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... Bearings: Pre-loaded to withstand axial/radial forces Spline Interface: Precision-cut for zero backlash connection to differential Failure Modes: Tooth Pitting: Fatigue wear from shock loads (causes whining...
... actuated with reinforced seals for high-pressure apply (60-100 psi) Bleed Channels: Prevent clutch drag during release Failure Modes: Spline Wear: Causes incomplete...
...: Case-hardened steel (HRC 60+) with ground tooth profiles Needle Bearings: Low-friction support for planetary pinions Failure Modes: Sun Gear Spline Wear: Causes 3-5-7 gear...
.../steel hybrid with laser-welded piston channel Integrated Piston: High-pressure seals (Vitron or HNBR) for rapid apply Failure Modes: Spline Wear: Causes clutch drag (delayed engagement, P0776 codes) Drum...
...-lipped HNBR or Viton for high-temp stability (>250°F) Bleed Circuit: Quick-release channels prevent clutch drag Failure Modes: Seal Roll-Over: Improper installation causes pressure leaks (O/D slippage) Bore...
... design for high-pressure stability (90-120 psi apply) Bearing Surfaces: Precision-ground for input shaft support Failure Modes: Spline Rounding: Causes clutch slippage (P0770 codes) Seal...
... internal splines for reduced wear against input shaft Thrust Control: Integrated washer surface (critical for axial play adjustment) Failure Modes: Spline Stripping: Causes gear spin (sudden 5-6 shift flare...
...-cut with anti-stick coatings Piston Assembly: High-temp seals (Vitron/HNBR) for 100+ psi apply pressure Failure Modes: Plate Glazing:...
...: Gen 5 multi-plate clutch (0-100% rear bias) Thermal Management: Temperature sensor triggers cooling protocol (>250°F) Failure Modes: Bearing Pitting: Contaminated fluid (G 055 529 A2) causes whine Clutch...
... Capacity: 400Nm (optimized for M260 2.0L turbo) Mechatronic Unit: Direct-mounted TCU with predictive shift strategy Failure Modes: Clutch Contamination: Degraded MB 236.21 fluid causes shudder (P0730) Valve...
...: Hardened steel with PTFE coating for low friction Position Sensors: Hall-effect type for TCU feedback (0.1mm accuracy) Failure Modes: Fork Pad Wear: Causes incomplete synchro engagement (grinding noise) Ra...
...: Lifetime lubricated (G 052 145 S2 fluid) Thermal Sensor: Monitors fluid temp (>130°C triggers TCU protection) Failure Modes: Bearing Brinelling: Impact loads create false brinelling marks (hum at 80km/h+) ...
...: Regulates fluid flow based on TCU temp readings Shift Logic: Simulates 7-step "stepped" ratios for driver familiarity Failure Modes: Belt Slippage: Low pulley pressure (P17F0, often from clogged filter) Pu...
... pulley pressure (40-90 bar adaptive) TCU Integration: Pre-programmed shift maps for 1.5L/1.6L engines Failure Modes: Belt Slip: Low primary pressure (P17F1, often from valve body wear) Pulley Galling: Conta...
... planetary + overdrive unit Shift Logic: Adaptive learning for throttle pattern recognition Failure Modes: 3-4 Clutch Burnout: Delayed shifts cause overheating (P0760) Valve Body Wear: Shift solenoid B stick...
... (30-120 psi base/300 psi clutch apply) Material: Aluminum die-cast with laser-bored channels Failure Modes: Solenoid Fatigue: Shift solenoids 3/5 wear first (P0756/P0776) Valve Bore...
Top Failure Modes: Stator Shaft Galling/Scoring Poor lubrication or debris causes wear on the stator support hub, leading to pressure loss. Bushing Wear The pump bushing wears, causing rotor misalignment an...
... gears Critical Specs: 142-148mm OD with 72±0.02µm surface finish Heat-treated to 58-62 HRC Failure Modes: Spline wear (>0.15mm play) Heat checking at >250°C Microfractures in casting voids Performance Note:...
... Critical Functions: Transmits 320Nm in 2nd/4th/6th gears Oil passages for clutch cooling (flow rate: 4–6 L/min) Failure Modes: Spline fretting (if backlash exceeds 0.1mm)...
... OD: 120–125mm, anodized for thermal resistance (max 200°C). Spline tolerance: ±0.03mm (wear >0.1mm causes slippage). Failure Modes: Spline shear (fatigue under abrupt shifts)....