8-Speed Automatic Transmission Diagnosis and...

122
Student Workbook 8-Speed Automatic Transmission Diagnosis and Repair

Transcript of 8-Speed Automatic Transmission Diagnosis and...

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Student Workbook

8-Speed Automatic TransmissionDiagnosis and Repair

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SAFETY NOTICE

Copyright © 2015 FCA US LLC

This publication’s purpose is to provide technical training information to individuals in the automotive trade. All test and repair procedures must be performed in accordance with manufacturer’s service and diagnostic manuals. All warnings, cautions, and notes must be observed for safety reasons. The following is a list of general guidelines:

• Proper service and repair is critical to the safe, reliable operation of all motor vehicles.• The information in this publication has been developed for service personnel, and can help when diagnosing and performing vehicle repairs.• Some service procedures require the use of special tools. These special tools must be used as recommended throughout this Technical Training Publication, the diagnostic manual, and the service manual.• Special attention should be exercised when working with spring- or tension-loaded fasteners and devices such as E-Clips, Cir-clips, snap rings, etc. Careless removal may cause personal injury.• Always wear safety goggles when working on vehicles or vehicle components.• Improper service methods may damage the vehicle or render it unsafe.• Observe all warnings to avoid the risk of personal injury.• Observe all cautions to avoid damage to equipment and vehicles.• Notes are intended to add clarity and should help make your job easier.

Cautions and warnings cover only the situations and procedures FCA US LLC has encountered

and advise the service trade of all conceivable ways in which service may be performed, or of the

undertaken any such broad service review. Accordingly, anyone who used a service procedure or tool that is not recommended in this publication, must be certain that neither personal safety, nor vehicle safety, is jeopardized by the service methods they select.

No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of FCA US LLC.

FCA US LLC reserves the right to make changes from time to time, without notice or obligation, in prices,

discontinue models. See your dealer for the latest information.

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8-Speed Automatic Transmission Diagnosis and Repair i

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1COURSE OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ACRONYMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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ii 8-Speed Automatic Transmission Diagnosis and Repair

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

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8-Speed Automatic Transmission Diagnosis and Repair iii

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8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 1

INTRODUCTION

COURSE OBJECTIVES

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2 8-Speed Automatic Transmission Diagnosis and Repair

ACRONYMS

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8-Speed Automatic Transmission Diagnosis and Repair 3

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4 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 5

LESSON 1

8-Speed Overview

2034-81_0001

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6 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 7

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8-Speed Automatic Transmission Diagnosis and Repair 9

L01_001

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10 8-Speed Automatic Transmission Diagnosis and Repair

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32034-81_0012

1 32 4

Page 19: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 11

1

2

2034-81_0224

1 2

Page 20: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

12 8-Speed Automatic Transmission Diagnosis and Repair

1

2

3

2034-81_0006

1 32

Page 21: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 13

1

2

3

L01_003

1 32

Page 22: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

14 8-Speed Automatic Transmission Diagnosis and Repair

1 2

2034-81_0002

1 2

NOTE: Mopar oil leak dye has not been approved for use with the 8- and 9-speed automatic

CAUTION: transmission in the center of the oil pan. The supports for the jack should be placed around the edge of the pan or rail.

Page 23: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 15

1

2

2034-81_0003

1 2

Page 24: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

16 8-Speed Automatic Transmission Diagnosis and Repair

90016656.ai

2

2034-81_0031

Page 25: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 17

L01_017

2

1

1 2

Page 26: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

18 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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Page 27: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 19

DEMONSTRATION 1

1.

Page 28: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

20 8-Speed Automatic Transmission Diagnosis and Repair

2.

Page 29: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 21

1.

2.

3.

Page 30: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

22 8-Speed Automatic Transmission Diagnosis and Repair

1.

2.

3.

4.

5.

6.

7.

Page 31: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 23

1.

2.

3.

4.

Page 32: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

24 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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Page 33: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 25

LESSON 2

Braking Rotating RatioA B C D EX X XX XX X X

X X XX X XX X X

X X XX X XX X XX X XX X

Page 34: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

26 8-Speed Automatic Transmission Diagnosis and Repair

Solenoid

(NC)

A

(NC)

B

(NC)

C

(NO)

D

(NO)

E

(NO)

TCC

(NC) (NO)X X X X

X X X X XX X X X XX X X X XX X X X XX X XX X XX X XXX X XX X X

Page 35: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 27

Solenoid

Current

Solenoids

Control

TCC

Low (mA)

Page 36: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

28 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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________________________________________________________________________________________________________________

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Page 37: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 29

ACTIVITY 1

1.

2.

3.

Page 38: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

30 8-Speed Automatic Transmission Diagnosis and Repair

1.

2.

Page 39: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 31

3.

Page 40: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

32 8-Speed Automatic Transmission Diagnosis and Repair

4.

5.

Page 41: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 33

6.

7.

8.

Page 42: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

34 8-Speed Automatic Transmission Diagnosis and Repair

9.

10.

Page 43: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 35

11.

12.

13.

Page 44: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

36 8-Speed Automatic Transmission Diagnosis and Repair

14.

15.

Page 45: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 37

16.

Page 46: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

38 8-Speed Automatic Transmission Diagnosis and Repair

1.

Page 47: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 39

2.

Page 48: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

40 8-Speed Automatic Transmission Diagnosis and Repair

3.

Page 49: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 41

4.

5.

6.

7.

8.

Page 50: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

42 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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Page 51: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 43

LESSON 3

Torque Converter

1

2

2034-81_0004

1 2

Page 52: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

44 8-Speed Automatic Transmission Diagnosis and Repair

1

2

2034-81_0013

1 2

Page 53: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 45

1

2

3

2034-81_0007

1 32

Page 54: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

46 8-Speed Automatic Transmission Diagnosis and Repair

4

1

2

5

3

2034-81_0009

1 42 53

CAUTION: The TCM can be damaged by electrostatic discharge (ESD). Always take precautions to avoid ESD when handling a valve body assembly. A wrist band grounding device is the most reliable method of diverting electrostatic discharge.

Page 55: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 47

15

3

4

2

2034-81_0010

1 42 53

NOTE: The oil pump cover bolts are made of lightweight aluminum alloy. These bolts MUST be replaced each time they are removed.

Page 56: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

48 8-Speed Automatic Transmission Diagnosis and Repair

3

12

4

2034-81_0005

1 32 4

Page 57: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 49

21 43 5 6 7 8

9

10

11

2034-81_0008

1 72 83 94 105 116

Page 58: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

50 8-Speed Automatic Transmission Diagnosis and Repair

3

1

2

2034-81_0025

1 32

NOTE: The snap rings must be replaced whenever they are removed.

CAUTION: The aluminum drums must be handled with care. Do not drop or dent the drums during service. Always inspect the drum carefully for excessive loss of metal around the snap ring retainer groove and for deformation.

Page 59: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 51

A B E C D

Holding Rotating{ {2034-81_0011

Page 60: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

52 8-Speed Automatic Transmission Diagnosis and Repair

1

2

3

2034-81_0023

1 32

NOTE:

Page 61: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 53

12 3

45

6

7

9

1011

121314151718 16

8

2034-81_0201

1 102 113 124 135 146 157 168 179 18

Page 62: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

54 8-Speed Automatic Transmission Diagnosis and Repair

Brake Clutch RatioA B C D EX X XX XX X X

X X XX X XX X X

X X XX X XX X XX X XX X

Solenoid

(NC)

A

(NC)

B

(NC)

C

(NO)

D

(NO)

E

(NO)

TCC

(NO) (NO)X X X X

X X X X XX X X X XX X X X XX X X X XX X XX X XX X XXX X XX X X

Page 63: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 55

1 2

45

3

2034-81_0215

1 42 53

Page 64: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

56 8-Speed Automatic Transmission Diagnosis and Repair

1 2 43 5

89

6

7

2034-81_0216

1 62 73 84 95

Page 65: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 57

2034-81_0202

Held

Rotating

Locked Rotating

Input

Output

4.714

DCEA B

P1 P2 P3 P40.000

4.714

Page 66: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

58 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0203

Held

Rotating

Locked Rotating

Input

Output

4.714

DCEA B

P1 P2 P3 P40.6670.000

3.143

Page 67: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 59

2034-81_0204

Held

Rotating

Locked Rotating

Input

Output

2.106

DCEA B

P1 P2 P3 P41.0003.000

2.106

Page 68: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

60 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0205

Held

Rotating

Locked Rotating

Input

Output

1.000

DCEA B

P1 P2 P3 P41.0000.5563.000

1.667

Page 69: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 61

2034-81_0206

Held

Rotating

Locked Rotating

Input

Output

1.285

DCEA B

P1 P2 P3 P41.2850.4643.000

1.285

Page 70: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

62 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0207

Held

Rotating

Locked Rotating

Input

Output

1.000

DCEA B

P1 P2 P3 P41.0001.0001.000

1.000

Page 71: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 63

2034-81_0208

Held

Rotating

Locked Rotating

Input

OutputDCEA B

P1 P2 P3 P40.8390.670

0.839

Page 72: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

64 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0209

Held

Rotating

Locked Rotating

Input

OutputDCEA B

P1 P2 P3 P41.0000.670

0.670

Page 73: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 65

2034-81_0210

Held

Rotating

Locked Rotating

Input

Output

4.714

DCEA B

P1 P2 P3 P4-1.0460.6700.000

-3.289

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66 8-Speed Automatic Transmission Diagnosis and Repair

Page 75: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 67

2034-81_0108

AC

E

HV-

A

CV-A

CV-B1

CV-C

CV-D

HV-

B2

CV-E

HV-

E

RED

-V

SOL

ASO

LLP

S

LP-V

SOL

CSO

L D

SOL

E

Cool

erLP

R-V

Pum

p Park

-V

Park

Cyl

SOL

Park

Pos-

V

PosD

-V

B1D

SOL

B

CV-B2

HV-

CH

V-D

TCC

SOL

TCC

TCC-

VSV

-TC

TC-V

Lubr

icat

ion

PR-V

TCH

2-V

Filte

r

RET-

V

TCH

1-V

Valve

Des

igna

tions

LP-V

Li

ne P

ress

ure

Valv

ePa

rk-V

Pa

rk P

awl R

elea

se V

alve

Pa

rk-C

yl P

ark

Paw

l Rel

ease

Cyl

inde

rR

ED-V

Pr

essu

re R

educ

ing

Valv

ePo

s-V

Posit

ion

Valve

PosD

-V D

efau

lt Po

sitio

n Va

lve

(Driv

ing

Def

ault

Mod

e)C

V-x

Clu

tch

Appl

y Va

lve

HV-

x H

oldi

ng V

alve

TC-V

To

rque

Con

verte

r Pre

ssur

e Va

lveTC

C-V

To

rque

Con

verte

r Clu

tch

Valv

eTC

Hx-

V To

rque

Con

verte

r Hol

ding

Val

vePR

-V

Prim

ing

Valv

eSO

L x

Sole

noid

LPR

-V

Lubr

icat

ion

Pres

sure

Rel

ief V

alve

SV-T

C

Switc

hing

Val

ve -

Torq

ue C

onve

rter

RET

-V

Line

Pre

ssur

e R

eten

tion

Valv

eR

B-V

Roc

ker B

all V

alve

HV-B1

RB-V

Conv

erte

r

Filte

r

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68 8-Speed Automatic Transmission Diagnosis and Repair

From Line Pressure Solenoid

To Main Line

To TCC, Prime, and Lube

1

3

2

4

5

2034-81_0214

1 42 53

Page 77: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 69

Filter

Lubrication

CoolerTC-V

TCH2-VTCH1-V

SV-TC

Converter

Reduced Solenoid Pressure

Regulated Line Pressure

TCC

TCC-V

SOLTCC

From LPS

Main Line Pressure

2034-81_0212

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70 8-Speed Automatic Transmission Diagnosis and Repair

Filter

Lubrication

CoolerTC-V

TCH2-VTCH1-V

SV-TC

Converter

Reduced Solenoid Pressure

Regulated Line Pressure

TCC

TCC-V

SOLTCC

From LPS

Main Line Pressure

2034-81_0213

Page 79: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 71

2034-81_0219

CTo Default Position Valve

HV-C

Regulated Line Pressure

VFS Control

CV-C

VB-V

SOL C

Page 80: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

72 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0220

HV-B2

B2

B1

Page 81: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 73

Stage 1 Stage 2 Stage 3

Clutch Pressure

CV-B1

B1

CV-B2

HV-B1

SOL B

B2

2034-81_0221

Page 82: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

74 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0223

PS Cyl

Park HoldSolenoid

RET-V

Park-V

SOLPark

RED-V

From C Clutch

Page 83: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 75

2034-81_0222

Park Position Reverse/Neutral Position Forward Position

PosD-V

Pos-V

System Pressure

From Park Solenoid

To C/D/E Clutch Valves

From Clutch C or Evia Shuttle Valve

Page 84: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

76 8-Speed Automatic Transmission Diagnosis and Repair

C E

CV-C CV-D CV-E

HV-E

RED-VSOLLPS SOL C SOL D SOL E

Park-V

Park Cyl

SOLPark

Pos-V

PosD-V

D

HV-C HV-D

RET-V

RB-V

From Pump

2034-81_0234

Page 85: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

8-Speed Automatic Transmission Diagnosis and Repair 77

A C E

HV-A

KV-A CV-B1 CV-C CV-D

HV-B2

CV-E

HV-E

RED-V

SOL ASOLLPS

LP-V

SOL C SOL D SOL E

CoolerLPR-V

Pump

Park-V

Park Cyl

SOLPark

B1 D

SOL B

CV-B2

HV-C HV-D

TCC

SOLTCC

TCC-VSV-TC

TC-V

Lubrication

PR-V

TCH2-V

Filter

RET-V

TCH1-V

HV-B1

RB-V

Converter

Filter

Pos-V

PosD-V

1

2

2034-81_0235

Page 86: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

78 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

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8-Speed Automatic Transmission Diagnosis and Repair 79

DEMONSTRATION 2

1.

2.

3.

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80 8-Speed Automatic Transmission Diagnosis and Repair

4.

1.

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8-Speed Automatic Transmission Diagnosis and Repair 81

2.

3.

4.

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82 8-Speed Automatic Transmission Diagnosis and Repair

1.

2.

3.

4.

5.

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8-Speed Automatic Transmission Diagnosis and Repair 83

6.

7.

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84 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 85

2034-81_0017

T C M

Power Actuator Supply

Actuator Supply

SOL - D SOL - B SOL - E SOL - CTCC SolenoidLine Pressure SolenoidPark Release Solenoid

Park Hold Solenoid

Temperature Sensor

“Park”Signal

+

_

Signal

Sensor Ground

OSSISS

Park Lock“Not Park” Position Sensor

SOL - A Ground

CAN-CBUSDedicatedCAN BUS

Ignition

CAN 1 HICAN 1 LOCAN 2 HICAN 2 LO

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86 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 87

3

1 22034-81_0019

1 32

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88 8-Speed Automatic Transmission Diagnosis and Repair

1

2

2034-81_0018

1 2

NOTE: The TCM internal temperature sensor can be viewed on the scan tool.

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8-Speed Automatic Transmission Diagnosis and Repair 89

1 2

2034-81_0020

1 2

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90 8-Speed Automatic Transmission Diagnosis and Repair

87

65

43

21

9

Solenoid A = Normally ClosedSolenoid B = Normally ClosedSolenoid C = Normally OpenSolenoid D = Normally OpenSolenoid E = Normally OpenTCC Solenoid = Normally ClosedLine Pressure = Normally OpenSolenoid

2034-81_0225

1 62 73 84 95

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8-Speed Automatic Transmission Diagnosis and Repair 91

Battery

ElectronicShifter Module

TransmissionControlModule

Dedicated

CANBUS

CAN-CBUS

Battery

Ground

Ground

IGN

_

+

_

+

_

+

_

+TRS Park Signal

To Other Modules

1

67

98

10

34

56

15

14139

1015

16

118

4

5

2

79

14

13 12

1

6

3

6 10

1 5

2034-81_0021

ESM Connector

TCM Connector

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92 8-Speed Automatic Transmission Diagnosis and Repair

L04_006

BATTERY

ASSEMBLY-POWERDISTRIBUTIONCENTER

CONNECTOR-CAN CDASH

MODULE-BODYCONTROL

IGNITIONOFF/RUN/

STARTCONTROLOUTPUT

IGNITIONOFF/RUN/

STARTCONTROLOUTPUT

DATABUS(+)ESHIFT

DATABUS(+)ESHIFT

CANC(+)

FUSE94

11

A1950.5

BR/RD

A1900.8

YL/RD

10A

FUSE-5715A

A0

19

1 2

C7 C3

INLINE-BODY/IP

INLINE-BODY/ENGINE

17

13

17

SP2284

CANC(-)

C3 C1 C124 2

2

2

15

D300.8YL

D290.8

VT/WT

20

20 29

29

INLINE-DASHRIGHT/ENGINE

INLINE-DASHRIGHT/ENGINE

INLINE-DASHRIGHT/IP

CONNECTOR-STARTCAN CIP

D4410.8

WT/OR

5 6

4

CANC(+)

CANC(-)

CANC(-)

CANC(+)

FUSEDB(+)

FUSEDB(+)

Z9110.5BK

F10.8

PK/WT

T8240.8

YL/DB

26

26

9

MODULE-RADIOFREQUENCYHUB

TRSPARK

SIGNAL

TRSPARK

SIGNALMODULE-TRANSMISSIONCONTROL

MODULE-ELECTRONICSHIFT

DATABUS(-)ESHIFT GROUND

14

Z9081.0BK

GROUND

G212

31

312

81

10

9

1 C6

5

5

6

6

6 7

D4400.8

WT/BR

3

22

22

D4410.5

WT/OR

D4300.35YL

D4400.5

WT/BR

DATABUS(-)ESHIFT

CANC(-)

CANC(+)

D4290.35GY

G206

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8-Speed Automatic Transmission Diagnosis and Repair 93

SISP

Selection of Driving Program

Choice Of Gears

ESCProgramSwitch

SelectorLever

ManualSelection

Fast-offDetection

CornerDetection SVD

Warm-up HighTemperature

City DrivingDetection

RollingResistanceDetection

Low FrictionDetection

CruiseControl

Driver TypeAssessment

Drive-off Engine Torque Kick-down Longitudinal

AccelerationLateral

Acceleration

2034-81_0226

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94 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 95

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96 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

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8-Speed Automatic Transmission Diagnosis and Repair 97

ACTIVITY 2

ANALYZE COMMUNICATION CIRCUITS

1.

2.

3.

4.

5.

6.

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98 8-Speed Automatic Transmission Diagnosis and Repair

7.

8.

9.

10.

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8-Speed Automatic Transmission Diagnosis and Repair 99

Notes: _________________________________________________________________________________________________________

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100 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 101

LESSON 5

2034-81_0001

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102 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

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8-Speed Automatic Transmission Diagnosis and Repair 103

ZF 8 Speed Automatic Transmission Diagnostic Worksheet

Dealer Name:

Last 8 Digits of VIN:

Transmission Software Level:

Vehicle Model:

Dealer Code:

Date of Complaint:

Customer Complained Of:Shift Quality

Contact Name:

Phone # & Fax #:

RO #: Mileage:

Repeat Complaint: Yes No

Vehicle Build Date: Vehicle Sale Date:

Engine Software Level:

Transmission Model No. 1090 (e.g. 1090 010 020)

Transmission Serial No:

Function

Noise

Limp Mode

Leak

Other

Defect Details:

NoYesTransmission / Vehicle Fault Codes Registered:

Codes Registered:

Transmission Identification Plate: Is engraved onto the Left Hand side of the transmission casing

ZF - APPROVAL CONFIRMATION:

Approval Number:

Approval Date:

Component to be Dispatched:

Component Dispatch Date:

Print Form

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104 8-Speed Automatic Transmission Diagnosis and Repair

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8-Speed Automatic Transmission Diagnosis and Repair 105

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106 8-Speed Automatic Transmission Diagnosis and Repair

8HP

45

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8-Speed Automatic Transmission Diagnosis and Repair 107

P4 Carrier/Output Shaft + Clutch D

Disc Pack 4 / 4

Oil Pum

p + Clutch A

Disc Pack 5 / 5

Clutch E

Disc Pack 6 / 6

Clutch C

Disc Pack 6 / 6

D Clutch Drum

Clutch B

Disc Pack 5 / 5

Transmission Housing

Parking Pawl

Valve B

ody Assem

bly + TCM

A

Torque Converter

P4 Annulus + P4 Annulus Drum

P4 Sun Gear +

C/E Clutch Drum

P3 Carrier

P3 Annulus

P2 AnnulusP3 Sun G

ear

P1 Annulus

P1/P2 Sun Gear

P2 Carrier

P1 Carrier

Extension Housing

Oil P

an/Filter Assem

bly

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108 8-Speed Automatic Transmission Diagnosis and Repair

2034-81_0240

pistons

valves

valvesvalve

screen

adaptervalvefilter

pressure springpiston

ballsballs

ball

rocker ball

2034-81_0242

SOL

Park

Hold

Park

Cyl

LP-V

RED-V

SV-TC

TCC-V

CV-B1

HV-B1

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8-Speed Automatic Transmission Diagnosis and Repair 109

2034-81_0243

TC-V

Pos-V

PosD-V

HV-B2CV-B2

HV-AHV-D

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110 8-Speed Automatic Transmission Diagnosis and Repair

Notes: _________________________________________________________________________________________________________

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8-Speed Automatic Transmission Diagnosis and Repair 111

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112 8-Speed Automatic Transmission Diagnosis and Repair

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WORLDWIDEThe special service tools referred to herein are required for certain service operations. These special servicetools or their equivalent, if not obtainable through a local source, are available through the following outlet:

Telephone 1-855-298-2687 2801-80th Street Kenosha, WI 53143, U.S.A. FAX 1-855-303-8985

Page 122: 8-Speed Automatic Transmission Diagnosis and Repairperception.fcaperformanceinstitute.com/FCARepository_con/topic... · 14 8-Speed Automatic Transmission Diagnosis and Repair ô r^

81-699-15023 Rev. 12/15/15

2016