Auto box knowledge AF40?

[NewcastleFalcon]

Hello

Due to a fault with my 56 reg Vectra cdti, I have begun to take an unhealthy interest in the automatic transmission.

The particular unit fitted to my car is

Aisin Warner TF-80SC, AF40/6

It may help other forum users if the thread could be used to assemble a bit of combined knowledge to assist whenever the dreaded spanner light appears, and the auto gearbox ceases either permanently or temporarily to what its supposed to and provide drive to the car.

My particular problem started with the symptom of a clunking gear change from 1-2 but in none of the other gears. This was reduced considerably by an oil change 12 months ago (just the 3-litre ish change via the drain plug though, not a 7 and a half ish litre proper flush out).

Last week though the spanner light appeared, and the transmission started losing drive and slipping (engine revs up no corresponding forward motion).

This was "cured" by pulling over, switching off ignition, switching on again, starting the engine, selecting drive and away we go-perfectly normal again. Over the course of the week if the drive was lost/spanner light appeared it was "cured" once again by the stop/start method.

Sunday-decided to do it on the A19 in busy traffic, got it recovered by AA to Vauxhall Main Dealers. One "Tech2" diagnostic session and the code P1743-Transmission Component Slipping together with a few incorrect ratio codes P0732,P0733,P0735 presumably consequent on the P1743.

Looking at the forum info on codes a more specific P1743 description of "Torque Converter Clutch Solenoid Failed" is listed although the Main Dealer insisted that their description was what "TECH2" said.

The main dealer advised me that they would have to go through a further series of tests (TIS as described on the invoice). This was going to cost another £240 plus VAT before they could tell me what the problem was and how they planned to fix it.

I could predict that "new" autobox, and "new" torque coverter, or new ECU would be the result. The cost of all that-more than the car is worth most likely is going to scrap a lot of very nice cars.

Whats the alternative?

So far-I have found an independant Vauxhall man who will carry out te further diagnostic tests for 1/3rd of the main dealer price.

I have begun to research automatic gearbox/torque converter specialists for exchange units.

I wonder if the problem could be fixed by replacing the TCC
solenoid, probably buried in the valve block of the somewhere but probably meat and drink to a good auto tramsmission workshop.

If any forum members would like to pile in with useful links to other forum threads, or other information I am sure it would help.

here is a link to a spare parts list for the AF40 box as a start

http://www.automaticchoice.com/Catalogue/aw_tf80sc.pdf


kind regards


Neil

[shadoweyes]

Hi, I cant think of a worse road than the A19 for anything bad to happen on, (am from the north east).
Now lets get down to the nitty gritty, mine is a 2.2dti fitted with the "rare" AF 33 box.
Christmas Eve just gone, after a week of endless codes, and switching on/off, i lost all drive altogether. If car goes cold then drive is restored for 20-30 seconds then nothing. Had been meaning to do something with it at work but never got round to it.
After getting it back to work, checked oil, level ok. Drained oil, colour ok and didnt smell burned. Looked for another box and converter, 3 weeks later, found recon one for £1800!!!!
Didnt want second hand cos theyre prone to water damage (more of which later), thought id take mine out to strip it as had nothing to lose. Box on floor, took converter out to find burn marks all over it, closer investigation showed it had just about welded itself together! Hence no drive.
Rummage around the parts bins at work rewarded me with converter from a 3.2 V6 petrol. Different part numbers but all notches etc lined up, spigot same, depth same etc, s*d it says i, in it goes. Car goes smooth as silk now.
Phoned a mate in an independant VX garage, they sell lots of converters.......that tells a story!
Sorry for rabbiting on but, a strong possibility for you.
Vectra auto box oil coolers have a tendancy to rot the seals built into the radiator, thus letting coolant into the oil, destroys boxes in no time. Drain a little oil onto a spoon and hold over a flame, anti freeze in the oil will show up when it starts boiling and spitting whereas oil will just smoke. Hope this is some help to you

[NewcastleFalcon]

Car goes smooth as silk now

Thats the end result I need! Thanks for your reply.

Spoke briefly to a chap from here http://www.automaticgearboxes-lancas.../services.html

I am sure they could help. Any forum members know any NE auto gearbox specialists?

regards Neil

[NewcastleFalcon]

http://www.scribd.com/doc/44175667/8/VOLVO-CITROEN

This is a detailed report with lots of pics/diagrams/charts

Presented by Bob Warnke ATRA Powertrain Expo 2009

It includes a section on common complaints including:

Harsh up or downshifts.

TCC slip, fluid overheat

RPM cycling at low speed or coast

Cause:

TCC clutch is not releasing or loss of TC modulation control.

Torque converter clutch control valve bore worn and/or secondary regulator valve bore worn.

For overheated conditions, also monitor cooler flow

Here is also a salutary tale of a recurring P1743 code, replacing very expensively X,Y, and Z only to find the fault reoccuring with an as yet indeterminant cause but probably A or B. Its a SAAB but the box is fitted to all sorts of vehicles.

http://www.saabcentral.com/forums/sh...d.php?t=153440

Neil

[barney490]

I have heard of alot of failure issues on Vauxhall front wheel drive autoboxes, not just Vectra. The biggy with them all is rad water getting into the autobox and wrecking everything. I was considering an auto, I like the lazy driving these days, but not with the problems they have. isn't it a shame, that modern vehicles have become so unrelieable with there major components. As has been said, this unit is used in alot of GM product.

[shadoweyes]

Fitting a separate oil cooler eliminates the possibility of water getting into the box. Makes a huge difference to how much cooler the box runs. Relatively cheap too, the kit i got for mine was £90.

[NewcastleFalcon]

I suspect that a new oil cooler, and a regular full 7-8 litre ATF change is likely to have a very beneficial effect. I am hoping it will ressurect my own AF40. I will give the forum and the internet a search to see if there is any assitance with the specifics of the job of installing a suitable cooler. Some kind of T-piece of plumbing may provide a convenient draining/fluid changing point.

thanks Neil

[NewcastleFalcon]

Found this very useful thread on replacement for the auto gearbox cooler

http://www.vectra-c.com/forum/showth...ght=oil+cooler

Neil

[Estate]

I was wondering, does battery voltage have anything to do with the Automatic gearbox?

I have a problem which no garage wish to assist me other than say just fit a new box but Id like to fix it if possible, when the car is started from cold the gear changes are brilliant and it runs smooth.

But when the engine reaches full operating temperature the gearbox makes very harsh changes... upshifts and downshifts, my battery kept dying on me so today while moving the car to my parking spot I had loss of power steering, no lights etc and the voltage across the battery was about 8.7v when I turned it off and checked with a voltmeter.

However whats confusing or could possibly be the soloution is that the car was cold when I moved it but it made very harsh gear engagements whilst switching from D to R. Still confusing as it only used to do this when the car was warmed up fully.

Sorry for not introducing myself before, been browsing this forum for a while and you guys ROCK!!!

[NewcastleFalcon]

Have contacted a local AT specialist, and he spoke knowlegably about the Vectra problem. It may be the case but the water or antifreeze ingress into the ATF is proably so well known in AT specialist circles that the instant diagnosis is probably unsurprising.

One thing to be said for the conversation was that the 12,000 mile/12 month guarantee offered makes me fairly confident that the AT specialist could resurrect the car.

I mentioned my desire for the first attempt to be a full flush and the fitting of an oil cooler. He reckoned this would be around £200 ish but he wouldn't take my money to do it.

From other research I suspect that my 56 Reg 1.9 Cdti would have the modifications to the standard cooler in the rad. Is there someway of proving this with Vin No's? One of the threads below also mentions a 'glycol' test. The coolant in the expansion tank has no sign of oil in at all.

The AT specialist indicated that the anti-freeze would destroy the friction linings in the box (he descibed them as being made up of "paper/mdf like material") the crud from which would circulate/block gearbox. He did mention a filter
which I haven't found mention of yet in AF40 boxes. Is their an internal filter? Maybe some metal mesh thing that may collect the crud?

Does anyone have access to VX, or maybe Aisin Warner diagrams of the AF40 box?

Any assistance gratefully received

Thanks Neil
ps
Here are a few links to other threads

AF40-differences
Need an AF40-gearbox!
big thread on changing auto transmission oil
AF40 Black Thick ATF and Jolt when engaging drive
How2-AF40 fluid change