Transaxle - Troubleshooting: Diagnosis Mazda Tribute I

INSPECTION AND VERIFICATION

The vehicle should be road tested, if possible, to verify the customer concern. Some clutch conditions may be attributed to a misadjusted clutch pedal height, linkage, or shift mechanism. These should be checked and corrected prior to attempting major disassembly procedures. Check that the transaxle is filled to the correct level with the specified lubricant.

DIAGNOSTIC FLOW CHART

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»(ref-174431-S11877311762005040800000) both KOER and KOEO.
8. Record all codes.

Scheme 89

PRELIMINARY INSPECTION

The following items must be checked before proceeding.

VISUAL INSPECTION

This inspection will identify modifications or additions to the vehicle operating system that can affect diagnosis.

1. Vehicle modification
2. Electronic add-on items: Air conditioning Generators Engine turbo Cellular telephone Cruise control CB radio Linear boosters Backup alarm signals Computer
3. The above items, if not correctly installed, will affect 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.
4. Leaks. For additional information, refer to «LEAKAGE INSPECTION»(ref-174431-S39350646372005040400000) .
5. Correct linkage adjustments. For additional information, «SELECTOR LEVER CABLE ADJUSTMENT»(ref-175776-S05138841362005042700000) .

Carry Out On-Board Diagnostics

After a road test, with the vehicle warm and before disturbing any connectors, carry out the QUICK TEST using the scan tool.

DIAGNOSTIC STRATEGY

Note. Do not take short cuts or assume that critical adjustments have already been made.

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

To correctly diagnose a concern, the technician should check for any related TSBs. To help identify connectors and wiring circuits, see TRANSMISSION .

1. Know and understand the customer concern.
2. Verify the concern by operating the vehicle.
3. Check fluid level and condition.
4. Check non-factory add-on items.
5. Check shift linkages for correct adjustment.
6. Check TSBs for 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, proceed to diagnosis by «AUTOMATIC TRANSAXLE TROUBLESHOOTING INDEX»(ref-174431-S39035155322005040400000) for further information and diagnosis.

By following the diagnostic sequence, the repair technician will be able to diagnose and repair the concern the first time.

Diagnosing electronically-controlled automatic transaxles is simplified by using the following procedures. One of the most important things to remember is that there is a definite procedure. 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 repair technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics With Diagnostic Tool

The Quick Tests can be used to diagnose the powertrain control module, sensors, and actuators of the CD4E transaxle.

The following is a guide for using the on-board diagnostic (OBD) Quick Tests and the scan tool.

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 Running
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

Other Scan Tool Features

Other diagnostic methods include the following

1. Parameter identification (PID) access mode, used to monitor sensors and actuators.
2. Freeze frame data access mode, used to view emission-related data values from specific PIDs.
3. Oxygen sensor monitor mode, used to monitor the oxygen sensor.

SPECIAL TESTING PROCEDURES

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

Line Pressure Test

The LINE PRESSURE CHART verifies that the line pressure is within specifications.

Scheme 90

1. Connect pressure gauge to line pressure tap.
2. Start engine and check line pressures. Refer to «LINE PRESSURE CHART»(ref-174431-S20782401292005040400000) to determine if line pressure is within specifications.
3. If line pressure is not within specifications, carry out on-board diagnostics and pinpoint test, air pressure check and repair main control system or pump as required.

Scheme 91

Line Pressure Diagnosis

If the line pressure is low at idle in all ranges check the following items

1. Low fluid level
2. Restricted inlet filter
3. Loose main body
4. Solenoid body or accumulator body to case bolts
5. Excessive leakage in pump
6. Case
7. Control bodies
8. Sticking main regulator valve or damaged inlet tube seal on inlet filter
9. Damaged gaskets or separator plate

If the line pressure is high at idle in all ranges then check the following items

1. Main regular valve
2. Solenoid body and wiring harness
3. Run «QUICK TEST»(ref-174431-S11877311762005040800000) .

Stall Speed Test

The Stall Speed Test checks the operation of the following items

1. Torque converter one-way clutch
2. Forward clutch
3. Low/reverse one-way clutch
4. Reverse clutch
5. Forward one-way clutch
6. Engine performance

Note. The stall test should only be carried out with the engine and transaxle at normal operating temperatures.

1. Connect a tachometer to the engine. CAUTION: Do not maintain wide open throttle (WOT) in any gear range for more than five seconds. CAUTION: If engine RPM recorded by the tachometer exceeds maximum specified RPM, release accelerator pedal immediately. Clutch or band slippage is indicated.
2. Press accelerator pedal to floor (WOT) in each range. Record RPM reached in each range. Stall speeds should be in appropriate range.

Scheme 92

After testing DRIVE (D) and REVERSE (R), move transaxle range selector lever to NEUTRAL (N) and run engine for about 15 seconds to allow torque converter to cool before testing next range.

If the stall speeds were too high (Scheme 93) If the stall speeds were too low, first check engine tune-up. If engine is OK, remove torque converter and check torque converter one-way clutch for slippage.

Scheme 93

Test Procedures

Carry out the following procedures.

1. Drain the transaxle. Remove main control cover.
2. Remove the main control as an assembly with the solenoid body assembly.
3. The inoperative clutches can be located by applying air pressure into the appropriate clutch port. Refer to Air Pressure Test Port Locations in this Section.
4. Install Transaxle Test Plate 49 UN30 7351 using six bolts. CAUTION: The coast clutch circuit should not be applied unless air pressure is maintained in the forward clutch circuit. Failure to do so can result in the coast clutch piston coming out of the forward clutch piston. NOTE: Refer to «REFERENCE: CLUTCH/BAND APPLICATION CHART NO. 601»(ref-175801-S00227576552005042700000) .
5. Apply air pressure 275 KPa (40 psi) to the appropriate clutch port. Refer to «AIR PRESSURE TEST PORT LOCATIONS»(ref-174431-S06729945152005040400000) . A dull thud may be heard, or movement felt when the clutch piston is applied. If clutch seals or check balls are leaking, a hissing may be heard.

Scheme 94

Air Pressure Test Results

If 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 clutches simultaneously, inspect the fluid passages in the case.

If air pressure applied to the accumulator fails to operate an accumulator, remove and inspect case passages and piston.

ROAD TESTING VEHICLE

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

Scheme 95

1. Bring engine and transaxle up to normal operating temperature.
2. Operate the vehicle with transaxle range selector lever in D position.
3. Apply minimum throttle and observe speeds at which upshift occurs and torque converter engages. Refer to Shift Speeds Chart. (Scheme 95) Also refer to Automatic Transaxle specifications. See «AUTOMATIC TRANSAXLE»(ref-175801-S34327899962005042700000). CAUTION: Do not exceed posted speed limits when carrying out this test.
4. Coasting 2-1 downshift procedure: accelerate vehicle from a stop to 19-24 km/h (12-15 mph). Release the accelerator, and coast down or lightly brake the vehicle. The coast downshift may be nearly imperceptible to the driver.
5. With the vehicle in D (fourth gear), depress the transaxle control switch. The transaxle should downshift to third gear. Remove foot from accelerator pedal; engine braking should occur. The torque converter clutch should disengage and then reapply.
6. Depress the accelerator pedal to floor. The transaxle should shift from third to second gear, or third to first, depending on vehicle speed.
7. With vehicle in D range above 80 km/h (50 mph) and less than half throttle, move the transaxle range selector lever from D range to manual 2 range and remove foot from accelerator pedal. The transaxle should immediately downshift into second gear. With the vehicle remaining in manual 2 range, move the transaxle range selector lever into manual 1 range and release the accelerator pedal. The transaxle should downshift into first gear at speeds below 48-56 km/h (28-32 mph). NOTE: Shift speed ranges are approximate for all applications. For specific applications (engine, axle ratio and application) refer to the Automatic Transaxle Specification Issue.
8. If the transaxle fails to upshift/downshift or the torque converter does not apply and release, refer to the «AUTOMATIC TRANSAXLE TROUBLESHOOTING INDEX»(ref-174431-S39035155322005040400000).

TRANSAXLE DRIVE CYCLE TEST

Note. The Transaxle Drive Cycle Test must be carried out exactly. Faults have to occur consecutively for codes P0731, P0732, P0733, and P0734 to be set.

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 D position, press transaxle control switch (TCS) (LED lamp should illuminate) and moderately accelerate from a stop to 64 km/h (40 mph). This allows the transaxle to shift into third gear. Hold the speed and throttle opening steady for a minimum of 15 seconds (30 seconds above an altitude of 4000 feet above sea level).
5. Press TCS (LED lamp should turn off) and accelerate from 64 km/h (40 mph) to 80 km/h (50 mph). This allows the transaxle to shift into fourth gear. Hold the speed and throttle opening steady for a minimum of 15 seconds.
6. With the transaxle in fourth gear and maintaining steady speed and throttle opening, lightly apply brake pedal (to operate stoplamps). Then hold the speed and throttle steady for an additional five seconds (minimum).
7. Brake to a stop and remain stopped for a minimum of 20 seconds.
8. Repeat Steps 4) through 6) at least five times.
9. Carry out «QUICK TEST»(ref-174431-S11877311762005040800000) and record continuous codes.

LEAKAGE INSPECTION

Leakage at the main control cover gasket often can be stopped by tightening the main control cover bolts to 16 N.m (12 lb-ft). If necessary, install a new main control cover gasket.

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

Check the cooler lines and fittings between the transaxle and the cooler in the radiator for looseness, wear, or damage. If leakage cannot be stopped by tightening a tube nut, install new parts. When fluid is found leaking between the case and the fluid tube connector, check for a missing or damaged O-ring, then tighten the fitting to maximum specification. Do not try to stop the fluid leak by increasing the torque beyond specification. This can cause damage to the case threads. If the leak continues, install a new fluid tube connector and tighten to specification. The same procedure should be followed for fluid leaks between the radiator and the fluid tube connector. Check the engine coolant in the radiator. If transaxle fluid is present in the coolant, the cooler in the radiator is probably leaking.

The cooler can be further checked for leaks by disconnecting the fluid cooler tubes for the fluid tube connectors and applying no more than 345 kPa (50 psi) air pressure to the fluid tube connectors. Remove the radiator cap to relieve the pressure buildup at the exterior of the fluid cooler tank. If the cooler is leaking or will not hold pressure, install a new cooler.

If leakage is found at the manual control lever, install a new manual control lever seal.

Check for fluid leaking from the differential seal. Leakage can result from a damaged seal, missing garter spring or worn front wheel driveshaft and joint. Install a new seal assembly or front wheel driveshaft and joint as necessary.

Check for fluid leaks in the pump to case interface. A leak may be due to a rolled pump lip seal or a damaged seal. Repair the pump assembly.

Leak Check Test

The following procedures should be used to determine the cause of the leakage before repair is made.

1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transaxle. Unless a considerable amount of makeup fluid has been added or the fluid has been changed, the red color should assist in pinpointing the leak.
2. Remove the converter housing. Clean off any fluid from the top and bottom of the converter housing, front of the case, and 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 converter housing and the front of the flexplate. The converter housing can be washed out using cleaning solvent and a squirt-type oil can. Blow dry all washed areas with compressed air.
4. Start and run the engine until the transaxle reaches normal operating temperature. Observe the back of the block and top of the converter housing for evidence of fluid leakage. Raise the vehicle on a hoist. Run the engine at fast idle, then at engine idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the transaxle. Observe the front of the flexplate, back of the block (in as far as possible) and inside the converter housing and front of the case. Run the engine until fluid leakage is evident and the source of leakage can be determined.

Leak Check Test With Black Light

Oil-soluble aniline or fluorescent dyes pre-mixed at the rate of 2.5 ml (1/2 teaspoon) of dye powder to 0.23 liter (1/2 pint) of transaxle fluid have proven helpful in locating the source of fluid leakage. Such dyes can be used to determine whether an engine oil or transaxle fluid leak is present, or if the fluid in the transaxle fluid cooler leaks into the engine coolant system. A black light must be used with the fluorescent dye solution.

TRANSAXLE BEARING CONE AND RACE INSPECTION

Inspect the pilot bearing for excessive wear or scoring. Install a new pilot bearing if necessary.

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Transaxle Fluid Cooler Flow Test

Note. The transaxle linkage adjustment, fluid level and line pressure must be within specification before carrying out this test. For transaxle fluid level checking procedures, refer to PRELIMINARY INSPECTION . For transaxle line pressure testing, refer to SPECIAL TESTING PROCEDURES .

1. Remove fluid level indicator from fluid filler tube.
2. Place funnel in fluid filler tube.
3. Raise vehicle on hoist and position suitable safety stands under vehicle.
4. Remove cooler return line (rear fitting) from fitting on transaxle case.
5. Connect one end of a hose to the cooler return line 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.
6. Remove safety stands and lower vehicle. Insert end of hose into funnel.
7. Start engine and run at idle with transaxle in NEUTRAL range.
8. When fluid flowing from hose is all liquid, an adequate amount of fluid should be observed (approximately 1.0 liter (1.0 quart) of liquid delivered in 15 seconds). If adequate flow is observed, test is completed.
9. If flow is not adequate, stop engine. Disconnect hose from cooler return line and connect it to converter-out line (front fitting) on case.
10. Repeat Steps 7 and 8. If flow is now liberal, carry out back flushing and cleaning procedures. Refer to «TRANSAXLE FLUID COOLER -- BACK FLUSHING AND CLEANING»(ref-175492-S05057350292005042100000) . If flow is still not liberal, repair the pump or converter.

1. Verify the customer's concern by operating the vehicle to duplicate the condition.
2. If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary.
3. Install new components if a fluid leak is found in any of the transaxle cooling components.
4. If the concern(s) remains after the inspection, determine the symptom(s) and go to «TROUBLESHOOTING INDEX - AUTOMATIC TRANSAXLE COOLING»(ref-174431-S38647370302005040400000) .

DIAGNOSTIC TROUBLE DEFINITIONS

Diagnostic Trouble Definitions

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

The Transaxle Tester is used to diagnose electronically-controlled transaxles and is used in conjunction with the pinpoint tests. The tests should be carried out in order. Installing the Transaxle Tester allows separation of the vehicle electronics and the transaxle electronics. Refer to the Transaxle Tester manual for these tests.

1. Bench Testing - Engine Off
2. Resistance/Continuity Test
3. Solenoid Voltage Test
4. Dynamic Testing - Engine On
5. EPC Solenoid
6. Transaxle Engagement
7. Upshifts/Downshifts
8. Torque Converter Clutch (TCC) Engagement
9. Coast Clutch Engagement
10. Turbine Shaft Speed (TSS) Sensor
11. Output Shaft Speed (OSS) Sensor
12. Transaxle Range (TR) Sensor
13. Switch Test - Park/Neutral, Backup Lamp, and Optional Circuits

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131