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1、ChassisnClutchnManual TransaxleC550 Manual TransaxleC15# Series Manual TransaxlenAutomatic TransaxleU540E Automatic TransaxleU340E Automatic TransaxlenDrive ShaftnSuspensionnBrakenSteeringnTire and WheelChassisnClutchClutch OverallDry single-plate clutch operatedby hydraulic pressure is used-C-T-MCl
2、utch CoverTypeDST*1Size mm (in.)200 (7.87)Clutch DiscFacing Size*2 mm (in.)200 x 140 x 3.5(7.87 x 5.51 x 0.14)Facing Area cm2 (in2.)160 (24.8)Master CylinderTypeConventionalCylinder Diameter mm (in.)15.87 (0.62)Release CylinderTypeNon-adjustableCylinder Diameter mm (in.)20.64 (0.81)*1: DST (Diaphrag
3、m Spring Turnover)*2: Outer Diameter x Inner Diameter x ThicknessSpecificationChassisnClutchReservoir TankClutch fluid reservoir tank and brake fluid reservoir tank are integrated for all models-C-T-MClutch Master CylinderBrake Fluid Reservoir TankChassisnC550 Manual TransaxleOverallC550 manual tran
4、saxle is used, basic construction and operation are same as Yaris/Echo-CChassisnC550 Manual TransaxleSpecification-CTransaxle TypeC550Gear Ratio(Counter GearRatio Included)1st3.5452nd1.9133rd1.3104th0.9735th0.804Reverse3.214Differential Gear Ratio3.944Oil Capacity Litter (US qts, lmp. qts)1.4 (1.48,
5、 1.23)Oil ViscositySAE 75W-90Oil GradeAPI GL-3ChassisnC15# Series Manual TransaxleOverallC15# series manual transaxle are used, basic construction and operation are same as Yaris/Echo-T-MChassisnC15# Series Manual TransaxleSpecification-T-MEngine Type1NZ-FE2NZ-FETransaxle TypeC150C154Gear Ratio(Coun
6、ter GearRatio Included)1st3.5452nd1.9043rd1.3104th0.9691.0315th0.8150.864Reverse3.250Differential Gear Ratio3.526Oil Capacity Litter (US qts, lmp. qts)1.9 (2.0, 1.7)Oil ViscositySAE 75W-90Oil GradeAPI GL-4 or GL-5ChassisnU540E Automatic TransaxleOverallU540E 4-speed automatic transaxle ECT has been
7、newly used-CChassisnU540E Automatic TransaxleSpecification-CEngine Type5A-FE8A-FETransmission TypeU540EGear Ratio1st2.7302nd1.5263rd1.0004th0.696Reverse2.290Differential Gear Ratio4.0324.350Fluid Capacity (include differential)Litter (US qts, lmp. qts)4.7 (4.97, 4.14)Fluid TypeATF Type T-IVChassisnU
8、540E Automatic TransaxleTorque ConverterA hydraulically operated lock-up mechanism type torque converter is used-CEngine Type5A-FE8A-FEOil Passage Diameter215 mm (8.46 in.)Torque Converter Type3-element, 1-step, 2-phase (with Lock-up Mechanism)Stall Torque Ratio1.96ChassisnU540E Automatic TransaxleO
9、il PumpTrochoid gear type oil pump is used. As a result oil pump has made more compact and the driving torque has been reduced-C-R-T-MDrive GearDriven GearPump BodyStator ShaftAssembly: Brake: Clutch: One-way ClutchInputChassisnU540E Automatic TransaxlePlanetary Gear UnitU540E effects the shifting o
10、f all speeds using 1 set of ravigneaux type planetary gear unit-CIntermediateShaftInputShaftFrontSunGearFront Ring GearRear Sun GearLongPinionGearShortPinionGearOutputB2FB1C1C2C3行星齿轮机构结构原理图: Brake: Clutch: One-way ClutchInputChassisnU540E Automatic TransaxlePlanetary Gear Unit Construction1st gear (
11、D or 2 position)-CIntermediateShaftInputShaftFrontSunGearFront Ring GearRear Sun GearLongPinionGearShortPinionGearOutputB2FB1C1C2C3ChassisnU540E Automatic TransaxlePlanetary Gear UnitFunction of components-CComponentFunctionC1Reverse ClutchConnects input shaft and front planetary sun gearC2Forward C
12、lutchConnects input shaft and rear planetary sun gearC3Rear ClutchConnects input shaft and intermediate shaftB12nd and 4th BrakeLocks front planetary sun gearB21st and Reverse BrakeLocks planetary carrierFOne-way ClutchLocks rear planetary carrier from turning counterclockwiseChassisnU540E Automatic
13、 TransaxlePlanetary Gear UnitOperation condition-C*1: After engaging, lock-up control is ON*2: After engaging, line pressure control is ON*3: After engaging, line pressure control is OFFShift Lever PositionGearShift Solenoid ValveC1C2C3B1B2FSL1SL2SL3DSLSLSRPParkXXRReverseXX/*2XX/X*3NNeutralXXXD1stXX
14、XX2ndXX/*1X/*13rdXXX/*2X/*1X/*1X4thX/*2X/*1X/*1X21stXXXX2ndXX/*1X/*1L1stXXXX: Signal ON, X: Signal OFF, : OperationChassisnU540E Automatic TransaxleValve BodyThe valve body consist following parts-CShift Solenoid Valve SL2Shift Solenoid Valve SL3Shift Solenoid Valve SL1Shift Solenoid Valve SRShift S
15、olenoid Valve SLShift Solenoid Valve DSLValve Body AssemblyChassisnU540E Automatic TransaxleValve BodyFunction of shift solenoid Valve-CShift Solenoid ValveFunctionSL1Control the B1 brake hydraulic pressureSL2Control the C2 brake hydraulic pressureSL3Control the line pressure that controls the hydra
16、ulic pressure for the C3 clutch and that for the B2 brakeDSLControl the lock-up clutch hydraulic pressureSLSwitch the lock-up relay valveSRSwitch the solenoid relay valveChassisnU540E Automatic TransaxleLayout of Components-CTransmission Control SwitchEngineECUECT ECUStop LightswitchDLC3ChassisnU540
17、E Automatic TransaxleLayout of Components-COutput Speed SensorInput Speed SensorNeutral Start Position SwitchShift Solenoid Valve SL2Shift Solenoid Valve SL1Shift Solenoid Valve SL3Shift Solenoid Valve SRShift Solenoid Valve SLShift Solenoid Valve DSLFluid Temp. SensorChassisnU540E Automatic Transax
18、leSystem Diagram-CEngine ECUFluid Temp. SensorNeutralStartSwitchInput Turbine Speed SensorDLC3Counter Gear Speed SensorSolenoidValvesStop Light SwitchCombination MeterECT ECUVehicleSpeedThrottle Valve Opening AngleEngine SpeedWater Temp.Torque Reduction?ChassisnU540E Automatic TransaxleCentrifugal F
19、luid Pressure Canceling MechanismA canceling fluid pressure chamber is used to prevent the generation of pressure by the centrifugal force-CClutchCentrifugal Fluid Pressure Applied to Canceling ChamberCentrifugal Fluid PressureTarget Fluid PressureInput ShaftPistonChassis-CECTECUEngineECUWater Temp.
20、SensorShift PositionSwitchThrottle Position SensorVehicle Speed SensorTransmissionControl Switch SolenoidValveControl ValveLock ValveCurrentFluid PressurenU540E Automatic TransaxleDirect Clutch Pressure ControlSolenoid valve regulated the clutch and brake hydraulic pressure without using an accumula
21、torC2, C3, B1 and B2ChassisnU540E Automatic TransaxleDirect Clutch Pressure ControlThe time lag in an inactive stroke was reduced by controlling a clutch by direct fluid pressure-CTimeDirect Clutch Pressure TypeFluid PressureAccumulator TypeShift Shock AbsorbingInactive StrokeTime lag ReductionChass
22、isnU540E Automatic TransaxleLine Pressure ControlLine pressure is optimally controlled in accordance with the engine torque information-CPrimary RegulatorThrottle PressurePumpLine PressureShift RangeThrottle Valve Opening AngleEngine SpeedShift PositionCurrentFluidPressureSolenoid Valve SL3ECTECUEng
23、ineECUChassisnU540E Automatic TransaxleEngine Torque ControlRetards the engine ignition timing temporarily to improve shift feeling during up or down shifting-CECTECUEngineECUIgnition TimingRetard SignalWater Temp.SensorShift PositionSwitchThrottle Position SensorCrankshaftPosition SensorVehicle Spe
24、ed SensorTransmissionControl SwitchTransmissionControl SignalRetardTimeDrive Wheel TorqueIgnitionTimingReduced Torque FluctuationsShift ChangeChassisnU540E Automatic Transaxle“N” to “D” Squat ControlWhen the shift lever is shifted from “N” to “D” range, the gear is temporarily shifted to 2nd and the
25、n to 1st to reduce vehicle squat-CChassisnU540E Automatic TransaxleClutch to Clutch Pressure ControlOptimal shift characteristics have been achieved through optimal hydraulic pressure settings-CControl ValveSignals from individual sensorsDisconnect Side ClutchSolenoid ValvesConnect Side ClutchLine P
26、ressureControl ValveECTECUEngineECUChassisnU540E Automatic TransaxleFail-safe FunctionThis function minimizes the loss of operability when any abnormality occurs in each sensor or solenoid valve-CMalfunctionInput Turbine Speed SensorFluid Temp. SensorSolenoid Valve SL1, 2Solenoid Valve SLSolenoid Va
27、lve DSLCommunication Line between Engine ECU and ECT ECUCrankshaft Position Sensor4th Upshift ProhibitChassisnU540E Automatic TransaxleOverdrive SwitchO/D switch changed from ON-OFF lock type to momentary type-CChassisnU340E Automatic TransaxleOverallThe compact, lightweight and high-capacity4-speed
28、 automatic transaxle Super ECT is used-R-T-MChassisnU340E Automatic TransaxleSpecificationTransmission TypeU340EGear Ratio1st2.8472nd1.5523rd1.0004th0.700Reverse2.343Differential Gear Ratio3.850Fluid Capacity (include differential)Litter (US qts, lmp. qts)6.8 (7.2, 6.0)Fluid TypeATF Type T-IV-R-T-MC
29、hassisnU340E Automatic TransaxlePlanetary Gear UnitU340E automatic transaxle effects the shifting of all speeds using 2 sets of planetary gear unit-R-T-M: Brake: Clutch: One-way ClutchInputOutputIntermediateShaftRear PlanetaryGearFront PlanetaryGearCounterDrive GearCounter Drive GearB2B1B3C1C2C3F2F1
30、ChassisnU340E Automatic TransaxleValve BodyThe valve body has a two-stage construction. All the solenoid valves are installed in the lower valve body-R-T-MAccumulators (B2, C3, C2)Linear Solenoid Valve (SL)Accumulator (C1)Fluid Temp. SensorUpper Valve BodyLinear Solenoid Valve (SLT)Shift Solenoid Va
31、lve (ST)Accumulator (B1)Lower Valve BodyShift Solenoid Valve (S2)Shift Solenoid Valve (S1)ChassisnU340E Automatic TransaxleValve BodyThe valve body has a two-stage construction. All the solenoid valves are installed in the lower valve body-R-T-MSolenoid ValveActionFunctionShift Solenoid ValveS1Switc
32、hes the 2-3 shift valveC1 clutch and B1,2 brake pressure controlS2Switches the 1-2, 3-4 shift valveC1,2 clutch and B1,2 brake pressure controlSTClutch to clutch pressure control3-4 and 4-3 shift valves controlLinear Solenoid ValveSLClutch pressure optimal controlLock-up clutch pressure controlSLTLin
33、e pressure controlLine pressure, secondary pressure and accumulator back pressure controlChassisnU340E Automatic TransaxleCentrifugal Fluid Pressure Canceling MechanismA canceling fluid pressure chamber is used to prevent the generation of pressure by the centrifugal force-R-T-MClutchCentrifugal Flu
34、id Pressure Applied to Canceling ChamberCentrifugal Fluid PressureTarget Fluid PressureInput ShaftPistonChassisnU340E Automatic TransaxleLine Pressure ControlLine pressure is optimally controlled in accordance with the engine torque information-R-T-MPrimary RegulatorThrottle PressurePumpLine Pressur
35、eShift RangeThrottle Valve Opening AngleEngine SpeedShift PositionCurrentFluidPressureSolenoid Valve SLTECTEngineEngine & ECT ECUChassisnU340E Automatic TransaxleClutch to Clutch Pressure ControlThe shift solenoid valve minutely controls the clutch pressure in accordance with the engine output and d
36、riving conditions-R-T-MLinear Solenoid Valve SLTAccumulator Control ValveC1B1SolenoidValve ST3-4 Shift Valve4-3 Timing Valve3-4 Timing ValveChassisnU340E Automatic TransaxleFail-safe FunctionThis function minimizes the loss of operability when any abnormality occurs in each sensor or solenoid valve-
37、R-T-MMalfunctionVehicle Speed SensorInput Turbine Speed SensorFluid Temp. SensorSolenoid Valve SLTSolenoid Valve SLSolenoid Valve STWater Temp. SensorKnock SensorThrottle Position Sensor4th Upshift ProhibitChassisnU340E Automatic TransaxleFail-safe FunctionCase of the malfunction in the solenoid val
38、ve S1 or S2-R-T-MAll Shift solenoids normalShift solenoid S1 malfunctionShift solenoid S2 malfunctionShift solenoid S1 and S2 malfunctionSolenoidGearSolenoidGearSolenoidGearSolenoidGearS1S2S1S2S1S2S1S2ONON1stXOFFON3rdONX2ndXX3rdONOFF2ndXOFF3rdONX2ndXX3rdOFFOFF3rdXOFF3rdOFFX3rdXX3rdOFFON4th XON4thOFF
39、X3rdXX3rdChassisnU340E Automatic TransaxleOverdrive SwitchO/D switch changed from ON-OFF lock type to momentary type-R-T-MChassisnDrive ShaftOverallDrive shaft uses the Tripod type CVJ (Constant-Velocity Joint) on the differential side, and Rzeppa type CVJ on the wheel side-C-R-T-MWheelSideLeft-hand
40、Differential SideWheelSideDifferential SideRight-handRzeppa Type CVJRzeppa Type CVJTripod Type CVJDynamic DamperChassisnSuspensionSuspension Line-upFront: MacPherson strut type suspensionRear: Torsion-beam type suspension with toe-conrrect bushings ( eta beam suspension)-C-R-T-MChassisnBrakeOverallF
41、ront: 14” Ventilated Disc BrakeRear: Leading Trailing Drum Brake 14” Solid Disc Brake (Thailand model)-C-R-T-MFront BrakeRear BrakeChassisnBrakeSpecification-C-R-MModelwithout ABS*1without ABS*2with ABSMaster CylinderTypeLockheed+LockheedPortless+LockheedDiameter mm (in.)20.64 (0.81)Brake BoosterTyp
42、e9” SingleFront BrakeType13” Ventilated Disc14” Ventilated DiscWheel Cylinder Dia. mm (in.)51.1 (2.01)Rotor Size (D x T) mm (in.)235 x 18(9.25 x 0.71)255 x 20(10.04 x 0.79)Rear BrakeTypeLeading Trailing DrumWheel Cylinder Dia. mm (in.)17.46 (0.69)Drum Inner Dia.mm (in.)200 (7.87)Brake Control Valve
43、TypeLSPVEBD*1: Only for DLX (8A-FE engine) Grade*2: Except DLX GradeChassisnBrakeSpecification-TModelwithout ABS*1without ABS*2with ABS*2Master CylinderTypeLockheed+LockheedPortless+LockheedDiameter mm (in.)20.64 (0.81)Brake BoosterType9” SingleFront BrakeType14” Ventilated Disc14” Ventilated DiscWh
44、eel Cylinder Dia. mm (in.)51.1 (2.01)Rotor Size (D x T) mm (in.)255 x 20(10.04 x 0.79)Rear BrakeTypeLeading Trailing Drum14” Solid DiscWheel Cylinder Dia. mm (in.)17.46 (0.69)30.2 (1.19)Drum Inner Dia.mm (in.)200 (7.87)Rotor Size (D x T) mm (in.)269 x 9(10.60 x 0.35)Brake Control Valve TypeLSPVEBD*1
45、: Only for 1.5J Grade*2: Except 1.5J GradeChassisnBrake Control SystemSystem Diagram (ABS with EBD)-C-R-T-MBrake FluidLevel WarningSwitchStop LightSwitchSpeedSensorsCombination MeterSpeedSensorsSpeed MeterABS Warning LightBrake System Warning LightDLC3BrakeActuatorSpeedSensorsSkidControlECUChassisnS
46、teeringA rack and pinion type gear and an engine revolution sensing type power steering* are used-C-R-T-M*: Except DLX grade of 8A-FE engineChassisnSteeringPower Steering PumpSpecification-C-R-T-MItem New ModelOperating speed rpm500 7000Theoretical Discharge Rate l/min5.4 3.3Relief Pressure MPa kgf/
47、cm2, psi)5.9 ChassisnSteeringSteering Wheel-C-R-T-MSteering Type4-spoke steering wheel with airbag is made of wood and leather*3-spoke steeringwheel with Airbag is made of urethane3-spoke steeringwheel without Airbag is made of urethaneDesign*: Wood and leather steering wheel is available for C mode
48、l of GXL-i/GLX-S grade (STD), GL/GL-i grade (OPT)ChassisnTire and WheelTire and Wheel Size and Design-C-R-T-MDestinationGrade-CDLXOthers*1-R1.5J1.5G, 1.5E1.5G (OPT)-T 1.5S*2 1.5E*2 1.5J1.5E1.5S, 1.5G*3 -M1.31.5G, 1.3ESize155/80R13 T 5 JJ175/65R14 5 JJ175/65R14 H 5 JJ185/55R15 5 JJ MaterialSteelAluminum*1: DLX-i, GL/GL-i, GLX-i, GLX-S*2: Only for Singapore and Brunei*3: Only for IndonesiaDesign
