Automatic Transmission - CD4E: Specifications Mercury Mariner I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

END PLAY SPECIFICATIONS

END PLAY SPECIFICATIONS

FORWARD/COAST CLUTCH PACK SPECIFICATIONS

FORWARD/COAST CLUTCH PACK SPECIFICATIONS

REVERSE CLUTCH PACK SPECIFICATIONS

REVERSE CLUTCH PACK SPECIFICATIONS

DIRECT CLUTCH PACK SPECIFICATIONS

DIRECT CLUTCH PACK SPECIFICATIONS

LOW/REVERSE CLUTCH PACK SPECIFICATIONS

LOW/REVERSE CLUTCH PACK SPECIFICATIONS

INTERMEDIATE AND OVERDRIVE SERVO SPECIFICATION

INTERMEDIATE AND OVERDRIVE SERVO SPECIFICATION

INTERMEDIATE/OVERDRIVE SERVO APPLY ROD SPECIFICATIONS

INTERMEDIATE/OVERDRIVE SERVO APPLY ROD SPECIFICATIONS

REVERSE/OVERDRIVE CARRIER ASSEMBLY PINION GEAR SPECIFICATION

REVERSE/OVERDRIVE CARRIER ASSEMBLY PINION GEAR SPECIFICATION

PUMP GEAR END SPECIFICATION

PUMP GEAR END SPECIFICATION

DRIVE SPROCKET ALIGNMENT NO 10 THRUST WASHER SPECIFICATIONS

DRIVE SPROCKET ALIGNMENT NO 10 THRUST WASHER SPECIFICATIONS

DRIVEN SPROCKET ALIGNMENT NO 11 SHIM SPECIFICATIONS

DRIVEN SPROCKET ALIGNMENT NO 11 SHIM SPECIFICATIONS

DIFFERENTIAL END PLAY NO 14 SHIM SPECIFICATIONS

DIFFERENTIAL END PLAY NO 14 SHIM SPECIFICATIONS

PUMP ASSEMBLY ROTATING TORQUE SPECIFICATION

PUMP ASSEMBLY ROTATING TORQUE SPECIFICATION

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Torque Demand

The torque demand downshift occurs automatically during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. The transaxle will disengage the torque converter clutch (TCC) to provide added acceleration, if applied.

Torque Converter

The torque converter is a 4 element assembly. The torque converter contains an impeller, a turbine, a reactor and a torque converter clutch (TCC) for increased fuel economy. It couples the engine to the turbine shaft assembly, provides torque multiplication and absorbs engine shock of gear shifting.

Torque Converter Clutch (TCC)

The torque converter clutch (TCC) provides a mechanical link or direct drive between the engine crankshaft and turbine shaft when applied. The application of the TCC is controlled by the powertrain control module (PCM). Under certain conditions, the PCM sends the appropriate signal to the TCC solenoid, which allows fluid pressure within the torque converter to force the TCC piston plate and dampener assembly against the cover creating a mechanical link between the engine and transaxle.

Torque Converter Clutch (TCC) Solenoid

The TCC solenoid is a pulse width modulating (PWM) style solenoid. The PWM solenoid is used to control the apply and release of the bypass clutch in the torque converter. By modulating the pulse width of the TCC solenoid, the pressure in the S4 circuit varies modulating the apply and release of the bypass clutch in the torque converter.

Torque Converter Diagnosis

Prior to installing a new or remanufactured torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection.
2. Know and Understand the Customers Concern.
3. Verify the Concern - Carry out the Torque Converter Operation Test.
4. Carry out Diagnostic Procedures. Carry out On-Board Diagnostics. Refer to «INTRODUCTION - GASOLINE»(ref-229953) article for Escape (gasoline) and Mariner or «INTRODUCTION- HYBRID ESCAPE»(ref-235202) article for Escape (Hybrid). Repair all non-transmission related DTCs first. Repair all transmission DTCs. Rerun on-board diagnostics to verify repair. Carry out Line Pressure Test. Refer to «SPECIAL TESTING PROCEDURES»(ref-232215-S40747337392006051600000). Carry out Stall Speed Test. Refer to «SPECIAL TESTING PROCEDURES»(ref-232215-S40747337392006051600000). Carry out Diagnosis by Symptom Routines. Refer to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000). Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and repair as required, before repairing the torque converter.

Torque Converter Clutch Operation Test

This test verifies that the torque converter clutch control system and the torque converter are operating correctly. Carry out the test as follows

1. Carry out On-Board Diagnostic Test. Refer to «INTRODUCTION - GASOLINE»(ref-229953) article for Escape (gasoline) and Mariner or «INTRODUCTION- HYBRID ESCAPE»(ref-235202) article for Escape (Hybrid).
2. Connect a tachometer to the engine.
3. Bring engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position.
4. After normal operating temperatures are reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap the brake pedal with the left foot.
5. Engine rpm should increase when the brake pedal is tapped, and should decrease about 5 seconds after the brake pedal is released. If this does not occur, see «TORQUE CONVERTER OPERATION CONCERNS»(ref-232215-S22027956892006051600000). Refer to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000). If the vehicle is at a stop and stalls in (D) at idle, move the transaxle range selector lever to the manual 1 position, see «TORQUE CONVERTER OPERATION CONCERNS»(ref-232215-S22027956892006051600000). Refer to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000). Repair as required. If the vehicle does not stall in manual 1, refer to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000).

PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID

Note. see scheme 10preceding these pinpoint tests.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. C1 ELECTRONIC DIAGNOSTICS Key in OFF position. Make sure the transaxle vehicle 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. Carry out KOEO Test until continuous DTCs have been displayed. Select Output State Test Mode (OTM). Select the mode ALL ON. Push START to turn outputs on. Push STOP to turn outputs off. Does vehicle enter OTM? Yes: REMAIN in OTM. GO to C2. No: PRESS START. If vehicle does not enter OTM, refer to «INTRODUCTION - GASOLINE»(ref-229953) article for Escape (gasoline) and Mariner or «INTRODUCTION- HYBRID ESCAPE»(ref-235202) article for Escape (Hybrid).
2. C2 CHECK ELECTRICAL SIGNAL OPERATION CAUTION: Do not pry on the connector. This will damage the connector and can result in a transaxle concern. Press button and pull up on the transaxle vehicle harness connector. Key in OFF position. Disconnect: Transaxle Connector. Use a mirror to inspect both ends of the connector for damaged or pushed-out pins, corrosion, loose wires and missing or damaged seals. Key in ON position. Measure the voltage between pin 1 and pin 7 of the transaxle vehicle harness connector. While observing the VOM, press STAR and STOP to cycle solenoid output on and off. Does the suspected solenoid output voltage change at least 0.5 volt? Yes : GO to C5 . No : GO to C3.
3. C3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS Key in OFF position. Disconnect: PCM. Disconnect: Transaxle Connector. Measure the resistance between the PCM pin T46 and the transaxle harness connector pin 7. Measure the resistance between the PCM pin C35 and C36 and the transaxle harness connector pin 1. Is each resistance less than 5 ohms? Yes : GO to C4. No : REPAIR open circuit(s). RECONNECT all components. RERUN Quick Test.
4. C4 CHECK SOLENOID/HARNESS FOR SHORTS TO POWER AND GROUND Disconnect: PCM. Disconnect: Transaxle Connector. Measure the resistance between the PCM pin T46 and the PCM pins C35 and C36. Measure the resistance between the PCM pin T46 and the PCM pins C47, C48 and C49 and chassis ground. Measure the resistance between the PCM pin T46 and the PCM pin T4 and chassis ground. Is each resistance less than 10,000 ohms? Yes : GO to C5. No : REPAIR short circuit(s). RECONNECT all components. RERUN Quick Test.
5. C5 TRANSAXLE FUNCTIONAL TEST CAUTION: Do not pry on the connector. This will damage the connector and can result in a transaxle concern. Press button and pull up on the transaxle vehicle harness connector. NOTE: LED will turn GREEN when solenoid activates and turns OFF when deactivated. LED will turn RED if an activated solenoid/harness is shorted to B+. LED will remain OFF if an activated solenoid/harness is shorted to ground or no continuity (open circuit). Disconnect: Transaxle Connector. Connect: Transmission Tester. Carry out the TCC Solenoid Function Test as outlined in the Transmission Tester Manual. Does TCC (LED green) activate when tester switch is pressed? Yes : GO to C6. No : GO to C7 .
6. C6 TRANSAXLE DRIVE CYCLE TEST Connect: PCM. Carry out Dynamic Testing as outlined in the Transmission Tester Manual. Does TCC activate (LED green) and engine rpm drop? Yes: INSTALL a new PCM. RECONNECT all components. RERUN On-Board Diagnostic tests. If symptoms are still present, REFER to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000). No: GO to C7.
7. C7 CHECK RESISTANCE OF SOLENOID/HARNESS Set Bench/Drive switch to BENCH mode. Rotate gear select switch to OHMS CHECK position. Measure the resistance between TCC jack and VPWR jack on the Transmission Tester. Is the resistance between 12.5 and 19.0 ohms? Yes : GO to C8. No : INSTALL a new solenoid body assembly.
8. C8 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND Measure the resistance between BAT - jack (engine ground) and TCC jack, and VPWR jack on Transmission Tester. Is the resistance greater than 10,000 ohms? Yes: INSTALL a new solenoid body assembly. No: REFER to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000) to diagnose torque converter clutch.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. D1 VERIFY TRANSMISSION RANGE (TR) SENSOR ALIGNMENT Make sure the TR sensor harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding. Verify shift linkage adjustment in the DRIVE position. Key in OFF position. Apply parking brake. Place the transaxle range selector lever in NEUTRAL. Verify that the TR sensor is correctly adjusted. Is the TR sensor correctly adjusted? Yes: GO to D2. No: ADJUST TR sensor. REFER to «TRANSMISSION RANGE (TR) SENSOR»(ref-232215-S36545236622006051600000). PLACE transaxle range selector in PARK. CLEAR the DTCs and RERUN the Quick Test.
2. D2 CHECK ELECTRICAL SIGNAL OPERATION CAUTION: Do not pry on the connector. This will damage the connector and can result in a transaxle concern. Press button and pull up on the transaxle vehicle harness connector. Disconnect: TR Sensor. Use mirror to inspect both ends of the connector for damaged or pushed-out pins, corrosion, loose wires and missing or damaged seals. Measure the voltage between pin 5 and pin 10 of the TR sensor harness connector. Key in ON position. Is the voltage between 4.75 and 5.25 volts? Yes: GO to D3. No: refer to «INTRODUCTION - GASOLINE»(ref-229953) article for Escape (gasoline) and Mariner or «INTRODUCTION- HYBRID ESCAPE»(ref-235202) article for Escape (Hybrid).
3. D3 CHECK CONTINUITY OF TR SENSOR HARNESS CIRCUITS CAUTION: Do not pry on the connector. This will damage the connector and can result in a transaxle concern. Press button and pull up on the transaxle vehicle harness connector. Key in OFF position. Disconnect: TR Sensor. Inspect for damaged or pushed-out pins, corrosion or loose wires. Disconnect: PCM. Measure the resistance between the PCM pin T41 and the TR sensor vehicle harness connector pin 5. Measure the resistance between the PCM pin T27 and the TR sensor vehicle harness connector pin 10. Is each resistance less than 5 ohms? Yes : GO to D4. No : REPAIR open circuit(s). RECONNECT all components. CLEAR the DTCs. RERUN Quick Test.
4. D4 CHECK TR SENSOR CIRCUIT FOR SHORTS TO POWER AND GROUND Disconnect: PCM. Disconnect: TR Sensor. Measure the resistance between the PCM pin T27 and the PCM pins B35, B36, B47, B48 and B49. Measure the resistance between the PCM pin T27 and the PCM pin T41. Is each resistance greater than 10,000 ohms? Yes : GO to D5. No : REPAIR short circuit. RECONNECT all components. CLEAR the DTCs. RERUN Quick Test.
5. D5 CHECK TRANSMISSION RANGE (TR) SENSOR RESISTANCE Disconnect: TR Sensor. Install the transmission tester. Connect MLP-D cable to TR sensor and Transmission Tester. Install appropriate overlay into the transmission tester. Measure the resistance between TR and SRTN of the TR Sensor. Verify the sensor resistance values in all gear positions. Refer to following table. TR SENSOR RESISTANCE Range Selector Position Resistance (Ohms) Volts P 3770 - 4607 4.41 R 1304 - 1593 3.60 N 660 - 807 2.93 (D) 361 - 442 2.09 2 190 - 232 1.37 1 78 - 95 0.68 Are all resistance values within specification? Yes: INSTALL a new the PCM. CLEAR the DTCs, RERUN Quick Test, then GO to D6. No: INSTALL a new TR Sensor and ADJUST. REFER to «TRANSMISSION RANGE (TR) SENSOR»(ref-232215-S36545236622006051600000). CLEAR the DTCs and RERUN Quick Tests.
6. D6 CHECK PARK/NEUTRAL CIRCUITS OF SENSOR Carry out the procedures outlined on the transmission tester overlay to verify the sensor PARK/NEUTRAL circuits in all gear positions. Monitor the status lamp on the tester for correct indications. Do the PARK/NEUTRAL circuits operate correctly and only in the correct gear position? Yes: GO to D7. If diagnosing a PARK/NEUTRAL circuit or starting system concern, REFER to «ENGINE - 2.3L»(ref-232194) or «ENGINE - 3.0L (4V)»(ref-232195). No: INSTALL a new TR sensor and ADJUST. REFER to «TRANSMISSION RANGE (TR) SENSOR»(ref-232215-S36545236622006051600000). CLEAR the DTCs and RERUN Quick Tests.
7. D7 CHECK REVERSE/BACKUP LAMP CIRCUITS OF SENSOR Carry out the procedures outlined on the tester overlay to verify the sensor REVERSE/BACKUP circuits in all gear positions. Monitor the status lamp on the tester for correct indications. Do the REVERSE/BACKUP circuits operate correctly and only in the correct gear position? Yes: If diagnosing a REVERSE/BACKUP circuit concern, REFER to «EXTERIOR LIGHTING»(ref-232250). No: INSTALL a new TR sensor and ADJUST. REFER to «TRANSMISSION RANGE (TR) SENSOR»(ref-232215-S36545236622006051600000). CLEAR the DTCs and RERUN Quick Tests.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. E1 ELECTRONIC DIAGNOSTICS Key in OFF position. Make sure the transaxle vehicle 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. Carry out KOEO Test until continuous DTCs have been displayed. Enter Output Test Mode (OTM). Refer to «ON-BOARD DIAGNOSTICS»(ref-232215-S30318432552006051600000). Select the mode ALL ON. Push START to turn outputs on. Push STOP to turn outputs off. Does vehicle enter OTM? Yes: REMAIN in OTM. GO to E2. No: PRESS START. If vehicle does not enter OTM, refer to «INTRODUCTION - GASOLINE»(ref-229953) article for Escape (gasoline) and Mariner or «INTRODUCTION- HYBRID ESCAPE»(ref-235202) article for Escape (Hybrid).
2. E2 CHECK ELECTRICAL SIGNAL OPERATION CAUTION: Do not pry on the connector. Pull up on the transaxle vehicle harness connector. Key in OFF position. Disconnect: Transaxle Connector. Use a mirror to inspect both ends of connector for damaged or pushed-out pins, corrosion, loose wires and missing or damaged seals. Key in ON position. Measure the voltage between pin 8 and pin 9 of the transaxle vehicle harness connector. While observing VOM, press START and STOP to cycle solenoid output on and off. Does the suspect solenoid output voltage change at least 0.5 volt? Yes : GO to E5 . No : GO to E3.
3. E3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS Key in OFF position. Disconnect: PCM. Inspect for damaged or pushed-out pins, corrosion or loose wires. Measure the resistance between the PCM pins C35 and C36 and the transaxle harness connector pin 9. Measure the resistance between the PCM pin T11 and the transaxle harness connector pin 8. Is each resistance less than 5 ohms? Yes : GO to E4. No : REPAIR open circuit(s). RECONNECT all components. CLEAR the DTCs and RERUN On-Board Diagnostics.
4. E4 CHECK HARNESS FOR SHORT TO POWER AND GROUND Key in OFF position. Disconnect: Transaxle Connector. Measure the resistance between the PCM pin T11 and the PCM pins C35 and C36. Measure the resistance between the PCM pin T11 and the PCM pins C47, C48 and C49. Measure the resistance between the PCM pin T11 and the PCM pin T41. Is each resistance greater than 10,000 ohms? Yes : GO to E5. No : REPAIR short circuit(s). RECONNECT all components. CLEAR the DTCs and RERUN On-Board Diagnostics.
5. E5 TRANSAXLE FUNCTIONAL TEST NOTE: LED will turn GREEN when solenoid activates and turn OFF when deactivated. LED will turn RED if activated solenoid/harness is shorted to B+. LED will remain OFF if an activated solenoid/harness is shorted to ground or no continuity (open circuit). Connect: PCM. Disconnect: Transaxle Connector. Install line pressure gauge at line tap on case. Connect: Transmission Tester. Set Bench/Drive switch to DRIVE mode. Rotate gear selector switch to 1st gear position. Carry out the EPC Functional Test as outlined in Transmission Tester Manual. Observe line pressure on gauge while pressing the EPC switch (engine must be running). Does EPC (LED) activate when EPC switch is pressed and line pressure drops? Yes : INSTALL a new PCM. RERUN On-Board Diagnostics. No : GO to E6.
6. E6 CHECK RESISTANCE OF SOLENOID/HARNESS Set Bench/Drive switch to BENCH mode. Rotate gear select switch to OHMS CHECK position. Measure the resistance between EPC jack and VPWR jack on the Transmission Tester. Is resistance between 3.75 - 5.92 ohms? Yes : GO to E7. No : INSTALL a new solenoid body assembly. CLEAR the DTCs. RERUN On-Board Diagnostics tests.
7. E7 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND Measure the resistance between BAT - jack (engine ground) and EPC, and VPWR/EPC PWR on the transmission tester. Is the resistance greater than 10,000 ohms? Yes: INSTALL a new solenoid body assembly. REFER to «MAIN CONTROL VALVE BODY»(ref-232215-S06519159022006051600000). RECORD and CLEAR the DTCs. RERUN On-Board Diagnostics tests. No: REFER to «DIAGNOSIS BY SYMPTOM»(ref-232215-S03959909232006051600000).

Fluid Leakage in Torque Converter Area

Use the following procedures to locate the exact source of leakage in the torque converter area. Leakage at the front of transaxle, as evidenced by fluid around the converter housing, may have several sources. By careful observation, it is possible in many instances to pinpoint the source of the leak before removing the transaxle from the vehicle. The paths which the fluid can take to reach the bottom of the converter housing are as follows

Scheme 22

1. Fluid leaking by the converter impeller hub seal lip will tend to move along the drive hub and onto the back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip of the seal will be deposited on the inside of the converter housing only, near the outside diameter of the housing.
2. Fluid leakage by the outside diameter of the converter impeller hub seal and the case will follow the same path as leaks by the inside diameter of the seal.
3. Fluid leakage from the converter-to-flexplate stud weld will appear at the outside diameter of the torque converter, on the back face of flexplate and in the converter housing only near the flexplate. If a converter-to-flexplate stud leak is suspected, remove converter and pressure check.
4. Engine oil leaks are sometimes incorrectly diagnosed as transaxle pump seal leaks. The following areas of possible leakage should be checked to determine if engine oil leakage is causing the concern.
5. Leakage at the valve cover may allow oil to flow over the converter housing or seep down between the converter housing and cylinder block causing oil to be present in or at the bottom of the converter housing. Oil plug leaks will allow oil to flow down the rear face of the cylinder block to the converter housing. Leakage at the crankshaft seal will work back to the flexplate and then into the converter housing.

TORQUE CONVERTER OPERATION CONCERNS: NO APPLY

DIAGNOSTIC ROUTINES - TORQUE CONVERTER OPERATION CONCERNS NO APPLY

TORQUE CONVERTER OPERATION CONCERNS: ALWAYS APPLIED/MAY STALL ENGINE

DIAGNOSTIC ROUTINES - TORQUE CONVERTER OPERATION CONCERNS ALWAYS APPLIED/MAY STALL ENGINE

TORQUE CONVERTER CLUTCH CONCERNS: CYCLING SHUDDER CHATTER

DIAGNOSTIC ROUTINES - TORQUE CONVERTER CLUTCH CONCERNS CYCLING SHUDDER CHATTER

1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter stud or studs, impeller hub or bushing are damaged. Discoloration (due to overheating). Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major metallic failure. Multiple clutches or clutch plate failures. Sufficient component wear which results in metallic contamination. Internal torque converter contamination present. For additional information refer to «TORQUE CONVERTER CONTAMINATION INSPECTION»(ref-232215-S03085256882006051600000).

Torque Converter Contamination Inspection

1. If a new or remanufactured torque converter is not being installed, the following steps must be completed.
2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the fluid.
3. Observe the color and odor of the fluid. The fluid should be red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure.
4. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the fluid or there is evidence of engine coolant or water, a new torque converter must be installed.
5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter.
6. Add 1.9 liter (2 qt.) of clean automatic transmission fluid into the converter and agitate by hand.
7. Thoroughly drain the fluid.

See also:
• PINPOINT TEST Z: INTERMITTENT
• JACKING AND LIFTING