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Ford Workshop Service and Repair Manuals

Diagnosis and Testing > < Transmission Ranges and Power Flow
Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (AW81-40) - Transaxle Electronic Control System Fiesta 2002.25 (11/2001-)
Description and Operation

Overview

 
Item
Part Number
Description
1
-
Transmission control unit
2
-
Data Link Connector (DLC)
3
-
Powertrain Control Module (PCM)
4
-
Instrument cluster
5
-
Generic Electronic Module (GEM)
6
-
Turbine Shaft Speed (TSS) sensor
7
-
Output Shaft Speed (OSS) sensor
8
-
Transmission Range (TR) sensor
9
-
Starter inhibit relay
10
-
Backup lamp relay
11
-
Transmission Fluid Temperature (TFT) sensor
12
-
Overdrive switch
13
-
Driver's side door ajar switch
14
-
Solenoid valves in the main control body

Transmission control unit

 
Item
Part Number
Description
1
-
Electrical connector, vehicle wiring harness
2
-
Electrical connector, transmission wiring harness

The transmission control unit is located in the engine compartment on the left-hand side member.

The transmission control unit evaluates incoming signals and controls the actuators accordingly.

The transmission control unit can be diagnosed with WDS via the DLC.

Gearshift strategies

Gearshift control

 
Item
Part Number
Description
A
-
Accelerator pedal position
B
-
Vehicle speed

The current ratio is selected by the transmission control unit either in accordance with the requirements for low fuel consumption or in order to meet the required driving performance.

The gearshift timing is selected in accordance with a gearshift map which is programmed into the control unit as a function of the accelerator pedal position and the vehicle speed.

For kick-down (accelerator pedal pressed down at least 95 %) the next lowest gear is selected, as long as the engine speed allows it. All gearshift timings are set by the transmission control unit to the upper shift characteristic.

The driver can feel the kickdown point in the accelerator pedal as a slight increase in resistance to the operation of the pedal.

    This is influenced by the following variables:

  • accelerator pedal position and actuation,
  • vehicle speed,
  • brake pedal position,
  • selector lever position.

    The following are actuated:

  • SSA shift solenoid valve,
  • SSB shift solenoid valve.

Hill climb mode

When the vehicle is in hill climb mode or towing a trailer, the transmission control delays gearshifts to prevent frequent shifting back and forth between the gears.

The transmission control unit determines hill climb mode or trailer operation from the change in throttle valve position supplied by the PCM in relation to the acceleration of the vehicle.

Depending on the driving resistance, the transmission control unit chooses between two gearshift maps which have been specially programmed for this purpose and in which the shift timings are again chosen as a function of the accelerator pedal position and the vehicle speed..

Hill descent mode

The hill descent mode is used to take better advantage of engine braking during hill descents.

A 'hill descent' situation is recognised by the transmission control unit if the vehicle is accelerating without operation of the accelerator pedal.

If in addition the brake is also depressed then the transmission control unit automatically shifts back from 4th into 3rd gear.

Cold start mode

    In order to reach operating temperature as quickly as possible under low ambient temperatures, gearshifts into 4th gear and engagement of the torque converter clutch (TCC) are suppressed if one of the following conditions is met:

  • Transmission fluid temperature below +20 °C
  • Coolant temperature below - 40°C

    The following are actuated:

  • SSA shift solenoid valve,
  • SSB shift solenoid valve,
  • Shift solenoid valve, TCC.

Overheating protection mode

The overheating protection mode serves to protect the transmission against overheating and the serious damage that this can cause.

If the transmission fluid temperature reaches a temperature of around 135 °C, the transmission control employs a shift pattern designed to prevent a further increase in the transmission fluid temperature.

When the transmission fluid temperature drops back below approx. 125 °C, the transmission control exits the overheating protection mode.

The MIL warning lamp is actuated by the transmission control unit if the transmission fluid temperature reaches approximately 140 °C.

The MIL warning lamp goes out again when the transmission fluid temperature drops back to below around 130 °C.

Main line pressure control

In order to ensure the highest possible efficiency of the automatic transmission and to limit the power losses from the fluid pump, the main line pressure is adapted accordingly by the main regulating valve as a function of the accelerator pedal position (driver torque demand) and the selector lever position.

    This is influenced by the following variables:

  • Accelerator pedal position and actuation
  • Selector lever position

    The following are actuated:

  • Main regulating valve

Engagement of the TCC

The TCC is engaged in 3rd and 4th gear depending on the current driving situation.

Engagement is controlled in accordance with the shift map stored in the control unit.

    This is influenced by the following variables:

  • Accelerator pedal position and actuation,
  • Vehicle speed,
  • Selector lever position,
  • Transmission fluid temperature,
  • Coolant temperature.

    The following are actuated:

  • Shift solenoid valve, TCC.

Torque reduction during gearshifts

In order to improve the quality of gearshifts and to avoid gearshift judder, the engine torque is reduced by the PCM in response to a request from the transmission control unit during gearshifts.

The engine torque is also reduced during engagement and disengagement of the TCC.

    This is influenced by the following variables:

  • Engine speed,
  • Engine load,
  • Transmission input speed,
  • Vehicle speed.

    The following are actuated:

  • PCM (torque reduction request signal via the CAN databus).

Pressure control during gearshifts

In order to ensure that the engagement of the clutches and brakes is as judder-free as possible, the main line pressure is reduced during gearshifts.

    This is influenced by the following variables:

  • Engine speed,
  • Engine load,
  • Transmission input speed,
  • Vehicle speed.

    The following are actuated:

  • Main regulating valve.

Shift timing adaptation during upshifts

In order to ensure that the engagement of the clutches and brakes is as judder-free as possible, the timing of the gearshift processes is monitored during upshifts.

In the event of any discrepancy from the target values, the main line pressure is adapted accordingly during the next gearshift.

The shift timing adaptation during upshifts is only active at transmission fluid temperatures between 50 °C and 120 °C.

    This is influenced by the following variables:

  • Engine load,
  • Accelerator pedal position,
  • Transmission input speed,
  • Vehicle speed,
  • Transmission fluid temperature,
  • Selector lever position.

    The following are actuated:

  • Main regulating valve.

Shift timing adaptation during shifts from 3rd to 4th gear

The shift from 3rd gear into 4th gear is the only gearshift during which a clutch is disengaged and a brake is engaged simultaneously.

In order to control the synchronized switching of the two components as exactly as possible, the shift timing solenoid valve is actuated accordingly.

In order to ensure that this particular gearshift is performed as judder-free as possible throughout the service life of the transmission, the gearshift is monitored by the two rotational speed sensors and the actuation of the shift timing solenoid valve is adapted accordingly.

The shift timing adaptation for gearshifts from 3rd gear into 4th gear is only active at transmission fluid temperatures between 30 °C and 120 °C.

    This is influenced by the following variables:

  • Engine load,
  • Accelerator pedal position,
  • Transmission input speed,
  • Vehicle speed,
  • Transmission fluid temperature,
  • Selector lever position.

    The following are actuated:

  • Shift timing solenoid valve.

Shift timing adaptation during shifts from 4th to 3rd gear

The shift from 4th gear into 3rd gear is the only gearshift during which a brake is disengaged and a clutch is engaged simultaneously.

In order to control the engagement of the clutch as precisely as possible, the main regulating valve is actuated accordingly in order to build up the actuating pressure at exactly the right time.

In order to ensure that this particular gearshift is performed as judder-free as possible throughout the service life of the transmission, the gearshift is monitored by the two rotational speed sensors and the actuation of the main regulating valve is adapted accordingly.

The shift timing adaptation for gearshifts from 4th gear into 3rd gear is only active at transmission fluid temperatures between 20 °C and 120 °C.

    This is influenced by the following variables:

  • Engine load,
  • Accelerator pedal position,
  • Transmission input speed,
  • Vehicle speed,
  • Transmission fluid temperature,
  • Selector lever position.

    The following are actuated:

  • Main regulating valve.

Reverse gear safety strategy

The transmission control unit prevents shifts into reverse gear while the vehicle is driving forwards, as otherwise serious transmission damage can be caused.

The reverse gear safety strategy is active when reverse gear is engaged with the selector lever at vehicle speeds in excess of 11 km/h.

In this case the transmission control unit actuates the shift timing solenoid valve, as a result of which the actuating pressure does not reach the reverse gear clutch or the reverse gear brake.

The reverse gear safety strategy is deactivated when the vehicle speed is below 9 km/h. The actuating pressure can then reach the reverse gear clutch and the reverse gear brake and the gearshift into reverse gear is performed.

    This is influenced by the following variables:

  • Vehicle speed,
  • Selector lever position.

    The following are actuated:

  • Shift timing solenoid valve.

Avoidance of gearshift judder during engagement of a transmission range

In order to prevent gearshift judder when moving the selector lever from N to D, the transmission control unit initially shifts into 2nd gear instead of 1st gear, and then immediately shifts back into 1st gear before the gearshift process is finished.

This reduces the amount of gearshift judder during engagement of a forward drive range.

    This is influenced by the following variables:

  • Selector lever position,
  • Accelerator pedal position,
  • Transmission input speed,
  • Vehicle speed,
  • Transmission fluid temperature.

    The following are actuated:

  • SSA shift solenoid valve,
  • SSB shift solenoid valve.

Torque reduction when pulling away

In order to protect the clutches against excessively high torque when pulling away, the PCM reduces the engine torque in response to a request from the transmission control.

If the accelerator pedal is depressed while the vehicle is pulling away, then the transmission control unit sends a corresponding signal requesting a torque reduction via the CAN databus.

    This is influenced by the following variables:

  • Selector lever position,
  • Accelerator pedal position,
  • Engine speed,
  • Transmission input speed,
  • Vehicle speed.

    The following are actuated:

  • PCM (torque reduction request signal via the CAN databus).

Selector lever positions

Selector lever position "P"

No gear is engaged in selector lever position "P".

The parking pawl is engaged manually via the selector lever cable and the selector shaft.

Selector lever position "R"

The reverse gear is engaged in selector lever position "R".

Selector lever position "N"

No gear is engaged in selector lever position "N".

The powertrain is not blocked.

Selector lever position "D"

In selector lever position "D" the transmission control will allow all gears to be engaged provided the overdrive switch is not operated.

If the overdrive switch is pressed then the transmission control prevents gearshifts into 4th gear or shifts back into 3rd gear.

Selector lever position "2"

Only the second gear is engaged when the selector lever is in position "2". Gearshifts into 1st gear are not permitted.

If the selector lever is moved to position "2" at higher speeds than are permitted for second gear, then the transmission control delays the downshift until the vehicle speed has slowed down enough.

In selector lever position "2" engine braking is effective when the vehicle is coasting.

Selector lever position "1"

Only the first gear is engaged when the selector lever is in position "1".

If the selector lever is moved to position "1" at higher speeds than are permitted for first gear, then the transmission control delays the downshift until the vehicle speed has slowed down enough.

In selector lever position "1" engine braking is effective when the vehicle is coasting.

Signal transmission on the CAN databus

 
Item
Part Number
Description
1
-
Transmission control unit
2
-
PCM
3
-
Instrument cluster
4
-
DLC

Engine speed

The engine speed is detected by the crankshaft position (CKP) sensor and passed on to the PCM.

The engine speed is transmitted from the PCM via the CAN databus to the transmission control unit.

    The transmission control unit uses this signal for:

  • Torque reduction during gearshifts,
  • Pressure control during gearshifts.

Engine load

The PCM determines a load signal which is transmitted via the CAN databus to the transmission control unit.

    The transmission control unit uses this signal for:

  • Torque reduction during gearshifts,
  • Pressure control during gearshifts,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Hill climb mode,
  • Hill descent mode.

Torque reduction request signal

Before performing a gearshift, the transmission control unit sends a signal via the CAN databus to the PCM requesting a torque reduction.

The PCM then reduces the engine torque, ensuring that the gearshift is as smooth and judder-free as possible.

Brake signal

The PCM receives a signal from the stoplamp switch when the brake pedal is depressed.

This signal is transmitted via the CAN databus to the transmission control unit.

    The transmission control unit uses this signal for:

  • Gearshift control,
  • Engagement of the TCC

Accelerator pedal position

The PCM receives the current accelerator pedal position signal from the Accelerator Pedal Position (APP) sensor.

This signal is transmitted via the CAN databus to the transmission control unit.

    The transmission control unit uses this signal for:

  • Controlling the main line pressure,
  • Gearshift control,
  • Engagement of the TCC,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Shift timing adaptation during shifts from 4th to 3rd gear,
  • Avoidance of gearshift judder during engagement of a transmission range,
  • Torque reduction when pulling away.

Coolant temperature

The coolant temperature is detected by the Engine Coolant Temperature (ECT) sensor and passed on to the PCM.

This signal is transmitted via the CAN databus to the transmission control unit.

    The transmission control unit uses this signal for:

  • Cold start mode,
  • Engagement of the TCC

Selector lever position

The transmission control unit transmits the selector lever position to the instrument cluster.

The instrument cluster uses the signal to send a request for a warning tone to the GEM when the selector lever is not in position "P" and the driver's door is opened.

Actuation of the MIL warning lamp

The MIL warning lamp is actuated by the instrument cluster if there are serious faults in the transmission control or if the transmission fluid temperature is excessively high.

The information required to actuate the MIL warning lamp is sent by the transmission control unit to the instrument cluster.

Actuation of the overdrive indicator lamp

The overdrive indicator lamp is located on the instrument panel.

The information required to actuate the overdrive indicator lamp is sent from the transmission control unit when the overdrive switch on the selector lever is pressed.

Warning tone request

    The transmission control unit sends a warning tone request to the instrument cluster if the following conditions are met:

  • The selector lever is not in position "P",
  • The driver's door is open.

The instrument cluster passes on the warning tone request to the GEM. The GEM generates the warning tone.

Sensors

TSS sensor

The TSS sensor is an inductive pickup.

It measures the transmission input speed via the outer plate carrier of the 3rd/4th gear clutch and sends the signal to the transmission control unit.

    The transmission control unit uses this signal for:

  • Torque reduction during gearshifts,
  • Pressure control during gearshifts,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Shift timing adaptation during shifts from 4th to 3rd gear,
  • Avoidance of gearshift judder during engagement of a transmission range,
  • Torque reduction when pulling away.

    Consequences of signal failure:

  • No TCC,
  • no torque reduction,
  • no shift timing adaptation,
  • no 4th gear.

OSS sensor

The OSS sensor is a Hall sensor.

It is mechanically connected via a gear to the input wheel of the differential assembly.

It measures the vehicle speed via the input wheel of the differential assembly and sends the signal to the transmission control unit.

    The transmission control unit uses this signal for:

  • Gearshift control,
  • Engagement of the TCC,
  • Torque reduction during gearshifts,
  • Pressure control during gearshifts,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Shift timing adaptation during shifts from 4th to 3rd gear,
  • Reverse gear safety strategy,
  • Avoidance of gearshift judder during engagement of a transmission range,
  • Torque reduction when pulling away,
  • Hill climb mode,
  • Hill descent mode.

    Consequences of signal failure:

  • No TCC,
  • no torque reduction,
  • no shift timing adaptation,
  • no 4th gear.

TR sensor

The TR sensor serves to signal the currently selected transmission range to the transmission control unit.

It is a switch which transmits the selected transmission range directly to the transmission control unit.

In addition, the starter inhibit relay is actuated by the PCM via the TR sensor when the selector lever is in the positions "P" or "N".

In selector lever position "R" the backup lamp relay is also actuated via the TR sensor.

    The transmission control unit uses this signal for:

  • Controlling the main line pressure,
  • Gearshift control,
  • Engagement of the TCC,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Shift timing adaptation during shifts from 4th to 3rd gear,
  • Reverse gear safety strategy,
  • Avoidance of gearshift judder during engagement of a transmission range,
  • Torque reduction when pulling away.

    Consequences of signal failure:

  • No TCC,
  • no shift timing adaptation.

TFT sensor

The TFT sensor is located in the oil pan on the main control body and is part of the transmission wiring harness.

It measures the current transmission fluid temperature and sends the signal to the transmission control unit.

    The transmission control unit uses this signal for:

  • Cold start mode,
  • Engagement of the TCC,
  • Shift timing adaptation during upshifts,
  • Shift timing adaptation during shifts from 3rd to 4th gear,
  • Shift timing adaptation during shifts from 4th to 3rd gear,
  • Overheating protection mode.

    Consequences of signal failure:

  • No TCC,
  • no shift timing adaptation,
  • no 4th gear.

Overdrive switch

The overdrive switch is located on the selector lever.

It allows the driver to suppress or enable gearshifts into 4th gear when "D" is selected.

The signal from the overdrive switch is transmitted to the transmission control unit.

When gearshifts into 4th gear are suppressed, the transmission control unit sends a corresponding signal via the CAN databus to the instrument cluster. The instrument cluster then actuates the overdrive indicator lamp.

    Consequences of signal failure:

  • no suppression of gearshifts into 4th gear.

Driver's side door ajar switch

The door ajar switch is located in the door lock on the driver's side.

When the door is closed a ground connection is signalled to the transmission control unit.

When the door is opened this ground connection is interrupted.

The transmission control unit uses the signal from the driver's side door ajar switch to warn the driver if the selector lever is not in position "P" and the driver's door is open.

In this case the transmission control unit transmits the warning tone request via the CAN databus to the instrument cluster.

The instrument cluster passes this request on to the GEM, which then generates a warning tone.

    Consequences of signal failure:

  • no warning tone request.

Actuators

Main regulating valve

 
Item
Part Number
Description
1
-
Main regulating valve

The main regulating valve is a proportional valve which converts the applied electric current into a proportional hydraulic pressure.

The currentless state corresponds to maximum pressure.

The main regulating valve is used to determine the main line pressure and therefore the actuating pressure for the clutches and brakes.

    Consequences of signal failure:

  • hydraulic emergency running mode.

SSA and SSB shift solenoid valves

 
Item
Part Number
Description
1
-
SSA
2
-
SSB

The SSA and SSB shift solenoid valves are used to switch the different hydraulic paths in the main control body.

They are actuated by the transmission control unit according to the required gear.

In their currentless state they are open.

    Consequences of signal failure:

  • hydraulic emergency running mode.

Actuation of the SSA and SSB shift solenoid valves

gear SSA SSB
1st gear On On
2nd gear On Off
3rd gear Off Off
4th gear Off On

Shift timing solenoid valve

 
Item
Part Number
Description
1
-
Shift timing solenoid valve

The shift timing solenoid valve is used to precisely control the timing of the engagement and disengagement of the 1st-3rd gear clutch.

In addition, it is also used to prevent engagement of reverse gear if the driver moves the selector lever to "R" while the vehicle is driving forwards at a speed in excess of 11 km/h.

It is actuated by the transmission control unit according to requirements.

In its currentless state the solenoid valve is closed.

    Consequences of signal failure:

  • hydraulic emergency running mode.

Shift solenoid valve, TCC

 
Item
Part Number
Description
1
-
Shift solenoid valve, TCC

The TCC shift solenoid valve is used to engage or disengage the TCC.

It is actuated by the transmission control unit according to requirements.

In its currentless state the solenoid valve is open and the TCC is not engaged.

    Consequences of signal failure:

  • Engagement of the TCC.

Starter inhibit relay

 
Item
Part Number
Description
1
-
Starter inhibit relay
NOTE:
NOTE:The engine cannot be started if the electrical connector is disconnected from the TR sensor.

The starter inhibit relay is located in the central junction box (CJB).

In the selector lever positions "P" and "N" a ground signal is directed from the PCM via the TR sensor to the starter inhibit relay, as a result of which the starter inhibit relay is actuated.

Backup lamp relay

 
Item
Part Number
Description
1
-
Backup lamp relay

The backup lamp relay is located in the relay box in the engine compartment.

When the selector lever is in position "R" the backup lamp relay receives a ground signal from the TR sensor and actuates the backup lamps as a result.

    Consequences of signal failure:

  • backup lamps inoperative.

Selector lever lock solenoid

 
Item
Part Number
Description
1
-
Locking pin

The selector lever lock solenoid is part of the selector lever.

When the ignition is switched on, the selector lever lock solenoid is actuated by depressing the brake pedal (signal from the stoplamp switch). This results in the locking pin being pulled back, and the selector lever can be moved out of "P".

The ground connection to the solenoid for the ignition key removal inhibitor is also made via the selector lever lock solenoid in all selector lever positions except "P".

    Consequences of signal failure:

  • If the signal from the stoplamp switch is missing or the ground connection is interrupted, then the selector lever can no longer be moved out of the position "P".

The selector lever lock can be manually released by removing the cover and pressing a suitable object into the opening on the selector lever until the selector lever can be moved out of the position "P".

The selector lever then re-locks if it is moved back to "P".

Solenoid for the ignition key removal inhibitor

 
Item
Part Number
Description
1
-
Solenoid for the ignition key removal inhibitor

The solenoid for the ignition key removal inhibitor is integrated in the ignition lock.

With the selector lever in position "P", the ground connection via the selector lever lock solenoid is interrupted.

The ignition key can be turned to "0" and removed from the ignition lock.

In all other selector lever positions the ground connection is made via the selector lever lock solenoid.

The locking pin of the solenoid for the ignition key removal inhibitor engages in the ignition lock.

The ignition key cannot be turned to "0" and removed from the ignition lock.

    Consequences of signal failure:

  • A short to ground will make it impossible to remove the ignition key from the ignition lock.
  • A break in the electrical circuit will make it possible to remove the ignition key from the ignition lock in all selector lever positions.

Diagnosis and Testing > < Transmission Ranges and Power Flow