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Automatic Transmission - External Controls: Diagnosis Mercury Monterey VIII

Steering Column 17 illustrations ~1848 words

Inspection and Verification

  1. Verify the customer concern by operating the transaxle external control.
  2. Visually inspect for obvious signs of mechanical and electrical damage, incorrect component installation and component misalignment. Verify that all circuit-related systems are functioning correctly. Refer to the following chart. VISUAL INSPECTION CHART Mechanical Electrical Damaged brake shift interlock actuator Damaged brake pedal position (BPP) switch Damaged shift cable and bracket Damaged steering column Damaged instrument cluster Failed fuse(s) Damaged wiring harness Loose or corroded connections
  3. If the fault is not visually evident, GO to «SYMPTOM CHART»(ref-234540-S18000353972006061000000) .

Symptom Chart

ConditionPossible SourcesAction
The shift interlock system does not release/lock correctlyCircuit(s) Fuse(s). Brake shift interlock actuator. BPP switch.GO to PINPOINT TEST A .
The shift control is out of correct gear relationshipShift control component(s). Internal transaxle component(s).GO to PINPOINT TEST B .
The selector lever indicator does not correspond to the gearSelector lever indicator adjustment.CHECK that the selector lever indicator adjustment is correct. REFER to SELECTOR LEVER CABLE ADJUSTMENT . ADJUST the selector lever indicator if necessary. TEST the system for normal operation. If the condition persists, GO to PINPOINT TEST B .
The control linkage is bindingShift control component(s). Internal transaxle component(s).GO to PINPOINT TEST C .
The gearshift lever will not shift through all gear rangesShift control component(s). Internal transaxle component(s).GO to PINPOINT TEST C .
Rattle, noise, buzz or other noiseGearshift lever. Steering column shrouds.INSPECT the gearshift lever and shrouds for damage and incorrect installation. REPAIR as necessary.
Water enters inside the vehicleShift cable rubber grommet.SECURE the grommet to the bulkhead.
Torn shift cable rubber grommet.INSTALL a new shift cable and bracket. REFER to SELECTOR LEVER CABLE AND BRACKET .

SYMPTOM CHART

Scheme 4

Scheme 4: PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
Scheme 4: PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. A1 CHECK THE POWER SUPPLY TO THE BRAKE SHIFT INTERLOCK ACTUATOR NOTE: Test Step A1 diagnoses why the brake shift interlock system does not release correctly. Key in OFF position. Disconnect: Brake Shift Interlock Actuator. Key in ON position. Apply the brake pedal. Measure the voltage between the brake shift interlock actuator pin 3 harness side and ground. Is the voltage greater than 10 volts? Yes : INSTALL a new brake shift interlock actuator. REFER to «BRAKE SHIFT INTERLOCK ACTUATOR»(ref-234540-S29873491262006061000000) . TEST the system for normal operation. No : REPAIR circuit. RECONNECT all components. TEST the system for normal operation. If the shift interlock system does not lock correctly, GO to A2 .
  2. A2 CHECK THE POWER SUPPLY TO THE BRAKE SHIFT INTERLOCK ACTUATOR Key in OFF position. Disconnect: Brake Shift Interlock Actuator. Key in ON position. Measure the voltage between the brake shift interlock actuator pin 1 harness side and ground. Is the voltage greater than 10 volts? Yes : GO to A3 . No : REPAIR circuit. RECONNECT all components. TEST the system for normal operation.
  3. A3 CHECK CIRCUIT FOR AN OPEN Key in OFF position. Measure the resistance between the brake shift interlock actuator pin 2 harness side and ground. Is the resistance less than 5 ohms? Yes : INSTALL a new brake shift interlock actuator. REFER to «BRAKE SHIFT INTERLOCK ACTUATOR»(ref-234540-S29873491262006061000000) . TEST the system for normal operation. No : REPAIR circuit. RECONNECT all components. TEST the system for normal operation.

PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP

  1. B1 CHECK THE SHIFT CONTROL COMPONENTS FOR DAMAGE Gain access to the shift control components. Key in ACCESSORY position. Apply the brake pedal. Observe all shift control components while shifting the gearshift lever through all ranges. Are any of the components damaged? Yes : REPAIR as necessary. REINSTALL all components. TEST the system for normal operation. No : GO to B2 .
  2. B2 CHECK THE SHIFT CABLE AND BRACKET INSTALLATION Check that the shift cable and bracket installation is correct. Is the shift cable and bracket installed correctly? Yes : GO to B3 . No : REINSTALL the shift cable. GO to B3 .
  3. B3 CHECK THE SHIFT CABLE ADJUSTMENT Check that the shift cable adjustment is correct. Refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-234540-S01015466282006061000000) . Is the shift cable adjusted correctly? Yes : GO to B4 . No : ADJUST the shift cable. GO to B4 .
  4. B4 CHECK THE SELECTOR LEVER INDICATOR ADJUSTMENT CHECK that the selector lever indicator adjustment is correct. REFER to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-234540-S01015466282006061000000) . Is the selector lever indicator adjusted correctly? Yes : GO to B5 . No : ADJUST the selector lever indicator. GO to B5 .
  5. B5 CHECK THE DIGITAL TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT Check that the digital transmission range (TR) sensor adjustment is correct. Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) . Is the digital transmission range (TR) sensor adjusted correctly? Yes : REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) for internal transaxle repair. No : ADJUST the digital transmission range (TR) sensor. REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) . TEST the system for normal operation. If the condition persists, REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) for internal transaxle repair.

PINPOINT TEST C: THE SHIFT CONTROL LINKAGE IS BINDING

  1. C1 CHECK THE SHIFT CONTROL LINKAGE FOR DAMAGE Key in ACCESSORY position. Apply the brake pedal. Move the gearshift lever through the gear ranges. Does the gearshift lever go through all the gear ranges freely? Yes : Concern is intermittent. No : GO to C2 .
  2. C2 CHECK THE SHIFT CONTROL LINKAGE WITH THE SHIFT CABLE DISCONNECTED FROM THE TRANSAXLE Key in OFF position. Position the air cleaner housing outlet aside. Disconnect the shift cable from the manual control lever at the transaxle. Key in ACCESSORY position. Apply the brake pedal. Move the gearshift lever through the gear ranges. Does the gearshift lever go through all the gear ranges freely? Yes : GO to C3 . No : GO to C4 .
  3. C3 CHECK THE MANUAL CONTROL LEVER AT THE TRANSMISSION Leave the shift cable disconnected from the manual control lever at the transmission. Move the manual control lever at the transmission through all the gear ranges. Does the manual control lever at the transmission go through all the gear ranges freely? Yes : GO to C4 . No : REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) . Problem may be internal to the transmission.
  4. C4 CHECK THE SHIFT CONTROL LINKAGE OPERATION WITH THE SHIFT CABLE DISCONNECTED FROM THE STEERING COLUMN Key in OFF position. Disconnect the shift cable from the steering column assembly. Key in ACCESSORY position. Apply the brake pedal. Move the gearshift lever through the gear ranges. Does the gearshift lever go through all the gear ranges freely? Yes : INSTALL a new shift cable and bracket. REFER to «SELECTOR LEVER CABLE AND BRACKET»(ref-234540-S36852922502006061000000) . No : REFER to «STEERING SYSTEM-GENERAL INFORMATION»(ref-234504) for steering column repair.

Scheme 7

Scheme 7: Selector Lever Cable Adjustment
Scheme 7: Selector Lever Cable Adjustment

Scheme 8

Scheme 8
Scheme 8
  1. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise 2 detents.
  2. Hang a 1.4 kg (3 lb) weight on the gearshift lever.
  3. Position the air inlet cover aside. Loosen the clamps. Separate the air inlet cover from the tube and position the air inlet cover aside.
  4. Adjust the shift cable. Disconnect the shift cable from the manual control lever. Pull the shift cable adjustment lock tab outward to the UNLOCK position. Place the manual control lever in the (D) position. Rotate the manual lever clockwise until travel stops. Then move the manual lever counterclockwise 2 detents to the (D) position. Connect the shift cable to the manual lever. Push the shift cable adjustment lock tab inward to the LOCK position.
  5. Remove the 1.4 kg (3 lb) weight.
  6. Verify the engine will start in PARK and NEUTRAL and the reversing lamps illuminate in REVERSE. If not, repeat the adjustment procedure.
  7. Check to make sure the digital transmission range (DTR) sensor is correct. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-234499) . Adjust the DTR sensor if necessary.
  8. Install the air inlet cover and the clamps.

Scheme 9

Scheme 9: Selector Lever Indicator Adjustment
Scheme 9: Selector Lever Indicator Adjustment

Scheme 10

Scheme 10
Scheme 10
  1. Remove the 2 screws and the instrument panel lower steering column opening cover.
  2. Remove the screws and the instrument panel opening cover reinforcement.
  3. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise 2 detents ((D) position).
  4. Hang a 1.4 kg (3 lb) weight on the gearshift lever.
  5. Rotate the thumbwheel to center the selector lever indicator in the middle of the (D) position.
  6. Remove the 1.4 kg (3 lb) weight.
  7. Rotate the gearshift lever into each detent to verify that the selector lever indicator matches the selected range. Readjust, if necessary.
  8. Install the instrument panel opening cover reinforcement. Tighten to 12 Nm (9 lb-ft).
  9. Install the instrument panel lower steering column opening cover. Tighten to 12 Nm (9 lb-ft).

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14
  1. Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-234519) .
  2. Remove the 2 screws and the instrument panel lower steering column opening cover. To install, tighten to 12 Nm (9 lb-ft).
  3. Separate the LH instrument panel finish panel from the instrument panel.
  4. Remove the RH instrument panel finish panel.
  5. Remove the screws and the instrument panel opening cover reinforcement. To install, tighten to 12 Nm (9 lb-ft).
  6. Remove the screws and the steering column opening brace. To install, tighten to 15 Nm (11 lb-ft).
  7. Position the selector lever indicator cable aside. Loosen the screw. To install, tighten to 4 Nm (35 lb-in). Disconnect the cable. Position the selector lever indicator cable aside.
  8. Remove the 4 nuts and the bracket, and lower the steering column. To install, tighten to 15 Nm (11 lb-ft).
  9. Remove the brake shift interlock actuator and the transmission shift selector position insert. Remove the 3 bolts. To install, tighten to 9 Nm (80 lb-in). Remove the brake shift interlock actuator and the transmission shift position insert.
  10. To install, reverse the removal procedure.

Scheme 15

Scheme 15: Removal and Installation
Scheme 15: Removal and Installation

Scheme 16

Scheme 16
Scheme 16
  1. Position the gearshift lever in the (D) position.
  2. Disconnect the shift cable from the steering column. Disconnect the shift cable from the shift assembly arm. Disconnect the shift cable from the steering column bracket.
  3. Push the rubber grommet through the bulkhead.
  4. Position the air inlet cover aside. Loosen the clamps. Separate the air inlet cover from the tube and position the air inlet cover aside.
  5. Remove the shift cable from the vehicle. Disconnect the shift cable from the manual control lever. Push back the lock tab and separate the shift cable from the bracket. Remove the shift cable from the vehicle.
  6. Remove the nut, bolts and the shift cable bracket. To install, tighten to 22 Nm (16 lb-ft). If removing the shift cable and bracket as an assembly, remove the assembly from the vehicle.
  7. To install, reverse the removal procedure. Adjust the shift cable before installing the air inlet cover. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-234540-S01015466282006061000000) .

Scheme 17

Scheme 17: Removal and Installation
Scheme 17: Removal and Installation

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the GENERAL PROCEDURES portion of «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-234526) .
  2. Remove the 2 screws and the instrument panel lower steering column opening cover. To install, tighten to 12 Nm (9 lb-ft).
  3. Separate the LH instrument panel finish panel from the instrument panel.
  4. Remove the RH instrument panel finish panel.
  5. Remove the screws and the instrument panel opening cover reinforcement. To install, tighten to 12 Nm (9 lb-ft).
  6. Remove the screws and the steering column opening brace. To install, tighten to 12 Nm (9 lb-ft).
  7. Position the selector lever indicator cable aside. Loosen the screw. To install, tighten to 4 Nm (35 lb-in). Disconnect the cable. Position the selector lever indicator cable aside.
  8. Remove the ignition switch lock cylinder. Rotate the ignition switch lock cylinder to the RUN position. Press the lock cylinder release pin and remove the ignition switch lock cylinder.
  9. Remove the lower steering column shroud. If so equipped, remove the tilt wheel handle and shank. Remove the 3 screws. Remove the lower steering column shroud.
  10. Remove the 4 nuts and the bracket, and lower the steering column. To install, tighten to 15 Nm (11 lb-ft).
  11. Remove the upper steering column shroud.
  12. Remove the gearshift lever pin and the gearshift lever. Discard the gearshift lever pin.
  13. To install, reverse the removal procedure.

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