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1 BL AUTOMATIC TRANSMISSION (AISIN 30-40 LEi) CONTENTS 2 1. SPECIFICATION 2. SYSTEM CONSTRUCTION 3. SYSTEM LAYOUT 4. POWER FLOW 5. COMPONENTS 6. SHIFT LOCK DEVICE INSTALLATION 7. ELECTRICAL CONTROL PARTS 8. HYDARULIC CONTROL SYSTEM 9. ELECTRONIC CONTROL 10. DIAGNOSIS 11. WIRING DIAGRAM 12. SHIFT PATTERN SPECIFICATION 3 General Specifications ENGINE A-2.5 TCI A/T Model 30-40LEi (AISIN AW) General 4 speed transmission (Full line pressure control) Maximum input torque (kg.m) Weight (kg) Torque converter Type Dia. (mm) ATF oil ATF capacity (liter) Adapted vehicle 3 Elements 1 Stage 2 Phases 254 3 Clutches, 4 Brakes, 3 OWCs Planetary gear Shift mode 35 79.8 Components Gear ratio 3.5 V6 3 Planetary gear sets (Simple type) 1,2,3,4/R 2.804, 1.531, 1.000, 0.705 / 2.393 P-R-N-D-2-L / SNOW(2WD only) CASTLE AUTO FLUID D - I I 9.2 TERRACAN(HMC), CROWN(TOYOTA), VOLVO 960 SYSTEM CONSTRUCTION 4 Block Diagram Engine Shift lever Torque 토크 converter 컨버터 Oil pump Input shaft Sensors & switches SCSV A Valve body Clutch Inhibitor switch Control valves SCSV B OWC DCCSV Brake PCSV Accumulators Planetary gear Output shaft C U ECU Output sensor Input sensor Propeller shaft T Power flow Hydraulic flow Mechanical flow Electrical flow SYSTEM LAYOUT 5 1 2 7 6 3 5 8 9 4 1. Output speed sensor To detect output shaft revolution 2. Neutral switch To detect "N" range(A/T) or "Neutral" range(M/T) 3. Elbow (cooler out) Way-out from a cooler hose to the A/T 4. Elbow (cooler in) Way-in to the cooler hose from the torque converter 5. Air Breather hose For air ventilation inside transmission 6. Oil temp. sensor To detect the oil temperature 7. Input speed sensor To detect input shaft revolution 8. Outer lever Connected to the control cable to change driving range 9. T/M wire Solenoid valves and sensors connection POWER FLOW C2 C1 Components and function COMPONENTS FUNCTION C0 O/D direct clutch Connect O/D sun gear and O/D carrier C1 Forward clutch Connect O/D input shaft and input shaft C2 Direct clutch Connect input shaft and Fr/Rr planetary sun gear B0 O/D brake Hold O/D sun gear B1 2nd coast brake Hold Fr/Rr planetary sun gear B2 2nd brake Hold counterclockwise rotation of Fr/Rr planetary sun gear (Hold outer race of F1) B3 1st & reverse brake Hold Fr planetary carrier F0 O/D OWC Connect O/D sun gear and O/D carrier, when O/D sun gear rotates faster than O/D carrier F1 NO.1 OWC Hold counterclockwise rotation of Fr/Rr planetary sun gear, when B2 operates. F2 NO.2 OWC Hold counterclockwise rotation of Fr planetary carrier 6 POWER FLOW 7 Components and operation B3 B2 B1 C2 C0 B0 C1 IN OWC 1(F1) OD OWC(F0) OD INPUT SHAFT OWC 2(F2) OUT INPUT SHAFT OUTPUT SHAFT POWER FLOW Components and operation 8 POWER FLOW 9 Components and operation P O S IT IO N S O L E N O ID CLUTCH S1 S2 SL P ON › OFF~ OFF~ R (V < 7 ) ON › OFF~ R (V > = 7 ) ON › N D 2 L C0 BRAKE GEAR O .W .C . R A T IO C1 C2 B0 B1 B2 B3 F0 F1 F2 ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF ~ OFF~ - OFF~ ON › OFF~ ON › OFF~ OFF~ OFF~ ON ON › OFF ~ OFF~ 2 .3 9 3 ON › OFF~ ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ ON › OFF ~ OFF~ - | ON › OFF~ OFF~ ON › OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF~ OFF ~ OFF~ - | 1 st ON › OFF~ OFF~ ON › ON › OFF~ OFF~ OFF~ OFF~ OFF~ ON › OFF ~ ON OFF › ~ 2nd ON › ON › OFF~ ON › ON › OFF~ OFF~ OFF~ ON › OFF~ ON › ON OFF › ~ OFF~ 1 .5 3 1 3 rd OFF~ ON › ON › ON › ON › ON › OFF~ OFF~ ON › OFF~ ON › OFF~ OFF~ 1 .0 0 0 4 th OFF~ OFF~ ON › OFF~ ON › ON › ON › OFF~ ON › OFF~ OFF~ OFF~ OFF~ 0 .7 0 5 1 st ON › OFF~ OFF ~ ON › ON › OFF ~ OFF~ OFF~ OFF~ OFF~ ON › OFF~ ON OFF › ~ 2 .8 0 4 2nd ON › ON › OFF ~ ON › ON › OFF ~ OFF~ ON › ON › OFF~ ON › ON › OFF~ 1 .5 3 1 3 rd OFF~ ON › OFF ~ ON › ON › ON › OFF~ OFF~ ON › OFF~ ON › OFF~ OFF~ 1 .0 0 0 1 st ON › OFF~ OFF ~ ON › ON › OFF ~ OFF~ OFF~ OFF~ ON › ON › OFF~ ON 2nd ON › ON › OFF ~ ON › ON › OFF ~ OFF~ ON › ON › OFF~ ON › ON › OFF~ › › | 2 .8 0 4 2 .8 0 4 1 .5 3 1 POWER FLOW 10 Principle of each range 3rd gear 1st /2nd gear C1 O/D C1 Fr / Rr Direct Speed coupling reduction 1. Power flow OD input shaft ÆOD gear set(coupling by C0) ÆFr/Rr (speed reduction by F2(1st gear), by B2&F1(2nd gear)) 2. Engine brake - D range 1st,2nd gear: non(F2,F1 free to clockwise) - 2 range: 1st gear(non), 2nd gear(operated by B1) - L range 1st,2nd gear: operated by B1, B3 4th gear O/D Direct Direct coupling coupling 1. Power flow OD input shaft Æ OD gear set(coupling by C0) ÆFr/Rr (coupling by C1 & C2) 2. Engine brake - D & 2 range: operates Reverse gear C1 O/D Fr / Rr C1 Fr / Rr Speed Direct increase coupling 1. Power flow OD input shaft Æ OD gear set (speed increase by B0) Æ Fr/Rr (coupling by C1&C2) 2. Engine brake - D range: operates O/D Fr / Rr Direct Reversed coupling rotation 1. Power flow OD input shaft Æ OD gear set (coupling by C0) Æ Fr/Rr (reverse rotation by B3) 2. Reverse inhibition control: C2