It should be said that before driving, ANY machine should be warmed up, do not “tear” until the car is fully warmed up. Automatic DP0, AL4 is helped by a special thermostat, it is both mechanical and electric, depending on the years of manufacture.
In this material, we will try to consider one of the ways to solve the problem of automatic transmission shocks, switching to emergency mode and other delights such as pressure spread.
I would like to repeat and re-voice what is NORMAL for this box (after all, this is a development since the 80s, it’s just constantly being upgraded)
• Drain the oil from the automatic transmission.
• Disconnect the connectors of the solenoid secant (sequential) valves by carefully lifting them with a screwdriver;
Old manufacturer ACUTEX, new Borg Warner.
• When replacing valves with a new model, they must be activated via Peugeot Planet 2000. Older software versions of AL4 computers are not compatible with new EMC!
• Unscrew 8 Torx, remove, wash. Under the cover there will be a small filter and an electrovalve-modulator, remove it, wash it.
• Assemble in reverse order.
3. Reinstallation of the hydroblock
• Before installing the GB, the service box recommends replacing these two rubber bands;
• Be careful not to get the wiring under the valve body, otherwise it can be damaged and you will have a short to the body.
WARNING : Make sure that the mechanical valve (6) engages in the projection (A) of the gear sector (16).
• Install the fixing bolt of the hydraulic unit (Tightening torque 0.8 da.Nm) Follow the sequence shown;
4. Fill in oil, check the level
• Fill in oil, 4.5 liters. We bring the automatic transmission oil temperature to 58-68 degrees (usually turning on the first fan speed or using 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, only removed, washed and swapped. It is recommended to replace the O-ring art. 2578. 13 Photo 1.
The location of the temperature sensor, if this sensor is not working, then the automatic transmission can also go into emergency mode. Changes with the scythe.2529 26
If you buy a new one, then change the EVM pressure control valve.
As it turned out, in this GB, the problem is not only 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 equipment, because. bore several kaknals and replace regular pushers with more advanced and tight ones.
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, including our region.
Today, there is a tendency to buy cars with front-wheel drive, equipped with power plants up to two liters, and an automatic transmission. French manufacturers needed such a transmission. The 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 done, with the joint efforts of the designers of PSA and Renault, an automatic hydromechanical transmission equipped with electronic control, marked AL4, was launched on the market.To date, the number of produced gearboxes of the model exceeds the output of similar products for cars with front-wheel drive and an engine with a volume of 1.4 - 2.0 liters.
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 marked as AL4 (HP16), there is a rare BVA designation.
Automatic transmission AL4 (DP0) was installed on cars:
The transmission was calculated for use on cars with front-wheel drive, paired with units with a volume of 1.4 to 2.0 liters. Some modifications of automatic transmissions differ in housing, 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 incorporated in the calculations is able to allow the mechanism 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 the automatic transmission AL4 (DP0) are presented in the table:
The main advantage, transmissions, reasonable cost, this allowed the machine to become popular among cars with a small engine size. 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 AL4 model was released, which was equipped with the Porsche Tiptronic System device, while the mechanics of the machine did not change
The gear box is located in the central part of the cabin. Purpose, selection of the desired mode, by acting on a special contactor device and a spool that switches hydraulic modes. The rocker is equipped with six positions, switching takes place by moving along the slot of the selector panel stream.
Gear selector positions:
P - parking mode, the transmission is blocked, the start of the power plant is possible;
R - reverse mode, when turned on, the reverse lights light up at the same time;
N - neutral mode, the launch 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 because they are controlled by the computer.
Important! To unlock the gear lever from the “P” position, you must turn on the ignition and press the brake pedal, “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 backstage to another. The transition from the following provisions without fail occurs through the provisions:
In order to satisfy the needs of the driver in driving with the use of additional high-speed modes, a software selector is structurally provided. The mechanism is equipped with three keys and is located on the side of the wings.
Gearshift rocker paired with program selector:
Standard program (none of the keys are pressed, the rocker in the "D" position):
The program is considered the main one, when using it, the computer analyzes the driving style and adapts it to road conditions and vehicle load. The main goal is to achieve lower fuel consumption and optimally distribute the effort;
Program "Sport" (pressed key "S", rocker in position "D"):
Using the program involves automatic gear shifting, but the computer prefers sporty style and does not pay attention to the amount of fuel consumed;
Program "Snow" (key pressed "*", slide in position "D"):
Using the program, the computer adapts to the conditions of the slippery road surface. Driving begins by using 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 (pressed the key "1", the rocker in position "2"):
The gearbox will only work in first gear.
When moving the backstage to the "P" position without depressing the brake pedal, the automatic transmission selector will be blocked. When the vehicle is stationary and the engine speed exceeds 2000 rpm, moving the lever to the "D" position does not shift gears.
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 illuminated software panel informs the driver:
Information about the position of the backstage lever;
Information about the program used;
Information about the transition to the backup mode.
Indication on the instrument panel:
Despite the positive reviews and popularity of the transmission, the AL4 automatic transmission has vulnerabilities. The problems observed in the mechanism, as a rule, occur in most boxes of this type.
A thud and jolts at start. Symptoms occur when you start moving without first 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 desired modes do not match the actual characteristics. The reason is a malfunction of the pressure regulator in the valve plate. In addition, a possible cause 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 in the AL4 automatic transmission, analyze the condition of the heat exchanger, replace the lubricant, remove the hydraulic unit and change the valves. If the mileage of the box is over 100,000 km, a 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 completion of work, reconfigure and clean the on-board computer of the car.
Pressure Regulator #144431:
The gears are switched with a delay. The breakdown is accompanied by jamming of the backstage lever in the “P” position. Sometimes on the contrary, the link is switched from a position without pressure on the brake pedal. As a rule, the culprit of non-standard behavior is a malfunction of the brake sensor.
To fix the problem, change the limit switch, check and change the damaged electrical harness of the switch.
Brake Pedal Limit Switch:
Knocking and jolts when the car is moving, flashing an error message. The behavior manifests itself in moving vehicles, both a warm and cold gearbox fails. Often there is an increase in the number of revolutions, although the gear shift does not occur, the car's clutch seems to be slipping.
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 unit.
Important! With such symptoms, stop using the car. Further driving on a faulty vehicle is fraught with a break in the brake of the hydraulic transformer.
To fix the problem, the automatic transmission is checked for transmission fluid leaks, the heat exchanger is checked, the hydraulic unit is dismantled with the replacement of valves. In addition, it is necessary to perform a complete replacement of the ATF fluid in the transmission. Strong wear and mileage of the box 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 backstage is accompanied by the absence of the selected mode indicator on the vehicle information display. Symptoms are observed mainly when the backstage is switched from the parking mode to the reverse mode, as well as when the backstage is switched from the standard mode to the neutral mode.
The cause of the AL4 automatic transmission malfunction lies in the breakdown of the gearbox switch. In addition, this behavior is typical when the device settings fail or the sector responsible for selecting the gears of the AL4 box fails. Also a possible reason is the selector cable, which is loosely fixed in the bracket and constantly pops out of it.
A switch malfunction is possible due to moisture ingress, factory defects, or severe wear. Elimination comes down to replacing or adjusting the above listed parts.
The described problems are often encountered when operating the AL4 / DP0 gearbox. Malfunctions are characterized by an implicit manifestation, they can be observed at any time during the use of the box, regardless of the mileage.
Gearbox switch:
The 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, so the oil change in the AL4 automatic transmission should be carried out regularly in compliance with all necessary rules and regulations.
Every 30,000 km it is necessary to check the level of transmission fluid in the box. If there are small smudges in the form of spots on the product, then the check is carried out daily so as not to miss the moment of large oil losses. Automatic transmission oil AL4 is controlled by a metal plug, which is provided structurally. The peculiarity of the plug is that it is composite 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, pre-heating the transmission fluid in the box to operating temperature;
Do not turn off the engine until the forced cooling fan turns on;
Translate the gear selector in turn to all modes, followed by transfer to the parking mode "P";
Turn off the engine;
Unscrew the control plug, having previously installed a container for draining mining;
Check for the appearance of small streaks of transmission fluid;
Important! Oil flows in a stream - excess of the liquid norm; small drops - the fluid rate is too low, there is no oil - underfilling of the working fluid. All these indicators have a negative impact on the transmission and require immediate replacement of the lubricant and bringing its level to normal.
Screw on the control plug.
In any case, in the AL4 automatic transmission, the oil is changed once every 40,000-60,000 km, depending on the operating conditions and the load on the box. The oil used for filling into 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 on special stands that will pump out all the lubricant from the system.
The Peugeot car 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 in 1892. Since the 70s of the twentieth century, Peugeot cars have consistently ranked in the top three European Cars of the Year. Peugeot specializes in the production of inexpensive, but modern city cars. The Peugeot brand is quite well known in Russia. For its cars, Peugeot uses both automatic transmissions of its own design and the development of companies specializing in their production: Aisin, Jatko, ZF.
Peugeot 308 with automatic transmission
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. The AL4, in a wide variety of modifications, is still used on a wide range of vehicles from a variety of manufacturers. AL4 is a fairly successful and independent development of French engineers. It was she who made it possible to popularize automatic transmissions in the vastness of Europe.
The weakest point of the AL4 is its cooling system. The AL4's cooling system uses a heat exchanger, and the transmission itself is constantly operating at extreme temperatures. In the summer and in traffic jams, the Peugeot 206 automatic transmission overheats, the electrician and valve body suffer from this. After a run of 80,000, the problem becomes very relevant and requires the attention of the car owner.
If AL4 does not overheat, it works almost forever. But if it is exposed to operation at too low or, conversely, high temperature - expect trouble. Such problems are borne by such a device of the cooling system.
Automatic transmission AL4 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 simply get tired of constant cleaning procedures. Therefore, the first thing Peugeot 206 owners do with these automatic transmissions is to change the heat exchanger to a radiator with a fan and all the necessary sensors. And the radiator can be put and reinforced.
The oil filter is disposable, and experts recommend changing it along with the oil as often as possible. There are numbers from 20,000 to 60,000 kilometers. Some even argue that it can not be changed. Indeed, it is possible, but only after 200,000 kilometers, along with the oil, it will also be necessary to change the box. 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 cars with this transmission. Together with them, during any repair or in the event of the release of one of the packages, all friction clutches change. They often order a set of pistons. Their rubber coating in these boxes dies fairly quickly.
In terms of electrics, automatic transmission Peugeot 206 is a leader in replacing the solenoid pressure regulator. It is advisable to change them with any intervention in the box, they work in a too loaded mode and do not last long.
It also doesn't hurt to change the bushings. If they are already worn out, the solenoids will die one by one. Bushings - an important element of the automatic transmission, act as 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 the remains of the box mechanisms and debris. The pump is working at maximum load, the solenoids are dying, and the clutches are burning before our eyes. It is better to change the bushings to non-original ones, from Sonnaks, they last longer.
The hydraulic block under such conditions is changed very often. He does not like overheating and dirty oil. When overheated, the metal of the hydraulic block may lead and this will mean that it needs to be replaced. Repairing a damaged one will be more expensive than ordering a new one.
If the clutches are burned out, they are changed only as a set. If at least one package burns 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 riding on burnt oil, a brake band is ordered.
The stuffing box and pump seals fail a little less often. Usually wet seals indicate a tired torque converter.
Iron rarely flies and mainly touches the second speed clutch pack.
Very old cars may require replacement of the rear planetary gear 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 manufactured 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 alternative to the AL4 for higher-end vehicles.
Automatic Peugeot 406 - very, very reliable. The main number of requests for repair is related to the Peugeot 406 automatic transmission with the replacement of tired sealing elements, gaskets and seals. The manufacturer claims that the oil in the Peugeot 406 automatic transmission is designed for a service life of ten years, and 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 the Peugeot 406 automatic transmission.
Usually all transmissions reach the service with a tired torque converter. Along with it, the oil pump fails.
For iron, one of the weak points is the drive gear caliper bearings. Relevant for drivers who like to "squeeze out" 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 costly repairs.
The only thing that can actually kill this box ahead of time is aggressive driving. Not fast, but aggressive. Smooth acceleration 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 - this 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 sizes 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. What engineers were able to play for a successful layout and weight distribution of the engine. This transmission is close to 100% efficient and shifts 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 indestructible automatic transmissions. The advent of this automatic transmission brought hydraulic transmissions back into service and made them competitive again, pushing out fashionable robotic gearboxes.
DON'T SPEND MONEY ON REPAINTS!
Peugeot 407 automatic transmission repair usually includes torque converter repair. This is the only truly weak point of these automatic transmissions. Like all six-speed and more. He works 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 lockup as actively as the modern counterparts of this automatic transmission, which prolongs its life.
Peugeot 307 automatic transmission repair is usually necessary if the automatic transmission has been running for some time in dirty and burnt oil.
The valve body, which is the second weak point of this box, suffers greatly from it. The oil is usually contaminated just from the torque converter, so these problems are closely related.
Like all automatic transmissions, Peugeot products are very complex mechanisms. Repairing them with your own hands 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 bells, the car ran about 135 thousand km.
Because in my case, the wear of the mechanical part was almost obvious, despite the stabilization of the pressure after replacing the valve, the error surfaced again at 150 thousand km. There was no money for a 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 engaged, slipping on an unheated box. Obviously, the brake burned out, and the box needs to be disassembled with removal - the procedure is not cheap. Thanks to autostart, the problem was solved up to 160 thousand km. By this point, a 20-minute warm-up of the box was required, which is unacceptable for urban use.
So, on a run of 165 thousand km., Scrolling through the Internet on the topic of all sorts of charades, it was decided to repair at the MAI. Due to the New Year holidays and a week-long queue before the New Year, the repair took a month without two days.
As usual, I post consignment note order-outfit.
63.000 rubles. This is an extremely budget repair of the box, especially considering where it was repaired. At the cost of work in other companies, 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. Red highlighted positions that I did not immediately find there.
As you can see, there was not much to cut out here.
Result: box runs like new. There is no emergency mode on a cold box, jerks when shifting gears, slipping when shifting gears are gone.
And finally, the main rule for operating an automatic transmission in winter is at least a slight warm-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 are based on a cold engine. Here, a slight advantage of the 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 from the engine.
I hope this ptso will give at least a small reason to doubt that there is no worse box than the AL4, and you should not piss with boiling water from it either.
PS I can answer questions only tomorrow
The first French four-speed Automatic transmission AL4 (DPO according to Renault specifications) was developed in 1999 by the joint efforts of French automotive companies Renault (Renault ) and PSA Peugeot Citroen (PSA Peugeot Citroen ). The developers initially had the task of creating a structurally simple and inexpensive automatic transmission for front-wheel drive vehicles with an engine capacity of 1.4 to 2.0 liters. To this end, they, in fact, managed 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 DPO automatic transmission repair (AL4 ) most often comes down to changing the oil, filter and gaskets. As for the “iron”, this automatic transmission is quite reliable - iron can easily go 200 thousand kilometers, and often more.
A typical weak point of the automatic transmission DPO (AL4) is EPC solenoid (main pressure solenoid , Solenoid-EPC ). Not only is the service life of the solenoids not great (often many times less than in analogues of the "Japanese" and "Americans"), the design features of the cooling (see below) also affect their condition. In any case, even the manufacturers themselves recognize this and recommend replacement at the first repair (this is especially true for older automatic transmissions, where the solenoids have design flaws). So that DPO solenoids (AL4 ) can be safely attributed to the category of consumables.
EPC solenoid automatic transmission DPO (AL4)
With regular overheating, an electrician suffers. The optimum operating temperature DP0 (AL4) ranges from 75 to 90 degrees, so in the 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 affect the condition of the automatic transmission in the best way (alas, this is a feature of all automatic transmissions with a heat exchanger).
About some other somewhat rarer, but still typical problems inherent in AL4 (DP0):
Fails quite often automatic transmission brake band - it, like solenoids (see above), can also be safely attributed to the category of consumables.
May suffer from overheating automatic transmission valve body - channels can be clogged with chips and other debris, which affects the correct operation hydraulic block . In rare cases, it can even reach deformity. hydraulic plates .
During the repair process, they are also quite often subject to replacement. friction discs (DPO clutches / AL4 ).
In progress automatic transmission repair AL4 (DPO ), usually a typical set consumables and spare parts comes down to the following list: repair kit (aka so-called. Overhaul Kit i.e. set of gaskets and seals ), clutch kit , piston kit , filter . Well, and a brake tape (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.
