2001 Technical Seminar

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1 2001 Technical Seminar

2 2000 TECHNICAL SEMINAR Automatic Transmission Rebuilders Association 2400 Latigo Avenue Oxnard, CA Phone:(805) Fax:(805) This manual has been developed by the Automatic Transmission Rebuilders Association (ATRA) Technical Department to be used by qualified transmission technicians in conjunction with ATRA s technical seminars. Since the circumstances of its use are beyond ATRA s control, ATRA assumes no liability for the use of such information or any damages incurred through its use and application. Nothing contained in this manual is to be considered contractual or providing some form of warranty on the part of ATRA. No part of this program should be construed as recommending any procedure which is contrary to any vehicle manufacturer s recommendations. ATRA recommends only qualified transmission technicians perform the procedures in this manual. This manual contains copyrighted material belonging to ATRA. No part of this manual may be reproduced or used in any form or by any means graphic, electronic or mechanical, including photocopying, recording, electronic or information storage and retrieval without express written permission from the ATRA Board of Directors. Public exhibition or use of this material for group training or as part of a school curriculum, without express written permission from the ATRA Board of Directors is strictly forbidden. ATRA and the ATRA logo are registered trademarks of the Automatic Transmission Rebuilders Association. Portions of materials contained herein have been reprinted with permission of General Motors Corporation, Service Technology Group ATRA, Inc. All Rights Reserved. Printed in USA.

3 2000 TECHNICAL SEMINAR iii Program Contents General Motors... 1 Ford Chrysler Imports (Nissan and Subaru) Reference

4 iv 2000 TECHNICAL SEMINAR ATRA Technical Department Lance Wiggins, Technical Director Mike Baird Weldon Barnett Bill Brayton Larry Frash Steve Garrett Evelyn Marlow Cliff McCormick Randall Schroeder David Skora Acknowledgements Thank you for attending the 2001 ATRA seminar. The people behind the scenes, putting programs like this together don t always get the recognition they deserve for the effort they put forth. Producing a seminar program of this type requires months of hard work. I would like to thank everyone who had a part in producing this program. I would like to offer a special thanks to the following persons for spending a lot of evenings and weekends making sure we produced the best information possible: Larry Frash, who spent hours ferreting-out many of the facts used in this manual, as well as the initial copywriting and drawing. Evelyn Marlow, who took great pains to make sure our line art was as clean as possible, against sometimes overwhelming odds. Cliff McCormick, whose skill with our digital camera provided us with a crisp and unique collection of images. Steve Garrett, who was instrumental in collecting the very latest information for our GM section. My personal thanks to all of you; we couldn t have done it without you. Lance Wiggins Technical Director

5 ORD UPDATES AND CHANGES 49 ord Updates and Changes Contents All Applications False Codes P1729 or P VSS / PSOM Problems Codes 452 /P R100 Squawking Noise in Reverse Backing up a Hill...57 No 3 4 Upshift or a 3 4 Shift Hunt When Using Cruise Control R100 / E4OD P0605 (RAM Test Error) or P0603 (KAM Test Error)...59 Valve Body Gasket and Separator Plate ID...60 Type 1 Case Gasket...62 Type 1 Valve Body Gasket...63 Type 2 Case Gasket...64 Type 2 Valve Body Gasket...65 Type 3 Case Gasket...66 Type 3 Valve Body Gasket...67 Type 4 Case Gasket...68 Type 4 Valve Body Gasket...69 Plate ID...70 No Reverse, Slips in Reverse...71 A4LD No Cooler Flow after Bellhousing Change...72 A4LD, 4R44E / 4R55E Pump Identification R44E, 5R55E 4R44E: No 2 nd, No 4 th After Rebuild 5R55E: No 3 rd, No 5 th After Rebuild...77 No TCC Apply R44E / 4R55E / 5R55E Low Line Pressure and No Line Rise...79 Extension Housing Leaks R70W Multiple Transmission Codes after Installing Exchange Transmission...81 AX4N / AX4S No Movement after Rebuild; Valve Body, Converter or Internal Problem...82 CD4E Passenger Side Axle Seal Wear, Noise or Vibration...89

6 50 ORD UPDATES AND CHANGES

7 ORD UPDATES AND CHANGES 51 All Applications alse Codes P1729 or P Econoline, Crown Victoria, Grand Marquis, and Town Cars may experience codes P1729 (4x4 Low Switch Error) or P1781 (4x4 Circuit Out of Self Test Range) in continuous memory. A check of the systems will show these to be false codes. Codes P1729 and P1781 are stored in continuous memory; they won t cause any driveability problems, or cause the Malfunction Indicator Lamp (MIL) or Transmission Indicator Lamp (TCIL) to light. Clear the codes from memory; if they return, ignore them. Repair any other codes per normal diagnostics. Don t replace or reflash the computer for these codes there is no correction for this problem at this time.

8 52 ORD UPDATES AND CHANGES VSS / PSOM Problems Codes 452 /P0500 There are a number of problems that can be related to the vehicle speed sensor (VSS). These problems can include: VSS related DTCs Hard upshifts Early or late upshifts No speedometer reading No speed reading with a scan tool The first thing you need to do is to determine whether the problem is in the speed sensor itself, or if the signal is being altered by a problem in the circuit. PCM VSS PSOM SCS GEM ABS/ 4WABS MSGC

9 ORD UPDATES AND CHANGES 53 VSS / PSOM Problems Codes 452 /P0500 (continued) Check the signal at the VSS with it disconnected and the drive wheels spinning. Voltage should be a minimum of 0.5 VAC. If not, check the reluctor or gear; if everything else looks okay, replace the sensor. 1 2 VSS+ VSS Shown from the terminal side of the sensor. If the VSS checks out okay, the problem could be due to a failure in one or more of these modules. Each of these modules shares the VSS signal, so each has the capability of influencing the VSS circuit. Instrument Cluster Connector (PSOM) ID Grnd VSS+ Test Pin 3 Test Pin 6 PSOM (+) PSOM ( ) Programmable Speedometer/ Odometer Module (PSOM) Vehicle Harness Connector Shown from the terminal side of the harness connector.

10 54 ORD UPDATES AND CHANGES VSS / PSOM Problems Codes 452 /P0500 (continued) Speed Control Servo Connector ID Shown from the terminal side of the harness connector. VSS+ GEM Module Connector ID VSS+ Shown from the terminal side of the harness connector.

11 ORD UPDATES AND CHANGES 55 VSS / PSOM Problems Codes 452 /P0500 (continued) ABS Connector ID VSS+ Shown from the terminal side of the harness connector. Message Center Connector ID VSS+ Shown from the terminal side of the harness connector.

12 56 ORD UPDATES AND CHANGES VSS / PSOM Problems Codes 452 /P0500 (continued) VSS+ (Pin 3) VSS (Pin 6) EEC-IV Connector ID VSS Only Shown from the terminal side of the harness connector. VSS (Pin 33) OBD-II Connector ID VSS Only VSS+ (Pin 58) Shown from the terminal side of the harness connector.

13 ORD UPDATES AND CHANGES 57 4R100 Squawking Noise in Reverse Backing up a Hill Models affected: 1999 F250 Heavy Duty and Super Duty F-series trucks with 5.4L or 6.8L gas engines. This condition is often due to low line rise; the computer command for line rise isn t adequate for the conditions. To correct this, Ford has issued an update computer calibration. Use the transmission tag number and calibration number to determine whether the truck you re working on requires this update. Application Ford Computer Calibration Update Transmission ID Tag 5.4L 49 State MER 5.4L CA NUY 6.8L 49 State YHH AEO BIH DOZ MCM 6.8L CA EAP FOT JUR JTY MFG NRR Calibration Number 9 VZA-AF 9 VZA-BJ 9 WAA-AA 9 WAA-AC 9 WAA-AF 9 WAA-AH 9 WAA-AI 9 WAA-BC 9 WAA-BD 9 WAA-BL 9 WAA-BV 9 WAA-BY 9 WAA-BZ

14 58 ORD UPDATES AND CHANGES 4R100 No 3 4 Upshift or a 3 4 Shift Hunt When Using Cruise Control Models affected: 1999 F-series Super Duty pickups with 7.3L diesel engines may experience a hunt between 3 rd and 4 th gears when using cruise control. In some cases, they may lose 4 th gear entirely. A calibration update has been issued to take care of this problem. Application F-250/350 F-450/550/650 F-250/350 Federal Federal California Ford Calibration Update Climate Warm Cold Warm Cold Warm Cold Transmission ID FIF NVK AGD CNH NSU FHP Calibration Code 9DTA-A R 9DTA-A U 9DTA-A S 9DTA-A V 9DTA-B H 9DTA-B K

15 ORD UPDATES AND CHANGES 59 4R100 / E4OD P0605 (RAM Test Error) or P0603 (KAM Test Error) Some OBD-II vehicles equipped with a 7.3L DI Turbo diesel engines have been showing up with the MIL (Malfunction Indicator Lamp) on. When you pull the codes, either P0603 or P0605 will appear. These codes may be caused by aftermarket devices designed to enhance engine and transmission driveability. Typically these devices plug into the harness between the computer and the vehicle harness, or on the J3 connector located at the back of the computer. Some of the vehicles may exhibit poor driveability; others will seem to operate just fine. In either case, the MIL may be lit. To repair the code, you ll need to remove the device and retest the vehicle for codes. If the problem doesn t return, the customer can then decide to leave it off, or return the vehicle to the person who originally installed device. J3 Connector

16 60 ORD UPDATES AND CHANGES 4R100 / E4OD Valve Body Gasket and Separator Plate ID Gasket ID There are four sets of valve body gaskets that cover E4OD/4R100. Here s how to choose the correct set of gaskets, by examining just the separator plate. Step 1: Check location A. If it has a hole at A, use type 2 gaskets. If it doesn t have a hole at A, go to step 2. Step 2: Check location B. If it doesn t have a hole at B, use type 4 gaskets. If it has a hole at B, go to step 3. Step 3: Check location C. If it has a round hole at C, use type 1 gaskets. If it has a slot at C, use type 3 gaskets. Plate Type Type Type Type Separator Plate Identification Location No Hole Hole No Hole No Hole A Location Hole Hole Hole No Hole B Location C Round Hole Round Hole Slot Slot

17 ORD UPDATES AND CHANGES 61 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Location A Location B Separator Plate Location C

18 62 ORD UPDATES AND CHANGES 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 1 Case Gasket E9TZ-7C155-B 1989 Gasket No Colors

19 ORD UPDATES AND CHANGES 63 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 1 Valve Body Gasket E9TZ-7D100-B Plain Black Stripe

20 64 ORD UPDATES AND CHANGES 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 2 Case Gasket 4TZ-7C155-A Yellow Stripe

21 ORD UPDATES AND CHANGES 65 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 2 Valve Body Gasket 5TZ-7D100-A Yellow Stripe

22 66 ORD UPDATES AND CHANGES 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 3 Case Gasket 6TZ-7C155-A Green Stripe

23 ORD UPDATES AND CHANGES 67 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 3 Valve Body Gasket 6TZ-7D100-A Green Stripe

24 68 ORD UPDATES AND CHANGES 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 4 Case Gasket 81Z-7C155-AA Blue Stripe

25 ORD UPDATES AND CHANGES 69 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Gasket ID (continued) Type 4 Valve Body Gasket 81Z-7D100-AB Blue Stripe

26 70 ORD UPDATES AND CHANGES 4R100 / E4OD VB Gasket and Separator Plate ID (continued) Plate ID Even though there are only four different sets of gaskets to choose from, there are several separator plates. This chart can help you identify the separator plate you have by its identification notches. On applications with more than one listing, either separator plate will work. Year Engine Size Separator Plate Application Separator Plate Plate ID Gasket Type F5TZ-7A008-A L, 5.0L, 5.8L, 7.3L, 7.5L F6TZ-7A008-B * 3 F5TZ-7A008-B* L, 7.5L, 5.8L E9TZ-7A008-A L, 5.0L, 5.8L, 7.3L, 7.5L F4TZ-7A008-A L, 5.0L, 5.8L, 7.3L, 7.5L F6TZ-7A008-B 4 F7TZ-7A008-AA L F7UZ-7A008-A A 4 F8UZ-7A008-CA F81Z-7A008-EA 4.2L, 4.6L, 5.4L, 7.3L F7TZ-7A008-A A L 7.3L (4R100 Only) F8UZ-7A008-A A 4 6.8L (E4OD) F8UZ-7A008-B A L, 4.6L, 5.4L F7TZ-7A008-A A Transmission Tags H, J, L, M Transmission Tags A, B, C, D, E, F F81Z-7A008-BA 4 F81Z-7A008-DA 4 * These replacement separator plates will only retrofit if you update the entire valve body assembly to 1996 parts.

ORD UPDATES AND CHANGES 71 4R100 / E4OD No Reverse, Slips in Reverse The Ford 4R100 and E4OD early and late accumulator bodies aren't interchangeable.

27 ORD UPDATES AND CHANGES 71 4R100 / E4OD No Reverse, Slips in Reverse The Ford 4R100 and E4OD early and late accumulator bodies aren't interchangeable and-later accumulator bodies have only three exhaust slots; earlier bodies have four. If you install a 1995 accumulator body with four slots on a later unit, reverse oil will exhaust through the line modulator exhaust slot and-Later Accumulator Body, with 3 Exhaust Slots 1995 Accumulator Body, with 4 Exhaust Slots

72 ORD UPDATES AND CHANGES A4LD No Cooler low after Bellhousing Change If you install an A4LD pump and plate on an unmodified 4R44/55E bellhousing, you ll end up with no cooler flow.

1 2 4 6 ) 6 This is a one-way interchange; there s no easy way to modify the A4LD bellhousing to work with the 4R44/55E pump and plate.

28 72 ORD UPDATES AND CHANGES A4LD No Cooler low after Bellhousing Change If you install an A4LD pump and plate on an unmodified 4R44/55E bellhousing, you ll end up with no cooler flow. But you can easily modify the 4R44/55E bellhousing to work with the A4LD pump and plate ) 6 This is a one-way interchange; there s no easy way to modify the A4LD bellhousing to work with the 4R44/55E pump and plate. To modify the 4R44/55E bellhousing: Extend the lube circuit passage through the additional bolt hole in the 4R44/55E bellhousing. Use the pump plate to make sure the lube passage is completely clear. Before Modification After Modification Remove the dam in the 4R44/55E bellhousing between the bolt hole and lube circuit.

29 ORD UPDATES AND CHANGES 73 A4LD No Cooler low (continued) Use the pump plate as a template to make sure the modified hole is extended enough to open the lube passage all the way through the plate. Partially blocked passage; remove material until the hole is clear

30 74 ORD UPDATES AND CHANGES A4LD, 4R44E / 4R55E Pump Identification The 4R44E/4R55E bellhousing is the only individual part of the two pump assemblies that you can easily interchange, with just a simple modification. However, you can interchange the complete assemblies, as long as you keep the components together as a set. The following illustrations identify the differences in these assemblies, to prevent mismatching components.

31 ORD UPDATES AND CHANGES 75 A4LD, 4R44E / 4R55E Pump Identification (continued)

32 76 ORD UPDATES AND CHANGES A4LD, 4R44E / 4R55E Pump Identification (continued)

78 ORD UPDATES AND CHANGES 4R44E/4R55E No

34 78 ORD UPDATES AND CHANGES 4R44E/4R55E No TCC Apply model 4R44E/4R55E transmissions may experience no TCC application. This may be due to a broken tip on the TCC solenoid. The repair is simple: Replace the solenoid. The updated solenoid part number is F77Z- 7G136-AA. Original Design Updated Design Original Design; Damaged

35 ORD UPDATES AND CHANGES 79 4R44E / 4R55E / 5R55E Low Line Pressure and No Line Rise A number of 4R44E, 4R55E and 5R55E transmissions have been showing up with low line pressure and/or no line rise. Symptoms of these problems include: Soft shifts Slips on acceleration Ratio errors Burned clutches and bands One common cause for this is a weak or bent EPC solenoid bracket. This allows the EPC solenoid to back out of the bore, causing line pressure to drop too low. If you run into one of these units, check the bore and the solenoid for wear and install a new bracket, part # XL2Z-7L491-AA. EPC Solenoid SSB SSA SSD/ CCS TCC Solenoid SSC Solenoid Brackets

36 80 ORD UPDATES AND CHANGES 4R44E / 4R55E / 5R55E Extension Housing Leaks A number of Rangers equipped with the 3.0L engine have been showing up with extension housing leaks. A further inspection reveals that the bushing has seized onto the driveshaft yoke, and spun in the housing. One likely cause of this problem is the computer programming: These computers originally allowed the vehicle to reach speeds in excess of 95 MPH. The driveshaft yoke seizes in the bushing due to lack of lube at these speeds, which causes it to spin in the tail housing. To correct the leak, replace the tail housing with part # F77Z-7A039-CA, and install an updated driveshaft. To correct the actual source of the failure, have the processor reprogrammed to prevent the vehicle from reaching such high speeds. Chassis Length Updated Driveshafts Ford P/ N 112" Wheelbase F87ZA-4602-AA 118" Wheelbase F87ZA-4602-EA 126" Wheelbase F87ZA-4602-PA

37 ORD UPDATES AND CHANGES 81 4R70W Multiple Transmission Codes after Installing Exchange Transmission In 1998 Ford s 4R70W changed its transmission connector. The illustrations show the terminal ID Pre-1998 Connector Pin Pre R70W Terminal Identification Function Pin Function 1 Shift Solenoid 1 6 EPC B+ 2 Shift Solenoid B+ 7 TCC B+ 3 TCC 8 TFT Ground 4 TFT 9 EPC Solenoid 5 Shift Solenoid On Connector Pin 1998-On 4R70W Terminal Identification Function Pin Function 1 TFT Ground 5 EPC Solenoid 2 TCC Solenoid 6 Shift Solenoid 1 3 Solenoid B+ 7 Shift Solenoid 2 4 TFT Signal

82 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild; Valve Body, Converter or Internal Problem Whenever you re facing a unit that won t move after a rebuild, the first question is

38 82 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild; Valve Body, Converter or Internal Problem Whenever you re facing a unit that won t move after a rebuild, the first question is whether the problem is caused by the valve body, converter or an internal transmission problem. The first step in this type of diagnosis is to monitor the signal from the input speed sensor with the transmission in gear and the drive wheels stopped. If you have a signal, the input shaft is turning, so the converter must be transmitting power: The problem has to be either in the valve body, or caused by an internal problem. If there s no signal from the input speed sensor, the input shaft probably isn t turning. That means the problem is either in the valve body or converter; that s the problem we ll discuss here.

ORD UPDATES AND CHANGES 83 AX4N / AX4S No Movement after Rebuild (continued) Converter or Control Problem? Remove the cooler lines and start the engine.

39 ORD UPDATES AND CHANGES 83 AX4N / AX4S No Movement after Rebuild (continued) Converter or Control Problem? Remove the cooler lines and start the engine. If cooler flow is good, the converter is full of oil. That means the valve body is doing its job, providing the oil necessary for the converter. So that solves the problem: The converter is the culprit. If you get little or no cooler flow it means there s no converter charge. This can be caused by a pump volume problem or a sticking converter regulator valve. Pump Volume Problem? If the pump volume is unable to meet the demands of the pressure regulator valve, the mainline regulator valve will cut off converter charge to maintain as much pump volume as possible. Check mainline and EPC pressures. EPC Mainline AX4N

84 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild (continued) Pump Volume Problem (continued) Direct Clutch Mainline EPC If mainline is extremely high, and EPC Normal May be a stuck

40 84 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild (continued) Pump Volume Problem (continued) Direct Clutch Mainline EPC If mainline is extremely high, and EPC Normal May be a stuck pressure regulator valve. AX4S/ AXODE EPC High (up to but not over 100 PSI) May be a bad EPC solenoid or electrical problem. Test accordingly. EPC High (over 100 PSI) Remove the spring from the pressure failsafe valve and block the valve toward the retaining clip with a 5 /16" rubber checkball. If mainline is extremely low, remove the side cover, and blow air into the mainline pressure tap. Look for signs of leaks in the mainline circuit. If there are no signs of leaks, you may have a bad pump.

failsafe valve and block the valve toward the retaining clip with a 5

41 ORD UPDATES AND CHANGES 85 AX4N / AX4S No Movement after Rebuild (continued) Pressure Problem Remove the spring from the pressure failsafe valve and block the valve toward the retaining clip with a 5 /16" rubber checkball. AX4N Pressure ailsafe Valve AX4S Pressure ailsafe Valve

in the pump shaft may be plugged, or the sleeve in the valve body rotated.

42 86 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild (continued) Converter Charge Problem If mainline is normal, the converter charge passage in the pump shaft may be plugged, or the sleeve in the valve body rotated. Either of these conditions will cut off converter charge oil to the converter.

ORD UPDATES AND CHANGES 87 AX4N / AX4S No Movement after Rebuild (continued) Converter Charge Problem (continued) The most common cause of no converter charge is the converter

43 ORD UPDATES AND CHANGES 87 AX4N / AX4S No Movement after Rebuild (continued) Converter Charge Problem (continued) The most common cause of no converter charge is the converter regulator valve sticks and blocks converter charge oil. To correct this problem, install a 20% 30% heavier spring in the converter regulator valve. Converter Regulator Valve AX4N

44 88 ORD UPDATES AND CHANGES AX4N / AX4S No Movement after Rebuild (continued) Converter Charge Problem (continued) Converter Regulator Valve AX4S

45 ORD UPDATES AND CHANGES 89 CD4E Passenger Side Axle Seal Wear, Noise or Vibration A number of Contours and Mystiques have been showing up with a noise or vibration when moving. An inspection usually reveals excessive wear on the passenger side axle seal. A likely source of the problem is if the wrong bolt holes were used to mount the intermediate axle shaft bracket. The original bracket has two sets of bolt holes: One set is used for the MTX-75 (manual transaxle) and the other for the CD4E applications. MTX-75 CD4E CD4E Original Axle Bracket To prevent this from happening any more, two axle support brackets are now available: One is for the MTX-75, the other for the CD4E. But this only prevents the problem if you use the correct bracket. The CD4E retainer bolts use these holes The MTX-75 retainer bolts use these holes CD4E: 5RZ-3A329- MTX-75: 5RZ-3A329-E

46 90 ORD UPDATES AND CHANGES

Automatic Transmission Rebuilders Association

2000 TECHNICAL SEMINAR Automatic Transmission Rebuilders Association 2400 Latigo Avenue Oxnard, CA 93030 Phone:(805) 604-2000 Fax:(805) 604-2005 http://www.atra-gears.com This manual has been developed