SHOP TALK

Those Dar
Darnn KMs:
Hyundai Takes a by Dennis Madden

U-Turn; Part 1
F
or years, Hyundai and Mitsubishi
shared a common gear train: the
old KM 175 series. It was a unit
people loved to hate, but when you got
right down to it, its odd simplicity made
it an easy build. Once you understood
how it was supposed to work, it was
easy to make it work.
Hyundai always seemed to be a
bit behind Mitsubishi. That is, when
Mitsubishi made a change, you didn’t
see it in the Hyundai for about two
years. In 1993 Hyundai broke from tra-
dition when they introduced the A4AF1
in the Scoupe. It was still a KM unit
— sort of — but it didn’t have an Figure 1
idler gear, so it sat on the left side of
the engine compartment rather than
the right. In 1995 they introduced the
Accent, equipped with this new unit.
Then, in 1996, the Elantra switched to
it, along with the Tiburon, introduced
that same year.
In 1997 Mitsubishi introduced the
F4A41 in the Mirage, and the larger
version, the F4A51, in the Diamante,
phasing out the KM series until it was
gone entirely for the 2001 model year.
It seemed as though Hyundai would
follow suit, and they did. In 1999 the
Sonata switched over to the F4A51.
Then all of a sudden, something
happened: Evidently an accountant fell
asleep and the engineers started spend-
ing money. Just before the close of
the 1999 model year, Hyundai came
out with a 6-solenoid version of the Figure 2
A4AF1. Enter the A4AF3 (Accent) and
A4BF2 (Elantra and Tiburon). What in behold, Hyundai scrapped it in 2001 we should become familiar with what
the world was goin’ on? for the Elantra and Tiburon, but kept it we’re working on…
At first these units seemed like a in the Accent — and they’re still using Before you begin working on this
flash in the pan; they’d surely be here it! It looks like we’re gonna have to unit, take a moment and jot down the
and gone like the Subaru Justy. Lo and work on this thing after all. So maybe information from the ID tag on the

4 GEARS August 2006

4DM-ShopTalk.indd 4 7/10/06 3:31:45 PM

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Sonnaxplaced.indd 5 6/22/06 11:21:56 AM

 Those Darn KMs: Hyundai Takes a U-Turn; Part 1
back of the bellhousing. Hyundai uses a
series of letters etched on a boss (figure PCA
1) that tell you some of the specifics.
The first digit will be either a T for SSC PCB
the A4AF3 in the Accent or U for the
A4BF2 in the Elantra/Tiburon. Figure
2 shows what each digit of the code
means.
Now, make sure you pay atten-
tion to the 3rd digit: That’s the final
drive ratio. If you get a car that’s been
worked on before, it just might have the
wrong unit in it… be careful.
Okay, so what did Hyundai change
and why? For the most part this unit
works the same as the 4-solenoid ver-
sion. They added a shift solenoid (shift
solenoid C) and a pressure control sole-
noid (pressure control solenoid B). SSB TCC
Let’s start with the shift solenoids: SSA
Figure 3 shows a chart with the sole-
noid firing order, along with a solenoid
connector view so you can test the sole-
noids. Notice in all cases there’s at least
one solenoid being energized. So what Gear SSA SSB SSC
happens for failsafe? If you unplug the 1st ON ON OFF
solenoids, the transmission stays in 3rd 2nd OFF ON OFF
gear just like the 4-solenoid version.
3rd OFF OFF ON
One feature they added for failsafe
though was a manual 2nd capability. In 4th ON OFF ON
the event it goes to failsafe and it isn’t
caused by a shift solenoid B failure, the Figure 3: Case Connector Pin View
computer will energize shift solenoid B
in manual 2nd or low. rear clutch and end clutch. The servo is What it didn’t do is control
So how about this new shift sole- dumped through the failsafe valve. If rear clutch pressure beyond the ini-
noid? Well, it controls two things: end SSC is stuck closed, it’ll go into neutral tial engagement. Once the rear clutch
clutch apply, and pressure reduction in when 4th gear is commanded. applied, the pressure control solenoid
4th gear. When shift solenoids A and B no longer had control of the rear clutch.
turn off, the trans goes into 3rd gear, Simple enough: Pressure control solenoid B now has
just like the earlier version. After the Now for pressure control control of the rear clutch during its
shift to 3rd the computer energizes shift solenoid B. initial engagement, as well as during
solenoid C and the end clutch applies. Pressure control solenoid B does the 4-3 downshift, leaving pressure
If Hyundai made a decent oil schematic, one thing and one thing only: It controls control solenoid A for shift feel and
you’d see there’s a latching mechanism pressure to the rear clutch. Prior to the L/R brake control. Prior to this addi-
— the end clutch valve — that keeps addition of this solenoid, the pressure tion, rear clutch apply during the 4-3
the end clutch on, regardless of the state solenoid had 3 main functions: shift was controlled only by an orifice
of shift solenoid C, once it’s applied. 1. Controlled the low/reverse in the separator plate. Funny thing
Shift solenoid C also provides a brake for reverse engagement, though, I don’t recall our phone ringing
cutback feature, once the trans shifts reverse lockout so reverse off the hook with harsh 4-3 downshift
into 4th. With the solenoid off, line won’t engage while moving complaints.
pressure is around 130 PSI. When the forward, and for manual low Hyundai has always been a little
solenoid is on, line pressure drops to engine braking. different, but as you can see, these
about 95 PSI. It’s a nice feature, but 2. Controlled pressure to the changes aren’t anything to be afraid
there are a few “out of sequence” servo and front clutch for shift of. In part 2 we’ll look at the electrical
issues shift solenoid C can cause. For feel into 2nd, 3rd and 4th. system that controls this unit, and then
example, if SSC is stuck open, the 3. Controlled rear clutch apply we’ll go into some complaints, testing,
transmission will shift to third when during drive engagement. and hydraulic changes. Pay attention:
second is commanded. The kooky thing We’re making a quick U-turn!
about this one is that 3rd gear is via the

6 GEARS August 2006

4DM-ShopTalk.indd 6 7/10/06 3:32:06 PM

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