Dodge 2006 Sprinter, Manual

Page: 1742 / 2315

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In cr ea sed ser vice life a n d r elia bilit y.
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Lower m a in t en a n ce cost s.
TRANSMISSION IDENTIFICATION
Th e t r a n sm ission ca n be gen er ica lly iden t ified
visu a lly by t h e pr esen ce of a r ou n d 13-wa y con n ect or
loca t ed n ea r t h e fr on t cor n er of t h e t r a n sm ission oil
pa n , on t h e r igh t side. Specific t r a n sm ission in for m a -
t ion ca n be fou n d st a m ped in t o a pa d on t h e left side
of t h e t r a n sm ission , a bove t h e oil pa n r a il.
TRANSMISSION GEAR RATIOS
Th e gea r r a t ios for t h e NAG1 a u t om a t ic t r a n sm is-
sion a r e a s follows:
1st Gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59:1
2n d Gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19:1
3r d Gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41:1
4t h Gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
5t h Gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83:1
Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16:1
TRANSMISSION HOUSING
Th e con ver t er h ou sin g a n d t r a n sm ission a r e m a de
fr om a ligh t a lloy. Th ese a r e bolt ed t oget h er a n d cen -
t er ed via t h e ou t er m u lt i-disc ca r r ier of m u lt i-disc
h oldin g clu t ch , B1. A coa t ed in t er m edia t e pla t e pr o-
vides t h e sea lin g. Th e oil pu m p a n d t h e ou t er m u lt i-
disc ca r r ier of t h e m u lt i-disc h oldin g clu t ch , B1, a r e
bolt ed t o t h e con ver t er h ou sin g. Th e st a t or sh a ft is
pr essed in t o it a n d pr even t ed fr om r ot a t in g by
splin es. Th e elect r oh ydr a u lic u n it is bolt ed t o t h e
t r a n sm ission
h ou sin g fr om u n der n ea t h . A sh eet
m et a l st eel oil pa n for m s t h e closu r e.
MECHANICAL SECTION
Th e m ech a n ica l sect ion con sist s of a in pu t sh a ft ,
ou t pu t sh a ft , a su n gea r sh a ft , a n d t h r ee pla n et a r y
gea r set s wh ich a r e cou pled t o ea ch ot h er. Th e pla n -
et a r y gea r set s ea ch h a ve fou r pla n et a r y pin ion
gea r s. Th e oil pr essu r e for t h e t or qu e con ver t er
lock-u p clu t ch a n d clu t ch K2 is su pplied t h r ou gh
bor es in t h e in pu t sh a ft . Th e oil pr essu r e t o clu t ch
K3 is t r a n sm it t ed t h r ou gh t h e ou t pu t sh a ft . Th e
lu br ica t in g oil is dist r ibu t ed t h r ou gh a ddit ion a l bor es
in bot h sh a ft s. All t h e bea r in g poin t s of t h e gea r set s,
a s well a s t h e fr eewh eelin g clu t ch es a n d a ct u a t or s,
a r e su pplied wit h lu br ica t in g oil. Th e pa r kin g lock
gea r is con n ect ed t o t h e ou t pu t sh a ft via splin es.
F r eewh eelin g clu t ch es F 1 a n d F 2 a r e u sed t o opt i-
m ize t h e sh ift s. Th e fr on t fr eewh eel, F 1, is su ppor t ed
on t h e ext en sion of t h e st a t or sh a ft on t h e t r a n sm is-
sion side a n d, in t h e lockin g dir ect ion , con n ect s t h e
su n gea r of t h e fr on t pla n et a r y gea r set t o t h e t r a n s-
m ission h ou sin g. In t h e lockin g dir ect ion , t h e r ea r
fr eewh eelin g clu t ch , F 2, con n ect s t h e su n gea r of t h e
cen t er pla n et a r y gea r set t o t h e su n gea r of t h e r ea r
pla n et a r y gea r set .
ELECTROHYDRAULIC CONTROL UNIT
Th e elect r oh ydr a u lic con t r ol u n it com pr ises t h e
sh ift pla t e m a de fr om ligh t a lloy for t h e h ydr a u lic
con t r ol a n d a n elect r ica l con t r ol u n it . Th e elect r ica l
con t r ol u n it com pr ises of a su ppor t in g body m a de of
pla st ic, in t o wh ich t h e elect r ica l com pon en t s a r e
a ssem bled. Th e su ppor t in g body is m ou n t ed on t h e
sh ift pla t e a n d scr ewed t o it .
St r ip con du ct or s in ser t ed in t o t h e su ppor t in g body
m a ke t h e con n ect ion bet ween t h e elect r ica l com po-
n en t s a n d a plu g con n ect or. Th e con n ect ion t o t h e
wir in g h a r n ess on t h e veh icle a n d t h e t r a n sm ission
con t r ol m odu le (TCM) is pr odu ced via t h is 13-pin
plu g con n ect or wit h a ba yon et lock.
SHIFT GROUPS
Th e h ydr a u lic con t r ol com pon en t s (in clu din g a ct u a -
t or s) wh ich a r e r espon sible for t h e pr essu r e dist r ibu -
t ion befor e, du r in g, a n d a ft er a gea r ch a n ge a r e
descr ibed a s a sh ift gr ou p. E a ch sh ift gr ou p con t a in s
a com m a n d va lve, a h oldin g pr essu r e sh ift va lve, a
sh ift pr essu r e sh ift va lve, over la p r egu la t in g va lve,
a n d a solen oid.
Th e h ydr a u lic syst em con t a in s t h r ee sh ift gr ou ps:
1-2/4-5, 2-3, a n d 3-4. E a ch sh ift gr ou p ca n a lso be
descr ibed a s bein g in on e of t wo possible st a t es. Th e
a ct ive sh ift gr ou p is descr ibed a s bein g in t h e sh ift
ph a se wh en it is a ct ively en ga gin g/disen ga gin g a
clu t ch com bin a t ion . Th e 1-2/4-5 sh ift gr ou p con t r ol
t h e B1 a n d K1 clu t ch es. Th e 2-3 sh ift gr ou p con t r ols
t h e K2 a n d K3 clu t ch es. Th e 3-4 sh ift gr ou p con t r ols
t h e K3 a n d B2 clu t ch es.
OPERATION
Th e t r a n sm ission con t r ol is divided in t o t h e elec-
t r on ic a n d h ydr a u lic t r a n sm ission con t r ol fu n ct ion s.
Wh ile t h e elect r on ic t r a n sm ission con t r ol is r espon si-
ble for gea r select ion a n d for m a t ch in g t h e pr essu r es
t o t h e t or qu e t o be t r a n sm it t ed, t h e t r a n sm ission ’s
power su pply con t r ol occu r s via h ydr a u lic elem en t s
in t h e elect r oh ydr a u lic con t r ol m odu le. Th e oil su pply
t o t h e h ydr a u lic elem en t s, su ch a s t h e h ydr odyn a m ic
t or qu e con ver t er, t h e sh ift elem en t s a n d t h e h ydr a u -
lic t r a n sm ission con t r ol, is pr ovided by wa y of a n oil
pu m p con n ect ed wit h t h e t or qu e con ver t er.
Th e Tr a n sm ission Con t r ol Modu le (TCM) a llows for
t h e pr ecise a da pt a t ion of pr essu r es t o t h e cor r espon d-
in g oper a t in g con dit ion s a n d t o t h e en gin e ou t pu t
du r in g t h e gea r sh ift ph a se, r esu lt in g in a n ot icea ble
im pr ovem en t in sh ift qu a lit y. Th e en gin e speed lim it
ca n be r ea ch ed in t h e in dividu a l gea r s a t fu ll t h r ot t le
a n d kickdown . Th e sh ift r a n ge ca n be ch a n ged in t h e
for wa r d gea r s wh ile dr ivin g, bu t t h e TCM em ploys a
down sh ift sa fegu a r d t o pr even t over-r evvin g t h e
en gin e. Th e syst em offer s t h e a ddit ion a l a dva n t a ge of
21 - 4 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA