Pinpoint Test A: Shift Solenoid

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1 Procedures 2004 Ford Freestar 3.9L Eng SES P0731 Pinpoint Test A: Shift Solenoid NOTE: Refer to TRANSAXLE INTERNAL HARNESS DIAGRAM for the transaxle internal harness diagram illustration. NOTE: Refer to TRANSAXLE VEHICLE HARNESS CONNECTOR for the transaxle vehicle harness connector illustration. A1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated; terminals are engaged in connector and in good condition before proceeding. Connect the diagnostic tool. Carry out KOEO Test until continuous DTCs have been displayed. Enter Output 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 Output OTM. GO to A2. No PRESS START. If vehicle does not enter OTM, refer to INTRODUCTION - CNG, FLEX-FUEL & GASOLINE. A2 CHECK THE ELECTRICAL SIGNAL OPERATION CAUTION: Do not pry on the connector. This will damage the connector and could result in a transaxle concern. Pull up on the connector harness. Disconnect: Transaxle Vehicle Harness Connector. Use a mirror to inspect both ends of the connector for damage or pushed out pins, corrosion, loose wires and missing or damaged seals. Connect the positive test lead to VPWR pin 2 and the negative test lead to the appropriate solenoid circuit pin 1, 6 and pin 8 of the vehicle harness connector. Pin Shift Solenoid 1 SSA 6 SSB www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 1/26

2 8 SSC Fig 1: Checking Electrical Signal Operation Place tester on the 20 volt scale. While observing the tester, press start and stop to cycle solenoid output ON and OFF. Does the suspect solenoid output voltage change at least 0.5 volts? Yes GO to A5. No GO to A3. A3 CHECK THE CONTINUITY OF THE SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS Key in OFF position. Disconnect: Transaxle Vehicle Harness Connector. Disconnect: Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corrosion or loose wires. Install the EEC-V Control System Breakout Box. Measure the resistance between the powertrain control module (PCM) signal test pin 27 at the EEC-V Control System Breakout Box and the SSA signal test pin 1 at the transaxle harness www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 2/26

3 connector. Fig 2: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (Test Pin 27) Measure the resistance between the powertrain control module (PCM) signal test pin 1 at the EEC-V Control System Breakout Box and the SSB signal test pin 6 at the transaxle harness connector. Fig 3: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (Test Pin 1) www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 3/26

4 Measure the resistance between the powertrain control module (PCM) signal test pin 53 at the EEC-V Control System Breakout Box and the SSC signal test pin 8 at the transaxle harness connector. Fig 4: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (Test Pin 53) Measure the resistance between the PCM signal test pin 71 at the EEC-V Control System Breakout Box and the signal test pin 2 at the transaxle harness connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 4/26

5 Fig 5: Checking Continuity Of Solenoid Signal And VPWR Harness Circuits (Test Pin 71) Is each resistance less than 5 ohms? Yes GO to A4. No REPAIR the open circuit(s). REMOVE the EEC-V Control System Breakout Box. RECONNECT all of the components. REPEAT the Quick test A4 CHECK THE SOLENOID HARNESS FOR SHORT TO POWER AND GROUND Key in OFF position. Disconnect: Transaxle Harness Connector. Disconnect: Powertrain Control Module (PCM). Install the EEC-V Control System Breakout Box. Measure the resistance between the PCM signal output pin 1 and test pin 71 at the EEC-V Control System Breakout Box. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 5/26

6 Fig 6: Checking Solenoid Harness For Short To Power And Ground (1 Of 6) Measure the resistance between the PCM signal out pin 53 and test pin 71 at the EEC-V Control System Breakout Box. Fig 7: Checking Solenoid Harness For Short To Power And Ground (2 Of 6) Measure the resistance between the PCM signal out pin 27 and test pin 71 at the EEC-V Control System Breakout Box. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 6/26

7 Fig 8: Checking Solenoid Harness For Short To Power And Ground (3 Of 6) Measure the resistance between the PCM signal output pin 27 and the test pins 24, 25, 51, 76, 77, 91 and 103 at the EEC-V Control System Breakout Box and chassis ground. Fig 9: Checking Solenoid Harness For Short To Power And Ground (4 Of 6) www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 7/26

8 Measure the resistance between the PCM signal output pin 1 and test pins 24, 25, 51, 76, 77, 91 and 103 at the EEC -V Control System Breakout Box and chassis ground. Fig 10: Checking Solenoid Harness For Short To Power And Ground (5 Of 6) Measure the resistance between the PCM signal output pin 53 and test pins 24, 25, 51, 76, 77, 91 and 103 at the EEC-V Control System Breakout Box and chassis ground. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 8/26

9 Fig 11: Checking Solenoid Harness For Short To Power And Ground (6 Of 6) Is each resistance greater than 10,000 ohms? Yes GO to A5. No REPAIR the short circuit(s). REMOVE the EEC-V Control System Breakout Box. RECONNECT all of the components. REPEAT the Quick Tests. A5 TRANSMISSION FUNCTIONAL TEST CAUTION: Do not pry on the connector. This will damage the connector and could result in a transaxle concern. Pull up on the connector harness. Disconnect: Transaxle Vehicle Harness Connector. Connect the diagnostic tool. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 9/26

10 NOTE: LED will turn GREEN when solenoid activates and turn off when deactivated. LED will turn RED if an ACTIVATED solenoid/harness is shorted to battery positive. LED will remain off if an ACTIVATED solenoid/harness is shorted to ground or no continuity (open circuit). Carry out all Static Testing - Engine OFF procedures for the shift solenoids. Refer to the transmission tester manual. Does solenoid (LED GREEN) activate? Yes GO to A6. No GO to A7. A6 TRANSMISSION DRIVE TEST Reconnect the PCM. Carry out the Dynamic Testing - Engine ON. Refer to the transmission tester manual. Does the vehicle upshift when commanded by the tester? Yes INSTALL a new powertrain control module. ERASE all codes and CARRY OUT the Transaxle Drive Cycle Test. Refer to TRANSAXLE DRIVE CYCLE TEST. RERUN the Quick Test. If DTCs are still present, refer to DIAGNOSIS BY SYMPTOM. No GO to A7. A7 CHECK THE RESISTANCE OF THE SOLENOID/HARNESS NOTE: Refer to the transmission tester for terminal locations. Place the Bench/Drive switch to BENCH mode. Rotate the Gear Select switch to the OHMS CHECK position. Connect the ohmmeter negative lead to the SS-1 jack and the positive lead to the VPWR jack on the tester. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 10/26

11 Fig 12: Checking Resistance Of Solenoid/Harness (1 Of 3) Record the resistance. The resistance should be between 15 and 30 ohms. Connect the ohmmeter negative lead to the SS-2 jack and the positive lead to the VPWR jack on the tester. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 11/26

12 Fig 13: Checking Resistance Of Solenoid/Harness (2 Of 3) Record the resistance. The resistance should be between 15 and 30 ohms. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 12/26

Fig 14: Checking Resistance Of Solenoid/Harness (3 Of 3) Connect the ohmmeter negative lead to the SS-3 jack and the positive lead to the VPWR jack on the tester. Record the resistance.

13 Fig 14: Checking Resistance Of Solenoid/Harness (3 Of 3) Connect the ohmmeter negative lead to the SS-3 jack and the positive lead to the VPWR jack on the tester. Record the resistance. The resistance should be between 15 and 30 ohms. Is the resistance for each solenoid between 15 and 30 ohms? Yes GO to A8. No NOTE: The out of specification condition may be caused by internal harness or solenoid concerns. GO to 9A9. A8 CHECK THE SOLENOID/HARNESS FOR SHORT TO GROUND Check for continuity between the BAT(-) jack (engine ground) and the appropriate jack with an ohmmeter or other low current tester (less than 200 milliamps). Solenoid Tester Jack www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 13/26

SSA SSB SSC SS-1/VPWR SS-2/VPWR SS-3/VPWR Fig 15: Checking Solenoid/Harness For Short To Ground Connection should show infinite resistance (no continuity). Does the connection show continuity?

14 SSA SSB SSC SS-1/VPWR SS-2/VPWR SS-3/VPWR Fig 15: Checking Solenoid/Harness For Short To Ground Connection should show infinite resistance (no continuity). Does the connection show continuity? Yes GO to A9. No Refer to DIAGNOSIS BY SYMPTOM. A9 INTERNAL ELECTRONIC DIAGNOSTICS Remove the transaxle side pan. Check that the internal harness connector is fully engaged on each shift solenoid. Check that the internal harness connector terminals are fully seated in the connector. Inspect the connector for damage. Are the above in good condition and engaged correctly? www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 14/26

15 Yes GO to A10. No REPAIR as required. A10 CHECK THE INTERNAL HARNESS (CONTINUITY) CAUTION: Do not probe into the connector terminals. This will damage the connector and could result in a transaxle concern. Disconnect: Internal Harness From Each Solenoid. For SSA, connect the positive lead from an ohmmeter to the tester jack SS-1 and the negative lead at the orange wire of the 2-wire connector. Fig 16: Checking Internal Harness (Continuity) (1 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. For SSB, connect the positive lead from an ohmmeter to the tester jack SS-2 and the negative lead at the pink wire of the 2-wire connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 15/26

16 Fig 17: Checking Internal Harness (Continuity) (2 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. For SSC, connect the positive lead from an ohmmeter to the tester jack SS-3 and the negative lead at the yellow wire of the 2-wire connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 16/26

17 Fig 18: Checking Internal Harness (Continuity) (3 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. For VPWR, connect the positive lead from an ohmmeter to the tester jack VPWR and the negative lead to the red wire of the 2-wire connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 17/26

18 Fig 19: Checking Internal Harness (Continuity) (4 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. For VPWR, connect the positive lead from an ohmmeter to the tester jack VPWR and the negative lead to the red wire of the 2-wire connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 18/26

19 Fig 20: Checking Internal Harness (Continuity) (5 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. For VPWR, connect the positive lead from an ohmmeter to the tester jack VPWR and the negative lead to the red wire of the 2-wire connector. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 19/26

Fig 21: Checking Internal Harness (Continuity) (6 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. Is the resistance for each solenoid less than 0.5 ohms? Yes GO to A11.

20 Fig 21: Checking Internal Harness (Continuity) (6 Of 6) Record the resistance. The resistance should be less than 0.5 ohms. Is the resistance for each solenoid less than 0.5 ohms? Yes GO to A11. No INSTALL a new internal harness. GO to A12. A11 CHECK THE INTERNAL HARNESS (SHORT TO GROUND) Check for continuity between BAT(-) jack (engine ground) and the appropriate wire at each solenoid with an ohmmeter or other low current tester (less than 200 milliamps). Solenoid Connector Wire VPWR SSA Orange Red SSB Pink Red SSC Yellow Red www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 20/26

Fig 22: Checking Internal Harness (Short To Ground) Connection should show infinite resistance (no continuity). Does the connection show continuity? Yes INSTALL a new internal harness. GO to A12.

21 Fig 22: Checking Internal Harness (Short To Ground) Connection should show infinite resistance (no continuity). Does the connection show continuity? Yes INSTALL a new internal harness. GO to A12. No GO to A12 A12 CHECK THE SOLENOID RESISTANCE AT THE SOLENOID For SSA, connect the ohmmeter to the negative terminal of the solenoid and to the positive terminal of the solenoid. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 21/26

22 Fig 23: Checking Solenoid Resistance At Solenoid (1 Of 3) Record the resistance. The resistance should be between 15 and 30 ohms. For SSB, connect the ohmmeter to the negative terminal of the solenoid and to the positive terminal of the solenoid. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 22/26

23 Fig 24: Checking Solenoid Resistance At Solenoid (2 Of 3) Record the resistance. The resistance should be between 15 and 30 ohms. For SSC, connect the ohmmeter to the negative terminal of the solenoid assembly and to the positive terminal of the solenoid. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 23/26

24 Fig 25: Checking Solenoid Resistance At Solenoid (3 Of 3) Record the resistance. The resistance should be between 15 and 30 ohms. Is the resistance for each solenoid between 15 and 30 ohms? Yes GO to A13. No INSTALL a new solenoid assembly. A13 CHECK THE SOLENOID FOR SHORT TO GROUND Check for continuity between (engine ground) and the appropriate shift solenoid terminal with an ohmmeter or other low current tester (less than 200 milliamps). www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 24/26

25 Solenoid Terminal SSA +/- SSB +/- SSC +/- Fig 26: Checking Solenoid For Short To Ground Connection should show infinite resistance (no continuity). Does the connection show continuity? Yes INSTALL a new solenoid assembly. No Refer to DIAGNOSIS BY SYMPTOM. SOLENOID OPERATION CHART SOLENOID OPERATION CHART Transmission PCM Gear 4F50N Solenoids www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 25/26

26 Range Selector Lever Position Commanded Eng Brake SSA SSB SSC P/N (1) P/N NO OFF (2) ON(2) OFF R R YES OFF OFF OFF (D) (OVERDRIVE) 1234 NONONOYES OFFOFFONON ONOFFOFFON OFFOFFONON D (DRIVE) 123 NONOYES OFFOFFON ONOFFOFF OFFOFFOFF MANUAL 1 12 (3) 3 (3) YESYESYES OFFOFFON ONOFFOFF OFFOFFOFF (1) (2) (3) When transmission fluid temperature is below 10 C (50 F) then SSA=OFF, SSB=ON, SSC=ON to prevent cold creep in NEUTRAL only. Not contributing to power flow. When a manual pull-in occurs above calibrated speed, the transaxle will downshift from the higher gear until the vehicle speed drops below this calibrated speed. www1.prodemand.com/print/index?content=tabs&module=true&tab=true&terms=true&ymms=false&classname= 26/26

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