奇怪的帕萨特自动变速器故障

风

<span id="title"><strong><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">一辆</span><span lang="EN-US"><font face="Times New Roman">2004</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">年款上海大众帕萨特</span><span lang="EN-US"><font face="Times New Roman">1.8 GSi</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">轿车，搭载大众</span><span lang="EN-US"><font face="Times New Roman">AG4 01N</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">型</span><span lang="EN-US"><font face="Times New Roman">4</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">前速电子控制自动变速器，用户反映该车变速器存在换挡冲击的症状。接车后我们对该车进行路试，确定该车变速器存在以下故障：①入前进挡和倒挡冲击。②入前进挡变速器动力接合后，变速器内部会长时间发出类似摩擦的声音。③</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡冲击严重。④汽车高速行驶时发动机转速与对应车速不匹配，明显感觉发动机转速偏高，感觉缺少</span><span lang="EN-US"><font face="Times New Roman">1</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">个挡，应该是液力变矩器锁止离合器工作不良。⑤随着车速的升高，变速器内部的噪声也会随之升高。</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"> </font></font></span></p><p class="MsoNormal" align="center" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"><img alt="" src="http://repair.uncars.com/Files/UpFiles/gzhpch/2007/0708/048/4801.jpg" border="0" /></font></font></span></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"><p></p></font></font></span> </p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">根据以往维修该款变速器的经验并结合该车的故障现象，必须对变速器进行解体维修。在将变速器分解后，经过仔细检查，在机械及液压部件方面发现了问题：①</span><span lang="EN-US"><font face="Times New Roman">N93</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">主油压调节电磁阀、</span><span lang="EN-US"><font face="Times New Roman">N92</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">和</span><span lang="EN-US"><font face="Times New Roman">N94</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">换挡品质电磁阀</span><span lang="EN-US"><font face="Times New Roman">(</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">图</span><span lang="EN-US"><font face="Times New Roman">1)</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">有问题，从而导致入挡冲击和换挡冲击的问题。②</span><span lang="EN-US"><font face="Times New Roman">K1</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">离合器</span><span lang="EN-US"><font face="Times New Roman">(</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">图</span><span lang="EN-US"><font face="Times New Roman">2)</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">内转鼓上的</span><span lang="EN-US"><font face="Times New Roman">4</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">个定位支架损坏，导致</span><span lang="EN-US"><font face="Times New Roman">K1</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">最下面的摩片花键不能与该转鼓接合，从而导致变速器制动入前进挡变速器动力接合后变速器内部长时间发出类似摩擦的声音。③通过目视观察液力变矩器外观发现，变矩器已经受过高温呈现出青蓝色，为此我们判定变矩器锁止离合器烧损。④差速器及主减速器内部因缺少齿轮油润滑，导致变速器噪音较大。</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"></span></font> </p><p class="MsoNormal" align="center" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"><img alt="" src="http://repair.uncars.com/Files/UpFiles/gzhpch/2007/0708/048/4802.jpg" border="0" /></span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"> <p></p></font></font></span></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">在更换损坏部件并按照大修标准作业后，将变速器装复后进行长时间路试，其他问题得以解决，但</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡冲击的问题仍然存在。而且有个现象比较特别，节气门开度越小</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡冲击感越强，如果恰恰在</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡点时松油门，冲击感会更加强烈，大油门时冲击感不明显。既然</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡冲击与节气门开度有直接关系，而变速器系统压力是随节气门开度增大而增大的，因此基本可以排除变速器内部机械元件的问题，同时也可以排除液压控制阀体及电磁阀的问题。因为从油路上分析，</span><span lang="EN-US"><font face="Times New Roman">2</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡时</span><span lang="EN-US"><font face="Times New Roman">N88</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀断电接通</span><span lang="EN-US"><font face="Times New Roman">1-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡离合器</span><span lang="EN-US"><font face="Times New Roman">K1</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">的油路，</span><span lang="EN-US"><font face="Times New Roman">N89</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀通电打开</span><span lang="EN-US"><font face="Times New Roman">2/4</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡制动器</span><span lang="EN-US"><font face="Times New Roman">B2</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">油路，</span><span lang="EN-US"><font face="Times New Roman">N90</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀通电切断</span><span lang="EN-US"><font face="Times New Roman">3/4</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡离合器</span><span lang="EN-US"><font face="Times New Roman">K3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">的油路；</span><span lang="EN-US"><font face="Times New Roman">3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡时</span><span lang="EN-US"><font face="Times New Roman">N88</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">继续断电</span><span lang="EN-US"><font face="Times New Roman">K1</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">继续接合，此时</span><span lang="EN-US"><font face="Times New Roman">N89</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀断电则切断</span><span lang="EN-US"><font face="Times New Roman">B2</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">的油路，</span><span lang="EN-US"><font face="Times New Roman">N90</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀断电接通</span><span lang="EN-US"><font face="Times New Roman">K3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">油路。</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡无非就是</span><span lang="EN-US"><font face="Times New Roman">B2</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">与</span><span lang="EN-US"><font face="Times New Roman">K3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">之间的切换，电磁阀之间的切换则是</span><span lang="EN-US"><font face="Times New Roman">N89</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">和</span><span lang="EN-US"><font face="Times New Roman">N90</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">之间的转换，同时</span><span lang="EN-US"><font face="Times New Roman">N92</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">电磁阀还需协助维持换挡点的工作压力</span><span lang="EN-US"><font face="Times New Roman">(</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">注：电磁阀全部为新部件</span><span lang="EN-US"><font face="Times New Roman">)</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">，因此问题应该出在控制信号上。</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"> <p></p></font></font></span></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">我们从自动变速器方面看不出什么问题，故决定将维修的重点转移到发动机方面。为此我们观察了发动机控制系统的动态数据，根据对发动机各工况下主要数据的分析，感觉空气流量计在怠速时的数值有些偏大</span><span lang="EN-US"><font face="Times New Roman">(</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">发动机转速在</span><span lang="EN-US"><font face="Times New Roman">760 r/min</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">时进气量为</span><span lang="EN-US"><font face="Times New Roman">3.6</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">～</span><span lang="EN-US"><font face="Times New Roman">3.9 g/s)</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">，于是决定更换空气流量计</span><span lang="EN-US"><font face="Times New Roman">(</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">图</span><span lang="EN-US"><font face="Times New Roman">3)</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">。更换空气流量计后继续试车，故障并无改观。继续观察节气门开度、电压信号及喷油脉宽信号，均正常，但为保险起见，我们替换了一个节气门并进行匹配，试车故障依旧。</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"></span></font> </p><p class="MsoNormal" align="center" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"><img alt="" src="http://repair.uncars.com/Files/UpFiles/gzhpch/2007/0708/048/4803.jpg" border="0" /></span></font></p><p class="MsoNormal" align="center" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"></span></font> </p><p class="MsoNormal" align="center" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">图3 空气流量计</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><span lang="EN-US"><font face="Times New Roman"><font size="2"> <p></p></font></font></span></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">此时维修陷入僵局。难道是控制单元出了问题？众所周知，大众</span><span lang="EN-US"><font face="Times New Roman">01M</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">、</span><span lang="EN-US"><font face="Times New Roman">01N</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">均有自学习功能，且需要长时间试车才能学习完毕。但此车已经长时间路试，故障均未排除，无奈只能替换控制单元尝试，但结果依然令人失望。此时大家都感到非常迷茫，难道还是液压方面的问题？在这种情况下，我们又重新更换了液压控制阀体，同时也将电磁阀线束一同更换，但故障症状丝毫没有改观。真是太奇怪了！难道是试车时间还不够长？第</span><span lang="EN-US"><font face="Times New Roman">2</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">天我们开此车跑了一次长途，回来后问题还是存在。</span></font></p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'"></span><span lang="EN-US"><p></p></span></font> </p><p class="MsoNormal" style="margin:0cm 0cm 0pt;text-indent:21pt;mso-char-indent-count:2.0;mso-char-indent-size:10.5pt"><font size="2"><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">至此，笔者决定对这辆“大油门没问题，油门越小问题越大”的故障车人为进行强制学习。在经过一段时间的反复大小油门试车后，</span><span lang="EN-US"><font face="Times New Roman">2-3</font></span><span style="font-family:宋体;mso-ascii-font-family:'times new roman';mso-hansi-font-family:'times new roman'">挡冲击故障终于得到解决。</span></font></p></strong></span>