Automatic Transmissions and Transaxles (Halderman Automotive Series)

314 Pages·2017·118.358 MB·English

by  James Halderman

Automatic
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JIM HALDERMAN brings a world of experience, s

knowledge, and talent to his work. His automotive service a
experience includes working as a flat-rate technician, n
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a business owner, and a professor of automotive
Seventh Edition
technology at a leading U.S. community college for more T
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than 20 years. a
n
s James D. Halderman
He has a Bachelor of Science Degree from Ohio Northern
a
University and a Master’s Degree in Education from Miami x
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University in Oxford, Ohio. Jim also holds a U.S. Patent for an electronic transmission e
control device. s

He is an ASE certified Master Automotive Technician and Advanced Engine H
a
Performance (L1) ASE certified. Jim is the author of many automotive textbooks all l
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e
published by Pearson Education Publishing Company. r
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ISBN-13: 978-0-13-461679-7
ISBN-10: 0-13-461679-0
9 0 0 0 0
www.pearsonhighered.com 9 780134 616797
AUTOMATIC
TRANSMISSIONS
AND TRANSAXLES
S E V E N T H E D I T I O N
James D. Halderman
330 Hudson Street, NY NY 10013
A01_HALD6797_07_SE_FM.indd 1 10/11/16 3:49 pm
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Library of Congress Cataloging-in-Publication Data
Names: Halderman, James D., author.
Title: Automatic transmissions and transaxles / James D. Halderman.
Description: Seventh edition. | Boston : Pearson Education, Inc., [2017] |
Includes index.
Identifiers: LCCN 2016040963 | ISBN 9780134616797 (alk. paper) | ISBN
0134616790 (alk. paper)
Subjects: LCSH: Automobiles—Transmission devices, Automatic. |
Automobiles—Transmission devices, Automatic—Maintenance and repair.
Classification: LCC TL263 .H30 2017 | DDC 629.2/446—dc23 LC record available at
https://lccn.loc.gov/2016040963
10 9 8 7 6 5 4 3 2 1
ISBN 10: 0-13-461679-0
ISBN 13: 978-0-13-461679-7
A01_HALD6797_07_SE_FM.indd 2 16/11/16 1:15 PM
Preface
Professional Technician series Part of the 7. All terms used adhere to the SAE J1930 standard.
Pearson Automotive Professional Technician Series, the seventh 8. Unlike other textbooks, this book is written so that the
theory, construction, diagnosis, and service of a particular
edition of Automatic Transmissions and Transaxles represents
component or system is presented in one location. There
the future of automotive textbooks. The series is a full-color,
is no need to search through the entire book for other
media-integrated solution for today’s students and instructors.
references to the same topic.
The series includes textbooks that cover all eight areas of ASE
certification, plus additional titles covering common courses.
The series is peer reviewed for technical accuracy. ase and naTef correlaTed NATEF-certified
programs need to demonstrate that they use course material
UPdaTes To The sevenTh ediTion Based on con- that covers NATEF and ASE tasks. All Professional Technician
versations and recommendations from automotive instructors textbooks have been correlated to the appropriate ASE and
and reviewers, the following updates have been incorporated in NATEF task lists. These correlations can be found in the
the new seventh edition: appendix.
1. Automatic transmission/transaxle hydraulic systems has
been greatly expanded and then split in to three chapters
a comPleTe insTrUcTor and sTUdenT
to make teaching and learning hydraulic systems easier:
sUPPlemenTs Package All Professional Technician
■■ Automatic Transmission Fluid, Filters And Coolers—
Chapter 2 textbooks are accompanied by a full set of instructor and
■■ Automatic Transmission/Transaxle Hydraulic System— student supplements. Please see page vi for a detailed list
Chapter 3 of supplements.
■■ Hydraulic Control Valves And Solenoids—Chapter 4
2. Updated throughout to match the latest ASE/NATEF tasks.
a focUs on diagnosis and Problem solving
3. Over 50 new full color line drawings and photos make the
The Professional Technician Series has been developed to
subject come alive.
satisfy the need for a greater emphasis on problem diagnosis.
4. Case studies added to selected chapters that include the
Automotive instructors and service managers agree that stu-
“three Cs” (Complaint, Cause and Correction).
dents and beginning technicians need more training in diagnos-
5. Global electrical symbols added to Chapter 8.
tic procedures and skill development. To meet this need and
6. All systems and components are described throughout
demonstrate how real-world problems are solved, “Real World
with the following format to make learning complex
Fix” features are included throughout and highlight how real-life
systems easier:
problems are diagnosed and repaired.
■■ Purpose and Function
The following pages highlight the unique core features that
■■ Parts and Operation set the Professional Technician Series book apart from other
■■ Diagnosis and Service automotive textbooks.
iii
A01_HALD6797_07_SE_FM.indd 3 16/11/16 5:01 PM
IN-TEXT FEATURES
Case Study
chapter 1
INTRODUCTION TSB to the Rescue
A Dodge Durango came in to the shop with a cus-
TO DRIVETRAINS
tomer complaint of delayed engagement into
reverse after sitting for a while. A check of a TSB
LEARNING OBJECTIVES KEY TERMS
(21-016-05) described filters with defective check
After studying this chapter, the reader should All-wheel drive (AWD) 16 Manual transmission 8
be able to: Automatic Overdrive 7 valves. Replacement of the filter cured this problem.
1. Define torque, and explain the relationship transmission 9 Pinion gear 8
2. bDeetswceriebne ttohreq uvaer aionuds hgoerasre tpyopwese ra.nd their effect BCeluvteclh g e8ar 6 PPiltacnhe td ciaamrreietre r1 14 SUMMARY:
3. oEonpxp esrlpaaietnieo gdne,. ator rrqautieo sa nadn dd itrheecitri oenff eocf tr ootna tvieohni.cle CDDiyofjnofneaisnrmteta non1tmti4a-vle et1elo4rc 4ity (CV) PPRloea(waRnrWee-wtra Dthrr)yae ne1gsl3e fdaerrri v sueen ti t 1116 Complaint—Customer complained of a delayed
4. Discuss the types of manual transmissions and Drive axle 14 Ring gear 11 engagement into reverse after the vehicle sat for a
transaxles that are currently in use. Driveshaft 14 Spiral bevel gear 6
5. Discuss automatic transmissions and the plane- Final drive 13 Spur gear 5 while.
tary gear sets used for automatic transmissions. Four-wheel drive Sun gear 11
6. Cfooumr-wpahreee rl edarri-vwe,h aenedl d arlilv-ew,h feroenl td-rwivhee seyl sdtreivmes, . Fro(4nWt-wD)h e1e6l drive TToorrqquuee c2onverter 11 Cause—The original filter had a defective check
7. Edrxipvela ainx lteh ea scsheamrabcltieesri.stics of drive shafts and GHae(lFaf Wrs rhDaat)if ot1 1373 TTTrrraaannnsssafmexrils ecs aio1s3ne 816 valve.
HHeolrisceapl ogweaerr 53 Un(Uiv-ejrosianlt )j o1in4t Correction—A replacement filter fixed the
Hypoid gear 6 Worm gear 6
concern.
CASE STUDY present students with actual automotive
scenarios and show how these common (and sometimes
1 uncommon) problems were diagnosed and repaired.
?
LEARNING OBJECTIVES AND KEY TERMS appear FREQUENTLY ASKED QUESTION
at the beginning of each chapter to help students and instruc-
Is It Lb-Ft or Ft-Lb of Torque?
tors focus on the most important material in each chapter. The
chapter objectives are based on specific ASE and NATEF tasks. The unit for torque is expressed as a force times the
distance (leverage) from the object. Therefore, the
official unit for torque is lb-ft (pound-feet) or Newton-
TECH TIP
meters (a force times a distance). However, it is com-
monly expressed in ft-lb and most torque wrenches
Solenoids Are Wear Items
are labeled with this unit.
Many technicians consider solenoids, especially
PWM solenoids, to be “wear items” and automati-
cally replace them if the transmission experiences
FREQUENTLY ASKED QUESTIONS are based on the
problems after about 90,000 miles (150,000 km).
author’s own experience and provide answers to many of the
most common questions asked by students and beginning ser-
vice technicians.
TECH TIPS feature real-world advice and “tricks of the
NOTE: Most of these “locking nuts” are grouped together
trade” from ASE-certified master technicians.
and are commonly referred to as prevailing torque nuts.
This means that the nut will hold its tightness or torque
and not loosen with movement or vibration.
iv
IN-TEXT FEATURES
A01_HALD6797_07_SE_FM.indd 4 10/11/16 3:49 pm
IN-TEXT FEATURES
NOTES provide students with additional technical informa-
SUMMARY
tion to give them a greater understanding of a specific task or
1. Vehicles are built as rear-wheel drive, front-wheel drive, 6. Manual transmissions use a clutch and automatic trans-
procedure. and four- or all-wheel drive. missions use a torque converter.
2. Engines develop torque and the drivetrains modify that 7. Transaxles combine the final drive gears and differential
torque to move the vehicle. with the transmission.
3. A variety of gears are used to modify torque. 8. Driveshafts and the drive axle complete the drivetrain.
4. The gear ratio is determined by dividing the number of 9. Four-wheel-drive and all-wheel-drive vehicles have a
driven gear teeth by the number of teeth on the driving transfer case or transfer gears and a second drive axle.
gear.
CAUTION: Do not perform this quick check on a PWM 5. Transmissions have gear ratios that a driver can select.
solenoid because the lower coil resistance will allow REVIEW QUESTIONS
excessive current flow that can damage the solenoid. 1. What is the difference between torque and horsepower? 4. What is an inter-axle differential?
2. How is a gear ratio calculated?
3. What are the common shift modes used in an automatic
transmission?
CAUTIONS alert students about potential damage to the CHAPTER QUIZ
1. Torque is ______. 6. The transmission is in first gear, which has a 2.5:1 ratio,
vehicle that can occur during a specific task or service a. A twisting force and the rear axle has a ratio of 2:1. What is the overall
b. The rate of doing work ratio?
c. Results in motion a. 2:1
procedure. d. The gear ratio b. 2.5:1
2. Gears can be used to ______________. c. 4.5:1
a. Increase speed d. 5:1
b. Increase torque 7. The type of gear set used in most automatic transmissions
c. Reverse direction is ______________.
d. All of the above a. Spur gears
3. If a gear with 20 teeth is driving a gear with 60 teeth, the b. Planetary gears
gear ratio is ______________. c. Helical gears
a. 2:6 d. Any of the above
WARNING b. 3:1 8. What shift mode should be used when descending a
c. 1:3 steep hill slowly?
d. 0.33:1 a. Drive (D)
4. Technician A says a helical gear is stronger than a spur b. Second (2)
gear. Technician B says a helical gear is noisier than a c. Neutral (N)
spur gear. Which technician is correct? d. Low (L)
Use caution during servo cover removal because a. Technician A only 9. Full-time four-wheel-drive vehicles use ______________.
b. Technician B only a. Transfer case
c. Both Technicians A and B b. Spiral bevel drive axles
some servos use a strong piston spring. These d. Neither Technician A nor B c. Three differentials
5. Which type of gear may be found in a rear-wheel-drive d. Both a and c
require a special tool to hold the spring compressed aax. lHe?ypoid 10. Wa. hFaotu irs dursiveeds thoa fttrsansfer engine torque to all four wheels?
b. Spiral Bevel b. A transfer case or power transfer unit
during retainer ring removal and then allow the cd..  SHpeulicral cd..  FAollu orf d tihffee raebnotivaels
spring to be safely extended.
INTRODUCTION TO DRIVETRAINS 17
WARNINGS alert students to potential dangers to them- THE SUMMARY, REVIEW QUESTIONS, AND CHAPTER
selves during a specific task or service procedure. QUIZ at the end of each chapter help students review the
material presented in the chapter and test themselves to see
how much they’ve learned.
INSTALLING A HIGHER STALL SPEED TORQUE CONVERTER STEP BY STEP
1Ahwi igrtehhs- ttlhiofert e csdat om1c9sk7h 1tao fCrtq hauenevd rc odoloenetv seC rantmeorta .irdole h caosr arenc atlfyte irnm darrivkee t 2T1ahn8e 5e 0sn tgRaiPlnlM es p,e ewqeuhdiipc ophfe itdsh ewn ositrthmo caak lh ftioogrrh qa-up seet rocfcooknrm veeanrngtecinre e wc baaumst tsnehosatt feftdo.r a t 7The cooling lines and the dip stick tube are removed. 8Auunsftibenorg lr taee mdtr aoanvnidsnm gre itsmhseoio vdner dijva eacsfkth.ear fst,u tphpeo crtrionsgs tmhee mtrabnesrm wiasssi on
3The inspection cover is removed. 4Tthhee etonrgqinuee bceo nrvoetartteerd ruestainingi nag f lbyowlthse aerl etu rrenminogv etodo rl.equiring 9Tsihoen baenldl hao suwsiinvge lb sooltcsk wete.re removed using a long exten- 10Tthhee ttorraqnusem cisosnivoenr tise rr esmtillo ivne dp lfarcoem. the engine with
STEP-BY-STEP photo sequences show
5The speedometer cable was removed. 6The vacuum hose to the modulator valve was removed. 11Tgheea rf lteexepthla aten dw faosu innds ptoe cbtee dn oformr carla.cks or worn ring 12Twhaes tfooruqnude tcoo bnev elertaekri nwga.s A rlel mseoavlse dw aenred rtehpel afrcoendt osena tlh is
transmission before it was returned to the customer. in detail the steps involved in performing a
continued ▶
64 CHAPTer 5 Torque ConverTers 65 specific task or service procedure.
v
IN-TEXT FEATURES
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SUPPLEMENTS
RESOURCES IN PRINT AND ONLINE
Automatic Transmissions and Transaxles
Name of Supplement Print Online Audience Description
Instructor ✔ Instructors NEW! The ultimate teaching aid: Chapter
Resource Manual summaries, key terms, chapter learning
0-13-460626-4 objectives, lecture resources, discuss/
demonstrate classroom activities, and
answers to the in-text review and quiz
questions.
TestGen ✔ Instructors Test generation software and test bank for
0-13-461684-7 the text.
PowerPoint ✔ Instructors Slides include chapter learning objectives,
Presentation lecture outline of the test, and graphics from
0-13-461687-1 the book.
Image Bank ✔ Instructors All of the images and graphs from the text-
0-13-461688-X book to create customized lecture slides.
NATEF Correlated ✔ Instructors Downloadable NATEF task sheets for easy
Task Sheets— customization and development of unique
for Instructors task sheets.
0-13-460625-6
NATEF Task ✔ Students Study activity manual that correlates NATEF
Sheets— Automobile Standards to chapters and page
for Students numbers in the text. Available to students at
0-13-461692-8 a discounted price when packaged with the
text.
VitalSource eBook ✔ Students An alternative to purchasing the print text-
0-13-461685-5 book, students can subscribe to the same
content online and save up to 50% off the
suggested list price of the print text. Visit
www.vitalsource.com
All online resources can be downloaded from the Instructor’s Resource Center: www.pearsonighered.com/irc
vi
SUPPLEMENTS
A01_HALD6797_07_SE_FM.indd 6 10/11/16 3:49 pm
ACKNOWLEDGMENTS
A large number of people and organizations have cooperated in Toyota Motor Sales, U.S.A., Inc.
providing the reference material and technical information used Tribco, Inc.
in this text. Waekon Corporation
Williams Technology Inc., Division of Delco Remy Int.
A-1 Automatic Transmissions
Yank Converters
Aceomatic Recon
ZF Group North American Operations
AFM, Raytech Automotive Components Comp.
Alto Products Corp.
American Honda Motor Company TECHNICAL AND CONTENT REVIEWERS The following
ATEC Trans-Tool and Cleaning Systems
people reviewed the manuscript before production and checked
Autotrans
it for technical accuracy and clarity of presentation. Their sug-
AxiLine, Hicklin Engineering
gestions and recommendations were included in the final draft of
BorgWarner, Morse TEC
the manuscript. Their input helped make this textbook clear and
Carl Borsani, Graphic Home
technically accurate while maintaining the easy-to-read style that
Tom Broxholm, Skyline College
has made other books from the same authors so popular.
Chassis Ear, Steelman
Tom Broxholm
Chrysler Corporation
Skyline College
Ethyl Corporation
Mark Ferner, Pennzoil-Quaker State Ron Chappell
Fluid Rx Santa Fe Community College
Fluke Corporation Curtis Cline
Ford Motor Company Wharton County Junior College
General Motors Corporation
Kenneth P. Dytrt
Goodall Manufacturing Co.
Pennsylvania College of Technology
Roger Griffen, Nissan North America, Inc.
Dr. David Gilbert
G-Tec
Southern Illinois University
HECAT Inc.
International Lubricants, Inc. Richard Krieger
Tony Jewel, Reedley College Michigan Institute of Technology
J.S. Products/Steelman Russell A. Leonard
KD Tools Ferris State University
Kent-Moore, SPX Corporation
William Milam
Life Automotive Products
Eastfield College
Dennis Madden, ATRA
Justin Morgan
The Mighty Mover
Sinclair Community College
Federal-Mogul Corp.
NEAPCO Inc. Joe Palazzolo
Nissan North America, Inc. GKN Driveline
OTC, SPX Corporation Greg Pfahl
Pennzoil-Quaker State Company. Miami-Jacobs Career College
Raybestos Aftermarket Products Co.
Jeff Rehkopf
Ken Redick
Florida State College
Rostra Precision Controls
Scott Russell
Slauson Transmission Parts, Christopher Wilson
Blue Ridge Community College
Snap-on Tools
Sonnax Industries Chuck Rockwood
SPX Filtran Ventura College
Superior Transmission Parts Eugene Talley
T.C.R.S. Inc., Hicklin Engineering Southern Illinois University
vii
ACKNOWLEDGMENTS
A01_HALD6797_07_SE_FM.indd 7 10/11/16 3:49 pm
Chuck Taylor PHOTO SEQUENCES We would also like to thank Chuck
Sinclair Community College Taylor of Sinclair Community College in Dayton, Ohio, plus
Ken Welch Greg Pfahl and James (Mike) Watson who helped with many
Saddleback College Press of the photos. A special thanks to Dick Krieger, Jeff Rehkopf,
and Tom Birch for their detailed and thorough review of the
Special thanks to instructional designer Alexis I. Skriloff manuscript before publication. Most of all, we wish to thank
James. Michelle Halderman for her assistance in all phases of manu-
script preparation.
James D. Halderman
viii
ACKNOWLEDGMENTS
A01_HALD6797_07_SE_FM.indd 8 10/11/16 3:49 pm
ABOUT THE AUTHOR
JAMES D. HALDERMAN Jim Halderman brings a world of
experience, knowledge, and talent to his work. His automotive
service experience includes working as a flat-rate technician, a
business owner, and a professor of automotive technology at a
leading U.S. community college for more than 20 years.
He has a Bachelor of Science degree from Ohio Northern
University and a Master’s degree in Education from Miami
University in Oxford, Ohio. Jim also holds a U.S. patent for an
electronic transmission control device. He is an ASE-certified
Master Automotive Technician and is also Advanced Engine
Performance (L1) ASE certified. Jim is the author of many auto-
motive textbooks all published by Pearson. He has presented
numerous technical seminars to national audiences, including
the California Automotive Teachers (CAT) and the Illinois College
Automotive Instructor Association (ICAIA). He is also a member
and presenter at the North American Council of Automotive
Teachers (NACAT). Jim was also named Regional Teacher of
the Year by General Motors Corporation and a member of the
advisory board for Technological Studies department at Ohio
Northern University. Jim and his wife, Michelle, live in Dayton,
Ohio. They have two children. You can reach Jim at:
[email protected]
ix
ABOUT THE AUTHOR
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