BL AISIN(3040LEI) AT

1

BL AUTOMATIC
TRANSMISSION
(AISIN 30-40 LEi)


CONTENTS

2

1.

SPECIFICATION

2.

SYSTEM CONSTRUCTION

3.

SYSTEM LAYOUT

4.

POWER FLOW

5.

COMPONENTS

6.

SHIFT LOCK DEVICE INSTALLATION

7.

ELECTRICAL CONTROL PARTS

8.

HYDARULIC CONTROL SYSTEM

9.

ELECTRONIC CONTROL

10.

DIAGNOSIS

11.

WIRING DIAGRAM

12.

SHIFT PATTERN


SPECIFICATION

3

General Specifications
ENGINE

A-2.5 TCI

A/T Model

30-40LEi (AISIN AW)

General

4 speed transmission (Full line pressure control)

Maximum input torque (kg.m)
Weight (kg)
Torque converter

Type
Dia. (mm)

ATF oil
ATF capacity (liter)
Adapted vehicle

3 Elements 1 Stage 2 Phases
254
3 Clutches, 4 Brakes, 3 OWCs

Planetary gear

Shift mode

35
79.8

Components

Gear ratio

3.5 V6

3 Planetary gear sets (Simple type)
1,2,3,4/R

2.804, 1.531, 1.000, 0.705 / 2.393
P-R-N-D-2-L / SNOW(2WD only)
CASTLE AUTO FLUID D - I I
9.2
TERRACAN(HMC), CROWN(TOYOTA), VOLVO 960


SYSTEM CONSTRUCTION

4

Block Diagram
Engine

Shift lever

Torque
토크 converter
컨버터

Oil pump

Input shaft

Sensors & switches
SCSV A

Valve body
Clutch

Inhibitor switch

Control valves

SCSV B

OWC

DCCSV

Brake

PCSV

Accumulators

Planetary gear
Output shaft

C
U

ECU
Output sensor
Input sensor

Propeller shaft

T

Power flow
Hydraulic flow
Mechanical flow
Electrical flow


SYSTEM LAYOUT
5

1

2

7

6

3

5

8

9

4

1. Output speed sensor

To detect output shaft revolution

2. Neutral switch

To detect "N" range(A/T) or "Neutral" range(M/T)

3. Elbow (cooler out)

Way-out from a cooler hose to the A/T

4. Elbow (cooler in)

Way-in to the cooler hose from the torque converter

5. Air Breather hose

For air ventilation inside transmission

6. Oil temp. sensor

To detect the oil temperature

7. Input speed sensor

To detect input shaft revolution

8. Outer lever

Connected to the control cable to change driving range

9. T/M wire

Solenoid valves and sensors connection


POWER FLOW

C2

C1

Components and function

COMPONENTS

FUNCTION

C0

O/D direct clutch

Connect O/D sun gear and O/D carrier

C1

Forward clutch

Connect O/D input shaft and input shaft

C2

Direct clutch

Connect input shaft and Fr/Rr planetary sun gear

B0

O/D brake

Hold O/D sun gear

B1

2nd coast brake

Hold Fr/Rr planetary sun gear

B2

2nd brake

Hold counterclockwise rotation of Fr/Rr planetary sun gear (Hold outer race of F1)

B3

1st & reverse brake

Hold Fr planetary carrier

F0

O/D OWC

Connect O/D sun gear and O/D carrier, when O/D sun gear rotates faster than O/D carrier

F1

NO.1 OWC

Hold counterclockwise rotation of Fr/Rr planetary sun gear, when B2 operates.

F2

NO.2 OWC

Hold counterclockwise rotation of Fr planetary carrier

6


POWER FLOW

7

Components and operation
B3
B2
B1

C2
C0

B0

C1

IN

OWC 1(F1)

OD OWC(F0)

OD INPUT SHAFT

OWC 2(F2)

OUT

INPUT SHAFT

OUTPUT SHAFT


POWER FLOW
Components and operation

8


POWER FLOW

9

Components and operation

P O S IT IO N

S O L E N O ID

CLUTCH

S1

S2

SL

P

ON ›

OFF~

OFF~

R (V < 7 )

ON ›

OFF~

R (V > = 7 )

ON ›

N
D

2
L

C0

BRAKE

GEAR

O .W .C .

R A T IO

C1

C2

B0

B1

B2

B3

F0

F1

F2

ON ›

OFF~

OFF~

OFF~

OFF~

OFF~

OFF~

OFF~

OFF ~

OFF~

-

OFF~

ON ›

OFF~

ON ›

OFF~

OFF~

OFF~

ON

ON ›

OFF ~

OFF~

2 .3 9 3

ON ›

OFF~

ON ›

OFF~

OFF~

OFF~

OFF~

OFF~

OFF~

ON ›

OFF ~

OFF~

-

|

ON ›

OFF~

OFF~

ON ›

OFF~

OFF~

OFF~

OFF~

OFF~

OFF~

OFF~

OFF ~

OFF~

-

|

1 st

ON ›

OFF~

OFF~

ON ›

ON ›

OFF~

OFF~

OFF~

OFF~

OFF~

ON ›

OFF ~ ON OFF
› ~

2nd

ON ›

ON ›

OFF~

ON ›

ON ›

OFF~

OFF~

OFF~

ON ›

OFF~

ON ›

ON OFF
› ~

OFF~

1 .5 3 1

3 rd

OFF~

ON ›

ON

›

ON ›

ON ›

ON

›

OFF~

OFF~

ON ›

OFF~

ON ›

OFF~

OFF~

1 .0 0 0

4 th

OFF~

OFF~

ON

›

OFF~

ON ›

ON

›

ON ›

OFF~

ON ›

OFF~

OFF~

OFF~

OFF~

0 .7 0 5

1 st

ON ›

OFF~

OFF ~

ON ›

ON ›

OFF ~

OFF~

OFF~

OFF~

OFF~

ON ›

OFF~ ON OFF
› ~

2 .8 0 4

2nd

ON ›

ON ›

OFF ~

ON ›

ON ›

OFF ~

OFF~

ON ›

ON ›

OFF~

ON ›

ON ›

OFF~

1 .5 3 1

3 rd

OFF~

ON ›

OFF ~

ON ›

ON ›

ON ›

OFF~

OFF~

ON ›

OFF~

ON ›

OFF~

OFF~

1 .0 0 0

1 st

ON ›

OFF~

OFF ~

ON ›

ON ›

OFF ~

OFF~

OFF~

OFF~

ON ›

ON ›

OFF~

ON

2nd

ON ›

ON ›

OFF ~

ON ›

ON ›

OFF ~

OFF~

ON ›

ON ›

OFF~

ON ›

ON ›

OFF~

›

›

|

2 .8 0 4

2 .8 0 4
1 .5 3 1


POWER FLOW

10

Principle of each range
3rd gear

1st /2nd gear

C1

O/D

C1

Fr / Rr

Direct
Speed
coupling reduction

1. Power flow
OD input shaft ÆOD gear set(coupling by C0) ÆFr/Rr
(speed reduction by F2(1st gear), by B2&F1(2nd gear))
2. Engine brake
- D range 1st,2nd gear: non(F2,F1 free to clockwise)
- 2 range: 1st gear(non), 2nd gear(operated by B1)
- L range 1st,2nd gear: operated by B1, B3
4th gear

O/D

Direct
Direct
coupling coupling

1. Power flow
OD input shaft Æ OD gear set(coupling by C0)
ÆFr/Rr (coupling by C1 & C2)

2. Engine brake
- D & 2 range: operates
Reverse gear

C1

O/D

Fr / Rr

C1

Fr / Rr

Speed
Direct
increase coupling

1. Power flow
OD input shaft Æ OD gear set (speed increase by B0)
Æ Fr/Rr (coupling by C1&C2)
2. Engine brake
- D range: operates

O/D

Fr / Rr

Direct Reversed
coupling rotation

1. Power flow
OD input shaft Æ OD gear set (coupling by C0)
Æ Fr/Rr (reverse rotation by B3)
2. Reverse inhibition control: C2


POWER FLOW
D range – 1st gear

11


POWER FLOW
D range – 2nd gear

12


POWER FLOW
D range – 3rd gear

13


POWER FLOW
D range – 4th gear

14

POWER FLOW
R range

15


COMPONENTS
1

16

2


COMPONENTS
1

17


COMPONENTS
2

18


COMPONENTS
Oil pump

19


COMPONENTS
OD clutch &
OD planetary gear

20


COMPONENTS
OD clutch

21

OD
OD clutch
clutch disc
disc
(2EA)
(2EA)

OD sun gear

Input speed
sensor tone
wheel (16EA)


COMPONENTS

22

OD clutch
Input shaft

Hub for OD
brake
Hub for OD
clutch

OD
OD Planetary
Planetary
gear
gear


COMPONENTS
Forward clutch

23


COMPONENTS

24

OD OWC (F0) and Forward clutch
OD

OD OWC
OWC (F0)
(F0)

Forward
Forward clutch
clutch


COMPONENTS

25

Forward clutch

Hub
Hub for
for Direct
Direct
clutch
clutch
Forward clutch
(5EA)