Automatic Transmission: Diagnosis Ford Focus II

Diagnostic Strategy

SPECIAL TOOL(S) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

Troubleshooting an electronically-controlled automatic transaxle is simplified by using the proven method of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.

Note. Do not take any shortcuts or assume that critical checks or adjustments have already been made.

Follow the procedures as written to avoid missing critical components or steps.

To correctly diagnose a concern have the following publications available

1. «INTRODUCTION - GASOLINE»(ref-249149) .
2. TSBs .
3. Wiring Diagram.

These publications provide the necessary information when diagnosing transaxle concerns.

Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.

Preliminary Inspection

1. Know and understand the customers concern.
2. Verify the concern by operating the vehicle.
3. Check the fluid levels and condition.
4. Check for non-factory add-on items.
5. Check shift linkages for correct adjustment.
6. Check TSBs regarding the concern.

Diagnostics

1. Carry out on-board diagnostic procedures key on engine off (KOEO) and key on engine running (KOER).
2. Record all diagnostic trouble codes (DTCs).
3. Repair all non-transaxle codes first.
4. Repair all transaxle codes second.
5. Erase all continuous codes and attempt to repeat them.
6. Repair all continuous codes.
7. If only pass codes are obtained, proceed to the «DIAGNOSIS BY SYMPTOM INDEX»(ref-255393-S07397024072007053100000) for further information and diagnosis.

Follow the diagnostic sequence to diagnose and repair the concern the first time.

Diagnostic Flow Chart

SPECIAL TOOL(S) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

Prior to carrying out the flow test, following items should be checked

1. Know and understand the customer concerns.
2. Check the fluid level and condition.
3. Verify the concern by operating the vehicle.
4. Check for non-factory installed items and verify correct installation.
5. Check the shift linkage adjustments.
6. Check TSBs for vehicle concerns.
7. Carry out quick test both KOER and KOEO.
8. Record all codes.

DIAGNOSTIC FLOW CHART

The following items must be checked prior to beginning the diagnostic procedures

Road Testing Vehicle

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

The Shift Point Road Test and Torque Converter Clutch Operation Test provide diagnostic information on transaxle shift controls and torque converter operation.

Shift Point Road Test

This test verifies that the shift control system is operating correctly.

1. Bring engine and transaxle up to normal operating temperature.
2. Operate the vehicle with the selector lever in the D position (overdrive switch ON).
3. Apply minimum throttle and observe the speeds at which upshift occurs and torque converter engages. Refer to the following «SHIFT SPEEDS CHART»(ref-255393-S09633817232007053100000) for the appropriate final drive ratio.
4. Stop the vehicle. Select the D position (overdrive switch OFF). Repeat Step 3. The transaxle will make all upshifts, except 3rd to 4th, and torque converter clutch apply should occur above 80 km/h (50 mph).
5. Press the accelerator pedal to the floor, wide open throttle (WOT). The transaxle should shift from 3rd to 2nd, or 3rd to 1st, depending on vehicle speed, and torque converter clutch should release.
6. With vehicle speed above 48 km/h (30 mph), move the transaxle range selector lever from D position to 1st position and release the accelerator pedal. The transaxle should immediately downshift to 2nd gear. When vehicle speed drops below 32 km/h (20 mph), the transaxle should downshift into 1st gear.
7. If transaxle fails to upshift/downshift or torque converter clutch does not apply/release, refer to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) for possible causes.

SHIFT SPEEDS CHART

Visual Inspection

This inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as

1. Electronic add-on items: air conditioning generator (alternator) engine turbo cellular telephone cruise control cb radio linear booster backup alarm signal computer
2. Vehicle modification

These items, if not installed correctly, will affect the powertrain control module (PCM), or transaxle function. Pay particular attention to add-on wiring splices in the PCM harness or transaxle wiring harness, abnormal tire size, or axle ratio changes.

1. Leaks; refer to «LEAKAGE INSPECTION»(ref-255393-S25409446962007053100000) in this article.
2. Correct linkage adjustments; refer to «AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS»(ref-255432) .

Carry Out On-Board Diagnostics (KOEO, KOER)

After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using scan tool. Refer to the INTRODUCTION - GASOLINE for diagnosis and testing of the powertrain control system.

SPECIAL TOOL(S) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

Diagnosing an electronically controlled automatic transaxle is simplified using the following procedures. It is important to remember that there is a definite procedure to follow. Do not take short cuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics with Scan Tool

Note. For detailed instruction and other diagnostic methods using the scan tool, refer to the tester and the INTRODUCTION - GASOLINE .

These quick tests should be used to diagnose the powertrain control module (PCM) and should be carried out in order.

1. Quick Test 1.0 - Visual Inspection
2. Quick Test 2.0 - Set Up
3. Quick Test 3.0 - Key ON, Engine OFF
4. Quick Test 4.0 - Continuous Memory
5. Quick Test 5.0 - Key ON, Engine RUN
6. Special Test Mode Wiggle Test Mode Output Test Mode
7. PCM Reset Mode
8. Clearing DTCs
9. OBD II Drive Cycle
10. Other Scan Tool Features

For further information on other diagnostic testing features using the scan tool, refer to the INTRODUCTION - GASOLINE . Other diagnostic methods include the following

1. Parameter Identification (PID) Access Mode
2. Freeze Frame Data Access Mode
3. Oxygen Sensor Monitor Mode

Transaxle Drive Cycle Test

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Note. The Transaxle Drive Cycle Test must be followed exactly. Transaxle failure must occur 4 times consecutively for shift error DTC code to be set, and 5 times consecutively for continuous torque converter clutch code to set.

Note. When carrying out the Transaxle Drive Cycle Test, refer to the SOLENOID OPERATION CHART - CONVERTER DISENGAGED for correct solenoid operation.

After carrying out the Quick Test, use the Transaxle Drive Cycle Test for checking continuous codes.

1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transaxle fluid level is correct.
4. With transaxle in O/D position, moderately accelerate from stop to 80 km/h (50 mph). This allows the transaxle to shift into 4th gear. Hold speed and throttle open steady for a minimum of 15 seconds. NOTE: PCA, EPC and VFS all refer to the solenoids. PCA is preferred for this transmission because the scan tool displays PCA.
5. With transaxle in 4th gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stop lamps. Then hold speed and throttle steady for a minimum of 5 seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat Steps 4 through 6 at least 5 times.
8. Carry out Quick Test and record continuous DTCs.

After On-Board Diagnostics

Note. The vehicle wiring harness, powertrain control module and non-transaxle sensors may affect transaxle operations. Repair these concerns first.

After the on-board diagnostic procedures are completed, repair all DTCs.

Begin with non-transaxle related DTCs, then repair any transaxle related DTCs. Refer to DIAGNOSTIC TROUBLE CODE (DTC) CHARTS for information on condition and symptoms. This chart will be helpful in referring to the correct article(s) and aids in diagnosing internal transaxle concerns and external non-transaxle inputs. The pinpoint tests are used in diagnosing transaxle electrical concerns. Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The INTRODUCTION - GASOLINE will aid in diagnosing non-transaxle electronic components.

Diagnostic Trouble Code (DTC) Charts

DIAGNOSTIC TROUBLE CODE CHART

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART

TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS PID CHART

Shift Solenoid Pre-Diagnosis

Use the shift solenoid operation chart when carrying out Pinpoint Test A. Refer to SPECIFICATIONS in this article.

SOLENOID OPERATION CHART - CONVERTER DISENGAGED

SOLENOID OPERATION CHART - CONVERTER ENGAGED

PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

Note. Refer to the Transaxle Vehicle Harness Connector illustration preceding these pinpoint tests. (Scheme 15)

Note. Refer to the Transaxle Internal Harness Diagram illustration preceding these pinpoint tests. (Scheme 14)

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. B1 ELECTRONIC DIAGNOSTIC SET UP Key in OFF position. Shift selector lever to position P. Check to make sure the transaxle harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Select Diagnostic Data Link. Select PCM. Select PID/Data Monitor and Record. Enter the following diagnostic mode on the scan tool: PIDs; TFT, TFTV. Does the vehicle enter PID/Data Monitor and Record? Yes : REMAIN in PID/Data Control. GO to B2 . No : REPEAT procedure to enter PID. If vehicle did not enter PID, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) for diagnosis of PCM.
2. B2 WARM-UP/COOL-DOWN CYCLE VERIFICATION While monitoring the TFT PIDs, carry out the following test: If transaxle is cold, run transaxle to warm it up. If transaxle is warm, allow transaxle to cool down. Do the TFT PIDs increase as the transaxle is warmed up or decrease as the transaxle is cooled or does the TFT or TFTV drop in and out of range? Yes : If the TFT PIDs increase as the transaxle is warmed or decrease as the transaxle is cooled, CLEAR all DTCs. Road test to verify if concern is still present. If concern is still present, REFER to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) , to diagnose transaxle overheating. If the TFT drops in and out of range, INSPECT for intermittent concern in the internal/external harness, sensor or connector. No : GO to B3 .
3. B3 CHECK POWERTRAIN CONTROL MODULE AND VEHICLE HARNESS FOR POWER Disconnect: Transaxle Vehicle Harness Connector. Visually inspect all wires and connectors for damage. Measure the voltage between transaxle vehicle harness connector pin 5, harness side and ground; and between transaxle vehicle harness connector pin 4, harness side and ground. Is voltage present? Yes : GO to B4 . No : GO to B5 .
4. B4 CHECK VEHICLE HARNESS FOR SHORT TO POWER Disconnect: PCM Connector. Measure the voltage between transaxle vehicle harness connector pin 5, harness side and ground; and between transaxle vehicle harness connector pin 4, harness side and ground. Is voltage present? Yes : REPAIR the circuit. TEST the system for normal operation. No : INSTALL a new PCM. TEST the system for normal operation.
5. B5 CHECK POWERTRAIN CONTROL MODULE AND VEHICLE HARNESS FOR GROUND Connect: PCM Connector. Measure the resistance between transaxle vehicle harness connector pin 5, harness side and ground; and between transaxle vehicle harness connector pin 4, harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to B7 . No : GO to B6 .
6. B6 CHECK VEHICLE HARNESS FOR SHORT TO GROUND Disconnect: PCM Connector. Measure the resistance between transaxle vehicle harness connector pin 5, harness side and ground; and between transaxle vehicle harness connector pin 4, harness side and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new PCM. TEST the system for normal operation. No : REPAIR the circuit. TEST the system for normal operation.
7. B7 CHECK VEHICLE HARNESS FOR OPEN Measure the resistance between transaxle vehicle harness connector pin 5, harness side and PCM connector pin 29, harness side. Measure the resistance between transaxle vehicle harness connector pin 4, harness side and PCM connector pin 41, harness side. Is the resistance less than 5 ohms? Yes : GO to B8 . No : REPAIR the circuit. TEST the system for normal operation.
8. B8 CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN SHORT TO GROUND Measure the resistance between transaxle vehicle harness connector pin 5 (component side, transaxle internal harness), and ground; and between transaxle vehicle harness connector pin 4 (component side, transaxle internal harness), and ground. Is the resistance greater than 10,000 ohms? Yes : GO to B9 . No : INSTALL a new transaxle internal harness. TEST the system for normal operation.
9. B9 CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN OPEN Measure the resistance between transaxle vehicle harness connector pin 5 (component side, transaxle internal harness), and transmission fluid temperature sensor internal harness connector pin 5; and between transaxle vehicle harness connector pin 4 (component side, transaxle internal harness), and transmission fluid temperature sensor internal harness connector pin 4. Is the resistance less than 5 ohms? Yes : GO to B10 . No : INSTALL a new transaxle internal harness. TEST the system for normal operation.
10. B10 CHECK RESISTANCE OF TFT SENSOR Measure the resistance between transaxle vehicle harness connector pin 5 (component side, transaxle internal harness), and transaxle vehicle harness connector pin 4 (component side, transaxle internal harness). Record the resistance. Resistance should be approximately in the following ranges: -20°C (-4°F) - 236-317 K ohms. 0°C (32°F) - 83.2-107 K ohms. 20°C (68°F) - 33.5-41.2 K ohms. 40°C (104°F) - 14.6-17.6 K ohms. 60°C (140°F) - 7.08-8.01 K ohms. 80°C (176°F) - 3.61-4.06 K ohms. 100°C (212°F) - 1.96-2.20 K ohms. 120°C (248°F) - 1.13-1.25 K ohms. 130°C (266°F) - 0.87-0.96 K ohms. Is the resistance in the range? Yes : REFER to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) to diagnose an overheating concern. No : INSTALL a new TFT sensor. TEST the system for normal operation.

PINPOINT TEST C: TRANSMISSION RANGE (TR) SENSOR

Note. Refer to the Transmission Range (TR) Sensor Connector illustration preceding these pinpoint tests. (Scheme 16)

Note. Refer to TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART .

Note. DTC code P0705 may also be set from an open ground in the taillamp circuit. Check and repair taillamp circuit as necessary.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. C1 VERIFY TR SENSOR ALIGNMENT Using a scan tool, view the TR_1, TR_2, TR_3 and TR_4 PIDs to determine if an internal fault is present in the transmission range (TR) sensor, refer to «TRANSMISSION RANGE (TR) SENSOR DIAGNOSTIC PID CHART»(ref-255393-S09188830822007053100000) in Transaxle Connector Layouts in this article. If an electrical issue exists in the TR sensor electrical circuit, 2 or more binary positions will show 1's. EXAMPLE OF BINARY POSITION Range Selection PID Code Result Reverse or Drive 1100 (Reverse and Drive input detected) High probability of a tail lamp ground concern. Clean grounds. Drive or Manual 1 0101 (Drive and Manual 1 input detected) High probability of internal arcing inside the TR sensor. Verify TR sensor alignment. Is the TR sensor correctly aligned? Yes : GO to C2 . No : ADJUST the TR sensor. TEST the system for normal operation.
2. C2 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT Verify that the shift cable/linkage is correctly adjusted. REFER to «AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS»(ref-255432) . Is the shift cable/linkage correctly adjusted? Yes : GO to C3 . No : ADJUST the shift cable/linkage REFER to «AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS»(ref-255432) . TEST the system for normal operation.
3. C3 CHECK POWER SUPPLY TRANSAXLE CIRCUIT FOR AN OPEN Disconnect: TR Sensor Connector. Key in ON position. Measure the voltage between TR sensor connector pin 1, harness side and ground. Is the voltage greater than 10 volts? Yes : GO to C4 . No : REPAIR power supply circuit 15 (GN/OG). TEST the system for normal operation.
4. C4 CHECK TR SENSOR CIRCUITRY FOR SHORT TO POWER Select PARK. Key in ON position. Measure the voltage between TR sensor connector pins 2, 3, 4, 5, 7 and 8 harness side and ground. Is voltage present? Yes : GO to C5 . No : GO to C7 .
5. C5 CHECK PCM FOR SHORT TO POWER Key in OFF position. Disconnect: PCM Connector. Key in ON position. Measure the voltage between TR sensor connector pins 2, 3, 4, 5, 7 and 8 harness side and ground. Is voltage present? Yes : REPAIR the circuit in question. TEST the system for normal operation. No : INSTALL a new PCM. TEST the system for normal operation.
6. C6 CHECK VEHICLE HARNESS FOR SHORT TO GROUND Key in OFF position. Disconnect: PCM Connector. Disconnect: Fuse F2.40 (10A). Measure the resistance between TR sensor connector pins 2, 3, 4, 5, 7 and 8 harness side and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new PCM. TEST the system for normal operation. No : REPAIR the circuit in question. TEST the system for normal operation.
7. C7 CHECK TR SENSOR CIRCUITRY FOR SHORT TO GROUND Key in OFF position. Connect: PCM Connector. Disconnect: Fuse F2.40 (10A). Measure the resistance between TR sensor connector pins 2, 3, 4, 5, 7 and 8 harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to C8 . No : GO to C6 .
8. C8 CHECK THE TR SENSOR RESISTANCE Connect: Fuse F2.40 (10A). Measure the resistance between TR sensor connector pins, component side, as follows: PARK position, TR sensor pins 6 and 5, 8 and 9 less than 1,000 ohms. REVERSE position, TR sensor pins 1 and 4 less than 1,000 ohms. NEUTRAL position, TR sensor pins 1 and 8 less than 1,000 ohms. DRIVE position, TR sensor pins 1 and 2 less than 1,000 ohms. 2 position, TR sensor pins 1 and 7 less than 1,000 ohms. 1 position, TR sensor pins 1 and 3 less than 1,000 ohms. Are the resistances within the expected values? Yes : INSTALL a new PCM. TEST the system for normal operation. No : INSTALL a new TR sensor. TEST the system for normal operation.

PINPOINT TEST D: ELECTRONIC PRESSURE CONTROL SOLENOID (PCA)

Note. Refer to the Transaxle Vehicle Harness Connector illustration preceding these pinpoint tests. (Scheme 15)

Note. Read and record all DTCs. All TR sensor and OSS DTCs must be repaired before entering Output State Control (OSC).

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. D1 ELECTRONIC DIAGNOSTICS SET UP Key in OFF position. Shift selector lever to position "P". Check to make sure the transaxle harness connector is fully seated, terminals are fully engaged in the connector and in good condition before proceeding. Install 300 psi pressure gauge into line tap. Connect the scan tool. Key in START position. Start and run the engine. Enter the following diagnostic mode on the scan tool: Diagnostic Data Link. Enter the following diagnostic mode on the scan tool: PCM. Enter the following diagnostic mode on the scan tool: Active Command Modes. Enter the following diagnostic mode on the scan tool: Output State Control (OSC). Enter the following diagnostic mode on the scan tool: Trans-Bench Mode. Does the vehicle enter the Trans-Bench Mode? Yes : REMAIN in Trans-Bench Mode. GO to D2 . No : REPEAT procedure to ENTER Trans-Bench Mode. If vehicle did not enter OSC, REFER to «INTRODUCTION - GASOLINE»(ref-249149) for diagnosis of PCM.
2. D2 SOLENOID FUNCTIONAL TEST Monitor pressure gauge. Enter the following diagnostic mode on the scan tool: Parameter; PCA. Select PCA Increase engine speed above 1,500 rpm. Select value: 50, 70, 90, 110, 130 or 150 psi. Press "SEND". Select another value "50-150 psi". Press "SEND". Enter the following diagnostic mode on the scan tool: XXX. Press "SEND". Does the pressure reading match the commanded pressure? Yes : CLEAR DTCs. TEST the system for normal operation. No : GO to D3 .
3. D3 CHECK VEHICLE HARNESS AND POWERTRAIN CONTROL MODULE FOR SHORT TO POWER Key in OFF position. Disconnect: Transaxle Vehicle Harness Connector. Visually inspect all wires and connectors for damage. Key in ON position. Measure the voltage between transaxle vehicle harness connector pin 7, harness side and ground; and between transaxle vehicle harness connector pin 2, harness side and ground. Is voltage present? Yes : GO to D4 . No : GO to D5 .
4. D4 CHECK VEHICLE HARNESS FOR SHORT TO POWER Key in OFF position. Disconnect: PCM Connector. Key in ON position. Measure the voltage between transaxle vehicle harness connector pin 7, harness side and ground; and between transaxle vehicle harness connector pin 2, harness side and ground. Is voltage present? Yes : REPAIR the circuit. TEST the system for normal operation. No : INSTALL a new PCM. TEST the system for normal operation.
5. D5 CHECK ELECTRICAL SIGNAL Measure the voltage between transaxle vehicle harness connector pin 7, harness side and transaxle vehicle harness connector pin 2, harness side. Activate solenoids (ON and OFF) while monitoring the voltage reading. Enter the following diagnostic mode on the scan tool: Trans-Bench Mode. Enter the following diagnostic mode on the scan tool: Parameter; PCA. Select a value "50-150 psi". Press "SEND". Select another value "50-150 psi". Press "SEND". Enter the following diagnostic mode on the scan tool: XXX. Press "SEND". Does the voltage change? Yes : GO to D6 . No : CHECK for open or short circuit in harness or PCM.
6. D6 CHECK THE TRANSAXLE INTERNAL HARNESS FOR SHORT TO GROUND Key in OFF position. Disconnect: PCA Solenoid Electrical Connector. Measure the resistance between transaxle vehicle harness connector pin 2 (component side, transaxle internal harness), and ground; and between transaxle vehicle harness connector pin 7 (component side, transaxle internal harness), and ground. Is the resistance greater than 10,000 ohms? Yes : GO to D7 . No : INSTALL a new transaxle internal harness. TEST the system for normal operation.
7. D7 CHECK THE TRANSAXLE INTERNAL HARNESS AN OPEN Measure the resistance between transaxle vehicle harness connector pin 2 (component side, transaxle internal harness), and transaxle internal harness connector pin 2; and between transaxle vehicle harness connector pin 7 (component side, transaxle internal harness), and transaxle internal harness connector pin 7. Is the resistance less than 5 ohms? Yes : GO to D8 . No : INSTALL a new transaxle internal harness. TEST the system for normal operation.
8. D8 CHECK SOLENOID RESISTANCE AT SOLENOID Key in OFF position. Measure and record the resistance between PCA solenoid pins. Is the resistance between 2.4 and 7.3 ohms? Yes : GO to D9 . No : INSTALL a new PCA solenoid. TEST the system for normal operation.
9. D9 CHECK SOLENOID FOR SHORT TO GROUND Measure and record the resistance between the PCA solenoid and the solenoid body. Is the resistance greater than 10,000 ohms? Yes : REFER to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) for diagnosis of pressure concerns. TEST the system for normal operation. No : INSTALL a new PCA solenoid. TEST the system for normal operation.

PINPOINT TEST E: TURBINE SHAFT SPEED (TSS) SENSOR AND OUTPUT SHAFT SPEED (OSS) SENSOR

Note. Refer to the Turbine Shaft Speed (TSS) Sensor and Output Shaft Speed (OSS) Sensor connector illustrations preceding these pinpoint tests. (Scheme 18)and (Scheme 17).

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

1. E1 ELECTRONIC DIAGNOSTICS SET UP Check to make sure the transaxle harness connectors are fully seated, terminals are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: Diagnostic Data Link. Enter the following diagnostic mode on the scan tool: PCM. Select Trans Priority. Select PID/Data Monitor and Record. Select the following PIDs: TSS or OSS. Does vehicle enter PID/Data Monitor and Record? Yes : REMAIN in PID/Data. GO to E2 . No : REPEAT procedure to ENTER PID. If vehicle did not enter PID, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) for diagnosis of PCM.
2. E2 DRIVE CYCLE TEST While monitoring the appropriate sensor PID, drive the vehicle so that the transaxle upshifts and downshifts through all gears. Does the TSS or OSS Speed PID increase and decrease with engine and vehicle speed? Yes : GO to E3 . No : If the TSS or OSS Speed PID does not increase and decrease with engine and vehicle speed, INSPECT for open or short in vehicle harness, sensor, a PCM concern or internal hardware concern. GO to E4 .
3. E3 DRIVE CYCLE TEST ERRATIC While monitoring the appropriate sensor PID, drive the vehicle so that the transaxle upshifts and downshifts through all gears. Is the TSS or OSS Speed PID signal erratic (drop to zero or near zero and return to normal operation)? Yes : If the sensor signal is erratic, INSPECT for intermittent concern in the harness, sensor or connector. GO to E4 . No : CLEAR all DTCs. Rerun OBD.
4. E4 CHECK THE VEHICLE WIRING HARNESS FOR A SHORT TO POWER Key in OFF position. Disconnect: TSS or OSS Sensor Connector. Disconnect: PCM Connector C175t. Key in ON position. Measure the voltage between TSS/OSS sensor connector pin 1, harness side and ground; and between TSS/OSS sensor connector pin 2, harness side and ground. Is there any voltage? Yes : REPAIR the circuit in question. TEST the system for normal operation. No : GO to E5 .
5. E5 CHECK THE VEHICLE WIRING HARNESS FOR A SHORT TO GROUND Key in OFF position. Measure the resistance between TSS/OSS sensor connector pin 1, harness side and ground; and between TSS/OSS sensor connector pin 2, harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to E6 . No : REPAIR the circuit in question. TEST the system for normal operation.
6. E6 CHECK THE VEHICLE WIRING HARNESS FOR AN OPEN CIRCUIT Key in OFF position. For TSS, measure the resistance between TSS sensor connector pin 1, harness side and PCM connector C175t pin 15; and between TSS sensor connector pin 2, harness side and PCM connector C175t pin 41. For OSS, measure the resistance between OSS connector pin 1, harness side and PCM connector C175t pin 6; and between OSS connector pin 2, harness side and PCM connector C175t pin 7. Is the resistance less than 5 ohms? Yes : GO to E7 . No : REPAIR the circuit in question. TEST the system for normal operation.
7. E7 CHECK RESISTANCE OF TSS SENSOR OR OSS. For TSS sensor, measure the resistance between TSS sensor connector pin 1, component side and TSS sensor connector pin 2, component side. For OSS, measure the resistance between OSS connector pin 1, component side and OSS connector pin 2, component side. Record the resistance. Resistance should be as follows: OSS 675-775 ohms at -20°C (-4°F). OSS 800- 920 ohms at 21°C (70°F). OSS 1210-1390 ohms at 160°C (302°F). TSS 273-333 ohms at -20°C (-4°F). TSS 330-390 ohms at 21°C (70°F). TSS 487-601 ohms at 160°C (302°F). Is the resistance within specification for the appropriate sensor? Yes : GO to E8 . No : INSTALL a new sensor. TEST the system for normal operation.
8. E8 CHECK SENSORS FOR SHORT TO GROUND For TSS sensor, measure the resistance between TSS sensor connector pin 1, component side and ground. For OSS, measure the resistance between OSS connector pin 1, component side and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new PCM. TEST the system for normal operation. If the condition still exists, REFER to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) for diagnosis of shift or torque converter concerns. No : INSTALL a new TSS or OSS sensor. TEST the system for normal operation. If the condition still exists, REFER to «DIAGNOSIS BY SYMPTOM»(ref-255393-S30097251742007053100000) for diagnosis of shift or torque converter concerns.

Special Testing Procedures

SPECIAL TOOL(S) Air Test Plate and Gasket 307-412 Hydraulic Pressure Gauge 307-132 (17-014)

Scheme 43

The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portion of the transaxle.

Line Pressure Test

Note. Certain sensor failures may cause high PC, FMEM (Failure Mode Effect Management) actions. Make sure that self-test and electrical repairs have been carried out, or test results may be incorrect.

This test verifies that the line pressure is within specifications.

Scheme 44

1. Connect pressure gauge to the line pressure tap.
2. Start engine and check line pressures. Refer to the following «LINE PRESSURE CHART»(ref-255393-S21537365562007053100000) to determine if line pressure is within specifications.
3. If line pressure is not within specification, refer to «LINE PRESSURE DIAGNOSIS CHART»(ref-255393-S21537365562007053100000) for line pressure concern causes.

LINE PRESSURE CHART

LINE PRESSURE DIAGNOSIS CHART

Stall Speed Test

This test checks operation of the following items

1. Torque converter clutch
2. Forward clutch
3. Low one way clutch assembly
4. Engine performance

Note. The Stall Speed Test should be carried out with the engine and transaxle at normal operating temperatures.

1. Connect tachometer to the engine. CAUTION: After testing each of the following ranges D, 2, 1 and R, move the selector lever to N (NEUTRAL) and run the engine at 1,000 rpm for about 15 seconds to allow the torque converter to cool before testing the next range. CAUTION: Do not maintain wide open throttle in any range for more than 5 seconds. CAUTION: If the engine RPM recorded by the tachometer exceeds maximum specified RPM, release the accelerator pedal immediately. Clutch or band slippage is indicated. NOTE: Prolonged use of this procedure may set Diagnostic Trouble Code P0712, P1783. After carrying out Stall Speed Test, run OBD Test and clear DTCs from memory.
2. Press accelerator pedal to floor (WOT) in each range. Record rpm reached in each range. Stall speeds should be as follows: STALL SPEED CHART Engine RPM All 2,200-2,700
3. If stall speeds were too high, refer to the following «STALL SPEED DIAGNOSIS CHART»(ref-255393-S42483984482007053100000) . If stall speeds were too low, first check the engine idle speed. If engine idle is OK, remove torque converter and check the torque converter one-way clutch for slippage. STALL SPEED DIAGNOSIS CHART Transaxle Range Selector Lever Position Possible Cause Above specification in D, 2 and 1 Forward clutch slipping. Above specification in 2 Intermediate/overdrive band slipping. Above specification in 1 and R Low/reverse clutch slipping. Above specification in R Reverse clutch slipping. Above specification in R Carry out road test to determine whether problem is in low/reverse clutch. Above specification in R Low/reverse clutch is defective.

Scheme 45

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 should 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. Refer to «MAIN CONTROL»(ref-255393-S40101431782007053100000) in this article.
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 (Scheme 43) 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.

Leakage Inspection

SPECIAL TOOL(S) 100W/12 Volt DC UV Lamp 164-R0751

Scheme 46

MATERIALS

Check the fluid filler tube at the transaxle case. If leakage is found here, install a new plug.

Check fluid tubes and fittings between the transaxle and the cooler for looseness, wear or damage. If leakage cannot be stopped by tightening a fluid tube nut, install new parts.

If the leak continues, install a new cooler line fitting and tighten to specification. The same procedure should be followed for fluid leaks between the cooler and the cooler line fittings in this article. Refer to TRANSAXLE-TRANSMISSION COOLING .

The cooler can be further checked for leaks. Refer to TRANSAXLE-TRANSMISSION COOLING .

If leakage is found at the transaxle range selector lever, install a new seal.

If leakage is found at the transaxle harness connector, install a new O-ring.

The transaxle has the following parts to prevent external fluid leakage

1. Sealer
2. Lip-type seals
3. O-ring seals
4. Seal rings
5. Seal grommets
6. Thread sealant
7. Pan fluid

Scheme 47

Leak Check Test

1. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transaxle. The red color should assist in pinpointing the leak.
2. Clean off any fluid from the top and bottom of the torque converter housing, the case and the rear face of the engine and oil pan. Clean the torque converter area by washing with a suitable nonflammable solvent and blow dry with compressed air.
3. Wash out the torque converter housing, and the front of the flexplate. The torque converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transaxle reaches its normal operating temperature. Observe the back of the cylinder block and the top of the torque converter housing for evidence of fluid leakage. Raise the vehicle on a hoist; refer to «JACKING AND LIFTING»(ref-255374) and run the engine at fast idle, then at engine idle, occasionally shifting to the D and R positions to increase pressure within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and inside the torque converter housing and front of the case. Run the engine until fluid leakage is evident and the probable source of leakage can be determined.

Leak Check Test With Black Light

Automatic Transmission/Power Steering Dye 164-R3701 or equivalent (specifically formulated for ATF) is used to detect a transmission fluid leak.

1. Add Automatic Transmission/Power Steering Dye to the transmission fluid. Use one 30.0 mL (1 oz) of dye solution for every 3.8L (4 qt.) of transmission fluid.
2. Start and run the engine until the transaxle reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as possible), inside the torque converter housing and the entire case until fluid leakage is evident and the probable source of leakage can be determined.

Transmission Fluid Cooler Flow Test

Note. The transaxle linkage adjustment, fluid level and line pressure must be within specification before carrying out this test. Refer to AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS for transaxle linkage adjustment procedure. For transmission fluid level checking procedures, refer to PRELIMINARY INSPECTION in this article. For transaxle line pressure testing, refer to SPECIAL TESTING PROCEDURES in this article.

1. Check the transmission fluid level and fill as necessary.
2. Remove the transmission fluid level indicator from the fluid filler tube and install the funnel in the fluid filler tube.
3. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING AND LIFTING»(ref-255374) . Inspect the transmission fluid cooler lines for damage. Install new transmission fluid cooler lines as needed.
4. Disconnect the cooler return hose from the cooler return tube.
5. Plug the cooler return hose to avoid transmission fluid loss.
6. Connect one end of a hose to the cooler return tube and route the other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube.
7. Start the engine and run at idle with the transaxle in NEUTRAL range until the automatic transmission fluid is warm. Temperature is important to the flow rate measurement. Once fluid flow no longer has air bubbles in it, remove the rubber hose from the funnel and insert it into a liter container. As soon as 0.95L (1 qt) is dispensed into the container, install the hose into the funnel. One quart of automatic transmission fluid should flow through the cooling system in approximately 17-21 seconds.
8. Once adequate flow is determined, shut off the engine, remove the extension hose and reassemble the cooler line with the constant tension clamp.
9. If flow is not adequate, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter-out line. If flow is now liberal, install a new transmission fluid cooler. Refer to «TRANSAXLE-TRANSMISSION COOLING»(ref-255433) .
10. Check the transmission fluid level and adjust as required.

Diagnosis By Symptom

SPECIAL TOOL(S) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

The Diagnosis by Symptom Index gives the technician diagnostic information, direction and suggest possible components, using a symptom as a starting point.

The Diagnosis by Symptom Index is divided into 2 categories: Electrical Routines, indicated by 200 series numbers; and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

Diagnosis by Symptom Chart Directions

1. Using the Symptom Index, select the Concern/Symptom that best describes the condition.
2. Refer to the routine indicated in the Diagnosis by Symptom Index.
3. Always begin diagnosis of a symptom with: Preliminary inspections. Verifications of condition. Checking the fluid levels. NOTE: Not all concerns and conditions with electrical components will set a diagnostic trouble code (DTC). Be aware that the components listed may still be the cause. Verify correct function of these components prior to proceeding to the Hydraulic/Mechanical Routines list.
4. Begin with the Electrical Routine, if indicated. Follow the reference or action statements. Always carry out the on-board diagnostic tests as necessary. Never skip steps. If the concern is still present after electrical diagnosis, then proceed to the Hydraulic/Mechanical Routines list.
5. The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could cause the concern. These components are listed in the removal sequence and by most probable cause. All components listed must be inspected to make sure of correct repair.

DIAGNOSIS BY SYMPTOM INDEX