4 Speed Automatic Gearbox with Electrohydraulic control Construction and Operation Self Study Programme No. 112 VAG | Service Department.4 Speed Automatic Gearbox for VW and Audi To fulfil the requirement: for: © reduced fuel consumption 0 lower exhaust emission 9 quieter running 0 good position in market a fully automatic four speed automatic gearbox was developed Advantages of the new gearbox © Better acceleration and hillclimbing with the wider range of ratios 0 Lover consumption through deletion of converter slip © Pcssibility of selecting economy and sports driving programnes © Quieter running by reduction of speed level © Four wheel drive compatible © Simplified repairs © Reduced range of partsContents Introduction and operation Gearbox layout Torque converter Planetary gears Power flow System layout Information senders Actuating units Self diagnosis Current flow diagram Detailed testing and repair instructions are given in the Passat Workshop Manual 1989, Automatic Gearbox 096 Booklet Edition 05.89.Selector lever positions Gearbox output locked mechanically Reverse Neutral, no torque transmission Forward range, all 4 gears change autonetically Forward range, 3 gears change eutomaticelly, 4th geer is not used = Forward range, Ist and 2nd gears change automatically, 3rd and 4th are not used 1 = Forward range, only the 1st geer is used nreozne Programme selection Near the selector lever is the ECO/Sport button with sport light Witn this button the driver can choose between a consumption oriented (Economy) and an output oriented (Sporty) driving programme. ECO = Light "OFF" Sport = Light "ON" Kickdown The kickdown switch is integrated in the accelerator Bowden cable and is actuated when the pedal is pressed past. the full throttle point. When switch is actuated the shift points are altered by the control unit. Starting The engine can only be started in P or N. Tow starting The engine cannot be sterted by pushing or towing the vehicle. With an automatic box this is not possible because the necessary operating oil pressure from the ATF pump is only present when the engine is running. ‘Towing The vehicle can be towed with the lever in position N. The speed must not be higher than 50 kn/n and the distance not more then 50 km. For lerger distances the vehicle must be lifted at the front, because when engine is not running the rotating parts in the gearbox sre not lubricated. 4ECO/Sport button ECO/Sport Light - é | ! | | | ! | Magnet for selector lever lock Selector lever lock The lever positions P, R and 1 are locked mechanically. The lock is released by pressure on the button on side of lever. When ignition is switched on a magnet (Shiftlock) prevents the lock from releasing. In order to move lever from "P" to "R" and from "N" into the driving ranges, the brakes must be operated, Vie the brake light switch the Digimat control unit is informed that the brake pedal has been operated and the magnetic lever lock is released.Introduction and operation Within the selected driving range ali re shifted automatically nd an electranie contro The shifting. ts done by an electronyd piece gearbox housing reharge ae with the Inthe yea @ the anc parts of the planetary gearbox Valve body Plate clutches Pinte brates Gearbox versione nelp co reduce ta and increnee the ease of CED win ‘GERMANY. ‘VOSS 521103 AC. Speads drive \ \ \ \ Wureafunction evaten 1 \ \ 1 ATF oi panGearbox Layout Planetary gears Stator support ATF pump Torque converter Final driveThe torque converter has two power circuits, a hydraulic one and ¢ mechonical one which bridges the converter slip. The stator support prevents the freevheel from turning Tne torque converter is mounted on the stator support. The ATF pump 3s a cear type pump. The planetary gears The core of the planetary gearbox is a Ravigneaux planetary gear set with three plate clutches end two plate brakes. The pinion crive shaft From the helicel output gear on the planetary gearbox the drive goes to the helical geer on the pinion shaft. The parking lock gear is also on this shaft. The final drive consists of @ helically toothed pinion and crown heel and a bevel gear differentiel with two planetary gears without locking function. Output to the wheels via drive shafts.Tn the torque converter there is eluays usp oF inpeller (Engine speed) and the Soin off the daferance ts roast verter is working in its Targest torque range. AS speed incre evolutions of pump end turbine equalize mare and mare. In order to reduce tte fuel consuaption thit is to make deiving mare econamical, the torque ie dridged over (acked) anda direct comection between engine ené gearbox 13 nade. 1d d:fferance between the ne (Gearbox input). Uhen Stator Pomp wheel Turbine I Concarter code Teeters “= rive for AIF pump ' 1 / I <7, 1 | 1 | | ' Pump shat reine shast Torsion damper for converter lack op The converter fed construction and hae only been cut open for fs, The allocetion of the converter depends on the gearbox, sdepted to the ongine Fitted. If there is visible comoge OFHydraulic power flow Engine --> pump--> turbine-->stator with freewheel support turbine shaft--> plate clutches Ki and k2. KL K2 Turbine shaft Drive for ATF pump freewheel support In 1st, 2nd and 3rd gears the engine torque is transmitted hydraulically anc load dependent via the converter to the planetary gearbox. The plate clutches K1 and k2 are connected to the turbine of the corverter. 12Mechanical power flow Engine--> pump shaft--> plate clutch «3 K3 Punp shaft In 3rd gear the torque is transmitted mechanically load-dependent or by by-paseing the converter vie the pump shaft ta the plate clutch K3. The 4th gear works mechanically via the pump shaft and the plate clutch K3. 13Sell sun The planetary gearbox consists mainly of: 1 Planetary gear sot 2 Plate clutches fing gear 2 Plate brakes. and 1 Roller freewheel The planetary gear set consists oft One simak and ene large sun gear, B'short and 3 long planet goers fang tho alanet corricr ard ring gear ‘The plate clutches and plate brakes fare operates hydraulically fron ute velve bod between converter and planetary gears. when Smell oun is deiyen. The lerge sev is detv fokes it possible to hold the Lerge sun. ‘The dicect clutch K'3 drives the plarat eaerier, which con be held with brake @ ‘The output takes place via the ring gear. They provige the pover flow clutch 1 is operavee tne luteh K 2, ond brake © 2 4 Inpulee whos for Kn rood speed sensor ke Long planet: gear Planet carrier \ / Short planet: gear \ aL Ralier fremeent Be Large sun‘The ATF pump 4s 2 specim. type gear pun. Zt is driven fron the corverter inpelier eng supplies tie volve body ene sift conponerts ith ATF ofl, volve body / targe sun ‘The valve body Gistributes the pressure created by the AIF pump to the smife components eecoreing to he orders ‘The manual valve 5 operated by the selector lover. supplies the shifting valves in the valve body with ATF oi2 pressure. Solenoid valves Nonvel valve With the manual valve the following gears Raverse © 1st gear anrual_ ond 0 ard gear hydraulic can be shifted without the control unit. The vebicle con be driven in these 3 gears Diginat control unit Multa-fune switeh 16This is how it works The selector lever ceble gives the Digimat control unit information about the position of the selector lever via the multi-function switeh. At the same tine the selector lever cable ond 0 rod operate the monvel valve in the valve body. The manual valve is thus moved into @ basic position, in which, in lever position "0", the full automatic progranme is available. The Digimat control unit switches the solenoid valves in the valve bocy according to the input signals from its information senders (e.g. road speed sensor, load potentioneter ...) The solenoid valves operate shifting valves in the valve body which supply ATF oil pressure to the shift components (plate clutches and brakes) in the gearbox. Via the shift components the engine torque is transmitted to the planetary gears. 7Short planet gare Planet carrier 18 nel Power flow Punp-Long planet gears 2, x L Ring goer ‘Sea. un Turbine shat ergs een | Short planet gears Selector lever position “D” 2nd gear and “2nd gear manual” The clutches K 1 and 2 a1 fprecsure from the manual valve: Vin solenoid valve EV 4 the clutch K 2 is switched to no pressure + The brake B 2 is operated by soleneid valve EY 2 and holds the Large sun jppliod with Power flow Punp—-> turbine-> turbine shaft--> clutch K 1 amol1 sun--> short plenet gears--> the Leng planet gears roll. round the large aun and drive the ring gear. 2L Aing gear Pump shaft || Selector lever position “D* 3rd gear mechanical 1 The control unit actustes solenoid valve EY 3. Thie closes the Girect clutch K 3 ord drives the planet carrier. The clutches K 1 and K'2 are switched by the menvol valve, the planetary geer set. is thus blocked and orks’ es a Solid unit. Pover transmission takes place via the diroct clutch K 3. Power flow Pump-> eluteh K 2--> planet corier--> planetary goor set 24 25i m the plaeat carrier and the large. Power flow Pump shoft—> eirect clutch K 3--> plonet carrier, the tong ring ‘rool round the large sun and drive the arong pleret gears Selector lever position “R” 2 800 The brake 8 1 rol. possibilities Power flowSail oun Long planet: gears Planet cerricr I Short planot gears Selector lever position “1” manus In lever position *I* the 1st gear ie shifted Vie the manual valve, The manutl valve actuates the eluten K'i end the brake 8 1. Other control | possibilities are blockes. Power flow Pusp-—> turbine--> wxbine shaft: cluten K'1--> sell sun--> short planet gears--> the long planet gears drive the ring gear The brake 6 1 helea the planet. cerrier 90 thet secoleration and over run oparation i= possible in ist. gear meewol atThe control unit J 217 Is mounted in the vehicle away from the gearbox. Tt processes the signals from the information senders (sensors) and controls the actuating units according to the signels Teceived. The Cigimat control unit is equipped with Self diagnosis end is suitable for the Rapid Data Transmission (V.A.G 1551). If the control unit or its voltage supply fail or if the solenoid valves become feulty when driving the gearbox continues to function in an emergency mode.The throttle valve potentiometer G 69 4s located on the carburation unit. It is fixed to and operated by the throttle. It gives the Digimat control unit continuous information about the Position of the throttle valve The following system functions are controlled by the throttle valve potentiometer: © the shift pointe © the main pressure © cptimum gearshift transition The throttle valve potentiometer has @ second slip ring which, on veticles with Digifant injection systems, replaces the idling and full throttle switch. ‘The road speed sensor G 68 is located in the gearbox housing. It senses the speed in the gearbox via the teeth on the impulse wheel. This speed signal is required by the Digimat control unit to initiate the gear shifting end to give smooth geer changes.The multifunction switch F 125 is located on the gearbox housing, is operated by the selector lever and has the following functions: 0 Transmitting the selector lever position to the Diginat control unit 0 Switching on the reversing lights 0 Blocking the starter when a driving range is engaged 0 Providing information about the switching on and off of the cruise control system The engine speed is given to the Digimet control unit from the Hall sender in the distributor via the engine control unit. It is required ac a replacement paraneter for a faulty Toed speed sensor. 36The kickdown switch F 8 is integrated in the accelerator Bowden cable and is actueted when the pedel is depressed past the full throttle point. When switch is operated the geershifts take place at a higher kickdown shift point and in addition downshifts ere initicted. ‘The ATF temperature feeler G 93 The ATF tenperature feeler is located on the valve body in the ATF oil. It monitors the ATF temperature continuously. When a certain tenperature limit is exceeded the gearshifts take place at higher engine speeds. With the higher engine speed the converter slip is reduced and this lowers the ATF temperature. As soon as the ATF temp- erature has dropped, the normal driving programme is resuned ATF temperature fecler 37‘The brake light switch F The brake Light switch is located on the pedal cluster. The information about pedal operetion is required for the Shiftlock function. The Eco/Sport button is located near the selector lever. Each time the button is pressed the system switches between Sport and Eco programme. When the engine has been started again the last programme selected is switched on end is indiceted by the sport. light. 38Solenoid valves in valve body N 88 - N 93 In the valve body on the gearbox there are 7 solenoid valves, which are controlled from the Digimat control unit and direct the oil pressure created by the ATF pump via the shift valves. The solenoid valves EV 1 to EV 4 supply oil pressure to the plate clutches and brakes. Ihe gearshift transitions are influenced by the solenoid volves EV 5 and EV 7. The modulation valve EM G regulates the main pressure in the valve body. The main pressure is created via the electrical current in the moduletion valve depending on gear, the shift progranme Eco/Sport, the load and the speed. With a small current 2 higher main pressure is created and vice versa. Ev2 EVIEV> EVS evo BVT EM6 39The switch for selector lever lock N 110 The electromagnet receives current fron terninal 15 and earth from control unit according to the information from the brake Light switch. When brekes are operated the earth is interrupted and the selector lever lock released. Relay for starter inhibitor and reversing light J 226 The reversing light and starter relay is in the central fuse and reley plate and is @ combined reley. The reversing relay switches the reversing lights. The starter relay makes starting possible only in P and N. to the reversing lights to starterEngine control unit During the goarshifting operation the Digimat control unit gives the engine control unit the information "Retard igrition". The engine comtrol unit moves the ignition in the retard direction which reduces the engine torque. When gearshifting operation is ended the engine control unit moves the ignition timing back to normel value, The Eco/Sport light is located is the small cluster Eco/Sport buttons, Eco/Sport light which is near the selector lever. The light comes on in the Sport programme 41The cruise control system J 213 gots ite supply voltage via the Digimat control unit. Input conditions are z forward driving tenge end a speed which has once exceeded 2 mininum of 30 km/h. The Diagnosis sockets are located under the cover in front of the selector lever. The K lead is for the rapid dete trancmission between the Oigimat control unit end the V.A.G 1551. The L lead serves to initiate the Fault display with the flash code and test Lemp.The Digimat control unit has Self diagnosis with permanent memory. Stored faults are retained even when the battery is disconnected. The Self diagnosis monitors the electrical signals fron the information senders and to the actuating units end carries out a self check of the Digimat control unit. Voltage supply With the Self Diagnosis one cennot check whether the individvel informeticn sencers and ectuating units are working properly mechanically. When reading the Fault menory display end then eliminating the faults one must take into account components which could be indirectly connected with the indicated faults. For example with the fault: "No signal from road speed sensor G68" The fault can be, as in most cases, a defective sensor or a faulty wire. The fault will however also be indicated with a defective or loose inpulse wheel for the road speed, slipping clutches or a too low ATF main pressure. In all three cases the control unit will receive faulty signals.es—s 2—J al® ale 2 2 Sy —s & | 3 @) aL ahs aa 5 (ies | ae 3 Now Noo Nor Ne Neo Nor 3% 7 Bw» BP Om 2 DM v