Automatic Transmission - Diagnosis - 4r100 Automatic Transmission Ford Econoline I

APPLICATION

Note. For Ford 4R100 transmission mechanical testing and repair, see FORD 4R100 OVERHAUL article.

TRANSMISSION APPLICATIONS

DESCRIPTION & OPERATION

The first step in diagnosing any driveability problem is verifying the customer's complaint with a test drive under the conditions the problem reportedly occurred. Before entering self-diagnostics, perform a careful and complete visual inspection. Most transmission control problems result from mechanical breakdowns or poor electrical connections. All models use OBD-II Electronic Engine Control-V (EEC-V) system. For additional information on the EEC-V system, see SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE.

Input signals from sensors are sent to the Powertrain Control Module (PCM). The PCM can determine when the time and conditions are right for a shift or converter clutch application. The PCM can also determine line pressure needed to optimize shift feel.

SELF-DIAGNOSTIC SYSTEM

Note. For engine related DTCs, see SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. These DTCs pertain to engine performance and must be repaired first, as engine performance and related component signals will affect transmission operation and diagnosis.

Diagnostic Formats

QUICK TEST and SYSTEM TESTS are diagnostic formats used to test and service EEC-V system. QUICK TEST allows technician to identify problems and retrieve Diagnostic Trouble Codes (DTC). SYSTEM TESTS check circuits, sensors and actuators.

Before starting any SYSTEM TEST, follow all steps in QUICK TEST to find correct SYSTEM TEST. If vehicle passes QUICK TEST and no driveability symptoms or intermittent faults exist, EEC-V system is okay.

Retrieving Codes

Fault codes are retrieved from EEC-V system through Data Link Connector (DLC). (Scheme 126) DLC is located below instrument panel, to left of steering column. Self-diagnostic test procedures are for use with New Generation Star (NGS) scan tool. If a generic scan tool is used, ensure tool is certified OBD-II standard and refer to scan tool manufacturers operating procedures.

Scheme 126

Diagnostic Trouble Codes (DTC)

During QUICK TEST, 3 types of DTCs are retrieved: KOEO, KOER and Continuous Memory Codes. See QUICK TEST for self-test procedures. Codes may be cleared from PCM memory after they have been recorded or repaired. See CLEARING CODES .

KOEO & KOER Codes (Hard Faults)

These codes indicate faults are present at time of testing. A hard fault may cause CHECK ENGINE or Malfunction Indicator Light (MIL) to go on and remain on until fault is repaired. If KOEO or KOER codes are retrieved during KOEO SELF-TEST or KOER SELF-TEST, use DTC IDENTIFICATION table to find correct testing and repair procedures.

Continuous Memory Codes (Intermittent Faults)

These codes are used to diagnose intermittent problems. Continuous memory codes are retrieved after KOEO SELF-TEST. These codes indicate a fault that may or may not be present at time of testing.

After noting and/or repairing fault, clear codes from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problem.

POWERTRAIN CONTROL MODULE (PCM)

The PCM is located on center of firewall in engine compartment. PCM controls transmission operation through 5 electronic solenoids consisting of 4 On/Off solenoids for shifting and torque converter clutch control and one variable force solenoid for line pressure control. All components are part of the transmission solenoid body and are not serviceable individually. The PCM has built-in self-diagnostic capability, fail-safe code and warning code display for the main input sensors and solenoid valves.

Accelerator Pedal (AP) Sensor (7.3L DI Diesel Only)

Accelerator Pedal (AP) sensor is mounted on accelerator pedal on models with 7.3L diesel engines only. The AP sensor detects position of accelerator pedal and sends information back to PCM as a voltage signal. If AP sensor or related circuits fail, PCM recognizes a fault and boosts line pressure to prevent damage to transmission. This will create harsher upshifts and engagements.

Air Conditioning Clutch (ACC) Switch

On factory installed A/C system, PCM receives signal voltage from ACC switch indicating that the air conditioning compressor clutch is engaged. The PCM uses the ACC switch signal to adjust line pressure to compensate for additional engine load. If the ACC switch fails with closed contacts, line pressure will be slightly lower with air conditioning off. If the ACC switch fails with open contacts, line pressure will be slightly higher with air conditioning on.

Anti-Lock Brake Speed Sensor

The Programmable Speedometer/Odometer Module (PSOM) receives input from rear anti-lock brake speed sensor, which is located on rear axle housing assembly. The PSOM then relays the signal to PCM and speed control module.

Barometric Pressure (BARO) Sensor (7.3L DI Diesel Only)

The PCM uses signal from BARO sensor to determine altitude at which vehicle is operating. PCM then adjusts EPC pressure and shift scheduling to the altitude.

Brake Pedal Position (BPP) Switch

The PCM receives a signal from the BPP switch when the brake switch is operated. Torque converter clutch is disengaged when brakes are applied. Malfunctioning switch will affect torque converter operation. BPP switch may also be known as the Brake On/Off (BOO) Switch.

Camshaft Position (CMP) Sensor (7.3L DI Diesel Only)

On 7.3L DI diesel engines, the CMP sensor provides engine RPM information to PCM. The RPM input signal is used to determine shift scheduling and EPC pressure.

Digital Transmission Range (TR) Sensor

The TR sensor is located on outside of transmission at manual lever. The TR sensor opens or closes a set of 4 switches that are monitored by the PCM. The internal switch signal corresponds with position of the shift selector lever. The TR sensor completes the neutral/start and back-up lights circuits. It also provides a Neutral signal for Generic Electronic Module (GEM) control of 4WD Low engagement on 4WD vehicles. Malfunction of the TR sensor may cause harsh engagements and firm shift feel. Improper shifting or shift selection and no engine cranking may also result.

Profile Ignition Pick-up (PIP)

The Ignition Control Module (ICM) generates a PIP signal (engine RPM) and sends it to PCM. The PIP determines transmission strategy, Wide Open Throttle (WOT) shift control, torque converter control and EPC pressure.

4WD Low (4WDL) Switch

Low range switch is located on transfer case cover. Switch modifies shift schedule for 4WD transfer case gear ratio. Early shifts will occur if switch fails in ON position. Delayed shifts will occur if switch fails in OFF position.

Intake Air Temperature (IAT) Sensor

The IAT sensor is used to help determine Electronic Pressure Control (EPC) pressures.

Mass Airflow (MAF) Sensor

The MAF signal is used for Electronic Pressure Control (EPC), shift and TCC scheduling. Sensor malfunction will affect shift and TCC scheduling.

Manifold Absolute Pressure (MAP) Sensor (Gasoline Engines)

On gasoline engines, MAP sensor senses atmospheric pressure to produce an electrical signal. Frequency of this signal varies with intake manifold pressure. The PCM monitors this to determine altitude. The PCM adjusts shift scheduling and EPC pressure.

Output Shaft Speed (OSS) Sensor

The OSS sensor is a magnetic pick-up that provides output shaft rotation speed to PCM. The OSS sensor is mounted externally on top of transmission case, near extension housing. PCM uses OSS sensor signal to help determine EPC pressure, shift scheduling and TCC operation.

Programmable Speedometer/Odometer Module (PSOM)

The PSOM receives input from rear anti-lock brake speed sensor, which is mounted on rear axle differential housing. Vehicle speed (MPH) signal is output to PCM. PSOM failure may cause harsh engagements, firm shift feel and abnormal shift scheduling. Unexpected downshifts may occur at closed throttle and abnormal TCC operation or engages at WOT. Transmission Control Indicator Light (TCIL) may flash.

Throttle Position (TP) Sensor

Note. On vehicles equipped with diesel engines, an Accelerator Pedal (AP) sensor is used. See Accelerator Pedal (AP) Sensor (7.3L DI Diesel Only) .

The TP sensor is a potentiometer mounted to the engine throttle body on gasoline engines. The PCM receives a signal from the TP sensor relaying throttle plate position. TP sensor failure will cause PCM to operate in fail safe mode and raise line pressure to prevent transmission damage. This condition will result in harsh engagements, firm shift feel, abnormal shift scheduling and TCC not engaging or cycling.

Transmission Control Switch (TCS) Or Transmission Control Indicator Lamp (TCIL)

TCS or TCIL is mounted on shift lever handle. Switch controls operation of 4th gear. TCIL indicates overdrive cancel mode activated (light on) and EPC circuit shorted (light flashing) or monitored sensor failure. Malfunction of switch will cause lack of 4th gear disable function.

Transmission Fluid Temperature (TFT) Sensor

The TFT sensor is located on the solenoid body assembly. The PCM monitors voltage across the TFT sensor to determine transmission temperature. Depending on temperature, the PCM controls Electronic Pressure Control (EPC) pressure, shift scheduling and TCC operation. TFT sensor inhibits TCC operation during warm-up and locks TCC if transmission fluid temperature is too high. Malfunction of sensor will cause incorrect line pressure and possible lack of TCC operation.

Turbine Shaft Speed (TSS) Sensor

The TSS sensor is a magnetic pick-up that sends information on the rotation speed of the coast clutch drum to the PCM. The TSS sensor is mounted external on transmission case, near bellhousing. TSS sensor helps determine Electronic Pressure Control (EPC) pressure, shift scheduling, and TCC operation.

Coast Clutch Solenoid (CCS)

The coast clutch solenoid provides coast clutch control by shifting coast clutch shift valve. The CCS is activated by pressing the TCS or by selecting "1" or "2" with transmission shift selector lever. In manual "1" and "2" , coast clutch is controlled by solenoid and hydraulically as a fail-safe to ensure engine braking. In Reverse, coast clutch is controlled hydraulically and the CCS is NOT activated.

Electronic Pressure Control (EPC) Solenoid

The EPC solenoid is a variable-force solenoid. The EPC receives signal from the PCM to control line pressure and line modulator pressure. If EPC fails in ON position, transmission is operated in fail-safe mode to avoid internal transmission damage.

Scheme 127

Scheme 128

Scheme 129

Scheme 130

1. ON/OFF solenoids (3) are used for electronic shift scheduling. Solenoids used are Shift Solenoid No. 1 (SS1), Shift Solenoid No. 2 (SS2) and Coast Clutch Solenoid (CCS). Solenoids control pressure to 3 shift valves and forward clutch control valve, located in valve body. See «SHIFT SOLENOID OPERATION»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. SHIFT SOLENOID OPERATION Shift Lever Position SS1 SS2 CCS Park On Off Off Reverse On Off Off Neutral On Off Off "D" (O/D ON) 1st Gear On Off (1) 2nd Gear On On (1) 3rd Gear Off On (1) 4th Gear Off Off (1) "D" (O/D OFF) 1st Gear On Off On 2nd Gear On On On 3rd Gear Off On On 2nd Gear (1) (1) On 1st Gear (2) Off Off On 1st Gear On Off On (1) PCM controlled. (2) Transmission is in 2nd gear until vehicle speed drops below calibrated speed.
2. When shift solenoid is always OFF, failure could be due to PCM and/or vehicle wiring malfunction, and/or solenoid electrically, hydraulically or mechanically stuck off. For shift symptoms (Scheme 127)and (Scheme 128).
3. When shift solenoid is always ON, failure could be due to PCM and/or vehicle wiring malfunction, and/or solenoid electrically, hydraulically or mechanically stuck off. For shift symptoms (Scheme 129)and (Scheme 130).

Torque Converter Clutch (TCC) Solenoid

The TCC solenoid receives a signal from the PCM. The TCC solenoid controls application and release of torque converter clutch. If solenoid fails in ON position, engine will run rough (shudder) and engine stalls in Drive at idle, low speeds with brake applied, or in manual 2nd gear. If solenoid fails in OFF position, torque converter clutch will not engage. Transmission Control Indicator Light (TCIL) may flash.

VISUAL INSPECTION

Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not pinched or cut. Check for non-factory installed equipment wired into transmission or PCM harness. Inspect air induction system for possible vacuum leaks. Check PCM, sensors and actuators for physical damage. Check engine coolant level. Check transmission fluid level and condition.

HARSH FORWARD ENGAGEMENT ONLY

See ENGAGEMENT FAULTS in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST E in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

HARSH REVERSE ENGAGEMENT ONLY

See ENGAGEMENT FAULTS in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST E in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

HARSH FORWARD & REVERSE ENGAGEMENT

See ENGAGEMENT FAULTS in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST E in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

SOME OR ALL SHIFTS MISSING

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST A and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

SOME OR ALL SHIFTS EARLY OR LATE

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST A and TEST B in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

ERRATIC OR HUNTING SHIFTS

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST A , TEST B , TEST C and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

SOFT OR SLIPPING SHIFTS

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST B and TEST E in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

HARSH SHIFTS

Perform QUICK TEST . Record DTCs. Perform TEST B , TEST D and TEST E in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO 1ST GEAR IN DRIVE, ENGAGES IN HIGHER GEAR

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST A and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO MANUAL 1ST GEAR

Perform QUICK TEST . Record DTCs. Perform TEST A and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO MANUAL 2ND GEAR

Perform QUICK TEST . Record DTCs. Perform TEST A and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO 1-2, 2-3 OR 3-4 UPSHIFT IN "D" POSITION

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST A in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO 4-3 OR 2-1 DOWNSHIFT

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform QUICK TEST . Record DTCs. Perform TEST A in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO 3-2 DOWNSHIFT

Perform QUICK TEST . Record DTCs. Perform TEST A and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO TCC ENGAGEMENT

Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST B and TEST C in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

TCC ALWAYS ENGAGED

Check engine idle speed. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST C in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

TCC CYCLING OR SHUDDERING

Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST C and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

POOR VEHICLE PERFORMANCE

Check for poor engine performance. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. Perform SHIFT SPEED ROAD TEST WITH "OD" OFF in FORD 4R100 OVERHAUL article. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST B , TEST C and TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

INCORRECT GEAR RATIO IN "D", "2" OR "1" POSITIONS

Perform SHIFT SPEED ROAD TEST in FORD 4R100 OVERHAUL article. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST A in SYSTEM TESTS. Repair TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

ENGINE WILL NOT CRANK

Perform QUICK TEST . Record DTCs. Perform TEST D in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

TRANSMISSION OVERHEATING

Check for poor engine performance. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. Perform SHIFT SPEED ROAD TEST WITH "OD" OFF in FORD 4R100 OVERHAUL article. Perform TORQUE CONVERTOR ENGAGEMENT TEST . Perform QUICK TEST . Record DTCs. Perform TEST C in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

NO ENGINE BRAKING WITH O/D CANCELLED, MANUAL "1" & "2" HAVE ENGINE BRAKING

Check for poor engine performance. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. Perform QUICK TEST . Record DTCs. Perform TEST G in SYSTEM TESTS. Repair as necessary. Clear codes and perform TRANSMISSION DRIVE CYCLE TEST . Repeat QUICK TEST and ensure DTCs are not present.

DIAGNOSTIC PROCEDURE

1. Perform «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . Record all DTCs. If any transmission codes are set, go to next step. If no DTCs are set, go to step 4 . If any engine related DTCs are set, repair them first. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. If no Continuous Memory Codes were set, go to step 4 .
2. If any DTCs set in previous step were Continuous Memory Codes, clear all codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes) . Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test) . If Continuous Memory Codes are set during transmission drive cycle test, go to next step. If Continuous Memory Codes are not set during transmission drive cycle test, go to step 4 .
3. Perform diagnostic test corresponding to code set. See «DTC IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. If problem is not corrected, go to next step. If problem is corrected, go to step 7 .
4. Diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If electronic trouble symptoms exist, go to next step. If no electronic trouble symptoms exist, go to step 6 .
5. Follow diagnostic tests corresponding to electronic trouble symptom. Perform static and drive tests. To perform static tests, use manufacturer provided transmission tester overlay. If drive test does not correct problem, go to next step. If drive test corrects problem, check for intermittent code. Check transmission circuit wiring harnesses and connectors for damage or poor connection.
6. Diagnose problem by mechanical symptom. See TROUBLE SHOOTING in FORD 4R100 OVERHAUL article. Perform any recommended repair procedures. Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test) .
7. Perform «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) and ensure no DTCs and no mechanical problems exist. If any DTCs exist, go to step 1 . If no DTCs exist, clear memory code. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes) .

Description

Following procedures are functional tests of EEC-V system. These basic test steps must be followed in sequence to avoid misdiagnosis

1. «VISUAL CHECK»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__visual-check)
2. «EQUIPMENT HOOKUP»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__equipment-hookup)
3. «KEY-ON-ENGINE-OFF (KOEO) SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test)
4. «KEY-ON-ENGINE-RUNNING (KOER) SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koer-self-test)
5. «COMPUTED TIMING CHECK»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__computed-timing-check)
6. «CONTINUOUS MEMORY SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__continuous-memory-self-test)

Diagnostic Aids

After each service or repair procedure has been completed, repeat QUICK TEST to ensure all EEC-V systems work properly and diagnostic trouble codes are no longer present.

Visual Check

Complete all steps in TROUBLE SHOOTING before proceeding to self-diagnostic tests. Ensure vacuum hoses and EEC-V wiring harnesses are properly connected.

Equipment Hookup

Apply parking brake, and place shift lever in "P" position. Block drive wheels. Turn off all electrical accessories. Connect appropriate test equipment to vehicle as follows

Scheme 131

1. Generic Scan Tool Ensure scan tool meets or exceeds OBD-II standard. Follow manufacturer's instructions to hook up equipment and record diagnostic trouble codes.
2. New Generation Star (NGS) Tester Turn ignition switch to OFF position. Connect adapter cable lead to diagnostic tester. (Scheme 131) Connect service connectors of adapter cable to vehicle Data Link Connector (DLC). See «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test).

KOEO Self-Test

Note. If self-test will not activate or TOOL COMMUNICATION ERROR is received, see SCAN TOOL UNABLE TO COMMUNICATE .

Ensure engine is at normal operating temperature. If engine does not start (or stalls after starting), continue KOEO SELF-TEST. Turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu.
2. Select year, engine, model and any additional information requested by scan tool.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CTRL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOEO ON-DEMAND SELF-TEST.
7. Turn ignition switch to ON position.
8. Follow operating instructions from scan tool menu.

KOER Self-Test

Ensure engine is at normal operating temperature. Turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu.
2. Select year, engine, model and any additional information requested by scan tool.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM - POWERTRAIN CTRL MODULE.
5. Select DIAGNOSTIC TEST MODE.
6. Select KOER ON-DEMAND SELF-TEST.
7. Start engine and allow to idle.
8. Follow operating instructions from scan tool menu.
9. Perform BOO and TCS cycling (if equipped).

Computed Timing Check

Ensure all accessories are off and engine is at normal operating temperature. Disconnect SPOUT connector. Connect timing light. Using ignition switch, start engine. Ignition timing should be about 10 degrees BTDC (base timing). Reconnect SPOUT connector. Timing should advance from base timing. If timing is not as specified, check for causes of incorrect timing such as damaged Crankshaft Position (CKP) sensor. For additional procedure, see SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE.

Continuous Memory Self-Test

Turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool (optional).
3. Select GENERIC OBD-II OPTIONS. Press CONT button if all OBD-II monitors are not complete.
4. Select DIAGNOSTIC TROUBLE CODES.
5. Turn ignition switch to ON position.
6. Follow operating instructions from scan tool menu.

KOEO & KOER Self-Test Codes

Record codes in order received. These codes indicate current faults in system and should be serviced in order of appearance. Use DTC IDENTIFICATION table to identify correct SYSTEM TEST to perform.

Pass Codes

SYSTEM PASS indicates no diagnostic trouble codes were recorded in that portion of test. If SYSTEM PASS is not retrieved in KOEO SELF-TEST, codes retrieved during KOER SELF-TEST may not be valid.

Continuous Memory Codes

These codes result from information stored by PCM during continuous self-test monitoring. Use these codes for diagnosis only when KOEO SELF-TEST and KOER SELF-TEST result in SYSTEM PASS and all steps in QUICK TEST are successfully completed. These codes indicate faults previously recorded. Fault may or may not be currently present. See DTC IDENTIFICATION table.

DTC IDENTIFICATION

CLEARING CODES

PCM Reset

After a PCM reset procedure, the following conditions will be met

1. All DTCs cleared from PCM memory.
2. All freeze frame data cleared from PCM memory.
3. All oxygen sensor test data cleared from PCM memory.
4. OBD-II system monitor status is reset.
5. DTC P1000 set in PCM memory.

To perform PCM reset using NGS scan tool, ensure connectors are properly connected. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool (optional).
3. Follow operating instructions from scan tool menu.
4. Select GENERIC OBD-II FUNCTIONS. Press CONT button if monitors are not complete.
5. Turn ignition switch to ON position.
6. Select CLEAR DIAGNOSTIC CODES.

All codes should now be cleared from PCM memory. If problem has not been corrected or fault is still present, hard code will immediately be reset in PCM memory.

Note. KOER self-test failure or TOOL COMMUNICATION ERROR message could result if a failure is present in MAF sensor, TR sensor, VSS or related circuits.

Perform this test when instructed during QUICK TEST or if directed here by other test procedures. This test is used to diagnose the following

1. Standard Corporate Protocol (SCP) communication circuits BUS (+) and BUS (-).
2. Wiring harness circuits (CHASSIS GROUND, PWR GND and VBAT).
3. Faulty Powertrain Control Module (PCM).

Scheme 132

Scheme 133

1. Verify Self-Test Procedure Is Correct This DTC indicates «KOER SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koer-self-test) cannot be completed. Ensure scan tool is correctly attached to DLC, located under dash panel. Ensure scan tool is not damaged or defective. If equipped with PTO, ensure PTO switch/actuator is in OFF position. Verify correct procedure was used to activate continuous memory, KOEO or KOER self-test. Correct as necessary. If no faults are found, go to next step.
2. Check VREF At Throttle Position (TP) Sensor Turn ignition switch to OFF position. Disconnect TP sensor. Turn ignition switch to ON position. Measure voltage between SIG RTN terminal and VREF terminal at TP sensor wiring harness connector. (Scheme 133) If voltage is 4-6 volts, go to next step. If voltage is not 4-6 volts, see TEST C in SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE.
3. Ability To Access Continuous Memory Codes If continuous memory codes are accessible, go to next step. If continuous memory codes are not accessible, go to step 7.
4. Ability To Activate KOEO Self-Test If KOEO self-test can be activated, go to next step. If KOEO self-test cannot be activated, go to step 6.
5. Ability To Activate KOER Self-Test If KOER self-test can be activated, DTC is false. Obtain PCM part number and check manufacturer for correct PCM application. If KOER self-test cannot be activated, go to next step.
6. Retrieve Any Continuous Memory Codes Perform «CONTINUOUS MEMORY SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__continuous-memory-self-test) under QUICK TEST. If any continuous memory codes are present, service DTCs as necessary before continuing. If unable to retrieve any continuous memory codes, go to next step.
7. Check Voltage To Data Link Connector (DLC) Inspect DLC for damage and repair as necessary. Turn ignition switch to ON position. Measure voltage between terminal No. 16 (B+) at DLC and engine ground. (Scheme 132) If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in B+ circuit.
8. Check DLC Ground Circuit Continuity Turn ignition switch to OFF position. Measure resistance between terminal No. 4 (CHASSIS GROUND ) at DLC and chassis ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in CHASSIS GROUND circuit.
9. Check DLC PWR GND Circuit Continuity Turn ignition switch to OFF position. Measure resistance between terminal No. 5 (PWR GND) at DLC and negative battery terminal. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in PWR GND circuit to DLC.
10. Perform Data Link Diagnostic Network Test Turn ignition switch to ON position. Using scan tool, perform DATA LINK DIAGNOSTICS. If PCM: NO RESPONSE/NOT EQUIPPED, PCM: NO RESPONSE CKT914 (BUS-) or PCM: NO RESPONSE CKT915 (BUS+) message is displayed, go to next step. If none of the specified messages are displayed, no problem is indicated at this time. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
11. Check Network Test Results If scan tool displayed CKT 914=ALL MODULE NO RESP/NOT EQUIP or CKT915=ALL MODULE NO RESP/NOT EQUIP message after performing DATA LINK DIAGNOSTICS test, proceed as follows: If only CKT 914=ALL MODULE NO RESP/NOT EQUIP message is displayed, go to step 12. If only CKT 915=ALL MODULE NO RESP/NOT EQUIP message is displayed, go to step 15. If both CKT 914=ALL MODULE NO RESP/NOT EQUIP and CKT915=ALL MODULE NO RESP/NOT EQUIP messages are displayed, repair open to BUS+ and BUS- circuits or repair short between BUS+ and BUS- circuits and all associated modules. If scan tool did not display CKT 914=ALL MODULE NO RESP/NOT EQUIP or CKT915=ALL MODULE NO RESP/NOT EQUIP message after performing DATA LINK DIAGNOSTICS test, proceed as follows: If CKT914=SOME MODULE NO RESP/NOT EQUIP or PCM: NO RESPONSE ON CKT 914 (BUS+) message is displayed, go to step 14. If CKT915=SOME MODULE NO RESP/NOT EQUIP or PCM: NO RESPONSE ON CKT 915 (BUS-) message is displayed, go to step 17.
12. Check BUS(+) Circuit For Short To Ground Turn ignition switch to OFF position. Disconnect PCM 104-pin connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between chassis ground and PCM connector terminal No. 16 (BUS+). If resistance is more than 50 ohms, go to next step. If resistance is 50 ohms or less, a short to ground in BUS(+) circuit or associated modules exists. See appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT.
13. Check BUS(+) Circuit For Short To Power Turn ignition switch to ON position. Measure voltage between PCM connector terminal No. 16 (BUS+) and chassis ground. If voltage is one volt or less, go to next step. If voltage is more than one volt, a short to power in BUS(+) circuit or associated modules exists. See appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT.
14. Check BUS(+) Circuit Continuity Turn ignition switch to OFF position. Measure resistance of BUS(+) circuit between PCM connector terminal No. 16 and 2 at DLC. (Scheme 132) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in BUS(+) circuit to DLC.
15. Check For Short To Ground Ensure PCM is disconnected. Measure resistance between PCM connector terminal No. 15 and chassis ground. If resistance is more than 50 ohms, go to next step. If resistance is 50 ohms or less, a short to ground in BUS(-) circuit or associated modules exists. See appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT.
16. Check For Short To Power Turn ignition switch to ON position. Measure voltage between PCM connector terminal No. 15 and chassis ground. If voltage is 6 volts or less, go to next step. If voltage is more than 6 volts, repair a short to power in BUS(-) circuit or associated modules exists. See appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT.
17. Check BUS(-) Circuit Turn ignition switch to OFF position. Measure resistance of BUS(-) circuit between PCM connector terminal No. 10 and 15 at DLC. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in BUS(-) circuit to DLC.
18. Power Take Off (PTO) Applications If vehicle is equipped with PTO, go to next step. If vehicle is not equipped with PTO, replace PCM.
19. Check PTO On/Off Input Turn ignition switch to ON position. While toggling PTO switch/actuator switch, measure voltage between breakout box pins No. 4 (PTO) and 51 or 103 (PWR GND). If voltage is less than one volt with PTO off, and more than one volt with PTO on, PTO circuit is okay. Replace PCM. If voltage is not as specified, see TEST FB in SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE.

ADDITIONAL SYSTEM FUNCTIONS

These additional diagnostic system features are available to help diagnose driveability problems and service EEC-V systems

1. «GENERIC OBD-II PARAMETER IDENTIFICATION (PID)»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__generic-obd-ii-parameter-identification-pid)
2. «NON-GENERIC OBD-II PARAMETER IDENTIFICATION (PID)»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__non-generic-obd-ii-parameter-identification-pid)
3. «ON-BOARD SYSTEM READINESS (OSR) TEST MODE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__on-board-system-readiness-osr-test-mode)
4. «FREEZE FRAME DATA MODE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__freeze-frame-data-mode)
5. «OXYGEN SENSOR TEST MODE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__oxygen-sensor-test-mode)
6. «OUTPUT TEST MODE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__output-test-mode)

Generic OBD-II Parameter Identification (PID)

Turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool (optional).
3. Select GENERIC OBD-II OPTIONS. Press CONT button if monitors are not complete.
4. Select PID/DATA MONITOR.
5. Turn ignition switch to ON position or start engine and allow to idle.
6. Follow operating instructions from scan tool menu.
7. Select PIDs and press START.

Non-Generic OBD-II Parameter Identification (PID)

Turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu.
2. Select year, engine, model and any additional information requested by scan tool.
3. Select GENERIC OBD-II OPTIONS. Press CONT button if monitors are not complete.
4. Select DIAGNOSTIC DATA LINK.
5. Select PCM - POWERTRAIN CTRL MODULE.
6. Select DIAGNOSTIC TEST MODES.
7. Select PID DATA MONITOR AND RECORD.
8. Turn ignition switch to ON position or start engine and allow to idle.
9. Follow operating instructions from scan tool menu.
10. Select PIDs and press START.

On-Board System Readiness (OSR) Test Mode

All OBD-II scan tools must display OSR test. The OSR will display monitors on the vehicle and status of all monitors; complete or not complete. If not complete, the scan tool will display which monitor has not completed. To enter OSR, turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool.
3. Follow operating instructions from scan tool menu.
4. Select GENERIC OBD-II FUNCTIONS. Press TEST button if all OBD-II monitors are not complete.
5. Start engine and allow to idle.
6. Select ON-BOARD SYSTEM READINESS.

Freeze Frame Data Mode

This mode allows access to emission related data values from some generic PIDs. These values are immediately stored in continuous memory when an emission related fault occurs. This provides a snapshot of the conditions that were present when the fault occurred. Freeze frame will be stored until PCM memory is erased. To access FREEZE FRAME DATA MODE, turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool (optional).
3. Follow operating instructions from scan tool menu.
4. Select GENERIC OBD-II FUNCTIONS. Press CONT button if OBD-II monitors are not complete.
5. Turn ignition switch to ON position.
6. Select FREEZE FRAME PID TESTS.

Oxygen Sensor Test Mode

This mode allows access to on-board sensor fault limits and actual values during test cycle. The test cycle has specific engine operating conditions that must be met for completion. This information is used to determine the efficiency of the catalytic converter. To access OXYGEN SENSOR TEST MODE, turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu (optional).
2. Select year, engine, model and any additional information requested by scan tool (optional).
3. Follow operating instructions from scan tool menu.
4. Select GENERIC OBD-II FUNCTIONS.
5. Select OXYGEN SENSOR TESTS.
6. Select appropriate oxygen sensor test and follow menu instructions.

Output Test Mode

This mode allows a technician to energize and de-energize most of the system output actuators on command. After accessing OUTPUT TEST MODE, outputs and cooling fans can be turned on and off separately. To access OUTPUT TEST MODE, turn ignition switch to OFF position. Ensure test equipment is properly attached. Program scan tool using the following steps

1. Select vehicle and engine selection menu.
2. Select year, engine, model and any additional information requested by scan tool.
3. Follow operating instructions from scan tool menu.
4. Select DIAGNOSTIC DATA LINK.
5. Select PCM - POWERTRAIN CTRL MODULE.
6. Select DIAGNOSTIC TEST MODE.
7. Select ACTIVE COMMAND MODE.
8. Select OUTPUT TEST MODE.
9. Turn ignition switch to ON position.
10. Follow operating instructions from scan tool menu.
11. Select either LOW SPEED FAN, HIGH SPEED FAN or ALL ON MODE.
12. Select START to turn outputs on. This step may cause link-up to PIDs.
13. Select STOP to turn outputs off.

Failure Mode Effects Management (FMEM)

FMEM MODE allows system operation when sensors fail or transmit signals that are out of normal operating range. During FMEM MODE, PCM substitutes a mid-range signal for defective sensor while continuing to monitor sensor. If faulty sensor signals return to normal operating range, PCM will use those signals. Depending on specific failure, a fault code may be set in PCM memory.

Hardware Limited Operational Strategy (HLOS)

If a number of system or sensor failures are present and PCM is not receiving enough information to operate, PCM will switch to HLOS MODE. PCM will output fixed values to allow operation of vehicle. Driveability concerns will be present. PCM will not output diagnostic trouble codes in this mode.

TORQUE CONVERTOR ENGAGEMENT TEST

1. Connect tachometer. Warm engine to normal operating temperature. Ensure transmission fluid level is correct. Maintain about 50 MPH. Release throttle for about 2 seconds, then reapply to previous setting. Engine RPM should increase when throttle is released and decrease in about 5 seconds after throttle is reapplied. Go to next step.
2. Maintain about 50 MPH. Apply light pressure to brake pedal so that brake lights operate. Engine RPM should increase as brake pedal is tapped, and then decrease about 5 seconds after pedal is released. If torque converter clutch operation is not as specified, see TCC operation concerns listed in «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) .

TRANSMISSION DRIVE CYCLE TEST

Note. The transmission drive cycle test must be followed exactly. Malfunctions have to occur 4 times consecutively for Continuous Memory Codes P0731, P0732, P0733 and P0734 to set, and 5 times consecutively for Continuous Memory Codes P0741 and P1741 to set.

1. After repairing any engine performance related DTCs, erase remaining transmission codes. Warm engine to normal operating temperature. Ensure transmission fluid level is correct. Shift transmission to "D" position. Come to a full stop. Press TCS on shifter handle. O/D OFF light should illuminate.
2. Accelerate from stop to 40 MPH. Hold speed for at least 15 seconds (30 seconds above 4000 ft.). Decelerate and bring vehicle to a full stop. Press TCS and accelerate to 50 MPH. Hold speed and throttle position steady for at least 15 seconds (30 seconds above 4000 ft..
3. While maintaining speed with transmission in 4th gear, lightly depress brake pedal and release (to operate brakelights). Hold speed for at least an additional 5 seconds. Bring vehicle to stop for at least 20 seconds with transmission in drive "D" position. Repeat steps 1) - 3) at least 5 times. Perform «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) and record Continuous Memory Codes.

TRANSMISSION SOLENOID CYCLING & DRIVE TEST (DYNAMIC TEST)

Preliminary Set Up

Connect transmission tester. Install pressure gauge to line pressure tap. See LINE PRESSURE TESTS under SYSTEM TESTS in FORD 4R100 OVERHAUL article. Set Bench/Drive switch to DRIVE MODE. Set tester Gear Select switch to "1" position. Ensure vehicle is in park "P" position. Start vehicle.

EPC Solenoid

Record line pressure. Line pressure should go to maximum pressure. If line pressure is not within specification, see TEST E in SYSTEM TESTS or LINE PRESSURE TEST RESULTS under SYSTEM TESTS in FORD 4R100 OVERHAUL article. Depress EPC switch. Line pressure should drop to minimum pressure. If line pressure is not within specification, see TEST E in SYSTEM TESTS or LINE PRESSURE TEST RESULTS under SYSTEM TESTS in FORD 4R100 OVERHAUL article.

Engagements

1. Ensure Bench/Drive switch is in DRIVE MODE. Rotate Gear Select switch to "1" position. Move shift selector lever from "P" to "R" position. Reverse should engage. Depress EPC switch. Line pressure should drop to idle pressure. If EPC solenoid functions correctly, go to next step. If EPC solenoid does not function correctly, see «TEST E»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__test-e-epc-solenoid) in SYSTEM TESTS or LINE PRESSURE TEST RESULTS under SYSTEM TESTS in FORD 4R100 OVERHAUL article.
2. While depressing EPC switch, move shift selector lever from "P" to "D" position. Vehicle should shift into drive with smooth engagement. Release EPC switch. Line pressure should rise to maximum pressure. Repeat previous step. Vehicle shift engagement should be firm with EPC switch released. If EPC solenoid functions correctly, see SYMPTOM TESTS in FORD 4R100 OVERHAUL article for engagement concerns. If EPC solenoid does not function correctly, see «TEST E»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__test-e-epc-solenoid) in SYSTEM TESTS or LINE PRESSURE TEST RESULTS under SYSTEM TESTS in FORD 4R100 OVERHAUL article.

Upshift/Downshift

Note. Upshifts and downshifts will be firm during this procedure. LEDs will turn Green when solenoids are activated and turn off when deactivated.

Remove line pressure gauge. Set Gear Select switch to "1" position. Move shift selector lever to "OD" position and accelerate to 15 MPH. Rotate Gear Select switch to "2" position. Vehicle should shift into 2nd gear. Accelerate to 25 MPH and rotate Gear Select switch to "3" position. Vehicle should shift into 3rd gear. Accelerate to 35-45 MPH and rotate Gear Select switch to "4" position. Vehicle should shift into 4th gear. Downshift in reverse order. Vehicle should downshift through each gear. Ensure appropriate shift solenoid LED activates and deactivates with each upshift or downshift.

Torque Converter Engagement

Accelerate and upshift vehicle into 3rd gear. Maintain constant speed and depress TCC switch. Torque converter clutch should engage, engine RPM should decrease, and LED should light Green. If TCC solenoid functions correctly, see SYMPTOM TESTS in FORD 4R100 OVERHAUL article for TCC engagement concerns. If TCC solenoid does not function correctly, see TEST C in SYSTEM TESTS or TORQUE CONVERTER under COMPONENT TESTS in FORD 4R100 OVERHAUL article for TCC engagement concerns.

Coast Clutch Engagement

Accelerate and upshift vehicle into 3rd gear. Release throttle and depress CCS switch on tester. Coast clutch should engage and LED should light Green. Release CCS switch, CCS should deactivate. If CCS functions correctly, see SYMPTOM TESTS in FORD 4R100 OVERHAUL article for CCS engagement concerns. If CCS does not function correctly, see TEST G in SYSTEM TESTS or SHIFTING FAULTS under TROUBLE SHOOTING in FORD 4R100 OVERHAUL article for CCS engagement concerns.

Output Shaft Speed (OSS) Sensor & Transmission Speed Sensor (TSS) Function Check (If Equipped)

Note. On models equipped with Output Shaft Speed (OSS) sensor and Transmission Speed Sensor (TSS), OSS and TSS function check may be performed on hoist. To identify components, see WIRING DIAGRAMS .

Set voltmeter to 20 volts A/C. Connect voltmeter leads to appropriate TSS jacks. Slowly accelerate vehicle and monitor voltmeter reading. Voltage should increase with vehicle speed. If TSS voltage does not change as specified, see TEST F in SYSTEM TESTS.

Transmission Tester Removal & Clearing Trouble Codes

Disconnect Transmission Tester from transmission connector. Install vehicle wiring harness to transmission connector. Install all heat shields that were removed. Disconnect tester power lead from vehicle. See CLEARING CODES to erase any DTCs that were set. Perform QUICK TEST to determine if any DTCs are present.

SUMMARY

If no Diagnostic Trouble Code (DTC) is present and transmission engagement or shifting condition still exists, see TROUBLE SHOOTING in FORD 4R100 OVERHAUL article.

SYSTEM TESTS

Note. SYSTEM TESTS are diagnostic formats used to test and service EEC-V system. See SELF-DIAGNOSTICS - EEC-V article in ENGINE PERFORMANCE. QUICK TEST allows technician to identify problems and retrieve service codes. SYSTEM TESTS check transmission circuits, sensors, solenoids and actuators. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure.

Procedures in SYSTEM TESTS are written for the use of the following Ford Motor Co. test equipment

1. New Generation Star (NGS) Tester (007-00500)
2. 104-Pin Breakout Box (014-00950)
3. Transmission Tester (007-00130)

HOW TO USE SYSTEM TESTS

1. Ensure all non-EEC related faults found while performing TROUBLE SHOOTING steps in FORD 4R100 OVERHAUL article have been corrected. DO NOT perform any SYSTEM TEST unless specifically instructed by a QUICK TEST procedure. Follow each test step in order until fault is found. DO NOT replace any part unless directed here to do so. When more than one code is retrieved, start with first code displayed.
2. SYSTEM TESTS ensure electrical circuits are okay before sensors or other components are replaced. Always test circuits for continuity between sensor and PCM. Test all circuits for short to power, opens or short to ground. Voltage Reference (VREF) and Voltage Power (VPWR) circuits should be tested with KOEO or as specified in SYSTEM TESTS.
3. DO NOT measure voltage or resistance at PCM. DO NOT connect any test light unless specified in testing procedure. All measurements are made by probing rear of connector. Isolate both ends of a circuit and turn ignition switch to OFF position when checking for shorts or continuity, unless instructed otherwise.
4. Disconnect solenoids and switches from harness before measuring continuity and resistance or applying voltage. After each repair, check all component connections and repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) .
5. An open circuit is defined as a resistance reading of greater than 5 ohms. This specification tolerance may be too high for some items in EEC-V system. If resistance approaches 5 ohms, always clean suspect connector and coat it with protective dielectric silicone grease. A short is defined as a resistance reading of less than 10 k/ohms to ground, unless stated otherwise in SYSTEM TESTS.

Fuel-contaminated engine oil may set some codes and effect engine performance. If oil is suspect, remove PCV valve from valve cover and repeat QUICK TEST . If problem is corrected, change engine oil.

Scheme 134

1. Electronic Diagnosis Ensure transmission harness connector is in acceptable condition. Repair as necessary. Connect scan tool to Data Link Connector (DLC). Perform «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test) until Continuous Memory Code(s) have been displayed. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). Select OUTPUT TEST MODE on scan tool. Select ALL ON MODE and press START. If vehicle enters Output Test Mode (OTM), go to next step. If vehicle will not enter OTM, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Check Electrical Signal Operation Disconnect transmission 12-pin connector. Inspect condition of connector. Repair as needed. Using DVOM, connect positive lead to transmission harness connector VPWR terminal. (Scheme 134) Connect negative lead to suspect solenoid circuit. Press START and STOP to cycle solenoid output on and off. Solenoid output voltage should change to about battery voltage while cycling outputs. If solenoid output voltage is as specified, go to step 6. If solenoid output voltage is not as specified, go to next step.
3. Check Continuity Of Solenoid Signal & VPWR Circuits Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install appropriate breakout box, leaving PCM disconnected. Measure and record resistance between suspect shift solenoid breakout box pin and corresponding transmission harness connector terminal. (Scheme 134) Measure and record resistance between breakout box VPWR pin and appropriate transmission harness connector terminal. (Scheme 134) If any resistance is greater than 5 ohms, repair open circuit. Connect all components. Disconnect breakout box. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If each resistance is 5 ohms or less, go to next step.
4. Check Shift Solenoid Circuits For Shorts To Power Measure and record resistance between breakout box shift solenoids No. 1 and No. 2 PCM signal pins, and between breakout box EPC control power pin. (Scheme 134) If any resistance is less than 10 k/ohms, repair short to power. Connect all components. Disconnect breakout box. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If each resistance is 10 k/ohms or more, go to next step.
5. Check Shift Solenoid Circuits For Shorts To Ground Measure and record resistance between breakout box shift solenoids No. 1 and No. 2 PCM signal pins and ground. (Scheme 134) Measure and record resistance between breakout box pins No. 51, 76, 77, 91 and 103 and ground. If any resistance is less than 10 k/ohms, repair short to ground. Connect all components. Disconnect breakout box. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If each resistance is 10 k/ohms or more, go to next step.
6. Solenoid Functional Test Connect transmission tester to transmission 12-pin connector. Perform solenoid voltage test. See tester manufacturers instructions. If solenoid activates (LED Green), go to next step. If LED does not light (solenoid shorted to ground or open circuit), or indicates short to battery voltage (LED Red), go to step 8.
7. Transmission Drive Test Disconnect breakout box and reconnect PCM connector. Perform transmission tester drive test. See tester manufacturers instructions. If vehicle does not upshift when operated by tester, go to next step. If vehicle upshifts when operated by tester, erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If DTCs are still present, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
8. Check Resistance Of Solenoids Place tester Bench/Drive switch to BENCH MODE. Place Gear Select switch in OHMS CHECK position. Connect ohmmeter negative lead to SS1 terminal and positive lead to VPWR terminal on tester. Record resistance. Connect ohmmeter negative lead to SS2 terminal and positive lead to VPWR terminal on tester. Resistance for both solenoids should be 20-30 ohms. If resistance is within specification, go to next step. If resistance is not within specification, replace solenoid body assembly. Erase all codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
9. Check Solenoid For Short To Ground Check continuity between BAT (-) tester terminal and SS1 and SS2 tester terminals. Check continuity between BAT (-) tester terminal and each VPWR terminal on tester. If continuity exists for any circuit, replace solenoid body assembly. Erase all codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If continuity does not exist, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).

TEST B: TFT ELECTRICAL CIRCUIT

1. Electronic Diagnosis Ensure transmission 12-pin connector is fully seated and terminals are fully engaged in the connector. Inspect connector for damaged pins, corrosion and loose wires. Repair as necessary. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to ON position. Select DIAGNOSTIC DATA LINK. Select PCM. Select PID/DATA MONITOR AND RECORD. If vehicle enters PID/DATA MONITOR AND RECORD state, remain in PID/DATA CONTROL and go to next step. If vehicle does not enter PID/DATA MONITOR AND RECORD state, repeat procedure. If vehicle still will not enter PID/DATA MONITOR AND RECORD state, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Warm-Up/Cool-Down Cycle While monitoring TFT PIDs, perform the following test: If transmission is cold, run engine to warm up transmission. If transmission is warm, allow transmission to cool down. If TFT PIDs increase as transmission warms up or decrease as transmission is cooled, erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test) to verify condition is still present. If condition is still present, see «TRANSMISSION OVERHEATING»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-overheating) in SYMPTOM TESTS. If TFT or TFTV drop in and out of range, inspect for intermittent condition in internal or external harness, sensor or connector. If TFT PIDs do not increase as transmission warms up or decrease as transmission is cooled, go to next step.
3. Check Electrical Signal Operation Ensure ignition switch is turned to OFF position. Disconnect transmission 12-pin connector. Inspect condition of connector. Repair as needed. Using DVOM, connect positive lead to transmission harness connector terminal No. 7 and negative lead to terminal No. 8. (Scheme 134) Turn ignition switch to ON position. If voltage is 4.75-5.25 volts, go to step 7. If voltage is not within specification, go to next step.
4. Check Continuity Of TFT & PCM Signal Return (SIG RTN) Circuits Turn ignition switch to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install breakout box leaving PCM connector disconnected. Measure and record resistance between breakout box TFT pin No. 37 and transmission harness connector terminal No. 7. (Scheme 134) Measure and record resistance between breakout box PCM SIG RTN pin No. 91 and transmission harness connector terminal No. 8. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit. Remove breakout box and connect all components. Erase trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
5. Check TFT Circuit For Short To VPWR & Ground Ensure ignition switch is turned to OFF position and PCM connector is disconnected. Using DVOM, measure and record resistance between breakout box TFT pin No. 37 and breakout box VPWR pins No. 71 and 97. (Scheme 134) Measure and record resistance between breakout box TFT pin and breakout box pins No. 51, 76, 77, 91, 103, and chassis ground. If any resistance is less than 10 k/ohms, repair circuits as necessary. Disconnect breakout box, reconnect all connectors. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If each resistance is 10 k/ohms or more, go to next step.
6. Check Resistance Of TFT Sensor/Harness Install transmission tester. Set tester Bench/Drive switch to BENCH MODE. Set Solenoid Select switch to OHMS CHECK. Connect ohmmeter leads to appropriate TFT terminals on tester. Measure and record resistance. Resistance should be within specification. See «TFT TEMPERATURE/RESISTANCE SPECIFICATION»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. If resistance is within specification for specific temperature, either warm up transmission or allow transmission to cool to check resistance at different temperatures. If resistance remains within specification, go to next step. If resistance is not within specification, replace solenoid body assembly. Connect all components. Erase trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). TFT TEMPERATURE/RESISTANCE SPECIFICATION Temperature °F (°C) (K/ohms) Resistance -40 To -4 (-40 To -20) 284-1062 -3 To 31 (-19 To -1) 100-284 32-68 (0-20) 37-100 69-104 (21-40) 16-37 105-158 (41-70) 5-16 159-194 (71-90) 2.7-5 195-230 (91-110) 1.5-2.7 231-266 (111-130) 8-1.5 267-302 (131-150).54-.8
7. Check TFT Sensor For Short To Ground Check continuity between BAT (-) tester terminal and both TFT terminals. If continuity exists, replace solenoid body assembly. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If continuity does not exist, replace PCM. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If codes are still present, check transmission fluid condition. Check for overheat condition. See «TRANSMISSION OVERHEATING»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-overheating) in SYMPTOM TESTS.

TEST C: TCC ELECTRICAL CIRCUIT

1. Electronic Diagnostics Ensure transmission harness connector is in acceptable condition and fully seated in solenoid body connector. Repair as necessary. Install scan tool to DLC. Perform «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test) until Continuous Memory Code(s) have been displayed. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). Select OUTPUT TEST MODE (OTM), select ALL ON and press START to activate outputs. If vehicle enters OTM, remain in OTM and go to next step. If vehicle will not enter OTM, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Check Electrical Signal Operation Disconnect transmission 12-pin harness connector. Inspect condition of connector. Repair as needed. Using DVOM, connect positive lead to transmission harness connector VPWR terminal No. 1. (Scheme 134) Connect negative lead to TCC terminal No. 4. Press START then STOP to cycle solenoid output on and off. If voltage changes to battery voltage, go to step 6. If voltage does not change or is low, go to next step.
3. Check Continuity Of TCC Solenoid Signal & VPWR Harness Circuits Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install breakout box, leaving PCM disconnected. Measure and record resistance between breakout box TCC pin and transmission harness connector terminal No. 4. (Scheme 134) Measure and record resistance between transmission harness connector terminal No. 1. and breakout box VPWR pins No. 71 and 97. (Scheme 134) If resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit. Reconnect all connectors. Disconnect breakout box. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
4. Check TCC Circuit For Short To Power Measure and record resistance between appropriate breakout box TCC pin and breakout box VPWR pins No. 71 and 97. (Scheme 134) If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair open circuit. Disconnect breakout box. Reconnect all connectors. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
5. Check TCC Circuit For Short To Ground Measure and record resistance between appropriate breakout box TCC pin and breakout box pins No. 51, 76, 77, 91, 103, and chassis ground. If all resistances are more than 10 k/ohms, go to next step. If any resistances are 10 k/ohms or less, repair short circuit(s). Disconnect breakout box. Reconnect all connectors. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
6. Solenoid Functional Test Connect transmission tester to transmission connector. Perform solenoid voltage test. See tester manufacturers instructions. If solenoid activates (LED Green), go to next step. If LED does not light (solenoid shorted to ground or open circuit), or indicates short to battery voltage (LED Red), go to step 8.
7. Transmission Drive Test Reconnect PCM connector. Perform transmission tester drive test. See tester manufacturers instructions. If TCC solenoid activates (LED Green) and engine RPM decreases when operated with tester, replace PCM. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If codes are still present, see «NO TCC ENGAGEMENT»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__no-tcc-engagement), «TCC ALWAYS ENGAGED»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__tcc-always-engaged) or «TCC CYCLING OR SHUDDERING»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__tcc-cycling-or-shuddering) in SYMPTOM TESTS. If engine RPM does not decrease when operated by tester, go to next step.
8. Check Resistance Of TCC Solenoid Set tester Bench/Drive switch to BENCH MODE. Set Select switch on tester to OHMS CHECK. Connect ohmmeter negative lead to transmission tester TCC terminal and positive lead to VPWR terminal. Measure and record resistance. Resistance should be 20-30 ohms for gasoline vehicles and 10-20 ohms for diesel vehicles. If resistance is within specification, go to next step. If resistance is not within specification, replace solenoid body assembly. Erase all trouble codes. Road test vehicle. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
9. Check Solenoid For Short To Ground Check continuity between BAT (-) tester terminal and both TCC terminals. If continuity exists, replace solenoid body assembly. Erase all trouble codes. Road test vehicle. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If continuity does not exist, see «NO TCC ENGAGEMENT»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__no-tcc-engagement), «TCC ALWAYS ENGAGED»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__tcc-always-engaged) or «TCC CYCLING OR SHUDDERING»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__tcc-cycling-or-shuddering) in SYMPTOM TESTS.

TEST D: DIGITAL TRANSMISSION RANGE (TR) SENSOR

Note. DTC P1705 may be set if transmission is not in "P" or "N" position when QUICK TEST is performed.

Scheme 135

Scheme 136

1. Verify Digital Transmission Range Sensor Alignment Turn ignition switch to OFF position. Place shift selector lever in "P" position. Ensure TR sensor connector is fully seated, terminals are fully engaged in connector and in good condition. Repair as necessary. Apply parking brake. Verify shift linkage is adjusted properly in "OD" position. Ensure TR sensor is correctly adjusted. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING. If sensor is correctly adjusted, go to next step. If sensor requires adjustment, clear trouble codes after adjustment. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
2. Check Electrical Signal Operation Place shift selector lever in "P" position. Disconnect TR sensor connector. Inspect both ends of connector for damage or pushed out pins, corrosion, loose wires and missing or damaged seals. If connector is okay and you are directed here to diagnose a DTC, go to next step. If diagnosing a starting problem, back-up lights condition or engagement condition, go to step 8. If connector needs repair, repair as necessary and clear trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
3. Check Electrical System Operation (Digital TR Sensor & PCM) Ensure ignition switch is turned to OFF position. Connect scan tool to DLC. Reconnect TR sensor. Turn ignition switch to ON position. Select TR PIDs TR and TR_D on scan tool. See «TR SENSOR PID OUTPUT SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. While observing scan tool display, move shift selector lever to each position and wiggle TR sensor wiring harness connector and tap on TR sensor lightly. If PID values do not change during wiggle or tap tests, TR sensor is okay. Diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If PID values change during wiggle or tap tests, go to next step. TR SENSOR PID OUTPUT SPECIFICATIONS Shift Selector Position TR PID TR _ D PID "P" P/N 0000 "R" REV 1100 "N" NTRL 0110 "D" OD (1) 1111 "2" MAN2 1001 "1" MAN1 0011 (1) PID will read DRIVE if OD cancel switch is ON.
4. Check Digital TR Sensor Operation Disconnect TR sensor connector. Connect TR "E" Cable and transmission tester to TR sensor. (Scheme 135) Install TR Sensor Overlay onto the tester. Perform TR sensor test as instructed on overlay. If TR "E" cable status lights match each selected gear position, TR sensor is okay. Go to next step. If TR "E" cable status lights do not match each selected gear position, replace and adjust TR sensor. See FORD MOTOR CO. AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING for adjustments. Clear DTCs. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
5. Check PCM Harness Circuits For Opens Turn ignition switch to OFF position. Ensure TR sensor is disconnected. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install breakout box, leaving PCM disconnected. Measure and record resistance between each specified breakout box pin and appropriate TR sensor harness connector terminal. See «TR SENSOR CIRCUIT IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. (Scheme 136) If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit. Remove breakout box and connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). TR SENSOR CIRCUIT IDENTIFICATION TR Sensor Terminal No. Circuit Description PCM/BOB Pin No. 1 Not Used N/A 2 Sensor Signal Return 91 3 Tray 64 4 TR1 (1) 17 Or (2) 34 5 TR2 49 6 TR4 50 7 Ground N/A 8 Neutral N/A 9 Ignition Switch N/A 10 Starter N/A 11 Back-Up Lights N/A 12 Starter Relay N/A (1) Applies to 7.3L (49-State) DI diesel models only. (2) Applies to all gasoline and 7.3L (Cal.) DI diesel models only.
6. Check PCM Circuits For Short To Power Or Ground Ensure TR sensor harness connector is disconnected. Measure resistance between specified breakout box pins. See «TR SENSOR/PCM CIRCUIT CHECK»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. If each measurement is more than 10 k/ohms, go to next step. If any measurement is less than 10 k/ohms, repair short circuit(s). Remove breakout box and connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). TR SENSOR/PCM CIRCUIT CHECK Application Measure Between BOB Terminals No. Gasoline & CNG Models Short To Power 71, 97 & 34, 49, 50, 64, 91 Short To Ground 34, 49, 50, 64 & 51, 76, 77, 91, 103 Diesel Models Short To Power 71, 97 & 17, 49, 50, 64, 91 Short To Power 17, 49, 50, 64 & 51, 76, 77, 91, 103
7. Check For Short Between TR/PCM Input Signal Wires Measure resistance between breakout box pins No. 34, 49, 50 and 64 on gasoline and CNG models (terminals No. 17, 49, 50 and 64 on diesel models). On all models, if each resistance is more than 10 k/ohms, replace PCM. Reconnect all connectors, clear DTCs. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If any resistance is 10 k/ohms or less, repair short circuit(s). Reconnect all connectors, clear DTCs. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
8. Check Non-PCM Internal TR Sensor Circuits Connect TR "E" Cable marked DIGITAL and transmission tester to TR sensor. (Scheme 135) Install DIGITAL TR Sensor Overlay onto transmission tester. Perform switch test as instructed on DIGITAL TR sensor overlay. If transmission tester status light does not turn Red, replace and adjust TR sensor. If transmission tester light turns Red, TR sensor is okay. For back-up lights concerns, see BACK-UP LIGHTS article in ACCESSORIES & EQUIPMENT. For 4WD Low condition, see «TEST TG»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__test-tg-4wd-low-4x4l-range). For neutral-sense and starting concerns, see SELF-DIAGNOSTICS - EEC-IV article in ENGINE PERFORMANCE.

TEST E: EPC SOLENOID

1. Electronic Diagnostics Ensure transmission harness connector is fully seated, terminals are engaged in connector and in good condition. Repair as necessary. Install scan tool to DLC. Perform «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test) until Continuous Memory Code(s) have been displayed. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). Select OUTPUT TEST MODE (OTM), select ALL ON MODE and press START to activate outputs. If vehicle enters OTM, remain in OTM and go to next step. If vehicle will not enter OTM, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Check Electrical Signal Operation Disconnect transmission 12-pin harness connector. Inspect condition of connector. Repair as needed. Using DVOM, connect positive lead to transmission harness connector EPC VPWR terminal No. 12. Connect negative lead to EPC signal terminal No. 11. (Scheme 134) Press START then STOP on scan tool to cycle solenoid output. If voltage changes to battery voltage, go to step 5. If voltage is not as specified, go to next step.
3. Check Continuity Of Solenoid Signal & VPWR Harness Circuit Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install breakout box, leaving PCM disconnected. Measure and record resistance between breakout box VPWR pins No. 71 and 97 and transmission harness connector EPC VPWR terminal No. 12. (Scheme 134) Measure and record resistance between breakout box PCM Signal pin No. 81 and transmission harness connector EPC signal terminal No 11. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit(s). Disconnect breakout box. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
4. Check Harness For Short To Power Or Ground Measure and record resistance between breakout box PCM Signal pin No. 81 and breakout box VPWR pins No. 71 and 97. (Scheme 134) Measure and record resistance between breakout box PCM Signal pin No. 81 and PCM breakout box ground pins No. 51, 76, 77, 91 and 103. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, repair short circuit(s). Disconnect breakout box. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
5. EPC Functional Test Reconnect PCM connector. Disconnect transmission 12-pin harness connector. Connect transmission tester to transmission connector. Connect line pressure gauge. See LINE PRESSURE TESTS in FORD 4R100 OVERHAUL article. Set Bench/Drive switch to DRIVE MODE. Set Gear Select switch on transmission tester to "1" position. Perform EPC function test. See transmission tester instructions. With engine running, observe line pressure on gauge while depressing EPC switch. EPC solenoid should activate (LED Green) and line pressure should drop when EPC switch is depressed. If solenoid operates correctly, replace PCM. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If solenoid does not operate, LED does not light (solenoid shorted to ground or open circuit), or indicates short to battery voltage (LED Red), go to next step.
6. Check Resistance Of Solenoid Ensure tester power is off. Set Bench/Drive switch to BENCH MODE. Set Gear Select switch on transmission tester to OHMS CHECK position. Connect ohmmeter negative lead to VPWR terminal. Connect positive lead to EPC terminal. If resistance is 3-5 ohms, go to next step. If resistance is not within specifications, replace solenoid body assembly. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
7. Check Solenoid For Short To Ground Check continuity between transmission tester BAT (-) terminal and EPC and EPC VPWR terminals on transmission tester. If continuity exists, replace solenoid body assembly. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If continuity does not exist, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).

TEST F: TURBINE SHAFT SPEED (TSS) & OUTPUT SHAFT SPEED (OSS) SENSORS

1. Electronic Diagnostics Ensure transmission 12-pin connector is fully seated, terminals are fully engaged in connector and in good condition. Repair as necessary. Install scan tool to DLC. Turn ignition switch to ON position. On scan tool, select DIAGNOSTIC DATA LINK. Select PCM. Select PID/DATA MONITOR AND RECORD MODE. Select OSS and TSS PIDS. If vehicle enters PID DATA MONITOR AND RECORD MODE, remain in PID DATA MONITOR AND RECORD and go to next step. If vehicle does not enter PID DATA MONITOR AND RECORD MODE, repeat procedure. If vehicle will still not enter mode correctly, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Drive Cycle Test While monitoring appropriate sensor PID, drive vehicle through all upshifts and downshifts. Use the following list to diagnosis OSS and TSS sensors: If OSS or TSS sensor PIDs increase with engine and vehicle speed, erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes) . Repeat road test to verify condition is still present. If condition is still present, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If OSS or TSS sensor PIDs do not increase or decrease with engine or vehicle speed, inspect for open or short in vehicle harness, sensor, a PCM condition or internal hardware condition. If OSS or TSS sensor signal is erratic, inspect for intermittent condition in internal/external harness, sensor or connector. If OSS or TSS sensor signal is steady, go to next step.
3. Check OSS & TSS Sensor Resistance Disconnect suspect OSS or TSS sensor harness connector. Using DVOM, measure resistance between terminals of suspect OSS or TSS sensor. Use «OSS & TSS SENSOR RESISTANCE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table for sensor resistances. If resistance is as specified, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If resistance is not as specified, replace affected sensor. OSS & TSS SENSOR RESISTANCE Sensor Resistance (Ohms) OSS Sensor (All Applications) 781-1979 TSS Sensor PTO Application 496-1244 Except PTO Application 781-1979

TEST G: COAST CLUTCH SOLENOID (CCS) SOLENOID

Note. If vehicle is equipped with PTO, PTO must be turned OFF.

1. Electronic Diagnostics Ensure transmission harness connector is fully seated, terminals are fully engaged in connector and in good condition. Repair as necessary. Connect scan tool to DLC. Perform «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test) until Continuous Memory Code(s) have been displayed. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). Select OUTPUT TEST MODE (OTM) on scan tool. Select ALL ON MODE and press START. If vehicle enters OTM, go to next step. If vehicle will not enter OTM, see «SCAN TOOL UNABLE TO COMMUNICATE»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) in DIAGNOSIS & TESTING.
2. Check Electrical Signal Operation Disconnect transmission 12-pin harness connector. Inspect condition of connector. Repair as needed. Using DVOM, connect positive lead to transmission harness connector VPWR terminal No. 1. Connect negative lead to CCS signal terminal No. 5. (Scheme 134) While observing DVOM, press START then STOP on scan tool to cycle solenoid output. If voltage changes to about battery voltage, go to step 5. If voltage does not change, go to next step.
3. Check Continuity Of CCS Solenoid Signal & VPWR Circuits Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged pins, corrosion and loose wires. Repair as necessary. Install breakout box, leaving PCM disconnected. Using DVOM, measure and record resistance between transmission harness connector terminal No. 5 and breakout box CCS solenoid signal pin No. 20 (gasoline vehicles) or No. 53 (diesel vehicles). (Scheme 134) Measure and record resistance between transmission harness connector terminal No. 1 and breakout box VPWR pins No. 71 and 97. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit(s). Disconnect breakout box. Reconnect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
4. Check CCS Circuit For Shorts To Power Or Ground Measure and record resistance between breakout box CCS solenoid signal pins No. 20 (gasoline vehicles) or No. 53 (diesel vehicles) and breakout box VPWR pins No. 71 and No. 97. (Scheme 134) Measure and record resistance between breakout box pin No. 20 (gasoline vehicles) or No. 53 (diesel vehicles), and breakout box pins No. 51, 76, 77, 91, 103, and chassis ground. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, repair short circuit(s). Disconnect breakout box. Reconnect all connectors. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
5. CCS Solenoid Functional Test Ensure ignition switch is turned to OFF position. Reconnect PCM connector. Disconnect transmission 12-pin harness connector. Connect transmission tester. Perform CCS voltage test. See tester instructions. If CCS solenoid activates (LED Green), go to next step. If solenoid does not operate, LED does not light (solenoid shorted to ground or open circuit), or indicates short to battery voltage (LED Red), go to step 7.
6. Transmission Drive Test While driving vehicle, perform CCS Dynamic Function Test. See tester instructions. If CCS solenoid activates (LED Green) and engine braking occurs, replace PCM and erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If condition is still present, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If CCS solenoid does not activate (no engine braking), go to next step.
7. Check Resistance Of Solenoid Ensure tester power is off. Set Bench/Drive switch to BENCH MODE. Set Gear Select switch on transmission tester to OHMS CHECK position. Connect ohmmeter to both CCS terminals on tester. If resistance is 20-30 ohms, go to next step. If resistance is not within specifications, replace solenoid body assembly. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
8. Check Solenoid For Short To Ground Check continuity between transmission tester BAT (-) terminal and both CCS terminals on transmission tester. If continuity exists, replace solenoid body assembly. Connect all components. Erase all trouble codes. See «CLEARING CODES»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__clearing-codes). Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If continuity does not exist, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).

TEST H: SOLENOID MECHANICAL FAILURE

Note. Repair all other DTCs before repairing the following DTCs: P1714, P1715 and P1740.

1. Electronic Diagnostics Ensure transmission harness connector is fully seated, terminals are fully engaged in connector and in good condition. Repair as necessary. Connect scan tool to DLC. Perform KOEO test until Continuous Memory Code(s) have been displayed. See «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If DTCs P1714, P1715 and/or P1740 are the only codes set, replace solenoid body assembly and go to next step. If any other DTCs are set, repair them first. Clear DTCs and perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test) . Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) and ensure no codes are set.
2. Transmission Drive Cycle Test Perform «TRANSMISSION DRIVE CYCLE TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__transmission-drive-cycle-test) . Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If vehicle upshifts and downshifts normally, go to next step. If vehicle does not shift normally, diagnose problem by symptom. See «SYMPTOM TESTS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) .
3. Retrieve DTCs Repeat «KOEO SELF-TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission__koeo-self-test) until Continuous Memory Code(s) are displayed. If DTCs P1714, P1715 and/or P1740 is reset, replace PCM. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If DTCs P1714, P1715 and P1740 are not reset and shifting problems still exist, electronic control system is okay. See TROUBLE SHOOTING in FORD 4R100 OVERHAUL article for mechanical diagnosis.

TEST TB: TRANSMISSION CONTROL SWITCH (TCS) & TRANSMISSION CONTROL INDICATOR LAMP (TCIL)

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs. Repeat QUICK TEST procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

Perform this test when instructed during QUICK TEST or if directed here by other test procedures. This test is used to diagnose the following

1. Wiring harness circuits (TCIL and TCS).
2. Faulty Powertrain Control Module (PCM).

Scheme 137

1. DTC P1780 This DTC indicates Transmission Control Switch (TCS) was not cycled during KOER self-test. Possible causes are: Faulty TCS. TCS not cycled during self-test. Open or short in wiring harness. Faulty PCM. Turn ignition switch to ON position. Using scan tool, select TCS PID. Cycle TCS switch, then hold switch depressed. If PID value switched from ON to OFF, then indicated ON when switch was depressed, repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) to cycle TCS. If PID value is not as specified, go to next step.
2. Check TCS Circuit Voltage Turn ignition switch to OFF position. Disconnect PCM 104-pin connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Measure voltage between PCM harness connector terminal No. 29 (TCS) and negative battery terminal while cycling TCS. If voltage reading does not cycle when TCS is cycled, go to next step. If voltage reading cycles when TCS is cycled, replace PCM. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission).
3. Check Circuit For Short To Ground Turn ignition switch to OFF position. Disconnect TCS connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between PCM harness connector terminal No. 29 (TCS) and negative battery terminal. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in TCS circuit.
4. Check Continuity Of TCS Circuits Connect ohmmeter positive lead to TCS key power at the fuse panel. Connect negative lead to power terminal at TCS wiring harness connector. Note resistance reading. Measure resistance between PCM harness connector terminal No. 29 (TCS) and TCS terminal at TCS wiring harness connector. If both resistance readings are less than 5 ohms, go to next step. If either resistance reading is 5 ohms or more, repair open TCS circuit.
5. Check Circuit For Short To Power Measure resistance between PCM harness connector terminals No. 29 (TCS) and 71 (VPWR). If resistance is more than 10 k/ohms, replace TCS. If resistance is 10 k/ohms or less, repair short to power in TCS circuit.
6. Check TCIL PID Turn ignition switch to ON position. Using scan tool, select TCIL PID. Cycle TCS. If PID value changes from ON to OFF, fault is intermittent. Go to «TEST Z»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If PID value does not change from ON to OFF, go to next step.
7. Check For Short To Ground In TCIL Circuit Ensure PCM 104-pin connector is disconnected. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. If TCIL turns off, replace PCM. If TCIL remains on, repair short to ground in TCIL circuit.
8. Check For DTC P1780 Perform «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If DTC P1780 is not present, go to next step. If DTC P1780 is present, go to step 1.
9. Check Voltage To TCIL Turn ignition switch to OFF position. Disconnect PCM 104-pin connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. Measure voltage between TCIL PCM connector terminal and negative battery terminal. (Scheme 137) If voltage is more than 2 volts, replace PCM. If voltage is 2 volts or less, check indicator bulb and fuse. Repair as necessary. If bulb and fuse are okay, repair open in circuit between PCM harness connector terminal and ignition switch.

TEST TG: 4WD LOW (4x4L) RANGE

Note. After each service or repair procedure has been completed, reconnect all components. Clear DTCs. Repeat QUICK TEST procedures to ensure all EEC-V systems are working properly and DTCs are no longer present.

Perform this test when instructed during QUICK TEST or if directed here by other test procedures. This test is used to diagnose the following

1. Electronic shift control module wiring harness circuits. (Scheme 138)and (Scheme 139).
2. Powertrain Control Module (PCM).

Note. Electronic shift control module is also referred to as Generic Electronic Module (GEM).

Scheme 138

Scheme 139

1. DTC P1729 & P1781 DTC P1729 indicates open or short in 4WD switch circuit. DTC P1781 indicates 4WD LOW switch position closed during QUICK TEST. If switch position was not 2WD or 4WD HIGH during KOEO SELF-TEST, select 2WD or 4WD HIGH. Repeat «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission). If switch position was as specified, go to next step.
2. Check Intermittent Circuit Failure Using scan tool, select 4WD LOW PID. Turn ignition switch to ON position. Cycle 4WD LOW switch to 2WD. Check for indication of fault while performing the following: Wiggle and bend small sections of wiring harness starting at transfer case working toward PCM. Lightly tap on transfer case wiring harness connector. Wiggle and bend small sections of wiring harness starting at instrument cluster working toward PCM. Fault will be indicated by PID value changing (ON/OFF). If any faults are found, isolate fault. Repair as necessary. If no faults are found, go to next step.
3. Check Signal From PCM Turn ignition switch to OFF position. Disconnect PCM 104-pin connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition switch to ON position. While cycling 4WD LOW switch, measure voltage between PCM harness connector terminal No. 14 and negative battery terminal. If voltage cycles, replace PCM. If voltage does not cycle, go to next step.
4. Check 4WD LOW Circuit Continuity Turn ignition switch to OFF position. Disconnect electronic shift control module. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Measure resistance between PCM connector terminal No. 14 and 4WD LOW terminal at electronic shift control module harness connector. (Scheme 138) If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in 4WD LOW circuit.
5. Check For Short To Power Or Ground Reconnect electronic shift control module. Measure resistance between PCM harness connector terminal No. 14 and negative battery terminal. Measure resistance between PCM harness connector terminals No. 14 and 71 (VPWR). If both resistance readings are more than 10 k/ohms, 4WD LOW circuit is okay. Check transfer case for mechanical fault. If any resistance reading is 10 k/ohms or less, repair short in 4WD LOW circuit.

Perform this test when instructed during QUICK TEST or if directed here by other test procedures. This system test is intended to diagnose and isolate intermittent concerns for the following

1. All engine control sub-systems.
2. Vehicles with coil pack ignition systems.

The intermittent test table is used to determine which test to perform for the suspect circuit. See INTERMITTENT TEST table. Corresponding Parameter Identification (PIDs) for each circuit are listed. Some circuits do not have an associated PID and can be measured with a Digital Volt-Ohmmeter (DVOM). If vehicle has coil pack ignition system with a no-start condition, perform ignition test. Go to step 21 .

INTERMITTENT TEST

1. Direction For Intermittent Diagnostic Path There are 2 main procedures used in this system test to isolate. Repair an intermittent condition. One procedure uses the Rotunda Distributorless Ignition System (DIS) Tester (007-00075) and the other uses a scan tool and a Digital Volt-Ohmmeter (DVOM). The distributorless ignition system tester is used on vehicles with coil pack ignition systems. If vehicle has a ignition condition and is equipped with coil pack ignition, go to step 21 . If vehicle is not as described, go to next step.
2. Perform PCM Reset Procedure If PCM reset procedure has already been performed, go to next step. If PCM reset procedure has not been performed, perform appropriate COMPUTER RELEARN PROCEDURE in APPLICATIONS & IDENTIFICATION. Ensure freeze frame data has been recorded before resetting PCM. After performing PCM reset procedure, go to next step.
3. Select PIDs Related To Symptom Scan tool and a list of PIDs must be used to indicate area of fault. Obtain symptom from customer description. Use REFERENCE VALUE SYMPTOM table and REFERENCE VALUE/PID MEASUREMENT SIGNAL table in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE to identity PIDs that relate to symptom. Make a list of symptom related PIDs and go to next step.
4. Symptom Verification Path to symptom verification is optional, but is recommended for the following reasons: If vehicle is in for a repeat repair. No DTCs are present. Customer has difficulty describing symptom. If symptom needs to be verified, go to next step. If symptom is known and does not need to be verified, go to step 11 .
5. Note All Available Data To Aid In Symptom Verification Collect as much data as possible to aid in determining intermittent fault area. Note any freeze frame data that was recorded in step 2) . Note any continuous memory codes that were present prior to performing COMPUTER RELEARN PROCEDURE in step 2) . Obtain any information from customer that would aid in determining fault area. Go to next step.
6. Attempt To Recreate Symptom Using scan tool, select and monitor PIDs displayed in freeze frame data (if available) and PIDs on list that were developed in step 3) . Using freeze frame data recorded earlier, recreate conditions described by each freeze frame PID. Pay particular attention to ECT LOAD, RPM and VSS PIDs. Use any information available from customer to aid in producing conditions for recreating symptom. When symptom occurs, press trigger on scan tool to begin recording. Refer to scan tool instruction manual for recorder function operation. If symptom is reproduced, go to step 11 . If symptom cannot be reproduced, go to next step.
7. Recreate Symptom Using Intermittent Road Test The intermittent road test procedure is the last attempt to locate area of condition before physically disturbing vehicle circuits. Road test is a set of instructions for monitoring PID values or making circuit measurements with a DVOM. Procedure is performed under 4 conditions: Key On Engine Off (KOEO), hot idle, with vehicle speed at 30 MPH and 55 MPH. On part of procedure that requires a road test at 30 MPH and 55 MPH, a ride along assistant is necessary. Use PID values and circuit values in pin voltage/PID value charts to compare with actual PID values and circuit measurements made during road test. To perform KOEO part of procedure, locate appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. Turn ignition switch to ON position. Using scan tool, select and monitor PID values. Using a DVOM, measure circuits at breakout box identified in pin voltage/PID value charts. Compare scan tool PID values with circuit values made with DVOM. If any values are out of range, go to step 11 . If all values are in range, go to next step.
8. Recreate Symptom Using Hot Idle Road Test Procedure Start engine and allow to idle. Ensure engine is at normal operating temperature. Continue to monitor same PIDs and circuits as in step 7) . If any values are out of range, go to step 11 . If all values are in range, go to next step.
9. Recreate Symptom Using 30 MPH Road Test Road test vehicle at 30 MPH and continue to monitor same PIDs and circuits as in step 7) . If any values are out of range, go to step 11 . If all values are in range, go to next step.
10. Recreate Symptom Using 55 MPH Road Test Road test vehicle at 55 MPH and continue to monitor same PIDs and circuits as in step 7) . If any values are out of range, go to next step. If all values are in range, it is now necessary to physically disturb selected circuit in an attempt to recreate intermittent condition. Go to next step.
11. Select Circuits To Be Tested From Intermittent Test Table Remain in scan tool PID selection menu. If steps 7) - 10) (intermittent road tests) were performed, select PIDs or circuits that values did not match PID values or circuit values made using DVOM and pin voltage/PID value chart. If steps 7) - 10) were not performed, select PIDs from PID list made in step 3) . On all applications, go to «INTERMITTENT TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table. Match selected PIDs to corresponding circuit in INTERMITTENT TEST table. It is possible to have more than one circuit to test. If a PID recording was made with scan tool in step 6) , it may be helpful to replay recording at this time. Using INTERMITTENT TEST table, determine test to perform (input or output). To perform input test, go to next step. To perform output test, go to step 16 .
12. KOEO Intermittent Input Test Using circuits selected from «INTERMITTENT TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table , select only recommended PIDs to monitor with scan tool. If a PID is not available for a circuit, use a DVOM to monitor circuit. Turn ignition switch to ON position. Locate area of suspect wiring or component fault. If input is a switch-type component, turn switch on manually. While observing PID/DVOM value, wiggle and pull on component wiring and connector. Lightly tap on component. If a fault is indicated, value will suddenly change. For correct values, see PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
13. KOER Intermittent Input Test Start engine and allow to idle. Continue to monitor PIDs and/or circuits as in step 12) . Turn ignition switch to ON position. Locate area of suspect wiring or component fault. If input is a switch-type component, turn switch on manually. While observing PID/DVOM value, wiggle and pull on component wiring and connector. Lightly tap on component. If a fault is indicated, value will suddenly change. For correct values, see HOT IDLE values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, turn ignition switch to OFF position and go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
14. KOEO Intermittent Water Soak Test Turn ignition switch to ON position. Continue to monitor PIDs and/or circuits as in step 13) . Locate area of suspect wiring or component fault. If input is a switch-type component, turn switch on manually. While observing PID/DVOM value, lightly spray water on suspect component, circuit and connector. Include any relays or relay modules associated with fault. If a fault is indicated, value will suddenly change. For correct values, see KOEO values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
15. KOER Intermittent Water Soak Test Start engine and allow to idle. Continue to monitor PIDs and/or circuits as in step 14) . Locate area of suspect wiring or component fault. If input is a switch-type component, turn switch on manually. While observing PID value, lightly spray water on suspect component, circuit and connector. Include any relays or relay modules associated with fault. If a fault is indicated value will suddenly change. For correct values, see HOT IDLE values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
16. KOEO Intermittent Output Test Using circuits chosen from «INTERMITTENT TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) table, select only recommended PIDs to monitor with scan tool. Use a DVOM to compare circuit values with scan tool PID values. If a PID is not available for a circuit, use a DVOM to monitor circuit. Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. Turn all outputs on. Locate area of suspect wiring or component fault. While observing PID value, wiggle and pull on component wiring and connector. Lightly tap on component. If a fault is indicated, value will suddenly change. Compare actual values with KOEO values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, exit OUTPUT TEST MODE and go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
17. KOER Intermittent Output Test Start engine and allow it to idle. Continue to monitor PIDs and/or circuits as in step 16) . Locate area of suspect wiring or component fault. While observing PID value, wiggle and pull on component wiring and connector. Lightly tap on component. If a fault is indicated, value will suddenly change. Compare actual values with HOT IDLE values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component. NOTE: For coil on plug applications, if a coil has been tapped and is suspect, turn ignition switch to OFF position. Remove coil. Connect DVOM between spark plug terminal and signal terminal of coil. Observe DVOM and tap on coil. A large fluctuation in resistance indicates an intermittent open in coil. Replace coil as necessary.
18. KOEO Output Intermittent Water Soak Test Turn ignition switch to ON position. Using scan tool, access OUTPUT TEST MODE. Turn all outputs on. Continue to monitor PIDs and/or circuits as in step 17) . Locate area of suspect wiring or component fault. While observing PID/DVOM value, lightly spray water on suspect component, circuit and connector. Include any relays or relay modules associated with fault. If a fault is indicated, value will suddenly change. Compare actual values with KOEO values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. lf no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
19. KOER Output Intermittent Water Soak Test Start engine and allow to idle. Continue to monitor PIDs and/or circuits as in step 18) . Locate area of suspect wiring or component fault. While observing PID value, lightly spray water on suspect component, circuit and connector. Include any relays or relay modules associated with fault. If a fault is indicated value will suddenly change. For correct values, see HOT IDLE values in appropriate pin voltage/PID value chart in PIN VOLTAGE/PID VALUE CHARTS article in ENGINE PERFORMANCE. If no fault is indicated, go to next step. If a fault is indicated, check each related connector for loose, damaged or corroded terminals. Repair as necessary. If connector(s) is okay, replace suspect component.
20. Check For Intermittent Mechanical Concerns If not done previously, perform an inspection of mechanical systems relating to DTC or symptom. Check the following: Check if engine rocks during acceleration. If excessive movement is detected, check motor mounts. Check for excessive component movement while driving vehicle during conditions that would cause vibrations (high RPM, rough roads, etc.). Check accelerator and transmission linkages for contact or interference. If any problems are detected, repair as necessary. If no problems are detected, fault cannot be identified at this time. Testing is complete.
21. Intermittent Ignition Test Procedure Ensure all accessories are off and battery is fully charged. Perform «QUICK TEST»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-diagnosis-4r100-automatic-transmission) . If any DTCs are present, service DTCs as necessary before continuing with this test. If no DTCs are present, connect Rotunda Distributorless Ignition System (DIS) Tester (007-00075) and go to next step.
22. Perform Self-Test Turn ignition switch to OFF position. Ensure all accessories are off. Install correct overlay on front of tester panel. Install appropriate program cartridge in slot. Connect proper harness adapter to DIS Tester 104-Pin PCM Adapter (007-00110). Set rotary knob to position 1. Ensure WIGGLE TEST switch is off. On all models, disconnect PCM 104-pin connector. Connect tester to PCM wiring harness connector. Turn ignition switch to ON position. Press RESET button on tester. Tester will perform a self-test and all test LEDs will light and a beep will be heard. If CASE GND fault memory LED stays on, connect a jumper wire between PCM case to ground and continue with test. If tester performs self-test and VPWR LED turns on, go to step 27 . If tester does not perform self-test or VPWR LED does not turn on, go to next step.
23. DIST Tester Check Turn ignition switch to OFF position. Disconnect DIS tester. Connect jumper wire between VPWR terminal at tester and positive battery terminal. Connect another jumper wire between PWR GND terminal at tester and negative battery terminal. If tester performs self-test, go to step 27 . If tester does not perform self-test, tester is not functioning properly. Replace tester. Retest.
24. Check For Open VPWR Circuit Turn ignition switch to ON position. Measure voltage between VPWR terminal at DIS tester and negative battery terminal. If voltage is more than 6 volts, go to next step. If voltage is 6 volts or less, repair open in VPWR circuit to PCM.
25. Check PWR GND Circuit Turn ignition switch to OFF position. Measure resistance between PWR GND terminal at tester and negative battery terminal. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in PWR GND circuit to PCM. Go to step 22 .
26. Wiggle Check Connect a jumper wire between PWR GND terminal at tester and negative battery terminal. Turn ignition switch to ON position. Set WIGGLE TEST switch on. Set MODE switch to "B" position. Wiggle and bend wiring harness and connectors. If tester resets, repair open in VPWR circuit to PCM. Go to step 22 . If tester does not reset, repair open in PWR GND circuit to PCM. Go to step 22 .
27. Check For Coil Faults Turn ignition switch to ON position. Press DIS tester RESET button and wait for tester to initialize. If COIL FAULT MEMORY LEDs are off, go to next step. If any COIL FAULT MEMORY LED is on or flashing, go to step 35 .
28. Check CASE GND/CKP SHIELD Leave ignition switch turned to ON position. If CASE GND/CKP SHIELD FAULT MEMORY LED is off, go to next step. If CASE GND/CKP SHIELD FAULT MEMORY LED is on or flashing, go to step 59 .
29. Check CKP BIAS Leave ignition switch turned to ON position. If CKP BIAS SYSTEM STATUS LED is on, go to next step. If CKP BIAS SYSTEM STATUS LED is off, go to step 49 .
30. Check For Coil Fault With DIS tester connected to vehicle, test drive vehicle. If vehicle will not start, crank engine for 5-10 seconds. If COIL FAULT MEMORY LEDs are off with engine running or during engine cranking, go to next step. If any COIL FAULT MEMORY LED is on, go to step 35 .
31. CASE GND/CKP SHIELD Fault With DIS tester connected to vehicle, test drive vehicle. If vehicle will not start, crank engine for 5-10 seconds. If CASE GND/CKP SHIELD FAULT MEMORY LED is off with engine running or during engine cranking, go to next step. If CASE GND/CKP SHIELD FAULT MEMORY LED is on, go to step 59 .
32. Check CKP Status With DIS tester connected to vehicle, test drive vehicle. If vehicle will not start, crank engine for 5-10 seconds. If CKP SYSTEM STATUS SIGNAL LED is off with engine running or during engine cranking, go to next step. If CKP SYSTEM STATUS SIGNAL LED is on, go to step 53 .
33. Check For CTO Fault With DIS tester connected to vehicle, test drive vehicle. If vehicle will not start, crank engine for 5-10 seconds. If CTO FAULT MEMORY LED is off with engine running or during engine cranking, go to next step. If CTO FAULT MEMORY LED is on, go to step 45 .
34. Check For CKP Signal With DIS tester connected to vehicle, test drive vehicle. If vehicle will not start, crank engine for 5-10 seconds. If CKP SIGNAL SYSTEM STATUS LED is on with engine running or during engine cranking, no fault is indicated at this time. Ignition system is okay and testing is complete. If CKP SIGNAL SYSTEM STATUS LED is off, go to step 53 .
35. Check For Open IGN START/RUN Circuit Turn ignition switch to OFF position. Disconnect ignition coil pack(s). Turn ignition switch to ON position. Measure voltage between IGN START/RUN terminal at ignition coil pack wiring harness connector and PWR GND terminal at DIS tester. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in IGN START/RUN circuit to coil pack(s).
36. Check For Short Turn ignition switch to OFF position. Measure resistance between PWR GND terminal and each COIL terminal at DIS tester. Measure resistance between VPWR terminal and each COIL terminal at DIS tester. If all resistance readings are 6 k/ohms or more, go to next step. If any resistance reading is less than 6 k/ohms, go to step 42 .
37. Check COIL Circuit Resistance Turn ignition switch to OFF position. Measure resistance between each COIL terminal at DIS tester and same terminal at ignition coil wiring harness connector. If each resistance reading is less than 5 ohms, go to next step. If any resistance reading is 5 ohms or more, repair open in appropriate COIL circuit. Retest system.
38. Check COIL Circuit For Short Together Measure resistance between each COIL terminal and all other COIL jacks at DIS tester. If all resistance readings are 10 k/ohms or more, go to next step. If any resistance reading is less than 10 k/ohms, go to step 43 .
39. Check For Hard Faults Reconnect coil pack(s). Turn ignition switch to ON position. Press DIS tester RESET button. Wait for initialization and coil test to run. If COIL FAULT MEMORY LEDs are off, go to next step. If any COIL FAULT MEMORY LED is on or flashing, go to step 44 .
40. Wiggle Test Mode B Set DIS tester WIGGLE TEST switch on. Set MODE switch to "B" position. Press RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If FAULT MEMORY LEDs are off, go to next step. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.
41. Wiggle Test Mode B With Coil Disconnected Turn ignition switch to OFF position. Disconnect coil pack(s). Turn ignition switch to ON position. Press DIS tester RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If FAULT MEMORY LEDs are off, replace PCM. Retest system. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.
42. Circuit Check Turn ignition switch to OFF position. Disconnect PCM. Reconnect DIS tester to vehicle wiring harness. Measure resistance between each COIL terminal and PWR GND terminal at DIS tester. Measure resistance between COIL terminal and VPWR terminal at DIS tester. If all resistance readings are 10 k/ohms or more, replace PCM. Retest system. If any resistance reading is less than 10 k/ohms, repair open in COIL circuit.
43. Check For Short Between Coils Ensure ignition is turned to OFF position. Disconnect PCM. Reconnect DIS tester between coils wiring harness. Measure resistance between each COIL terminal and all other COIL jacks at DIS tester. If all resistance readings are 10 k/ohms or more, replace PCM. Retest system. If any resistance reading is less than 10 k/ohms, repair short between COIL circuits.
44. System Visual Check Ensure ignition is turned to OFF position. Check ignition system connectors for loose, damaged or corroded terminals. Repair as necessary. Retest system. If connectors are okay, replace ignition coil pack(s).
45. Circuit Check Measure resistance between CTO terminal and PWR GND terminal at DIS tester. Measure resistance between CTO terminal and VPWR terminal at DIS tester. If any resistance reading is less than 1 k/ohms, go to next step. If both resistance reading are more than 1 k/ohms, go to step 47 .
46. Isolate CTO Short Leave ignition switch turned to OFF position. Disconnect PCM. Reconnect DIS tester to vehicle wiring harness. Measure resistance between CTO terminal and PWR GND terminal at DIS tester. Measure resistance between CTO terminal and VPWR terminal at DIS tester. If both resistance readings are 1 k/ohms or more, replace PCM. Retest system. If any resistance reading is less than 1 k/ohms, repair fault in CTO circuit.
47. Wiggle Test Mode B Turn ignition switch to ON position. Set DIS tester WIGGLE TEST switch on. Set MODE switch to "B" position. Press DIS tester RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If all FAULT MEMORY LEDs are off, go to next step. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.
48. Wiggle Test On 6-cylinder models, set DIS tester MODE switch to "A" position. On 8-cylinder models, set MODE switch to "C" position. On all models, press DIS tester RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If all FAULT MEMORY LEDs are off, replace PCM. Retest system. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.
49. Check CKP BIAS Turn ignition switch to OFF position. Disconnect CKP sensor connector. Turn ignition switch to ON position. Press DIS tester RESET button and wait 5 seconds for initialization. If CKP BIAS SYSTEM STATUS LED is off, go to next step. If CKP BIAS SYSTEM STATUS LED is on, go to step 51 .
50. Isolate Short Circuit Ensure ignition is turned to OFF position. Disconnect PCM 104-pin connector. Reconnect tester to vehicle wiring harness. Measure resistance between CKP+ terminal and PWR GND terminal at DIS tester. Measure resistance between CKP+ terminal and VPWR terminal at DIS tester. If both resistance readings are more than 10 k/ohms, replace PCM. Retest system. If any resistance reading is 10 k/ohms or less, repair fault in CKP+ circuit.
51. Circuit Check Measure resistance between CKP- terminal and PWR GND terminal at DIS tester. Measure resistance between CKP- terminal and VPWR terminal at DIS tester. If any resistance reading is 10 k/ohms or less, go to next step. If both resistance readings are more than 10 k/ohms, replace CKP sensor. Retest system.
52. Isolate Short Circuit Ensure ignition is turned to OFF position. Disconnect PCM 104-pin connector. Reconnect DIS tester to vehicle wiring harness. Measure resistance between CKP- terminal and PWR GND terminal at DIS tester. Measure resistance between CKP- terminal and VPWR terminal at DIS tester. If both resistance readings are more than 10 k/ohms, replace PCM. Retest system. If any resistance reading is 10 k/ohms or less, repair fault in CKP- circuit.
53. Check CKP Signal Press DIS tester RESET button and wait 5 seconds for initialization. Crank or start engine. If CKP SIGNAL SYSTEM STATUS LED is off with engine running or during engine cranking, go to next step. If CKP SIGNAL SYSTEM STATUS LED is on, go to step 58 .
54. Circuit Check Turn ignition switch to OFF position. Disconnect CKP sensor connector. Measure resistance between CKP+ terminal at CKP sensor wiring harness connector and CKP+ terminal at DIS tester. Measure resistance between CKP- terminal at CKP sensor wiring harness connector and CKP- terminal at DIS tester. If both resistance readings are less than 5 ohms, go to next step. If any resistance reading is 5 ohms or more, repair CKP circuit. Retest system.
55. Check For CKP+ Short Leave ignition switch turned to OFF position. Measure resistance between CKP+ terminal and jacks for CKP-, PWR GND and VPWR at DIS tester. If any resistance reading is 10 k/ohms or less, go to next step. If all resistance readings are more than 10 k/ohms, go to step 57 .
56. Isolate Short Circuit Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector. Reconnect DIS tester to vehicle wiring harness. Measure resistance between CKP+ terminal and jacks for CKP-, PWR GND and VPWR at DIS tester. If any resistance reading is 10 k/ohms or less, repair CKP+ circuit. Retest system. If all resistance readings are more than 10 k/ohms, replace PCM. Retest system.
57. CKP Sensor Check Turn ignition switch to OFF position. Inspect CKP sensor and pulse wheel for damage and correct alignment. Service CKP sensor and pulse wheel as necessary. If no problems are found, replace CKP sensor. Retest system.
58. Wiggle Test Mode B: CKP Circuit Turn ignition switch to ON position. Set DIS tester WIGGLE TEST switch on. Set MODE switch to "B" position. Press DIS tester RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If FAULT MEMORY LEDs are off, go to next step. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.
59. Check CKP SHD For Short To Power Turn ignition switch to OFF position. Measure resistance between CASE GND/CKP SHD terminal and VPWR terminal at DIS tester. If resistance is 10 k/ohms or less, go to next step. If resistance is more than 10 k/ohms, go to step 61 .
60. Isolate Short Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector. Reconnect DIS tester to vehicle wiring harness. Measure resistance between CASE GND/CKP SHD terminal and VPWR terminal at DIS tester. If resistance is 10 k/ohms or less, repair CASE GND/CKP SHD circuit. Retest system. If resistance is more than 10 k/ohms, replace PCM. Retest system.
61. Wiggle Test Mode B: CKP Circuit Turn ignition switch to ON position. Set DIS tester WIGGLE TEST switch on. Set MODE switch to "B" position. Press DIS tester RESET button and wait 5 seconds for initialization. Wiggle and bend wiring harness and connectors. If FAULT MEMORY LEDs are off, repair CASE GND/CKP SHD circuit. Retest system. If any FAULT MEMORY LED is on, press RESET button and wait for initialization. Continue to test until intermittent fault is located. Repair as necessary. Retest system.

REMOVAL & INSTALLATION

Note. For 4R100 transmission component removal & installation information, see FORD 4R100 OVERHAUL article.

Disconnect negative battery cable. Remove any component necessary to gain access to PCM. For PCM location, see POWERTRAIN CONTROL MODULE LOCATION table. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. On Pickup, removal of fender liner may be necessary to slide PCM out. To install, reverse removal procedure.

POWERTRAIN CONTROL MODULE LOCATION

1999 Expedition & Navigator 5.4L Transmission Wiring Diagram. Scheme 140

1999 "E" Series (5.4L CNG) Transmission Wiring Diagram. Scheme 141

1999 "E" Series (Except 7.3L DI Turbo Diesel) Transmission Wiring Diagram. Scheme 142

1999 "E" Series (7.3L DI Turbo Diesel) Transmission Wiring Diagram. Scheme 143

1999 F150/250 Light Duty Transmission Wiring Diagram. Scheme 144

1999 F250/350 Super Duty (5.4L & 6.8L) Transmission Wiring Diagram. Scheme 145

1999 F250/350 Super Duty (7.3L DI Turbo Diesel) Transmission Wiring Diagram. Scheme 146

See also:
• QUICK TEST
• CLEARING CODES
• Accelerator Pedal (AP) Sensor (7.3L DI Diesel Only)
• TEST E
• TRANSMISSION DRIVE CYCLE TEST
• TEST D
• TEST B
• TORQUE CONVERTOR ENGAGEMENT TEST
• TEST C
• TEST G
• VISUAL CHECK
• EQUIPMENT HOOKUP
• KEY-ON-ENGINE-OFF (KOEO) SELF-TEST
• KEY-ON-ENGINE-RUNNING (KOER) SELF-TEST
• COMPUTED TIMING CHECK
• CONTINUOUS MEMORY SELF-TEST
• F
• H
• TG
• TB
• GENERIC OBD-II PARAMETER IDENTIFICATION (PID)
• NON-GENERIC OBD-II PARAMETER IDENTIFICATION (PID)
• ON-BOARD SYSTEM READINESS (OSR) TEST MODE
• FREEZE FRAME DATA MODE
• OXYGEN SENSOR TEST MODE
• OUTPUT TEST MODE
• TRANSMISSION OVERHEATING
• NO TCC ENGAGEMENT
• TCC ALWAYS ENGAGED
• TCC CYCLING OR SHUDDERING