Automatic Transmission Internal Diagnosis

AutomotiveElectricalDiagnosis

AED.08

Wiring HarnessDiagnosis & Repair

Student Guide

AutomaticTransmission

InternalDiagnosis

Course Guide ATID.01

Course Guide

Student Guide

IG_ATID01_Covers 122010:AED_08F.qxd 12/28/2010 8:07 AM

SAFETY FIRST

Appropriate service methods and proper repair procedures are essential for safe,reliable operation of all motor vehicles as well as the personal safety of the individualperforming the repair. There are numerous variations in procedures, techniques, toolsand parts for servicing vehicles, as well as in the skill of the individual performing theservice. This module cannot possibly anticipate all such variations and provide adviceor caution to each. Accordingly, anyone who departs from the instruction provided inthis module must first establish that they compromise neither their personal safety northe vehicle integrity by their choice of methods, tools or parts. The following listcontains general warnings that should always be followed while working on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires underbody work.

• Be sure the ignition switch is always off unless otherwise specified by a procedure.

• Set the parking brake when working on the vehicle.

• Operate the engine only in a well ventilated area.

• Keep clear of moving parts when the engine is running.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator,exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on a vehicle.

Within this module you will find Notes, Cautions and Warnings which provide criticalinformation and help you do your job safely and efficiently. Below are the definitionsof these terms.

When you see a Note, Caution or Warning, be certain you understand the messagebefore you attempt to perform any part of a service procedure.

NOTEThe purpose of a Note is to help you do your job more efficiently. A Note mayprovide additional information to help clarify a particular point or procedure.

CAUTIONA Caution alerts you to the possibility of damage to tools, equipment, or thevehicle. A Caution recommends that a procedure must be done in a certain wayto avoid potential problems resulting from improper techniques or methods.

WARNINGA Warning alerts you to the highest level of risk. Warnings inform you that aprocedure must be done in a particular way to minimize the chances of anaccident that could result in personal injury or even loss of life.


Copyright © 2011 Kia Motors America, Inc.

All rights reserved. No part of this publication may be reproduced, stored electronically, or transmitted in anyform or by any means without prior written approval from Kia Motors America, Inc. (“KMA”). KMA reserves theright to make changes in the descriptions, specifications, or procedures.

The content of this course is intended for informational and educational purposes only. Any reliance placed onsuch information is therefore strictly at your own risk. In no event will Kia Motors America, Inc. ("KMA") or Kia

University be liable for any loss or damage including, without limitation, indirect or consequential loss or damage,property loss, damage, personal injury or death caused to any persons arising out of or in connection with the

use of this course.

While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot beguaranteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of anyinformation contained in these course materials. Nothing in this course is intended as a guarantee of success.


TT-ATID207-IL-CG016th Printing - January 2011


Course Titl

Module Title

Automatic Transmission Internal Diagnosis

ATID Course Guide Module 01 1

COURSE OVERVIEW

COURSE GOAL

COURSE OBJECTIVES

EXPECTATIONS

TARGET AUDIENCES

The Automatic Transmission Internal Diagnosis Course provides Kia service technicians with the opportunity to increase their ability and efficiency by using the A/T diagnostic flowchart as outlined in the A/T TSB to verify, and diagnose concerns internal to an automatic transmission in determining if the unit should be replaced or not. The goal of this course is to train Kia service technicians with the skills required to increase their diagnose proficiency through intermediate to advanced level hands-on, instructor supervised guided practices including: � Internal A/T problem � ATF level and condition inspections � Use of the Kia A/T Diagnostic Flowchart This course is designed to develop the skills required to diagnose internal Kia automatic transmissions related concerns. Critical service topics include: � Use of the Kia A/T Diagnosis Flowchart � Proper use of the updated A/T Tester Pro � Determining whether an A/T unit should be repaired

or replaced � An individual performance assessment at the end of

the course measures mastery of the course content. Upon completion of this course, the Kia Service Technician will be able to demonstrate with 80% or greater accuracy: � A/T diagnostic procedures using the Kia A/T

Diagnosis Flowchart and A/T Core Data Form � Use of the current A/T Tester � Whether to repair or replace a Kia A/T. In this course, you will be expected to inspect various automatic transmissions and use diagnostic processes to fix the vehicle on the first visit. During the hands-on activities, you will often be working as a team. By actively engaging in each activity, you will maximize your learning experience. While in the shop, feel free to ask the instructor questions at any time. The target audience for ATID consists of Kia Senior and Master Service Technicians who will diagnosis A/T concerns.

2 ATID Course Guide Module 01


PREREQUISITES The following web courses must be completed prior to the start of the ATID course: � Kia Automatic Transmission Maintenance � Introduction to Kia A/T Diagnosis

ABOUT TRAINING MODULES

THEORY

GUIDED PRACTICE

PERFORMANCE ASSESSMENT

GETTING THE MOST OUT OF THIS COURSE

Today's complex automotive technology demands that you, the professional Kia service technician, stay up to-date with the latest service information, special tools and complex repair procedures. We have adopted a modular training delivery system that breaks-down the critical information into logical groups. First, you will be presented with system theory and operation, and then given a chance to practice what you have learned. Finally, we will test what you have learned through a Performance Assessment. A Theory Module explains the subject This allows you to obtain a working knowledge of a component or system, which helps guide you to successful diagnosis and repair. The Guided Practice Module allows you the opportunity to familiarize yourself through hands-on experience. The tasks are to be instructor supervised and verified. These exercises may include: the use of service manuals or Kia service information system, accessing Kdealer.net, lab disassembly and reassembly, live vehicle activities and much more. The Performance Assessment Module provides you the opportunity to demonstrate and prove that you can diagnose A/T related concerns. Each technician must successfully complete this module. It is designed to test your cognitive (knowledge) in diagnosing a customer concern. These modules are designed to be part of a structured training plan consisting of lecture, interactive classroom discussion and hands-on shop activities under the direction of a trained Kia instructor. After completing the course modules, your understanding of the material will be verified through the Performance Assessment module; you must pass the written and hands-on evaluations.

Course Titl

Module Title


ATID Course Guide Module 01 3

COURSE MATERIAL

AGENDA

PERFORMANCE SCORECARD

COURSE ACHIEVEMENT

SCORECARD ROUTING

Mod

ule

Num

ber

Mod

ule

Titl

e

Theo

ry

Gui

ded

Pra

ctic

e D

iagn

osis

Per

form

ance

A

sses

smen

t

Gui

de

ATID 01 Course Guide X ATID 02 A/T Reman

Process X

ATID 03 Preliminary Inspection X

ATID 04 A/T Diagnostic Flowchart

X

ATID 05 ATID Guided Practice X

ATID 06 Performance Assessment X

ATID.01 Course 8:00 – 8:30 amATID.02 Reman Process 8:30 – 9:00 amATID.03 Preliminary Inspection 9:30 – 10:15 amBreak 10:15 – 10:30 amATID.04 Flowchart Diag 10:30 – 12:00 pmLunch 12:00 – 1:00 pmATID.04 Continued 1:00 – 2:00 pmATID.05 A/T Diagnostic 2:00 – 3:00 pmBreak 3:00 – 3:15 pmATID.06 PA 3:15 – 4:15 pmWrap up 4:15 – 4:45 pm

The Performance Scorecard is used to track your performance on guided practices, diagnosis & troubleshooting, and any written knowledge assessments. A final score of 80% or higher is needed for completion credit of this course. One copy of the scorecard is yours, and one copy is used to update your Kia technical training records. Should you not complete the course, the third copy is forwarded to your Kia District Parts and Service

4 ATID Course Guide Module 01


COURSE MANAGEMENT

TAKE NOTES

ASK QUESTIONS

TEAMWORK

LEARN AT EVERY OPPORTUNITY

ICONS

The course and its materials are here for you to learn and keep. Use them and your time in a way that will benefit you when you return to your dealership. Make drawings, jot down notes, and highlight these materials to help you remember important details. Each module is designed with ample margins for your important notes. If you do not understand something in this course, ask your instructor for clarification. Asking questions is strongly encouraged to help you get the most out of this course. During the hands-on activities, you will often be working as a team. By actively engaging in each activity, you will maximize your learning experience. While in the lab, feel free to ask the instructor questions at any time. This course is an opportunity for you to learn in a controlled environment under the guidance of a trained Kia instructor. Through active participation you can build confidence in your abilities to diagnose, customer concerns right the first time, every time! The Reference Icon indicates you must refer to additional publications in order to complete the questions or activity. The Video Icon indicates there is a video segment corresponding to the module information. The Activities Icon indicates an activity that supports a critical learning objective. These activities are offered to help you master the material. The Feedback Icon indicates a progress check meant to provide you with feedback on your understanding of the course material.

AutomaticTransmissionInternalDiagnosis

Theory Module ATID.02

Automatic TransmissionProgram

Student Guide

IG_ATID02_Covers 122009:AED_08F.qxd 12/28/2010 8:09 AM Page 1

SAFETY FIRST


















The content of this course is intended for informational and educational purposes only. Any reliance placed onsuch information is therefore strictly at your own risk. In no event will Kia Motors America, Inc. ("KMA") or KiaUniversity be liable for any loss or damage including, without limitation, indirect or consequential loss or damage,property loss, damage, personal injury or death caused to any persons arising out of or in connection with the

use of this course.



TT-ATID207-IL-TH026th Printing - January 2011


Course

Module Title


ATID A/T Remanufacturing Process Theory Module 02 1

TARGET AUDIENCE

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

REQUIRED MATERIALS

TIME TO COMPLETE

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose and repair Kia automatic transmissions. The goal of this module is to inform the Kia Service Technician on the processes required to properly document and return a Kia A/T for remanufacturing. Given this module, and a written performance assessment test, the technician will be able to complete the following with 80% or greater accuracy: � Accurately document the diagnosis of the customer

concern � Proper handling of the replacement assembly � Proper preparation of the core for remanufacturing � Understanding the remanufacturing process Module pages contain the power point images; study each illustration and take notes based on the classroom presentation and discussion. In order to complete this module, you will need the following items: � A/T TSB � A/T Parts Bulletin � A/T remanufacturing concerns � Preferred writing instrument Approximately 30 minutes.

2 ATID A/T Remanufacturing Process Theory Module 02


INTRODUCTION

PURPOSE

When diagnosing a customer A/T related concern, a systematic approach for diagnosing to the point of replacing the A/T assembly. In this module, we will follow the A/T assembly through the Kia process of: � Inspections � Diagnosis to the point of failure � Remanufacture To efficiently return the A/T assembly, while securing dealership core credit and reducing the possibly of chargeback.

Course

Module Title



Tech diagnose replacement of the A/T: � DPSM approval � Assembly ordered (Fed/CA) � Unit arrives � Note shipping items: � Documentation � New serial number � TC bolted down � Side gear retainers � ATF hoses � Cooler flush � Cap in VSS

Returning the core: � Case � Not disassembled/damaged � Exchange any exterior components � Documentation � TC bolted, A/T in bag/ATF, Side gears

and ATF hose. � Charge back may occur Written docs: ATCDF, warranty claim information and shipping slip



Core is picked up within 2 days of claim At shipping center, core is visually inspected for shipping docs, missing parts or fluid leaking Authorizes the $1K core charge return Reverse logistics reduces core charge return time. From dist. Center, core goes to San Diego for export to Tijuana, Mexico Explain what TransLead is. TransLead inspects the core for prior disassembly and proper documentation. Shown: Cores received and logged into computer management system. Documentation is issued under new serial number for assembly If returned core is a reman, core is noted for inspection to determine failure Core removed from case and placed on plywood board for forklift movement. The exterior is “dry” cleaned. Shipping case is sent for cleaning.

Course

Module Title



Returned remanufactured units are inspected and tested on a dyno based upon the RO and A/T Core Data Form. If failure is confirmed, the core continues on the line to be remanufactured If not, the core is shipped to the inspection room for tear down to determine the point of failure. All cores are taken to the start of a U-shaped remanufacturing line. Core is mounted on stand for draining and disassembled. Pan is removed with a rubber hammer No gasket uses sealer If pan damaged during removal, pan is replaced. ATF is inspected Valve body: � Removed � Sent to a clean room for inspection � Remanufactured with new electrical

components and wiring � Tested. Valve body Unit loses ID with A/T core.



Remanufactured valve bodies Torque Converter: � Sent to be cut apart � Inspected and worn parts replaced � Including the fins, OWC and bearing Inspection sheet documentation shown Turbine and Pump sections are welded back together

Course

Module Title



Balance is checked. If out of specification, unit is discarded. The core is: � Completely disassembled � Sorted into racks for cleaning &

inspection � Hard parts separate from soft parts � Case is removed from the stand Parts are cleaned by: � Hand washing and then � Hot washed (shown)



Spray cans are used to paint the: � Case � Pan � Pump cover Hard parts are replaced if necessary Parts come from the parts department Soft parts are shown in the background � Replaced as needed � CA units have new soft parts

Course

Module Title



Steels are replaced as needed Assembly starts Assembly Final drive assembled: � New bearings if necessary � End play adjusted � Most pressure port plugs installed � Valve body installed � Torque is done with preset Torque

wrenches � Pan sealed/installed



TC installed � Filled with ATF � Unit mounted to tester � Quick disconnect installed at test

ports 100% of units tested Test results are: � Printed out � Included with internal documents Unit removed ATF drained from pan Plugs installed into line pressure ports. � Line pressure testing is no longer

allowed due to case damage. � Plugs are marked/painted as a

tamper indicator. Case is vacuum tested for ATF leaks Installed for shipping: � ATF hose & dipstick tube plug � Axle plugs � TC hold down � VSS plug Reman serial number applied to case

Course

Module Title



Assemblies: � Placed in the shipping case � Cooler flush can � Washers if needed � Document bag � Caution tag � Part number

RH side: Empty clean cases LH side & background: Completed assemblies waiting shipping to PDC When returned cores disassembled in the component room, the failed causal components are kept for recall by the supplier. Information is compared to causal number on submitted documentation



Broken or cracked case should be marked and documented prior to returning the core by technician. This damage could have been done: � Before the repair � Cause of the concern � After removal from vehicle

Should be documented by technician Exterior damage should be well marked and documented by technician

Course

Module Title



Damaged pan possibly the cause of the concern This new reman A/T assembly was not installed into a vehicle and returned as a core. Note: No marks around the boltholes

Course

Module Title





NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________


InternalDiagnosis

Guided Practice ATID.03

Automatic TransmissionPreliminary Inspection

Student Guide


SAFETY FIRST




















use of this course.



TT-ATID207-IL-GP036th Printing - January 2011


Module Title


ATID Preliminary Inspection Guided Practice Module 03 1

TARGET AUDIENCE

MODULE GOALS

MODULE OBJECTIVES

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose Kia A/T. The goal of this module is to train the technician to perform properly the preliminary A/T inspection prior to verifying the customer’s concern. Given this module, a vehicle, required tools/materials and upon completion, the technician will have perform the following tasks with 80% or greater accuracy: � Measure the vehicle’s engine coolant temperature

and ATF temperature using a scan tool � Accurately determine the A/T ATF level and

condition � Given ATF samples, determine those that have any

abnormal odor, contamination, or indication of A/T internal damage.

� Check the operation and adjustment of the range

switch. � Perform a lag test. � Determine if the MIL is ON. � Given a Kia scan tool, retrieve engine and A/T DTCs

if the MIL is ON.

2 ATID Preliminary Inspection Guided Practice Module 03


MODULE INSTRUCTIONS

REQUIRED MATERIALS

TIME TO COMPLETE

Carefully read and follow the instructions for each task. Answer the questions and fill in the blanks with the requested information as you perform the task. When you have finished, have your training instructor evaluate your work and sigh-off on the scorecard that it has been complete. In order to complete this module, you will need the following items: � Kia vehicle with A/T and dipstick � 2009 Borrego 3.8L without dipstick � Kia scan tool � ATF Samples � White Paper for Inspection � Wheel Chocks � Writing Instrument Approximately 45 minutes

Module Title



INTRODUCTION

INTRODUCTION

In this module, we will perform the following tasks that are required before the test drive and while verifying the customer’s A/T related concern. � Check the fluid level and condition � Check the operation of the range switch and shift

position indicator � Perform a lag test � Retrieve and clear any DTCs if the MIL is ON Station 1: Assigned vehicle (5 points)

� ATF inspection � Range switch check � Lag Time test � MIL check � DTC retrieval

Station 2: Assigned vehicle (3 points) � ATF inspection

Station 3: Fluid Samples (2 points)

� Determine condition of ATF samples � Describe the results



ATF INSPECTION

All A/T diagnosis begins with an inspection of the ATF for: � Correct level � Condition & Color � Odor � Unknown fluid � Evidence of internal A/T failure NOTE: New ATF is red in color. With time and normal A/T operation, the color will change to light brown. If the fluid has a burnt smell, it is an indication that the clutches have been slipping. This may be caused by: � Low fluid level � Wrong fluid type � Internal problems � Electrical problems � Vehicle being driven aggressively � Incorrect towing Evidence of clutch material or metal flakes, internal damage has occurred, replacement may be necessary.

Module Title



STATION 1:

ATF INSPECTION

Using the vehicle provided, check the temperatures and ATF level, then record the results below. Use a scan tool to determine the temperatures. Engine temperature (Key ON, engine OFF): _________________________ Degrees F A/T temperature (Key ON, engine OFF): _________________________ Degrees F Fluid level inspection procedure: 1. Park the vehicle on a flat, level surface. 2. Wipe all dirt or contaminates from around the ATF

level dipstick before removing it. 3. Set the parking brake, ensure that the gear select

lever is in “Park”, and start the engine. 4. Shift through all gears then return to “Park”. This

will fill the torque converter and all circuits with ATF.

5. Check the fluid level on the dipstick. 6. Turn off the engine. ATF level: LOW NORMAL OVERFULL Condition: ___________________________________

“Hot” Operating Range – 158-176° F

“Cold” ATF Level Indicator Range



STATION 1: CONTINUED

RANGE SWITCH

LAG TEST

MIL STATUS

Does the engine start in park and neutral YES NO Does the engine start in any other position? YES NO Does the indicator show the correct position for each position? YES NO What is the approximate amount of time for the A/T to engage? Park to Reverse ________________________________ Park to Drive __________________________________ Is the MIL on? YES NO If the MIL is ON, what does this indicate? _____________________________________________ List any DTCs stored. __________________________________________________________________________________________

Module Title



STATION 2:

ATF INSPECTION ON DIPSTICK LESS A/T

BORREGO 3.8L

Using the vehicle provided, check the temperatures and ATF level, then record the results below. Use a scan tool to determine the temperatures. A/T fluid temperature should be between 130° and 140 °F (54° - 60°C) A/T temperature (Key ON, engine OFF): _________________________ Degrees F Fluid level inspection procedure: 1. Park the vehicle on a flat, level surface. 2. Set the parking brake, ensure that the gear select

lever is in “Park”, and start the engine. 3. Shift through all gears then return to “Park”. This

will fill the torque converter and all circuits with ATF.



STATION 2 CONTINUED:

4. Safely raise the vehicle to a height that allows you to gain access to the fill and overflow plugs

5. Place a drain pan below the A/T then remove the fill

and overflow plugs 6. Observe the flow of ATF from the overflow plug. 7. Install and tighten the overflow plug. 8. Install and tighten the fill plug. 9. Lower the vehicle and turn off the engine. 10. How did the ATF flow from the overfill port?

___________________________________ Discuss your results with your instructor. Clean up your area when finished.

Module Title



STATION 3:

ANALYZING FLUID SAMPLES

Analyze the ATF and determine what’s wrong if anything. Take a small amount of the supplied ATF samples and place it on the paper supplied. Visually look, feel, and smell each sample. Determine if the fluid is good, burnt, contaminated, contains clutch material or metal flakes and describe below. Sample 1: __________________________________________________________________________________________ Sample 2: __________________________________________________________________________________________ Sample 3: __________________________________________________________________________________________ Sample 4: __________________________________________________________________________________________ Sample 5: __________________________________________________________________________________________ Sample 6: __________________________________________________________________________________________



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________

Module Title



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________


InternalDiagnosis

Theory Module ATID.04

Automatic TransmissionDiagnostic Flowchart

Student Guide

IG ATID04_Covers 122010:AED_08F.qxd 12/27/2010 3:56 PM Page 1

SAFETY FIRST




















use of this course.



TT-ATID207-IL-TH046th Printing - January 2011



ATID Diagnostic Flowchart Theory Module 04 1

TARGET AUDIENCE

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

REQUIRED MATERIALS

TIME TO COMPLETE

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose and repair Kia automatic transmissions. The goal of this module is to train the Kia Service Technician with the skills required to diagnose A/T related concerns using the A/T Diagnostic Flowchart to determine if the cause is internal and the assembly needs to be replaced. Given this module, and a written multiple-choice test, the technician will be able to complete the following with 80% or greater accuracy: � Proper use of the A/T Diagnostic Flowchart � Proper use of the GDS to:

o Retrieve and clear DTCs o Retrieve current A/T data

� Analysis of ATF levels and conditions � Analysis of range switch and lag-test results � Proper use of the GR8-1299 � Proper use of the A/T Tester Plus � Analysis of stall-test results � Analysis of voltage drop test results Carefully read the material, take notes based on the classroom discussion and study each illustration. Throughout the module, there will be Progress Check questions for you to answer. You may use the module to answer the questions. In order to complete this module, you will need the following items: � A/T Diagnostic Flowchart � A/T Core Data Form (ATCDF) � A/T Tester Pro � Power Supply � Preferred writing instrument Approximately 2 hours, 45 minutes.

2 ATID Diagnostic Flowchart Theory Module 04


INTRODUCTION

PURPOSE

The A/T Diagnostic Flowchart and A/T Core Data Form (ATCDF) are the keys to your success in properly troubleshooting and diagnosing A/T problems. In this module, we will follow the: � A/T Diagnostic Flowchart � The 5-step process To quickly and efficiently diagnose A/T system for internal malfunctions and concerns. The purpose of the A/T Flowchart is to provide you with a systematic plan, based on the Kia 5-step Troubleshooting Process, for correcting a customer’s A/T related concern the first time, every time. The ATCDF is used to document your findings and pass this information on to the warranty system and the A/T remanufacturing facility. NOTE: Both the Flowchart and ATCDF are printable from the A/T web courses and the TSB on KGIS.



A/T DIAGNOSTIC FLOWCHART

The A/T Diagnostic Flowchart is what you will follow to guide your diagnosis. It has the steps needed to accurately diagnose most A/T concerns.



A/T CORE DATA FORM (ATCDF)

The ATCDF is where you will record your findings while

following the Flowchart in verifying and diagnosing a customer’s A/T related concern.



REPAIR ORDER (RO)

The above RO is the type used in this course. It’s used by the dealership “customer care” team to track and document the service or repairs on a customer’s vehicle. While the RO may look different from one dealer to another, they have the same basic information: � Owner information � Vehicle information � History of the previous 4 or 5 service/repairs at your

dealership � Recommended services � Customer concern(s)

Customer states: A/T Slips between 2nd and 3rd when cold



SERVICE ADVISOR SECTION

You begin by reviewing the customer’s stated concern on the RO, if necessary with the service advisor to assure no misunderstanding. NOTE: An incorrect description of the customer’s concern may lead to misdiagnosis. Based upon the customer’s stated concern, circle the nature code that best describes the condition.



2ND OR SUBSEQUENT REPAIR ATTEMPT

After you have reviewed the customer concern, it’s time to look at the service and warranty history to determine if this is a 2nd or subsequent A/T related repair. If so, open a TechLine web case for assistance and advise your service manager who may contact the DPSM as necessary.

10/01/00 000001 8129 Jones 0213 W ATM Assy Leaks, others



FLUID CHECK

The inspection starts with a check of the ATF level and condition: � Parking brake applied � Engine running � A/T in “Park” or “Neutral” The condition of the ATF typically fall into 4 categories: � Normal—light brown color with no abnormal odors. � Burnt—dark brown color with an odor similar to

burnt toast. � Contaminated — dark brown color containing clutch

material, metal particles or other fluids. � Water or coolant contaminated — milky color � NOTE: It is not critical at this time to have the engine

and A/T up to normal operating temperature.

COLD

HOT



RANGE SWITCH – LAG TEST

The A/T range switch typically does not get out of adjustment unless there has been some type of service that would require disconnecting the shift cable, engine, or A/T. Adjustable range switches typically have an alignment procedure that uses a pin that aligns two holes on the switch. Refer to the service information for the correct procedure for the vehicle you are diagnosing. Possible customer concerns are that the: � Engine may not start � The A/T does not go into “Reverse” or “Drive” � There may be shift flare The Lag Test is performed to determine if there is excessive time required for the A/T to engage when shifting from “Neutral” to “Reverse” and “Neutral” to “Drive”. Typically, it should take less than one second but may require up to 2 seconds for it to engage. Take 3 time measurements for each test and use the average value. The results may not be accurate if MIL ON with A/T related DTC and it back up mode.



SHIFT INTERLOCK CONTROL

SHIFT INTERLOCK

In this schematic the ATM key lock control module receives the ignition switch input on terminal 1, the “P” Park input from the range switch on terminal 4 and the brake switch input on terminal 2. The ATM and KEY solenoids are energizes by grounding the solenoids.



MANUAL RELEASE

SHIFT INTERLOCK RELEASE

The shift interlock is designed to prevent the gear shift from being placed into gear without the brake pedal being depressed. This is controlled with a solenoid that operates when the ignition key is on and the brake pedal is depressed. The shift lock can be manually released by placing the ignition key in the slot and pressing on the release tab while moving the shifter into neutral. Then the vehicle can be started. Some vehicles such as the RIO may use a cable to perform this function, with no power required.



MIL STATUS –RECORD AND CLEAR DTCS

If the Malfunction Indicator Light (MIL) is on, it typically indicates an engine or A/T emission related DTC has been stored. Use the scan tool, retrieve the DTC, record freeze frame data and DTC on the RO, then erase it before the test-drive.



TEST DRIVE

Test-drive the vehicle under similar conditions as reported by the customer, if a DTC was retrieved and cleared, be sure to duplicate Freeze Frame data during the test drive. Attempt to duplicate the customer’s concern and determine if the concern is a normal condition or is there a problem. Contact the service advisor for further information. If necessary have the customer demonstrate the condition if you are unable to verify the concern.



TEST DRIVE RESULTS

Based on the results of your test drive you will follow

one of the diagnostic paths on the Flowchart: � No Trouble Found � Engine Operation Concern � A/T Performance Concern � A/T Related Noise Concern � Fluid Leak Concern



NO TROUBLE FOUND

If during your test drive, you do not experience the

customer’s concern and/or you did not experience an A/T malfunction, contact the service advisor to get additional information. This may also require the customer driving the vehicle and demonstrating what they are experiencing. If the transmission is operating as designed, it may be necessary to have the customer drive another vehicle to demonstrate its operation. You could also review the owner’s manual with them.



ENGINE OPERATION CONCERN

It is possible to have an engine related problem that

feels like an A/T problem. Most engine drivability concerns have a related DTC. � Use the Kia scan tool to: � Check for DTCs. � Inspect current engine data. � Compare with service information. Engine mechanical problems may require further diagnosis such as: � Vacuum � Exhaust leaks � Fuel pressure � Ignition tests � Compression checks � Cylinder leak down test � Restricted intake or exhaust � Timing belt/chain



A/T RELATED NOISES

When diagnosing noises, it may be difficult to

determine if the cause is from the tires, bearings, axles, engine or A/T. Use a stethoscope or chassis ears to determine the origin of the noise. If you have determined it is an A/T related noise, then drive a vehicle of the same model and year. If the noise is worse than the compared vehicle and there is no noise related service bulletin, open a TechLine WEB case to review diagnosis. Prior to ordering A/T assembly replacement, contact the DPSM for authorization.



A/T FLUID LEAKS

External ATF leaks may occur from: � Gaskets. � Damaged o-rings. � Connectors. � Cooler lines. During your visual inspection for leaks, check for physical damage. This may be from: � Accident damage. � Driving over debris. � Improper repairs or modifications. � Incorrect towing. � Improper use of a floor jack causing damage to the

A/T oil pan or case. It is important to mark the location of the leak on the A/T core prior to returning it due to the difficultly in visually finding the point of the leak at the plant. Prior to ordering A/T assembly replacement, contact the DPSM for authorization. Currently Kia does not authorize performing A/T pressure checks.



FILL IN ATCDF

With this section completed, now fill out the related section on the ATCDF.



A/T PERFORMANCE – REPAIR HISTORY – RELATED SERVICE INFORMATION

If you have verified the concern, and it is an A/T

Performance Concern, it is time to analyze/diagnose the concern. You will need to review the vehicle repair with warranty history and research related service information such as TSBs, Technical Times etc. for the verified concern using GDS.



BATTERY AND CHARGING SYSTEM VOLTAGE

Your first check when diagnosing an A/T Performance

Concern is to inspect and test for proper battery and charging system voltage. The battery is the heart of all electronic components on the vehicle. If a computer does not see the proper input value or apply the proper output signal, the system being controlled will not function as designed.



BATTERY AND CHARGING SYSTEM TEST

Always test the battery before performing any other diagnosis. If any conditions warrant repairs, perform them before you continue with your diagnosis. � Battery test

o Good battery o Good recharge o Charge & retest o Replace battery o Bad cell-replace

The current Kia recommended method is to use the GR8-1299 Multitasking Battery and Electrical Diagnostic Station to perform the test using the conductance method to determine the battery’s ability to store electricity. Conductance is a measure of the plate surface available in the battery to determine how much electrical energy the battery can store. In most cases, the analyzer can test the battery in the vehicle without recharging. Since no loads are placed on the battery, this test procedure is completely safe. If the battery does not pass the test, perform the necessary repairs before continuing with your diagnosis. Attach a print-out of the test results to the RO.



DTCS

Now is the time to begin the troubleshooting process.

The next step is to record if the MIL is ON or OFF, and use the scan tool to check for DTCs in the ENGINE and AUTO TRANS menus. You will follow one of the following three paths on the flowchart based on your results: � Drivability/Engine Related DTC � No DTC Found � A/T Related DTC



DRIVABILITY RELATED DTCS

If you have drivability DTCs, always follow the service information for diagnosing the DTC. You should be here in the Flowchart if the MIL came on during your test drive and you retrieved an engine related DTC. If you did not clear the DTC prior to the test drive, clear the DTC and re-test drive.



A/T RELATED DTCS

If you have an A/T related DTC, use the current service information and follow the appropriate diagnostic procedure. Open a TechLine web case if assistance is necessary. NOTE: A DTC maybe stored with the MIL OFF. Use a scan tool to check for both engine and transmission related DTC



NO DTC FOUND –CURRENT DATA

If you are directed here because of no DTC found, in the engine or A/T systems, use the scan tool to analyze A/T current data. Compare A/T data with the vehicle’s service information. If the data is not within specification, diagnose the circuit(s) where the data is out of specification. Refer to the appropriate service information for component troubleshooting and circuit diagnosis.



A/T TESTER PLUS

The A/T Tester Plus replaces all previous Kia automatic transaxle testers. NOTE: Consult the A/T Tester Plus Operation Manual for Sub Cable Application Table It allows you to monitor the Transmission Control Module (TCM) or Powertrain Control Module (PCM) control of the solenoids and it allows you to manually shift the transmission. This will help you determine if the transmission problem is internal or external.



A/T TESTER PLUS

MODES OF OPERATION

The tester has two modes of operation: • Normal Mode “Nor” • Test Mode “Test” The Normal Mode allows the TCM/PCM to control the A/T while the operator observes the status of the solenoids during test-drives. The Test Mode allows the operator to manually select each forward gear of the A/T and observe the state of the solenoids. When the tester is cycled from normal to test mode, it electrically checks the A/T internal wiring and solenoids for shorts and opens. A/T Tester Plus is updatable by a download you’re your pc and additional A/T cable, if necessary. The A/T Tester Plus consists of: a. The tester b. Main/Power cable d. Sub-cable e. Operation manual



A/T TESTER PLUS

SUB CABLE

The process of using the A/T tester is straightforward. 1. With Key OFF and Engine OFF. 2. Install the A/T Tester Plus sub cable between the

engine room harness connector and the A/T connector.

3. Connect the sub cable to the main cable, and then

attach the main cable to the tester.

4. Connect the sub cable to the battery. Note: A/T will not operate correctly with only the sub cable connected. Caution: Do not use the A/T Tester Plus with the Kia scan tool at the same time.



A/T TESTER PRO

SELECT VEHICLE

5. Turn the key to ON 6. Press vehicle up/down button for more than 1

second to access vehicle selection. 7. Press the vehicle up/down button again to select the

vehicle you are diagnosing then press N/T to confirm.

NOTE: The A/T Tester Plus may be damaged and will not function properly if the wrong vehicle is selected.



A/T TESTER PLUS

TEST DRIVE AUTOMATIC MODE

1. Next, press the N/T button to cycle between Normal and Test modes pausing in the Test mode for a few seconds to test the solenoids for shorts or opens then select Normal mode for the test drive.

2. Test-drive the vehicle in the automatic shift normal

(“Nor”) mode and observe the solenoid operation.

SOLENOID COMMANDS As the transmission shifts, the solenoid commands can be observed on the display and compared to the appropriate chart in the manual. Also, observe the shift quality and Damper Clutch Control (DCC) lock-up sometimes referred to as Torque Converter Clutch (TCC) for any unusual characteristics such as shift shock, slipping for delayed shift.



A/T TESTER PLUS

TEST DRIVE MANUAL MODE

1. Turn the key to the OFF position for 10 seconds

2. .Turn the key to the ON position 3. Use the N/T button and cycle between normal and

test mode leaving it in the Test mode.

4. Turn the key OFF for 10 seconds the turn the key back ON

5. Test-drive the vehicle in the manual shift test

(“Test”) mode and manually shift the vehicle in the forward gears using the tester and observe the solenoid operation.

6.

NOTE: Shift shock can be felt due to line pressure at full.

WARNING: Transmission may be in gear when the A/T Tester Plus indicates “N” or Neutral position and vehicle will move if the brake is released.



A/T TESTER PLUS

DCC LOCK-UP

7. With the A/T Tester Plus is still in the Test mode, operate the vehicle in 4th gear with the engine speed above 1600 RPM.

8. Press the DCC button. The DCC engagement should

be felt and the engine RPM should drop ~ 200-400 RPM when the DCC engages.

After using the A/T Tester Plus, clear any DTCs that were set.



FILL IN ATCDF

After you have finished with the A/T Tester Plus, record your results on the ATCDF.



TORQUE CONVERTER STALL TEST

The torque converter stall test is performed after using the A/T Tester Plus and the A/T is at normal operating temperature. The stall test will help you determine if there is slippage or a malfunction of hydraulic components. Brake torque the A/T in “Drive” and “Reverse” while observing the engine RPM on the scan tool. If the RPM is too high, the A/T needs replacement. If the RPM is too low, check engine performance. If OK replace the A/T. Note: To prevent A/T damage, do not hold down the accelerator pedal for more than 5 seconds. Allow sufficient cooling of the ATF by idling the engine in “Park” or “Neutral” for at least one minute between tests.



A/T RELATED WIRING AND CONNECTIONS

Wiring harnesses, connectors and terminals are all essential parts of any electrical circuit. The harness provides the path for current between components as well as to the battery and chassis ground connections.

The A/T wiring is typically located in the engine harness where it is subjected to very harsh conditions that can cause circuit problems. The terminals in the connectors provide the electrical connection for the circuits. It is in this area where problems may exist, like loose fitting female terminals that can cause intermittent concerns. You must consider the entire circuit, including grounds, when inspecting related wiring harnesses and connectors. Caution: Always push/pull with the connector not the wiring.



TERMINAL AND INTERMITTENT TESTING

To prevent causing loose fitting terminals, never insert a test light, meter lead or other tool into the terminal unless directed by the service information. Use the correct terminal size T connectors (A, B, C) to connect to the terminals to test a circuit or back-probe the circuit that requires testing. To help identify an intermittent connection, carefully wiggle each connector in the harness, using a meter or scan tool to monitor the circuit. If the circuit changes value, the connector is suspect and the terminal tension should be checked.



GROUND INSPECTIONS

Besides inspecting wires and connectors, power feed and ground lines and connection points can also be a source of problems. This may be due to loose or weakened attaching hardware or corrosion at the terminal.

A ground problem may be found with a visual inspection or by using the voltage drop method. During your visual inspection, don’t overlook the obvious with wiring, connectors and grounds: • Collision damage. • Chaffed wires against sharp metal edges, including pinched wires. • Battery acid causing terminal corrosion. • Damaged connectors. • Connectors not fully seated. • Terminals backed out. • Previous substandard repairs. • Use of snap & lock together wire connectors. • Aftermarket accessories incorrectly installed such as towing and radio/phone accessories. Circle your results on the ATCDF.



TECHNICIAN COMMENTS

This is where the technician records their comments regarding what they found during their diagnosis. Since the ATCDF is returned with the core, the remanufacturer gets direct comment from the technician. Record your comments on what issues were encountered during diagnosis and troubleshooting. Add any comments relative to that A/T, especially why the A/T needs to be replaced.



FILL IN ATCDF

Finish recording your results on the ATCDF. Close the TechLine WEB case, if opened. Prior to ordering A/T assembly replacement, contact the DPSM for authorization.



ALLOWABLE EXTERNAL REPAIRS



ALLOWABLE EXTERNAL REPAIRS CONTINUED



PRIOR TO REPLACING THE A/T

Before ordering a remanufactured A/T, recheck all your information on the ATCDF and decide if an external repair will fix the concern or if it requires a replacement A/T. If it’s determined that the A/T must be replaced, the District Parts and Service Manager (DPSM) must authorize the replacement repair under warranty. Remember that TechLine cannot authorize an A/T replacement, only the DPSM. If a replacement A/T is authorized there are two types of remanufactured A/T units: � federal remanufactured A/T unit (49 state) � California remanufactured A/T unit If the A/T is being replaced in the state of California, it requires a California certified remanufactured unit. California has strict requirements for remanufactured A/T units, which require certain parts, such as clutches, be replaced not just inspected, therefore the cost of the California remanufactured A/T unit is slightly more expensive. Your parts department should refer to Kia Parts Bulletin No. 1910-0006 for the correct A/T part number and record the part and serial numbers from the two A/T units onto the ATCDF. Before installing the remanufactured A/T unit, do a visual inspection to determine that it is the correct replacement. Completely drain the A/T prior to removing it from the vehicle. Transfer the components from the removed A/T unit to the remanufactured A/T unit, including: � Vehicle speed sensor � Fill tube � Other related parts as necessary



CAUSAL CODE

Circle the causal code that best describes the root cause of failure on the ATCDF. Root cause is the primary failure, not secondary failures. NOTE: The casual codes changed effective August 2005. CA1: BURNT FLUID The ATF may be described as very dark to black in color with a burnt toast smell. Friction materials may also be felt in the fluid. CA2: CRACKED CASE The case may be best described as having an identifiable crack in it. Mark the location for easy reference. CA3: POROUS CASTING The case may be best described as having an ATF leak weeping from an identifiable area of the casting. The location has been marked. CA4: LACK/LOW ATF The ATF may be described as not being measurable on the dipstick. CA5: STICKING/SEIZED The A/T internal components, including shift rod, may be described sticking or seized. CA6: FAILED TEST – DCC The DCC may be described as not applying due to internal A/T electronics or hydraulics. CA7: FAILED A/T TESTER This may be described as the internal A/T has failed the short or open solenoid, manual or auto test mode of the A/T Tester Pro. CA8: LEAKING-SEAL The A/T may be described has having an external leak due to a seal. CA9: LEAKING-GASKET The A/T may be described has having an external leak due to a gasket.



A/T COOLER FLUSH Whenever an A/T is replaced, the ATF cooler and lines

must be flushed to remove any contaminates such as metal particles and friction material.

If these particles were allowed to remain in the cooler, eventually they could be circulated through the A/T, or restrict the flow of ATF, and lead to future A/T damage. Be sure to flush the cooler in both directions to ensure all contaminants are removed. The ATF cooler is flushed using the Kia Transmission Cooler Flush, P/N UM990 CH001. Be sure to inspect cooler hoses for deterioration, cracks or leaks. You will not receive new hoses with the remanufactured A/T. Kia Transmission Cooler Flush aerosol cans contain hazardous material. Be sure to dispose of the can in accordance with federal, state, and local regulations. The Material Safety Data Sheet (MSDS) is available at www.kiachemicals.com.



ENGINE COOLING

The engine cooling system is something that could be easily overlooked. The radiator and A/T cooler perform two separate but equally important functions. The radiator removes heat from the engine and it removes heat from the A/T. The A/T cooler removes heat from the A/T and passes it into the coolant, but it also picks up heat from the coolant and passes it onto the A/T to help bring it up to operating temperature as soon as possible. Therefore, do not overlook the engine cooling system. When replacing the A/T always check the coolant for signs of ATF, which would indicate that the A/T cooler is leaking internally. Also, check the radiator for blockage in the coolant tubes and cooling fins. With the A/C condenser being placed in front of the radiator, it is easy to overlook debris that has collected between the condenser and radiator, which could affect airflow through the radiator. Remove debris. Blow air through radiator and condenser from the cooling fan side. For best results, you may need to remove the cooling fans.



COMPONENT TRANSFER AND ELECTRICAL CONNECTIONS

Install and adjust if necessary, the: • Range switch • Vehicle speed sensor • Input and output speed sensor • Dipstick Connect electrical connectors: • Vehicle speed sensor • Input and output speed sensors • Range switch • A/T harness connector



FILL A/T WITH DIP STICK, CHECK FOR LEAKS AND ATF CHART

After you have installed the remanufactured A/T, and have transferred all appropriate components, remember to fill the A/T with the correct ATF. Be sure to check the ATF level with the engine and A/T at normal operating temperature in Park or Neutral. Check for leaks on the A/T and all the lines and hoses. The following chart guides you to which fluid is required. Always refer to the current service information for the correct ATF requirement.

SP III Dexron Kia Red-1 Shell M-1375.4

SP IV

Amanti 04-09 Sorento 03-04 Sorento 05-07 Borrego 4.6L Forte 2011 Forte 2010 Borrego 3.8L Optima 2011- Optima 01-10 Sedona 2011- Rio 05- Sorento 2011- Rondo 07-10 Sportage 2011- Sedona 01-10 Sephia 95-01 Soul 10- Spectra 02-09 Sportage 05-10 Sportage 95-02

NOTE: The Sephia (94-97) OEM A/T uses Dexron, but a remanufactured A/T uses SP III. The Kia branded ATF must be used for warranty repairs (except Dexron.)



FILL AND INSPECTING A/T WITHOUT DIP STICK

BORREGO 4.6L 6HP26 FLUID LEVEL

WARM UP PROCEDURE

The 6HP26 transmission requires a different ATF level inspection procedure. � Shell M1375.4 is required. � The engine and transmission must be at room

temperature. � Connect the scan tool and view ATF temperature on

the A/T current data screen. � Park the vehicle on a level surface and set the

parking brake. � With the transmission in Park start the engine. � With your foot on the brake shift the transmission

through all ranges from park, to reverse, into neutral then drive and finally 3rd using the sport mode.

� Stay in each position for at least three seconds,

when finished return the park position. � Allow the transmission to reach 86° to 95° F then

shut the engine off. � Do not use a “stall test” to raise the ATF

temperature, and do not let the ATF temperature go over 122° F.



FILL AND INSPECTING A/T WITHOUT DIP STICK CONTINUED

BORREGO 4.6L The 6HP26 A/T only has one plug on the passenger side (right) towards the rear for both fill and level inspection. � Remove the filler plug. � ATF should drip from the filler hole, if it does not,

add fluid until it does. � Install the filler plug and torque to 25 foot pounds.




BORREGO 3.8L JATCO A5SR2 FLUID LEVEL

WARM UP PROCEDURE

The JATCO transmission also requires a different ATF level procedure. � The engine and transmission must be at room




through all ranges from park, to reverse, into neutral then drive.

� Stay in each position for at least three seconds � When finished return the park position � Allow the transmission to reach 86° to 95° F. � Do not use a “stall test” to raise the ATF

temperature, and do not let the ATF temperature go over one hundred twenty-two degrees Fahrenheit.

Note: While the JATCO A5SR2 is also used in the Sorento, the Sorento has a dip stick to measure the ATF level.




FILL PLUG OVERFLOW PLUG

BORREGO 3.8L The A5SR2 A/T has two plugs, one on the passenger

side (right) towards the front for fill and driver (left) towards the front for level inspection. � Remove the inspection and overflow plug � ATF should drip from the overflow hole, if it does

not add fluid at the fill plug until it does � Install the filler plug and overflow plugs, and torque

to 25 foot pounds.




2011 SORENTO A6LF2 & A6MF2

FLUID LEVEL

WARM UP PROCEDURE

The A6LF2 and A6MF2 transmission also requires a different ATF level inspection procedure. � SP IV ATF is required. � The engine and transmission must be at room




through all ranges from park, to reverse, into neutral then drive and finally 3rd using the sport mode.

� Stay in each position for at least three seconds,

when finished return the park position. � Allow the transmission to reach 86° to 95° F. Do not use a “stall test” to raise the ATF temperature, and do not let the ATF temperature go over 122° F.




The A6LF2 and A6MF2 transmission has three plugs, a rubber fill plug on the top of the valve body cover, an oil level plug on the side of the valve body cover, and a drain plug on the bottom of the case. � Remove the oil level plug � ATF should drip from the oil level hole, if it does not

add fluid at the fill plug until it does Install the oil level plug, and torque to 25 - 32 foot pounds. If the rubber fill plug was removed replace the plug.

Oil Fill Plug

Oil Level Plug

Oil Drain Plug



A/T ADAPTIVE VALUE RESET & RELEARN RESET

KIA VEHICLES REQUIRING A/T ADAPTIVE VALUE

RESET/RELEARN

ADAPTIVE RESET

DRIVING RELEARN

STATIC SHIFT RELEARN

The PCM/TCM contain logic to compensate for normal wear over the life of the A/T. Adaptive value reset and relearn must be performed to provide optimum shift quality after completing the following repairs: � Replace the A/T unit � Replace PCM or TCM � Reprogram the PCM or TCM

Adaptive values must be reset using the following procedure depending on model and year.

Model Disconnect Negative Battery cable for 10 seconds

Use Kia scan tool in A/T menu

Amanti 2004 2005 – Borrego 2009 – Forte 2010 – Optima 2001-2004 2005 – Rio 2006 – Rondo 2007 – Sedona 2002 – 2004 2005 – Sorento 2005 – Soul 2010 – Spectra 2004.5 – Sportage 2005 –

Using the Kia scan tool: � Select “Init OF TCU Learning” � Ign Key ON, Engine OFF � Shift lever in P or N and Click the OK button � Ign Key OFF for 10 seconds

After resetting the adaptive values with either method, the driving and static shift must be relearned.

� ATF temperature just over 120 F � Drive from a stop shifting 1st to 3rd gears @ 30%

TPS (Approx. 3000 RPM shift) o 5 speed: 1st to 4th gears

� Repeat until shock/flare is eliminated � Stop vehicle, shift into N for 3 seconds � Shift from N to D for 2 seconds

o Repeat 3-5 times until no N to D shock � Shift from N to R for 2 seconds

o Repeat 3-5 times until no N to R shock



FINAL STEP

The final step in any repair is to confirm that the repair has corrected the problem and that no new problems have been created. Completion of the paperwork is also part of the final step. After filling the A/T with the proper amount and type of ATF, test drive the vehicle again. Confirm the customer’s concern has been repaired. Be sure to drive the vehicle in the same manner and conditions as used to duplicate the vehicle complaint originally. Return the vehicle to the shop and check the ATF level again. Top off as required.



PARTS RETURN

Core return requirements (covered in the A/T TSB and parts bulletin): • Secure the removed torque converter to the removed A/T using the supplied hold-down bracket and bolt. • Install all plastic/rubber plugs and the two (2) side gear holders/retainers to prevent the side gears from falling out of position. • Record the serial number of the removed unit on the ATCDF. • Place the removed unit in the plastic shipping container. • Enter all information from the ATCDF into the DCS Dealer Parts Core Return Entry screens and print the A/T Diagnosis & Shipping Document. • Place all necessary documents in the plastic bag provided with the replacement A/T and secure inside the shipping container, including:

� Kia A/T Diagnosis and Shipping document � Kia A/T Core Data Form � Copy of the Repair Order (RO) with

Technicians notes

• Arrange shipment of the removed A/T in accordance with Parts Bulletin No. 1910-006.



A/T CORE ASSEMBLY RETURN – BROKEN OIL PUMP TABS

SPECTRA A/T

2009 – BORREGO 4.6L

The A/T pump has changed starting with the: � 2006 Spectra Federal � 2007 Spectra California These A/Ts uses a rotor-type ATF pump, shown above, with an outer and inner rotor that’s driven by the torque converter. CAUTION: When removing and installing an A/T with a rotor-type pump as shown above, the torque converter should not be removed from the pump. This can cause the inner rotor to fall out of place and not allow re-installation of the torque converter drive hub with out damaging the pump’s inner rotor driven “ears”, as shown above on the right side. This usually occurs when securing the torque converter to the A/T. Secure the torque converter to the removed A/T using the supplied hold-down bracket and bolt, ASAP. The previous Spectra A/T (shown on the left) used a trochoidal gear-type pump or crescent, shown on the left, because of the metal shape between the two eccentric drive and driven gears inside the pump.

Torque Converter Hub

Outer Rotor

ATF Pump - Drive Inner Rotor



SUMMARY

The ATCDF and A/T Diagnostic Flowchart must be used during diagnosis of a customer’s A/T related concern. In this module, we have covered every step of both the ATCDF and A/T flowchart to verify, diagnose, troubleshoot, repair and confirm the repair. We learned the three sections of ATCDF: • Service Advisor • Technician • Parts We reviewed the A/T repairs and components that can be repaired under warranty. We learned that DPSM authorization is required to replace an A/T, and we reviewed the proper documentation that is required to be returned with the A/T core.



PROGRESS CHECK A separate answer sheet is provided in this course for you to record your best answer on.

1. Technician A says that if the stall test results are too low you should check engine performance. Technician B says that if the stall test results are too high you should check engine performance Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

2. All of the following are correct about using the GDS,

EXCEPT. a. Test the vehicle battery b. Update the A/T Tester Pro c. Retrieve and clear DTCs d. Retrieve current A/T data

3. Technician A says that you only need to check ATF

level and condition after the test drive. Technician B says that you should check ATF level and condition before the test drive. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

4. The GR8-1299 can be used to check the battery condition and charging system voltage a. True b. False

5. Technician A says that you can use the A/T Tester

Plus to check A/T solenoids for an open or short. Technician B says that you can use the A/T Tester Plus to check the A/T external wiring Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B



6. The GDS can be used to test the A/T solenoids during the test drive. a. True b. False

7. Technician A says that the PCM or TCM controls the

A/T solenoids when the A/T Tester Plus in the Normal mode. Technician B says that the A/T Tester Plus controls the A/T solenoids when the A/T Tester Plus is in the Test mode Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

8. Technician A says that some range switches are

adjustable. Technician B says that all lag tests are adjustable. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

9. Technician A says that the circuit must be turned

OFF to perform a voltage drop test. Technician B says that the circuit must be turned ON to perform a voltage drop test. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

10. Technician A says that a stall test is checking the

maximum RPM during wide open throttle. Technician B says that a stall test is checking the minimum RPM during wide open throttle. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B



11. Technician A says that the A/T Tester Plus can be used to display A/T solenoid resistance Technician B says that the A/T Tester Plus can be used to test the DCC. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

12. Technician A says that if the ATF level is low, you should notify the DPSM and replace the A/T Technician B says that if the AFT has evidence of clutch material and metal particles, you should notify the DPSM and replace the A/T Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

13. Technician A says that a voltmeter is used to measure ground circuit voltage drop. Technician B says that an ohmmeter is use to measure ground circuit voltage drop. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B

14. Technician A says to use the A/T Diagnostic Flowchart to guide your diagnosis. Technician B says to use the Automatic Transmission Data Core Form to guide your diagnosis. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B



15. Technician A says that you must flush the A/T cooler when replacing an A/T Technician B says that you must perform an adaptive value data procedure. Who is correct? a. Technician A b. Technician B c. Both Technician A & B d. Neither Technician A nor B



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________


Guided Practice ATID.05

Automatic TransmissionDiagnostic Guided Practice

Student Guide


SAFETY FIRST



















use of this course.



TT-ATID207-IL-GP056th Printing - January 2011


Module Title


ATID A/T Diagnosis Guided Practice Module 05 1

TARGET AUDIENCE

MODULE GOAL

MODULE OBJECTIVES

The target audience for this module consists of Kia Senior and Master Service Technicians who will diagnose and repair Kia automatic transmissions. The goal of this module is for technicians to practice 7 key areas of inspecting and testing the internal operation of an automatic transmission. Given this module, a vehicle, and upon completion, the technician will be able to perform the following tasks with 80% or greater accuracy. � Given a VIN and the GDS, the technician will be able

to check and print the service information related to the task below.

� Given appropriate service information, the

technician will be able to inspect the range switch and perform a time lag test.

� Given a Kia scan tool, the technician will be able to

check the MIL and retrieve and clear DTCs. � Given the GR8-1299, and the appropriate service

information, the technician will be able to test the battery and charging system voltage.

� Given a Kia scan tool, and the appropriate service

information, the technician will be able to view and compare current A/T data.

� Given the A/T Tester Plus, and the appropriate

service information, the technician will be able to connect and operate the A/T Tester Plus.

� Given this module, and the appropriate service

information, the technician will be able to perform a stall test.

2 ATID A/T Diagnosis Guided Practice Module 05


MODULE INSTRUCTIONS

REQUIRED MATERIALS

Carefully read and follow the instructions for each task. Answer the questions and fill in the blanks with the requested information as you perform the task. When you have finished, have your training instructor evaluate your work and sign-off that it has been properly completed. In order to complete this module, you will need the following items: Vehicles: � 2010 Optima � 2011 Rio � 2011 Soul Tools: � Scan tool - GDS � GR8-1299 � Hand tools � A/T Tester Plus � GDS with internet connection and printer � Lift � Wheel chocks Resources: � A/T Diagnostic Flowchart, service information � A/T Tester Plus operation manual

o Solenoid Valve Operation Table � A/T TSB Other: • Preferred writing instrument

TIME TO COMPLETE Approximately 1 hour

Module Title



TASK STATIONS

Station 1: Use the Global Diagnostic System (GDS) to check TSB, Tech Times, Pit Stop and service information (5 points)

Station 2: Check the range switch and perform a lag

test (5 points) Station 3: Check DCC operation using the A/T Tester

Plus Use the A/T Tester Plus to perform and automatic and manual test with vehicle on lift. (5 points)

Station 4: Test vehicle and observe operation

Check MIL status Retrieve and clear DTC (5 points)

Station 5: Test battery and charging system voltage

(5 points) Station 6: Perform stall test (5 points) Station 7: Perform a voltage drop test of the A/T

ground circuit (5 points)



STATION 1 GDS

VIN AND CUSTOMER CONCERN

Using the GDS, VIN and customer concern supplied by your instructor and listed below: � Review and print the warranty history for previous

A/T related repairs � Perform a detail search for information relating to

the customer concern and print your results � Look up and print service information relating to

range switch adjustment, lag and stall test. VIN: KNAGE123065023526_______________________ Customer concern: _____________________________________________ _____________________________________________ History search results: _____________________________________________ If the results indicate a 2nd or subsequent similar A/T repair, what is your next step? _____________________________________________ _____________________________________________ Detail search results on service information: _____________________________________________ _____________________________________________

Module Title



STATION 2 RANGE SWITCH AND LAG TEST

CHECK RANGE SWITCH

LAG TEST

RESULTS

1. Check if the vehicle starts in both: a. “Park” and “Neutral”. YES NO b. “Reverse” and “Drive”. YES NO

2. Check the shift cable and indicator selection. 3. Move the shift lever to “Neutral”, and then shift to

“Drive”. Record the elapsed time. ____________ 4. Move the shift lever to “Neutral”, and then shift to

“Reverse”. Record the elapsed time. __________ 5. Turn the engine OFF. Did the switch operate correctly in all positions? YES NO If no what would you do next? _____________________________________________ Did the shift indicator operate correctly in all positions? YES NO Is the lag time acceptable? YES NO If no what would you do next? _____________________________________________ See your instructor and discuss the results.



STATION 3 A/T TESTER PLUS

SETUP

Using the assigned vehicle and A/T Tester Plus, install the appropriate cables to the tool and the vehicle. 1. Using the A/T Tester Plus operation manual, select

the proper sub cable for the vehicle that you are testing.

2. Connect the sub cable to the tester main cable. 3. Connect the tester main cable and power cable to

the A/T Tester Plus body. 4. Open the hood and remove the air cleaner housing

and/or the battery in order to access the solenoid valve connector on the A/T case.

NOTE: Use caution when releasing the connector locking tab to prevent damage. Some require pressing down on the connector before pressing the tab, while others require lifting the tab. 5. Disconnect the vehicle wiring harness from the

solenoid valve connector. 6. Connect the A/T Tester sub cable between the

solenoid valve connector and the vehicle wiring harness.

7. Reinstall the air cleaner and/or battery. 8. Pass the A/T Tester and cable through the

passenger window as required.

Module Title



9. Set the lift to raise the vehicle. Caution: Have your instructor inspect the lift setup before raising the vehicle. 10. Raise the vehicle according to the lift manufacturers’

safety and operating instructions. Continue until all four wheels are approximately six inches off the ground.



STATION 3 A/T TESTER PLUS (CONT.)

AUTOMATIC TEST

1. Turn the Ign. Key from OFF to the ON position. 2. Press the “Vehicle Up/Down” button for at least 1

second; the tester will switch to the vehicle selection mode.

3. Press the “Vehicle Up/Down” button to select the

appropriate vehicle, press the “N/T” button to confirm the selection.

4. Press the “N/T” button to cycle between the test

modes indicated in the chart below to check for opens and/or shorts in the solenoid circuits.

Test Display Mode Sequence

Automatic Shift Test

Test Test�Nor�Test�NorNor Nor�Test�Nor

NOTE: If the A/T Tester indicates an open and/or short, stop the test, diagnose and repair the problem before continuing. 5. Start the vehicle. 6. If the vehicle is equipped with “ESP/TCS”, make

sure to turn this feature OFF. 7. Move the transaxle shift lever to the “Drive”

position. Have your team member observe the display during the test drive. Compare it with the solenoid table in the A/T Tester operation manual.

Module Title



STATION 3 A/T TESTER PLUS (CONT.)

MANUAL TEST

1. Turn the key OFF, then to ON. 2. Press the “N/T” button to cycle between the test

modes indicated in the chart below to check for opens and/or shorts in the solenoid circuits.

Test Display Mode Sequence

Manual Shift Test

Test Test�Nor�TestNor Nor�Test�Nor�Test

NOTE: If the A/T Tester indicates an open and/or short, stop the test, diagnose and repair the problem before continuing. 3. Start the vehicle. Warning: When using the A/T Tester Plus, the display may indicate that the A/T is in Neutral but the A/T may still be in gear due to the internal setup of the A/T. Do not attempt to work on the vehicle until the A/T Tester Plus is disconnected and erase all DTCs. 4. If the vehicle is equipped with “ESP/TCS”, make

sure to turn this feature OFF. 5. Move the transaxle shift lever to the “Drive”

position. NOTE: To avoid severe shift-related shock and potential damage to the transaxle and/or drivetrain, perform all manual upshifts and downshifts at appropriate engine and vehicle speeds. 6. Compare it with the solenoid table in the A/T Tester

operation manual. Have your teammate press the “Gear Up/Down” button from “Gear 1” to “Gear 5” and observe the display during the test drive. Compare it with the solenoid table in the A/T Tester operation manual.



STATION 3 A/T TESTER PLUS (C0NT.)

DCC OPERATION TEST 1. Drive the vehicle in 4th gear and maintain a steady speed with engine above 1600 RPM.

2. Press the “DCC button”. The DCC engagement

should be felt and the engine should drop ~ 200-400 RPM when the DCC engages

Did the DCC lock-up? YES NO In what mode does the A/T Tester Plus test the solenoids for opens and shorts? ________________ How do you change gears when in the “Test” mode? __________________________________________ See your instructor and discuss the results.

Module Title



STATION 4 MIL AND SCAN TOOL

CHECK MIL STATUS RETRIEVE DTC

Safely operate vehicle on the lift in D range and observe operation Does the A/T shift through all gears? YES NO If NO, describe the condition. _____________________________________________ Check MIL status, is it ON? YES NO If the MIL is ON retrieve any DTCs and record below: DTC: Description: ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ ________ ___________________________________ Go into current A/T data, inspect the related DTC values and record results below: ____________________________________________ ____________________________________________ ____________________________________________



STATION 5 MIDTRONICS – SCAN TOOL

TEST BATTERY AND CHARGING SYSTEM

VIEW CURRENT A/T DATA

For an AT Performance Concern the ATDFC recommends testing the battery and system voltage. Using the GR8-1299, test the battery and charging system voltage of the vehicle assigned to you. Print the results and record the battery and charging system voltage test results below: Battery Voltage Battery CCA Battery Condition Charging System Voltage

Module Title



STATION 6 STALL TEST

PERFORM STALL TEST

1. Review the service information and note the maximum stall RPM and time.

Stall test rpm specification ____________________ Maximum stall test time ______________ 2. Apply the parking brake and chock the wheels. 3. Use a scan tool and observe engine rpm. 4. Start the engine, and with engine at normal

operating temperature, apply and maintain foot on the brake pedal, place the gear selector in “Drive”.

5. Rapidly depress the throttle pedal to WOT. 6. Observe maximum rpm. NOTE: do not hold the throttle open for more than five seconds. Allow the engine to idle for one minute to cool the ATF and A/T. 7. Perform the same test in “Reverse”. 8. Record maximum RPM reached during both tests

below. What was the maximum rpm Drive _____________ Reverse ___________ Did the vehicle pass the stall test? YES NO If the stall test results are too high, what would you do next? __________________________________________________________________________________________ If the stall test results are too low, what would you do next? __________________________________________________________________________________________



STATION 7 GROUND TEST

PERFORM VOLTAGE DROP TEST ON GROUND CIRCUIT

Perform a voltage drop test on the transmission related ground circuit. Use GDS and identify the transmission related grounds. _______________________________________________________________________________________________________________________________________ What was the measured voltage? _____________________________________________ Would the amount of voltage drop measured be a concern? YES NO See your instructor and discuss the results.

Module Title



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________


PerformanceAssessment ATID.06

PerformanceAssessment

Student Guide


SAFETY FIRST



















use of this course.



TT-ATID206-IL-PA066th Printing - January 2011


Course Title

Module Title


ATID Performance Assessment Module 06 1

Automatic Transmission Internal Diagnosis Performance Assessment Module

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

The goal of this module is to allow the technician to be tested on the ATID course information related to Kia automatic transmission internal concerns. Given ATID course materials, the technician will be able to choose proper A/T internal diagnoses and related answers with 80% or greater accuracy. Carefully read and follow the instructions. Answer the questions and fill in the blanks with the requested information. When you have finished, your training instructor will have papers graded. Possibly by students exchanging papers. The instructor will record the results on the scorecard provide a final course score. For further scorecard information, refer to the course guide.

2


ATID Performance Assessment Module 06

AFTER READING THE QUESTION, RECORD THE

BEST ANSWER

Each question is valued at 1 point unless other wise

indicated.

1. Technician A said Nature Codes identify the cause of the customer’s concern and is filled out after the fault has been diagnosed. Technician B said Nature Codes identify the nature of the customer’s concern and is filled out based on the customer concern. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

2. Technician A states when analyzing a customer transmission concern, vehicle warranty history should be obtained from the TechLine. Technician B states vehicle warranty history may be accessed on the GDS tool. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

3. You are diagnosing 2005 Spectra with 45,000 miles.

The service history indicates that the fluid had been inspected, and replaced according to the maintenance schedule. The customer concern is slow to engage and slipping. You have inspected the fluid and determined that the level is correct but it has an unusual smell and contains metal particles. You have verified the customer concern. What is your next step? a. Replace the fluid and filter b. Replace the transmission c. Call TechLine for further guidance d. Tell the service adviser that there is evidence of

abuse and the A/T is not under warranty.

Course Title

Module Title



4. 2006 Optima is back after the transmission has been

replaced under warranty. You have verified the customer new concern of “Will not engage in DRIVE.” What should the next step be? a. Inspect and adjust the range switch b. Replace the fluid with the correct fluid c. Use the A/T Tester Plus to check the

transmission solenoid operation d. Use the scan tool and check A/T current data

5. You are conducting a lag test on a Kia vehicle.

a. All Kia vehicle lag tests are more than 1 second b. Most Kia vehicle lag tests are listed in the service

manual c. Only rear wheel drive Kia vehicles have lag test

specifications d. All Kia vehicle lag tests are 10 seconds or more

6. A technician finds the MIL light is on prior to the

test drive. Which of the following would be his next step? a. Record current A/T Data and prior to the test-

drive contact TechLine. b. Diagnose and repair MIL fault prior to test drive. c. Ignore MIL and proceed with test drive. d. Record and clear code prior to test-drive.

7. You are conducting a test drive to verify a customer

concern of transaxle not shifting properly. a. You should use the A/T Tester Plus during the

test drive b. You should use the scan tool during the test

drive c. You should change the fluid before the test drive d. You should drive the vehicle under the customer

stated conditions

4



8. You are diagnosing a customer concern of a fluid

leak on an A/T transaxle under warranty. After cleaning, you observe fluid leaking from the oil pan. What should you do? a. Reseal the pan b. Obtain DPSM approval to replace transmission c. Call TechLine for authorization to replace

transmission d. Replace the pan gasket

9. When diagnosing a transmission noise concern, all

the following could apply EXCEPT: a. Test drive to verify noise and replace

transmission b. Use a stethoscope to verify origin of internal

transmission noise c. Run vehicle on the rack to isolate origin of

internal transmission noise d. Use chassis ears to isolate origin of internal

transmission noise

10. After performing a stall test, the vehicle failed for RPM too low. What is the most likely next step? a. Internal transmission slip b. Transmission fluid is low or incorrect fluid type. c. DCC lockup engaging too soon d. Diagnose engine performance

11. Technician A says that the adaptive value must be

reset after replacing an A/T assembly. Technician B says that the Driving Relearn and Static Shift Relearn must also be performed after replacing an A/T assembly. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

Course Title

Module Title



12. Technician A says a battery that fails the

conductance test could cause an A/T related drivability concern. Technician B says that a charging system problem could cause an A/T related drivability concern. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

13. Technician A states when diagnosing an A/T related

drivability concern; you must always use the AT Tester Plus before test driving the vehicle. Technician B states the AT Tester Plus is used to manually check for DCC lockup. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

14. After confirming an A/T related concern, the next

step would be to: a. Clear DTC codes and test drive to see if code

returns b. Record freeze frame data before test drive to

duplicate concern c. Use the GDS to assist with analyzing the

concern. d. Check current data for correct information

15. While observing current A/T data with the scan tool,

you notice that is A/T fluid temperature is at -14 degrees Fahrenheit. You have diagnosed the circuit and determined that the sensor is at fault. What would be your next step? a. Call the technical assistance line and get repair

approval b. Replace the sensor c. Reset the adaptive learn d. Replace the A/T

6



16. Technician A says that the A/T Tester Plus should be connected to the DLC connector to work properly. Technician B says that you must connect the A/T Tester Plus sub cable to the battery to work properly. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

17. When selecting the vehicle on the A/T Tester Plus,

the ignition switch must be in which position? a. Accessory b. Lock c. Off d. ON

18. Technician A says the “Norm” mode of the A/T

Tester Plus allows you to record the solenoid operation, which can be reviewed at a later time Technician B says the “Norm” mode of the A/T Tester Plus allows you to manually test the resistance of the solenoids. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

19. Technician A says the “Test” mode of the A/T Tester

Plus allows you to, manually control the solenoid operation. Technician B says the “Test” mode of the A/T Tester Plus test the solenoids for an open or short Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

Course Title

Module Title



20. Technician A says A/T Tester Plus allows you to control DCC lockup in the “Norm” mode. Technician B says A/T Tester Plus allows you to control DCC lockup in the “Test” mode. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

21. Technician A says the stall test is only performed in

the drive “D” position. Technician B says if the stall test rpm is too high, the A/T requires replacement. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

22. Technician A states never insert a test light, meter lead or other tool into the terminal unless directed by the service information. Technician B states use the correct terminal size T connectors (A, B, C) to connect to the terminals to test a circuit. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

23. Technician A says a ground problem may be found

by using the voltage drop method. Technician B says voltage drop testing only works on ground circuits. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

8



24. What is required prior to replacing an A/T assembly under warranty? a. Obtain approval from TechLine b. Filing the warranty claim c. Notify your parts department d. Notify your DPSM

25. When returning an A/T core, all of the following is

required, EXCEPT? a. Secure the torque converter with the hold down

bracket b. Install the two (2) plastic side gear retainers c. Place all necessary documents in the plastic bag

provided with the replacement A/T and secure inside the shipping container

d. Remove the serial number tag.

26. You have discovered a cracked case as cause of ATF leak concern. Which of the following should apply? a. Clean and mark location of cracked case before

returning transmission core b. You should attempt to repair the crack before

replacing the A/T assembly c. Both A and B d. None of the above

27. Technician A says that during the inspection process at the A/T remanufacturing facility the transmission is inspected for prior disassembly. Technician B says that during the inspection process at the A/T remanufacturing facility the transmission is inspected for proper documentation Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

Course Title

Module Title



28. Technician A says that all returned remanufactured A/T units are dyno tested. Technician B says that only returned A/T units with shifting problems are dyno tested Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

29. Technician A says that all torque converters included

with the remanufactured A/T are new units. Technician B says that all torque converters included with the remanufactured A/T are cut open, inspected, serviced, and reused. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

30. Technician A says that valve bodies are tested and

remanufactured on a separate assembly line. Technician B says that the valve body is tested, remanufactured and returned to the same transmission for assembly. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

31. Technician A says that a California remanufactured A/T is only installed in a Kia vehicle that is being repaired in California, regardless of its emission standards. Technician B says that a California remanufactured A/T is only installed in a Kia vehicle that meets California emission standards. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

10



32. Technician A says that the solenoids can be replaced under warranty. Technician B says that only parts listed in the “Kia Remanufactured Automatic Transmission Program” can be replaced. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

33. Technician A says that Kia policy allows pressure

testing of the A/T if it is in the service manual. Technician B says that Kia policy allows pressure testing for diagnosis of all A/Ts. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

34. Technician A says that when using the A/T Tester

Plus during vehicle ID selection, the ignition key must be in the OFF position. Technician B says that when using the A/T Tester Plus it should be set to Normal mode to test drive in the automatic shift normal mode. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

35. Technician A says that you can use the Kia scan tool

while operating the A/T Tester Plus. Technician B says that you should use the Kia scan tool to clear any DTC stored after having used the A/T Tester Plus. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

Course Title

Module Title



36. Technician A says that the vehicle will operate normally with only the A/T Tester Plus sub-cable connected. Technician B says that vehicle will default to the fail-safe mode with only the A/T Tester Plus sub-cable connected. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

37. Technician A says that the A/T Tester Plus is

updatable. Technician B says that the A/T Tester Plus can be used on all Kia vehicles. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

38. Technician A says that you use the GSD to update the A/T Tester Plus. Technician B says that you reprogram the A/T Tester Plus with a serial cable and pc. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

39. Technician A says that the internal A/T solenoids and related wiring are tested for opens or shorts when using the A/T Tester Plus. Technician B says that the A/T solenoid wiring harness on the vehicle side is also tested when using the A/T Tester Plus. Who is correct? a. A only b. B only c. Both Technician A and B d. Neither Technician A nor B

12



40. Adaptive value reset must be performed after completing all of the following, EXCEPT, a. Replace A/T b. Replace PCM or TCM c. Reprogram PCM or TCM d. Allowable external repairs (TSB)

Course Title

Module Title



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________

14



NOTE PAGE

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________

Course Title

Module Title



ATID

16



Automatic Transmission Internal Diagnosis

Documents

Transcript of Automatic Transmission Internal Diagnosis