Automatic Transaxle/transmission - FNR5: Specifications Mercury Milan I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

a Specific tightening sequence is required. See the appropriate procedures.

Torque Converter Diagnosis

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Prior to installing a new 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 torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection.
2. Know and Understand the Customer Concern.
3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test; refer to «Torque Converter Operations Test»(ref-271121-S34569358992007110800000).
4. Carry out Diagnostic Procedures. Run on-board diagnostics; refer to «On-Board Diagnostics with Scan Tool»(ref-271121-S22927295422007110800000). Repair all non-transaxle related DTCs first. Repair all transaxle DTCs. Rerun on-board diagnostic to verify repair. Carry out the Line Pressure Test. Refer to «Line Pressure Test»(ref-271121-S39094671372007110800000). Carry out the Stall Speed Test. Refer to «Stall Speed Test»(ref-271121-S33982096542007110800000). Carry out the Diagnosis by Symptom Index. Refer to «Diagnosis By Symptom»(ref-271121-S23670010462007110800000). 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 necessary before installing a new or remanufactured torque converter.

Torque Converter Operations Test

This test verifies that the torque converter clutch control system and the torque converter are operating correctly.

1. Carry out the Self Test. Refer to «On-Board Diagnostics with Scan Tool»(ref-271121-S22927295422007110800000). Check for DTCs. Refer to «Diagnostic Trouble Code (DTC) Charts»(ref-271121-S09337318542007110800000).
2. Connect a scan tool.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in D position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap the brake pedal with the left foot.
5. The engine rpm should increase when brake pedal is tapped, and decrease about 5 seconds after pedal is released. If this does not occur, see Torque Converter Operation Concerns. Refer to «Diagnosis By Symptom»(ref-271121-S23670010462007110800000).
6. If the vehicle stalls in D at idle with vehicle at a stop, move the position selector lever to L position. If the vehicle stalls, refer to «TORQUE CONVERTER OPERATION CONCERNS: ALWAYS APPLIED/STALLS VEHICLE»(ref-271121-S07076090812007111500000). Repair as necessary. If the vehicle does not stall in D position. Refer to «Diagnosis By Symptom»(ref-271121-S23670010462007110800000).

PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (ONLY)

Note. Refer to the Transaxle Main Valve Body Vehicle Harness Connector illustration Transaxle Connector Layouts.

Note. Refer to the Transaxle 5th Gear Valve Body Vehicle Harness Connector illustration Transaxle Connector Layouts.

Note. Refer to the Transaxle Main Valve Body Internal Harness Connector illustration Transaxle Connector Layouts.

Note. Refer to the Transaxle 5th Gear Valve Body Internal Harness Connector illustration Transaxle Connector Layouts.

Note. Read and record all DTCs. All transmission range (TR) sensor and output shaft speed (OSS) DTCs must be repaired before entering output state control (OSC).

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. A1 ELECTRONIC DIAGNOSTICS SETUP Key in OFF position. Select PARK. Make sure the transaxle harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding. Connect the diagnostic tool. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Diagnostic Data Link Enter the following diagnostic mode on the diagnostic tool: PCM Enter the following diagnostic mode on the diagnostic tool: Active Command Modes Enter the following diagnostic mode on the diagnostic tool: Output State Control (OSC) Enter the following diagnostic mode on the diagnostic tool: Trans-Bench Mode Does vehicle enter Trans-Bench Mode? YES: REMAIN in Trans-Bench Mode. Go to A2. NO: REPEAT procedure to enter Trans-Bench Mode. If vehicle did not enter Trans-Bench Mode, REFER to the «Introduction - Gasoline Engines»(ref-268480) for diagnosis of PCM.
2. A2 WIGGLE TEST Remain in Trans-Bench Mode. Select the following PIDs to be monitored: SSPCA SSPCB SSPCC SSD SSE SSF Select "ON" to turn suspect solenoid on. Press "SEND". Wiggle all wiring and connectors to the transaxle. Monitor the Solenoid State for changes. Select "OFF" to turn solenoid off. Press "SEND". Does the suspect solenoid(s) fault state change? YES : REPAIR the circuit. TEST the system for normal operation. NO : Go to A3 .
3. A3 CHECK SOLENOID FUNCTION Turn each solenoid ON and OFF. Does the solenoid turn ON and OFF when commanded and can solenoid activation be heard? YES : Go to A4 . NO : Go to A5 .
4. A4 OSC TRANS-DRIVE TEST (GEAR OR TCC) Carry out OSC Trans-Drive Mode. Select "GEAR" for Shift Solenoids or follow procedures for GEAR. Select "TCC" for Torque Converter Clutch. Follow procedures of «TCC in Drive Mode»(ref-271121-S25324841862007110800000). Does the transaxle upshift and downshift or torque converter engage/disengage when commanded? YES: CLEAR all DTCs. Road test to verify if concern is still present. If concern is still present, REFER to «Diagnosis By Symptom»(ref-271121-S23670010462007110800000) to diagnose shift or torque converter concern. NO: Go to A5.
5. A5 CHECK FOR BATTERY VOLTAGE Disconnect: Transaxle Vehicle Harness Connector C1534 Disconnect: Transaxle Connector C1535 Visually inspect all wires and connectors for damage. Measure the voltage between transaxle vehicle harness connector, harness side, and ground as follows: SSPCA - Transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - Transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - Transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - Transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - Transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - Transaxle connector C1535-1, circuit CET44 (BU/BN). Is the voltage greater than 10 volts? YES : Go to A7 . NO : Go to A6 .
6. A6 CHECK FOR SHORTS TO GROUND Key in OFF position. Measure the resistance between transaxle vehicle harness connector, harness side, and ground as follows: SSPCA - Transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - Transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - Transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - Transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - Transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - Transaxle connector C1535-1, circuit CET44 (BU/BN). Are the resistances greater than 10,000 ohms? YES : Go to A8 . NO : REPAIR the circuit in question. TEST the system for normal operation.
7. A7 CHECK FOR SHORT TO BATTERY VOLTAGE Disconnect: TCM Connector C2352a Key in ON position. Measure the voltage between transaxle vehicle harness connector, harness side, and ground as follows: SSPCA - Transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - Transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - Transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - Transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - Transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - Transaxle connector C1535-1, circuit CET44 (BU/BN). Is any voltage present? YES : REPAIR the circuit in question. TEST the system for normal operation. NO : INSTALL a new TCM. TEST the system for normal operation.
8. A8 CHECK FOR OPENS Disconnect: TCM C2352A Measure the resistance between TCM connector pins, harness side, and transaxle vehicle harness connector pins, harness side, for the suspected solenoid as follows: SSPCA - TCM C2352a-8 - transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - TCM C2352a-16 - transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - TCM C2352a-7 - transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - TCM C2352a-14 - transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - TCM C2352a-13 - transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - TCM C2352a-12 - transaxle connector C1535-1, circuit CET44 (BU/BN). Are the resistances less than 5 ohms? YES : Go to A9 . NO : REPAIR the circuit in question. TEST the system for normal operation.
9. A9 ELECTRICAL SIGNAL CHECK Connect: TCM Connector C2352a Key in ON position. Measure the voltage between transaxle vehicle harness connector, harness side, and ground for the suspected solenoid as follows: SSPCA - Transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - Transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - Transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - Transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - Transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - Transaxle connector C1535-1, circuit CET44 (BU/BN). Enter the following diagnostic mode on the diagnostic tool: Trans - Bench Mode Select Parameter SSPCA, SSPCB, SSPCC, SSD, SSE or SSF. Select ON. Press SEND. Measure the voltage while cycling the solenoid ON and OFF for the suspected solenoid as follows: SSPCA - Transaxle connector C1534-3, circuit VET13 (GY/BU). SSPCB - Transaxle connector C1534-9, circuit VET14 (VT/GN). SSPCC - Transaxle connector C1534-1, circuit VET15 (YE/GY). SSD - Transaxle connector C1534-6, circuit CET18 (GY/YE). SSE - Transaxle connector C1534-8, circuit CET19 (VT/GY). SSF - Transaxle connector C1535-1, circuit CET44 (BU/BN). Select "OFF", press "SEND". Does the voltage change? YES : Go to A10 . NO : INSTALL a new TCM. TEST the system for normal operation.
10. A10 CHECK SOLENOID RESISTANCE Measure the resistance between solenoid pin and solenoid body component side for suspected solenoid as follows: SSPCA - Transaxle connector C1534-3 and Body - 1.0-4.2 ohms. SSPCB - Transaxle connector C1534-9 and Body - 1.0-4.2 ohms. SSPCC - Transaxle connector C1534-1 and Body - 1.0-4.2 ohms. SSD - Transaxle connector C1534-6 and Body - 10.9-26.2 ohms. SSE - Transaxle connector C1534-8 and Body - 10.9-26.2 ohms. SSF - Transaxle connector C1535-1 and Body - 10.9-26.2 ohms. Are the resistances within specification? YES : If SSPCA, SSPCB or SSPCC solenoid is suspected, go to A11 . If SSD, SSE or SSF solenoid is suspected, go to A12 . NO : INSTALL a new SSPCA, SSPCB, SSPCC, SSD, SSE or SSF solenoid. TEST the system for normal operation.
11. A11 CHECK SSPCA, SSPCB, SSPCC SOLENOID FOR A SHORT TO GROUND Measure the resistance between suspected solenoid pin 1, component side and solenoid body. Is the resistance less than 5 ohms? YES : INSTALL a new SSPCA, SSPCB or SSPCC solenoid. TEST the system for normal operation. NO : Go to A12 .
12. A12 CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN OPEN Measure the resistance between transaxle internal harness connector pins and suspected solenoid connectors as follows: SSD - Between transaxle internal harness connector C1534-6 and transaxle internal harness solenoid connector pin 6. SSE - Between transaxle internal harness connector C1534-8 and transaxle internal harness solenoid connector pin 8. SSF - Between transaxle internal harness connector C1535-1 and transaxle 5th gear valve body internal harness solenoid connector pin 1. Are the resistances less than 5 ohms? YES : Go to A13 . NO : INSTALL a new transaxle internal harness. TEST the system for normal operation.
13. A13 CHECK THE TRANSAXLE INTERNAL HARNESS FOR AN OPEN Measure the resistance between transaxle internal harness connector pins and suspected solenoid connectors as follows: SSPCA - Between transaxle internal harness connector pin 3 and transaxle harness solenoid connector pin 3. SSPCB - Between transaxle internal harness connector pin 9 and transaxle internal harness solenoid connector pin 9. SSPCC - Between transaxle internal harness connector pin 1 and transaxle internal harness solenoid connector pin 1. Are the resistances less than 5 ohms? YES : Go to A14 . NO : INSTALL a new transaxle internal harness. TEST the system for normal operation.
14. A14 CHECK THE TRANSAXLE INTERNAL HARNESS GROUND CIRCUIT Measure the resistance between transaxle internal harness connector pins and ground eye hook as follows: SSPCA - Between transaxle internal harness solenoid connector pin 11 and ground eye hook. SSPCB - Between transaxle internal harness solenoid connector pin 12 and ground eye hook. SSPCC - Between transaxle internal harness solenoid connector pin 10 and ground eye hook. Are the resistances less than 5 ohms? YES : INSTALL a new TCM. TEST the system for normal operation. NO : INSTALL a new transaxle internal harness. TEST the system for normal operation.

Transmission Fluid Leakage in Torque Converter Area

In diagnosing and correcting transmission fluid leaks in the pump support and gear and torque converter area, use the following procedures to locate the exact cause of the leakage. Leakage between the transaxle and engine, as evidenced by fluid around the torque converter housing, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of leakage before removing the transaxle from the vehicle. The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the illustration. The 5 steps following correspond with the numbers in the illustration.

Scheme 89

1. Transmission fluid leaking by the pump seal lip will tend to move along the impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, transmission fluid leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near the outside diameter of the housing. Transmission fluid from the vent assembly may move along the impeller hub and onto the back of the impeller housing. Transmission fluid from a converter hub weld leak will move along a path on the inside of the converter housing.
2. Transmission fluid leakage by the outside diameter of the pump seal and pump body will follow the same path that leaks by the inside diameter of the pump seal follow. Transmission fluid from a converter hub weld leak will move along a path on the inside of the converter housing.
3. Transmission fluid that leaks by a pump-to-case screw or pump gasket will be deposited on the inside of the torque converter housing only. Transmission fluid will not be deposited on the back of the torque converter.
4. Transmission fluid leakage from the converter drain plug, (model-dependent) converter seal weld or converter-to-flexplate stud weld will appear at the outside diameter of the torque converter on the back face of the flexplate, and in the converter housing only near the flexplate. Transmission fluid leaks from the torque converter will leave a ring of transmission fluid around the inside of the torque converter housing.
5. Engine oil leaks are sometimes incorrectly diagnosed as transaxle pump gasket leaks. The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the concern. Leakage at the valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to be present in or at the bottom of the torque converter housing. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.

Torque Converter

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-271121-S15426044802007110800000).

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 transmission fluid.
3. Observe the color and odor of the transmission fluid. The transmission 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 transmission fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the transmission 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 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand.
7. Thoroughly drain the transmission fluid.

Torque Converter Hub Seal

Special Tools Illustration Tool Name Tool Number Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Install, Drive Pinion Oil Seal 205-115 (15058)

Scheme 90

Scheme 91

Material

Material

See also:
• JACKING AND LIFTING