Automatic Transmission: Other Ford Focus I рестайлинг

DIRECT CLUTCH HUB SHIM SELECTION CHART

DIRECT CLUTCH HUB SHIM SELECTION CHART

TRANSFER SHAFT SHIM SELECTION CHART

TRANSFER SHAFT SHIM SELECTION CHART

Differential Shaft Shim Selection Chart

Differential Shaft Shim Selection Chart

LINE PRESSURE

LINE PRESSURE

STALL SPEED

STALL SPEED

Range Selection

The transaxle range selector has six positions: P, R, N, D, 2, 1.

Scheme 123

Manual Selector Lever Position "P"

In manual selector lever position "P" no gear is selected. The parking pawl is engaged manually by the manual selector lever cable and the shift shaft.

For safety reasons, always apply the parking brake whenever the vehicle is parked.

Manual Selector Lever Position "R"

In manual selector lever position "R" reverse gear is selected. REVERSE allows the vehicle to be operated in a rearward direction, at a reduced gear ratio.

Manual Selector Lever Position "N"

In manual selector lever position "N" no gear is selected. The driveline is not locked, so the wheels are free to rotate.

The vehicle may be started in NEUTRAL.

Manual Selector Lever Position "D"

In manual selector lever position "D" and when the O/D switch is not pressed, the transmission control allows all the gears to be selected. When the O/D switch is pressed, shifting into fourth gear is prevented or the transmission shifts down to third gear.

Manual Selector Lever Position "1"

In manual selector lever position "1" only first gear is selected. In addition to the first gear one-way clutch, the transmission control closes the reverse gear brake to produce engine braking effect in overrun.

If the manual selector lever is moved to position "1" at an excessive vehicle speed for first gear, the transmission control only allows the downshift to take place when the corresponding vehicle speed has been reached.

Manual Selector Lever Position "2"

In manual selector lever position "2" only second gear is selected. The transmission control does not allow shifting into first gear.

If the manual selector lever is moved to position "2" at an excessive vehicle speed for second gear, the transmission control only allows the downshift to take place when the corresponding vehicle speed has been reached.

Scheme 124

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Scheme 136

Scheme 137

The torque converter transmits engine torque hydraulically to the transmission input shaft.

The stator boosts the torque to the input shaft (approximately 85% difference in speed between the impeller and the turbine).

The stator is made of synthetic resin to reduce weight.

To increase the efficiency of the automatic transmission, the torque converter has an apply clutch. When the torque converter lock-up clutch is closed, the torque is transmitted directly from the crankshaft through the torque converter housing to the transmission input shaft.

The torque converter clutch is applied hydraulically by the PCM by means of the solenoid valves in the valve body in third and fourth gears. Apply is dependent on the throttle position, vehicle speed and manual selector lever position.

Scheme 138

The fluid pump is a crescent gear pump and is driven directly from the crankshaft by means of drivers on the converter impeller hub. The fluid pump is bolted to the transmission housing.

The stator support is part of the fluid pump. Splines on the support locate and hold the converter stator.

Planetary gear sets

The individual gears are shifted by means of two planetary gear sets, connected one behind the other.

Clutches and bands

The individual ratios are selected by means of four multiplate clutches, a brake band and a roller one-way clutch.

The components are controlled by the PCM through pulse width modulation (PWM) solenoid valves.

Scheme 139

The valve body contains six solenoid valves

1. three PWM solenoid valves (pulse width modulation solenoid valves
2. two shift solenoid (on/off) valves
3. one main regulating valve (variable force solenoid).

The individual clutches and bands are supplied pressure from the PWM solenoid valves and the shift solenoid (on/off) valves and thus the gears are shifted.

The PWM solenoid valves allow direct actuation of the clutches and bands to ensure extremely smooth gear shifting through precise pressure regulation.

The shift solenoid (on/off) valves switch the hydraulic path to the clutches and bands, reducing the number of required modulating valves.

The main regulating valve (variable force solenoid) ensures that sufficient hydraulic pressure is available in all operating conditions.

PWM solenoid valves 1-3

PWM solenoid valves 1, 2 and 3 control the pressure to the bands and clutches.

Shift solenoid (on/off) valves 1 and 2

The shift solenoid (on/off) valves switch the different oil passages in the valve body to direct the pressure to the individual clutches and bands.

The use of the shift solenoid valves are needed for direct actuation of the individual clutches and bands.

Main regulating valve

The main regulating valve (variable force solenoid) controls the required main line pressure for the individual transmission ranges.

The main line pressure is controlled dependent on the current engine load.

Scheme 140

The shift lever is secured on a square on the manual shaft. Axial movement of the selector lever cable is changed into rotation of the manual shaft.

In the transmission, the manual shaft operates the parking pawl engaging lever and the actuating lever of the manual valve.

The manual valve, a valve operated entirely manually, is moved by means of the manual valve actuating lever in the valve body.

The manual valve guarantees the functions during hydraulic emergency operation.

Scheme 141

The transmission end of the manual selector lever cable is attached to a ball on the lever on the manual shaft.

The cable abutments are secured to the transmission housing, and then to the bracket of the manual selector lever.

The adjuster for the manual selector lever cable is located at the transmission side of the sheath.

At the manual selector lever end the cable is clipped onto a ball.

Scheme 142

The final drive input gear is splined to the planet carrier of the front planetary gear set and drives the transfer shaft input gear of the intermediate gear stage.

The transfer shaft output gear of the intermediate gear stage drives the final drive assembly.

The torque is transmitted to the halfshafts through the final drive assembly.

The differential offsets differences in speed of rotation of the halfshafts.

The intermediate gear stage is designed so that the final drive ratio can be adapted to requirements when the automatic transmission is used in conjunction with different engines.

Scheme 143

Scheme 144

The PCM is located under the trim panel on the right-hand A-pillar.

On vehicles with automatic transmissions, the EEC-V PCM controls the transmission in addition to the engine management system. In this case, a module with 104 pins is used.

The PCM evaluates the incoming signals from the individual sensors and actuates the solenoid valves in the valve body of the transmission directly according to the operating state.

Diagnostic checks can be carried out on the transmission through the data link connector (DLC) above the central junction box (CJB).

Emergency operating program

If correct gear shifting can no longer be guaranteed due to failure of certain signals, the PCM changes to an emergency operating program.

The driver is informed of the operation of the emergency operating program by the illumination of the powertrain warning indicator in the instrument cluster.

Continued motoring is guaranteed in the following limited conditions

1. maximum main line pressure.
2. 3rd gear in manual selector lever positions "D", "2" and "1" without the torque converter lock-up clutch.
3. reverse gear in manual selector lever position "R".

Throttle Position (TP) Sensor

The TP sensor is located on the throttle body.

It supplies the PCM with information about the position of the throttle plate.

It also detects the speed of actuation of the throttle plate.

The PCM uses the signals for the following functions among other things

1. to determine the shift timing
2. to control the main line pressure
3. to control the torque converter lock-up clutch
4. for kickdown.

In case of absence of the TP signal the engine control uses the signals of the MAF and IAT sensors as a substitute signal. The main line pressure is increased and hard shifts may occur.

Mass Air Flow (MAF) And Intake Air Temperature (IAT) Sensor

The MAF sensor is located between the air cleaner housing and the air intake hose leading to the throttle housing.

The IAT sensor is incorporated in the housing of the MAF sensor.

The MAF sensor in conjunction with the IAT sensor provides the PCM with the primary load signal.

The PCM uses the signals for the following functions among other things

1. to control the shift operations
2. to control the main line pressure.

If the MAF sensor fails, the signal of the TP sensor is used as a substitute.

Crankshaft Position (CKP) Sensor

The CKP sensor is located on the engine/transmission flange.

The CKP sensor is an inductive sensor which provides the PCM with information about the engine speed and position of the crankshaft.

The signal is used for the following functions among other things

1. to control the torque converter lock-up clutch
2. to check the torque converter slip
3. to control the main line pressure.

No substitute signal is available for the CKP sensor. If the signal is not present, the engine stops.

Turbine Shaft Speed (TSS) Sensor

The TSS sensor is located in the transmission housing over the transmission input shaft.

The TSS sensor is an inductive sensor which senses the speed of rotation of the transmission input shaft.

The signal is used for the following functions

1. to control the shift operations
2. to control the torque converter clutch
3. to check the torque converter slip.

If the TSS sensor fails, the signal of the output shaft speed (OSS) sensor is used as a substitute signal.

Scheme 145

The OSS sensor is located in the transmission housing above the rotor in the differential.

The OSS sensor is an inductive sensor which detects the vehicle speed by means of a rotor on the differential.

The signal is used for the following functions among other things

1. to determine the shift timing
2. to supply the vehicle speed input signal for the PCM.

If the OSS sensor fails, the signal of the TSS sensor is used as a substitute signal.

Scheme 146

The TR sensor is located on the manual shaft on the transmission housing.

When the manual shaft is moved by means of the manual selector lever cable, an engagement pin in the inner ring of the TR sensor moves through the different positions. The signals are transmitted to the PCM, the reversing lamps and the starter inhibitor relay.

Note. Correct operation of the TR sensor is only guaranteed when the manual selector lever cable is adjusted correctly.

The signals of the TR sensor are used for the following functions

1. to recognize the manual selector lever position
2. to actuate the starter inhibitor relay
3. to actuate the reversing lamps

No substitute signal is available for the TR sensor.

If the connection is cut, the vehicle cannot be started.

Stoplamp Switch

The brake pedal position (BPP) switch is mounted on the brake pedal bracket.

It switches the stoplights on and tells the EEC-V PCM when the brakes are applied.

The signal of the stoplamp switch is used by the PCM for the following functions

1. to release the torque converter lock-up clutch when the brake pedal is depressed
2. to switch off the manual selector lever shift lock when the brake pedal is depressed in "P".

No substitute signal is available for the BPP switch.

If the connection to the BPP switch is cut, the manual selector lever cannot be moved out of "P".

Air Conditioning

If the PCM registers a kickdown signal (WOT, throttle plate opened 95%), the air conditioning is switched off for a maximum of 15 seconds.

Starter Inhibitor Relay

The relay prevents the engine starting in manual selector lever positions "R", "D", "2" and "1".

The relay obtains the information about the position of the selector lever directly from the TR sensor.

Ignition Key Lock Solenoid

The solenoid is incorporated in the ignition lock. In manual selector lever position "P" the ground connection to the solenoid is cut. The locking pin does not engage in the ignition lock.

In all the other manual selector lever positions, the ground connection to the solenoid is closed and the locking pin engages in the ignition lock.

When the manual selector lever is not in position "P", removal of the ignition key is prevented.

Powertrain Warning Indicator

The powertrain warning indicator is located in the instrument cluster and is colored orange.

Scheme 147

It lights to tell the driver that the transmission control has switched to the emergency operating program or that the transmission fluid temperature is too high.

Know And Understand The Concern

In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer contact may be necessary in order to begin to verify the concern. Understand the conditions as to when the concern occurs, for example

1. Hot or cold vehicle temperature
2. Hot or cold ambient temperature
3. Vehicle driving conditions
4. Vehicle loaded/unloaded

After understanding when and how the concern occurs, proceed to verify the concern.

Verification Of Condition

This article provides information that must be used in both determining the actual cause of customer concerns and executing the appropriate procedures.

The following procedures must be used when verifying customer concerns for the engine.

Determine Customer Concern

Note. Some transaxle conditions can cause engine concerns. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the following items

1. Hot or cold vehicle operating temperature
2. Hot or cold ambient temperatures
3. Type of terrain
4. Vehicle loaded/unloaded
5. City/highway driving
6. Upshift
7. Downshift
8. Coasting
9. Engagement
10. Noise/vibration - check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent.

Shift Speeds Chart

SHIFT SPEEDS

Shift Linkage Check

Check shift linkage adjustment by matching the detents in the transaxle range selector lever with those in the transaxle. If they match, the error is in the indicator. Do not adjust the shift linkage.

Hydraulic leakage at the manual control valve can cause delay in engagements and slipping while operating if the linkage is not correctly adjusted; refer to TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS for shift linkage adjustment.

Check TSBs

Refer to all TSBs which pertain to the transaxle concern and follow the procedure as outlined.

Output State Control (OSC) Mode

Note. The Output State Control (OSC) Mode may not be functional on some 2.3L PZEV applications.

Output State Control (OSC) allows the technician to take control of certain parameters to function the transaxle. For example, OSC allows the technician to shift the transaxle only when commanding a gear change. If the technician commands 1st gear in OSC, the transaxle will remain in 1st gear until the technician commands the next gear. For another example, the technician can command a shift solenoid to turn on or off when carrying out an electrical circuit check. OSC has two modes of operation for transaxle, the BENCH MODE and the DRIVE MODE. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC.

Note. To operate OSC, the transmission range (TR) sensor and the vehicle speed sensor (VSS) must be operational. No diagnostic trouble codes (DTCs) related to the TR sensor or the VSS can be present.

Note. Technician should perform a key off before initiating any OSC activities in order to clear any previously learned Failure Mode Effects Management (FMEM) actions from the vehicle memory.

1. The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to vehicle requirements for each individual test.
2. If the vehicle requirements are NOT MET when SENDING the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted.
3. If, AFTER SENDING an OSC value, the vehicle requirements are no longer met, the PCM will cancel the OSC value and NO ERROR message will appear. Once the vehicle requirements are met again, the PCM will automatically SEND the previous OSC value without any additional actions required by the technician.
4. The OSC value XXX may be sent anytime to cancel OSC.

Output State Control (OSC) Procedures

1. Carry out visual inspection and vehicle preparation as necessary.
2. Select "Vehicle and Engine Selection" menu.
3. Select appropriate vehicle and engine.
4. Select "Diagnostic Data Link."
5. Select "Powertrain Control Module."
6. Select "Diagnostic Test Mode."
7. Select "KOEO On-Demand Self Test and KOER On-Demand Self Tests."
8. Carry out test and record DTCs.
9. Repair all non-transaxle DTCs.
10. Repair all VSS and TR sensor DTCs.
11. Make sure that VSS/TR sensors are functional.
12. Select "Active Command Modes."
13. Select "Output State Control."
14. Select "Trans-Bench Mode or Trans-Drive Mode."

OSC - Transaxle Bench Modes

The following Transaxle Bench Modes may be used or necessary during diagnostics.

SSA, SSB in BENCH MODE

The BENCH MODE allows the technician to carry out electrical circuit checks on the following components

1. SSA - Activates SSA OFF or ON.
2. SSB - Activates SSB OFF or ON.

OSC "SSA/B" BENCH MODE operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Transaxle range selector level in P.
4. Key ON.
5. Engine OFF.

OSC Command Values

1. OFF - turns solenoid OFF.
2. ON - turns solenoid ON.
3. XXX - cancels OSC sent value.
4. SEND - sends the values to PCM.

BENCH MODE Procedure for SSA, SSB

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - SSA, SSB (= SS1, SS2)."
6. Select "ON" to turn solenoid ON.
7. Press "SEND" to send command.
8. Select "OFF" to turn solenoid OFF.
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

SSC, SSD and SSE in BENCH MODE

The BENCH MODE is also used to test the functionality of pulse width modulated solenoids of the transaxle. During BENCH MODE, the SSC/D/E solenoids can ramp in increments of 25% from 0% to 100% duty cycle and 100% to 0% duty cycle.

The OSC functions for the parameters SSC/D/E allow the technician to choose the following options

1. SSC - Activates SSC to selected values.
2. SSD - Activates SSD to selected values.
3. SSE - Activates SSE to selected values.
4. 00 - sets SSC/D/E duty cycle to 00%
5. 25 - sets SSC/D/E duty cycle to 25%
6. 50 - sets SSC/D/E duty cycle to 50%
7. 75 - sets SSC/D/E duty cycle to 75%
8. 100 - sets SSC/D/E duty cycle to 100%

OSC "SSC/D/E" BENCH MODE operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Transaxle range selector level in P.
4. Key ON.
5. Engine ON.
6. Engine speed at least 1,500 RPM.
7. Pressure gauge installed (optional).

OSC Command Values

1. 00 - sets SSC/D/E duty cycle to 00%
2. 25 - sets SSC/D/E duty cycle to 25%
3. 50 - sets SSC/D/E duty cycle to 50%
4. 75 - sets SSC/D/E duty cycle to 75%
5. 100 - sets SSC/D/E duty cycle to 100%
6. XXX - cancels OSC value sent.
7. SEND - sends the values to PCM.

BENCH MODE Procedure for SSC, SSD and SSE

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDS" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - SSC, SSD, SSE."
6. Select Value "0-100%."
7. Press "SEND" to send command.
8. Select "XXX" to cancel at any time.
9. Press "SEND" to send command.

PCA in BENCH MODE

Note. PCA, EPC and VFS all refer to the solenoids . PCA is preferred for this transmission because the diagnostic tool display PCA.

The BENCH MODE is also used to test the functionality of the transaxle electronic pressure control. During BENCH MODE, the PCA solenoid can ramp in increments of 20 PSI from 50 PSI to 150 PSI and 150 PSI to 50 PSI.

Note. PCA pressure represents transaxle line pressure. The technician should measure PCA pressure using the line pressure tap.

The OSC function for the parameter PCA allows the technician to choose the following options

1. EPC - Activates PCA to selected values.
2. 50 - sets PCA pressure to 50 PSI.
3. 70 - sets PCA pressure to 70 PSI.
4. 90 - sets PCA pressure to 90 PSI.
5. 110 - sets PCA pressure to 110 PSI.
6. 130 - sets PCA pressure to 130 PSI.
7. 150 - sets PCA pressure to 150 PSI.

OCS "PCA" BENCH MODE should ONLY be operated to check PRESSURE FUNCTIONALITY using an installed pressure gauge when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor are operational.
3. Key ON.
4. Engine ON.
5. Engine speed at least 1,500 RPM.

OSC "PCA" BENCH MODE should ONLY be operated to compete PCA SOLENOID CIRCUIT PINPOINT TESTS when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Transmission range selector lever in P.
4. Key ON.
5. Engine ON.

OSC Command Values

1. 50 - sets PCA pressure to 50 PSI.
2. 70 - sets PCA pressure to 70 PSI.
3. 90 - sets PCA pressure to 90 PSI.
4. 110 - sets PCA pressure to 110 PSI.
5. 130 - sets PCA pressure to 130 PSI.
6. 150 - sets PCA pressure to 150 PSI.
7. XXX - cancels OSC sent value.
8. SEND - sends the values to PCM.

BENCH MODE Procedure for PCA

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans-Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - PCA."
6. Select Value "50-150 PSI."
7. Press "SEND" to send command.
8. Select "XXX" to cancel at any time.
9. Press "SEND" to send the command.

OSC - Transmission DRIVE MODES

The DRIVE MODE allows control of three transaxle parameters. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC. The recommended procedure, when using the DRIVE MODE, is to control one parameter at a time.

The DRIVE MODE allows the technician to carry out the following functions on the transaxle

1. GEAR - allows upshifts or downshifts.
2. TCC - engages or disengages the torque converter clutch.
3. FIRM_SFT - commands a higher control pressure during upshift only.

Electronic Pressure Control solenoid A (EPC) for this transaxle cannot directly be controlled during DRIVE MODE testing. Pressures may be raised during an upshift via the firm shift control function (FIRM_SFT).

GEAR In DRIVE MODE

This OSC function is used to test the transaxle shift functions.

Note. When the technician commands 1st gear during OSC mode, engine braking is automatically activated for 1st gear. Be aware that normal transaxle operation does not use engine braking in 1st gear.

The OSC function for the GEAR parameter allows the technician to choose the following options

1. 1 - PCM selects first gear.
2. 2 - PCM selects second gear.
3. 3 - PCM selects third gear.
4. 4 - PCM selects fourth gear.

OSC "GEAR" Mode operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs.
3. Engine "ON."
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. Gear selected is equal to or below maximum gear available (PID "GEARTOP").
7. Maximum vehicle speed for downshift into first gear is 40 km/h (25 mph).
8. Maximum vehicle speed for downshift into second gear is 97 km/h (60 mph).
9. Maximum vehicle speed for downshift into third gear is 204 km/h (127 mph).
10. Minimum vehicle speed for an upshift to fourth gear is 32 km/h (20 mph).

OSC Command Values

1. 1 - PCM selects first gear.
2. 2 - PCM selects second gear.
3. 3 - PCM selects third gear.
4. 4 - PCM selects fourth gear.
5. XXX - cancels OSC sent value.
6. SEND - sends the values to PCM.

DRIVE MODE Procedure For GEAR

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans-Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - GEAR."
6. Select Value "1-4."
7. Press "SEND" to send command.
8. Re-Select Value "1-4."
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND" to send command.

TCC In DRIVE MODE

This OSC function is used to test whether the torque converter clutch is engaging and disengaging correctly.

The OSC function for the TCC parameter allows the technician to choose the following

1. TCC - activates TCC OFF and ON.
2. ON - turns TCC ON.
3. OFF - turns TCC OFF.

OSC "TCC OFF" DRIVE MODE operates ONLY when

1. VSS and TR sensors are operational.
2. No VSS and TR sensor DTCs present.
3. Engine ON.
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. No transaxle gear shifts are in progress.

OSC "TCC ON" DRIVE MODE operates ONLY when

1. VSS and TR sensors are operational.
2. No VSS and TR sensor DTCs present.
3. Engine "ON".
4. Transaxle range selector lever in O/D.
5. Vehicle speed is greater than 3 km/h (2 mph).
6. Transaxle in second or higher gear.
7. TFT is between 16°C and 133°C (60°F and 270 °F).
8. Brake is "OFF" when vehicle speed is below 20 mph.
9. Engine speed at least 1,500 RPM.
10. Speed ratio across the converter (PID "TCCRAT") is between 0.70 and 1.05.
11. No transaxle gear shifts are in progress.

OSC Command Values

1. OFF - Turns TCC OFF.
2. ON - Turns TCC ON.
3. XXX - Cancels OSC value sent.
4. SEND - Sends the values to PCM.

Drive Mode Procedure for TCC

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - TCC."
6. Select "ON" to turn TCC ON.
7. Press "SEND" to send command.
8. Select "OFF" to turn TCC OFF.
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND" to send command.

FIRM_SFT in DRIVE MODE

This OSC function is used to raise pressure during an upshift to determine whether the pressure control system is functioning correctly. Firmer shifts indicate that the pressure control system works at higher pressure. The best test for isolating pressure control system problems is to carry out the EPC solenoid test in BENCH MODE using a hydraulic pressure gauge.

The OSC functions for the parameter FIRM_SFT allows the technician to choose the following options

1. FIRM_SFT - Activates the firm shift channel.
2. ON - sets control pressure high for all upshifts (determined by the PCM).
3. OFF - sets control pressure to normal for all upshifts (determined by the PCM).

OSC "FIRM_SFT" DRIVE MODE operates ONLY when

1. VSS and TR sensor are operational.
2. No VSS and TR sensor DTCs present.
3. Transaxle range selector lever in O/D.
4. Engine "ON."
5. Key "ON."
6. Vehicle speed greater than 2 mph.
7. TCC cannot be forced ON using NGS OSC mode (PID "OSCTCC" not equal to ON)

OSC Command Values

1. ON - sets control pressure high for all upshifts (determined by the PCM)
2. OFF - sets control pressure to normal for all upshifts (determined by the PCM)
3. XXX - cancel OSC for FIRM_SFT
4. SEND - sends the values to the PCM

DRIVE MODE Procedure for FIRM_SFT.

Follow operating instructions from the NGS menu screen

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - FIRM_SFT."
6. Select "ON" to turn Firm Shift Mode ON.
7. Select "SEND" to send command.
8. Select "OFF" to turn Firm Shift Mode OFF.
9. Select "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Select "SEND" to send command.

Using Output State Control (OSC) And Accessing PIDs

To confirm that the OSC value was sent by the NGS and the PCM has accepted the OSC substitution, a corresponding PID or PIDs for each OSC parameter should be monitored. Additional PIDs should be monitored to help the technician adequately diagnose the transaxle.

The following is a list of OSC parameters and their corresponding PIDs

To confirm that the OSC substitution occurred, SEND the OSC value and monitor the corresponding PID value. If no ERROR MESSAGE was received and the value of the corresponding PID is the same as the value sent from OSC, then the OSC substitution was successful.

The following general PID list may be of use to the technician when exercising OSC

Before Pinpoint Tests

Note. Before entering pinpoint tests, check the powertrain control module wiring harness for correct connections, bent or broken pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and actuators for damage. Refer to INTRODUCTION - CNG, FLEX-FUEL & GASOLINE .

Note. If a concern still exists after electrical diagnosis, refer to DIAGNOSIS BY SYMPTOM .

If DTCs appear while carrying out the on-board diagnostics, refer to DIAGNOSTIC TROUBLE CODE CHARTS for the appropriate repair procedure. Prior to entering pinpoint tests, refer to any TSBs for transaxle concerns.

Engine Idle Speed Check

Refer to INTRODUCTION - CNG, FLEX-FUEL & GASOLINE for diagnosis and testing of the engine idle speed.

Line Pressure Chart

LINE PRESSURE

Air Pressure Tests

Transaxle Pressure Test Plate

Scheme 148

A no-drive condition can exist even with correct transaxle fluid pressure because of inoperative clutches or bands. An erratic shift can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the failure.

Follow the procedure to determine the location of the inoperative clutch or band by introducing air pressure into the various test plate passages.

Note. Use only dry, regulated 3 bar maximum air pressure.

Apply air to the appropriate passage(s). A dull thud should be felt or heard or movement could be observed when the component applies. There should be no hissing sound when the component is fully applied.

1. Drain transaxle fluid and remove the transaxle fluid pan.
2. Remove the main control valve body. For additional information, refer to «MAIN CONTROL»(ref-207762-S14512245412005120200000) .
3. Install the transmission test plate and gasket. Use the transmission fluid pan bolts to hold the Test Plate down. Tighten the bolts to 10 Nm (89 lb-in).
4. Apply air to the appropriate clutch port (refer to the figure above). A dull thud may be heard or movement felt when the component is applied or released. If clutch seals or check balls are leaking, a hissing sound may be heard.

If test results indicate that the servos do not operate, disassemble, clean and inspect them to locate the source of the concern.

If air pressure applied to the clutch passages fails to operate a clutch, or operates another clutch simultaneously, disassemble and use air pressure to check the fluid passages in the center support and clutches to detect obstructions.

4F27E Transmission

DIAGNOSIS BY SYMPTOM INDEX

Routine 201A/301A - Engagement Concern: No Forward in O/D ONLY

ROUTINE 201A/301A - ENGAGEMENT CONCERN: NO FORWARD IN O/D ONLY

Routine 201B/301B - Engagement Concern: No Forward ONLY (All Positions)

ROUTINE 201B/301B - ENGAGEMENT CONCERN: NO FORWARD ONLY (ALL POSITIONS)

Routine 202/302 - Engagement Concern: No Reverse

ROUTINE 202/302 - ENGAGEMENT CONCERN: NO REVERSE

Routine 203/303 - Engagement Concern: Harsh Reverse ONLY

ROUTINE 203/303 - ENGAGEMENT CONCERN: HARSH REVERSE ONLY

Routine 204A/304A - Engagement Concern: Harsh Forward ONLY

ROUTINE 204A/304A - ENGAGEMENT CONCERN: HARSH FORWARD ONLY

Routine 204B/304B - Engagement Concern: Harsh Forward ONLY

ROUTINE 204B/304B - ENGAGEMENT CONCERN: HARSH FORWARD ONLY

Routine 205/305 - Engagement Concern: Delayed/Soft Reverse ONLY

ROUTINE 205/305 - ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE ONLY

Routine 206/306 - Engagement Concern: Delayed/Soft Forward

ROUTINE 206/306 - ENGAGEMENT CONCERN: DELAYED/SOFT FORWARD

Routine 207/307 - Engagement Concerns: No Forward and No Reverse

ROUTINE 207/307 - ENGAGEMENT CONCERNS: NO FORWARD AND NO REVERSE

Routine 208/308 - Engagement Concerns: Harsh Forward and Reverse

ROUTINE 207/307 - ENGAGEMENT CONCERNS: NO FORWARD AND NO REVERSE

Routine 209/309 - Engagement Concerns: Delayed/Soft Forward and Reverse

ROUTINE 209/309 - ENGAGEMENT CONCERNS: DELAYED/SOFT FORWARD AND REVERSE

Routine 210/310 - Shift Concerns: Some/All Shifts Missing (AUTOMATIC MODE ONLY)

ROUTINE 210/310 - SHIFT CONCERNS: SOME/ALL SHIFTS MISSING (AUTOMATIC MODE ONLY)

Routine 211/311 -Shift Concerns: Timing Concerns - Early/Late

ROUTINE 211/311 -SHIFT CONCERNS: TIMING CONCERNS - EARLY/LATE

Routine 212/312 - Shift Concerns: Timing Concerns - Erratic/Hunting

ROUTINE 212/312 - SHIFT CONCERNS: TIMING CONCERNS - ERRATIC/HUNTING

Routine 213/313 - Shift Concerns: Feel - Soft/Slipping

ROUTINE 213/313 - SHIFT CONCERNS: FEEL - SOFT/SLIPPING

Routine 214/314 - Shift Concerns: Feel - Harsh (Some/All)

ROUTINE 214/314 - SHIFT CONCERNS: FEEL - HARSH (SOME/ALL)

Routine 215/315 - Shift Concerns: No 1st Gear In Drive, Engages In Higher Gear

ROUTINE 215/315 - SHIFT CONCERNS: NO 1ST GEAR IN DRIVE, ENGAGES IN HIGHER GEAR

ROUTINE 215/315 - SHIFT CONCERNS: NO 1ST GEAR IN DRIVE, ENGAGES IN HIGHER GEAR

Routine 217/317 - Shift Concerns: No Manual 2nd Gear

ROUTINE 217/317 - SHIFT CONCERNS: NO MANUAL 2ND GEAR

Routine 220/320 - Shift Concern: No 1-2 Shift

ROUTINE 220/320 - SHIFT CONCERN: NO 1-2 SHIFT

Routine 221/321 - Shift Concern: No 2-3 Shift

ROUTINE 221/321 - SHIFT CONCERN: NO 2-3 SHIFT

Routine 222/322 - Shift Concern: No 3-4 Shift

ROUTINE 222/322 - SHIFT CONCERN: NO 3-4 SHIFT

Routine 223/323 - Shift Concern: No 4-3 Shift

ROUTINE 223/323 - SHIFT CONCERN: NO 4-3 SHIFT

Routine 224/324 - Shift Concern: No 3-2 Shift

ROUTINE 224/324 - SHIFT CONCERN: NO 3-2 SHIFT

Routine 225/325 - Shift Concern: No 2-1 Shift

ROUTINE 225/325 - SHIFT CONCERN: NO 2-1 SHIFT

Routine 226/326 - Shift Concern: Soft/Slipping 1-2

ROUTINE 226/326 - SHIFT CONCERN: SOFT/SLIPPING 1-2

Routine 227/327 - Shift Concern: Soft/Slipping 2-3

ROUTINE 227/327 - SHIFT CONCERN: SOFT/SLIPPING 2-3

Routine 228/328 - Shift Concern: Soft/Slipping 3-4

ROUTINE 228/328 - SHIFT CONCERN: SOFT/SLIPPING 3-4

Routine 229/329 - Shift Concern: Soft/Slipping 4-3

ROUTINE 229/329 - SHIFT CONCERN: SOFT/SLIPPING 4-3

Routine 230/330 - Shift Concern: Soft/Slipping 3-2

ROUTINE 230/330 - SHIFT CONCERN: SOFT/SLIPPING 3-2

Routine 231/313 - Shift Concern: Soft/Slipping 2-1

ROUTINE 231/313 - SHIFT CONCERN: SOFT/SLIPPING 2-1

Routine 232/332 - Shift Concern: Harsh 1-2 Shift

ROUTINE 232/332 - SHIFT CONCERN: HARSH 1-2 SHIFT

Routine 233/333 - Shift Concern: Harsh 2-3 Shift

ROUTINE 233/333 - SHIFT CONCERN: HARSH 2-3 SHIFT

Routine 234/334 - Shift Concern: Harsh 3-4 Shift

ROUTINE 234/334 - SHIFT CONCERN: HARSH 3-4 SHIFT

Routine 235/335 - Shift Concern: Harsh 4-3 Shift

ROUTINE 235/335 - SHIFT CONCERN: HARSH 4-3 SHIFT

Routine 236/336 - Shift Concern: Harsh 3-2 Shift

ROUTINE 236/336 - SHIFT CONCERN: HARSH 3-2 SHIFT

Routine 237/337 - Shift Concern: Harsh 2-1 Shift

ROUTINE 237/337 - SHIFT CONCERN: HARSH 2-1 SHIFT

Routine 251/351 - Other Concerns: Shift Lever Efforts High

ROUTINE 251/351 - OTHER CONCERNS: SHIFT LEVER EFFORTS HIGH

Routine 252/352 - Other Concerns: External Leaks

ROUTINE 252/352 - OTHER CONCERNS: EXTERNAL LEAKS

Routine 253/353 - Other Concerns: Poor Vehicle Performance

ROUTINE 253/353 - OTHER CONCERNS: POOR VEHICLE PERFORMANCE

Routine 255/355 - Other Concerns: Engine Will Not Crank

ROUTINE 255/355 - OTHER CONCERNS: ENGINE WILL NOT CRANK

Routine 256/356 - Other Concerns: No Park Range

ROUTINE 256/356 - OTHER CONCERNS: NO PARK RANGE

Routine 257/357 - Other Concerns: Overheating

ROUTINE 257/357 - OTHER CONCERNS: OVERHEATING

Routine 259/359 - Other Concerns: No Engine Braking In Manual 1

ROUTINE 259/359 - OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1

Routine 263/363 - Other Concerns: Slips/Chatters In 1st Gear

ROUTINE 263/363 - OTHER CONCERNS: SLIPS/CHATTERS IN 1ST GEAR

Routine 264/364 - Other Concerns: Slips/Chatters In 2nd Gear

ROUTINE 264/364 - OTHER CONCERNS: SLIPS/CHATTERS IN 2ND GEAR

Routine 282/382 - Other Concerns: Slips/Chatters In 3rd Gear

ROUTINE 282/382 - OTHER CONCERNS: SLIPS/CHATTERS IN 3RD GEAR

Routine 283/383 - Other Concerns: No Engine Braking In ALL Gears

ROUTINE 283/383 - OTHER CONCERNS: NO ENGINE BRAKING IN ALL GEARS

Material

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & HOISTING»(ref-162603-S22452453972004060700000) .
2. Disconnect the return hose from the transmission fluid cooler.
3. Attach a length of suitable drain hose to the transmission fluid cooler return tube.
4. Lower the vehicle.
5. Insert the drain hose into a calibrated 10 liter (10.5 quarts) container.
6. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
7. Switch OFF the engine.
8. Remove the fluid level indicator from the fluid level indicator tube.
9. Add 3 liters of automatic transmission fluid to the transaxle.
10. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
11. Switch OFF the engine.
12. Add 3 liters (3.17 quarts) of automatic transmission fluid to the transaxle.
13. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
14. Switch OFF the engine.
15. Raise the vehicle.
16. Remove the length of suitable drain hose from the transmission fluid return hose.
17. Connect the return hose to the transmission fluid cooler.
18. Lower the vehicle.
19. Add 3 liters (3.17 quarts) of automatic transmission fluid to the transaxle.
20. Install the fluid level indicator to the fluid level indicator tube.
21. Run the engine.
22. Check the automatic transmission fluid level and fill if necessary.

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & HOISTING»(ref-162603-S22452453972004060700000) .
2. Disconnect the return hose from the transmission fluid cooler. Push the connector fitting into the cooler line. Press the yellow release button. Pull the connector fitting off the cooler line.
3. Attach a length of suitable drain hose to the transmission fluid cooler return tube.
4. Lower the vehicle.
5. Insert the drain hose into a calibrated 10 liter (10.5 quarts) container.
6. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
7. Switch OFF the engine.
8. Remove the fluid level indicator from the fluid level indicator tube.
9. Add 3 liters of automatic transmission fluid to the transaxle.
10. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
11. Switch OFF the engine.
12. Add 3 liters (3.17 quarts) of automatic transmission fluid to the transaxle.
13. Run the engine at idle and pump out 3 liters (3.17 quarts) of automatic transmission fluid.
14. Switch OFF the engine.
15. Raise the vehicle.
16. Remove the length of suitable drain hose from the transmission fluid return hose.
17. Connect the return hose to the transmission fluid cooler.
18. Lower the vehicle.
19. Add 3 liters (3.17 quarts) of automatic transmission fluid to the transaxle.
20. Install the fluid level indicator to the fluid level indicator tube.
21. Run the engine.
22. Check the automatic transmission fluid level and fill if necessary.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

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1. Remove the fluid pan. For additional information, refer to «FLUID PAN, GASKET AND FILTER»(ref-207762-S14631942112005120200000) .
2. Disconnect the transmission fluid temperature (TFT) sensor electrical connector.
3. Remove the fluid filter.
4. Remove the ground wire bolt. Disconnect the electrical connectors and remove the main control wiring harness. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid EPC; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black).
5. Remove the main control valve body and accumulators.
6. Remove the accumulator pistons and springs.

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1. Install the accumulator pistons and springs. Accumulator 1 and 2. Accumulator N and D.
2. Install the main control valve body.
3. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown.
4. Install the main control valve wiring harness, connect the electrical connectors and install the ground wire bolt. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid EPC; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black).
5. Install the fluid filter.
6. Connect the TFT sensor electrical connector.
7. Install the fluid pan.
8. Fill and check the fluid level.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & HOISTING»(ref-162603-S22452453972004060700000) .
2. Place a drain pan beneath the output shaft speed (OSS) sensor.
3. Remove the OSS sensor. Disconnect the electrical connector. Remove the bolt. Inspect the OSS bore.
4. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.

Scheme 168

1. Install the OSS sensor. Connect the electrical connector.
2. Lower vehicle.
3. Check the transmission fluid level and add automatic transmission fluid as necessary.
4. Start the engine and move the transaxle range selector lever through all gear positions.

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1. Loosen the strut and spring assembly top mount nuts by five turns.
2. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
3. Loosen the tie-rod end retaining nut.
4. Using the special tool, detach the tie-rod from the wheel knuckle. Remove and discard the retaining nut.
5. Detach the lower arm from the wheel knuckle.
6. Using the special tools, detach the halfshaft from the transaxle. Allow the oil to drain into a suitable container.
7. Remove the halfshaft seal.

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1. Using the special tools, install the halfshaft seal.
2. Attach the halfshaft to the transaxle.
3. Attach the lower arm to the wheel knuckle.
4. Attach the tie-rod end to the wheel knuckle.
5. Install the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
6. Tighten the strut and spring assembly top mount nuts.
7. Check the transmission fluid level and top off with automatic transmission fluid, if necessary.

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1. Loosen the strut and spring assembly top mount nuts by five turns.
2. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
3. Separate the lower arm from the wheel knuckle.
4. Remove and discard the center bearing cap and locknuts.
5. Remove the halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container.
6. Remove the halfshaft seal.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

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1. Inspect the transaxle during disassembly.
2. Remove the output shaft speed (OSS) sensor. Remove the bolt. Remove the OSS.
3. Remove the turbine shaft speed (TSS) sensor.
4. While holding the lever, remove the manual control lever.
5. Remove the transmission range (TR) sensor.
6. Remove the special tool.
7. Using the special tool, remove the torque converter.
8. Using the special tool, mount the transaxle to a bench.
9. Remove the bolts.
10. Using the two 10 mm bolts, remove the fluid pump.
11. Remove the fluid pump seals.
12. Remove the forward clutch thrust washer.
13. Remove the forward clutch assembly.
14. Remove the forward clutch hub.
15. Rotate the transaxle 180 degrees.
16. Remove the end cover.
17. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
18. Remove the direct clutch hub bearing shim.
19. Remove the end cover seals.
20. Remove the end cover to case seals.
21. Remove the direct clutch cylinder thrust bearing.
22. Remove the intermediate/overdrive band anchor bolt.
23. Remove the intermediate/overdrive band.
24. Remove the intermediate/overdrive drum assembly.
25. Remove the planet gear assembly.
26. Remove the low/reverse clutch plate retaining ring.
27. Remove the low/reverse clutch plates, pressure plate and bevel ring.
28. Remove the low one-way clutch retaining ring.
29. Remove the low one-way clutch inner race.
30. Remove the low/reverse clutch return spring.
31. Remove the low/reverse clutch piston.
32. Using the special tool, remove the transaxle fluid pan. Remove the bolts. Using the special tool, remove the transaxle fluid pan.
33. Clean the silicone from the transaxle fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
34. Disconnect the transmission fluid temperature (TFT) sensor.
35. Remove the fluid filter.
36. Remove the ground wire bolt, disconnect the electrical connectors and remove the wire harness. Solenoid SSC; Color N (Neutral). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid EPC; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black).
37. Remove the 13 main control valve body bolts.
38. Remove the transaxle internal harness electrical connector.
39. Remove the accumulator pistons and springs.
40. Remove the manual lever shaft roll pin.
41. Remove the manual lever shaft.
42. Remove the O-ring seals from the manual lever shaft.
43. Remove the control lever assembly.
44. Remove the three intermediate/overdrive piston servo cover bolts and the servo cover.
45. Remove the O-ring seal.
46. Remove the intermediate/overdrive servo piston.
47. Remove the intermediate/overdrive servo piston return spring.
48. Rotate the transaxle 180 degrees.
49. Remove the bolts and separate the converter housing from the transaxle case.
50. Remove the differential assembly.
51. Remove the parking pawl assembly cover. Remove the bolts and the parking pawl assembly cover.
52. Remove the parking pawl abutment. Unclip the spring. Remove the pin. Remove the lever. Remove the parking pawl abutment.
53. Remove the spring.
54. Remove the transfer shaft gears.
55. Using the special tool, lock the final drive input gear.
56. Rotate the transaxle 180 degrees.
57. Using the special tools, remove the final drive input gear bearing retainer nut.
58. Remove the special tools.
59. Rotate the transaxle 180 degrees.
60. Remove the special tool.
61. Rotate the transaxle 180 degrees.
62. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
63. Remove and discard the collapsible spacer.
64. Using a suitable chisel, remove the final drive input gear bearing.
65. Using the special tools, remove the final drive input gear bearing inner race.
66. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.

Scheme 226

MATERIAL SPECIFICATION

Scheme 227

1. Using the special tools, remove the differential case bearings.
2. Remove the differential pinion shaft. Remove and discard the roll pin. Remove the pinion shaft.
3. Remove the differential side gears. Rotate the differential pinion gears 90 degrees and remove the differential pinion gears with the thrust washers. Remove the differential side gears with the thrust washers.
4. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
5. Inspect the differential parts of damage and wear. Pinion gear teeth and bores Side gear teeth and five splines Thrust washers Differential pinion shaft Differential case bearing and surfaces

Scheme 228

Scheme 229

1. Lubricate the gears and thrust washers with clean automatic transmission fluid.
2. Install the different pinion gears and thrust washers. Install the differential side gears and thrust washers. Install the differential pinion gears and thrust washers by rotating 90 degrees.
3. Install the differential pinion shaft. Install the pinion shaft. Install the roll pin.
4. Using the special tool, install the differential case bearings.

Scheme 230

MATERIAL SPECIFICATION

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1. Remove the top portion of the pump.
2. Inspect the lower portion of the pump and gear pocket for nicks, scratches, gouges or wear.
3. Remove the pump seal.
4. Inspect the upper portion of the pump for nicks, scratches or gouges.
5. Inspect the pump gears of nicks, scratches or gouges.

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1. Lubricate the gears and thrust washers with clean automatic transmission fluid.
2. Using the special tool, install the pump seal. Lubricate the gears and thrust washers with automatic transmission fluid.
3. Install the top portion of the pump.

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1. Using the special tools, remove the right-hand side transfer shaft gear bearing.
2. Using the special tool and a press, remove the left-hand side transfer shaft gear bearing while separating the gears.

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1. Using the special tool, install the right-hand side transfer shaft gear and park gear assembly.
2. Using the special tool, assemble the gears and install the left-hand side transfer shaft gear bearing.

Scheme 243

MATERIAL SPECIFICATION

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1. Remove the forward clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, install the forward clutch assembly in a suitable press.
3. Using the special tool, remove the forward clutch balance piston snap ring.
4. Remove and inspect the forward clutch balance piston.
5. Remove the forward piston return spring.
6. Remove the forward clutch piston assembly.

Scheme 249

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1. Soak the internal spline clutch plates in clean automatic transmission fluid for 15 minutes before assembly.
2. Inspect the forward clutch piston bore surfaces for nicks or scratches. Install a new balance piston if necessary.
3. Lubricate and install the forward clutch piston assembly.
4. Install the forward piston return spring.
5. Lubricate and install the forward clutch balance piston.
6. Using the special tool, install the forward clutch assembly in a suitable press.
7. Using the special tool, install the forward clutch balance piston snap ring.
8. Install the forward clutch pressure, friction and steel plates. Install the plates. Install the retaining ring. Check the clearance. For additional information, refer to «SPECIFICATION»(ref-207762-S13826748132005120200000) .

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1. Remove the reverse drum snap ring.
2. Remove the sun gear.
3. Remove the sun gear thrust bearing.
4. Remove the direct clutch hub.
5. Remove the direct clutch thrust bearing.
6. Remove the direct clutch assembly.

MATERIAL SPECIFICATION

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1. Remove the direct clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the selective snap ring.
3. Remove the direct clutch balance piston.
4. Remove the direct clutch return spring.
5. Remove and inspect the direct clutch piston.

Scheme 267

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Scheme 271

1. Soak the internal spline clutch plates in clean automatic transmission fluid for 15 minutes before assembly.
2. Inspect the direct clutch piston bore surfaces for nicks or scratches. Install a new direct clutch piston if necessary.
3. Lubricate and install the direct clutch piston.
4. Install the direct clutch return spring.
5. Install the direct clutch balance piston.
6. Using the special tool, install the selective snap ring.
7. Install the direct clutch pressure, friction and steel plates. Install the plates. Install the retaining ring. Check the clearance. For additional information, refer to «SPECIFICATION»(ref-207762-S13826748132005120200000) .

Scheme 272

MATERIAL SPECIFICATION

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1. Remove the reverse clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the reverse clutch piston return spring retainer ring and retainer.
3. Remove the reverse clutch piston return spring.
4. Remove the reverse clutch piston assembly.
5. Inspect the seal bore in drum, inner and outer seals.

Scheme 278

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1. Soak the internal spline clutch plates in clean automatic transmission fluid for 15 minutes before assembly.
2. Lubricate and install the reverse clutch piston assembly.
3. Install the reverse clutch piston return spring.
4. Using the special tool, install the reverse clutch piston return spring retainer and retainer ring.
5. Install the reverse clutch pressure, friction and steel plates. Install the plates. Install the retaining ring. Check the clearance. For additional information, refer to «SPECIFICATIONS»(ref-207762-S13826748132005120200000) .

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1. Inspect the planet internal bearing for damage.
2. Remove the snap ring.
3. Remove the rear planet assembly.
4. Remove the thrust bearing.
5. Remove the forward planet sun gear.
6. Remove the thrust bearing.
7. Remove the forward planet assembly.
8. Inspect the low and reverse ring gear.
9. Remove the top retainer of the one-way clutch.
10. Remove the top one-way clutch ring.
11. Remove the low one-way clutch assembly.
12. Remove the lower one-way ring.

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1. Install the lower one-way ring.
2. Inspect the rollers and the springs of the one-way clutch.
3. Make sure the low one-way clutch is installed with the tab pointing in the direction as shown.
4. Install the low one-way clutch.
5. Install the top one-way clutch ring.
6. Install the top retainer of the one-way clutch.
7. Install the forward planet assembly.
8. Install the thrust bearing.
9. Inspect the front sun gear retaining ring.
10. Install the forward planet sun gear.
11. Install the thrust bearing.
12. Install the rear planet assembly.
13. Install the snap ring.

Scheme 307

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1. Remove the solenoid body bolts and the solenoid body.
2. Remove and discard the solenoid body gaskets.
3. Remove and discard the seals.
4. Disassemble the main control valve body.

Scheme 311

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1. Install new control valve body plate assembly and separator gaskets.
2. Assemble the main control valve body.
3. Install the seals.
4. Tighten the solenoid body bolts.
5. Tighten the remaining bolts in the sequence shown.

Scheme 314

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1. Remove the halfshaft seals (left-hand side shown).
2. Using the special tools, remove the differential case bearing cups (left-hand side shown).
3. Using the special tools, remove the final drive input gear bearing cup.
4. Using the special tool, remove the transfer shaft gear bearing cups (left-hand side shown).
5. Remove the funnel.
6. Rotate the transaxle 180 degrees.
7. Using the special tools, remove the final drive input gear bearing cup.

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1. Using the special tools, install the final drive input gear bearing cup.
2. Rotate the transaxle 180 degrees.
3. Install the funnel.
4. Using the special tools, install the left-hand side transfer shaft gear bearing cup.
5. Using the special tools, install the final drive input gear bearing cup (left-hand side shown).
6. Using the special tools, install the left-hand side differential case bearing cup.
7. Using the special tools, install the halfshaft seals (left-hand side shown).

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MATERIAL SPECIFICATION

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Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

1. Using the special tool, install the final drive input gear bearing. Install the final drive input gear bearing. Install the special tool.
2. Using an arbor press and the special tools, seat the final drive input gear bearing.
3. Install a new collapsible spacer.
4. Using the special tool, position the final drive input gear.
5. Rotate the transaxle 180 degrees.
6. Using the special tools, install the final drive input gear bearing.
7. Rotate the transaxle 180 degrees.
8. Using the special tool, lock the final drive input gear.
9. Rotate the transaxle 180 degrees.
10. Using the special tools, tighten the nut to achieve the preload specification.
11. Rotate the transaxle 180 degrees.
12. Unlock the special tool.
13. Rotate the transaxle 180 degrees.
14. Using the special tools, measure the rotating torque.
15. After achieving the correct torque, remove the special tools and stake the nut to prevent movement.
16. Rotate the transaxle 180 degrees.
17. Position the transfer shaft gears in the transaxle case.
18. Install the parking pawl return spring.
19. Connect the spring. Install the parking pawl abutment. Install the lever. Install the pin. Connect the spring.
20. Install the parking pawl assembly cover and bolts.
21. Install the differential case assembly.
22. Position the bearing cups.
23. Install the special tools.
24. Using the special tools, assemble the transaxle for end play measurement. Position the converter housing. Install the special tool bolts and seat the case cover flat.
25. Remove the converter housing. Remove bolts. Remove the converter housing.
26. Remove the special tools.
27. Remove the bearing cups.
28. To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim. For additional information, refer to «SPECIFICATION»(ref-207762-S13826748132005120200000) .
29. To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim. For additional information, refer to «SPECIFICATIONS»(ref-207762-S13826748132005120200000) .
30. Using the special tool, install the correct transfer shaft shim and bearing cup in to the converter housing.
31. Using the special tool, install the correct differential shaft shim and differential case bearing cup into the converter housing.
32. Apply a one millimeter thick bead of Loctite 5699.
33. Position the converter housing on the transaxle case and install the bolts.
34. Install the intermediate/overdrive band servo piston return spring.
35. Install the intermediate/overdrive servo piston.
36. Install the O-ring seal.
37. Install the intermediate/overdrive band servo piston cover.
38. Install the shifter assembly and bolt.
39. Install the new O-rings on the manual lever shaft.
40. Install the manual lever shaft.
41. Install a new manual lever shaft roll pin.
42. Loosely install the transmission range (TR) sensor.
43. Check accumulator bores and pistons for steps and install the accumulator pistons in their respective bores.
44. Install the thinner and longer neutral drive accumulator springs.
45. Install the neutral drive accumulator piston.
46. Install the 1-2 accumulator springs.
47. Install the 1-2 accumulator piston.
48. Inspect the seals. Lubricate and install the transaxle internal harness electrical connector.
49. Install the main control valve body.
50. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown.
51. Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid EPC; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black).
52. Install the fluid filter.
53. Connect the transmission fluid temperature (TFT) sensor.
54. Apply a bead 1.5 mm diameter of Motorcraft TA-29 to the transaxle fluid pan.
55. Install the transaxle fluid pan.
56. Rotate the transaxle 180 degrees.
57. Install the low/reverse clutch piston.
58. Install the low/reverse clutch return spring.
59. Install the bevel ring with the outer edge of the beveled ring up towards the top of the case.
60. Inspect the position of the bevel ring. Make sure the low/reverse clutch piston is seated. Make sure the bevel ring is installed with the inside edge facing down.
61. Install the low one-way clutch inner race.
62. Install the low one-way clutch retaining ring.
63. Install the low/reverse plates and pressure plate.
64. Install the low reverse clutch plate selective retaining ring. Check the clutch clearance.
65. Install the planet assembly.
66. Inspect the planet assembly installation.
67. Check to make sure that the one way clutch is correctly installed. Rotate the planet assembly clockwise and counterclockwise.
68. Install the intermediate/overdrive drum assembly.
69. Install the intermediate/overdrive band.
70. Install the direct clutch cylinder thrust bearing with the rollers facing up.
71. Install new end cover-to-case seals.
72. Install new end cover seals.
73. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater.
74. Measure the gap between the transaxle end cover and the transaxle assembly. Position the transaxle end cover on the transaxle assembly. Measure the gap between the transaxle end cover and the transaxle assembly.
75. Remove the transaxle end cover.
76. Choose and install the correct direct clutch hub bearing shim: Line 1: total amount of shim thickness used during transaxle end cover mock up. Line 2: measure the gap between transaxle end cover and transaxle case. Line 3: subtract Line 2 from Line 1 to obtain the actual clearance. Line 4: subtract 0.05 mm (0.002 in) from Line 3 for maximum shim thickness. Subtract 0.50 mm (0.020 in) from line 3 for the minimum thickness shim.
77. Apply a 1 mm (0.04 in) bead of sealer to the transaxle end cover.
78. Install the transaxle end cover.
79. Using the special tool, collapse the intermediate/overdrive band to specification, then back out three and a half turns.
80. Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.
81. Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown.
82. Install the intermediate/overdrive band anchor bolt.
83. Rotate the transaxle 180 degrees.
84. Install the forward clutch hub.
85. Install the forward clutch assembly.
86. Install the forward clutch thrust washer.
87. Lubricate and install new fluid pump seals.
88. Install the fluid pump (do not force the pump down at this time).
89. Install the fluid pump bolts. Use the bolts to seat the fluid pump. Tighten bolts in an alternating sequence.
90. Install the output shaft speed (OSS) sensor.
91. Install the turbine shaft speed (TSS) sensor.
92. Using the special tool, align the TR sensor and tighten the bolts.
93. Install the manual control lever.
94. Install the torque converter.
95. Using the special tool, secure the torque converter.

Scheme 391

MATERIAL SPECIFICATION