Automatic Transaxle System: Other Kia Sorento I рестайлинг

A5SR1/ 2

ITEM CONTENT CHART

MAJOR COMPONENTS AND THEIR FUNCTIONS

COMPONENTS FUNCTION CHART

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1. N range Since the forward and reverse brakes are released, driving force of input shaft is not transmitted to output shaft.
2. P range Since the forward and reverse brakes are released, as those in the N range, driving force of input shaft is not transmitted to output shaft. Parking pawl that is linked with select lever parking gear meshes with and fastens output shaft mechanically.
3. D, M2, M3, M4, M5 range 1st speed Fastens the front brake. The front brake and the forward one-way clutch regulate reverse rotation of the mid sun gear. The 1st one-way clutch regulates reverse rotation of the rear sun gear. The 3rd one-way clutch regulates reverse rotation of the front sun gear. Since the middle sun gear rotates forward during deceleration, the forward one-way clutch runs idle and engine brake is not activated. * POWER FLOW Input shaft ==> Front internal gear ==> Front carrier ==> Rear internal gear ==> Rear carrier ==> Middle internal gear ==> Middle carrier ==> Output shaft
4. D, M3, M4, M5 range ratio 2nd Fasten the front brake. The front brake and the forward one-way clutch regulate reverse rotation of the mid sun gear. The 3rd one-way clutch regulates reverse rotation of the front sun gear. The direct clutch is coupled and the rear carrier and the rear sun gear are connected. * POWER FLOW Input shaft ==> Front internal gear ==> Front carrier ==> Rear internal gear ==> Rear carrier ==> Rear carrier ==> Middle internal gear ==> Middle carrier ==> Output shaft
5. D, M3, M4, M5 range 3rd speed Fastens the front brake. The 3rd one-way clutch regulates reverse rotation of the front sun gear. The high & low reverse clutch is coupled and the middle and rear sun gears are connected. * POWER FLOW Input shaft ==> Front internal gear ==> Front carrier ==> Rear internal gear ==> Rear carrier ==> Rear carrier ==> Middle internal gear ==> Middle carrier ==> Output shaft
6. D, M4, M5 range 4th speed The front brake is released and sun gear turns freely forward. The input clutch is coupled and the front and middle internal gears are connected. Driving force is conveyed to the front internal gear, the middle internal gear, and the rear carrier and the three planetary gears rotate forward as a unit. * POWER FLOW Input shaft ==> Front internal gear ==> Front carrier ==> Rear internal gear ==> Rear carrier ==> Middle internal carrier ==> Middle carrier ==> Output shaft
7. D, M5 range 5th speed The front brake fastens the front sun gear. The direct clutch is released and the rear carrier and rear sun gear are disconnected. * POWER FLOW Input shaft ==> Front internal ==> Front carrier ==> Rear internal input shaft ==> Middle internal ==> Rear carrier ==> Rear sun gear ==> Middle sun carrier ==> Middle carrier ==> Output shaft
8. R range The front brake fastens the front sun gear. The high & low reverse clutch is coupled and the middle and rear sun gears are connected. The reverse brake fastens the rear carrier. * POWER FLOW Input shaft ==> Front internal ==> Front carrier ==> Rear internal ==> Rear sun gear ==> Middle sun gear ==> Middle carrier ==> Output shaft

Scheme 80

MAIN COMMUNICATION SIGNAL

MAIN COMMUNICATION SIGNAL CHART

LINE PRESSURE CONTROL

1. If the engine control unit sends the input torque signal equivalent to the engine driving force to the A/T control unit (TCM), the A/T control unit (TCM) controls line pressure solenoid.
2. This line pressure solenoid controls the pressure regulator valve as the signal pressure and adjusts the pressure of the operating oil discharged from the oil pump to the line pressure most appropriate to the driving plate.

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1. A/T control unit (TCM) has stored in memory a number of patterns for the optimum line pressure characteristics according to driving conditions.
2. In order to obtain the most appropriate line pressure characteristic to meet the current driving state, the TCM controls the line pressure solenoid current valve and thus controls the line pressure. Normal line pressure control. Each clutch is adjusted to the necessary pressure to match the engine drive force. Back-up control (Engine brake) Line pressure according to speed is set during shift down by select operation while driving. During shift change Set to line pressure that is necessary for shift change. Therefore, line pressure characteristic is set according to input torque and shift types. At low fluid temperature When the A/T fluid temperature drops below the prescribed temperature, in order to speed up the action of each friction element, the line pressure is set higher than the normal line pressure characteristic.

SHIFT CONTROL

1. The clutch pressure control solenoid is controlled by the signals from the switches and sensors. Thus the clutch pressure is adjusted to be appropriate to the engine load state and vehicle driving state. It becomes possible to finely control the clutch hydraulic pressure with high precision and a smoother shift change characteristic is attained.

Scheme 86

Shift description

Controls clutches with optimum timing and fluid pressure in response to engine speed, engine torque information, and etc.

LOCK-UP CONTROL

Lock-up control is to enhance delivery efficiency by preventing the torque converter from slipping, engaging the lock-up piston into the torque converter.

It operates lock-up solenoid control in response to a signal from A/T control unit (TCM) and lock-up control valve behavior control, engages or releases the lock up piston of the torque converter.

LOCK-UP OPERATING CONDITION TABLE

LOCK-UP OPERATING CONDITION CHART

Lock-up control valve control

1. In the lock-up control valve, there is operating fluid pressure circuit linked into the lock-up piston and lock-up solenoid operates valve shift in response to a signal from the A/T control unit.
2. Operating fluid pressure circuit that is applied to the lock-up piston chamber is controlled with the release or apply sides.

Scheme 87

Lock-up released

1. In the lock-up control valve, there is operating fluid pressure circuit connected into the lock-up piston and lock-up solenoid operates valve shift in response to a signal from the A/T control unit. Therefore, the lock-up piston is not coupled.

Lock-up applied

1. During the lock-up applied status, lock-up apply pressure is generated having the lock-up control valve to L/U by the lock-up solenoid. Therefore, press the lock-up piston to be coupled.

Smooth lock-up control

1. A/T control unit (TCM) controls current value that is output to the lock-up solenoid when shifting lock-up applied state from lock-up released state. Therefore the lock-up clutch is temporarily set to half-clutched state when shifting the lock-up applied state to reduce the shock.

Half-clutched state

1. Changes current value that is output to the lock-up solenoid from A/T control unit (TCM) to gradually increase lock-up solenoid pressure. In this way, the lock up apply pressure gradually rises and while the lock-up piston is put into half-clutched status, the lock-up piston operating pressure is increased and the coupling is completed smoothly.

ENGINE BRAKE CONTROL

1. The forward one-way clutch delivers driving force from the engine to the rear wheel but reverse driving from the wheel drive is not delivered since the one-way clutch is idling.

Therefore low coast brake solenoid is operated to prevent the forward one-way clutch from idling so that the engine brake is operated in the same as before.

Scheme 88

1. The operation of the low coast brake solenoid switches the low coast brake switch valve and controls the coupling and releasing of the low coast brake. The low coast brake reducing valve controls the low coast brake coupling force.

CONTROL VALVE

CONTROL VALVE FUNCTIONS

CONTROL VALVE FUNCTIONS CHART

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1. Installing location: The valve body upper part
2. Function: To obtain A/T fluid pressure stability by compensating for solenoid & valve body unit fluid pressure differential.
3. Principle: Install additional ROM onto valve body of automatic transmission and input fluid pressure differential of solenoid & valve body so that TCM reads the input data to perform fluid pressure compensation.
4. Maintenance When replacing with a new TCM in the vehicle TCM automatically reads SUB ROM DATA during IG ON. At this time, shift range valve is off for about 2.5 second. When replacing A/T (regardless of new or old ones) in the vehicle Must erase SUB ROM DATA stored in TCM. With the ignition ON (engine OFF), maintain 50% throttle opening in R range while using the TCU SUB ROM RESET mode on the scan tool. TCM reads SUB ROM DATA from a new A/T upon IG ON again after IG OFF. Moving TCM from vehicle A to another vehicle B Perform the same way as in step 2 .

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1ST GEAR

* (Scheme 91)for L (number) valve name.

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VERIFICATION OF VEHICLE REPAIR

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Refer to DTC P0601 .

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A/T RANGE PATTERN

A/T RANGE PATTERN CHART

Scheme 101

1. Connect scan tool to data link connector (DLC).
2. Ignition "ON" & Engine "OFF".
3. Monitor the "TRANSMISSION RANGE SWITCH" parameter on the scan tool.
4. Move selector lever from "P" range to "D" range.
5. Does "TRANSMISSION RANGE SWITCH" follow the reference data? YES Fault is intermittent caused by poor contact in the sensor's and/or PCM/TCM's connector or was repaired and PCM/TCM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration or damage. Repair or replace as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S00097967702008020400000) " procedure. NO Go to " «TERMINAL & CONNECTOR INSPECTION»(ref-278800-S31634033152008020400000) " procedure.

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Scheme 102

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Refer to DTC P0711 .

Refer to DTC P0711 .

Scheme 103

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

SIGNAL WAVEFORM

Refer to DTC P0716 .

Scheme 104

1. Connect scan tool to data link connector (DLC).
2. Engine "ON".
3. Monitor the "INPUT SPEED SENSOR 1" parameter on the scan tool.
4. Driving at speed of over 12.42 MPH (20km/h) at 1 gear. Specification : Increasing Gradually
5. Does "INPUT SPEED SENSOR" follow the reference data? YES Fault is intermittent caused by poor contact in the sensor's and/or PCM/TCM's connector or was repaired and PCM/TCM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration or damage. Repair or replace as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S32229984532008020400000) " procedure. NO Go to " «TERMINAL & CONNECTOR INSPECTION»(ref-278800-S13087424182008020400000) " procedure.

Refer to DTC P0716 .

Scheme 105

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Scheme 106

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in general information.
4. Are any DTCs present ? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

OPERATING ELEMENT OF EACH SHIFTING RANGE

Stall test procedure in D2 and reason

Procedure

1. Warm up the engine
2. After positioning the select lever in "D", depress the foot brake pedal fully. After that, depress the accelerator pedal to the maximum * The slippage of 2nd gear operating parts can be detected by stall test in D2

Reason for stall test

1. If there is no mechanical defaults in A/T, all slippage occurs in the torque converter.
2. Therefore, engine revolution is output, but input and output speed revolution must be "zero" due to wheel's lock.
3. If 2nd gear operating parts have faults, input speed revolution will be out.
4. If output speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring is required.

1. 5. Is "STALL TEST" within specification? YES Go to " «SIGNAL CIRCUIT INSPECTION»(ref-278800-S33796167242008020400000) " procedure. NO Go to " «COMPONENT INSPECTION»(ref-278800-S19315292392008020400000) " procedure. CAUTION: Do not let anybody stand in front of or behind the vehicle while this test is being carried out. Check the A/T fluid level and temperature and the engine coolant temperature. Fluid level: At the hot mark on the oil level gauge. Fluid temperature : 176-212°F (80-100°C). Engine coolant temperature : 176-212°F (80-100°C). Chock both rear wheels (left and right). Pull the parking brake lever on with the brake pedal fully depressed. The throttle should not be left fully open for more than eight seconds. If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine at 1,000 RPM to let the A/T fluid cool down before carrying out subsequent tests.

Scheme 107

1. Connect Scan tool.
2. Engine "ON".
3. Monitor the "INPUT & OUTPUT SPEED SENSOR" parameter on the scan tool.
4. Accelerate the Engine speed until about 2000 RPM in the 2nd gear. Specification : INPUT SPEED - (OUTPUT SPEED x 2nd GEAR RATIO) < or = 200 RPM
5. Does "INPUT & OUTPUT SPEED SENSOR" within specifications? YES Go to " «COMPONENT INSPECTION»(ref-278800-S19315292392008020400000) " procedure. NO Check condition of Input & Output Speed Sensor and sensor wiring. Repair as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S22260693442008020400000) " procedure.

Scheme 108

1. Connect Scan tool.
2. Engine "ON".
3. Monitor the "OIL PRESSURE. S/W 1,2,3,5,6" parameter on the scan tool.
4. Move select lever to "D" range and operate vehicle within 2nd gear condition. OIL PRESSURE SWITCH SPECIFICATION Shift position Oil Pressure Switch I/C (SW3) H & LR/C (SW6) H & LR/C (SW6) FR/B (SW1) LC/B (SW2) P X o X o X R X o X o X N X o X o X D 1st gear X X X o X 2nd gear X X o o X 3rd gear X o o o X 4th gear o o o X X 5th gear o o X o X
5. Is oil pressure value within specifications? YES Repair AUTO TRANSAXLE (Clutch or Brake) as necessary and Go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S22260693442008020400000) " procedure. NO Replace AUTO TRANSAXLE (BODY CONTROL VALVE faulty) as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S22260693442008020400000) " procedure.

Refer to DTC P0731 .

Refer to DTC P0731 .

Stall test procedure in D4 and reason

Procedure

1. Warm up the engine
2. After positioning the select lever in "D" or "ON" of the HOLD SW (Operate UP SHIFT in case of "SPORTS MODE"), depress the foot brake pedal fully after that, depress the accelerator pedal to the maximum. * The slippage of 4th gear operating parts can be detected by stall test in D4

Reason for stall test

1. If there is no mechanical defaults in A/T, all slippage occurs in the torque converter.
2. Therefore, engine revolution is output, but input and output speed revolution must be "zero" due to wheel's lock.
3. If 4th gear operating parts have faults, input speed revolution will be out.
4. If output speed revolution is output. It means that the foot brake force is not applied fully. Remeasuring is required.

1. 5. Is "STALL TEST" within specification? YES Go to " «SIGNAL CIRCUIT INSPECTION»(ref-278800-S31574206762008020400000) " procedure. NO Go to " «COMPONENT INSPECTION»(ref-278800-S22055349592008020400000) " procedure. CAUTION: Do not let anybody stand in front of or behind the vehicle while this test is being carried out. Check the A/T fluid level and temperature and the engine coolant temperature. Fluid level: At the hot mark on the oil level gauge. Fluid temperature : 176-212°F (80-100°C). Engine coolant temperature : 176-212°F (80-100°C). Chock both rear wheels (left and right). Pull the parking brake lever on with the brake pedal fully depressed. The throttle should not be left fully open for more than eight seconds. If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine at 1,000 RPM to let the A/T fluid cool down before carrying out subsequent tests.

Scheme 109

1. Connect scan tool.
2. Engine "ON"
3. Monitor the "INPUT & OUTPUT SPEED SENSOR" parameter on the scan tool.
4. Accelerate the Engine speed until about 2000 RPM in the 4th gear. Specification : INPUT SPEED - (OUTPUT SPEED x 4th GEAR RATIO) < or = 200 RPM
5. Does "INPUT & OUTPUT SPEED SENSOR" within specifications? YES Go to " «COMPONENT INSPECTION»(ref-278800-S22055349592008020400000) " procedure. NO Check condition of Input & Output Speed Sensor and sensor wiring. Repair as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S31024940212008020400000) " procedure.

Scheme 110

1. Connect scan tool.
2. Engine "ON".
3. Monitor the "OIL PRESSURE. S/W 1,2,3,5,6" parameter on the scan tool.
4. Move select lever to "D" range and operate vehicle within 4th gear condition. OIL PRESSURE SWITCH SPECIFICATION Shift position Oil Pressure Switch I/C (SW3) H & LR/C (SW6) H & LR/C (SW6) FR/B (SW1) LC/B (SW2) P X o X o X R X o X o X N X o X o X D 1st gear X X X o X 2nd gear X X o o X 3rd gear X o o o X 4th gear o o o X X 5th gear o o X o X
5. Is oil pressure value within specifications? YES Repair AUTO TRANSAXLE (Clutch or Brake) as necessary and Go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S31024940212008020400000) " procedure. NO Replace AUTO TRANSAXLE (BODY CONTROL VALVE faulty) as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S31024940212008020400000) " procedure.

Refer to DTC P0731 .

Refer to DTC P0731 .

Scheme 111

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Scheme 112

Refer to DTC P0741 .

Refer to DTC P0741 .

Refer to DTC P0741 .

Refer to DTC P0741 .

Refer to DTC P0741 .

Refer to DTC P0741 .

Refer to DTC P0741 .

Scheme 113

A/T RANGE PATTERN

Scheme 114

1. Connect scan tool to data link connector (DLC).
2. Ignition "ON" & Engine "OFF".
3. Monitor the "SPORTS MODE SELECT S/W, SPORTS MODE UP S/W, SPORTS MODE DOWN S/W" parameter on the scan tool.
4. Move selector lever to "SPORTS MODE".
5. Does "SPORTS MODE SELECT SAN" follow the reference data? YES Fault is intermittent caused by poor contact in the sensor's and/or PCM/TCM's connector or was repaired and PCM/TCM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration or damage. Repair or replace as necessary and go to " «VERIFICATION OF VEHICLE REPAIR»(ref-278800-S20683771982008020400000) " procedure. NO Go to " «TERMINAL & CONNECTOR INSPECTION»(ref-278800-S38819047042008020400000) " procedure.

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scan tool and select "Diagnostic Trouble Codes (DTCs)" mode.
2. Using a scan tool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.
4. Are any DTCs present? YES Go to the applicable troubleshooting procedure. NO System performing to specification at this time.

Refer to DTC U0001 .

Refer to DTC U0001 .

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1. Remove the battery (-) terminal (A).
2. Remove the engine cover (A).
3. Remove the 02 sensor connectors (A).
4. Remove the under cover (A).
5. Drain the automatic transmission fluid.
6. Remove the front propeller shaft (A). (4WD)
7. Remove the front muffler (A) and the heat protector.
8. Remove the rear propeller shaft (A).
9. Remove the transmission oil level gauge (A).
10. Remove the shift cable cover (A).
11. Remove the shift cable (A).
12. Remove the oil cooler pipes (A).
13. Remove the drive plate cover (A).
14. Remove the drive plate bolts (A) NOTE: Remove the bolts (A-6ea) while rotating the crankshaft clockwise.
15. Remove the transmission lower mounting bolts (A).
16. Remove the starter motor mounting bolts (A) and the other bolts (B).
17. Remove the mounting bolts (A) while supporting the transmission with a jack.
18. Lower the jack slightly to simplify removal of electrical connectors and bolts on the upper part of the transmission.
19. Disconnect the transmission wire harness connectors.
20. Remove the vehicle speed sensor connector (A).
21. Remove the transfer case connectors (A). (4WD)
22. Remove the transmission upper mounting bolt (A, B).
23. Remove the transmission (2WD) or transmission/transfer case assembly (4WD) (A).