Automatic Transaxle/transmission - FNR5: Other Ford Fusion I рестайлинг

Material

Material

LINE PRESSURE CHART

LINE PRESSURE CHART

STALL SPEED CHART

STALL SPEED CHART

Throttle Position (TP) Sensor

The Throttle Position (TP) sensor is located on the Throttle Body (TB).

It supplies information to the PCM about the position of the throttle plate. The TCM receives the signal from the PCM.

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

The TCM 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 TCC.
4. for kickdown.

In case of absence of the TP signal, the engine control uses the signals of the Mass Air Flow (MAF) and Intake Air Temperature (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 Mass Air Flow (MAF) sensor is located between the air cleaner housing and the air intake hose leading to the throttle housing.

The Intake Air Temperature (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 TCM receives the signals from the PCM and uses them 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 Crankshaft Position (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 TCM receives the signals from the PCM and uses them for the following functions among other things

1. to control the TCC.
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.

Scheme 474

Turbine Shaft Speed (TSS) Sensor

The Turbine Shaft Speed (TSS) sensor is located on the transaxle housing over the input shaft.

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

The signal is used for the following functions

1. to control the shift operations.
2. to control the TCC.
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.

Intermediate Shaft Speed Sensor

The intermediate shaft speed sensor is located on the transaxle housing over the intermediate shaft.

The intermediate shaft speed sensor is an inductive sensor which senses the speed of rotation of the intermediate shaft.

The signal is used for the following functions

1. to determine the shift timing.
2. to control the shift operations.
3. to control the TCC.

If the intermediate shaft speed sensor fails, the signals of the OSS and TSS sensors are used as a substitute signal.

Output Shaft Speed (OSS) Sensor

The OSS sensor is located in the transaxle 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 TCM.

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

Scheme 475

The Transmission Range (TR) sensor is located on the manual control lever shaft on the transaxle housing.

When the manual control lever shaft is moved by means of the 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 TCM, 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 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.

Brake Pedal Position (BPP) Switch

The Brake Pedal Position (BPP) switch is mounted on the brake pedal bracket.

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

The signal of the Brake Pedal Position (BPP) switch is received by the TCM from the PCM and used for the following functions

1. to release the TCC when the brake pedal is depressed.
2. to switch off the 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 selector lever cannot be moved out of P.

A/C

If the PCM registers a kickdown signal (Wide Open Throttle (WOT), throttle plate opened 95%), the A/C 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 and L.

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 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 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 476

This indicator 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 concern 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 part 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 Turbine Shaft Speed (TSS) 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

Selector Lever Linkage Check

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

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

Check TSBs

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

Using Output State Control and Accessing PIDs

To confirm that the output state control value was sent by the scan tool and the PCM has accepted the output state control substitution, a corresponding PID for each output state control parameter must be monitored. Additional PIDs should be monitored to help the technician adequately diagnose the transmission.

Before Pinpoint Tests

Note. Before entering pinpoint tests, check the transaxle, vehicle, Transmission Control Module (TCM) and PCM wiring harnesses 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 the Introduction - Gasoline Engines article.

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 (DTC) Charts for the appropriate repair procedure. Prior to entering pinpoint tests, refer to any TSBs for transaxle concerns.

Transaxle Connector Layouts

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

TRANSMISSION RANGE (TR) SENSOR DIAGNOSIS CHART

Pinpoint Tests - OSC Equipped Vehicle

Special Tools Illustration Tool Name Tool Number 73 III Automotive Meter 105-R0057 or equivalent Transmission Fluid Pressure Gauge Assembly 307-004 (T57L-77820-A) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 487

Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary.

GEAR in Drive Mode

Drive Mode for GEAR operates only when

1. Output Shaft Speed (OSS) and Transmission Range (TR) sensor are operational.
2. No OSS and TR sensor DTCs set.
3. Engine ON.
4. Torque Converter Clutch (TCC) is OFF (TCC cannot be engaged).
5. Selector lever is in D.
6. Vehicle speed is above 3 km/h (2 mph).

Note. Read and record all DTCs.

Note. Before entering pinpoint tests, check the transaxle, vehicle, TCM and PCM wiring harnesses 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 the Introduction - Gasoline Engines article.

After the On-Board Diagnostic (OBD) 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 Engines article will aid in diagnosing non-transaxle electronic components.

Pinpoint Tests

Refer to SYSTEM WIRING DIAGRAMS article for Fusion, SYSTEM WIRING DIAGRAMS article for Milan or SYSTEM WIRING DIAGRAMS article for MKZ for schematic and connector information.

Engine Idle Speed Check

Refer to the Introduction - Gasoline Engines article for diagnosis and testing of the engine idle speed.

Main Control

Material

Scheme 488

Material

Scheme 489

Material

Scheme 490

Material

Scheme 491

Halfshaft Seal - LH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Output Shaft Seal 307-572

Halfshaft Seal - RH

Special Tools Illustration Tool Name Tool Number Handle 205-153 (T80T-4000-W) Installer, Output Shaft Seal 307-572

Transmission Range (TR) Sensor

Special Tools Illustration Tool Name Tool Number Alignment Tool, Transmission Range Sensor 307-571

Scheme 492

Transaxle Support Insulator

Special Tools Illustration Tool Name Tool Number Support Bar, Engine 303-F072

Material

Scheme 493