Mitsubishi Galant

1990 — 2001 of release

Repair and car operation



Mitsubishi Galant
+ Identification numbers of the car
+ Governing bodies
+ Settings and routine maintenance
+ Engine
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Control systems of the engine
- Manual transmission
   + 5-step manual box of gear shifting (RKPP)
   - Automatic transmissions (AT)
      General information and functioning principle
      AT problem diagnostics - the general information
      The adjustments made without removal of AT from the car
      Removal and installation of the pallet of a case of AT
      Removal, installation and adjustment of the sensor switch of permission of start
      Removal and AT installation
      Major maintenance of AT
   + Transfer case
+ Coupling and transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





AT problem diagnostics - the general information

AT refusals occur on one of the following five reasons more often:

a) Decrease in efficiency of return of the engine;
b) Violation of adjustments;
c) Malfunction of hydraulics;
d) Mechanical damages;
e) Failures of the onboard processor / its alarm chain.

Problem diagnostics always should begin with the simplest checks: estimate level and ATF condition (see. Head of Control and routine maintenance), check adjustment of drives of gear shifting and a butterfly valve. Further, carry out trial runs of the car for the purpose of determination of efficiency of the brought corrections. If to eliminate a problem it was not possible, it is necessary to drive away the car on car repair shop for more detailed diagnostics with use of the special equipment. The description of violations of functioning of AT some of symptoms is provided in the Section devoted to problem diagnostics of knots and systems of the car at the beginning of the real Management.

List of the most typical refusals of AT

See also corresponding subsection in the Section devoted to problem diagnostics of knots and systems of the car in Introduction to the real Management.


Transmission provides car movement forward or back

· Adjustment of drafts of switching is broken;
· ATF/is underestimated level hydraulic pressure as a result of violation of passableness of the oil filter, the wrong installation of klapanny assembly, or damage of the reduktsionny valve/managing director of the valve of the converter of rotation fell.

Movement is absent in provisions "D" and "2"

· The forward coupling of coupling is faulty

Forward transfers do not function

· The back coupling of coupling is faulty;
· The N-D accumulator valve is faulty.

The engine глохнет when switching transmission from the situation "N" in situation "D" or "R"

· The engine does not develop the demanded capacity;
· Klapanny assembly of AT is incorrectly established;
· The control ball of klapanny assembly is jammed;
· The valve of coupling of the converter of rotation, or the N-D accumulator valve is faulty.

The box revolves at advance


· ATF/hydraulic level pressure fell;
· The one-pass coupling of coupling is faulty;
· Klapanny assembly is faulty;
· The back coupling of coupling is excessively worn-out.

The box revolves at reverse inclusion


· ATF/hydraulic level pressure fell;
· The brake contour lowered transfers/reverse is faulty;
· The forward coupling of coupling is excessively worn-out;
· Klapanny assembly is faulty.

Too weak reception of the car at movement on the 2nd and 3rd transfers takes place


· ATF/hydraulic level pressure fell;
· The rotation converter is faulty;
· The back coupling of coupling is faulty;
· Faulty/are wrong klapanny assembly is established;
· Brake assembly of inclusion of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken.

Efficiency of braking by the engine in a mode "L" is reduced


· Klapanny assembly is faulty;
· Brake assembly of modes lowered transfers/reverse is faulty.

Turns останова the converter of rotation are excessively underestimated


· The capacity developed by the engine is insufficient;
· The rotation converter is faulty.

Turns останова the converter of rotation are excessively overestimated


· ATF/hydraulic level pressure fell;
· The one-pass coupling of coupling is faulty;
· The forward coupling of coupling is faulty;
· The back coupling of coupling is faulty;
· Klapanny assembly is faulty.

The car moves at the transmission transferred to the situation "N"


· The lobby or the back coupling of coupling is faulty.

Transmission is not transferred to parking situation


· Adjustment of a drive of switching is broken;
· The mechanism of inclusion of the situation "R" is faulty.

Discrepancy between chosen and actually joining modes takes place


· ATF/hydraulic level pressure fell;
· Klapanny assembly is faulty;
· The forward coupling of coupling is faulty;
· The brake tape of inclusion of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The operating regulator is faulty.

There is no transmission switching on a low gear in any of provisions


· Serviceability of functioning of a butterfly valve is broken;
· The valve of switching of 1/2 transfers is faulty;
· The valve of switching of 2/3 transfers is faulty;
· The operating regulator is faulty.

Serviceability of switching of transmission from the 1st transfer on the 2nd is broken


· ATF/hydraulic level pressure fell;
· Passableness of the oil filter is broken;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The forward coupling of coupling is faulty;
· The operating regulator is faulty;
· Klapanny assembly is faulty.

Serviceability of switching of transmission from the 2nd transfer on the 3rd is broken

· ATF/hydraulic level pressure fell;
· Passableness of the oil filter is broken;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The forward coupling of coupling is faulty;
· The operating regulator is faulty;
· Klapanny assembly is faulty.

Switching of the 1st transfer on the 2nd and on the 3rd occurs to the 2nd too sharply

· Adjustment of a cable of a drive of a butterfly valve is broken;
· Klapanny assembly is faulty;
· The operating regulator is faulty;
· The forward coupling of coupling is faulty;
· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken.

Switching of the 3rd transfer on the 2nd and on 1st occurs to the 2nd too sharply

· The brake tape of the kickdown mode is faulty;
· Adjustment of the servo-driver of the kickdown mode is broken;
· The operating regulator is faulty;
· Klapanny assembly is faulty.

The rotation converter at work publishes a howling sound

· The oil pump is faulty.

The converter of rotation jingles at work

· The driving disk burst;
· Weakened a bolt of fastening of the converter of rotation to a driving disk.

Primary checks

 PERFORMANCE ORDER

1. During a short trip warm up transmission to normal working temperature.
2. Check ATF level (see. Head of Control and routine maintenance):

a) If liquid has not enough, make the corresponding adjustment, having added necessary quantity of fresh ATF. Be convinced of correctness of the carried-out adjustment according to indications measuring щупа, then check transmission on existence of signs of external leaks;
b) If level is excessively high, merge surplus of ATF, then check it on existence of traces of presence of the cooling liquid, testifying to violation of tightness of internal partitions of the radiator separating its heat exchanger from lateral tanks with ATF;
c) If ATF is made foam, empty transmission and fill it with fresh liquid, - merged ATF check on existence of traces of presence of cooling liquid.
3. Check installation of turns of idling of the engine (see. Head of the Power supply system and release). In case of need drive away the car on car repair shop for performance of the corresponding adjustments.

If the engine not as it should be, it is not necessary to start performance of primary checks of transmission until the corresponding corrections will be made.

4. Make sure of correctness of adjustment and smoothness of a course of a draft/cable of a drive of switching of draft.


Diagnostics of leakages of ATF

General information

The majority of leaks easily come to light at visual check. Repair usually consists in replacement of the corresponding defective epiploon or laying. If to reveal a leak source during external survey it is not possible, act, as it is described below.

First of all it is necessary to exclude probability of a mistake in definition of the nature of leak. It is not necessary to confuse ATF to impellent oil or brake liquid (transmission liquid usually has dark red color).

For identification of a source of leak make short (some kilometers) a trip, then park the car over the outspread blank sheet of a cardboard. Later few minutes the source of leak can be revealed in the wake of liquid dripping on a cardboard.

Attentively examine a suspected site and a surface surrounding it, special attention giving to joints of interfaced prokladochny surfaces. For the purpose of expansion of a corner of the review use a pocket pocket mirror.

If to reveal a leak source still it is not possible, carefully wipe a surface of a suspected site the rags moistened with solvent, then dry it.

Make one more short trip, this time often changing speed of movement, then again examine the cleaned suspected site.

After identification of a source of leak, it is necessary to define and eliminate the reason of its development, and only then to pass to performance of necessary recovery operations. Replacement of the damaged laying will not lead to desirable result if to leave not eliminated the defect of the interfaced surface which has led to an exit of a sealant out of operation. So, the deformed flange it is necessary отрихтовать.

In below-mentioned subsections the most typical reasons of development of leakages of ATF and a condition which should be executed that there was no recurrence are listed.

Part from the listed requirements cannot be executed without use of the special equipment. In this case the car should be driven away on car repair shop.


Leaks through prokladochny surfaces

 PERFORMANCE ORDER

1. Periodically examine the pallet of a case of transmission. Check existence on the places and reliability of a tightening of fixing bolts, watch, that on a cover there were no traces of mechanical damages (deformation of the pallet can lead to failure of the klapanny assembly located in transmission).
2. Excessively hard tightening of fixing bolts, violation of passableness of the ventilating line, mechanical damage of a sealing surface of a case of transmission, laying destruction, and also emergence of cracks belong to number of the possible reasons of development of leaks via the pallet or a poroznost of walls of a case. If laying of the pallet or a case of transmission is formed by a hermetic pillow, the probability of the wrong choice of type of the last is not excluded. To leaks through laying of the pallet can lead also case overflow by transmission liquid, or increase of pressure of ATF.


Leaks through epiploons and cuffs

 PERFORMANCE ORDER

1. Level/pressure of ATF, violation of passableness of a ventilating branch pipe, mechanical damage of walls of a landing nest, damage out of operation belong to number of the most typical reasons of an exit of epiploons of transmission excessively high actually an epiploon, or the wrong installation of the last. The probability of damage of a pin of the shaft passed in an epiploon, or excessive люфт the last as a result of wear of bearings is not excluded also.
2. Check a condition and correctness of landing of a sealing cuff of a directing tube measuring щупа. Periodically examine on existence of signs of leaks a surface around an arrangement of a driving gear wheel of the speedometer/sensor of speed (VSS). In case of need make replacement of a sealing ring.


Leaks through defects in walls of a case of transmission

 PERFORMANCE ORDER

1. Formation of cracks or a time in a body of a case of transmission can be the reason of development of leakages of ATF, - consult at specialists of car-care center.
2. Check tightness of shtutserny knots of connection of hoses of a cooler of ATF.


Leaks through сапун and a jellied mouth

 PERFORMANCE ORDER

Leaks through сапун ventilation or a jellied mouth can occur owing to overflow of transmission, hit in ATF of cooling liquid, passableness violation сапуна / a ventilating branch pipe or returnable drainage openings.


Check of serviceability of functioning of mechanical subsystems of AT

Check on completely braked car (stall test)

 PERFORMANCE ORDER

1. Operability of transmission and the engine is made by measurement of frequency of rotation of a cranked shaft in the provisions "R" and "D" AT at completely braked car.

ATF should be heated-up to normal working temperature (50 ÷ 80°С). Duration of each check should not exceed five seconds. Check should be made strengths of two people: one should watch wheels of the car, the second makes necessary manipulations in car salon.

2. Brake lobbies and back wheels of the car.
3. Connect to the engine a tachometer.
4. Completely cock the parking brake.
5. The left foot squeeze out against the stop a pedal of a foot brake.
6. Transfer a control lever a transfer case to the situation H2.
7. Start the engine. Transfer the AT selector lever to situation "D", squeeze out against the stop a pedal of gas and quickly consider tachometer indications.

If during check performance back wheels of the car start to rotate before frequency of rotation of the engine will reach demanded value (2300 ÷ 2600 rpm), release a pedal of gas and stop check.

8. Make similar check with transfer of transmission to the situation "R".
9. If frequency of rotation of the engine in both cases appears identical and below demanded, therefore, the engine does not develop full capacity, or the coupling of a free wheeling of the AT hydrotransformer is faulty.

If frequency is lower demanded on 600 rpm, the hydrotransformer is probably faulty actually.

10. If frequency of rotation of the engine is higher than transmission demanded in situation of "D", it can testify to excessive pressure decrease in the main highway, pro-slipping in the coupling of a free wheeling No. 2, violation of serviceability of functioning of the coupling of a free wheeling of a raising planetary row, or pro-slipping in the coupling of direct transfer of a transfer case.
11. Excess of frequency of rotation of the engine in the provision "R" of transmission testifies to pressure drop in the main highway, pro-slipping in the coupling of direct transfer, pro-slipping in a brake of the first and back transfers, violation of serviceability of functioning of the coupling of a free wheeling of a raising planetary row, or pro-slipping in the coupling of direct transfer of a transfer case.
12. If turns of the engine are overestimated in both provisions of transmission, means, or pressure excessively fell in the main highway, or level of ATF does not correspond to demanded value, or serviceability of functioning of the coupling of a free wheeling of a raising planetary row is broken, or pro-slipping in the coupling of direct transfer of a transfer case takes place.


Check of time of delay of switching

 PERFORMANCE ORDER

1. If at the engine working at single turns to transfer the selector lever to one of advance ranges, till a start of motion should pass some time. On duration of this delay it is possible to judge serviceability of functioning of blocking couplings of a raising planetary row, a forward course, direct transfer and a brake of the first and back transfers.

Check should be made on the heated-up engine to normal working temperature. The end result should be received a method of averaging of results of three checks, between each of which should pass not less than one minute. It is provided detailed descriptions of a course of performance of this check below.

2. Completely cock the parking brake. Transfer a control lever of a transfer case to the situation H2.
3. Start the engine and check turns of its idling, - in case of need make the corresponding adjustment.
4. Transfer the selector lever from the situation "N" to situation "D" and by means of a stop watch measure delay time, - average value of three consecutive measurements should not exceed 1.2 seconds.
5. Operating in a similar manner, define time of a delay of inclusion of a reverse gear which should not exceed 1.5 seconds.
6. Too low pressure in the main highway, violation of serviceability of functioning of the coupling of a forward course, the coupling of a free wheeling of a raising number of planetary assembly, or a brake of the first and back transfers can be the reason of excessive size of a delay of inclusion.


Hydraulic checks

General information

 PERFORMANCE ORDER

For performance described below checks the help of the assistant is required.

1. Check level and ATF condition (see. Head of Control and routine maintenance).
2. During a short trip warm up transmission to normal working temperature.
3. To Poddomkratta the car also establish it on props, - driving wheels should appear completely torn off from the earth.
4. Operating according to instructions of manufacturers of the device, connect a tachometer. Arrange a tachometer so that its indicator was well looked through from a driver's place.
5. Find unions of connection of a manometer on lateral walls of a case of transmission, near the line of its joint with the pallet. Turn out a stopper and connect a transitional nozzle of a measuring instrument to the corresponding union.

For some measurements the manometer with a scale to 28 kgfs/cm2 (is required see. Specifications).


6. Make measurements of hydraulic pressure of AT at various turns of the engine and in various positions of the lever of the selector. Compare results of measurements to requirements of Specifications. In case of need make the corresponding regulriovka, replace defective components.
7. Having finished measurements tighten jams of unions with demanded effort.


The analysis of results of check of pressure in lines

F3А21 transmission

 PERFORMANCE ORDER

1. Excessively low pressure in provisions "D", "L" and "2" at normal indications in the situation "R" testifies to existence of leaks in a contour of the back coupling of coupling, or through a sealing ring of the accumulator 1-2.
2. The underestimated pressure in provisions "D" and "R" at norm in situation "L" speaks about leaks in a contour of the forward coupling of coupling.
3. The underestimated pressure in provisions "D" and "L" at normal in situation "2" is the certificate of leaks in a contour lowered transfers/reverse.
4. The lowered pressure in all modes can indicate malfunction of the oil pump, weakening of bolts of fastening of klapanny assembly, violation of passableness of the filter or jamming of the valve of a regulator of pressure.


F4А20 series transmissions (F4А22 and F4A23/33/51)

 PERFORMANCE ORDER

1. The reasons of understating/overestimate of pressure in all lines can be: violation of passableness of the oil filter, violation of adjusting parameters of an operating regulator, jamming of the valve of a regulator of pressure, the wrong pressure of dumping of the oil pump, leakage of ATF in klapanny assembly.
2. The wrong reduktsionny pressure can testify to violation of passableness of the reduktsionny filter, jamming of the reduktsionny valve, or development of leaks in klapanny assembly.
3. The wrong pressure in the line of a brake contour of the kickdown mode speaks about violation of serviceability of functioning of the servo-driver of a mode, or refusal of functioning of klapanny assembly.
4. The reasons of the wrong indication at measurement of pressure of the forward coupling of coupling can be: leakages of ATF in the kickdown mode servo-driver, or klapanny assembly, refusal of klapanny assembly, leak on the piston or the holder of the coupling.
5. The wrong pressure of the face coupling indicates leakages of ATF on the coupling / клапанной to assembly, or violation of serviceability of functioning by the last.
6. The wrong pressure in the brake line lowered transfers/reverse indicates leakages of ATF on a site between klapanny assembly and a transmission case (a sealing ring), refusal of functioning of klapanny assembly or leak via the piston or the holder of the corresponding brake assembly.
7. The reasons of the wrong indication at measurement of pressure of the converter of rotation can be: leakages of ATF in a maslookhladitel, or lines of a connecting path, violation of serviceability of functioning of the converter, leak through an epiploon of primary shaft, jamming of the electromagnetic valve of coupling of the converter (TCCSV valve), or failure of the valve of management of the converter.


Check of pressure of an operating regulator (F3А21 transmission)

 PERFORMANCE ORDER

1. Need for performance of this check arises only in case of violation of correctness of the moments of switching of transmission. Adjustment of a cable of a drive of a butterfly valve should not be thus broken.
2. Connect a manometer to the corresponding union on a transmission case.
3. Consider measuring instrument indications in the provision "D" of transmission. Compare results of measurement to requirements of Specifications.
4. At the set speed of movement of the car jamming of the valve of an operating regulator, or violation of passableness of the filter of a regulator can be the reason of deviations of pressure.
5. The operating regulator should in due time and react smoothly to measurement of speed and come back to base pressure (0 ÷ 20 kPa) at a vehicle stop.


Trial runs

Tests should be made at heated-up to normal working temperature (50 ÷ 80 °C) by ATF.


The moments of switching of modes of a transfer case (Н2, Н4 and L 4) are various, besides, in the L4 mode are forbidden inclusion of the 4th transfer and hydrotransformer blocking.


Check in a range of "D" in normal and sports operating modes of AT

 PERFORMANCE ORDER

1. Transfer the AT selector lever to situation "D", squeeze out against the stop a pedal of gas and hold her in this situation. Check the moments of gear shifting 1-2, 2-3 and 3-4, - compare results of check to requirements of Specifications.
2. Check is made for normal and sports modes of functioning of AT.
3. Absence of switching 1-2 testifies to an entrance out of operation the electromagnetic valve No. 2, or a valve 1-2 zalipaniye.
4. For absence of switching 2-3 the electromagnetic valve No. 1 answers, the probability of a zalipaniye of the valve of switching 2-3 is not excluded also.
5. In the absence of switching 3-4 check a valve 3-4 condition.
6. Violation of serviceability of functioning of a butterfly valve and valves of switching 1-2/2-3/3-4 can appear the reason of failure of the moments of gear shifting.
7. Absence of blocking of the hydrotransformer speaks failure of the electromagnetic valve No. 3, or a zalipaniye the valve of inclusion of blocking.
8. Estimate smoothness of gear shifting. By the reason of emergence of pushes violation of serviceability of functioning of the hydroaccumulator, or the control ball valve can be put excessively high pressure in the main highway.
9. Moving with the blocked hydrotransformer, or on the 4th transfer, estimate intensity of vibrations and a noise background.

Violation of balancing of the driveshaft can be the reason of emergence of vibrations and noise also.

10. Disperse the car before inclusion of the 4th transfer and, braking, define the moments of switching 4-3, 3-2 and 2-1. compare results of check to requirements of Specifications.
11. Estimate smoothness lowering switchings.
12. Check quality of blocking of the hydrotransformer, - at uniform movement on the 4th transfer blocking should occur for speed about 75 km/h. Slightly press a gas pedal, - turns of the engine should not change considerably, otherwise blocking of the hydrotransformer is broken.


Check in a range “2”

 PERFORMANCE ORDER

1. Transfer the AT selector lever to situation "2", squeeze out against the stop a pedal of gas and hold her in this situation.
2. Define the moment of switching 1-2, compare result of check to requirements of Specifications.

In this mode of switching 2-3, 3-4 and blocking of the hydrotransformer are forbidden; at movement with speed of 100 km/h and above braking by the engine is forbidden.

3. Moving on the 2nd transfer, release a pedal of gas and estimate efficiency of braking of the car the engine. If braking is absent, therefore, the brake of providing this mode is faulty.


Check in a range of "L"

 PERFORMANCE ORDER

1. At mode "L" inclusion any raising switchings are forbidden, - the car should move all the time on the first transfer.
2. Release a pedal of gas and estimate intensity of braking by the engine. If braking is absent, therefore, the brake of inclusion of the first and back transfers is faulty.
3. Estimate noise level and vibrations in the course of car braking by the engine.


Check in “R” range

 PERFORMANCE ORDER

Transfer the AT selector lever to the situation "R" and begin movement in squeezed out against the stop a gas pedal, - pro-slipping of frictional elements of management should be absent.


Check in a range of "R"

 PERFORMANCE ORDER

Park the car on a bias not less than 5 ° and transfer the selector lever to the situation "R", the parking brake do not cock, - the car should remain motionless.