OBJECTIVES After studying Chapter 9 the reader should

OBJECTIVES After studying Chapter 9, the reader should be able to: 1. Identify the components of a torque converter. 2. Explain the purpose for each torque converter component. 3. Describe the fluid flow inside a torque converter. 4. Explain the operation of a torque converter clutch. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

INTRODUCTION • The torque converter, commonly called a converter, is a type of fluid coupling that transmits power from the engine’s crankshaft to the transmission input (turbine) shaft. It has two important purposes as it transfers the engine torque to the transmission: – It serves as an automatic clutch so the vehicle can be stopped with the engine running and the transmission in gear. – It multiplies torque while the vehicle is accelerating to improve acceleration and pulling power. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

INTRODUCTION FIGURE 9 -1 The torque converter is mounted on the engine’s crankshaft and transfers power to the transmission. (Courtesy of Toyota Motor Sales USA, Inc. ) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

INTRODUCTION FIGURE 9 -2 A fluid coupling transfers power through fluid, from one set of vanes to the other. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CONSTRUCTION • Most torque converters have four major elements: an impeller, turbine, stator, and converter clutch. FIGURE 9 -3 The major parts of a four-element torque converter are the clutch disc, turbine, stator, and impeller shown in this cutaway view. The turbine is splined to the transmission input shaft, and the stator is splined to the stationary reaction shaft at the front of the transmission. (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CONSTRUCTION FIGURE 9 -4 A three-element torque converter has a turbine, stator, and pump or impeller. (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CONSTRUCTION FIGURE 9 -5 This cutaway view of a fourelement torque converter shows the relationship of the internal parts. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CONSTRUCTION FIGURE 9 -6 The flexplate connects the converter to the crankshaft. The pilot of the converter fits the end of the crankshaft to center the converter to the crankshaft. (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CONSTRUCTION FIGURE 9 -7 Most torque converters have a round cross section (left). Some new transmissions use a shorter, elliptical, squashed converter (right). Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood FIGURE 9 -8 The stator one-way clutch allows the stator to rotate freely during the coupling phase, but stops counterclockwise rotation during torque multiplication. (Courtesy of Toyota Motor Sales USA, Inc. ) © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

WHAT IS AN AIR-COOLED TORQUE CONVERTER? • Some early torque converters used with smaller engines are air cooled. • They have a shroud with fins attached to the rear of the converter cover to force cooling air flow past the converter. FIGURE 9 -9 These air-cooled torque converters have shrouds that pump cooling air past the impeller. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION • A torque converter is a hydrodynamic unit. • It transfers power through the dynamic motion of the fluid. • Most other hydraulic units transfer power through the static pressure of the fluid. FIGURE 9 -10 When the engine is running, fluid in the impeller is thrown outward and into the vanes of the turbine. (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION FIGURE 9 -11 The two major operating conditions of a converter are stall and coupling. These conditions shift back and forth depending on throttle opening and vehicle load. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION FIGURE 9 -12 The fluid flowing around the guide ring is called vortex flow (a). The fluid flow around the converter is called rotary flow (b). (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION FIGURE 9 -13 If a ball is thrown against a wall, kinetic energy in the ball will cause it to bounce back (a). The energy remaining in the fluid striking the turbine vanes will cause the fluid to bounce back in a similar manner (b). Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION • Torque Multiplication • Coupling Phase Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION FIGURE 9 -14 The fluid flow from the turbine is turned to the same direction as the impeller by the stator vanes. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

OPERATION FIGURE 9 -15 The vortex flow, torque multiplication, and efficiency of a torque converter change as the turbine speed increases relative to the impeller. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

TORQUE CONVERTER CLUTCHES • The converter clutch is a large clutch disc called a • pressure plate or clutch disc. • It has friction material and a damper assembly attached to it and it is splined to the turbine FIGURE 9 -16 The clutch disc of a TCC has lining on the outer edge where it can contact the inner side of the cover. While released, there is a fluid flow between the disc and the cover. Note that the clutch disc is splined to the turbine. (Courtesy of Chrysler Corporation) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

TORQUE CONVERTER CLUTCHES FIGURE 9 -17 TCC release fluid flows through the center of the turbine shaft to the front of the clutch disc (left). Pressure to apply the clutch enters between the converter hub and the stator support (right). Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

TORQUE CONVERTER CLUTCHES FIGURE 9 -18 The turbine has a series of damper strings that connect to the clutch disc (a). Many clutch discs have a damper assembly at the center (b). (a is courtesy of Chrysler Corporation; B is courtesy of Tribco, Inc. ) Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

TORQUE CONVERTER CLUTCHES FIGURE 9 -19 A four-cylinder engine has two power impulses every revolution, and these impulses cause the crankshaft to speed up momentarily. During this time, the damper springs will compress to absorb the speed fluctuation. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

TORQUE CONVERTER CLUTCHES • Controlled TCC Capacity Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CVT TORQUE CONVERTER • Most CVT transmissions use a low-profile elliptical torque converter with a lock-up clutch. • Since CVTs are infinitely variable, the torque converter is not needed once the vehicle is moving. • Therefore the converter is used to multiply the torque to get the vehicle moving from a stop, and then becomes a mechanical connection between the engine and the CVT. • The torque converter clutch apply will occur at about 12 mph (20 kph) and stay locked until the vehicle comes to a stop. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED • Stall is when the turbine is held stationary while the converter housing and impeller are spinning. • This is done by shifting the transmission into gear and applying the brakes to hold the drive wheels stationary. • The importance of stall speed is that an engine must be able reach an rpm where enough torque is available to accelerate the vehicle, but not running so fast that there is poor fuel economy and excessive noise Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED FIGURE 9 -20 A technician measures stall speed while testing a transmission. This test is performed using extreme caution because of the potentially dangerous conditions. The test period is limited to 5 seconds because of potential transmission damage. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED • Stall Factors – The actual stall speed of a torque converter is determined by several factors: • • The amount of engine torque, The diameter of the converter, The angle of the impeller vanes, The angle of the stator vanes. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED FIGURE 9 -21 The stall speed of a torque converter must match the engine for good vehicle driveability. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED FIGURE 9 -22 Converter diameter helps determine stall speed. Along with other factors, it is used to help select the correct replacement converter. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

STALL SPEED FIGURE 9 -23 On some converters, it is possible to see the impeller fin angle from the outside. The converter on the right has rearward or negative fin angles that will produce a higher stall speed than the on the left, which has forward or positive fin angle. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

SUMMARY 1. A torque converter hydraulically connects the engine to an automatic transmission and will multiply the engine torque under certain conditions. 2. Torque converters utilize an impeller, turbine, stator, and lock-up clutch. 3. Stall and coupling are the extremes of torque converter operation. Stall occurs when the impeller and turbine are operating at different speeds, and coupling occurs when the impellers are turning at nearly the same speed. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

SUMMARY 4. Torque converter clutches are used to mechanically connect the engine to the transmission. During lock-up, torque converter slippage will be eliminated and fuel mileage will improve. 5. The factors that affect torque converter stall are converter diameter, angle of the vanes, and the torque of the engine. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

REVIEW QUESTIONS 1. The two purposes for a torque converter are to serve as an automatic _____ and to multiply the engine’s _____. 2. List the four elements of a typical torque converter. 3. The torque converter is bolted to the _____. 4. The torque converter’s input member is the _____ and the output member is the _____. 5. The stator is the _____ member of the torque converter and is splined onto the reaction shaft through a _____ clutch. 6. The flow of fluid from the impeller to the turbine is called a _____ flow. The circular flow of fluid leaving the impeller is called _____ flow. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

REVIEW QUESTIONS 13. A torque converter clutch uses _____ springs to smooth out _____ vibrations. 14. Some torque converter clutches use a _____-filled clutch to smooth out torque converter clutch application. 15. Torque converter stall is when the _____ is held stationary and the _____ is spinning. 16. Stall speed is the _____ rpm that an engine can turn while the turbine is _____. 17. Stall testing can be used to check _____ and _____ condition. 18. Vehicles with small engines typically use a torque converter that has a _____ stall speed, and vehicles with a powerful engine use a torque converter with a _____ stall speed. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

REVIEW QUESTIONS 19. Four factors that affect torque converter stall speed are: a. b. c. d. Engine _________ diameter Impeller _____ angle Stator fin _____ Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 1. Student A says that a torque converter is a hydraulic connection between the engine and transmission. Student B says that a torque converter clutch will increase the torque to the transmission. Who is correct? a) b) c) d) Student A Student B Both A and B Neither A nor B Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 2. The input member of the converter is the a) b) c) d) turbine. stator. impeller. All of these Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 3. Student A says that the flexplate connects the torque converter to the crankshaft. Student B says that the torque converter is considered part of the transmission. Who is correct? a) b) c) d) Student A Student B Both A and B Neither A nor B Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 4. Student A says that fluid motion inside a converter is controlled by the guide ring. Student B says that fluid motion inside a converter is controlled by the stator vanes. Who is correct? a) b) c) d) Student A Student B Both A and B Neither A nor B Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 5. The fluid flow from the impeller through the turbine and stator is called a) b) c) d) rotary flow. impeller flow. vortex flow. turbine flow. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 6. The fluid flow around the circumference of the converter is called a) b) c) d) rotary flow. impeller flow. vortex flow. turbine flow. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 7. A strong vortex flow will a) b) c) d) cause the stator clutch to lock. release the stator clutch. circulate through the guide ring. All of these Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 8. During the coupling phase the a) b) c) d) vortex flow nearly stops. stator clutch locks. rotary flow nearly stops. flow stops. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 9. A torque converter is more efficient while a) b) c) d) stopped at a stop sign. accelerating hard. accelerating under a light throttle. cruising. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 10. Student A says that at stall speed the impeller is spinning as fast as the engine can drive it. Student B says that at stall speed the turbine is stationary. Who is correct? a) b) c) d) Student A Student B Both A and B Neither A nor B Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 11. In most lock-up torque converters, lock-up occurs when the a) b) c) d) fluid flow in the converter is reversed. converter switch valve is moved by the lock-up solenoid. turbine speed reaches a certain rpm. converter speed reaches a certain rpm. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 12. In a lock-up torque converter, the a) clutch plate is splined onto the turbine shaft. b) clutch lining transfers power through a mechanical connection during lock-up. c) fluid is passing through the torque converter. d) Both A and B Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 13. Lock-up torque converters use a damper assembly to dampen a) b) c) d) noise. torsional vibration. lateral force. spring oscillations. Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 14. Stall testing can be used to find a) b) c) d) problems with the torque converter. slipping clutches. slipping bands. All of these Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458

CHAPTER QUIZ 15. A large-diameter torque converter will a) b) c) d) have a higher stall speed. have a lower stall speed. not have an effect on stall speed. All of these Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458