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自动变速箱是汽车动力传递的核心部件,内部结构精密复杂,维修时需根据故障类型更换相应零件,以恢复其正常运转。从机械传动到液压控制,再到电子辅助系统,可更换的零件覆盖多个系统,每个零件的功能都直接影响变速箱的性能。
Automatic transmission is the core component of automobile power transmission, with a precise and complex internal structure. During maintenance, corresponding parts need to be replaced according to the type of fault to restore its normal operation. From mechanical transmission to hydraulic control, and then to electronic auxiliary systems, replaceable parts cover multiple systems, and the function of each part directly affects the performance of the gearbox.
传动系统的易损件是维修中常见的更换对象。离合器片与制动器片是传递动力的关键部件,长期摩擦会导致表面磨损或烧焦,当出现换挡顿挫、动力传递迟滞时,需拆解检查并更换。这类零件多采用铜基或纸基摩擦材料,更换时需保证新件厚度均匀(误差不超过 0.1 毫米),与钢片贴合紧密。行星齿轮组中的齿轮若出现齿面剥落、裂纹或断齿,会引发运转异响,必须整体更换齿轮组,同时检查行星架的磨损情况,必要时一同更换,确保齿轮啮合间隙在 0.1-0.3 毫米的标准范围内。单向离合器(如滚柱式、楔块式)若出现卡滞或打滑,会导致换挡方向错误,需按型号更换,安装时注意方向标记,避免反向装错。
The vulnerable parts of the transmission system are common replacement objects in maintenance. The clutch plate and brake plate are key components for transmitting power. Long term friction can cause surface wear or burning. When shifting jerks or power transmission delays occur, they need to be disassembled, inspected, and replaced. These types of parts often use copper based or paper-based friction materials, and when replacing them, it is necessary to ensure that the thickness of the new part is uniform (with an error of no more than 0.1 millimeters) and closely adheres to the steel sheet. If the gears in the planetary gear set have tooth surface peeling, cracks or broken teeth, it will cause abnormal operation noise. The gear set must be replaced as a whole, and the wear of the planetary carrier must be checked. If necessary, they should be replaced together to ensure that the gear mesh clearance is within the standard range of 0.1-0.3 millimeters. If a one-way clutch (such as a roller type or wedge type) gets stuck or slips, it can cause the shifting direction to be incorrect. It needs to be replaced according to the model, and attention should be paid to the direction markings during installation to avoid reverse installation.
液压控制系统的密封件与阀体组件常需更换。变速箱油液通过液压管路传递压力,橡胶密封圈、油封长期受高温油液侵蚀会老化失效,导致漏油,维修时需将所有密封件统一更换为耐油耐高温的氟橡胶材质,尤其阀体与壳体结合处的密封垫,需保证平整度以防止渗漏。阀体是液压控制的核心,内部滑阀卡滞或阀孔磨损会导致油压异常,轻度磨损可通过研磨修复,严重时需更换全新阀体,新阀体需经过压力测试,确保各档位油压偏差不超过 5%。蓄压器活塞若出现磨损或密封不良,会影响换挡平顺性,更换时需检查活塞与缸筒的配合间隙,确保在 0.02-0.05 毫米之间。
The seals and valve body components of hydraulic control systems often need to be replaced. The transmission oil transmits pressure through hydraulic pipelines, and rubber seals and oil seals will age and fail due to long-term erosion by high-temperature oil, leading to oil leakage. During maintenance, all seals need to be replaced with oil and high-temperature resistant fluororubber materials, especially the sealing gasket at the joint between the valve body and the housing, which must ensure flatness to prevent leakage. The valve body is the core of hydraulic control, and internal spool valve jamming or valve hole wear can cause abnormal oil pressure. Mild wear can be repaired by grinding, and in severe cases, a new valve body needs to be replaced. The new valve body needs to undergo pressure testing to ensure that the oil pressure deviation of each gear does not exceed 5%. If the accumulator piston is worn or poorly sealed, it will affect the smoothness of gear shifting. When replacing, it is necessary to check the fit clearance between the piston and the cylinder to ensure it is between 0.02-0.05 millimeters.
电子控制系统的传感器与执行器是高频更换零件。转速传感器(如电磁式、霍尔式)若失效,会导致变速箱无法判断换挡时机,出现锁档或冲击,更换时需确保插头接线正确,信号输出稳定(电压波动范围不超过 ±0.2V)。电磁阀负责控制液压油路通断,线圈烧蚀或阀芯卡滞会引发换挡延迟,需按原型号更换,新电磁阀需进行通电测试,确保响应时间在 50-100 毫秒内。控制单元(TCU)若出现程序故障或硬件损坏,会导致变速箱进入保护模式,轻度故障可通过重新编程解决,严重时需更换全新控制单元,更换后需进行自适应学习,匹配发动机与变速箱的运行参数。
The sensors and actuators of electronic control systems are high-frequency replacement parts. If the speed sensor (such as electromagnetic or Hall type) fails, it will cause the gearbox to be unable to determine the shifting timing, resulting in gear lock or impact. When replacing, it is necessary to ensure that the plug wiring is correct and the signal output is stable (voltage fluctuation range does not exceed ± 0.2V). The solenoid valve is responsible for controlling the on/off of the hydraulic oil circuit. Coil erosion or valve core jamming can cause gear shift delay, and it needs to be replaced with the original model. The new solenoid valve needs to be tested with power to ensure a response time of 50-100 milliseconds. If there is a program failure or hardware damage in the control unit (TCU), it will cause the gearbox to enter protection mode. Mild faults can be resolved by reprogramming, and in severe cases, a new control unit needs to be replaced. After replacement, adaptive learning is required to match the operating parameters of the engine and gearbox.
阀体附件与滤清器是预防性更换的重点。变速箱油滤清器(内置纸质滤芯或外置金属滤芯)在油液循环中过滤杂质,长期使用会堵塞导致油压下降,维修时必须更换,同时清洗滤网壳体,避免残留杂质二次污染。油液冷却器若内部堵塞或泄漏,会影响油液散热,导致油温过高(超过 120℃),需更换同规格冷却器,安装前用高压气吹通管路,确保无堵塞。液力变矩器的锁止离合器若打滑,会导致油耗上升、动力损失,轻度磨损可通过更换锁止片修复,严重时需整体更换变矩器,新变矩器需进行动平衡测试(不平衡量不超过 5 克厘米),防止运转时产生振动。
The valve body accessories and filters are the focus of preventive replacement. The transmission oil filter (with a built-in paper filter or an external metal filter) filters impurities in the oil circulation. Long term use can clog and cause a decrease in oil pressure. It must be replaced during maintenance, and the filter screen housing must be cleaned to avoid secondary pollution from residual impurities. If there is internal blockage or leakage in the oil cooler, it will affect the heat dissipation of the oil and cause the oil temperature to be too high (over 120 ℃). It is necessary to replace the cooler with the same specification and blow the pipeline with high-pressure air before installation to ensure that there is no blockage. If the lock up clutch of the hydraulic torque converter slips, it will cause an increase in fuel consumption and power loss. Mild wear can be repaired by replacing the locking plate, and in severe cases, the torque converter needs to be replaced as a whole. The new torque converter needs to undergo a dynamic balance test (with an imbalance of no more than 5 grams per centimeter) to prevent vibration during operation.
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