Ford Workshop Service and Repair Manuals

Construction features, transmission differential side

WARNING:The ESD protection measures must be adhered to without fail, as otherwise the transmission electronics could be destroyed.

WARNING:Electrical connectors to and from the automatic transmission control electronics must only be separated or connected when no voltage is present.

WARNING:Because of bodily electrostatic charge, connectors must not be disturbed, as this may cause damage to the transmission control electronics.

NOTE:In order for the diagnosis of the automatic transmission to be meaningful, all other systems such as the PCM, IC and ABS must be operating correctly, because through the CAN databus they may have an effect on the TCM and therefore on the transmission control.

NOTE:Electrical faults which appear - even only momentarily - when the ignition is switched on, will be stored in the fault memory of the relevant control unit and may have effects on the control system. Loose connections and fuses or connectors which have been removed or disconnected for testing purposes all count as electrical faults.

Introduction

WARNING:Adhere to the ESD protection measures listed below without fail, as otherwise the transmission control electronics could be destroyed

NOTE:Always take into account TSBs and OASIS messages.

NOTE:Do not take any short cuts or assume that critical checks or adjustments have already been made.

NOTE:Follow the test procedure described in the WDS/IDS exactly. In this way, test steps or important component tests are prevented from being overlooked.

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.

Details of ESD protection

When dealing with the mechatronics, for example during a repair, suitable protective measures must be taken, especially ESD protection.

The term ESD means: Electro Static Discharge.

A person who is electrostatically charged and not earthed carries a voltage field with them, and so endangers "electrostatically sensitive components" which are contained in the control electronics. Carelessness when working on the transmission, touching the contacts of the central connector with the hand or making measurements using a multimeter will destroy the control electronics.

Preliminary inspection

NOTE:Many concerns with an automatic transmission are caused by incorrect operating conditions or operating error on the part of the driver. It is therefore very important to include the environment when making a diagnosis.

Apply the parking brake and move the selector lever to the "P" position when:

• Parking the vehicle,
• performing tests or making adjustments,
• leaving the vehicle standing with the engine running.

Know and understand customer concern

The problem must be fully understood before fault diagnosis is started, in order to clearly establish the cause of a concern. Detailed information from the customer may be needed for this.

Ask the customer under which conditions the concern appears. For example:

• Cold or warm engine?
• At what engine speed, vehicle speed, load?
• In which gear or range?
• At high or low outdoor temperature?
• With the vehicle loaded or empty?
• On what road surface?
• In what driving situation:
  -

  while accelerating?
  -

  on overrun?
  -

  when shifting up or down?
• Do noises occur?
• What is the quality of the shift?
• Does the gear engaged correspond to the display?
• When the incorrect operation occurred, did a warning appear in the IC?

Verification of Condition

NOTE:If noise or vibration is a concern, check for dependency on: rpm, vehicle speed, gear range or temperature.

NOTE:In some cases, faults in the automatic transmission may cause concerns over the way the engine runs. For example, it can cause the engine to stall if the torque converter lock-up clutch does not disengage.

If necessary and it is possible, ask the customer to demonstrate the concern to you. It may also be an error in the way in which the vehicle is operated. Reproduce the fault by possibly driving the vehicle yourself.

Visual Inspection

The visual inspection extends to obvious damage to mechanical or electrical components, e. g.

• Electrical connectors and cable connections
• Ease of operation of the selector lever
• Selector lever position and selector lever display
• Fluid leakage
• Transmission fluid level check
• Transmission fluid quality check
• Modifications/retrofitting/tuning
• Damage

If any causes for a concern are found during the visual inspection, they must be corrected before any further checks are made.

Electrical connectors and cable connections

Electrical connectors to and from the automatic transmission control electronics must only be separated or connected when no voltage is present.

Ease of operation of the selector lever

A selector lever which is difficult to move may be the cause of a customer concern. Therefore move the selector lever through all positions and in doing so check it for ease of movement. If there is difficulty in movement, detach the cable from the transmission and move the lever again, to determine whether the stiffness is caused by the transmission or the cable.

Selector lever position and selector lever display

This test is possible with the vehicle stationary and the engine running, and while driving. When moving through the selector lever positions, compare the position selected with the display in the instrument cluster.

For adjustment work
REFER to: Wählhebelseilzug einstellen (307-05 Äußere Schaltung - Automatikgetriebe - Fahrzeuge ausgestattet mit 6-Gang Automatikgetriebe (AWF21), General Procedures).

Test for fluid leaks

CAUTION:Only use the automatic transmission fluid approved by Ford.

CAUTION:Do not use a pressure washer or steam cleaner near any electrical connector.

NOTE:Refer to the service instructions for the frequency of changing the automatic transmission fluid.

NOTE:Careful location of the source of leaks can avoid unnecessary or expensive repairs.

Thoroughly clean the transmission, engine and surrounding area. Depending on the severity of the leak, a short or longer road test should be performed. It can also be useful to look for leaks with the vehicle on the lifting platform and the engine idling. Check that the fluid which has leaked out is really transmission fluid, and not engine oil.

Transmission fluid level check

It is not possible to check the level of the transmission fluid visually, because there is no dipstick. If there is a concern, the transmission fluid level must be checked.

If it is necessary to check the transmission fluid level, the fluid must be drained and refilled, REFER to: (307-01 Automatikgetriebe - Fahrzeuge ausgestattet mit 6-Gang Automatikgetriebe (AWF21))

Fluid quality check

NOTE:Dirty or overheated transmission fluid can cause impairment. The quality of the transmission fluid should therefore be tested if there is a concern.

Check the automatic transmission fluid for contamination and smell. If there are signs of contamination, a test amount must be drained off through a paper filter and checked. If the automatic transmission fluid smells burnt, this indicates overheating.

Modifications/retrofitting/tuning

Additional aftermarket systems (e.g. air conditioning, car telephone, cruise control, etc. etc.) which are not approved by Ford, or which have been unprofessionally installed, and also chip and engine tuning, can have an effect on the engine and transmission management and lead to faults.

Diagnostics

Electrical faults which appear, even only momentarily, when the ignition is switched on, will be stored in the fault memory of the relevant control unit and may have effects on the control system. Loose connections and fuses or connectors which have been removed or disconnected for testing purposes all count as electrical faults.

In order for the diagnosis of the automatic transmission to be meaningful, all other systems such as the PCM, IC and ABS must be operating correctly, because through the CAN databus they may have an effect on the TCM and therefore on the transmission control.

Perform a WDS/IDS self-test on the vehicle

In the self-test, the WDS/IDS downloads all the stored DTCs from the fault memories of the individual controllers and displays them on its screen.

• Print out the DTCs (faults) displayed (this is important for later analysis and/or in the case of a guarantee).
• Read out the freeze frame data belonging to each DTC and print them out.
• Check the conditions under which the fault occurred.
• Clear all fault memory, because stored faults may have an effect on the control process.

Fault finding road test with WDS/IDS

After the road test repeat the WDS/IDS selft-test.

Perform diagnosis with WDS/IDS.

In the event of fault codes, follow the instructions given by the WDS/IDS.

Rectify the faults displayed in the WDS/IDS.

Clear all fault memories again.

Functional test

To verify the function after the repair has been carried out, road test the vehicle and then run a WDS self test to check that no DTCs (faults) have been stored.