Torque Converters

We offer a comprehensive regeneration of converters of all types - whether used in classic automatic transmissions or in continuously variable transmissions (CVT). We service passenger vehicles and vans, ensuring that drive systems are fully operational. In the process, we use state-of-the-art diagnostic and regeneration equipment, as well as spare parts of the highest quality. Each process carried out in our service regeneration completes rigorous quality testing and is subject to 24-month unlimited mileage warranty.

If you have noticed signs of damage, get a professional service - converter repair w Turbo-Tec will restore your vehicle's full power and smooth running.

Genesis and application.

The earliest automatic transmission designs used a torque converter clutch, which has been developed over time to the design we know today torque converter. The converter is part of the classic automatic transmission and some designs of CVT-type continuously variable transmissions. Converter regeneration has become a key service - it allows the drive train to be restored to full efficiency without the need for costly component replacement.

The hydrokinetic clutch is a simpler device that was used in some older automatic transmissions. Its main function is to allow the smooth transfer of power from the engine to the transmission by eliminating the rigid connection between the two. The hydrokinetic clutch consists of two main components: a pump (connected to the engine) and a turbine (connected to the transmission). Both components are enclosed in a housing filled with fluid (ATF oil). The pump, driven by the engine, produces a flow of oil that sets the turbine in motion, transmitting torque to the transmission. The hydrokinetic clutch works on the principle of energy transfer through the fluid, allowing for a smooth, if somewhat lossy, power transfer.

Torque converter is a more advanced device that has replaced the torque converter clutch in modern automatic transmissions. In addition to the power transfer function, torque converter has the ability to increase torque, which improves system efficiency and vehicle performance. The torque converter consists of three main components: pump, turbine and stator. The pump, connected to the engine, produces a flow of oil that drives the turbine, connected to the gearbox. A stator, located between the pump and the turbine, directs the oil flow, increasing the efficiency of power transmission. The stator has a unidirectional clutch, which allows it to rotate in one direction while locking in the opposite direction, increasing torque under certain conditions, such as starting from a standstill. Additionally, modern torque converters are equipped with a locking mechanism (known as a lock-up clutch) that eliminates slippage between the pump and the turbine, providing a direct connection between the engine and the transmission. This significantly reduces fuel consumption by reducing power flow losses.

Construction and principle of operation.

The torque converter consists of several basic components:

1. Housing - torque converter is enclosed in a sealed metal housing which houses the internal components and gear oil. The housing is connected by a flywheel to the motor and rotates with it.
2. Pump - is connected to the converter housing and rotates with it. It is the component that directly receives torque from the engine, driving the gear oil into a swirling motion by means of a series of vanes.
3. Turbine - is located inside the converter opposite the pump and is connected to the gearbox input shaft. The turbine blades are positioned to intercept the gearbox oil flow produced by the pump, causing the turbine to rotate and transmit torque to the gearbox.
4. Stator - is located between the pump and the turbine on a fixed shaft. It is the key component that directs the flow of oil between the turbine and the pump. The stator has vanes that change the direction of oil flow, increasing the efficiency of torque transfer. It is fitted with a unidirectional clutch, which allows it to rotate in one direction only. When there is a large speed difference between the pump and turbine, the stator locks, allowing the oil to be directed back to the pump at a greater angle, increasing torque. Stator regeneration is a procedure that restores the factory parameters.
5. Lock-up clutch - a mechanism to reduce or eliminate the speed differential between the pump and the turbine to reduce fuel consumption.
6. Bearings and seals - elements responsible for the smooth movement of the converter elements rotating independently of each other and for maintaining the tightness of the connections.

Operating principle. When the engine is running, the pump rotates with it, putting the gear oil in a swirling motion. The gear oil is pushed by the pump blades onto the turbine blades. The gear oil jet hits the turbine blades, causing the turbine to rotate. The turbine is connected to the input shaft of the gearbox, so its rotation transfers torque to the gearbox, which drives the vehicle. As the oil flows through the turbine, it changes direction and returns towards the pump. At this point, the stator, which is mounted on a fixed shaft with a one-way clutch, directs the oil flow back to the pump blades at a greater angle. This increases the torque and improves the efficiency of power transmission. The greatest torque amplification effect is achieved when there is a lot of slip between the pump and the turbine, i.e. mainly when starting from a standstill. The unidirectional coupling in the stator allows it to lock in one direction to change the direction of the oil flow, but rotate freely in the other, minimising energy loss when the pump and turbine are rotating at almost equal speed. W modern torque converters there is a locking mechanism that eliminates internal slippage at higher speeds. When the vehicle reaches a certain speed, the locking mechanism activates, directly connecting the pump to the turbine. This creates a direct connection between the engine and transmission, which improves fuel efficiency and reduces power loss. When the efficiency of these processes decreases, it is sometimes necessary to converter repair or full converter regeneration.

Converter reconditioning - step by step repair process

Professional converter regeneration at Turbo-Tec follows strictly defined steps, which guarantees the reproducible quality and long service life of the component:

1. The process starts with emptying the converter of any residual oil. The converter housing then needs to be cut open, which is done on a lathe. All internal components of the converter are thoroughly cleaned to remove dirt, deposits and residues of used gear oil. Special cleaners and equipment such as ultrasonic cleaners are used for this.
2. After cleaning, all components are carefully inspected for wear, damage and cracks. The pump and turbine blades and stator are assessed, the operation of the stator's one-way clutch is checked, the condition and degree of wear of bearings, vibration dampers and spline connections and more.
3. Worn or damaged components are replaced with new remanufactured ones. Most commonly, bearings, friction lining or lock-up clutch discs, seals and other mechanical components that show signs of wear are replaced.
4. Once all the necessary components have been replaced and repaired, the converter is reassembled. The components are precisely aligned and assembled, and the housing is welded again to ensure tightness. The welding is carried out on a special automatic station, which ensures that an even and tight weld is made around the entire circumference of the converter housing.
5. However, in order to be 100% sure that the weld has been carried out correctly, in the next step the converter leakage test is carried out. The converter balance is then checked and, if necessary, corrected.
6. The final stage is marking and painting the converter.

Thanks to advanced control methods and procedures converter regeneration Turbo-Tec gives an effect comparable to that of a brand-new part, and a properly executed converter repair restores full functionality of the system for a long time.

Causes and types of damage

Symptoms that may indicate a defective torque converter are:

1. Jerking during gear changes.
2. "Slipping" drive, acceleration problems.
3. Engine choking when starting from a standstill.
4. Noises and vibrations.
5. Transmission overheating.
6. Increased fuel consumption.

The most common failures of torque converters are:

1. Damage or wear to the friction lining or discs/plates of the lock-up clutch
2. Damage to pump and turbine blades
3. Bearing wear
4. Worn or damaged stator
5. Wear or damage to seals
6. Damage to connections (splines and others)

If you notice the above symptoms, do not hesitate to - converter repair carried out by specialists will help avoid serious gearbox failures.

Turbo-Tec - your partner in converter regeneration

Since 2005 Turbo-Tec has specialised in services such as converter regeneration, stator regenerationrepair of automatic transmissions or engine electronics. Our experience and technical facilities allow us to carry out even the most demanding repairs. We serve both individual customers and garages in Poland and Europe.

Choose a proven service - converter repair w Turbo-Tec is your guarantee of quality, safety and a long life for your vehicle. Contact us today and restore the efficiency of your transmission.