Mg hs as23 principle and functions manual p2

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D3 geargear

Power ow in D3 gear

With the improvement of vehicle speed and running to the

appropriate conditions, the transmission control module

(TCM) processes the input signals from the transmission

input and output shaft speed sensor, throttle position sensor

and other vehicle sensors to determine when the command

connects 1/3/5/7 clutch ow solenoid S3, S7 and A37 oil circuit

pressure solenoid S5 and A15 oil circuit ow solenoid S7, and

command 1/3/5/7 gear clutch engagement At the same time,

command to close 2/4/6/R clutch ow solenoid S4, S8, A6R oil

circuit pressure solenoid S6, and A24 oil circuit ow solenoid

S8 At the same time, the transmission is shifted to 3rd gear

Engage 1/3/5/7 gear clutch

• 1/3/5/7 clutch ow solenoid S3

Open 1/3/5/7 clutch ow solenoid S3, so that S1 signal enters

into 1/3/5/7 clutch circuit Then, 1/3/5/7 clutch oil is conveyed

to the clutch actuator cylinder assembly through #1 ori ce

• Clutch actuator cylinder assembly

1/3/5/7 clutch oil enters the clutch actuator cylinder assembly,

then overcomes the spring force, moves the 1/3/5/7 gear clutch

piston, and engages the 1/3/5/7 gear clutch plate

Engage 35 gear shifting fork assembly

• S7 and A37 oil circuit pressure solenoid S5

Open S7 and A37 oil circuit pressure solenoid S5, so that

energy accumulator oil enters the S7/37 actuator circuit Then,

S7/37 actuator oil is conveyed to A15 oil circuit ow solenoid

S7 and 1/3/5/7 gear logic valve through #7 ori ce

• A15 oil circuit ow solenoid S7

Open A15 oil circuit ow solenoid S7, so that S7/37 actuatoroil enters 15 actuator circuit Then, 15 actuator oil is conveyed

to 1/3/5/7 gear logic valve through #8 ori ce

• 1357 gear logic valveS7/37 actuator oil enters into the 7th gear circuit through1/3/5/3 gear logic valve 15 actuator oil enters into the 1stgear circuit through 5/3/5/7 gear logic valve Both the 3rd gearoil pressure and 5th gear oil pressure are conveyed to the 3/5gear shifting fork actuator piston assembly

• 3/5 gear shifting fork actuator piston assemblyWith the 3rd gear oil pressure greater than the 5th gearoil pressure, move the 3/5 gear shifting fork actuator pistonassembly to the 3rd gear position, so as to drive the 3/5 gearshifting fork assembly, and the transmission is switched to 3rdgear

Release of 2/4/6/R gear clutch

• 2/4/6/R clutch ow solenoid S4Command to close the 2/4/6/R clutch ow solenoid S4, sothat 2/4/6/R clutch oil pressure is discharged from the clutchactuator cylinder assembly

• Clutch actuator cylinder assembly2/4/6/R clutch oil pressure is discharged from the clutchactuator cylinder assembly, so that the spring moves the2/4/6/R gear clutch piston, and the 2/4/6/R gear clutch plate

is released

Release of 2/6 gear shifting fork assembly

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• S8 and A6R oil circuit pressure solenoid S6

Command to close S8 and A6R oil circuit pressure solenoid

S6, so that S8/6R actuator oil pressure is discharged from A24

oil circuit ow solenoid S8 and 2/4/6/R gear logic valve

Command to close A24 oil circuit ow solenoid S8, so that

24 actuator oil pressure is discharged from 2/4/6/R gear logic

valve

• 2/4/6/R gear logic valve

2nd gear oil pressure is discharged to 24 actuator circuit

through 2/4/6/R gear logic valve 2nd gear oil pressure is

discharged to 24 actuator circuit through 6/4/6/R gear logic

valve

• 2/6 gear shifting fork actuator piston assembly2nd gear oil pressure and 6th gear oil pressure are dischargedfrom 2/6 gear shifting fork actuator piston assembly, and at thesame time, the 2/6 gear shifting fork actuator piston assembly

is moved to Neutral (N) position

Build oil pressure and ready to shift

• 2/4/6/R clutch pressure solenoid S2Keep 2/4/6/R clutch pressure solenoid S2 open, so that energyaccumulator oil enters the S2 signal circuit Then, S2 signal

ow is conveyed to 2/4/6/R clutch ow solenoid S4 through

#12 ori ce for shifting to the 4th gear

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D4 geargear

Power ow in D4 gear

connects 2/4/6/R clutch ow solenoid S4, S8 and A6R oil

circuit pressure solenoid S6 and A24 oil circuit ow solenoid

S8, and command 2/4/6/R gear clutch engagem ent At the

same time, command to close 1/3/5/7 clutch ow solenoid

S3, S7, A37 oil circuit pressure solenoid S5, A15 oil circuit

ow solenoid S7, and 1357/246R logic valve pressure control

solenoid S9 At the same time, the transmission is shifted to

4th gear

Engage 2/4/6/R gear clutch

• 2/4/6/R clutch ow solenoid S4

Open 2/4/6/R clutch ow solenoid S4, so that S2 signal enters

into 246R clutch circuit Then, 2/4/6/R clutch oil is conveyed

2/4/6/R clutch oil enters the clutch actuator cylinder assembly,

then overcomes the spring force, moves the 2/4/6/R gear

clutch piston, and engages the 2/4/6/R gear clutch plate

Engage 4R gear shifting fork assembly

• 1357/246R logic valve pressure control solenoid S9

Command to close 1357/246R logic pressure control solenoid

S9, so thatS9 signal oil pressure is discharged from 1/3/5/7 gear

logic valve and 2/4/6/R logic valve

• S8 and A6R oil circuit pressure solenoid S6Open S8 and A6R oil circuit pressure solenoid S6, so thatenergy accumulator oil enters the S8/6R actuator circuit.Then, S8/6R actuator oil is conveyed to A24 oil circuit owsolenoid S8 and 2/4/6/R gear logic valve through #9 ori ce

• A24 oil circuit ow solenoid S8Open A24 oil circuit ow solenoid S8, so that S8/6R actuatoroil enters 24 actuator circuit Then, 24 actuator oil is conveyed

to 2/4/6/R gear logic valve through #10 ori ce

• 2/4/6/R gear logic valveWhen S9 signal oil pressure is discharged, the spring moves the2/4/6/R gear logic valve to the released position 24 actuatoroil enters into the 4th gear circuit through 2/4/6/R gear logicvalve S8/6R actuator oil entersintothe reversecircuitthrough2/4/6/R gear logic valve Both the 4th gear oil pressure andreverse gear oil pressure are conveyed to the 4R gear shiftingfork actuator piston assembly

• 4R gear shifting fork actuator piston assemblyWith the 4th gear oil pressure greater than the reverse gearoil pressure, move the 4th gear shifting fork actuator pistonassembly to the 4th gear position, so as to drive the 4R gearshifting fork assembly, and the transmission is switched to 4thgear

Release of 1/3/5/7 gear clutch

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Command to close the 1/3/5/7 clutch ow solenoid S3, so

that 1/3/5/7 clutch oil pressure is discharged from the clutch

actuator cylinder assembly

1/3/5/7 clutch oil pressure is discharged from the clutch

actuator cylinder assembly, so that the spring moves the

1/3/5/7 gear clutch piston, and the 1/3/5/7 gear clutch plate is

released

Release of 35 gear shifting fork assembly

Command to close S7 and A37 oil circuitpressure solenoid S5,

so that S7/37 actuator oil pressure is discharged from A15 oil

circuit ow solenoid S7 and 1/3/5/7 gear logic valve

15 actuator oil pressure is discharged from 1/3/5/7 gear logic

valve

• 1/3/5/7 gear logic valveWhen S9 signal oil pressure is discharged, the spring moves the1/3/5/7 gear logic valve to the released position, so thatthe 3rdgear oil pressure and 5th gear oil pressure are discharged fromthe 1/3/5/7 gear logic valve

• 3/5 gear shifting fork actuator piston assembly3rd gear oil pressure and 5th gear oil pressure are dischargedfrom 3/5 gear shifting fork actuator piston assembly, and at thesame time, the 3/5 gear shifting fork actuator piston assembly

• 1/3/5/7 clutch pressure solenoid S1Keep 1/3/5/7 clutch pressure solenoid S1 open, so that energyaccumulator oil enters the S1 signal circuit Then, S1 signal

ow is conveyed to 1/3/5/7 clutch ow solenoid S3 through

#13 and #20 ori ces for shifting to the 5th gear

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D5 geargear

Power ow in D5 gear

connects 1/3/5/7 clutch ow solenoid S3, S7 and A37 oil

S7 and 1357/246R logic valve pressure control solenoid S9,

and command 1357 gear clutch to engage At the same time,

command to close 2/4/6/R clutch ow solenoid S4, S8, A6R oil

circuit pressure solenoid S6, and A24 oil circuit ow solenoid

S8 At the same time, the transmission is shifted to 5th gear

Engage 3/5 gear shifting fork assembly

Open 1357/246R logic valve pressure control solenoid S9, so

that energy accumulator oil enters the S9 signal circuit Then,

S9 signal ow is conveyed to 1/3/5/7 gear logic valve and 2/4/6/R

gear logic valve through #3 ori ce

• S7 and A37 oil circuit pressure solenoid S5Open S7 and A37 oil circuit pressure solenoid S5, so thatenergy accumulator oil enters the S7/37 actuator circuit Then,S7/37 actuator oil is conveyed to A15 oil circuit ow solenoidS7 and 1/3/5/7 gear logic valve through #7 ori ce

• A15 oil circuit ow solenoid S7Open A15 oil circuit ow solenoid S7, so that S7/37 actuatoroil enters 15 actuator circuit Then, 15 actuator oil is conveyed

• 1/3/5/7 gear logic valveThe S9 signal ow is conveyed to the 1/3/5/7 gear logicsolenoid, and overcomes the spring force to move the logicvalve so that the S7/37 actuator oil enters the 3rd circuitthrough the logic valve 15 actuator oil enters into the 1stgear circuit through 5/3/5/7 gear logic valve Both the 3rd gearoil pressure and 5th gear oil pressure are conveyed to the 3/5gear shifting fork actuator piston assembly

• 3/5 gear shifting fork actuator piston assemblyWith the 5th gear oil pressure greater than the 3rd gearoil pressure, move the 3/5 gear shifting fork actuator pistonassembly to the 5th gear position, so as to drive the 3/5 gearshifting fork assembly, and the transmission is switched to 5thgear

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Command to close the 2/4/6/R clutch ow solenoid S4, so

that 2/4/6/R clutch oil pressure is discharged from the clutch

actuator cylinder assembly

2/4/6/R clutch oil pressure is discharged from the clutch

actuator cylinder assembly, which makes the spring move the

2/4/6/R gear clutch piston, and the 2/4/6/R gear clutch plate

is released

Release of 4R gear shifting fork assembly

valve

• 2/4/6/R gear logic valveS9 signal ow is conveyed to the 2/4/6/R gear logic valve,overcomes the spring force and moves the logic valve, whichmakes the oil pressure of 2nd and 6th gear is discharged fromthe 2/4/6/R gear

• 4R gear shifting fork actuator piston assemblyReverse gear oil pressure and 4th gear oil pressure aredischarged from 4R gear shifting fork actuator piston assembly,and at the same time, the 4R gear shifting fork actuator pistonassembly is moved to Neutral (N) position

#12 ori ce for shifting to the 6th gear

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D6 geargear

Power ow in D6 position

connects 2/4/6/R clutch ow solenoid S4, S8 and A6R oil

S8, and control 2/4/6/R gear clutch engagement At the same

time, command to close 1/3/5/7 clutch ow solenoid S3, S7,

A37 oil circuit pressure solenoid S5, and A15 oil circuit ow

solenoid S7 At the same time, the transmission is shifted to

6th gear

Engage 2/4/6/R gear clutch

Open 2/4/6/R clutch ow solenoid S4, so that S2 signal enters

into 246R clutch circuit Then, 2/4/6/R clutch oil is conveyed

2/4/6/R clutch oil enters the clutch actuator cylinder assembly,

then overcomes the spring force, moves the 2/4/6/R gear

clutch piston, and engages the 2/4/6/R gear clutch plate

Engage 2/6 gear shifting fork assembly

Open S8 and A6R oil circuit pressure solenoid S6, so that

energy accumulator oil enters the S8/6R actuator circuit

Then, S8/6R actuator oil is conveyed to A24 oil circuit ow

solenoid S8 and 2/4/6/R gear logic valve through #9 ori ce

• A24 oil circuit ow solenoid S8Open A24 oil circuit ow solenoid S8, so that S8/6R actuatoroil enters 24 actuator circuit Then, 24 actuator oil is conveyed

to 2/4/6/R gear logic valve through #10 ori ce

24 actuator oil enters into the 4th gear circuit through 2/2/6/Rgear logic valve S8/6R actuator oil enters the 6th circuitthrough 2/4/6/R gear logicvalve Both the 2nd gear oil pressureand 6th gear oil pressure are conveyed to the 2/6 gear shiftingfork actuator piston assembly

• 2/6 gear shifting fork actuator piston assemblyWith the 6th gear oil pressure greater than the 2nd gearoil pressure, move the 2/6 gear shifting fork actuator pistonassembly to the 6th gear position, so as to drive the 2/6 gearshifting fork assembly, and the transmission is switched to 6thgear

Release of 1/3/5/7 gear clutch

• 1/3/5/7 clutch ow solenoid S3Command to close the 1/3/5/7 clutch ow solenoid S3, sothat 1/3/5/7 clutch oil pressure is discharged from the clutchactuator cylinder assembly

• Clutch actuator cylinder assembly1/3/5/7 clutch oil pressure is discharged from the clutchactuator cylinder assembly, so that the spring moves the1/3/5/7 gear clutch piston, and the 1/3/5/7 gear clutch plate isreleased

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Release of 35 gear shifting fork assembly

Command to close S7 and A37 oil circuitpressure solenoid S5,

so that S7/37 actuator oil pressure is discharged from A15 oil

circuit ow solenoid S7 and 1/3/5/7 gear logic valve

15 actuator oil pressure is discharged from 1/3/5/7 gear logic

valve

• 1/3/5/7 gear logic valve

5th gear oil pressure is discharged to 15 actuator circuit

through 1/3/5/7 gear logic valve 3rd gear oil pressure is

discharged to S7/37 actuator circuit through 1/3/5/7 gear logic

valve

• 3/5 gear shifting fork actuator piston assembly3rd gear oil pressure and 5th gear oil pressure are dischargedfrom 3/5 gear shifting fork actuator piston assembly, and at thesame time, the 3/5 gear shifting fork actuator piston assembly

• 1/3/5/7 clutch pressure solenoid S1Keep 1/3/5/7 clutch pressure solenoid S1 open, so that energyaccumulator oil enters the S1 signal circuit Then, S1 signal

ow is conveyed to 1/3/5/7 clutch ow solenoid S3 through

#13 and #20 ori ces for shifting to the 7th gear

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D7 geargear

Power ow in D7 position

connects 1/3/5/7 clutch ow solenoid S3, S7 and A37 oil circuit

pressure solenoid S5 and A15 oil circuit ow solenoid S7, and

control 1/3/5/7 gear clutch engagement At the same time,

command to close 2/4/6/R clutch ow solenoid S4, S8, A6R

oil circuit pressure solenoid S6, A24 oil circuit ow solenoid

S8, and 1357/246R logic valve pressure control solenoid S9

At the same time, the transmission is shifted to 7th gear

• 1357 clutch ow solenoid S3

Engage 17 gear shifting fork assembly

Command to close 1357/246R logic pressure control solenoid

S9, so thatS9 signal oil pressure is discharged from 1/3/5/7 gear

logic valve and 2/4/6/R logic valve

Open S7 and A37 oil circuit pressure solenoid S5, so thatenergy accumulator oil enters the S7/37 actuator circuit Then,S7/37 actuator oil is conveyed to A15 oil circuit ow solenoidS7 and 1/3/5/7 gear logic valve through #7 ori ce

• A15 oil circuit ow solenoid S7Open A15 oil circuit ow solenoid S7, so that S7/37 actuatoroil enters 15 actuator circuit Then, 15 actuator oil is conveyed

• 1/3/5/7 gear logic valveWhen S9 signal oil pressure is discharged, the spring moves the1/3/5/7 gear logic valve to the released position, which makesthe S7/37 actuator oil enters the 7th gear circuit through thelogic valve 15 actuator oil enters into the 1st gear circuitthrough 1/3/5/7 gear logic valve Both the 7th gear oil pressureand 1st gear oil pressure are conveyed to the 17 gear shiftingfork actuator piston assembly

• 1/7 gear shifting fork actuator piston assemblyWith the 7th gear oil pressure greater than the 1st gear oilpressure, move the 1/7 gear shifting fork actuator pistonassembly to the 7th gear position, so as to drive the 1/7 gearshifting fork assembly, and the transmission is switched to 7thgear

• 2/4/6/R clutch ow solenoid S4Command to close the 2/4/6/R clutch ow solenoid S4, sothat 2/4/6/R clutch oil pressure is discharged from the clutchactuator cylinder assembly

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2/4/6/R gear clutch oil pressure is discharged from the clutch

actuator cylinder assembly, which makes the spring move the

2/4/6/R gear clutch piston, and the 2/4/6/R gear clutch plate is

released

Release of 2/6 gear shifting fork assembly

valve

When S9 signal oil pressure is discharged, the spring moves the2/4/6/R gear logic valve to the released position, so that the2nd gear oil pressure and 6th gear oil pressure are dischargedfrom the 2/4/6/R gear logic valve

• 2/6 gear shifting fork actuator piston assembly2nd gear oil pressure and 6th gear oil pressure are dischargedfrom 2/6 gear shifting fork actuator piston assembly, and at thesame time, the 2/6 gear shifting fork actuator piston assembly

#12 ori ce , so as to realize downshift

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Speci cations

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·Width

·Height

349.6mm512.6mm406.8mm

List of Disposable Assembly Parts:

Locking boltSpring PinShift fork shaft bushing 15x15Inpu t shaft oil sealCone BearingDifferential half axle oil sealOil de ectorDriven Shaft Front BearingGear selection/shift shaft needle bearing

Spring pin (5x26)Gear selection/shift shaft oil sealGear selection/shift shaft bushing

CirclipGear selection/shift shaft linear bearing

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Gear shift control pinOil plug washer

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Description and Operation

System Layout

Transmission Assembly Layout

1 Flange Bolt

2 Closing Panel

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Transmission AssemblyAssemblyAssembly andandand AccessoriesAccessories

1 Bolt - Gear Selection/Shift Bracket

2 Gear Selection/Shift Bracket

3 Oil Level Plug Washer

4 Oil Level Plug

5 Oil Plug

6 Neutral Position Sensor

7 Bolt - neutral position sensor

8 Locating Pin

9 Reverse Lamp Switch/Interlock Pin Washer

10 Reverse Lamp Switch

11 Interlock Pin

12 Oil Plug Washer

13 Transmission Assembly

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3 Gear Selection/Shift Shaft Oil Seal

4 Gear Selection/Shift Shaft Sleeve

5 Gear Shift Cover

6 Gear Selection Rocker Arm Assembly

7 Bolt

8 Circlip

9 Gear Selection/Shift Shaft Linear Bearing

10 Gear Selection/Shift Shaft

11 Gear Shift Control Pin

12 Neutral Position Sensor Signal Block

13 Gear Selection/Shift Sleeve

14 Gear Selection Rocker Arm Shaft Sleeve 1

15 Inner Gear Selection Rocker Arm Assembly

16 Gear Selection Rocker Arm Shaft Sleeve 2

17 Gear Shift Cover Locating Pin

18 Shift Fork Shaft Bushing

19 Spring Pin

20 1st/2nd Gear Fork

21 Shift Fork Shaft 1

22 5th/6th gear fork

23 Reverse Gear Fork

24 Shift Fork Shaft 2

36 Inner Hexagon Bolt

37 Gear Selection/Shift Shaft Needle Bearing

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Input ShaftShaft AssemblyShaft Assembly

1 Inpu t Shaft Front Bearing

2 Inpu t Shaft Rear Bearing

3 Locking Bolt

4 Inpu t Shaft Assembly

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Output ShaftShaftShaft 111 AssemblyAssembly

1 Output Shaft 1

2 1st Gear Needle Bearing and Inner Ring

3 Output Shaft 1st Gear Assembly

4 1st/2nd Gear Synchronizer Assembly

5 2nd Gear Needle Bearing and Inner Ring

6 Output Shaft 2nd Gear Assembly

7 5th Gear Needle Bearing and Inner Ring

8 Output Shaft 5th Gear Assembly

9 5th/6th Gear Synchronizer Assembly

11 6th Gear Needle Bearing and Inner Ring

12 Output Shaft 1 Assembly

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Output ShaftShaftShaft 222 AssemblyAssembly

1 Output Shaft 2 Front Bearing

2 Output Shaft 2

3 Reverse Gear Needle Bearing

4 Output Shaft Reverse Gear Assembly

5 Reverse Gear Synchronizer Assembly

6 3rd Gear Needle Bearing And Inner Ring

7 Output Shaft 3rd Gear Assembly

8 3rd/4th Gear Synchronizer Assembly

10 4th Gear Needle Bearing And Inner Ring

11 Output Shaft 2 Assembly

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Reverse IdlerIdlerIdler GearGearGear ShaftShaft AssemblyShaft Assembly

1 Thrust Bearing

2 Reverse Idler Gasket

3 Reverse Idler Needle Bearing

4 Reverse Idler

5 Reverse Idler Shaft

6 Inner Hexagon Flat Head Bolt

7 Bolt

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Differential AssemblyAssembly

1 Differential Axle Shaft Oil Seal

10 Axle Shaft Gear Gasket

11 Axle Shaft Shaft Gear

12 Bolt

13 Differential Assembly

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Overview

This vehicle is equipped with a 6-speed manual transmission

The shift lever is located at the center cons ole of the

passenger compartment, it provides the driver with 7 choices

for variable speed position, namely, 1st gear, 2nd gear, 3rd

gear, 4th gear, 5th gear, 6th gear and reverse gear The gears

of all positions are engaged by the synchronizer The drive

shaft is tted in the differential assembly at the rear of the

transmission, and it is used to transmit the driving force to the

wheel The transmission housing is made of cast aluminum,

and is connected to the engine cylinder block with bolts The

transmission input shaft and output shaft are supported by

bearings The transmission clutch case is equipped with an oil

ller plug, and there is an oil drain plug at the lower rear side

of the transmission main housing, both of them are sealed

with an aluminum washer The transmission is lled with

lubricating oil so as to lubricate the internal components in a

splashing manner

Gear Shift and Gear Selection

Gear selection is realized by manipulating the shift lever tted

at the center console of the passenger compartment Both

cables have one end connected to the bottom of the shift

lever, and the other end connected to the gear selection

rocker arm and gear shift rocker arm tted outside the

transmission through the connector ring assembly In the

transmission case,the fork shaft is connected with the fork,

turn an appropriate synchronizer to shift to the forward gear

or the reverse gear

The interlock pin cooperates with the set pin to restrict the

sleeve motion When a gear is selected, the sleeve position is

restricted by the interlock pin in the axial direction, and the

set pin will lock the radial motion of the sleeve through sleevegroove

Reverse Gear SwitchThe reverse lamp plunger switch is tted on the transmissionrear housing

Neutral Position Sensor*

For the vehicle equipped with intelligent Stop/Start fuel savingsystem function, the neutral position sensor is xed on thecontrol seat of the transmission, and identi es whether thetransmission is in neutral position by detecting the gearselection/shift shaft position in a non-touch manner With theneutral position as the centre, the area within 8° range bothleft and right sides is de ned as the neutral area, and the areaoutside this range will be cons idered as non-neutral area.The operating temperature of the sensor is: -40~140℃

Sensor Harness End Connector EB076

De nition of Sensor PINs1: Power (12V)

2: N1 (neutral signal 1)3: N2 (neutral signal 2)4: Ground

DifferentialDifferential withtraditional design xed the driven gear of mainreducing gear to differential housing with bolts, differentialhousing supports the planetary shaft pin, planetary gear and

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sun gear The differential assembly is supported by bearings in

the transmission housing

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Transmission Assembly

Drivetrain changesthe speed and directionof rotation through

the engagement between different gears of the input shaft and

output shaft, thereby generating 7 forward gears of different

speed ratio and 1 reverse gear The gear wheels of all other

gears are constantly engaged If the 1st gear is selected,

the synchronizer gear ring is pressed by the synchronizer

gear bushing so as to contact with the conical ring of the

corresponding gear selected In this way, the speeds of both

synchronizer hub and gear are synchronized Ensure that the

taper head on the gear selection/shift sleeve can select the

gear accurately and the gears are remained in the correct

work position After being transmitted from the engine to

the transmission input shaft through the clutch,the torque is

transmitted to the output shaft pinion and main reduction

driven gear and then to the drive shaft through the selected

gear The operation of the 2nd, 3rd, 4th, 5th, 6th and reverse

gears is the same with that of the 1st gear When the reverse

gear is selected, the reverse gear tooth (integrated with the

input shaft) is engaged with the output shaft reverse gear

tooth and reverse idler gear, hence, the rotation direction of

the driven shaft is changed and the reverse gear is achieved

Gear Shift and Gear Selection

When the shift lever is moved to the 1st gear position, the

shift lever will control the gear selection/shift rocker arm

through the cable The gear selection rocker arm rotates

and moves the gear selection/shift shaft through the torque

of the cable, and the gear selection/shift taper head on the

gear selection/shift shaft moves along with it and locates at

the groove of the 1st/2nd shift fork, at this time, the gear

selection/shift taper head shall be completely separated from

the groove of 3rd/4th taper head One end of the interlock

pin will lock 1st/2nd gear Then the gear shift rocker arm

rotates the gear selection/shift shaft through the torque of the

cable, and the gear selection/shift sleeve rotates along with the

gear selection/shift shaft, one side of the gear selection/shift

taper head turns 1st/2nd gear taper block to drive the

operation of 1st/2nd gear synchronizer so as to achieve the

gear selection/shift function of the 1st gear The operations

of other forward gears are the same as that of the 1st gear

When the shift lever is moved to reverse gear position, the

reverse gear wheel is engaged with the reverse idler gear to

change the rotation direction of the output shaft

Neutral Position Sensor*

The neutral signal adopts independent 2-way redundancy

design, to guarantee the safety and reliability of the output

signal (N1, N2) Through hardwires, the N1 signal is inputted

toBCMand the N2 signal to ECM When the transmission is

in neutral position, N1 is a low level signal (Lo), while N2 is a

high level one (Hi); and it is vice versa when the transmission

is engaged at a gear other than neutral

High level is an approximate value that battery voltagesubtracts 2V, and low level is about 0~1.5V

Refer to Diagnosis Manual - Engine - Engine Fuel and ControlSystem - Diagnose Information and Procedure for detailsDifferential

The differential allows the wheels to rotate at different speedswhen the output torques are the same The pinion integratedwiththe output shaft is engaged with the nal drive driven gear

of the differential assembly When the output shaft rotates, andthe wheels swivel straight forward, the torque will be applied

to the whole assembly, and the planetary gear does not rotate.The torque is transmitted to the wheels through drive shaft.When the vehicle takes a turn, the inner wheels will pass ashorter distance at a lower speed Thus it drives the planetarygear to rotate, and the outer sun gear offersa higher speed forouter wheels

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Power Sequence

1 Differential Assembly

2 Output Shaft 1st Gear Assembly

3 Output Shaft 2nd Gear Assembly

6 Output Shaft 1

7 Inpu t Shaft

8 Output Shaft 2

10 Output Shaft 3rd Gear Assembly

11 Output Shaft Reverse Gear Assembly

12 Reverse Gear Assembly

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1st gear

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2nd gear

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3rd gear

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4th gear

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5th gear

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6th Gear

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R Gear

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Speci cations

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Model Dry Single Disc , Hydraulic Booster Clutch

Diameter of driven plate: 240mm

Diameter of pressure plate 240mm

Thickness of driven plate:

New

Service limit

7.3—7.9mm6.5mmDepth of rivet:

New

Service limit

1.2mm (above the rivet head)0.2mm (above the rivet head)Wear loss of driven plate:

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Description and Operation

System Layout

Clutch System Layout

1 Clutch Master Cylinder

2 Clamp - Brake Fluid Reservoir Hose

3 Clutch Master Cylinder Hose

4 Clip - Clutch Hard Pipeline

5 Clutch Hard Pipeline

6 Clutch Master Cylinder Hose

7 Clutch Master Cylinder Pipeline Assembly Bracket

8 Bolt - Clutch Master Cylinder Pipeline Assembly Bracket

9 Clutch Hose Bracket

10 Clamp - Clutch Hose

11 Bolt - Clutch Hose Bracket

12 Manual Transmission

13 Central Release Cylinder Pipeline Assembly

14 Plug - Central Release Cylinder Pipeline Assembly

15 Rubber Plug

16 Central Release Cylinder

17 Bolt - Central Release Cylinder

18 Bolt - Clutch Cover Assembly

19 Clutch Cover Assembly

20 Driven Plate

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Overview

This is a three-piece diaphragm clutch with self-adjusting

function, equipped with a hydraulic clutch release system

This system consists of two main parts, a master cylinder and

a central release cylinder

Clutch Hydraulic System

The master cylinder of the clutch is directly tted on the pedal

box in the passenger compartment, and the push rod is xed

to the clutch pedal box by master cylinder fastening clips

The clutch pipeline is connected to the master cylinder with a

rotary connector, and this kind of connector is useful for re t

and adjustment The other end of the pipeline is connected

to the central release cylinder with quick connector The

pipeline is of a exible type for easy re t and also can buffer

the replacement and vibration generated by the engine

The cylinder connecting piece tted on the manual

transmission case, and the central release cylinder coaxial

with the transmission input shaft form a release mechanism,

the clutch pipeline from the cylinder connecting piece is

connected to the pipeline of the master cylinder through the

quick connector

Clutch Mechanical System

The vehicle with manual transmission is equipped with double

mass ywheel The clutch cover assembly is tted on the

ywheel with three locating pins and is xed with six bolts

Clutch Cover Assembly

The clutch cover assembly is composed of the diaphragm

spring, pressure plate and cover The pressure plate is made

of cast iron and has a smooth plane machined to connect the

driven plate There are 3 pull rings on the outer ring of thepressure plate , whichis then connected to the housing through

a spring The spring is composed of three quenched andtempered steel sheets When the clutch pedal is depressed, itwill pull the pressure plate away from the driven plate Clutchhousing is punched by steal plate

The diaphragm spring is a cas t ring with 18 release ngers inits inner ring There are two round support rings tted onthe housing so that the diaphragm spring can rotate betweenthem The diaphragm spring is not directly connected to thepressure plate When the release bearing applies stress on therelease nger of the diaphragm spring, the diaphragm springwill rotate around the support ring to leave the pressure plate And meanwhile, the spring of the pressure plate connected tothe housing will also be away from the driven plate

Driven Plate

1 Driven plate body

2 Friction plate

3 Spline hubThe driven plate is tted between the ywheel and thepressure plate Its feature is that the spline hub engages thespline on the transmission input shaft The friction plate iscom posed of two discs, which are riveted on each side of thedriven plate body The rivets are tted in the notches in thefriction plate as well as that at the other side to protect thepressure plate and ywheel from damage

Trang 37

Clutch Master Cylinder Sensor

The clutch master cylinder sensor is tted to the master

cylinder for detecting the position of the clutch master

cylinder piston

Fit a permanent magnet to the clutch master cylinder piston

The magnet produces different magnetic eld strength for

different sensor varied with the piston motion

According to the different working states of the clutch master

cylinder, the sensor shall output at most 3 signals:\

• Digital signal: Clutch top-position switch, applied to the

constant speed cruise system

• PWMSignal: Apply to supply the electronic parking

brake

• Digital signal: Clutch bottom-position switch, applied to

supply the engine Stop/Start system

For the engine Stop/Start system (Such as equipments), clutch

bottom-position switch relative to clutch top-position switch

and PWM signal is independent and used to redundancy

check

Trang 38

Hydraulic Operation

When the clutch pedal is depressed, the piston moves in the

master cylinder The piston drives the uid in the master

cylinder to move along the clutch pipeline This pressure is

applied on the piston of the central release cylinder and the

piston will move under the action of hydraulic pressure

When the clutch pedal is released, the release nger of the

diaphragm spring returns to its original position, which pushes

the uid in the central release cylinder to ow back, allowing

the master cylinder piston to return to its original position

Mechanical Operation

When the clutch pedal is depressed, the push rod pushes the

piston to move The pressure produced by the piston motion

is transferred to the central release cylinder, the central release

cylinder pushes the release nger of the diaphragm spring,

and the diaphragm spring will rotate around the support ring

on the pressure plate housing Following the deformation of

the diaphragm spring, its pressure on the pressure plate will

disappear Three leaf springs will pull the pressure plate away

from the driven plate

Disappearance of the pressure on the driven plate applied by

the pressure plate reduces the frictional force between the

driven plate and ywheel The driven plate will skid on the

ywheel and can not transmit the power of the ywheel to

the transmission input shaft

When the clutch pedal is released, the stress on the central

release cylinder will disappear Disappearance of this pressure

allows the diaphragm spring to return to its original position,

the release nger goes back to its original position, pushing

the uid back to the master cylinder from the central release

cylinder

The diaphragm spring rotates around the support ring on the

pressure plate housing, and applies pressure on the pressure

plate, and the pressure plate will overcome the resistance of

the leaf spring, move towards the ywheel and apply stress on

the driven plate

The pressure on the driven plate applied by the pressure plate

increases the frictional force between the driven plate and

ywheel When the clutch pedal is released, the frictional

force will increase, the rotational motion of ywheel is

transmitted to the driven plate , and then it is transferred to

the transmission input shaft

When the pedal is fully released, the force on the pressure

plate applied by the diaphragm spring will press the driven plate

on the ywheel, making no skidding between them

Clutch Master Cylinder Sensor

The clutch master cylindersensor mainly supply 2 switch signal:

• Clutch top-position switch (CTS) signal:

When the clutch pedal is depressed, the clutch starts

to work The clutch position sensor supply a clutchhigh-position switch (CTS) signal for EMS; the signalapplies to the constant speed cruise; its travel is 3–7mm(From the top)

• Clutch bottom-position switch (CBS) signal:

When the clutch pedal achieves the maximum travel, theclutch disengages completely The clutch position sensorsupply a CBS signal for the BCM; this signal will be used

by the stop/start system; its travel is 19-25mm (From thetop)

Trang 39

Power Transfer Unit -AWD

Speci cations

Trang 40

Lubricant Model Idemitsu Apolloil Wide Gear LW 80W-90 GL5

Maximum Output Torque 1,000Nm

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Số trang	249
Dung lượng	8,92 MB
File đính kèm	MG hs as23 principle and functions manual p2.zip (9 MB)