It should be said that before driving, you should warm up ANY machine, do not “tear” until the car is fully warmed up. The DP0, AL4 automatic device is assisted in this by a special thermostat, it is both mechanical and electrical, depending on the years of manufacture.
In this article, we will try to consider one of the ways to solve the problem of automatic transmission shocks, transition to emergency mode and other delights such as pressure spread.
I would like to repeat and reiterate that it is NORMAL for this box (after all, this is a development since the 80s, it is just constantly being modernized)
• Drain the automatic transmission oil.
• Disconnect the connectors of the electromagnetic secant (sequential) valves by carefully lifting them with a screwdriver;
Old manufacturer ACUTEX, new Borg Warner.
• When replacing the valves with a new sample, they must be activated through the Peugeot Planet 2000. Old software versions of AL4 computers are not compatible with new EMC!
• Unscrew 8 torxes, remove, wash. Under the lid there will be a small filter and an electrovalve-modulator, remove it, wash it.
• Putting it up in the reverse order.
3. Reinstalling the valve body
• Be careful not to get the wiring under the valve body, otherwise it can be damaged and you will have a short circuit to the body.
ATTENTION: Make sure the mechanical valve (6) fits into the shoulder (A) of the toothed sector (16).
• Refit the fixing bolt of the hydraulic unit (Tightening torque 0.8 da.Nm) Follow the sequence shown;
4. Fill in oil, check the level
After assembly, fill in new oil. Mobil ATF LT 71141 (earlier they were released under the esso and total brands, but total was bought by mobile).
• Fill in oil, 4.5 liters. Bring the automatic transmission oil temperature to 58-68 degrees. (Usually turning on the first fan speed or using the Peugept Planet 2000);
As you can see, basically only one valve wears out. Photo 2.
Disassembled valve. So the valve does not need to be disassembled just to be removed, rinsed and swapped. It is recommended to replace the O-ring art. 2578.13 Photo 1.
The location of the temperature sensor, if this dachik is not working properly, then the automatic transmission can also get into emergency mode. Changes with the scythe.2529 26
If you buy a new one, you change the EVM pressure control valve.
As it turned out, this GB is not only a problem with two valves, but also the rods themselves, in some places they are simply not tight. In order to fix this, the European supplier to the conveyors of automotive giants and the manufacturer of parts, SONNAX, made a repair kit, one BUT, it can be delivered in high-precision technology, because boring of several channels and replacement of standard pushers with more advanced and sealed ones will be done.
VIDEO
Since the French cars came to our market, the popularity of technology has been constantly growing. Automotive giants PSA Group (Peugeot Citroen) and Renault Group supply products to 200 countries of the world, including our region.
Today there is a tendency to buy cars with front-wheel drive, equipped with power plants with a volume of up to two liters, and an automatic transmission. French manufacturers required such a transmission. Desired characteristics of the designed gearbox, small dimensions and weight, but not at the expense of reliability and compatibility with popular power plants.
After the work carried out, by the joint efforts of the designers of PSA and Renault, an automatic hydromechanical transmission equipped with electronic control, labeled AL4, was launched on the market. To date, the number of produced gearboxes of the model surpasses the production of similar products for cars with front-wheel drive and an engine with a volume of 1.4 - 2.0 liters in terms of indicators.
The AL4 automatic transmission was introduced to the automotive market in 1999. Initially, the unit was intended for installation on Renault cars, according to the company's classification, the transmission was marked as DP0.The gearbox was installed on popular Renault models and soon began to be used on the PSA Group conveyor, the transmission began to be labeled as AL4 (HP16), there is a rare designation BVA.
Automatic transmission AL4 (DP0) was installed on cars:
The transmission was designed for use on front-wheel drive vehicles, paired with 1.4 to 2.0 liter units. Some automatic transmission modifications differ among themselves in the case, drive gears and settings. The automatic transmission is simple and reliable, the design does not provide for unnecessary parts and mechanisms. The margin of safety laid down in the calculations is able to give the mechanism the ability to withstand an impulse with a force of up to 210 Nm, however, to increase the resource, these indicators are limited by the settings.
Brief technical characteristics of automatic transmission AL4 (DP0) are presented in the table:
The main advantage, transmissions, reasonable cost, this allowed the automatic machine to become popular among cars with a small engine displacement. The gearbox received positive reviews and popularity, which later made it possible to take the automatic transmission as the basis for an improved modification. Together with Siemens, an improved model AL4 was released, which was equipped with a Porsche Tiptronic System, while the mechanics of the machine did not change
The transmission slide is located in the center of the passenger compartment. Purpose, selection of the desired mode, by acting on a special device of the contactor and the spool, which switches the modes of hydraulics. The rocker is equipped with six positions; switching takes place by moving along the groove of the selector panel.
Gear selector lever positions:
P - parking mode, transmission is locked, start of the power plant is possible;
R - reverse mode, when turned on, the reverse lights simultaneously light up;
N - neutral mode, the start of the power plant is possible;
D - automatic adaptation mode "Drive", shifting forward gears from first to fourth and vice versa;
3 - Automatic mode, limited to three gears (1-2-3 and vice versa);
2 - Automatic mode, limited to two gears (1-2 and vice versa);
Modes "2" and "3" are automatically limited as they are controlled by the computer.
Important! To unlock the gear lever from the "P" position, turn on the ignition and press the brake pedal, the "Shift-Lock" function.
The gearbox is equipped with a special mechanical protection mechanism that prevents damage to the transmission parts in the event of an incorrect transition from one position of the wings to another. The transition from the following provisions without fail occurs through the provisions:
In order to meet the needs of the driver in driving with the use of additional speed modes, a program selector is structurally provided. The mechanism is equipped with three keys and is located on the side of the stage.
Shift rocker paired with a program selector:
Standard program (no keys pressed, rocker in position "D"):
The program is considered the main one; when using it, the computer analyzes the driving style and adapts it to the road conditions and the load of the car. The main goal is to achieve lower fuel consumption and optimal distribution of effort;
Program "Sport" (key "S" pressed, slide in position "D"):
The use of the program assumes automatic gear shifting, but at the same time the computer gives preference to a sporty style and does not pay attention to the amount of fuel consumed;
Snow program ("*" key pressed, curtain in "D" position):
Using the program, the computer adapts to the conditions of the slippery road surface. Driving begins with second or third gear, with infrequent downshifts. This mode allows you to reduce the wear of the gearbox mechanisms and increase its service life;
Mode of forced limitation of the first gear (key "1" is pressed, the rocker is in position "2"):
The transmission will only operate in first gear.
When you move the wings to the "P" position without pressing the brake pedal, the automatic transmission selector will be locked. When the vehicle is stationary and the engine speed is greater than 2000 rpm, there is no gear shift when the lever is moved to the "D" position.
Important! When the ignition is turned off and then turned on, the computer automatically switches to the standard program.
Indication on the information board:
During the operation of the box, the backlit program panel informs the driver:
Information about the position of the rocker arm;
Information about the program being used;
Information about the transition to the standby mode.
Instrument panel display:
Despite the positive reviews and popularity of the transmission, AL4 automatic transmissions have vulnerabilities. The malfunctions observed at the mechanism, as a rule, occur with most boxes of this type.
Dull knocking and jolts at the start. Symptoms occur if you start driving without preliminary warming up the box. The reason for this manifestation lies in the difference in oil pressure indicators. The data used by the computer to calculate the required modes does not match the actual characteristics. Cause, malfunction of the pressure regulator in the valve plate. In addition, a possible reason is an insufficient level of transmission fluid, and a violation of the tightening torques of the bolts that secure the valve body.
To eliminate the defect, they check if oil is leaking into the AL4 automatic transmission, analyze the condition of the heat exchanger, replace the lubricant, remove the hydraulic block and change the valves. If the mileage of the box is more than 100,000 km, full service will be required, including dismantling, disassembly, flushing, of the valve plate. In the future, the stove will need to be adjusted and adjusted. After completing the work, reconfigure and clean the on-board computer of the car.
Pressure regulator No. 144431:
Gears are shifted with a delay. Breakage is accompanied by jamming of the rocker arm in the "P" position. Sometimes, on the contrary, the rocker switches from a position without pressure on the brake pedal. Typically, the culprit for non-standard behavior is a malfunction of the brake sensor.
To eliminate the problem, change the limit switch, check and replace the damaged electrical harness of the switch.
Brake pedal limit switch:
Knocking and jolting when the car is moving, flashing error message Behavior manifests itself in a moving vehicle, both warm and cold gearboxes fail. An increase in the number of revolutions is often observed, although there is no gear change, the clutch of the car seems to slip.
The reason lies in the breakdown of the valve that controls the blocking of the hydraulic transformer, as well as in the hydraulic valve, which is responsible for the correct pressure in the hydraulic block.
Important! With these symptoms, stop using the car. Further driving on faulty vehicles is fraught with breakage of the hydraulic transformer brake.
To eliminate the problem, the automatic transmission is checked for transmission fluid leaks, the heat exchanger is checked, the hydraulic block is dismantled with the replacement of valves. In addition, a complete ATF fluid change in the transmission must be performed. Strong wear and box mileage over 100,000 km indicates the advisability of replacing the hydraulic unit with a new one. The work is accompanied by the subsequent loading of a new program into the on-board computer of the car.
Switching the scenes is accompanied by the absence of the indicator of the selected mode on the vehicle's information board. Symptoms are observed mainly when switching the scenes from parking mode to reversing mode, as well as when switching the scenes from standard mode to neutral mode.
The cause of the AL4 automatic transmission malfunction lies in the breakdown of the gearbox switch.In addition, this behavior is typical in the event of a device settings failure or a failure of the sector responsible for the selection of gears of the AL4 gearbox. Also a possible reason is the selector cable, which is loosely fixed in the bracket and constantly jumps out of it.
A switch malfunction is possible due to moisture ingress, factory defect, severe wear and tear. Elimination boils down to replacing or adjusting the above listed parts.
The problems described are often encountered in the operation of the AL4 / DP0 gearbox. Malfunctions are characterized by an implicit nature of the manifestation, they can be observed during any period of use of the box, regardless of the mileage.
Gearbox switch:
Al4 variable gearbox is a reliable and trouble-free unit, provided that the mechanism is serviced in a timely manner. The transmission is demanding on the quality of the fluid and its level, therefore the oil change in the AL4 automatic transmission should be carried out regularly in compliance with all the necessary rules and regulations.
Every 30,000 km, it is necessary to check the transmission fluid level in the box. If there are small smudges in the form of spots on the product, then the check is carried out daily in order not to miss the moment of large oil losses. The automatic transmission oil AL4 is controlled with a metal plug, which is provided constructively. The peculiarity of the plug is that it is integral and at the same time serves both to control the liquid level and to drain the oil from the box.
Level control is carried out as follows:
Install the car on a lift, preheating the transmission fluid in the box to operating temperature;
Do not turn off the engine until the forced cooling fan turns on;
Transfer the gear selector one by one to all modes with the subsequent transfer to the parking mode "P";
Turn off the engine;
Unscrew the check plug, having previously installed a container for draining the mining;
Check the appearance of small drips of transmission fluid;
Important! Oil flows in a jet - excess of the fluid norm; small drops - the fluid rate is understated, there is no oil - the working fluid is underfilled. All these indicators have a negative impact on the transmission and require immediate replacement of the lubricant and bringing its level to normal.
In any case, in the AL4 automatic transmission, the oil is changed at intervals of once, every 40,000-60,000 km, depending on the operating conditions and the load on the box. The oil used for filling the transmission must meet the Dexron-III level, as a rule, it is ATF LT 71141 ESSO or Mobil. A complete replacement will require about seven liters of fluid, a partial replacement requires four liters.
It is better to carry out a complete replacement at special stands that will pump out all the lubricant from the system.
The Peugeot automobile concern is one of the main French and European car manufacturers, part of the Peugeot-Citroen concern. The history of the Peugeot brand began more than a century and a half ago. The first Peugeot cars were assembled back in 1892. Since the 70s of the twentieth century, Peugeot cars have consistently ranked among the top three European Automobiles of the Year. Peugeot specializes in the production of inexpensive but modern city cars. The Peugeot brand is well known in Russia. For its cars, Peugeot uses both its own automatic transmissions and the developments of firms specializing in their production: Aisin, Jatko, ZF.
Peugeot 308 with automatic gearbox
Peugeot 206 and 308 cars were equipped with four-speed automatic transmissions AL4 from the Peugeot-Citroen association. This automatic transmission has been produced since 1999 and is designed for front-wheel drive vehicles with engines up to 2 liters. AL4 in a wide variety of modifications is still used on a wide range of vehicles from a wide variety of manufacturers. AL4 is quite successful and independent development of French engineers.It was she who made it possible to popularize automatic transmissions in the vastness of Europe.
The AL4's weakest point is its cooling system. The AL4 cooling system uses a heat exchanger, and the transmission itself is constantly working at the extreme temperature regime. In the summer and in traffic jams, the Peugeot 206 automatic transmission overheats, the electrician and the valve body suffer from this. After a mileage of 80,000, the problem becomes very urgent and requires the attention of the car owner.
If the AL4 does not overheat, it will run almost forever. But if it is subjected to exploitation at too low or, conversely, high temperatures - expect trouble. Such a design of the cooling system carries such problems.
AL4 automatic transmission for Peugeot 206 and 308
The heat exchanger is also very sensitive to the purity of the oil. Dirt clogs its insides, and the pipes themselves and the heat exchanger simply stop cooling the transmission.
The heat exchanger itself is not at all cheap, and you can just get tired of the constant cleaning procedures. Therefore, the first thing that the owners of the Peugeot 206 do with these automatic transmissions is to change the heat exchanger to a radiator with a fan and all the necessary sensors. Moreover, the radiator can be supplied and reinforced.
The oil filter is disposable, and experts recommend changing it along with the oil as often as possible. Numbers from 20,000 to 60,000 kilometers are heard. Some even argue that it can not be changed. Indeed, it is possible, but only after 200,000 kilometers, the box will need to be changed along with the oil. Repair of automatic transmission Peugeot 308 and 206 in this case will no longer be relevant.
Repair kits are usually ordered original, and they fit all vehicles with this transmission. Together with them, during any repair or in the event of the release of one of the packages, all clutches are changed. A set of pistons is often ordered for them. Their rubber coating in these boxes dies pretty quickly.
For electrics, automatic transmission Peugeot 206 is among the leaders in replacing the solenoid pressure regulator. It is advisable to change them with any intervention in the box, they work in an overloaded mode and do not serve for a long time.
It also does not hurt to change the bushings. If they are already worn out, the solenoids will die one by one. Bushings are an important element of the automatic transmission, they play the role of seals. If they wear out, they begin to leak pressure. As a result, the electronic control unit opens all the valves in the valve body to the full, driving a huge amount of oil through it. Which, in turn, abrades all the insides of the valve body with remnants of gearbox mechanisms and debris. The pump runs at maximum load, the solenoids die, and the clutches burn before our eyes. It is better to change the bushings to non-original ones, from Sonnax, they last longer.
The hydraulic block changes very often under these conditions. He really does not like overheating and dirty oil. If overheated, the metal of the hydraulic block can lead, and this will mean the need to replace it. Repairing a damaged one will be more expensive than ordering a new one.
If the clutches are burnt out, they are changed only as a set. If at least one bag is burnt out, it will saturate all the oil and then the rest of the clutches, which will also inevitably burn out.
Hydraulic block, automatic transmission AL4
Teflon rings are ordered less often - for drivers who loved slipping.
If the box was rolling on burnt oil, order a brake band.
A little less often the oil seal and pump seals fail. Usually wet seals indicate a tired torque converter.
Iron rarely flies and mainly touches the second speed clutch package.
Older cars may require replacement of the rear planetary gear set and rear cover. This automatic transmission is very simple and easy to repair.
VIDEO
Peugeot 406 cars were equipped with a four-speed automatic transmission 4HP20 made by ZF. This transmission has been used for a huge range of front-wheel drive vehicles around the world with engines up to three liters. This transmission is the main AL4 alternative for higher class vehicles.
Automatic transmission Peugeot 406 - very, very reliable.The main number of calls for repairs is associated with the Peugeot 406 automatic transmission with the replacement of tired sealing elements, gaskets and oil seals. The manufacturer claims that the oil in the Peugeot 406 automatic transmission is designed for a service life of ten years; the filter does not need to be changed either. And this is one of the few automatic transmissions where the manufacturer does not cheat, and the car can really drive its ten years before a major overhaul without changing the oil.
Rubberized pistons, oil seals and pump cuffs are the most common spare parts for automatic transmission Peugeot 406.
Usually, all transmissions arrive at the service with a tired torque converter. Together with it, the oil pump fails.
For iron, one of the weak points is the bearings of the drive gear caliper. Relevant for drivers who like to "squeeze" the car.
On the electrical side - a valve body clogged with dirt and shavings. Solenoids can live for about eight years.
Increased fuel consumption often indicates wear on the torque converter clutch. If you do not pay attention to this, then soon a small nuisance will turn into a chain of problems and expensive repairs.
The only thing that can actually kill this box ahead of time is aggressive driving. Not fast, but aggressive. Smooth acceleration even up to 240 km / h on the highway is not scary at all. But the gas to the floor at every traffic light and at every opportunity and then the brake is scary for any box.
Peugeot 307 and 407 cars were equipped with six-speed automatic TF80SC from Aisin. This transmission has been improved since 2001 and is designed for cars with engine displacement up to 4 liters. By itself, this automatic transmission is simply brilliant.
Valve body TF80SC for Peugeot 307 and 407
Engineers were able to fit it into the engine compartment and take a place equivalent to a manual transmission. Than engineers could play for a successful layout and weight distribution of the engine. This transmission is close to 100% efficient and shifts gears quickly and smoothly for maximum fuel economy and acceleration performance. At the same time, the shifts remain smooth, almost imperceptible, and the reliability remains at the level of the old unkillable automatic transmissions. The advent of this automatic transmission brought hydraulic transmissions back into operation and made them competitive again, displacing fashionable robotic transmissions.
DO NOT SPEND MONEY ON REPAINING!
Repair of the Peugeot 407 automatic transmission usually includes the repair of the torque converter. This is the only really weak point of the automatic transmission data. Like all six-speed and more. He's working too hard. And this automatic transmission still uses outdated friction linings, not bearings. True, the settings of this automatic transmission do not use the torque converter lock as actively as modern counterparts of this automatic transmission, which prolongs its life.
Repair of the Peugeot 307 automatic transmission is usually necessary if the automatic transmission has been running for some time on dirty and burnt oil.
The valve body suffers greatly from it, which is the second weak point of this box. The oil usually gets contaminated just from the torque converter, so these problems are closely related.
Like all automatic transmissions, Peugeot products are highly complex mechanisms. Do-it-yourself repairs will require experience, knowledge, the necessary tools and equipment. However, on the AL4 transmission, for example, many European masters learned to repair automatic transmissions.
VIDEO
So what do we have. At the time of the first calls, the car ran about 135 thousand km.
Because in my case, the wear of the mechanical part was almost obvious, despite the pressure stabilization after replacing the valve, the error surfaced again at 150 thousand km. There was no money for the bulkhead, so I waved the valves again. The pressure spread after replacement was greater than the allowable one, but less than the emergency operation threshold. However, twitching soon began when the first gear was turned on, slipping on an unheated box. Obviously, the brake has burned out, disassembly of the box with removal is required - the procedure is not cheap. Thanks to autostart, the problem was solved up to 160 thousand km. At this point, a 20-minute warming up of the box was required, which is unacceptable for urban use.
So, on the run of 165 thousand km., Flipping through the Internet on the topic of all sorts of sharazhniki, it was decided to be repaired in MAI. Due to the New Year's holidays and the weekly queue before the new year, the renovation took a month without two days.
As expected, I spread waybill work order.
63,000 rubles. This is an extremely budgetary repair of the box, especially considering where it was repaired. At the cost of work in other firms, it was possible to save up to 5 thousand rubles, but I personally got tired of cutting out. Standard warranty - 20,000 or a year.
Comparison of prices for spare parts with existential. Positions that I did not find on the move there are highlighted in red.
As you can see, there was not much to cut out here.
Result: the box runs like new. There is no emergency mode on a cold box, jerks when engaging a gear, slipping when shifting gears are gone.
And finally, the basic rule of automatic transmission operation in winter is at least a little warming up of the box before driving. Roughly speaking, 0-10 degrees - 30 seconds on drive or reverse, -10 - 0 - 2-4 minutes, less than -10 - preferably at least 5 minutes. All figures include a cold engine. Here the small advantage of AL4 is that it does not have its own radiator, it uses a common cooling system with the engine, so when the engine warms up, the oil is partially heated by the engine.
I hope this ptso will give at least a little reason to doubt that there is no worse AL4 box, and you shouldn't piss with boiling water from it either.
Shl I can answer the questions only tomorrow
First French four-stage AL4 automatic transmission (DPO according to Renault specifications) was developed in 1999 by the joint efforts of the French car manufacturers Renault (Renault ) and PSA Peugeot Citroen (PSA Peugeot Citroen ). Initially, the developers were faced with the task of creating a structurally simple and inexpensive automatic transmission for front-wheel drive cars with engine displacement from 1.4 to 2.0 liters. To this end, they, in fact, coped quite successfully - automatic transmission DP0 / AL4 turned out to be quite effective, structurally simple and has a fairly low cost.
During the initial period of operation, maintenance and repair of automatic transmission DPO (AL4 ) most often comes down to changing the oil, filter and gaskets. As for the "hardware", this automatic box is quite reliable - the iron can easily go 200 thousand kilometers, and often more.
A typical weak point of the DPO (AL4) automatic transmission is EPC solenoid (main pressure solenoid , Solenoid EPC ). Not only is the service life of the solenoids not great (often several times less than in the analogs of the "Japanese" and "Americans"), but also the design features of the cooling (see below) affect their condition. In any case, even the manufacturers themselves admit this and recommend replacement at the first repair (this is especially true for age-old automatic transmissions, where the solenoids have design flaws). So that DPO solenoids (AL4 ) can be safely attributed to the category of consumables.
Solenoid EPC, automatic transmission DPO (AL4)
With regular overheating, the electrician suffers. The optimum operating temperature DP0 (AL4) ranges from 75 to 90 degrees, so in summer it is important for the car owner to minimize the operation of the transmission in overheating mode. However, operation at extremely low temperatures, as well as at high temperatures, does not in the best way affect the state of the automatic transmission (alas, this is a feature of all automatic transmissions with a heat exchanger).
About some other somewhat rarer, but still typical malfunctions inherent in AL4 (DP0):
Fails quite often automatic transmission brake band - it, like the solenoids (see above), can also be safely attributed to the category of consumables.
May suffer from overheating valve body automatic transmission - the channels can be clogged with shavings and other debris, which affects the correct operation hydraulic unit ... In rare cases, it can even reach deformation. hydraulic plates .
During the repair process, they also need to be replaced quite often. friction discs (clutches DPO / AL4 ).
In progress repair of automatic transmission AL4 (DPO ), as a rule, a typical set consumables and spare parts boils down to the following list: repair kit (aka so-called. Overhaul kit i.e. set of gaskets and oil seals ), clutch kit , set of pistons , filter ... Well, and a brake band (sometimes together with a drum), solenoids (see above).
Video (click to play).
Summarizing the above, we can say that the DPO (AL4) automatic transmission, due to its structural simplicity, has established itself as a completely reliable and fairly maintainable solution. More than one year has passed since the appearance of this transmission and the masters have already accumulated a lot of experience in its repair and maintenance.
