Transmission Diagnostics & Repair

Transmission general data The 4-speed automatic transmission BTR M74LE with a longitudinal positioning for RWD vehicles was designed in 1988 by BTR company on commission from a Korean automaker SsangYong for its flagship SUV Korando. In 1989, this RWD transmission was launched in mass-production. In most cases, the M74LE transmission was mated with 2-3-liter engines and found application in RWD SsangYong models - Rexton, Actyon, Korando etc. The 6-speed automatic transmission DSI-6 \ M78LE (M96) was developed in 2008 by specialists of former BTR bureau with a new Chinese owner Geely under a new brand DSI. It is more advanced modification of the 6-speed automatic transmission with a longitudinal positioning paired with the 2-liter engines SsangYong Actyon. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATRWD93,5BTR M74LE Technical issues and repair guidelines In most cases, М74 and М78 transmission models require ATF change and filter replacement during the overhaul. In addition, specialists usually order the pan gasket. For reassembly of М78 (and М74) specialists order the repair kit of gaskets and seals /Overhaul kit and a complete kit of friction components. Brake bands (Intermediate (Direct, High/ Reverse) ) are also considered to be spare parts for this transmission. The rear brake band is replaced in case of burnt fluid and uneven wear-out and the band clearance, in order to exclude kicks in the process of gears shifting. Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comScheme

Transmission general data The 6F24 transmission model replaced not very successful M11 model in 2013. This transmission has been installed on Dodge Dart, Jeep Compass, Patriot MK since 2013. In terms of design, this transmission is a copy of the A6MF transmission. For integration of this transmission with SsangYong engines, engineers had to modify electrical part of this transmission, including solenoids and the software. Technical issues and repair guidelines This transmission has the same typical problems as A6MF1 and A6MF2 transmissions. The ATF change should be performed after 80 travelling thousand kilometers, but the fluid condition should be controlled every 20 thousand kilometers. In case of aggressive driving manner it may be necessary to change the fluid earlier. The filter for the 6F24 unit is replaced only with removal of the cover and repair/cleaning of the valve body. Specialists recommend to clean the valve body and replace the filter after 120-140 thousand kilometers (when detecting first signs of improper gears shifting) without waiting for wear-out of solenoids. Transmission specialists repair the torque converter if the fluid becomes very hot and gets rapidly contaminated. Engineers of SsangYong adjusted the valve body operation for 6F24 not very carefully, therefore the torque converter slipping (as in Hyundai) and aggressive driving behavior may lead to the lock-up clutch damage by the torque converter by the end of the car warranty period. How to repair this transmission (Videos)A6MF1 4WD TeardownA6MF1 TRANSMISSION TEAR DOWN

Transmission general data Mercedes in cooperation with Getrag had developed 7-speed DSG (7G-DCT) with a dual clutch by 2012. This transmission is intended for vehicles of А, B, CLA, GLA classes. Mercedes has taken into account the experience of VAG in this field and equipped its DCT with a wet clutch, which can operate withmore powerful engines. This transmission is equipped with an electric oil pump, which is engaged when a quick start is required or in case of the maximum load. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type7DCTFWD3507,26236.21 Technical issues and repair guidelines The fluid quality monitoring is the only measure required during the first years of operation of this transmission. After 60-80 thousand kilometers, it is recommended to check the fluid state and change with the filter, if some contamination or smell is detected. Mercedes engineers delicately adjusted the mechanism of gears shifting in this transmission and ATF contamination can significantly change the performance capacity of the dual-clutch mechanism. Therefore 7-DCT has two fine mesh filters: 1. One filter is positioned In the pan – metal-plastic filter with a felt membrane. It is recommended to replace it and change fluid after 100 thousand kilometers. 2. The second filter is placed outside – the filter-cartridge. It should be replaced yearly or after travelling 30-40 thousand kilometers. How to repair this transmission (Videos)7G-DCT Mercedes-Benz 7G-DCT 7G-TRONIC PLUS7G-TRONIC Plus Transmission Instruction manuals and useful linksLink typeSourceDescriptionpdfautocats.wsSystem description 724.0webbevo.mercedes-benz.com7-G DCT transmission oilpdfalltranz.co.nzScheme 724.0

Transmission general data The A-727 is a 3- speed automatic transmission designed and manufactured by Chrysler in the early 1960-s (replaced A488). Since then, this gearbox mainly had been mounted on a different Chrysler cars. This gearbox is extremely adjustable and powerful enough to operate with 450hp engines. Therefore, A-727 may be easily used for Chrysler, GM or AMC vehicles. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type3ATRWD8,23,8Mopar ATF+3 Technical issues and repair guidelines This type of transmission may be specified by peculiarly shaped 14-bolt oil pan. The A-727 uses a paper fluid filter and has 2 transmission bands (reverse and kick-down). It had been one of the most adaptable Chrysler gearboxes for over 3 decades, due to its durability and efficiency. Therefore many automakers selected A-727 for their products. After some time this transmission received new names and broken up into 2 categories of the 36RH and 37RH gearboxes, where "3" specifies that it is a 3-speed gearbox, "6/7" are strength indications, "R" means that it is designed for RWD application. How to repair this transmission (Videos)A727 Transmission Rebuild - Part-1727 from a first gen Cummins rebuild part 1727 from a first gen Cummins rebuild part 2 Instruction manuals and useful linksLink typeSourceDescriptionpdfshop.ukrtrans.bizRepair manual A727webhotrod.com15 Tips to Improve Your 727 Torqueflite Transwebnovak-adapt.comGuide to the Chrysler 727webWikipediaTorqueFlite A727 (36RH/37RH)

Transmission general data MENA is a continuously variable transmission of the first generation produced by Honda (all range including MENA, SETA, SENA, META has a common name Multimatic). These transmissions had been installed in Honda HR-V of the first generation from 1998 until 2005. In fact, it is one CVT which has 4 modifications. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type∞CVTFWD5,93,2Honda Genuine CVT In fact, these CVTs (together with M4VA (S4VA, S4PA, S4MA)) are considered to be one of the oldest CVTs produced by Honda. As a matter of fact, it is one CVT in several modifications. Modifications of CVT are bound to letter designation of the car body: · GH1 – MENA · GH2 — SETA · GH3 – SENA · GH4 – META Typical issues Honda CVTs related to the Multimatic series (META/SETA/SENA/MENA) usually have the same issues as CVTs of the M4VA (S4VA,S4PA,S4MA) series. Actually, META series was designed on the basis of the M4VA -Problems with starting from the rest (jerks, speed drift when applying D+brake). This problem is fixed by replacement of the start package valve. In neglected cases specialists replace the start package. -Problems with speed drifts in the process of acceleration have 2 solutions: 1) Replacement of the gear ratio valve 2) replacement of seals on the input shaft. This procedure requires partial disassembly of the gearbox. It is desirable to use the original repair kit of gaskets. -Problem with the reverse. This problem is caused by damage of reverse brake elements. This problem is solved by CVT disassembly and welding. In addition, it is required to replace piston rubbers of the reverse brake – these rubbers may tear leading to problems with the reverse. To prevent any further problems with the reverse, it is recommended to replace reverse friction clutches.

Transmission general data AP is the 4-speed automatic gearbox created by Automotive Products and the BMC for MINI vehicles. The prototype of this famous gearbox was released in 1962. It took about a decade of engineering and manufacturing efforts before ordinary 2-speed gearbox turned into the unique 4-speed automatic gearbox. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATFWD Technical issues and repair guidelines This was a great achievement to manufacture a 4-speed automatic gearbox that could be operated like a manual unit. It was one of the first automatic gearboxes with east-west mounting produced for FWD vehicles. Moreover, the construction of this gearbox implies the usage of lubricating oil instead of common ATF. This gearbox was also installed in BMC ADO16 and Austin vehicles. Specialists claim, that the crankcase oil should be changed every 10 thousand kilometers, because the oil condition is very important for this type of gearbox. One of the most common malfunctions in this transmission is related to the F-clutch that may get out of order because of the gearbox construction peculiarities (clutch gets the drive torque after multiplication via the gearbox). How to repair this transmission (Videos)Classic Mini Remote Gearbox RebuildOld Classic Mini Gearbox Rebuild - Part 1Old Classic Mini Gearbox Rebuild - Part 2Old Classic Mini Gearbox Rebuild - Part 3Old Classic Mini Gearbox Rebuild - Part 4Classic Mini Differential Rebuild - Part 1Classic Mini Differential Rebuild - Part 2Classic Mini Idler Gear - Setting The End FloatFitting the crankshaft and checking the endfloatFitting the pistons, camshaft & oil pumpSetting the cam timing

Transmission general data The first two modifications 722.1 and 722.2 of the family of automatic transmissions are rarely found in repair services. Commonly, this automatic transmission is installed on cars produced in the 80th. Owners of cars with the 722.2 transmission prefer the transmission rebuilding in order to preserve a rare car. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATRWD74236.12 Technical issues and repair guidelines Visually the automatic transmission 722.2 is distinguished by small square pan with reinforcement ribs. The automatic mechanism controlling the process of gear shifting is located in the pan of the housing and appears to be a separate unit in contrast with automatic transmission designs of the following series. Shafts and planetary gears in this automatic transmission are highly precise and of high quality almost without application of aluminum alloy and plastic, seals are made of metal rings. The resource of these parts is much higher than the resource of friction components and in some cases of the car itself. If the transmission starts to transmit the rotation of shafts improperly, shifts gears with jolts, then it is required to perform the emergency repair (in this case replacement of some friction elements). Further usage of a faulty transmission may lead to its replacement. Signs of pumps damage consist in leaks between the transmission and the torque converter. In case of the pump wedging, it is required to replace the torque converter. How to repair this transmission (Videos)Mercedes 190E Teardown Instruction manuals and useful linksLink typeSourceDescriptionwebWikipediaMercedes-Benz first series automatic transmissionpdftransmax.co.nzScheme 722.2webcardiagn.comDownload link on Manual 722.2webcardiagn.com722.1-722.2 Transaxle Service Manual See link

Transmission general data BW65/BW66 automatic transmission is mounted on the BMW Bavaria (1971 – 1974) and Jaguar XJ6 (1980-1987). This complex system combines electronic, mechanical and hydraulic components. But despite of high degree of safety some problems may occur in the process of transmission operation. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type3ATRWD104-4,5ATF Type F Technical issues and repair guidelines When the slippage takes place during the operation of this type of transmission it may lead to slow gear-shifting and vibrations, therefore it is an important signal for visiting repair services. The most common problems related to this transmission are: - shortage or surplus of oil; - long slippage; - sharp driving dynamics. The sleeve and other parts of BW65/66 transmission can get overheated that usually leads to overheat cracks and other mechanical damages.

Transmission general data The BW-35 is an A/T manufactured by the BorgWarner in the 1950s particularly for engines with the capacity of less than 200 cu.in. The modification 35 is a 3-speed A/T coupled to the engine by a three-element torque converter. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type3ATRWD8,24,5Type F Fluid, Dexron II Technical issues and repair guidelines Engine power is converted into hydrokinetic energy and this provides smooth application or driving torque. This transmission has 3-forward and 1- reverse transmission ratio. It was constructed for operation with Type-F oil, which is not so popular today as Dexron. The hydraulically operated control unit includes a valve location and a pump activated by the engine. The automatic gearbox includes a planetary set having 2 center gears, 3 sets of 3-epicyclic gears which can be found in a planet gear holder and follower gear. Instruction manuals and useful linksLink typeSourceDescriptionpdfvolvoenthusiastsclubRepair manual BW35

Transmission general data The 6-speed FWD automatic transmission FW6A-EL with the east-west mounting was developed by Aisin for Mazda. This transmission was installed on Mazda CX-5 with the 2.0 liter engine, Mazda-3, Mazda-6. In terms of design, this transmission is very similar to the U660E transmission produced by AisinWarner. This transmission is considered to be the main competitor of ZF 6HP19-21. The FW6A-EL transmission has the torque converter with a double lock-up clutch that helps to accelerate the transmission faster and with higher efficiency. However, frequent usage of kick-down may lead to failures. This transmission employs reliable Aisin solenoids – linear type solenoids with anodized manifold, which is built into the solenoid body. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type6ATFWD30085ATF-FZ Skyactiv This transmission is a “rare guest” in the repair services, repair specialists mainly change oil and filter. It is recommended to change ATF after reaching the mileage of 100 thousand kilometers, and then every 50-60 thousand miles. It is required to monitor ATF transparency regularly, because with aggressive driving style ATF may get contaminated much earlier. In rare cases, transmission specialists face the problem when the torque converter lock-up damages the pump. The issue is expressed in vibrations and leakages through the pump seal. In this case specialists not only replace the seal, but also repair the torque converter and replace clutches. Another problem, similar to the issue in U660E, is wear of the case center bearing. This problem occurs when drivers get carried away with the kick-down on cold oil. One more typical problem of this transmission is damage of the double drum High/Low. After running 100 thousand kilometers it is also recommended to monitor the ATF temperature and the heat exchanger operation, similar to VW problems with the TF60-SN transmission. In old cars repair specialists advice to clean the heat-exchanger during full ATF change, to ensure reaching of 300 thousand kilometers mileage before the overhaul. Instruction manuals and useful linksLink typeSourceDescriptionpdfalltranz.coScheme FW6AELwebnema.clubDTC P0731 1GR incorrect ratiowebnema.clubDTC P0746 Pressure control solenoid stuck off

Transmission general data The 6-speed C635 dual dry clutch transmission (DDCT) was produced by Fiat and was presented in 2010 with AWD, FWD, and manual versions. Since then, this transmission has been installed on Alfa Romeo 159, Brera, Gulia, Milano, MiTo, Spider. This transmission was designed thanks to collaboration of Fiat, Magnetti Marelli and BW. The maximum torque transmission capacity of the C635DDCT is equal to 350 Nm. Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type6DCTFWD3502,11,9Addinol ATF DCT The total weight of this transmission is 81 kilograms, including ATF and TCU. The advanced technologies implemented in this transmission guarantee uninterrupted torque transmission and traction without any losses of power in the process of gear shifting. The Start/Stop feature helps to reduce fuel consumption by 10% in comparison with standard hydro-mechanical transmissions. Transmission repair specialists point out that the C635DDCT transmission is extremely sensitive to the ATF condition. Constant monitoring of the ATF status may prolong the service life of this transmission. How to repair this transmission (Videos)Fiat Dual Dry Clutch Transmission Instruction manuals and useful linksLink typeSourceDescriptionwebWikipediaFPT C635 DDCT transmission

Transmission general data The CVT transmission version named TF690 (Lineartronic) was designed in 2008 for Subaru Outback with the engine capacity equal to 2.5 liters. The second generation was named as TR580. In 2010, this CVT was tested on Impreza with the engine capacity from 1.6 to 2.0 liters. Starting from 2012, this transmission also found application on other Subaru models. The design of middle class CVTs includes a chain instead of a push belt. This CVT is quite sensitive to the fluid state, its cleanness and temperature. There is a special type of oil for this CVT named as SUBARU CVT Oil Lineartronic II (K0425Y0710). Number of gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type∞CVTAWD35012,55,6SUBARU CVT Oil Lineartronic II Technical issues and repair guidelines The repair kit of gaskets and seals is used to replace rings and gaskets. Rubber rings are replaced when the CVT unit is overheated or if it operates with contaminated fluid (including chips) for a long time. In case when frictions burn to the glue layer, the filter with the mesh is also replaced in the process of the TF690 reassembly. Burnt frictions and Forward steel discs are the first to be replaced. Next on the popularity of the replacement are the metal frictions of the Starter package. The starter pack is responsible for turning the cones on and off when stopping and shifting the lever to the neutral position. Transfer frictions also appear in replacement operations. They are responsible for distribution of torque on rear\front wheel drive. The TR580 unit has problems with the valve body and a set of solenoids. In previous models these components caused the failure of electrics when the transmission operated with contaminated oil for a long time or under extreme loads and temperatures. When the wear-out of the belt and cones is neglected, then it is necessary to replace the cones. A typical problem with CVT cones in Subaru is related to the input shaft bearing, pressed in the transmission body. This bearing is cranked by vibrations at maximum speeds, and then it breaks. How to repair this transmission (Videos)Valvebody Replacement with code P2764Breaking down a TR-580