch
2 3 4 3. Clamping ring
4. Cover for primary mass with starter rim
5. Guide sleeve for ball cam Clutch 1
6. Large shift lever
Dual-mass flywheel
5 6 7 8 9 10 11 7. Ball cam for clutch 1
8. Adjusting disc Clutch 1
9. Small shift lever with guide piston for clutch 2
10. Adjusting disc Clutch 2
11. Ball cam for clutch 2
Engaging system
1. What is the function of the adjusting discs in the engaging system?
The adjusting discs compensate the axial tolerances of different components.
2. How is a wrong axial play (clearance) noticeable?
Separation problems and clutch slipping.
DSG – Gearbox unit

3 4 5 6 7 8 9 10 1. Drive shaft 2 9. Pump shaft
2 1. 2. ZMS (dual-mass flywheel) 10. Output shaft 1
2
3.
. 4 3. Clutch 2 11. Oil pump
.
4. Clutch 1 12. Transmitter wheel Output
1 5. Pump shaft shaft 2
11 6. Spur gear of axle drive 13. Output shaft 2
7. Transmitter wheel Drive shaft 2 14. Reverse gear shaft
16 8. Transmitter wheel Drive shaft 1 15. Dual clutch

16. Drive shaft 1
12 17. Hydraulic cylinder
18 19
18. Shift fork 2/4
6. 5. 17 19. Shift fork 3/1
13 20. Shift fork N/5
15
14 21. Shift fork R/6
22. Magnet for path sensors
22
1. What must be considered while repairing the
transmitter wheel?
The strong magnet can destroy the transmitter wheel. 20
21
Transmission - Power transmission (DSG 02E)
1st gear 2nd gear 3rd gear
Reverse gear
4th gear 5th gear 6th gear
Oil circuit
Oil cooler
Pressure oil filter
Gear actuator
Oil filter unit
Oil spray
tube for
cooling the Suction oil filter
toothed Oil pump
wheels Ford Powershift System
Oil intake
Mechatronics Impeller wheels
of the toothed
Oil pump Oil sump Drive wheels
-gear
VW DSG System Oil pressure tube
for hydraulic unit
Oil return
Housing gear
pump
BMW SMG system
Oil circuit – Function for VW DSG system

1. Oil pump
1
2. Pressure relief valve
4 3. Principle pressure slide
13 3 4. Pressure control valve
2
5. Clutch cooling oil-slide
6. Clutch cooling oil - Pressure control valve
5 7. Oil cooler
12 7
8. Oil spray tube
9. Oil sump
11 10. Lubrication / cooling of toothed wheels
10 8 11. Pressure oil filter
6
12. Suction filter
9
13. Return to the oil pump
1. What is the size of the working pressure?

3-20 bar. (Depending on the engine torque and ATF-temperature).
2. At what pressure does the pressure relief valve open?
32 bar.
Mechatronics unit – Ford (Powershift)

1. Hydraulics module
2. Valve block
3
3. Electronic transmission control unit
4. Sensor for shift fork positions 1st and 3rd gear
4 5. Sensor for shift fork position 2nd and 4th gear
6. Speed sensor of the input shaft for the even shafts
5
7. Sensor for shift fork position 6 as also speed sensor of
the input shaft for uneven shafts
8. Sensor for the shift fork position 5th gear and reverse
6
gear
7
1 2 9 8
1. What must be considered while changing the electronic transmission control unit?
The sealing must be changed under the electronic transmission control unit, it must be
installed in the correct position and it must be programmed with the diagnostic device.
Mechatronics unit – BMW

1. Hydraulics module
2. Record shift valves
3. Switching cylinder
4. Integrated speed sensors
5. Shift gear path sensors
6. Integrated parking lock sensors
7. Electronic control unit
1
4
7 1. How does the transmission control unit
record the temperature of the oil
2 container?
5
The ECU records the oil temperature
3 6
from the clutch- and SMG-housing. The
5
transmission control unit calculates this
data with the help of a specific
mathematical model.
Mechatronics unit – VW (DSG 6-speed)

1 1. Central plug
3 2
2. Path sensors for gear actuators
1 3. Transmission control unit
4
4. Transmission output speed sensors
(2 units)
5. Drive shafts Speed sensors
5
16 6. Channel plate
15 6 7. Pressure limiting valve
14
8. Multiplexer spool valve
2 9. Hydraulic control unit
13 10. Safety valve 1
12 7 11. Gear actuators
12. Safety valve 2
8 13. Cooling oil valve
11 9 14. Clutch valves

10 15. System pressure control valve
16. Hydraulic pressure sensors
1. Which temperature sensors are obstructed in the transmission control unit?
Transmission oil sensor and control unit temperature sensor.
2. What is the function of transmission output-speed sensors?
The speed sensors measure the vehicle speed and the driving direction.

10 1. Transmission input speed transmitter
1 CAN CAN 2. Drive shaft transmitter (1 and 2)
3. Transmission output speed transmitter (2 units)
2
4. Transmitter for transmission oil temperature restricted
3 to multi-disk clutch
5. Hydraulic pressure sensor
4 11
12
6. ECU temperature transmitter in ECU
5 7. Transmission oil temperature transmitter in ECU
13 8. Gear switch in the steering wheel
6
14 9. Gear switch - path sensor
7
18 10. ECU for selector lever
15
11. Selector lever lock (magnet)
8 16 12. Principle pressure valve
17 13. Clutch valves
9
14. Cooling oil valves
15. Gear actuator valves
16. Multiplexer valve
1. What type of transmitter is used? 17. Safety valves
All transmitters are hall sensors. 18. Transmission control unit
Hydraulic control
1
1. Principle pressure
2. Pressure control valve 1
2
4 3. Safety valve 1
3 5 12
6
4. Pressure control valve 2
7 x Yx y x y x y
5. Safety valve 2
10 Solenoid valve without 6. Hydraulic sensor 1
9 9 9 9
current
8 7. Hydraulic sensor 1
A B C D
8. Clutch valve 1
12 12
9. Gear actuator valves 1-4
11 10.Clutch valve 2
x Yx y x y x y
11.Multiplexer valve
13
Solenoid valve with current 12.Solenoid valve
3 1 N 5 R 6 4 2 13.Shift fork
1. What is the function of the Multiplexer valve?

The Multiplexer enables controlling of eight hydraulic cylinders with four solenoid
valves.

9 1. Oil pressure accumulator
2. Hydraulic oil pump
8 1
3. Engine for hydraulic oil pump
7 4. Valve block
5. Transmission input speed
6. Clutch actuator
6
7. Clutch servo sensor
2
8. Vehicle plug
5
9. Gear actuator
3
4
1. How much is the system pressure?

Approx. 70 bar, the system pressure controls the transmission control unit with the help
of a hydraulic pressure sensor.
2. How much is the storage volume of the hydraulic accumulator?
0.2 litre.
Maintenance / Diagnosis – Oil level check (VW)
1 2
1. Oil level
2. Overflow pipe
3. Locking screw
4. Sealing plug
Pre-requisite (s) for test:

 Transmission oil temperature: 35...50 °C
 Engine in idling condition
42
 Selector lever position P.
Check oil level:

Unscrew the locking screw [3]. After unscrewing the locking screw, the transmission oil must flow from the overflow pipe [2] till the
overflow pipe is emptied. In case of a correctly filled automatic transmission, approx. 1 drop drops from the overflow pipe per
second. Screw the locking screw with a new sealing.
Maintenance / Diagnosis – Adjustment
The function 'Adjustments' means programming of different components and functions of the automatic transmission control unit.
Following adjustments can be carried out:
Programming the transmission - and clutch parameters:
Changing the mechatronics module
Changing the clutch
Error entry: Mechatronics module malfunction, basic setting faulty
The adjustment contains:

 Basic setting of gear actuator and path sensors
 Program synchronous points
 Program clutch scanning points
 Reset principle pressure output values
 Reset steering wheel key for Tiptronic
 Reset ESP and Tempomat
Summary
1. How does the wet dual clutch system work?

Two gears can always be engaged at the same time. One of the clutches operates the odd gears
(1, 3, 5 and R), the other operates the even gears (2, 4, 6).
2. What must be considered while repairing the transmitter wheel?
The strong magnet can destroy the transmitter wheel.
3. May the wet dual clutches be fragmented?
No! Laminated disk packs are preset by the factory.
4. At what pressure does the pressure relief valve open?
32-bar.
5. What is the function of the Multiplexer valve?
The Multiplexer enables the controlling eight hydraulic cylinders with four solenoid valves.
Table of contents

Automated Shift Transmission (AST) - historical overview
Ford Fiesta Durashift Opel Corsa C Toyota Yaris Toyota Corolla

EST (2002) Easytronic (2001) MultiMode (2004) MultiMode (2004)
Getrag LuK Aisin
Opel Astra H Easytronic Toyota Corolla Verso

Ford Fusion Durashift Opel Astra G Easytronic
(2004) MultiMode (2004)
EST (2006) (2004)
Automated Shift Transmission (AST) – Characteristics
The important characteristics of the automated shift transmission are:

•Compact design,
•High efficiency,
•Adjusting the available transmission is possible
•More cost-effective than the stepped automatic transmission or continuously
variable transmission,
•Easy operation,
•Suitable switching strategies in order to achieve an optimal fuel consumption
or best consumption values and
•interruption in traction force while switching.
1. Which functions must be changed so that the shift transmission is adapted to the
automated shift transmission?
- Clutch actuation
- Gear switch movement in the direction X and Y.
2. How are these functions triggered?
Pneumatically, hydraulically, electrically, electro-hydraulically.
Automated Shift Transmission (AST) - system overview

Crankshaft sensor Gasoline injection
Engine
Accelerator pedal
sensor Engine speed
Engine ECU Diesel injection

Engine speed CAN
Kick down switch Selecting and engaging a gear
Transmission
Neutral switch
Clutch actuator
Reverse gear switch AMT ECU

Speed sensor
Hand brake switch
Tone
Position sensor for gear
switch
Brake light switch
Shift Lever
Gear main switch
Instrument cluster
Transmission lock
(Solenoid)
Function selection
DLC3
1. Can the AST transmission be manually switched?

Yes, sequentially.
AST components – electrical components

5 1. Clutch actuator
2 3 2. Clutch movement sensor
3&5
3. Engine 1
4. Movement sensor 1
1
5. Engine 2
6. Movement sensor 2
7. Transmission speed sensor
8. Tip lever
8
9. Transmission control unit
4 6 7
1&9
Opel Easytronic Toyota MultiMode

9
MTA Manual Transmission
1. Which components have been fitted at the ECU-housing?

Clutch actuation unit, gear switch and gear engaging module.
AST components – clutch actuator (Opel – Bosch)

1 2 3 4
5 1. Actuator - engine
2. Electronic Control Unit
3. Worm
4. Worm gear
5. Worm gear shaft
6. Pins
7. Position sensor
8. Compensation spring
10 9. Lifter
10.Master cylinder
9 8 7 6
1. Where is the transmission control unit of Opel Easytronic

located?
It is integrated in the clutch actuator.
2. How does the clutch actuator actuate the clutch?
With oil pressure.
AST components – clutch actuator (Toyota – Aisin)

4 5
1 1
2
1. Clutch movement sensor
2. Clutch actuator
3. Release lever
8
4. Worm shaft
5. Worm gear
6. Pushrod
7. Rotation point
8. Return spring
7 3
Source: Toyota 3 6
1. Where is the transmission control unit of Toyota Yaris MMT located?

In the engine compartment behind the instrument cluster.
2. How does the clutch actuator actuate the clutch?
With the pushrod.
AST components – DC-motors for selecting and engaging gear

1 2 3 4 5 1. Thin armature form for high
dynamics
2. Vibration-resistant winding
3. 20-pole ring magnet and dual
hall sensor
4. Armature bearing with
pressed ball bearing (axial
securing with clamping
collar)
5. Massive pinion for gear
transmission intervention
Shift fork shafts Direction of

Direction of selection
switching
Gear selection and

gear engaging
module
Opel (Bosch) Toyota (Aisin)
Speed sensors for transmission control
IS – Sensor current (supply and signal)

RM – Measuring resistor (in ECU)
URM – Signal voltage
UV – Supply voltage
US – Sensor voltage
1. How does the sensor react after coming in contact with oil?
It does not react, the sensors are oil-proof.
2. Does the sensor send a signal without voltage supply?
No, the hall sensor requires voltage supply
3. Starting from what speed does the hall sensor send a signal?
The sensor can generate one speed signal from zero (1/min).
Linear position recording
1. Oil-resistant housing
3
2. Electrical connection via stamping grid
3. Printed circuit board with cat-in hall
elements
4. Slides with permanent magnet
4 5. Locating pin
2
1
Front view Rear view
1. Linear position sensor functions using which principle?

Hall principle.
2. Where else is the sensor used?
In automatic transmission (AT).
Rotary position recording

0
Hall IC
-55  55 
4.5
Output voltage (V)

Short-circuit ring s
ard
upw
2.5 tch
Clu
a rds
nw
h dow
Hall IC Hall IC
0.5 tc
Clu
-55 0 55
Degree of rotation of sensor ()
Sensor output characteristic
1., 3., 5., Switching 2., 4., R
1. With which sensor is this sensor comparable?

5., R Selecting 1., 2.
Hall sensor.
DST
Clutch adjustment
Upper steering rack Steering rack (upper pressure plate 1. Pivot ring
Clutch cover
2. Helical spring
3. Setting ring
4. Cover
lower steering rack Spring
5. Sensor DS
(lower pressure plate)
6. Cover stop
upper Adjusting 1
pressure plate wedge 3
2
5
lower pressure plate
Pressure plate
below above Spring seat Upper pressure plate
6
Adjusting rotated 3
wedge
Conventional Adjusting
clutch clutch 4
Source: LuK
1. Why is the automatic adjustment

necessary?
Actuation force changes (increases) if
the force of the clutch disc decreases.
Before the adjustment After the adjustment
Source: Toyota
Selector lever 1. Gearshift lever

3 2
4 2. Gear response
3. Gear - main switch
5
4. Transmission lock signal
5. Shift lever position sensor
6. Transmission lock Solenoid
7. Transmission lock Unlocking button
6 Link 2 Link 2
+
Link 1
7
1
1. Which operating modes can be

executed by the system?
- Automatic
- Manual (sequential)
R  N  E, M Link 1
Adjustments, programming (Opel Easytronic)
1. The adjustment must be carried out after which servicing

activities?
- After replacing the components - transmission adjusting
element and transmission control unit.
- After working on the component manual transmission.
Summary
1. How does the speed transmitter react when it comes in contact with oil?
It does not react, the transmitters are oil-proof.
2. The adjustment must be carried out after which servicing activities?
After replacing the components - transmission adjusting element and transmission
control unit. After working on the component manual transmission.
3. Where is the transmission control unit of Opel Easytronic located?
It is integrated in the clutch actuator.
4. Why is the automatic adjustment necessary?
Actuation force changes (increases) if the force of the clutch disc decreases.
5. Which functions must be changed so that the shift transmission is adapted to the
automated shift transmission?
-Clutch actuation
-Gear switch movement in the direction X and Y.
Table of contents
• AUTOMATIC SHIFT • CONTINOUSLY VARIABLE

Continuously Variable Transmission (CVT) - historical overview
Nissan Maxima 3.5 V6 Nissan Qashqai Mercedes A/B class 2.0 Nissan Murano 3.5 V6
(2008) (2008) (2004/2005) (2008) Audi Multitronic A4/A6
(2000)
Renault Megane III

VDT (NL/DE) LuK (DE)
Scenic / Grand Scenic
(alias Bosch GS-CT)
(2009)
Jatco (JP)
Seat Exeo Multitronic

(2008)
Toyota Avensis 1.8/2.0 Citroën C-Crosser
(2009) Toyota iQ 1.0 Dodge Caliber 2.0
(2008) Peugeot 4007
(2008)
(2008)
Continuously Variable Transmission (CVT)

• Hydrodynamic converter or
multi-disk clutch as drive-off element
• Direct transmission with cone pulley
and steel thrust belt (variator)
• High pressure hydraulics (expensive)
• Electrohydraulic control
• Predominant in the Asian market
• Jatco global market leader (CVT)
Advantage Disadvantage
- No interruption in the traction force - Still less customer acceptance
- Torque transmission up to (380 Nm) - Expensive
- Spread angle up to 6.25
- Best driving comfort
Continuously Variable Transmission (CVT) - Functional principle
Engine
speed
Wheel
Secondary
Engine Torque
speed
Primary
Engine Animation
Torque
Overdrive Low ratio
1. How does the distance between the discs change?

With the help of the oil pressure.
Continuously Variable Transmission (CVT) - System overview

1. Engine
1 3 4
5 2. Pump
2
3. Converter
4. Planetary gear
6 5. Steel thrust belt
6. Drive disk (primary pulley)
8 7. Output disk (secondary
7
pulley)
8. Differential
9. Electronic engine control
10. Electrohydraulic
module (hydraulic valves,
sensors, actuators)
9 11. Automobile cable harness
10
11
1. What is the function of the planetary

wheel set?
It indicates the reverse gear.
CVT variants – Mercedes-Benz Autotronic

1. Primary belt pulley set
2. Slip band
3 3. Secondary belt pulley set
7 4. Automatic transmission
control unit
5. Torque converter
6. Transmission oil pump
7. Simple planetary wheel set
5 with multi-disk clutch
1
4
Source: Mercedes-Benz
1. What is the function of the two clutches?

The torque converter connects the engine to the gear.
The multi-disk clutch ensures that the gears are changed (front and reverse).
CVT variants – Audi Multitronic

1 2
1. Reverse gear clutch 5. Hydraulic
3
2. Gearing level control unit
3. Variator 6. Transmission control unit
4. Plate link chain 7. Planetary wheel set
8. Forward clutch
8 5
1. What is the special feature of the Audi CVT transmission?

Audi uses a chain instead of a belt.
2. What is the advantage of this solution?
The torque can be larger (Max:300Nm).
CVT components – Variator

2 1 1. Movable pulley
2. Fixed pulley
3. Steel thrust belt
4. Spring
5. 'p' side pressure of the
transmission oil.
3
5
1. What is the function of the hydraulic piston?

The friction of the belt pulley ensures the torque
transmission, the value of friction depends on oil
pressure which presses the hydraulic piston.
Video
CVT components – Variator

2 5 6
1 7
1 3
3
4
8
9
10 Source: Audi
4 11
Underdrive Overdrive
1. Torque sensor 7. Adjustable cone pulley

1. What is the function of the pressure 2. Chain 8. Adjusting cylinder
sensor? 3. Disk set 1 9. Pressure spring
4. Disk set 2 10. Pressing cylinder
The pressure sensor regulates the 5. Pressing cylinder 11. Adjustable cone pulley
contact pressure of the discs. 6. Disc spring
CVT components – Steel thrust belt
Thrust belt Steel band package
CVT components – Plate link chain

Cone pulleys of the
variator
Cradle pressure pieces
Plates
Source: Audi
CVT components – CVT oil pump

6 1. Oil pump housing
1 2. Axial washer
7 9
5 8 3. Driver
4. Outer segment
5. Inner segment
1 6. Segment springs
2 2 7. Seal role
4 8. Bar spring
5 12 11 9. Stop pin
10. Crescent
11. Pinion
12. Hollow wheel
2 4
10
Source: Audi
1. Why is an efficient oil pump required?

Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
ECU and sensors 1
1. Sensor for transmission output

speed
6 2. Multi-function switch
2
3. Sensor for transmission input
5
speed
4. Sensor -1- for hydraulic pressure
(clutch pressure)
5. Sensor -2- for hydraulic pressure
(contact pressure)
6. Sensor for transmission oil
temperature
4 3
Source: Audi
1. What is the special feature of the ECU?

The ECU along with the sensors forms a unit; checking is possible only via diagnosis of
ECUs.
2. Which sensors are integrated in the ECU?
Sensor for transmission input speed; sensor for transmission output speed multi-function
switch; sensor for transmission oil temperature.
Maintenance / diagnosis
1. Oil pan
2. Overflow pipe
3. Combined oil filling- / oil
level plug
5
4. Locking screw
5. Oil level
1. What must be considered while changing the ATF?

The oil temperature must be controlled from actual values.
Summary
1. What is the function of the two clutches?

The torque converter connects the engine to the gear.
The multi-disk clutches ensure that the gears are changed (front and reverse).
2. What is the special feature of the ECU?
The ECU along with the sensors forms a unit; checking is possible
only via diagnosis of ECUs.
3. Why is an efficient oil pump required?
Because the adjustment of the pulley requires a high oil pressure in CVT
and it must also lie at low speeds.
4. What is the function of the hydraulic piston?
The friction of the belt pulley ensures the torque transmission,
the value of friction depends on oil pressure which presses the hydraulic
piston.
5. What is the special feature of the Audi CVT transmission?
Audi uses a chain instead of a belt.
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Additional Information
Reference books ISBN Order number
Automotive handbook) (25th edition) 978-38348-01388 1 987 723 001
Automobile electricals,Automobile electronics (4th edition)) 978-35282-38728 1 987 723 501
Gasoline engine management 978-38348-00376 1 987 723 504
Safety systems and comfort
and convenience system (3rd edition)) 978-35282-38735 1 987 723 503
Diesel engine management 978-35281-38752 1 987 723 502
Gasoline engine management
Emission technique for spark-ignition engines 978-3-86522-000-41 987 722 020
Gasoline injection system K-Jetronic 978-3-86522-001-11 987 722 009
Gasoline injection system KE-Jetronic 978-3-86522-002-81 987 722 021
Gasoline injection system L-Jetronic 978-3-86522-003-5 1 987 722 010
Gasoline injection system Mono-Jetronic 978-3-86522-028-81 987 722 033
Ignition in spark-ignition engine 978-3-86522-006-61 987 722 030
Gasoline engine management –
basic principles and components) 978-3-86522-004-21 987 722 036
Gasoline engine management - Motronic Systems 978-3-86522-005-91 987 722 029
Diesel engine management
Diesel in-line fuel-injection pumps 978-3-86522-013-4 1 987 722 057
Diesel engine management at a glance 978-3-86522-007-3 1 987 722 058
Helix-controlled diesel distributor-type injection pumps 978-3-86522-012-7 1 987 722 014
Solenoid-controlled diesel distributor-type injection pumps 978-3-86522-008-0 1 987 722 059
Diesel injection system) Unit injector / Unit pump system 978-3-86522-009-7 1 987 722 056
Electronic diesel control EDC 978-3-86522-011-01 987 722 035
Diesel-Accumulator Common Rail (CR) injection system 978-3-86522-010-31 987 722 062
Exhaust-gas technology for diesel engines 978-3-86522-082-0 1 987 722 061
Safety systems and comfort and convenience systems)
Conventional and electronic brake systems 978-3-86522-014-1 1 987 722 023
Driving stability systems 978-3-86522-015-8 1 987 722 026
Safety systems and comfort and convenience systems) 978-3-86522-019-6 1 987 722 037
Audio, Navigation and Telematics 978-3-86522-020-21 987 722 032
Adaptive cruise control ACC 978-3-86522-018-9 1 987 722 034
+Electronic transmission Control EGS 978-3-86522-026-4 1 987 722 027
Commercial vehicle compressed air systems(1): Fundamentals,
systems and drawings 978-3-86522-016-5 1 987 722 015
Commercial vehicle compressed air systems(2): Devices 978-3-86522-017-2 1 987 722 016 Additional information on the topics
Automobile electricals / automobile electronics
Batteries and vehicle electrical systems 978-3-86522-024-0 1 987 722 003
handled in this training program as
Generators and starting systems 978-3-86522-025-7 1 987 722 028 well as other topics of interest can
Lighting technology and wind shield and rear-window cleaning 978-3-86522-023-3 1 987 722 039
Micro-electronics in the automobile 978-3-86522-022-6 1 987 722 022 be found in the following
Sensors in the automobile 978-3-86522-021-9 1 987 722 031 publications by Robert Bosch
Networking in automobile 978-3-86522-276-3 1 987 722 067
Hybrid drives, fuel cells and alternative fuels 978-3-86522-277-0 1 987 722 065 GmbH. They can be procured from
publishing houses.

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Instruction leaflet for occupational safety

Call 123 in case of injuries.

Please do not alter or reset the settings on the training vehicles.

Guidelines for PL location visitors

• AUTOMATIC TRANSMISSION (AT) • Maintenance / Diagnosis

• Overview / Design • Summary

• Torque converter • DUAL CLUTCH GEARBOX

• Oil pump • Overview / Design

• Planetary gear • Clutch systems

• Switching elements • Gearbox unit

• Mechatronics module • Oil circuit

• Maintenance / Diagnosis • Maintenance

• AUTOMATED SHIFT • CONTINOUSLY VARIABLE

• Clutch actuator • Components

• Selecting and engaging a gear • Maintenance

• Transmission sensors • Summary

• AUTOMATIC TRANSMISSION (AT) • Maintenance / Diagnosis

• Overview / Design • Summary

• Torque converter • DUAL CLUTCH TRANSMISSION

• Oil pump • Overview / Design

• Planetary gear • Clutch systems

• Switching elements • Gearbox unit

• Mechatronics module • Oil circuit

Overview of the automatic transmission

Double clutch Automatic Continuously

Actuators ECU Actuators Sensors Variator with belt

Clutch actuator with Electro-hydraulics Electronics Hydraulics

• AUTOMATIC TRANSMISSION (AT) • Maintenance / diagnosis

• Overview / Design • Summary

• Torque converter • DUAL CLUTCH TRANSMISSION

• Oil pump • Overview / Design

• Planetary gear • Clutch systems

• Switching elements • Gearbox unit

• Mechatronics module • Oil circuit

Automatic transmission (AT)

ZF 6-speed 6HP26 (BMW) since 2003

Mercedes 7-speed Tronic Mercedes 7-speed Tronic Plus

Automatic transmission (AT) - Characteristics

 Hydrodynamic converter as drive-off element

Structure of a modern automatic transmission (AT)

1. Name the parts of the torque converter!

Torque converter - Functional principle

The ventilator is switched on and rotating (left). If

Torque converter - Structure and function

1. Name the main parts of the torque converter!

Torque converter - converter clutch

Oil supply / converter clutch closed

1. Which type of the oil pump is used in the range of AT transmission?

Planetary gear - Basic principle

Simpson-Planetary wheel set

Ravigneaux-planetary wheel set

Lepelletier-planetary wheel set

Planetary gear – Ravigneaux-planetary wheel set (7-speed Tronic)

Planetary wheel set – Mercedes 7-speed Tronic

1. Short planetary wheel

Ravigneaux-wheel set Simple wheel set

Switching elements – multi-disk clutch

Mercedes 7-speed Tronic

Switching elements – Brakes

1. Which types of brakes are used?