CM Automatic Transaxle F4A51, A5HF1

2 Variation Line-up

3 Appearance A5HF1 A/T ASSY (λ-3.8, D-2.2L) F4A51 A/T ASSY (μ-2.7L) F4A51 vs. A5HF1

4 ItemsF5A51A5HF1 VehicleXG Grendure(3.5L)TG Torque (kg m) Length (mm)430 T/CON size (mm)Φ 260 (New design) Number of OWC2 Planetary carriers3 Frictional elements4 Clutch 2 Brake 1 Band Accumulators6 Solenoid valves67 (1 VFS) Gear shift position7 or H-MATICH-MATIC Comparison Major specification

5 New features - Increased width by 2mm : output gear, differential drive gear - Single side plate : O/D clutch, 2 nd brake - Increased piston size of the reduction band - Increased bearing size by Φ5 mm A5HF1 (Compared with F5A51) - Increased number of pinion gears of O/D planetary gear : 34 - Increased number of pinion gears of direct planetary gear : 34 - Case/Housing : Newly designed and reinforced - Flat torque converter (Higer torque capacity) - Increased differential size (Size 6.1 7) - Valve body with VFS (with reservoir)

6 1) Features - Reinforced converter housing (More & thicker ribs) - New case design 2) Benefits - Increased binding force - Less bending vibration - Increased vehicle NVH performance TM case Converter housing (A5HF1) New features Reinforced Case/Housing

7 O/D, DIR planetary gear F5A51 (Three pinions)F5A51 (Four pinions) Output gear (Increased width by 2mm) Differential gear (Increased width by 2mm) For durability Oil reservoir (A5HF1 only) New features

8 Flat Torque converter AT Model Items Mid sized ATBig sized AT Current (F4A42) New (A5GF1) Current (F5A51) New (A5HF1) DiameterΦ246Φ236Φ260 Width (mm) Max. torque (kgfm) New features

9 Double sideSingle side SSP (Single Sided Plate) New features

10 SSP (Single Sided Plate) New features [Clutch disc] [Clutch plate] Up sidedown side Up side down side ItemsU/DO/DRevDir Material BWA D BWA BWA Usage4 DSP 1 SSP 6 23 Disc inner diameter Φ123 Φ152Φ87 Disc outer diameter Φ148 Φ166Φ122 Waves10EA DSP 6EA SSP - 11EA- Endplay (mm) 1.7±0.11.1±0.11.6±0.10.7±0.1 ItemsL/R2NDRED Material BWA BWA SD- 177-B Usage6 DSP 1 SSP 6 WRAP Disc inner diameter Φ161Φ152.8 Drum Φ134 Disc outer diameter Φ Waves10EA-- Endplay (mm) 1.65 ~ ~1.55 -

11 New features VFS - Purpose : To improve fuel consumption. (1.8%) ComparisonPurpose Unnecessary high pressure Optimum pressure TPS Gear Line pressure (bar) Optimum line pressure Improved efficiency Lower fuel consumption Regulator valve Pump Line pressure Solenoid valve Regulator valve Pump Controlled pressure Line pressure Line pressure (bar)

12 Sports mode lever, A/T relay location Lambda A/T relay : in Junction Box New features MELCO TCM only

13 ATM Shift lock New features

14 TCM location (Delphi 2.7L, 3.3L) New features Delphi PCM (2.7L, 3.3L) MELCO TCM (D-2.2L) A/T relay

15 Total 25 items Current data (Delphi PCM)

16 Specification VFS valve VFSVFS 1. Supply Pressure 2. Control Pressure 3. Frequency 4. Current range 5. Coil resistance 7.1 kgf/cm2 6.3 ~ 0kgf/cm2 (Normally high) 600 Hz 0 ~ 1.1 A 4.35 ± 0.35 Ω - Current vs. Controlled line pressure 1,100 ~ ~ 10.5Bar(D-Range) 4.9 ~ 15.5Bar(R-Range) - Supply pressure : reducing pressure Control Supply Exhaust

17 VFS Cooler pipe from the inside valve body VFS valve Pipe for VFS cooling VFS valve Oil dam for cooling (A5HF1 only)

18 Oil passage to use the reducing pressure for the source pressure of VFS The oil passage(channel) to supply the reducing pressure for the source pressure of VFS Application: - 4-speed A/T (F4A51) - 5-speed A/T (A5HF1) VFS valve

19 VFS(+) From AT relay P CM : VFS(-) VFS: (-) control type by TCM as same as others and the VFS power is supplied through A/T relay as conventional MELCO system. UD 2nd OD LR DCC VFS A/T relay UD(-) 2nd(-) OD(-) LR(-) DCC(-) VFS(-) NF(2.0, 2.4) PCM (Siemens & Melco) Comparison (Siemens & Melco)

20 VFS output Comparison (Siemens) P, N S-1 st D-1 st

21 VFS(+) VFS(-) - VFS: (+) control type by TCM VFS power is not supplied through A/T relay but from PCM directly. - PWM solenoid valves : (-) control type by TCM UD 2nd OD LR DCC RED VFS A/T relay UD(-) 2nd(-) OD(-) LR(-) DCC(-) RED(-) VFS(+) VQ (All), MG(2.7) PCM (Delphi) Comparison (Delphi)

22 VFS output Comparison (Delphi) P, N R D-1 st

23 Driving at sport mode 1 st gear VFS output waveform [VFS current] Comparison (Delphi) [Current data of VFS at S1]

24 VFS output waveform At P/N range [VFS current] Comparison (Delphi) [Current data of VFS at P/N]

25 Line pressure control

26 UD clutch pressure control N D control VFS output waveform [VFS current] [Current data of VFS at D1, vehicle stop]

27 N D control UD pressure : 4.7 kg/cm 2 0 kg/cm 2 [ UD clutch pressure at N D control] ND1 (vehicle stop)N D UD clutch pressure control 1.6

28 [ UD clutch pressure vs. VFS output while driving at D/S] 10.5 kg/cm 2 Driving at D range D45/S45 UD clutch pressure control 4.7 D1/S1 D23/S23 UD pressure while shifting at D/S (Max. pressure : 10.5 kg/cm 2 ) 5.8 kg/cm 2 0 kg/cm 2

29 VFS output (short to GND) With VFS failure (N D control range) UD pressure : 5.8 kg/cm 2 0 kg/cm 2 ND1 (Vehicle stop)N D [ UD clutch pressure with VFS failure while N D control] UD clutch pressure control

30 With VFS failure (Driving at D range) UD pressure : 10.5 kg/cm 2 D45 /S12 D123/S123 [ UD clutch pressure with VFS failure while driving at D/S] UD clutch pressure control

31 N R control LR brake pressure control VFS output waveform [VFS current] [Current data of VFS at R]

32 LR pressure VFS output (duty 14%) [ LR brake pressure vs. VFS output while N R control ] 6.5 kg/cm 2 N R N R control 3.0 kg/cm 2 NR at idle 68% LR brake pressure control

33 Driving at R VFS output (duty 14%) LR pressure_6.5 kg/cm 2 N R 3.0 kg/cm 2 NDriving at R 68% 17.0 kg/cm 2 [ LR brake pressure vs. VFS output while driving at R] LR brake pressure control

34 With VFS failure (N R) LR pressure at R : 6.5 kg/cm 2 [ LR brake pressure with VFS failure at N R] LR brake pressure control N RNDriving at R LR pressure at N : 9.0 kg/cm 2

35 With VFS failure (Driving at R) At N : 9.0 kg/cm 2 N Driving at R R (Driving) : 17.5 kg/cm 2 [ LR brake pressure with VFS failure while driving at R ] LR brake pressure control ND R (Static): 6.5 kg/cm 2

36 AT control relay UD SOLV/V OD SOLV/V LR SOLV/V DCC SOLV/V K-line RED SOLV/V 2ND SOLV/V VFS Input speed sensor IG ON & GND Inhibitor switch Oil temperature sensor Brake switch PCMPCM PCMPCM CAN Inputs & Outputs Output speed sensor

37 Reset function Purpose : when replace an AT transaxle, pressure data of the AT memorized in the PCM needs to be reset to put in the new pressure data. After PCM resetting, proper PCM learning procedure should be followed.

38 ND, NR Learning (1)The learning zone for Static Shift is decided depending on the ATF temperature (- 5~120 ) and engine speed < 1000rpm. (2)After N R or N D shift, select N range for 4sec or more and repeat several times) (1)Remain the TPS 1.6±0.15V (Throttle ) and shift up D1 D5 several times (around 5 times) (2)Perform the procedure (1) at TPS > 2.5V & TPS < 1.2V Power On Down Shift Learning Reset function Preparation : Initialize ETS and warm up the engine at P idle for TPS learning.

39 1. The switch control signal will be shared with Engine Coolant Temp Sensor. 2. More accurate high temperature detection 3.R1 = 3,600, R2 = TR On : 348 Ω, Off : (3, ) Ω Oil temperature sensor Temp. (˚C) Resistance (k ) ± ± Temp vs. Resistance

40 Oil temperature sensor PCM controls the TR according to the temperature condition. 1) ECT 50 ˚C, OTS 80 ˚C : TR OFF (3, ) Ω 2) ECT 50 ˚C, OTS 80 ˚C : TR ON OFF (Pulse) 3) ECT 50 ˚C, OTS 80 ˚C : TR ON OFF (Pulse) 4) ECT 50 ˚C, OTS 80 ˚C : TR ON 348 Ω * ECT : Engine Coolant Temperature, OTS : Oil Temperature Sensor TR ON (for ECT) TR OFF (for OTS) TR ON (for OTS) TR OFF (for ECT)

41 CH A: engine coolant sensor (44 ) CH B: AT Oil Temp sensor (49 ) CH A: engine coolant sensor (54 ) CH B: A/T Oil Temp sensor (60 ) Oil temperature sensor High side for ECT (TR ON) Low side for OTS : (TR OFF) Ch A : ECT Ch B : OTS Output waveform

42 When the oil temperature sensor is short to Ground, the trouble is detected immediately and P0712 is displayed. Hi-scan service data is fixed 214 º C however the replaced oil temperature by PCM is 85 ºC. Failsafe Oil temperature sensor short to GND (P0712) No VFS control : Maximum line pressure

43 P0712 (Oil temperature sensor Short to ground) This DTC code is set when the ATF temperature output voltage is lower than a value generated by thermistor resistance, in a normal operating range, for approximately 1 second or longer. The TCM regards the ATF temperature as fixed at a value of 85°C DTC Description

44 Oil temperature sensor open (0713) When the oil temperature sensor is open, the trouble is not detected immediately and ND, NR, PR shift shock is severe. The trouble will be detected around 5 minutes after driving. Hi-scan data is fixed -40 º C however the replaced oil temperature by PCM is 85 ºC. Failsafe

45 DTC Description P0713 (Oil temperature sensor Open or short to B+) This DTC code is set when the ATF temperature output voltage is higher than a value generated by thermistor resistance, in a normal operating range, for an extended period of time. The TCM regards the ATF temperature as fixed at a value of 85°C.

46 DTC Description P0711 (Oil temperature sensor rationality check, OBD area only) 1)Rationality error - 7hr after key-off and starts engine, - Temperature difference between oil temperature and coolant temperature minutes after engine running 2)Abnormal change of oil temperature - Oil temperature change 20 for 1 second after engine starts 3)Stuck error - Oil temperature change for 10 minutes after engine running 0.5 4)Warm-up error - Engine rpm 1000, - Ouput speed 1000, - Oil temperature

47 AT relay VFS 16 V 33 V Main duty signal AT relay control signal Feedback PWM solenoid valve VFS PWM signal VFS signal Sensing Driver + - PCM B76 A20 A60 B22, B3, B45, B42, B44, B43 B75 B59 Main relay driver Feedback 20A 10A AT relay

48 1.P0885 (AT relay ) - A20 circuit short to GND for 5 seconds after IG on or engine running - 10A fuse for B76 is open 2.P0890 (AT relay voltage low) - A60 circuit short to GND for 2 seconds - AT relay fuse (20A) is open 3.P0891 (AT relay voltage high) - A60 circuit voltage 20V for 2 seconds (for detecting surge voltage) Failsafe : AT relay off 3 rd gear fixed at D DTC Description

49 Failsafe AT relay voltage low (P0890) [Current data while driving at D : - AT relay OFF 3 rd gear fixed, - Pressure sol. OFF Max. line pressure] [P0890 is displayed 20A fuse for AT relay is open]

PWM solenoid valves : UD, OD, LR, 2 nd, RED, DCCSV 2. Normally high type : duty 100% pressure release, duty 0% Pressure apply 3. Operating frequency : Hz (DCCSV: 30.64HZ), 4. Resistance : 3.2±0.3 Ω PWM solenoid valves A/T relay PWM solenoid PWM control signal Sensing

51 Duty control PWM Solenoid output (UD solenoid valve) Duty 100% (solenoid ON) Duty 0% (solenoid OFF) ON PWM solenoid valves

52 Current data of DCCSV [DCCSV OFF condition][DCCSV ON condition] PWM solenoid valves Damper control : solenoid 100% ON (Damper clutch slip should be 0) Damper clutch operation : D 3,4,5 (3 rd gear – To Be Determined) -29 oil temperature when IG is on, 2 nd gear fix Oil temperature (Gradient 7% or more) : High temperature mode 2 nd 3 rd gear (2 nd gear & 3 rd gear range extended, 2 nd gear lock-up available)

53 3 rd 4 th 5 th gear 100 % [Damper clutch is disengaged while shifting] 2 nd 3 rd gear 94.5 % 0 % [DCCSV duty is gradually increasing] Current data of DCCSV PWM solenoid valves

54 When A PWM solenoid valve (except TCC solenoid) is open or short the failure is detected immediately. And the PCM turns the AT relay off resulting in 3 rd gear fixed at D range (including Sports mode). Failsafe PWM solenoid open or short When A PWM solenoid valve (except TCC solenoid) is open or short the failure is detected immediately. And the PCM turns the AT relay off resulting in 3 rd gear fixed at D range (including Sports mode). Variable line pressure control is inhibited and maximum line pressure is generated.

55 VFS (Variable Force Solenoid) B/T R1(Sense resistor) VFS PWM signal VFS Enable signal Sensing signal VFS Driver Sensing signal 1. Normally high type : duty 100% pressure release, duty 0% Pressure apply (6.3 kgf/cm 2 ) 2. Operating frequency : 600 Hz 3. Current range : 0 ~1.1A 4. Resistance : 4.35±0.35 Ω

56 P0748 is detected as soon as VFS circuit is open or short. When the VFS fails, variable pressure control is not available but AT relay is controlled normally. (Max. pressure) So PWM solenoid valves are operated as scheduled without shift shock while shifting up and down. Failsafe VFS solenoid

57 Failsafe Inhibitor switch circuit open (D range signal) When the D range signal is open, PCM controls the vehicle according to the previous range signal. After engine starts shift lever moves P-R-N-D in sequence, D range control will be substituted by N range signal. UD clutch pressure is not applied so vehicle cannot move. Sports mode also cannot be available because the power supplied via D range terminal of inhibitor switch.