Automatic transmissions

We offer specialised regeneration of automatic gearboxes of various types - classic with converter and DCT/DSG dual-clutch. We deal with designs used in passenger and commercial vehicles. 

Repair process for automatic transmissions we carry out using the latest diagnostic equipment and remanufacturing technology, and we select all spare parts only of the highest quality. The high quality is backed up by a 24-month unlimited mileage warranty.

Genesis and application.

The history of automatic transmissions can be traced back to the early 20th century, when engineers began experimenting with methods of automatically changing gears in cars. The first trials took place in the 1920s and 1930s, but it was not until 1939 that General Motors introduced the first truly automatic transmission, known as the Hydra-Matic. This was a ground-breaking development that made it possible to change gears smoothly without the need for manual intervention by the driver.

The Hydra-Matic quickly became popular and its design was used by many other car manufacturers. In the 1950s and 1960s. automatic gearboxes have become increasingly common in the United States, becoming a symbol of modernity and convenience. In Europe and Asia, their popularity grew somewhat more slowly, mainly due to different driver preferences and differences in road design and driving styles.

The 1970s and 1980s saw further developments in automatic transmission technology. More advanced hydraulic systems and the first versions of electronic control were introduced, allowing even better control over gear changes and reducing fuel consumption. During this period automatic transmissions have become more reliable and available on a wide range of vehicles, from cars to trucks and buses.

The 1990s saw a real technological revolution, when computers and electronics began to play a key role in the management of gearbox operation. The first electronically controlled automatic transmissionswhich were able to adapt their operation to the road conditions and the driver's driving style. Thanks to this automatic gearboxes have become even more efficient and user-friendly.

In the 21st century automatic transmission technology continues to evolve. Today's transmissions offer a range of operating modes, including sport, economy or off-road modes, as well as systems that allow manual steering via steering wheel-mounted paddles. There are also new designs such as Continuously Variable Transmission (CVT) and Dual-Clutch Transmission (DCT), which combine the advantages of automatic and manual transmissions.

W Turbo-Tec We are familiar with all gearbox generations - so we are able to carry out both regeneration of automatic gearboxes in classic designs, as well as servicing the latest CVT or DSG models.

Construction and principle of operation.

Classic automatic transmissions (with torque converter and planetary gear set).

Classic automatic gearbox, also often referred to as a planetary gearbox, is a complex mechanism that consists of several key components. Each of these components plays a vital role in transferring power from the engine to the wheels, while also allowing gear ratios to be changed smoothly without driver intervention.

Heart classic automatic transmission constitutes an assembly of planetary gears. Each consists of three main parts: the sun wheel, the planetary wheels (also called satellites) and the ring wheel. The sun wheel is at the centre, the planet wheels (satellites) revolve around it and are connected to the ring wheel. This arrangement allows for different combinations of gear ratios depending on which wheel is driven, which is stopped and which transmits power.

The clutches and brakes, which are hydraulically actuated, are responsible for controlling the power flow and shifting gears. In a classic automatic transmission, there is an oil pump that supplies pressurised oil to various parts of the transmission, including the clutches and brakes. When a gear change is required, the corresponding clutch is engaged or disengaged, allowing the ratio in the planetary transmission to be changed.

A torque converter is also a key component of the classic automatic transmission. It is located between the engine and gearbox and acts as a hydraulic clutch. The torque converter consists of three main parts: pump, turbine and stator. The pump is connected to the crankshaft of the engine via the flywheel, the turbine to the input shaft of the gearbox and the stator is located between the two. When the engine is running, the pump sets the oil in motion to transfer power to the turbine, after which the stator directs the flow of the returning oil in such a way as to increase the efficiency of torque transmission.

The operation of the classic automatic transmission is controlled by a hydraulic and electronic system. The hydraulic system manages the flow of fluid to the clutches and brakes, while the electronic system monitors various driving parameters such as vehicle speed, engine load or throttle position. Based on this data, the control computer (TCU - Transmission Control Unit) decides when and what gear ratio to select. A TCU without an electronic controller is called a valve block, while mechatronics is the component that integrates the valve block and the electronic controller of the automatic transmission.

To sum up, classic automatic gearbox is a high-tech device that combines mechanical, hydraulic and electronic components to ensure smooth and efficient gear changes. The planetary gearbox, clutches and brakes, torque converter and controls work together to provide a comfortable and convenient driving experience. Whether you have a classic converter design or a modern DSG, our automatic transmission service will ensure that your vehicle is fully operational.

Continuously variable transmissions (CVTs).

CVT transmission (Continuously Variable Transmission), or continuously variable transmission, works on the principle of smooth gear changes, which distinguishes it from traditional manual and automatic transmissions. A key component of the CVT design is a chain and two sets of bevel wheels (known as variators).

The chain is made of durable metal or composites and transmits power from the motor to the drive wheels. Each pair of pulleys, one connected to the input shaft and the other to the output shaft, consists of two conical discs that can move along the shaft axis. When the discs change their distance from each other, the active diameter along which the chain moves changes. Decreasing the distance between the discs causes the chain to move to a larger diameter, which increases the gear ratio, while increasing the distance causes the chain to move to a smaller diameter, which decreases the gear ratio.

The movement of the cones in relation to each other is controlled by a hydraulic system that adjusts the active diameter on which the chain operates, enabling smooth gear changes. CVT transmission control is carried out by a sophisticated electronic system that monitors engine performance, vehicle speed, accelerator pedal position and other factors. Based on this data, the system decides on the optimum variator setting to provide the best possible gear ratio for a given situation.

A planetary gear set can be found in CVT transmissions, which allows additional gear changes or the realisation of operating modes such as reverse. The planetary gear set increases the flexibility and operating range of the CVT transmission.

Thanks to its design CVT transmission offers flexible and stepless gear changes, resulting in a smoother ride, better performance and optimised fuel consumption. The CVT is particularly popular in hybrid and urban vehicles where comfort and efficiency are priorities. The CVT transmission's cooling and lubrication system ensures that the bevel wheels and chain are properly lubricated and cooled, minimising friction and wear and ensuring the reliability and durability of the transmission.

Turbo-Tec automatic transmission service specialises in both CVT continuously variable transmissions and DCT/DSG dual-clutch transmissions.

Dual-clutch transmissions (DCT/DSG).

Dual-clutch automatic transmission, also known as DCT (Dual-Clutch Transmission) or DSG (Direct-Shift Gearbox), is an advanced mechanism that combines the features of both automatic and manual transmissions. 

The basic element of the DCT transmission are two clutches: one responsible for the even gears (2, 4, 6) and the other for the odd gears (1, 3, 5, 7). These clutches operate on the principle of wet clutches (immersed in oil) or dry clutches, depending on the design and purpose of the transmission. The operation of the clutches is controlled by electronics, which enables them to be engaged and disengaged precisely.

Another important component is the two input shafts, one of which is located inside the other. One shaft is responsible for the odd gears and the other for the even gears. This allows the next gear to be prepared for engagement at the same time, minimising interruptions in power delivery during gear changes.

DCT gearshift mechanism consists of a set of toothed gears that are located on both input shafts. These gears are responsible for the different ratios and their engagement and disengagement is controlled by a hydraulic circuit and synchronisation mechanisms. The gears are changed by moving the forks and pinning the corresponding gears together, allowing the required ratio to be selected.

Dual-clutch transmission control is carried out by a sophisticated electronic system known as the TCU (Transmission Control Unit). The TCU monitors various driving parameters such as vehicle speed, engine load, throttle position and driver preference (driving mode). Based on this data, the TCU decides which clutch to engage, when to change gear and which gear ratio to select for optimum performance and driving economy.

In a dual-clutch transmission, the lubrication and oil cooling system is also a very important component. In the case of wet clutches, oil is used to lubricate and cool the clutches for longer life and reliability. The oil circulates in a closed circuit, and a pump and cooler maintain its proper pressure and temperature.

Each type of gearbox requires a different service approach - when returning a vehicle to the Turbo-Tec you have the assurance that it will be handled by a specialised automatic transmission service.

How the regeneration of an automatic transmission proceeds - step by step

Automatic gearbox is first pre-cleaned and then disassembled. After disassembly, its components are cleaned in special equipment such as chemical and ultrasonic cleaners. The clean parts are then carefully inspected for wear, damage and other defects. Components that do not meet the requirements are replaced with new or reconditioned parts.

The next stage is replacement of worn or damaged parts. In a classic automatic transmission, these are usually clutch and brake discs, brake bands, seals, sealing rings, hydraulic valves and bearings. In some cases, the oil pump may need to be remanufactured or replaced, as well as torque transmission components.

In DCT/DSG type gearboxes, the double clutch is always replaced with a brand new one. Mechanical or electronic malfunctions of the mechatronics, bearing damage are also a common problem. Less frequently, synchronisers, gears and other mechanical components need to be replaced. During the process regeneration of automatic gearboxes all oil filters used in a given gearbox are always changed. It is worth noting that, in addition to the oil filters accessible from the outside, some models of gearboxes also have filters located inside the housing, which cannot be changed without disassembling the gearbox.

Removed from automatic transmission hydraulic controller (valve block/mechatronics) is also disassembled into its component parts and thoroughly cleaned. After replacing seals and other worn or damaged components, it is reassembled and tested on a special test bench. Dynamically, the controller's parameters are tested in a test reproducing its operation in the gearbox - above all, the pressure of the oil reaching the individual actuators that control the gear changes. 

The torque converter, which is part of a classic automatic transmission (and some CVT transmission designs), also undergoes a remanufacturing process. This involves cutting the converter apart, cleaning all the components and then inspecting them. All seals are replaced, as well as worn or damaged parts, such as the lock-up clutch linings or plates/discs, bearings, stator one-way clutch, etc. After the installation of the new components, the torque converter is prepared for welding, which is carried out on a special automated device. The torque converter's tightness is then checked, followed by measuring and, if necessary, correcting its balance.

The final stage of remanufacturing is the completion of the box and the evaluation of the tightness and operation of the components, as well as a final quality check. Thanks to this repair of automatic transmissions at Turbo-Tec ensures that the system is fully restored to working order.

Causes and types of damage

Symptoms that may indicate a faulty automatic transmission:

1. Lack of smooth gear changes - delays, jerks or gear changes that are too abrupt.
2. No gear change or limited gear change, no gears.
3. No response or delayed response when switching between P-R-N-D modes.
4. Jerks or bumps when switching between P-R-N-D modes.
5. Drive slippage - the engine increases speed, but the vehicle does not increase speed in line with the engine speed.
6. Lack of transmission - the engine revs up but the vehicle does not start.
7. Noise, vibration audible/perceptible while driving.
8. Oil leakage from the transmission.

If you notice jerking, slipping or oil leaks - don't wait. Professional repair of automatic transmissions at Turbo-Tec will avoid major costs.

The most common defects in automatic transmissions are:

1. Wear of friction discs, damage to clutches and brakes
2. Damage to the torque converter
3. Worn or damaged oil pump
4. Damage to seals
5. Damage to the valve body/mechatronics
6. Worn or damaged bearings
7. Malfunction of the electronic transmission control unit

Regeneration of automatic gearboxes You save money compared to buying a new or remanufactured unit, while maintaining high reliability. In addition, you extend the life of the original components and care for the environment - less waste, less consumption of raw materials.

Why choose Turbo-Tec?

• Experience since 2005 - thousands of remanufactured gearboxes.
• Branches throughout Europe - We serve private customers and garages.
• Modern machinery - specialised test benches, test stands for mechatronics and converters.
• 24-month unlimited mileage warranty - full security for our customers.
• Comprehensive automatic transmission service - from diagnosis to repair to installation and final testing.

Bet on the industry leader - choose Turbo-Tec and benefit from the best automatic transmission service in Poland and Europe.

Contact us - put your trust in a reliable automatic transmission service

Is your gearbox starting to give you problems? Then come to Turbo-Tec! We offer a fast and professional repair of automatic transmissions with a full guarantee of quality. Whether you are interested in a comprehensive regeneration whether the current automatic transmission service, we provide support at the highest level.

Call us today or visit our service centre - see why Turbo-Tec is the leader in gearbox remanufacturing in Poland and Europe.