In detail: do-it-yourself repair of a Peugeot 408 automatic transmission from a real master for the site my.housecope.com.
Equipped with a part of Peugeot cars. The automatic transmission is aggregated with engines of the TU, XU, EW, DW, EP6 families and is produced at the enterprises of the company "PEUGEOT"
Automatic transmission has four forward gears, one rear and a torque converter lockup clutch:
Maximum torque: 210 Hm
Weight: about 75 kg.
Active and auto-adaptive automatic transmission system
An identification index is installed on the machine. Engraved on the lid, it consists of the manufacturer's index and the serial number of the product.
The AL4 automatic transmission consists of four parts:
Main unit
Torque converter block
Hydraulic unit block
Lid
The hydraulic unit is located at the rear of the automatic transmission. it is not equipped with a dipstick
In addition to the normal gearshift modes, the AL4 automatic transmission has a sequential (sequential switching type TIPTRONIC PORSCHE) gear shifting by the driver and the selector for selecting special programs such as sport mode, and forcibly switching on the first and second gear.
The principle of operation of the hydraulic part of the automatic transmission does not differ from the principle of operation of a conventional torque converter. It is equipped with a two-way torque converter lock-up clutch, which provides a mechanical connection between the engine and an automatic transmission (automatic)
Torque transmission.
The torque converter lock-up clutch is hydraulically controlled by a solenoid valve located on the hydraulic block. The operating mode of the torque converter lock-up clutch is included in the computer program of the machine.
Planetary gear AL4 automatic transmission It has:
Four forward gears
Reverse gear
Selector neutral position
Video (click to play).
This is a planetary gear type "SIMPSON 2"
Also, the automatic transmission has an installed speed sensor.
The automatic transmission hydraulic system contains:
oil pump
strainer
hydroaccumulator
thermostat
heat exchanger
solenoid valve for flow through the heat exchanger
six sequential switching solenoid valves
unloading valve
pressure control solenoid valve
pressure limiter
The oil temperature sensor in the box is built into the internal wiring near the valve body and informs the computer about the temperature of the oil inside Automatic transmission.
The turbine wheel rotation sensor is installed next to the left wheel drive, informs the computer about the rotation of the turbine wheel, the sensor information determines the decision to change gear, it also detects slip in the torque converter.
The output rotation sensor is located immediately behind the main electrical block, it informs about the output element rotation speed. Together with the turbine wheel speed information, the need for gear shifting is taken into account. Information about slippage (slippage of locking clutches) and brakes is also transmitted to determine the required moment for switching. In the Peugeot 307 and 807, this sensor information is replaced by the speed sensor information provided by the ABS and ESP.
Linear pressure sensor. Installed at the very bottom of the box. It provides the computer with information about the line oil pressure value. This information enables the computer to compare the measured pressure with the value entered into the computer, as well as to regulate it by acting on the pressure solenoid valve.
The Box Computer has a connection:
with ABS system to support the engaged gear during regulation
with fan information to improve cooling
with climate control system, to deactivate when switching
In order to avoid various mistakes when driving a car equipped with an automatic transmission, a protection system has been introduced associated with the backstage lever (selector)
The "Shift lock" function locks the selector lever in the parking position (P), using an electromagnet installed in the selector panel. The selector is unlocked with the ignition on and the brake pedal depressed.
Mechanical blocking of the key (prevents its removal from the lock) if the position of the selector when the ignition is turned off is not in the parking position.
Engine start interlock
Blocks the start of the engine if the selector is not in the park or neutral position.
Next to the selector lever are the buttons for switching programs
Gear shifting occurs at higher engine speeds, with deceleration, the shift is delayed.
The car starts moving away from the second or third gear, gear changes are less frequent.
The first gear is forcibly included.
It warns the driver about the presence of an anomaly (error) in the operation of the automatic transmission, which can impair the operation of the toxicity reduction system. The box computer detects the error and transmits it to the engine computer, which in turn turns on the signaling device EOBD check engine
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Good day! How long did the box last? I repaired the box on the car of my wife Peugeot 307, changed everything, the box did not go through the summer!
Well, this machine is not so easy to get over, besides, and the al4 box itself is capricious, so it's no wonder that after the bulkhead it did not take long for you
This AL4 automatic transmission is installed not only on Peugeot cars, but also on other models too. The box is completely unreliable, it often throws errors in the form of blinking of the sport mode and snowflakes, it often kicks in the ass when switching and it is better to change the oil in it more often, at least once every 30-40 thousand
Change the solenoid valves in the valve body, and you will be happy. Before you scold the box, learn how to use it and keep an eye on it. I already have 230 thousand mileage on AL4 and everything works smoothly.
The most problematic gearbox is considered to be the German DSG. But in vain! Some "machines" for "French" and "Japanese" are also not very hardy
You can whine as much as you like about the unreliability and criticize the AL4 automatic gearbox. however, let's be objective. The main working part, on which the operability depends on 51%, it contains oil, and if someone is pressed by a toad to check and change it on time, and then complain that the AL4 machine box is enough only for the summer, then this is more likely a problem of illiterate operation, and the AL4 construct is wonderful.
What are you all driving here, this box is not killed at all.
The box is super! 270000km behind… I changed the oil 3 times, started to kick when switching from the first to the second so that they hit the rear), changed the oil sensor and filter…. Already 20,000 no problems)
Guys need advice on automatic transmission 2.0 petrol
The box on my Peugeot 308 passed 280,000, there have never been any problems and still works without jerks and jerks, I always warm up both in winter and in summer.
Gemini: And so dear Pyzhevody and owners of AL4, a description of the problem and its real SOLUTION, suffered for three years, shoveled a lot of information and came to the conclusion that you can do it yourself and for (3t.r). BEGINNING, there was a strong water hammer, it manifested itself only in traffic jams and on a hot one, we begin to get under way, it is imperative that the switch was from the first to the second, we stop, then we start to get under way, and the car stops, we add gas and then a strong blow, as if we drove into the ass, on cold and in the winter mode it was not.Here is the solution, we remove the left wheel, the front fender liner, weaken the automatic transmission pillow so that it would lie on the stretcher, we see the rear cover, remove and change five O-rings, three on the lid and two on the piston, everything is done gently and neatly, put back, hard, but probably. For a week I go not a single blow, the heat outside (30), super.
We put a new gasket (red), in the background - the old gasket. Putting the box back together.)
It was hard to put the lid back on, very carefully you need to install it and tighten it carefully with 4 screws (top-bottom and left-right). Do not overdo it, the lid may crack. In this case, it is useful to twist the brake disc of this left wheel back and forth so that the torque reaches the box through the drive shafts. Next, fill in fresh oil, drain the excess on a warm running engine and try to get under way. We accelerated 1.5-2 thousand revolutions for 3-4 minutes on the drive - the car did not go. They began to remember whether everything was installed in place, like everything. Heart beat treacherously. Uncle Yura gave the gas in reverse gear and “oh, miracle” - the car rushed off the bat. Well, the reaction did not disappoint - the car slowed down 10 cm from the sofa, which was behind. Then we rode a little around the neighborhood - everything is gut, rides like new. We started work at 13, finished at 20, broke 2 "stars" from the tool kit. Stock up on non-standard square nozzles and 16 heads for loosening the bolts in the silent blocks. I write "we", but in fact Uncle Yura was working, I just looked and was surprised at the calmness and accuracy of the Master's work. Thank you for help! I would never have dared to do it myself!
Soon I will also perform this procedure. Post has been editedkluz83: 28 September 2012 - 17:52
Gemini: And so dear Pyzhevody and owners of AL4, a description of the problem and its real SOLUTION, suffered for three years, shoveled a lot of information and came to the conclusion that you can do it yourself and for (3t.r). BEGINNING, there was a strong water hammer, it manifested itself only in traffic jams and on a hot one, we begin to get under way, it is imperative that the switch was from the first to the second, we stop, then we start to get under way, and the car stops, we add gas and then a strong blow, as if we drove into the ass, on cold and in the winter mode it was not. Here is the solution, we remove the left wheel, the front fender liner, weaken the automatic transmission pillow so that it would lie on the stretcher, we see the rear cover, remove and change five O-rings, three on the lid and two on the piston, everything is done gently and neatly, put back, hard, but probably. For a week I go not a single blow, the heat outside (30), super.
We put a new gasket (red), in the background - the old gasket. Putting the box back together.)
It was hard to put the lid back on, very carefully you need to install it and tighten it carefully with 4 screws (top-bottom and left-right). Do not overdo it, the lid may crack. In this case, it is useful to twist the brake disc of this left wheel back and forth so that the torque reaches the box through the drive shafts. Next, fill in fresh oil, drain the excess on a warm running engine and try to get under way. We accelerated 1.5-2 thousand revolutions for 3-4 minutes on the drive - the car did not go. They began to remember whether everything was installed in place, like everything. Heart beat treacherously. Uncle Yura gave the gas in reverse gear and “oh, miracle” - the car rushed off the bat. Well, the reaction did not disappoint - the car slowed down 10 cm from the sofa, which was behind. Then we rode a little around the neighborhood - everything is gut, rides like new. We started work at 13, finished at 20, broke 2 "stars" from the tool kit. Stock up on non-standard square nozzles and 16 heads for loosening the bolts in the silent blocks. I write "we", but in fact Uncle Yura was working, I just looked and was surprised at the calmness and accuracy of the Master's work. Thank you for help! I would never have dared to do it myself!
Soon I will also perform this procedure.
There is also information, a week ago I changed the rings, when they collected, started, switched to drive, but the car does not go, not forward, not backward, you give gas, revs (2200-2400), it is no longer like everything else, it stands still. Dismantled again, looked, everything is intact, in place, put together and again the same story, does not go. DID THE FOLLOWING, one got behind the wheel, put it on the drive and began to accelerate, and the other pushed from behind and about a MIRACLE the car jerked slightly and drove off. In three cases where I changed rings, the machines behaved differently.
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 material, 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)
Light tremors in AL4 are acceptable! This is truly a design feature of the AL4. There are parts in the automatic transmission that have excessive inertia;
Check engine mountings! Before dealing with jolts, be sure to check the condition of the engine mountings. If the pillows are worn out - of course, replace;
Attention to the level and properties of the oil in the machine! Every 20 thousand runs, check the oil level or make a partial oil change. Partial replacement is done without disassembling the machine, in five minutes, 4 liters. Replacing and checking the level should only be done by competent specialists, since the correct oil level in AL4 is set according to the regulations for half a page;
The planetary of this box is extremely reliable, in my practice I have never seen a DP0 with dead gears.
• Drain the automatic transmission oil. • Disconnect the battery. • Place a container for collection for subsequent disposal. Drain everything.
• Disconnect the connectors of the electromagnetic secant (sequential) valves by carefully lifting them with a screwdriver; • Disconnect 6 solenoid secant valves; • Remove 7 screws (3).
Old manufacturer ACUTEX, new Borg Warner. The main differences, the new solenoid valve has a black connector and is held together by 4 clips, the old one is a white connector and is held together with a knurled bezel. Outwardly - everything, inside it is also slightly modified, the main differences in the frequency of the valve operation: ACUTEX - 50Hrz, Borg Warner - 100Hrz.
• 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! • EMC for a new sample are replaced by PARNO!
• After removing the valve body, flush all valves (top and side);
• 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
• Before installing GB, 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 circuit to the body.
ATTENTION: Make sure the mechanical valve (6) fits into the shoulder (A) of the toothed sector (16).
• We put in place, otherwise the gears will not change, again carefully we check that the wires are inside;
• Refit the fixing bolt of the hydraulic unit (Tightening torque 0.8 da.Nm) Follow the sequence shown; • Connect 6 secant solenoid valves; • Ensure correct operation of the gear change mechanism in all positions. To do this, connect the battery, turn the key to the first position, press on the brake and see if all gears are turned on correctly;
Install: • Crankcase (2) with a new gasket; • Crankcase mounting bolt (1) (Tightening torque 1.0 da.Nm); • Air filter sleeve.
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); • With the engine running: Remove the level plug (6 edges, 19 mm each).
If the oil flows out in a thin stream and then drips, the level is correct.
• Oil flows out in the form of drops, and then stops flowing; • Switch off the engine; • Allow to cool; • Add 0.5 liters of oil; • Start the procedure over again; • Periodically replace the sealing gasket of the drain plug; • Tighten the plug (Tightening torque 2.4 da.Nm).
Memo: Filled oil volume: - after draining the oil - 3.5-4 liters.; - after draining the fluid and replacing the hydraulic block - 4-4.5 liters.;
1. The valve body, the second screw from the right, for a hexagon, regulates the pressure. My pressure rose by one full revolution by 0.3 (in case the pressure does not rise after flushing). The optimal pressure is considered to be 3 bars at XX in D, in fact, it can be in the range of 2.55-3.0, this is normal, but 2.55 is the lowest threshold! After rinsing, you can half turn tighten up… During the operation (that way five years) the spring got hooked a little. If it still does not reach the required pressure, then simply drain the oil again, remove the valve body cover and, without removing the valve body itself, tighten it again. But this SHOULD be done very carefully! Because there are a lot of complaints, I want to WARN you IN ADVANCE, if you twist it, then twist it by a quarter, or even less. The reason is trivial, twist more, there will be a large pressure, the standard pressure at XX is 2.8-3 bars, can you imagine what will happen to the box when 6.0 bars are wound? Better not to know!
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 (but it's better to look at the wine).
Swap valve 2, consisting of an o-ring (B) and valve (2), art. 2574.16
Renault analog 77 01 208 174, the rest of the valves under number (A) are removed one at a time, washed, cleaned and replaced (so everything is in turn). Do not touch the rest of the adjusting screws.
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.
