Automatic Transaxle (F21-450)

2 EngineA/TNASMES GEN OthersChinaChile Lambda 3.8L F (AISIN) S-3.0 V6 VGT EURO EURO EURO L V6 Common rail diesel engine (S-engine) and 3.8 L V6 gasoline engine (Lambda) are used for EN. S- engine is the first used in HMC and Lambda engine is already used for NF, TG, CM. Power Train Variation

3 ItemS- V6 3.0 LLambda V6 3.8 L Fuel Injection typeCRDi (1600bar)MPI Displacement2,9593,778 Bore x Stroke (mm)84 x 8996 x 87 Timing systemChain Performance Output max.233 ps260 ps Torque max.45kgfm35kgfm Appearance Engine Line-Up

4 EngineA/TNASMESGEN Lambda 3.8L F (AISIN) S-3.0 V6 VGT-- [6 speed AT, F (AISIN)] Application

5 ItemsSpecifications EngineS3.0 V6 CRDI DieselLambda 3.8 V6 Gasoline A/T modelF (AISIN MODEL:TF81-SC) TypeFF 6-speed Driving type2WD4WD2WD4WD Max. Torque45kgm Torque converter3 elements 2 phases 1 stage Stall speed (rpm)2279rpm2410rpm Gear ratio 1 st nd rd th th th Reverse3.394 Specification

6 ItemsSpecifications Elements Clutch3 (Multiple disc type) Brake2 (One band and one multiple disc type) OWC1 (Roller type) Solenoid valve On/Off2 Solenoids (S1, S2) Linear6 Solenoids (SLC1,SLC2,SLC3,SLB1,SLT,SLU) TGS lever typeStep gate type 4 positions (P,R,N,D) with sports mode ATF Spec.JWS-3309 (Grade: T-4) Quantity7L ATF service intervalMaintenance free ATF level adjustmentOver flow checking type Specification

7 Driving typeEngineA/T Part numberAW Part NumberRemarks 2WD(LSD) CRDI S-3.0 V TFF013 LSD (DOM. Only) 2WD TFF014 4WD TFF015 2WD Lambda 3.8 V / TFF016/TFF017 4WD / TFF018/TFF019 Part Information

8 (1): A/T model number (2): Serial number (3): HMC part number Identification

9 Integrated position sensor with TCM (TCM + Separated inhibitor switch) (Integrated TCM & inhibitor switch) Main Features Position Sensor

10 Start motor and reverse lamp control Main Features Inhibitor switch Power(5V) POS1 POS2 Ground TCU Reverse Lamp Relay Start Relay Shift Lock Solenoid

11 Over flow plug (EN A/T) Over flow method for ATF level checking Oil level gauge (previous A/T) Main Features

12 Plug 1 (oil filling hole) Plug 2 (over flow) The oil level gauge was eliminated in this transaxle and Over flow plug has been applied to check the level. Oil level is adjusted with the over flow system. Over flow plug ATF level Check

13 Procedure 1. Park the vehicle on the plane area 2. Remove plug 1 3. Remove plug 2 (over flow plug) 4. Add ATF if there is no drops from plug 2 5. Install Plug 2 with O-ring and add 0.5 liter of ATF. 6. Start the engine and move the shift lever from P to D 2times (stay 2 seconds at each shift position) 7. Remove the plug 2 when the ATF temperature reaches 50~60, 8. If the oil drains drop by drop, tighten the plug with O-ring (new one) ATF level Check

14 C3 B1(Band) C1 F1 B2 C2 Counter drive gear Counter driven gear Construction Mechanical System

15 Description of components Clutch / Brake Operation C1 C1 Clutch Connects front planetary carrier to rear planetary rear sun gear C2 C2 Clutch Connects intermediate shaft to rear planetary carrier C3 C3 Clutch Connects front planetary carrier to rear planetary middle sun gear B1 B1 Brake Locks rear planetary middle sun gear B2 B2 Brake Locks rear planetary carrier F1 One- way Clutch Locks counterclockwise rotation of rear planetary carrier Mechanical System Counter Drive Gear Oil Pump Assy. Input Shaft Differential Gear Assy. Counter Gear Assy. Rear Planetary GearFront Planetary Gear Sun Gear Ring Gear Pinion Gear Sun Gear Ring Gear Lock

16 Operation of components Mechanical System Shift Position SolenoidClutchBrakeOne-way Clutch SLC1SLC2SLC3SLB1S1S2C1C2C3B1B2F1 PΟΟΟΟ R V11kph ΟΟΟΟ------Ο- NΟΟΟΟ D 1ST-ΟΟΟ--Ο----Ο E/G B-ΟΟΟΟΟΟ---ΟΟ 2ND-ΟΟ---Ο--Ο-- 3RD-Ο-Ο--ΟΟ--- 4TH--ΟΟ--ΟΟ---- 5THΟ--Ο--ΟΟ--- 6THΟ-Ο---Ο-Ο--

17 D range 1 st gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D1ST-ΟΟΟ--Ο----Ο Power Flow

18 D range 2 nd gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D2ND-ΟΟ---Ο--Ο-- Power Flow

19 D range 3 rd gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D3RD-Ο-Ο--ΟΟ--- Power Flow

20 D range 4 th gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D4TH--ΟΟ--ΟΟ---- Power Flow

21 D range 5 th gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D5THΟ--Ο--ΟΟ--- Power Flow

22 D range 6 th gear Shift Position SolenoidClutchBrake One-way Clutch SLC 1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 D6THΟ-Ο---Ο-Ο-- Power Flow

23 Reverse gear Shift Position SolenoidClutchBrake One-way Clutch SL C1 SLC 2 SLC 3 SLB 1 S1S2C1C2C3B1 B2B2 F1 R V11kph ΟΟΟΟ------Ο- Power Flow

24 Power (Battery, IG), Ground, Inhibitor switch, Input speed sensor, Output speed sensor, ATF Temperature sensor Sports mode switch CAN signals Shift SOL (S1, S2) Lock up SOL (SLU) Line pressure SOL (SLT) B1 SOL (SLB1) C1 SOL (SLC1) C2 SOL (SLC2) C3 SOL (SLC3) Engine start signal Reverse lamp signal Shift lock signal (USA,CAN) TCM (Aisin) Outputs Inputs Inputs & Outputs

25 Integrated components A/T & TCM assembly TCM (including inhibitor switch) TCM connector B - Inhibitor switch position signals (except sports mode switch) - Input and output speed sensors - ATF temperature sensor - All solenoid valves Inputs & Outputs

26 Integrated position sensor F21 (Integrated position sensor with TCU) Conventional type (NSW) Component TCU and NSW integrated unitTCU and NSW separate components Range decision method Non contact type (Detection by Hall IC) Contact type (Energization by fixed and moving contacts) Position Sensor

27 Hall IC position sensor Internal wiring from position sensor to TCM (4 terminals) - Sensor power (5V) - Position 1 - Position 2 - Ground Features - Shift position detection by voltage difference between position 1 & 2 - Neutral position learning : after replacement of TCM or AT assembly - Diagnosis : only by the scan tool - Defected parts : replace the TCM Integrated position sensor

28 Principle The contact-less type Hall IC position sensor has been applied to enhance the durability and reliability. TCM will detect the shift range by receiving the output voltage the Position 1 & 2 Integrated position sensor Shaft Core Hole IC Magnet Core

29 Starting motor control Shift lock (NA only) Reverse lamp Start lock [TCM connector A] The shift range information is used for TCM to control not only shifting but also engine start motor, reverse lamp and shift lock solenoid. Integrated position sensor

30 N position learning Conditions - IG ON - N position - Engine stop - Vehicle speed 0Kph When? - After AT replacement - After TCM replacement Integrated position sensor

31 N position calibration Two arrows must be aligned each other 1) Select P range and IG ON (engine off) 2) Move the shift lever into N range. 3) Align the arrow marks on the TCM cover and inhibitor switch inner rotor and tighten the nut in the shift cable. 4) Following the instruction, teach N position using the scanner. 5) Move the shift lever into P position and IG off. 6) After 5 seconds, check the shift range information on both cluster and scanner moving the shift lever from P to D range. (Upon removing battery, the memorized N position in TCM will not be erased) Integrated position sensor

32 Input speed sensor is installed in the T/M case and it detects the C2 drum rotating speed. Output speed sensor detects the rotating speed of counter drive gear. Based on these signals, TCM will control shifting time, damper clutch and so on. Input & Output Sensor [Output speed sensor] [Input speed sensor] Counter Drive Gear speed sensor (SP) speed sensor (NIN) C2 Clutch Drum

33 Features Output speed sensor connector Input speed sensor connector - Hall IC type - with defected input speed sensor : replace the sensor replace after removing oil pan & valve body - with defected output speed sensor : replace the AT assembly Diagnosis : check the output signal from the sensor connector while rotating the wheels (NG replace the AT) - Failsafe : 3 rd gear fix Input & Output Sensor Hi Low 0

34 The oil temperature sensor, which is integrated with the transmission wires, is installed on the front valve body. It directly detects the oil temperature within the hydraulic pressure control circuit and transmits a signal based on that temperature to the TCM ATF Temperature Sensor Oil Temperature Sensor

35 Features - NTC type sensor - with defected sensor : replace the wiring assembly (ATF sensor cannot be separated from the wiring) - Failsafe : 80 fix (Lock up available, No self-learning control) Temp. ( )Resistance( ) ~ ~ 0.27 ATF Temperature Sensor Temperature/degree C Resistance/ohm

36 Shift control solenoid valve (S1, S2) S1 S2 According to the ON or OFF status of S1 or S2, the 1st gear engine brake operates or the gear shifts into change. As a fail-safe function, if any shift solenoid abnormality occurs, the TCM will disable the current to the solenoids. Solenoid Valve ohm/20degree C Temperature/degree C Resistance/ohm Reference value

37 Shift control solenoid valve (S1, S2) - For engine brake : B2 operates when S1 ON & S2 ON - Failsafe : 3 rd gear fix (all solenoids off) Solenoid Valve GearSLC1SLC2SLC3SLB1S1S2 1 st -ΟΟΟ-- E/G Brake -ΟΟΟΟΟ 2 nd -ΟΟ--- 3 rd -Ο-Ο-- 4 th --ΟΟ-- 5 th Ο--Ο-- 6 th Ο-Ο---

38 Shift control solenoid valve (SLC1, SLC2, SLC3, and SLB1 ) SLB1SLC3 SLC2SLC1 The solenoids linearly control hydraulic pressure in response to signals output from the TCM. Through this, it controls hydraulic pressure to the clutch (C1, C2, and C3) and brakes (B1) for smooth shifting. Solenoid Valve EX OUT IN

39 Shift control solenoid valve (SLC1, SLC2, SLC3, and SLB1 ) - For gear shifting from 1 st ~ 6 th gear - Current control linear solenoid valve - Normally high type : Solenoid ON disengaged, OFF engaged - Failsafe : 3 rd gear fix (all solenoids off) Solenoid Valve ohm/20degree C Resistance/ohm Temperature/degree C Pressure (kPa) Current (A) Pressure by Current (SLC1,SLC2,SLC3,SLB1)

40 Line Pressure control solenoid valve (SLT) In accordance with the value decided in the TCM based on throttle opening signal and engine torque, line hydraulic pressure is controlled by linearly changing the comparable throttle pressure. Through this, it controls operating hydraulic pressure to the clutch and brakes for smooth shifting. SLT EX OUT IN Solenoid Valve

41 - For line pressure control by throttle angle and engine torque - Current control linear solenoid valve - Normally high type : Solenoid ON low line pressure, OFF maximum line pressure - Failsafe : 3 rd gear fix (all solenoids off) Solenoid Valve ohm/20degree C Resistance/ohm Temperature/degree C Pressure (kPa) Current (A) Pressure by Current (SLT) Line Pressure control solenoid valve (SLT)

42 Lock up control solenoid valve (SLU) SLU The lock-up is logically engaged from \3rd gear (S-3.0), 4th gear (Lambda 3.8). But in case of S-3.0, it is very difficult to be engaged from 3rd gear while actual driving condition, that is it is available from 4th gear on the normal road driving. - Resistance : 5 ~ 5.6 (20 ) - Failsafe : 3 rd gear fix (all solenoids off) EX OUT IN Solenoid Valve

43 IG (TCU2 10A) +B (TCU1, 15A) Fuse open : communication error with scan tool : 3 rd gear fix (all solenoids off) Power Supply IG +B GND TCM IG S/W Fuse Battery

44 If the AT or the TCM are replaced, or TCM software is overwritten, be sure to initialize the learnt values and perform initial learning. Only in D range (Not in sports mode). (1) Warm up - ATF temperature : 66 ~ 110 (if not, initial learning cannot be performed) - Do not attempt to raise the oil temperature by stalling the engine (2) N-D, N-R shift learning - N D Maintain 3 seconds at each shift position and repeat 5 times - N R Maintain 3 seconds at each shift position and repeat 5 times (3) Gear shift learning - TPS angle 25 ~ 35% D range 1 st gear to 6 th gear (over 110 kph) coast driving bring the vehicle to a stop within 60 seconds Repeat 10 times. (4) Check learning results TCM Learning

45 Line pressure - At D range idle : 372 ~ 432 kPa, - At R range idle : 580 ~ 695 kPa C1 port C3 port Current Pressure Line Pressure Inspection 2,000 1, IdleStall 300 1,000 R rangeD range Oil pressure (kPa) TPS ratio SLT current (mA) R range D range

46 TCM Terminal Assignment Terminal NO. MarkTerminal Name Terminal NO. MarkTerminal Name A1+BBattery voltageB1SLTGLine pressure control solenoid [SLT-] A2-BlankB2S2Shift solenoid No.2 [S2] A3TIP UPTiptronic input signal upB3SLTLine pressure control solenoid [SLT+] A4TIP DOWNTiptronic input signal downB4SLUGLock-up control solenoid [SLU-] A5STLKStart lock output signalB5S1Shift solenoid No.1 [S1] A6CAN LCAN communication L line (Low)B6-Blank A7TIP MTiptronic input signal ManualB7OTGOil temperature sensor [OT-] A8-BlankB8OTOil temperature sensor [OT+] A9GNDTCM GroundB9SLULock-up control solenoid [SLU+]

47 Terminal NO. MarkTerminal Name Terminal NO. MarkTerminal Name A10-Battery voltageB10SLC1GShift control solenoid assy. [SLC-1] A11IGBlankB11SLC1Shift control solenoid [NIN+] A12-Tiptronic input signal upB12NIN+Input speed sensor [NIN+] A13RVSTiptronic input signal downB13NIN-Input speed sensor [NIN-] A14CAN HStart lock output signalB14SLC3Shift control solenoid assy. [SLC3+] A15-CAN communication L line (Low)B15-Blank A16SFLTiptronic input signal ManualB16SLB1GShift control solenoid assy. [SLB1-] B21SLB1BlankB17SLC2Shift control solenoid assy. [SLC2-] B22SLC3GB18SLC2gShift control solenoid assy. [SLC2-] B20SP-TCM GroundB19SP+Output speed sensor [Sp+] TCM Terminal Assignment