ZF_Workbook-transmission-6-8HP.pdf

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Workbook
Transmission Technology
Transmission
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Table of content
1. Transmission History .....................................................................................3
2. 6HP Design ....................................................................................................4
3. Adaption .....................................................................................................25
3. Oil change Service and Mechatronic ...........................................................38
4. 6HP Overhaul ..............................................................................................60
6. 8 HP Transmission .......................................................................................80
7. Identification of the Transmission ............................................................... 85
8. Troubleshooting ........................................................................................ 113
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History of Automatic Transmissions
16 basic types in 769 versions
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The hydrodynamic torque converter
Converter operating principle
The torque converter consists of the impeller, the turbine wheel, the reaction element (stator)
and the oil content needed to transmit the torque.
The impeller, which is driven by the engine, imparts a circular flow of the oil in the converter.
This oil strikes the turbine wheel, which causes the flow to change its direction. The oil flows
out of the turbine wheel close to the hub and strikes the stator, where its direction is changed
again to a direction for re-entering the impeller.
The change in direction at the stator generates a torque reaction that increases the torque
reaching the turbine. The ratio between the turbine and the impeller torque is referred to as
torque multiplication or conversion.
The greater the difference in speeds of rotation at the impeller and the turbine, the greater the
increase in torque.
The maximum increase is obtained when the turbine wheel is stationary. As turbine wheel
speed increases, the amount of torque multiplication gradually drops. When the turbine wheel
is rotating at about 85% of the impeller speed, torque conversion reverts to 1.
That is to say torque at the turbine wheel is no higher than at the impeller.
The stator, which is prevented from rotating backwards by a freewheel and the shaft in the
gearbox housing, runs freely in the oil and overruns the freewheel. From this point on, the
converter acts only as a fluid coupling.
During the torque conversion process, the stator ceases to rotate and bears against the
housing via the freewheel.
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Torque converter
(1)
Space behind lock-up clutch
(2)
Lock-up clutch piston
(3)
n_Mot
(4)
Lined plate of lock-up clutch
(5)
Torsional vibration damper
(6)
Converter cover
(7)
Turbine wheel
(8)
Pump wheel
(9)
Stator
(10)
Stator freewheel
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