Transmission Description - visualbits.netvisualbits.net/Car Stuff/Ford Ranger 1993-1999/07...

DESCRIPTION AND OPERATION

Transmission Description

The 4R44E automatic transmissions are electronically controlled four-speed units.

The 4R44E transmission is used with the 2.3L and 3.0L engine applications.

These transmissions feature a four element torque converter with a torque converter clutch (TCC). The geartrain includes:

� Three compound planetary gearsets � Three bands � Three multi-plate clutches � Two one-way clutches

The hydraulic functions are directed by electronic solenoids to control:

� Engagement feel � Shift feel � Shift scheduling � Modulated TCC applications � Timing of the 3-2 T.D. and K.D. shifts � Engine braking (with O/D canceled) utilizing the coast clutch � Manual 1st timing

Transmission View

Section 07-01A: Transmission, Automatic, 4R44E

1997 Aerostar, Ranger with 2.3L, 3.0L Engines Only Workshop Manual

of 21997 Aerostar/Ranger

2011-04-28file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK71A01.HTM~gen~ref.HTM

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Identification Tags

Models are identified by a service identification tag affixed to the assembly. Typical service identification tags are shown below. Located Under Extension Housing Bolt

Assembly Plant Bar Code I.D. Label Located on Fluid Pan



Page 1 of 21997 Aerostar/Ranger


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Exploded Views

Transmission, Exploded View — 4R44E (2.3L, 3.0L)





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Item Part

Number Description

1 7902 Converter Assembly — (Contains Piston Type Clutch) (Model Dependent)

2 379299-S2 Nut — (Att. Converter Assembly to Flex Plate) (4 Req'd)

3 7017 Shaft — Input



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4 7A248 Seal Assembly — Converter Hub to Converter Housing (Also in Converter Housing Assembly)

5 E804595-S300

Screw and Seal Assembly — M10 x 33 (Att. Converter Housing to Case) (8 Req'd)

6 7976 Housing Assembly — Converter (Model Dependent)

7 7B472 Plate — Fluid Pump Adapter

8 7A136 Gasket — Converter Housing to Case

9 7A248 Seal Ring — Fluid Pump Support

10 W701431-S300

O-Ring — Fluid Pump Shaft to Inner Gear (Also in Pump Assembly)

11 7A103 Support and Gear Assembly — Fluid Pump

12 7D014 Washer — Fluid Pump Input Thrust (Select Fit — 7 Variables) No. 1

13 W701429-S309M

Screw Flange Head — 8.8 Allen — M8 x 35 (Att. Pump Assembly Converter Housing) (6 Req'd)

14 7A248 Seal Ring — Fluid Pump

15 E825100-S100

Nut and Seal Assembly — Hex Intermediate and O/D Band Adjustment/Lock (2 Req'd)

16 7C492 Screw — Intermediate and O/D Band Adjuster/Lock (2 Req'd)

17 7D430 Strut — Intermediate and O/D Band Anchor (2 Req'd)

18 7A653 Bracket — O/D Band Lever to Case (Not Serviced Separately)

19 7D433 Shaft — O/D Actuating Lever

20 7330 Lever — Intermediate and O/D Band Servo (2 Req'd) (Model Dependent)

21 7D029 Strut — Intermediate and O/D Band Apply (2 Req'd)

22 7D034 Band Assembly — Intermediate and O/D (2 Req'd)

23 7L669 Drum Assembly — O/D Brake and Coast Clutch

24 7D404 Seal Ring — Coast Clutch and Direct Clutch Piston — Inner (2 Req'd)

25 7A548 Seal Ring — Coast Clutch Piston — Outer

26 7A262 Piston — Coast Clutch

27 7A480 Spring — Coast and Direct Clutch Piston (40 Req'd)

28 7A527 Retainer — Coast Clutch Piston Spring

29 E860125-S Ring Retaining — 63 mm — Coast and Direct Clutch Piston in the Brake Drum (2 Req'd)

30 7B442 Plate — Coast (2 Req'd) and Direct (4 Req'd) Clutch External Steel

31 7B164 Plate Assembly — Coast (2 Req'd) and Direct (4 Req'd) Clutch Internal Friction

32 7B066 Plate — Coast and Direct Clutch Pressure (2 Req'd)



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33 E860126-S/129-S

Ring Retaining — Coast and Direct Clutch Plates (Select Fit) (2 Req'd)

34 7660 Adapter — Coast Clutch to O/D Carrier

35 7D063 Gear Assembly — Sun Overdrive

36 7D235 Race — Sun Gear Thrust Bearing — Rear (All) No. 12

37 7B446 Carrier Assembly — Planetary Gear O/D (With Trigger Wheel)

38 7L495 Bearing Assembly — O/D Planet Thrust No. 2

39 7653 Gear — Overdrive Ring

40 7A658 Shaft Assembly — Center Overdrive Ring (Includes O/D Overrunning Clutch 7C109)

41 W702037-S300

Ring Retaining — 110.1 mm O/D Center Shaft in O/D Ring Gear

42 W702465-S300

Ring Retaining — Center Support in Case

43 7M153 Bearing Assembly — Center Shaft Thrust No. 3-5 and No. 9 (3 Req'd)

44 E826160-S76

Nut and Cage Assembly — S/L Met. M6 (Att. Center Support to Case)

45 E804373-S Screw Cap — 8.8 Allen M6 x 20 (Att. Center Support to Case)

46 7M101 Sensor — Turbine Shaft Speed With Wire to 16-Pin Connector

47 W702297-S300

Screw — Cap M6 x 15 (Att. Turbine Shaft Speed Sensor to Center Support)

48 7A130 Support Assembly — Center

49 7D014 Bearing Assembly — Intermediate Brake Drum Thrust (Select Fit — 4 Variables) No. 4

50 7D433 Shaft — Intermediate Band Actuating Lever

51 7D044 Drum Assembly — Intermediate Brake and Direct Clutch

52 7A548 Seal Ring — Direct Clutch Piston — Outer

53 7A262 Piston — Direct Clutch

54 7A527 Retainer — Direct Clutch Piston Spring

55 7A360 Cylinder Assembly — Forward Clutch

56 7A548 Seal Ring — Forward Clutch Piston — Inner

57 7A548 Seal Ring — Forward Clutch Piston — Outer

58 7A262 Piston Assembly — Forward Clutch

59 7A480 Spring — Forward Clutch Piston (15 Req'd)

60 7A527 Retainer — Forward Clutch Piston Spring

61 E860109-S Ring Retaining 34 mm — Forward Clutch Piston and Spring in Forward Clutch Cylinder



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62 7B070 Spring — Forward Clutch Cushion

63 7B442 Plate — Forward Clutch External Steel (5 Req'd)

64 7B164 Plate Assembly — Forward Clutch Internal Friction (5 Req'd)

65 7B066 Plate — Forward Clutch Pressure

66 E860115-S/118-S

Ring Retaining — Forward Clutch Plates in Forward Clutch Cylinder (Select Fit)

67 7D234 Bearing Assembly — Forward Ring Gear Hub Thrust No. 6A

68 7D090 Washer — Forward Clutch Thrust No. 6B

69 E860122-S Ring Retaining 87 mm — Forward and Output Shaft Ring Gears to Hubs (2 Req'd)

70 7B067 Hub — Forward Ring Gear

71 7D392 Gear — Forward Ring (72 External Teeth and 57 Internal Teeth)

72 7F374 Bearing Assembly — Forward Planet Thrust No. 7

73 7A398 Planetary Assembly — Forward (4 Pinion) (Serviced as 6-Pinion Only)

74 E860121-S Ring Retaining 39 mm — Input Shell to Sun Gear Assembly (2 Req'd)

75 7D063 Gear Assembly — Sun (Forward)

76 7D064 Shell — Input

77 7M151 Bearing Assembly — Reverse Planet Carrier Thrust No. 8

78 W702037-S300

Snap Ring

79 7D006 Planet Assembly — Reverse (3 or 4 Pinion) (Serviced as 6 Pinion Only) (Model Dependent)

80 7B176 Sleeve — Output Shaft

81 7A153 Gear — Output Shaft Ring

82 E860527-S Ring Retaining 25 x 2 mm — Output Shaft in Case

83 7D164 Hub — Output Shaft

84 7C498 Drum Assembly — Reverse Brake (Includes Low Overrunning Clutch)

85 7D095 Band Assembly — Reverse

86 7M150 Bearing Race (2 Pieces) — Output Shaft Hub Thrust No. 10A

87 7M150 Bearing Assembly — Output Shaft Hub Thrust No. 10B

88 7R205 Bearing Assembly — Output Shaft to Case (Part of Case Assembly)

89 7L339 Retainer — Splash Fluid

90 7B368 Washer — Output Shaft Thrust No. 11



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91 7M092 Gear — Transmission Parking (2.3L/3.0L)

92 7060 Shaft Assembly — Output (4x2)

93 7086 Gasket — Extension Housing

94 7A441 Pawl — Parking

95 7D070 Spring — Parking Pawl Return

96 7D071 Shaft — Parking Pawl

97 7A039 Housing Assembly — Extension (4x2)

98 7A034 Bushing — Extension Housing (4x2) (Also in Extension Housing)

99 7052 Seal Assembly — Extension Housing to Slip Yoke (Also in Extension Housing Assembly)

100 E804137-S72

Stud — (Att. Extension Housing to Case)

101 E800152-S72

Screw — M10 x 30 (Att. Extension Housing to Case) (5 Req'd)

102 7060 Shaft Assembly — Output (4x4)

103 7A039 Housing Assembly — Extension (4x4)

104 N605804-S100

Screw — M10 x 45 (Att. 4x4 Extension Housing to Transfer Case) (2 Req'd)

105 W701271-S309

Nut — (Att. Outer and Inner Manual Levers to Shaft) (2 Req'd)

106 7A256 Lever Assembly — Manual Control — Outer

107 N806933-S100

Screw — M6 x 25 (Att. Transmission Range Sensor to Case) (2 Req'd)

108 7F293 Sensor — Digital Transmission Range (DTR)

109 7A308 Shaft — Manual Valve Outer to Inner Lever

110 E840125-S Pin — Spring (Retains Outer Manual Lever to Case)

111 7B498 Seal Assembly — Main Control Lever (Also in Case Assembly)

112 7A115-117 Lever — Manual Valve — Inner

113 7A232 Rod Assembly — Parking Pawl Actuating

114 7E332 Spring Assembly — Manual Valve Detent

115 E800185-S Screw — M6 x 30 (Att. Detent Spring to Main Control)

116 7Z409 Connector Assembly (16-Pin with Wire Harness to 6 Solenoids)

117 W703015-S300

O-Ring — 16-Pin Connector Assembly to Case (2 Req'd)

118 7005 Case Assembly (Model Dependent)

119 84280020 Spring — Retains 16-Pin Connector in Case

120 E450102-S80

Plug — Pipe Line and EPC Pressure (Part of Case Assembly) (2 Req'd) (Not Serviced Separately)

121 7034 Vent Assembly — Also in Case Assembly (4x4)



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122 7034 Vent Assembly — Also in Case Assembly (4x2)

123 7A160 Tube — Lube Fluid Inlet — Short (Also in Case Assembly)

124 7D273 Connector Assembly — Fluid Tube (Also in Case Assembly) (2 Req'd)

125 7D028 Spring — Intermediate Servo Piston (Model Dependent)

126 7D021 Piston and Rod Assembly — Intermediate and O/D Servo (2 Req'd) (Model Dependent)

127 7D027 Cover and Seal Assembly — Intermediate and O/D Servo (2 Req'd) (Model Dependent)

128 7D040 O-Ring — Servo Cover to Case Intermediate and O/D Servo (2 Req'd)

129 E860343-S Ring Retaining — 67 x 1.5 mm (Intermediate and O/D Servos in Case) (2 Req'd)

130 E804357-S76

Screw — Torx M6 x 21 (Att. Separating Plate to Main Control) (Also in Main Control Assembly)

131 7G383 Solenoid — (EPC) (Also in Main Control Assembly)

132 7G484 Solenoid Assembly (Shift) (Also in Main Control Assembly) (4 Req'd)

133 W702951-S300

O-Ring — Shift Solenoid to Main Control (Large) (15x1.5) (4 Req'd)

134 W702949-S300

O-Ring — Shift Solenoid to Main Control (Small) (13x1.5) (4 Req'd)

135 7G136 Solenoid Assembly — Converter Clutch with Clamp (Also in Main Control Assembly)

136 7L491 Clamp (SS1 and SS3) Solenoids (Also in Main Control) (Not Serviced Separately)

137 7L491 Clamp — Converter Clutch/SS4/SS2 and EPC Solenoids (Also in Main Control) (Not Serviced Separately)

138 E800155-S Screw — M6 x 12 (Att. Solenoid Clamps to Main Control) (2 Req'd)

139 7C155 Gasket — Control Valve Body to Case

140 7A008 Plate — Valve Body Separating (Part of Main Control Assembly) (Not Serviced Separately)

141 7D100 Gasket — Control Valve Body Separating (Also in Main Control)

142 7A100 Control Assembly — Main (Model Dependent)

143 E800154-S Screw — M6 x 45 (Att. Main Control to Case) (4 Req'd)



146 7423 Seal Ring — Reverse Servo Piston — Small (Also in



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Bushings, Bearing and Thrust Washer Locator — 4R44E

Piston Assembly)

147 7423 Seal Ring — Reverse Servo Piston — Large (Also in Piston Assembly)

148 7D189 Piston Assembly — With Rod and Retainer — Rear Band Servo (Select Fit)

149 7L173 Gasket — Reverse Servo Cover to Case

150 7D036 Cover — Reverse Servo

151 E800156-S Screw — M6 x 20 (Att. Reverse Servo Cover to Case) (4 Req'd)

152 7A469 O-Ring — Fluid Filter Assembly — Small

153 7A098 Filter Assembly — Fluid Pan (4x2)

154 7A469 O-Ring — Fluid Filter Assembly — Large

155 7E290 Magnet — on Inner Bottom Surface (Not Serviced Separately)

156 7A191 Gasket — Fluid Pan

157 W701203-S309M

Screw — M8 x 16 (Att. Fluid Pan to Case) (18 Req'd)

158 7A194 Pan — Fluid (4x2)

159 7A098 Filter Assembly — Fluid Pan (4x4)

160 7A194 Pan — Fluid (4x4)

161 E800329-S Screw — M6 x 55 (Att. Fluid Filter to Main Control)



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Item Part

Number Description

1 7D014 No. 1 Selective Washer

2 7L495 No. 2 Needle Bearing

3 7M153 No. 3 Needle Bearing

4 7D014 No. 4 Selective Needle Bearing


6 7D234, No. 6A Needle Bearing and No. 6B Bushing



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Seals, Rings and Gaskets Locator — 4R44E

7D090

7 7F374 No. 7 Needle Bearing



10 7M150 No. 10A Bearing Race and 10B Needle Bearing Assembly

11 7B368 No. 11 Washer

12 7D235 No. 12 Race

13 — Needle Bearing (Part of 7B446 O/D Planetary Assembly) (Not Serviced Separately)

14 — Bushing (Part of 7D063 O/D Sun Gear) (Not Serviced Separately)

15 — Bearing, Seal Assembly and Sleeve (Not Serviced Separately)

16 — Bushing (Part of 7L201 Pump Assembly) (Not Serviced Separately)

17 — Bushing (Part of 7976 Converter Housing) (Not Serviced Separately)

18 — Bushing (Part of 7L201 Pump Assembly) (Not Serviced Separately)

19 — Bushing (Part of 7A039 and Serviced Separately)

20 7R205 Needle Bearing

21 — Needle Bearing (Part of 7D006 Reverse Planetary Assembly) (Not Serviced Separately)

22 — Needle Bearing (Part of 7A398 Forward Planetary Assembly) (Not Serviced Separately)

23 — Needle Bearing (Part of 7060 Output Shaft) (Not Serviced Separately)

24 — Needle Bearing (Part of 7A398 Forward Planetary Assembly) (Not Serviced Separately)







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Item Part Number Description

1 7A548 Seal Ring

2 7A548 Seal Ring

3 7A548 Seal Ring

4 7086 Gasket (Transmission Extension)

5 7052 Seal Assembly (Extension Housing)

6 W702949-S300 O-Ring (Large)

7 W702951-S300 O-Ring (Small)

8 7A191 Gasket (Fluid Pan)



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9 7C155 Gasket (Valve Body Upper)

10 7D100 Gasket (Valve Body Lower)

11 7423 O-Ring (Reverse Servo Piston)

12 7L173 Gasket (Reverse Servo Plate Cover)

13 W702951-S300 O-Ring (Small)

14 W702949-S300 O-Ring (Large)

15 7B498 Seal Assembly (Manual Cover Lever)

16 E825100-S100 Nut and Seal

17 7A469 O-Ring (Large) (Fluid Filter Assembly)

18 7A469 O-Ring (Small) (Fluid Filter Assembly)

19 7D404 Seal Ring

20 W703015-S300 O-Ring

21 E825100-S100 Nut and Seal

22 7A548 Seal Ring

23 7L323 O-Ring

24 7D040 O-Ring (Intermediate/Overdrive Servos)

25 7A248 Seal Assembly (Converter Hub)

26 E804595-S200 Screw and Seal Assembly

27 7A136 Gasket (Fluid Pump)

28 7A248 Seal Ring (Fluid Pump)

29 W701431-S300 O-Ring

30 7D404 Seal Ring



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Transmission Range Operation

The 4R44E transmission range selector lever has six positions: P, R, N, D, 2, 1. The driver selects the required gear position by moving the selector lever to the various positions. Interlocking cables and linkages connect the selector lever to the transmission. This allows the selector lever to move internal linkages and the manual control valve, which signals the driver demand.

Park

No powerflow is transferred through the transmission in PARK. The manual lever shaft, which is connected to a park rod, presses the parking pawl into the park gear on the output shaft. This locks the output shaft and prevents the vehicle from rolling. However, for safety reasons, the parking brake should be applied whenever the vehicle is parked.

While the engine can be started in either P or N position, the ignition key can only be removed in PARK.

Reverse

Reverse gear allows the vehicle to be operated in a rearward direction, at a reduced gear ratio. When overdrive has been cancelled, engine braking is provided in the R position with the coast clutch applied.

Neutral

As in PARK, there is no power transferred through the transmission. However, the final drive is not locked by the parking pawl, so the wheels are free to rotate. The vehicle may be started in the N position, but the ignition key cannot be removed.

Overdrive

In the (D) position, the transmission will upshift or downshift 1-2-3-4 automatically.

When overdrive has been canceled by turning the transmission control switch on, the transmission will not upshift to 4th gear. Engine braking is provided in 1st, 2nd, 3rd and reverse gears with the coast clutch applied.

2nd Position

Selection of the 2 position provides a 2nd gear hold position from a manual upshift or downshift. When the 2 position is selected from a stop, the transmission will start in second gear. This allows for maximum traction on slippery surfaces. Engine braking is provided in the 2 position when the transmission control switch (TCS) is on or off.

1st Position

The 1 position provides a 1st gear hold after an automatic or manual downshift. The transmission is prevented from downshifting above a specific speed (approximately 48 km/h [30 mph]) to protect the powertrain from overspeeding. Engine braking is provided in the 1 position when the transmission control switch (TCS) is on or off.





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Transmission Shift Patterns

Upshifts

Transmission upshifting is controlled by the powertrain control module (PCM). The PCM receives inputs from various engine or vehicle sensors and driver demands to control shift scheduling, shift feel and torque converter clutch operation.

Downshifts

Under certain conditions the transmission will downshift automatically to a lower gear range (without moving the range selector lever). There are three categories of automatic downshifts: Coastdown, Torque Demand and Forced or Kickdown shifts.

Coastdown

The coastdown downshift occurs as the name indicates, when the vehicle is coasting down to a stop.

Torque Demand

The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. The transmission will also disengage the torque converter clutch to provide added acceleration, if applied.

Kickdown

For maximum acceleration, the drive can force a downshift by pressing the accelerator pedal to the floor. A forced downshift into a lower gear (3rd, 2nd or 1st) is possible below calibrated speeds. For all shift speeds, specifications are subject to variations due to tire size, engine and transmission calibration requirements.





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Transmission Control Switch and Lamp Operation

The transmission control switch (TCS) is a driver-controlled momentary contact switch mounted on the end of the transmission range selector lever. When the TCS is activated, 4th gear operation (overdrive) is canceled, coast clutch is applied, and engine braking is provided in 1st, 2nd, 3rd and reverse gears.

The transmission control indicator lamp (TCIL) is located on the transmission range selector lever in the Aerostar and on the instrument panel in the Ranger. The TCIL indicates that the transmission control switch (TCS) has been depressed and 4th gear has been cancelled. The TCIL will flash if the powertrain control module (PCM) detects a concern in certain transmission related sensors or solenoids.





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Main Components and Functions

Torque Converter

The 4R44E uses a four element torque converter. The converter contains the standard internal components (turbine, impeller, and stator) for transfer of power and multiplication of torque. It also utilizes a disc type torque converter clutch (TCC) for maximum fuel economy.

The operation of the main torque converter components is as follows:

� The converter cover and impeller are connected to the engine crankshaft. Rotation of the cover and impeller by the engine crankshaft sets the fluid in motion.

� The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain by way of the turbine shaft.

� The stator redirects the fluid going back to the impeller, from the turbine. By directing fluid back to the impeller in the same direction as engine rotation, the stator multiplies engine torque.

When applied, the TCC provides a mechanical link between the converter turbine and the engine, allowing for a direct mechanical power transfer from the engine to the transmission. The converter clutch pressure plate is applied and released by fluid pressure, which is controlled by the powertrain control module (PCM). The PCM controls the torque converter clutch using a pulse-width modulated TCC solenoid.

Torque Converter Clutch (TCC) Damper

The torque converter clutch damper assembly functions only when the torque converter clutch is applied. Torque Converter Assembly





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Impeller and Cover

The impeller sets the fluid in motion and directs it to the turbine. The impeller is welded to the converter cover.

Turbine

The turbine is the driven member of the converter. It is driven by fluid from the impeller and transfers the hydraulic power to the transmission. When the converter lockup clutch is engaged, the power is transferred mechanically.

Reactor

The reactor is equipped with heavily curved vanes and its center hub has an one-way clutch which prevents the stator from rotating opposite to the engine rotation. The reactor reverses the fluid and returns it to the impeller in the direction of impeller rotation. The one-way clutch prevents the force of this fluid from turning the stator against the impeller and turbine.

The reactor one-way clutch is built into the reactor (stator) and prevents it from rotating opposite to engine rotation.

Torque Converter Clutch

The clutch is joined to the turbine by means of the externally splined hub of the turbine and also internally splines within its own assembly.

When engaged the clutch friction plate bears against the inside of the converter cover, thereby producing a direct mechanical connection between the pump housing and the turbine.

Geartrain

Power is transmitted from the torque converter to the planetary gearsets through the input shaft.


1 — Cover (Part of 7902)

2 — Thrust Washer (Part of 7902)

3 — Converter Damper Plate (Part of 7902)

4 — O-Ring (Part of 7902)

5 — Turbine Assembly (Part of 7902)


7 — Snap Ring (Part of 7902)

8 — Reactor (Part of 7902)

9 — One-Way Clutch Assembly (Part of 7902)


11 — Thrust Bearing (Part of 7902)

12 — Impeller Assembly (Part of 7902)



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By holding and driving certain numbers of the gearsets, four forward ratios and one reverse ratio are obtained and transmitted to the output shaft and differential.

The ratios from the planetary gearsets are:

� 2.474:1 in 1st (Low) � 1.474:1 in 2nd (Intermediate) � 1.000:1 in 3rd (Drive) � .75:1 in 4th (Overdrive) � 2.1:1 in Reverse

Planetary Gearset — Overdrive

The planetary gear overdrive carrier is driven by the input shaft. The planetary gearset overdrive carrier drives the center shaft via the overdrive one-way clutch in 1st, 2nd and 3rd gears.

In overdrive, the overdrive sun gear is held, causing the pinion gear to rotate around the overdrive sun gear. The pinion gears in turn drive the overdrive ring gear resulting in an overdrive output ratio of 0.75:1.

The overdrive planetary gearset is also internally splined to the coast clutch for engine braking.

Planetary Gearset — Forward

The forward planetary gearset is splined to the output shaft.


1 7A658 Center Shaft Assembly

2 7653 Overdrive Ring Gear

3 7L495 No. 2 Overdrive Planetary Thrust Bearing

4 7B446 Overdrive Planetary Gear Carrier Assembly

5 7D063 Overdrive Sun Gear Assembly



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The forward planetary gearset is driven by the forward ring gear when the forward clutch is applied. The forward planetary gearset pinions drive the forward sun gear. The forward sun gear is splined to the input shell.

Input Shaft

The input shaft is supported by two bushings in the stator support. End positioning of the input shaft is controlled by the splines in the converter turbine and the overdrive planetary carrier.

Output Shaft

The output shaft is supported by two bushings in the case and by the slip yoke bushing in the extension housing. End positioning is controlled by the parking pawl gear and snap ring or shoulder and by the reverse ring gear hub and snap ring.

Planetary Gearset — Low/Reverse

Item Part

Number Description

1 7D044 Intermediate Brake and Direct Clutch Drum Assembly

2 7C096 No. 5 Forward Clutch Cylinder Thrust Bearing

3 7A360 Forward Clutch Cylinder Assembly

4 7D234 No. 6A Forward Ring Gear Hub Thrust Bearing

5 7D090 No. 6B Forward Clutch Thrust Washer

6 7D392 Forward Ring Gear

7 7F374 No. 7 Forward Planetary Thrust Bearing Assembly

8 7A398 Forward Planetary Assembly

9 7D064 Input Shell

10 7D063 Forward Sun Gear Assembly



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The low/reverse planetary gearset is connected to the low/reverse brake drum by lugs from the low/reverse brake drum to the lugs of the low/reverse planetary gearset.

The low/reverse planetary gearset is driven by the forward sun gear which is splined to the input shell.

The splines of the forward sun gear drive the pinions in the low/reverse planetary gearset. The pinions of the low/reverse planetary gearset drive the output shaft ring gear and output shaft hub which is splined to the output shaft.

The low/reverse planetary gearset is held via the low one-way clutch in the low/reverse brake drum assembly, when the low/reverse band is applied.

Apply Components

Bands — Overdrive

Hydraulic pressure is applied to the front side of the overdrive servo. This pressure causes the servo to stroke and apply force to the band, causing the overdrive brake and coast clutch drum to be held.

The overdrive band holds the overdrive brake and coast clutch drum to the case in 4th gear. This causes the overdrive sun gear to be held stationary through the coast clutch adapter and the overdrive brake and coast clutch drum.


1 7C498 Reverse Brake Drum Assembly

2 E860122-S Retaining Ring

3 7D164 Output Shaft Hub


5 7A153 Output Shaft Ring Gear

6 7M153 No. 9 Reverse Planetary Carrier Thrust Bearing

7 7D006 Reverse Planetary Gearset

8 W702037-S300 Retaining Ring

9 7A166 No. 8 Reverse Planetary Carrier Thrust Bearing

10 E860121-S Retaining Ring (2 Req'd)


12 7D064 Input Shell



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Bands — Intermediate

Hydraulic pressure is applied to the front side of the intermediate servo. This pressure causes the servo to stroke and apply force to the intermediate band, causing the intermediate brake and direct clutch drum to be


1 7L493 Overdrive Servo Cover Assembly

2 7D021 Overdrive Servo Piston and Rod Assembly

3 7330 Overdrive Band Servo Lever

4 7D034 Overdrive Band Assembly

5 7D029 Overdrive Band Apply Strut

6 7A653 Overdrive Band Lever to Case Bracket

7 7D430 Overdrive Band Anchor Strut

8 7C492 Overdrive Band Adjuster/Lock Screw

9 7L669 Overdrive Brake and Coast Clutch Drum Assembly



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held.

The intermediate band holds the intermediate brake and direct clutch drum to the case in 2nd gear. This causes the input shell and the forward sun gear to be held stationary.

Item Part

Number Description

1 7D064 Input Shell

2 7D044 Intermediate Brake and Coast Clutch Drum Assembly

3 7D034 Intermediate Band Assembly

4 7L493 Intermediate Servo Cover Assembly

5 7D021 Intermediate Servo Piston and Rod Assembly

6 7330 Intermediate Band Servo Lever

7 7D029 Intermediate Band Apply Strut

8 7D430 Intermediate Band Anchor Strut



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Bands — Low/Reverse

Hydraulic pressure is applied to the front side of the reverse servo. This pressure causes the servo to stroke and apply force to the reverse band, causing the reverse brake drum to be held.

The reverse band holds the reverse brake drum to the case in manual 1st and reverse gears. This causes the reverse planetary assembly to be held stationary.

Clutches — Coast

9 7C492 Intermediate Band Adjuster/Lock Screw


1 7D095 Low/Reverse Band Assembly

2 7C498 Low/Reverse Brake Drum Assembly

3 7D189 Low/Reverse Servo Piston Assembly



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The coast clutch is a multi-disc clutch made up of steel and friction plates. The coast clutch is applied with hydraulic pressure and disengaged by return springs and exhaust of the hydraulic pressure. It is housed in the overdrive brake and coast clutch drum. The coast clutch is applied when the transmission control switch (TCS) is on and hydraulically applied in 2 and 1 positions. When the coast clutch is applied, it holds the planetary gear overdrive carrier and disengages the overdrive one-way clutch preventing overrunning. This uses engine compression to help slow the vehicle and provide engine braking.

Clutches — Direct

The direct clutch is a multi-disc clutch made up of steel and friction plates. The direct clutch is applied with hydraulic pressure and disengaged by return springs and exhaust of the hydraulic pressure. It is housed in the intermediate brake and direct clutch drum. The intermediate brake and direct clutch drum provides two functions. In drive, the direct clutch is applied and coupled to the forward clutch in 3rd and 4th gears. This drives the input shell and forward sun gear at a ratio of 1:1.

In reverse, the direct clutch is applied and coupled to the forward clutch and input shell. Since the forward


1 E860126-S/129-S

Retaining Ring (Select Fit)

2 7B066 Coast Clutch Pressure Plate

3 7B164 Coast Clutch Internal Plate — Friction (2 Req'd)

4 7B442 Coast Clutch External Plate — Steel (2 Req'd)


6 7A527 Coast Clutch Piston Spring Retainer

7 7A480 Coast Clutch Piston Spring (20 Req'd)

8 7A258 Coast Clutch Piston

9 7A548 Coast Clutch Piston Outer Seal Ring

10 7D404 Coast Clutch Piston Inner Seal Ring




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sun gear is splined to the input shell, this causes the forward sun gear to drive the pinions of the reverse planetary assembly that is being held by the reverse band in reverse rotation. This in turn drives the output shaft ring gear and hub at a ratio of 2.1:1.

Clutches — Forward

The forward clutch is a multi-disc clutch made up of steel and friction plates. The forward clutch is applied with hydraulic pressure and disengaged by return springs and exhaust of the hydraulic pressure. The forward clutch is applied in all forward gears and driven by the center shaft. The forward clutch also holds and drives the forward ring gear and hub when hydraulically applied.


1 E860126-S/129-S


2 7B066 Direct Clutch Pressure Plate

3 7B164 Direct Clutch Internal Plate — Friction (4 Req'd)

4 7B442 Direct Clutch External Plate — Steel (4 Req'd)


6 7A527 Direct Clutch Piston Springs Retainer (8 Tabs)

7 7A480 Direct Clutch Piston Spring (20 Req'd)

8 7A258 Direct Clutch Piston

9 7A548 Direct Clutch Piston Outer Seal Ring

10 7D404 Direct Clutch Piston Inner Seal Ring




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One-Way Clutches — Overdrive

The overdrive one-way clutch is a sprag-type one-way clutch that is pressed into the overdrive center shaft.


1 E860115-S/118-S Retaining Ring (Select Fit)

2 7B066 Forward Clutch Pressure Plate

3 7B164 Forward Clutch Internal Plate — Friction

4 7B442 Forward Clutch External Plate — Steel

5 7B070 Forward Clutch Cushion Spring


7 7A527 Forward Clutch Piston Spring Retainer

8 7A480 Forward Clutch Piston Spring (15 Req'd)

9 7A262 Forward Clutch Piston Assembly

10 7A548 Forward Clutch Piston Outer Seal Ring

11 7A548 Forward Clutch Piston Inner Seal Ring


13 7M153 No. 5 Forward Clutch Cylinder Thrust Bearing



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The overdrive one-way clutch is driven by the inner race of the overdrive planetary gear carrier. The overdrive one-way clutch holds and drives the outer race of the center shaft in 1st, 2nd, 3rd and reverse gears.

The overdrive one-way clutch overruns during all coast operations and is always overrunning in 4th gear.

One-Way Clutches — Low

The 2.3L and 3.0L use a spring and roller one-way clutch. The low one-way clutch holds the low/reverse brake drum and reverse planetary assembly to the case in 1st gear only and overruns in all other gears.

Hydraulic System

Pump

The fluid pump provides the fluid pressure required to charge the torque converter, main control assembly, transmission cooling system, lubrication system and apply devices.



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The 4R44E has a positive displacement gear and crescent-type pump which is shaft-driven by the torque converter cover.

Filter

All fluid drawn from the pan passes through the fluid filter. The fluid filter and its accompanying seals are part of the fluid path to the fluid pump.

The fluid filter also has a bypass section. This allows the fluid which is vented at the main regulator valve to be recirculated to the pump without passing through the filtering element.


1 W701429-S309M Fluid Pump-to-Converter Housing Screws (6 Req'd)

2 7D014 No. 1 Fluid Pump Input Thrust Washer (Nylon)

3 7A103 Fluid Pump Support and Gear Assembly

4 W701431-S300 Fluid Pump Shaft-to-Inner Gear O-Ring

5 7L323 Fluid Pump Support Seal Ring

6 7A136 Fluid Pump Gasket

7 7B472 Fluid Pump Adapter Plate

8 7976 Converter Housing Assembly

9 E804595-S200 (8 Req'd)

Converter Housing-to-Case Screw and Seal Assembly

10 7A248 Converter Hub-to-Converter Housing Seal Assembly



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Main Control

The main control assembly and related components are part of the pressure side of the 4R44E hydraulic system. The main control assembly consists of the solenoids, the valve body assembly and the separator plate.

All valves inside the main control assembly are anodized aluminum. They cannot be sanded, filed or dressed in any way that may damage the valve surface. If the valves have any scratches, burrs or nicks that prevent free movement, the main control assembly must be replaced. Main Control Assembly



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1 — Valve Manual

2 7E335 Retainer — Valve Plug (7 Req'd)

3 — Plug — Valve Retainer

4 — Valve — Forward Modulator

5 — Spring — Forward Modulator





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8 — Valve — EPC Boost

9 — Spring — EPC Boost

10 7E336 Retainer — Valve Plug

11 — Sleeve — Pressure Boost Valve

12 — Valve — Pressure Boost

13 — Spring — Pressure Boost

14 — Spring — Oil Pressure Regulator

15 — Retainer — Main Regulator Spring

16 — Valve — Pressure Regulator

17 — Plug — Valve Retainer (3 Req'd)

18 — Spring — Forward Engagement

19 — Valve — Forward Engagement Control

20 7G484 Solenoid — Shift (4 Req'd)

21 — Spring — 3-2 (K.D./T.D.) (2 Req'd)

22 — Valve — 3-2 (K.D.)

23 — Spring — Manual Low (1)

24 — Valve — Manual Low (1)


26 — Valve — 3-2 (T.D.)

27 — Valve — 3-4 Shift

28 — Spring — 3-4 Shift


30 — Spring — Thermostat Bypass

31 — Valve — Thermostat Bypass

32 — Valve — Thermostatic Bypass



35 — Spring — Cooler Limit

36 — Valve — Cooler Limit

37 7G136 Solenoid — Torque Converter Clutch (TCC)

38 — Valve — Converter Clutch

39 — Spring — Converter Clutch




43 — Spring — Converter Clutch (3.0L and 4.0L Only)


45 — Valve — Coast Clutch

46 — Spring — Coast Clutch



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— Plug — Valve Retainer

48 — Valve — 3-2 Downshifts

49 — Spring — 3-2 Downshifts

50 7G383 Solenoid — EPC (VFS)










60 — Valve — Reverse Modulation

61 — Spring — Reverse Modulation (2 Req'd)



64 7L491 Clamp — SS1/SS2

65 7L491 Clamp — SS3/CCS/EPC/TCC

66 E800155-S72 Screw — Retain Solenoid Clamps (2 Req'd)

67 7D132 I.D. Plate

68 — Body — Valve

69 7D100 Gasket — Separator Plate

70 7A008 Plate — Separator

71 E804357-S Screw — Retain Separator Plate (3 Req'd)

72 7N113 Screen — EPC Limit Circuit

73 7D376 Extension Housing Lube Orifice

74 7E368 Valve EPC Limit (Metal)

75 7E368 Valve Converter Relief (Plastic)

76 7E340 Spring — EPC Limit/Converter Relief (2 Req'd)

77 7E195 Ball (4 Req'd)



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Transmission Electronic Control System

Electronic System Description

Shift scheduling, timing and feel (line pressure), as well as torque converter clutch (TCC) operation in the 4R44E are controlled electronically by the powertrain control module (PCM).

Input signals from various engine sensors give the PCM information about the engine's operating state. Other inputs are based on driver demands, such as the accelerator pedal position, which is monitored by the PCM using the throttle position (TP) sensor. Inputs are also supplied by the transmission itself. The turbine shaft speed (TSS) sensor and the transmission fluid temperature (TFT) sensor supply information to the PCM.

Using these input signals, the PCM can determine when the time and conditions are right for a shift or TCC application. The PCM controls six solenoids: three ON/OFF solenoids for upshifts and downshifts, one for pulse-width modulated control of the torque converter clutch, one for electronic line pressure control, and one ON/OFF solenoid for coast clutch application. Component Locator





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Powertrain Control Module (PCM) 12A650:

Description:

The powertrain control module (PCM) controls various engine functions and provides control of the 4R44E transmissions.

The PCM responds to inputs and operates solenoids for electro-hydraulic control of line pressure, shift scheduling, torque converter clutch (TCC) scheduling and coast clutch control for coast braking.

The PCM has the ability to:



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� Monitor its input and output devices for the presence of faults. � Store diagnostic trouble codes (DTCs) related to detected faults. � Alert the driver for some detected faults by turning on the malfunctioning indicator lamp (MIL) in the

instrument cluster. � Display information when a service technician connects diagnostic equipment.

Diagnostic Trouble Codes:

P0603, P0605.

Air Conditioning (A/C) Clutch 2884:

Description:

An electro-magnetic air conditioning (A/C) clutch is energized when the clutch cycling pressure switch closes. The switch is located on the suction accumulator-drier. The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor driveshaft.

When engaged, the A/C clutch is an input to the PCM to adjust electronic pressure control (EPC) pressure for the additional load on the engine. It is also used to adjust TCC modulation when the A/C clutch is engaged.

Symptoms:

Failed ON — EPC pressure slightly low with A/C off. Failed OFF — EPC pressure slightly high with A/C on. If erratic A/C operation occurs, the customer may feel improper TCC apply and release.


P1460.

Brake On/Off (BOO) Switch 13480:

Description:

The brake on/off (BOO) switch is connected to the brake pedal. When the brake pedal is pressed, the BOO switch has closed contacts allowing a voltage signal to the PCM.

The PCM may release TCC when the brakes are applied.

Symptoms:

Failed ON — converter clutch will not engage at less than 1/3 throttle. Failed OFF or not connected — converter clutch will not disengage when brake is applied.


P1703.

Engine Coolant Temperature (ECT) Sensor 12A648:



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Description:

The engine coolant temperature (ECT) sensor detects the temperature of engine coolant and supplies the information to the PCM.

The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For automatic transmission applications, the ECT is used to control TCC solenoid operation. For engine control applications, the ECT signal is used to modify ignition timing, exhaust gas recirculation (EGR) flow, and air-to-fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator.

Symptoms:

Torque converter clutch solenoid will always be "off," resulting in reduced fuel economy.


P0117, P0118, P1116, P1117.

Electronic Ignition (EI) System:

Description:

The electronic ignition (EI) system has a crankshaft position (CKP) sensor and ignition coil packs. The CKP sensor sends crankshaft position information to the PCM. The rpm signal in the transmission strategy is then used for torque converter clutch control, EPC and shift scheduling.

Symptoms:

Engine malfunction, no torque converter clutch engagement.


P0300-P0306, P0320, P0340, P1351-P1364.

4x4 Low (4x4L) Switch:

Description:

The low range switch is located on the transfer case cover. It provides an indication of when the 4x4 transfer case gear system is in the low range.

NOTE: Not all 4x4L switch concerns will set a DTC. Refer to Diagnosis by Symptom or pinpoint tests if shifts are delayed in 4x4L or shift early in normal mode.

Transmission Function:

Modifies shift schedule for 4x4L transfer case gear ratio.

Symptoms:

Failed on — Early shift schedule in 4x2 and 4x4H. Failed off — Shifts delayed in 4x4L. If the 4x4 low indicator light fuse is blown, the transmission will shift according to 4x4 low shift schedule regardless of transfer case position.


P1781, P1729.



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Intake Air Temperature (IAT) Sensor 12A697:

Description:

The intake air temperature (IAT) sensor is used to determine the EPC pressure. It also provides the electronic fuel injection system with mixture (fuel and air) temperature information. The IAT is used both as a density corrector for airflow calculation and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant temperature (ECT) sensor, except it is packaged to improve sensor response time.

Symptoms:

Incorrect EPC pressure either high or low resulting in either harsh or soft shifts.


P0112, P0113, P0114.

Mass Air Flow (MAF) Sensor 12B579:

Description:

The mass air flow (MAF) sensor directly measures the mass of the air flowing into the engine. The sensor output is a DC (analog) signal ranging from about 0.5 volts to 5.0 volts used by the processor to calculate the injector pulse width for stoichiometry. For transmission strategies, this sensor is used for EPC pressure control, shift, and torque converter clutch scheduling.

Symptoms:

Incorrect shift schedule, high/low EPC pressure. Incorrect torque converter engagement scheduling and symptoms similar to a throttle position (TP) sensor malfunction. Soft or firm shift based on EPC/line pressure. Soft shifts may be caused by a restricted air inlet.


P0102, P0103, P1100, P1101.

Transmission Control Switch (TCS) 7G550:

Description:

The transmission control switch (TCS) is a momentary contact switch. When the driver presses the button of the TCS, a signal is sent to the PCM. At the same time, the PCM also causes the transmission control indicator lamp (TCIL) in the instrument panel to turn on or off.

When the TCS is initially pressed, the PCM disables transmission operation in D position/4th gear. At the same time, coast braking in 2nd gear and 3rd gear occurs because the coast clutch is applied.

When the button of the TCS is pressed again, the PCM enables 4th gear operation, releases the coast clutch and turns off the TCIL.

Symptoms:



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If the TCS fails with open contacts, no disabling of 4th gear and enabling of coast braking in 2nd and 3rd gear in D position is possible.


P1780.

Transmission Control Indicator Lamp (TCIL):

Description:

The transmission control indicator lamp (TCIL) is located in the instrument panel for Ranger and on the end of the shift lever for Aerostar. It is labeled O/D OFF. The transmission control switch (TCS) and the PCM control the on/off operation of the TCIL.

When the driver initially presses the button of the TCS, the TCIL turns on to indicate that transmission operation in 4th gear is disabled. When the driver presses the TCS again, the TCIL turns off. The TCIL will flash if the EPC solenoid is shorted or a monitored sensor has failed.

Symptoms:

If the TCIL fails on or off, the driver may have an incorrect indication of transmission operation or monitored sensor malfunction.

Diagnostic Trouble Code:

N/A.

Throttle Position (TP) Sensor 9B989:

Description:

The throttle position (TP) sensor is a potentiometer mounted on the throttle body. The TP sensor detects the position of the throttle plate and sends this information to the processor assembly as varying voltage signal.

The PCM uses the monitored voltage level of the TP sensor for control of EPC pressure, torque converter clutch operation and shift scheduling.

If a malfunction occurs in the TP sensor circuit, the processor will recognize that the TP sensor signal is out of specification. The processor will then operate the transmission in a high capacity mode to prevent transmission damage.

Symptoms:

Harsh engagements, firm shift feel, abnormal shift schedule, torque converter clutch does not engage, or torque converter clutch cycling.


P0121-P0123, P1120, P1121, P1124, P1125.

Programmable Speedometer/Odometer Module (PSOM):



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The programmable speedometer/odometer module (PSOM) receives input from the rear brake anti-lock sensor, which is mounted on the rear axle differential housing. The PSOM processes this input signal information and relays it to the powertrain control module and the speed control module. This signal tells the powertrain control module the vehicle speed in miles per hour (mph). The PSOM is also used as an input in determining shift scheduling and electronic pressure control.

Symptoms:

Harsh engagements, firm shift feel, abnormal shift schedule, unexpected downshifts may occur at closed throttle. Torque converter clutch will not engage, elevated EPC pressures.

NOTE: EPC shorted to ground or failed low may result in a false VSS code. Diagnose EPC concerns first. Then recheck VSS input and PSOM.


P0500, P1500, P1501.

Vehicle Speed Sensor (VSS) 9E731:

Description:

The vehicle speed sensor (VSS) is a magnetic pickup that sends a signal to the processor assembly. This VSS signal tells the processor assembly the vehicle speed.

The PCM uses this information to control shift scheduling and EPC pressure.

Symptoms:

Harsh engagements, firm shift feel, abnormal shift schedule, unexpected downshifts may occur at closed throttle. Torque converter clutch will not engage, elevated EPC pressures.

NOTE: EPC shorted to ground or failed low may result in a false VSS code. Diagnose EPC concerns first. Then recheck VSS.


P0500, P1500, P1501.

Transmission Fluid Temperature (TFT) Sensor:

Description:

The transmission fluid temperature (TFT) sensor is located on the transmission main control body wiring harness assembly. It is a temperature-sensitive device called a thermistor. The resistance value of the TFT will vary with temperature change. The processor monitors the voltage across the TFT to determine the temperature of the transmission fluid.

The processor assembly uses this initial signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule allows quicker shifts when the transmission fluid temperature is cold. The processor also inhibits torque converter clutch operation at low transmission fluid temperatures and corrects EPC pressures for temperature.

Symptoms:

Torque converter clutch engagement and stabilized shift schedules happen too soon after a cold start.



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Harsh or soft shifts.


P0712, P0713, P1711, P1783.

Digital Transmission Range (DTR) Sensor 7F293:

Description:

The digital transmission range (DTR) sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in Park and Neutral, the back-up lamp circuit in Reverse and the neutral sense circuit (4x4 only) in Neutral. The DTR sensor also sends a digital output signal to the powertrain control module (PCM) indicating the position of the manual lever (P, R, N, D, 2, 1).

Symptoms:

Engagement concerns, wrong gear, no shifts, increase in EPC pressure.


P0705, P0708, P1705, P1704.

Turbine Shaft Speed (TSS) Sensor 7M101:

Description:

A turbine shaft speed (TSS) sensor is a magnetic pickup that sends a signal to the processor assembly that indicates transmission turbine shaft input speed.

The TSS sensor provides torque converter turbine speed information for torque converter clutch control strategy. Also used in determining static EPC pressure settings.

Symptoms:

Increased engine rpm on engagements, harsh shifts (converter engaged), delayed shifts with hard apply (slip/bump feel).


P0715.

Electronic Pressure Control (EPC) Solenoid 7H144:

Description:

The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. It supplies EPC which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two pressures control clutch application pressures.



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Symptoms:

Maximum EPC pressure, harsh shifts and engagements, may set a false VSS code. Zero EPC pressure — no 2nd and 4th gear, slips in 1st and 3rd with high input torque.


P1746*, P1747*.

*Output circuit check, generated only by electrical conditions.

Torque Converter Clutch (TCC) Solenoid 7F037:

Description:

The torque converter clutch (TCC) solenoid is used in the transmission control system to control the application, modulation, and release of the torque converter clutch.

Symptoms:

Failed ON — engine runs rough/vehicle shudder, engine stalls in Drive at low idle speeds (1st, 2nd, 3rd, or 4th gear). Failed OFF — torque converter never engages.


P0743*, P1744**.


**May also be generated by a non-electrical transmission hardware condition.

Coast Clutch Solenoid (CCS) 7G484:

Description: The coast clutch solenoid (CCS) is an on/off solenoid.

The PCM uses the coast clutch solenoid to control the apply and release of the coast clutch.

Symptoms:

If the coast clutch solenoid fails ON, coast braking occurs in all gears (except in 4th gear).

If the coast clutch solenoid fails OFF, no effect will be apparent.


P1754*.

Shift Solenoid Assemblies (SS1, SS2, SS3) (7G484):

Description:

Three on/off solenoids are used for electronically controlled shift scheduling. The three solenoids are located on the main control assembly. The solenoids are two-way, normally open style.



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1 O/W=TCS "ON"

Solenoids SS1, SS2, and SS3 provide gear selection of 1st through 4th by controlling the pressure of the three shift valves.

SS1 Symptoms:

Improper gear selection depending on failure mode and manual lever position. Failed ON — 1st and 2nd. Failed OFF — 2nd, 3rd and 4th gears only.


P0750*, P0751**, P0731**, P0732**, P0733**, P0734**.

SS2 Symptoms:

Improper gear selection depending on failure mode and manual lever position. Failed ON — 2nd gear only. Failed OFF — 1st, 3rd and 4th gears only.


P0755*, P0756**, P0731**, P0732**, P0733**, P0734**.

SS3 Symptoms:

Improper gear selection depending on failure mode and manual lever position. Failed ON — No engine braking, 4th gear and incorrect gear ratios. Failed OFF — 1st, 2nd, 3rd only.


P0760*, P0761**, P0733**, P0734**.


**May also be generated by a non-electrical transmission hardware condition.

SHIFT SOLENOID OPERATION CHART — 4R44E

Transmission Range Selector Lever Position

Powertrain Control Module (PCM) Gear Commanded

4R44E Solenoid States

Engine Braking SS1 SS2 SS3 CCS

P/N P/N No On Off Off Off

R R Yes 1 On Off Off O/W 1

(D) (Overdrive) 1 2 3 4

No No No No

On On Off Off

Off On Off Off

Off Off Off On

Off Off Off Off

(D) 1 1 2 3

Yes Yes Yes

On On Off

Off On Off

Off Off Off

On On On

Manual 2 2 Yes On On Off On

Manual 1 1 Yes On Off Off On



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DIAGNOSIS AND TESTING

Diagnostic Strategy

Troubleshooting an electronically controlled automatic transmission 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.

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

Follow the procedures as written to avoid missing critical components or steps.

To properly diagnose a concern the technician should have the following publications available:

� Service Manual � Transmission Reference Manual � Powertrain Control/Emissions Diagnosis (PC/ED) Manual � OASIS Messages � Technical Service Bulletins (TSBs) � Electrical/Vacuum Troubleshooting Manual (EVTM)

These publications provide the information required when diagnosing transmission concerns.

Using the Diagnostic Flow Chart as a guide, follow the steps as indicated.

Preliminary Inspection

� Know and understand the customer's concern. � Verify the concern by operating the vehicle. � Check the fluid level and condition. � Check for non-factory add-on items. � Check shift linkages for proper adjustment. � Check TSBs and OASIS messages for the concern.

Diagnostics

� Perform On-Board Diagnostic Procedures, key on engine off (KOEO), key on engine running (KOER). � Record all diagnostic trouble codes (DTCs). � Repair all non-transmission codes first. � Repair all transmission codes second. � Erase all continuous codes and attempt to repeat them. � Repair all continuous codes. � If only pass codes, proceed to Diagnosis By Symptom Charts for further information and diagnosis.

By following the diagnostic sequence the service technician will be able to diagnose and repair the concern the first time.





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Diagnostic Flow Chart





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Preliminary Inspection

The following items must be checked before proceeding.

Know and Understand the Concern

This section provides information which must be used in determining the actual cause of customer concerns and performing the appropriate service procedures.

Verification of Condition

The following procedures must be used when verifying customer concerns for the transmission.

Required Equipment

Required equipment to diagnose the 4R44E transmission consists of:

� Rotunda Transmission Tester 007-00130, part of Rotunda Transmission Tester Kit, or equivalent. � Rotunda New Generation STAR (NGS) Tester 007-00500 or equivalent. � Rotunda EEC-V 104-pin Breakout Box 014-00950 or equivalent. � Rotunda 73 Digital Multimeter 105-R0051 or equivalent. � Rotunda Transmission Range (TR) Sensor Cable "E" 007-00111 or equivalent. � Digital TR Sensor Overlay 007-00131, used with Rotunda Transmission Range (TR) Cable "E" 007-

00111. � Rotunda 4R44E/4R55E Overlay/Cable 007-00106, part of Transmission Tester Kit.

Determine Customer Concern

NOTE: If noise/vibration, check for dependencies: rpm, vehicle speed, shift, gear, range, or temperature.

NOTE: Some transmission conditions may cause engine concerns. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle usage and dependent driving conditions. Pay attention to the following items:

� Hot or cold vehicle operating temperature � Hot or cold ambient temperatures � Type of terrain � Vehicle loaded/unloaded � City/highway driving � Upshift � Downshift � Coasting � Engagement





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� Noise/vibration

Check Fluid Level and Condition

Fluid Level Check

NOTE: If the vehicle has been operating for an extended period at high speeds in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the oil to cool before checking.

Under normal circumstances, check the transmission fluid level during normal maintenance, it does not require a change. For severe duty only, change the fluid at 80,450 km (50,000 miles), since the vehicle does not use up transmission fluid. If the transmission is not working properly, or if there is some sign of fluid leakage, the fluid level should be checked.

It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. The fluid level can be checked without driving the vehicle if the outside temperature is above 10°C (50°F).

With the vehicle on a level surface, start the engine and move the transmission range selector lever through all of the gear ranges, allowing sufficient time for each position to engage. Securely engage the transmission range selector lever in the Park position, fully set the parking brake control (2780) and leave the engine running.

Wipe off the fluid level indicator cap, pull thefluid level indicator (7A020) out and wipe the indicator end clean. Insert the fluid level indicator back into the oil filler tube (7A228) and make sure it is fully seated. Pull the fluid level indicator out and read the fluid level.

CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and outside temperature is above 10° C (50°F).

When checking fluid at normal operating temperature, the fluid level should be within the crosshatched area on the fluid level indicator. When the vehicle has not been driven, and outside temperature is above 10° C (50°F), the fluid level should be between the holes in the fluid level indicator.



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High or Low Fluid Level

CAUTION: If the fluid level is high, damage to the vehicle may occur. Excess fluid must be removed.

A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic line pressure, which may result in harsh/soft shifts or engagements, damage to the clutch materials, improper torque converter operation, and fluid coming out of the vent. Refer to Fluid Change — Drain/Refill in this section.

A fluid level that is too low will affect transmission operation, causing slipping, slow engagements, or damage to internal hardware. Low levels may also indicate that a leak is present in the fluid system. If the fluid level is low, add fluid using the procedures shown in Adding Fluid in this section.

Adding Fluid

CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure.

Before adding any fluid, be sure that the correct type is used. MERCON V® XT-5-QM is stamped on the container.

Add fluid in 0.25L (1/2 pint) increments through the filler tube to bring the level to the correct area on the dipstick. If an overfill occurs, excess fluid must be removed.

Fluid Change — Drain/Refill

Normal maintenance and lubrication does not necessitate periodic automatic transmission fluid changes. For severe duty applications, change the fluid at 80,450 km (50,000 miles).

To remove excess fluid, disconnect the cooler feed line at the cooler. Attach a rubber hose to the line and



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insert the other end into a drain pan. Crank the engine for a short period of time (do not allow the engine to start) to remove a quantity of transmission fluid. Reattach the cooler line to the cooler. Start the engine. Move the transmission range selector lever through all gear ranges. Recheck the fluid for the proper level. Continue to add or subtract fluid until the proper level is reached. If a major service (e.g., clutch, band, bearing, etc.) is required, the unit will have to be removed. At this time, the torque converter (7902), transmission cooler, and cooler lines must be flushed to remove any contaminates. Refer to the Converter and Fluid Cooler Cleaning and Inspection procedure.

When used under severe duty conditions the transmission fluid filter/screen assembly should be replaced at 80,450 km (50,000 miles). The transmission fluid should be drained from the transmission and torque converter and refilled with MERCON V® XT-5-QM or equivalent MERCON® approved fluid as specified to the proper level.

When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level as outlined.

Procedures for Drain and Refill

� Normal Maintenance � Not required with normal use.

� Severe Duty Maintenance � Change fluid at 80,450 km (50,000 miles) intervals using MERCON 5® XT-5-QM or equivalent.

CAUTION: Use only MERCON V® XT-5-QM transmission fluid. Use of any other fluids may result in a transmission malfunction or failure.

Maintenance Procedure

1. Loosen, then remove, the transmission fluid pan attaching screws to drain the fluid.

2. Remove and discard old pan gasket.

3. Thoroughly clean the pan and the transmission case pan rail surface.

4. Install new pan gasket onto pan and install pan to case with screws. Tighten screws to 13-15 Nm (115-133 lb-in).

5. Add 2.8 liters (3 quarts) of MERCON V® XT-5-QM or equivalent MERCON® approved fluid to transmission through the fill tube.

6. Start the engine. Move transmission range selector lever through all gear ranges, checking for engagements.

7. Check and adjust transmission fluid in 0.25 liter (1/2 pint) increments to proper level (cross-hatched area of fluid level indicator at normal operating temperature).

Major Service/Overhaul

1. Loosen, then remove, the transmission fluid pan attaching bolts to drain fluid.


3. Perform required internal repair and cleaning as required.



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4. Thoroughly flush torque converter, cooler lines and transmission in-tank radiator cooler and auxiliary cooler (if equipped).

5. Replace fluid filter and seal assembly.

6. Install cleaned pan and new pan gasket with screws. Tighten screws to 13-15 Nm (115-133 lb-in).

7. Add 3.7 liters (4 quarts) of MERCON V® XT-5-QM or equivalent MERCON® approved fluid to the transmission through the fill tube.

8. Start engine. Move the transmission range selector lever through all gear ranges, checking for engagements.

9. Check and adjust the transmission fluid level in 0.25 liter (1/2 pint) increments to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature).

Fluid Condition Check

1. Check the fluid level. Refer to the Fluid Level Check for proper procedure.

2. Observe color and odor of the fluid. It should be red, not brown or black. Odor may indicate an overheating condition, clutch disc or band failure.

3. Use an absorbent white facial tissue and wipe the fluid level indicator. Examine the stain for evidence of solid particles and for engine coolant signs (gum or varnish on fluid level indicator) .

If particles are present in the fluid or there is evidence of engine coolant or water, the transmission fluid pan (7A194) must be removed for further inspection.

If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive particles in the transmission fluid pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning and flushing the torque converter and transmission cooling system.

During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made.

After the transmission has been serviced, all diagnostic tests and adjustments listed in the Diagnosis By Symptom Charts must be completed to make sure that the problem has been corrected.

Road Testing Vehicle

The Shift Point Road Test and Torque Converter Clutch Operation Test provide diagnostic information on transmission shift controls and torque converter operation.

Shift Point Road Test

This test verifies that the shift control system is operating properly.

1. Bring engine and transmission up to normal operating temperature. 2. Operate vehicle with transmission selector in (D) range. 3. Apply minimum throttle and observe speeds at which upshift occurs and torque converter engages.

Refer to the following Shift Speeds chart. (Also refer to Automatic Transmission Specifications Issue



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FPS-12180-97.) 4. Stop the vehicle. Depress transmission control switch (TCS) to activate D range. Repeat Step 3.

Transmission will make all upshifts except 3-4 and torque converter clutch apply should occur above 46 km/h (27 mph).

5. Press accelerator pedal to floor, wide open throttle (WOT). Transmission should shift from third to second, or third to first, depending on vehicle speed, and torque converter clutch should release.

6. With vehicle speed above 48 km/h (30 mph), move transmission range selector lever from D range to 1 range (LOW) and release accelerator pedal. Transmission should immediately downshift to second gear. When vehicle speed drops below 32 km/h (20 mph), transmission should downshift into first gear.

7. If transmission fails to upshift/downshift or torque converter clutch does not apply/release, refer to Diagnosis By Symptom Index for possible causes.

1 Shift Speed Ranges are approximate for all applications. For specific applications (Engine, Axle Ratio and Application) refer to the Automatic Transmission Specification Issue FPS-12180-97.

Torque Converter Diagnosis

Prior to torque converter replacement all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter.

Begin with the normal diagnostic procedures as follows:

1. Preliminary inspection.

2. Know and understand the customer's concern.

3. Verify the concern.

SHIFT SPEEDS — KM/H (MPH) 1

Throttle Position Range Shift KM/H (MPH) Range 1

Closed Throttle (D) 3-2 19-32 (12-20)

(D) 2-1 10-23 (6-14)

Minimum Throttle (D) 1-2 14-27 (9-17)

(D) 2-3 26-43 (16-27)

(D) 3-4 64-85 (40-53)

Part Throttle (D) 1-2 29-47 (18-29)

(D) 2-3 50-71 (31-44)

(D) 3-4 89-116 (55-72)

(D) 4-3 68-100 (43-62)

(D) 3-2 40-61 (25-38)

Wide Open Throttle (D) 1-2 53-72 (33-45)

(D) 2-3 98-127 (61-79)

(D) 3-2 93-119 (58-74)

(D) 3-1, 2-1 47-66 (29-41)

Manual Pull-In 1 2-1 40-62 (25-38)



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� Perform the Torque Converter Clutch Operation Test. Refer to the procedure in this section.

4. Perform diagnostic procedures.

� Run on-board diagnostics. Refer to the procedure in this section. � Repair all non-transmission related DTCs first. � Repair all transmission DTCs. � Rerun on-board diagnostic to verify repair.

� Perform Line Pressure Test . Refer to the procedure in this section. � Perform Stall Speed Test . Refer to the procedure in this section. � Diagnosis By Symptom Routines . Refer to the procedure in this section.

� Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and repair as required, before replacing the torque converter.

Torque Converter Operation Test

This test verifies that the torque converter clutch control system and the torque converter are operating properly.

1. Connect tachometer to engine. 2. Bring engine to normal operating temperature by driving vehicle at highway speeds for approximately

15 minutes in (D) range. 3. After normal operating temperature is reached, maintain constant vehicle speed of about 80 km/h (50

mph). Release throttle for about two seconds then reapply throttle to previous setting. 4. Engine rpm should increase when throttle is released and decrease in about five seconds (converter

engagement) after throttle is reapplied. If this does not occur, refer to Torque Converter Clutch Operation Concerns in the Diagnosis By Symptom Index .

Visual Inspection

This inspection will identify malfunctions to the vehicle operating system that may affect diagnosis.

� Vehicle modification � Electronic add-on items

� Air conditioning � Generator (alternator) � Engine turbo � Cellular telephone � Cruise control � CB radio � Linear booster � Backup alarm signal � Computer

� Leaks — Refer to Leakage Inspection in this section. � Proper linkage adjustments — Refer to Section 07-05 in this service manual.

These items, if not installed properly, will affect powertrain control module or transmission function. Pay particular attention to add-on wiring splices in the powertrain control module harness or transmission wiring harness, abnormal tire size, or axle ratio changes.



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After a road test, with the vehicle warm and before disturbing any connectors, perform the Quick Test using Rotunda New Generation STAR (NGS) Tester 007-00500 or equivalent. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual for diagnosis and testing of the automatic transmission.

Check TSBs and OASIS

Refer to all Technical Service Bulletins and OASIS messages which pertain to the transmission concern and follow the procedures as outlined.

Perform On-Board Diagnostics

After a road test, with the vehicle warm and before disturbing any connectors, perform Quick Test using Rotunda New Generation STAR (NGS) Tester 007-00500 or equivalent. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual for diagnosis and testing of the automatic transmission.



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Diagnostics

Diagnosing electronically controlled automatic transmissions is simplified using the following procedures. It is important to remember that there is a definite procedure to follow. Do not take short cuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the service technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics With NGS

NOTE: For detailed instructions and other diagnostic methods using the NGS, refer to the Powertrain Control/Emissions Diagnosis Manual or NGS instruction guide.

NOTE: If using a generic scan tool, refer to the Powertrain Control/Emissions Diagnosis Manual for instructions on performing OBD procedures.

The Quick Tests are in the Powertrain Control/Emissions Diagnosis Manual (PC/ED). These tests can be used to diagnose the powertrain control module (PCM) (12A650), sensors and actuators of the 4R44E transmission.

The following is a guide for using the On-Board Diagnostic (OBD) Quick Tests and the New Generation STAR (NGS) Tester.

Quick Test 1.0 — Visual Inspection

Perform the Visual Check and Vehicle Preparation procedures as outlined in the Powertrain Control/Emissions Diagnosis Manual.

Inspect the following:

� Air cleaner and inlet ducting. � All engine vacuum hoses for damage, such as leaks, cracks, blockage, proper routing, etc. � Powertrain control module (PCM) system wiring harnesses for proper connections, bent or broken

pins, corrosion, loose wires, proper routing, etc. � Sensors, actuators and powertrain control module (PCM) for physical damage. � Engine coolant for proper level. � Transmission fluid for proper level and condition. � Any non-factory installed items wired into the transmission or PCM harnesses.

Perform all necessary servicing before continuing with Quick Tests.

Quick Test 2.0 — Set Up

Connect Rotunda New Generation STAR Tester 007-00500 or equivalent to Data Link Connector (refer to vehicle owner manual for connector location).

The following are steps to run OBD II procedures.





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Vehicle and Tester Preparation

Prepare the vehicle as follows:

� Transmission range selector lever in PARK. � Engine to operating temperature. � Apply parking brake. � Block wheels. � Turn off all electrical loads including A/C and defroster. (If A/C is ON, DTC P1460 will set.)

Prepare the NGS as follows:

� Key OFF. � Verify that the proper program card is inserted in the NGS. � Connect J1962/16-way DCL cable adapter to the NGS. � Connect NGS DCL cable adapter securely into the vehicle's DCL connector. � Connect the NGS power supply cable to the vehicle battery power supply through cigarette lighter or

at the battery with alligator clip adapter. � Key ON or start vehicle if necessary. � The NGS is now ready to communicate with the PCM.

Quick Test 3.0 — Key On, Engine Off (KOEO)



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CAUTION: Do not replace parts based on a code, perform Pinpoint Tests first.

� The key on engine off (KOEO) test provides "hard" diagnostic trouble codes (DTCs) present at the time of testing.

� Always service the "hard" DTCs first.

Performing KOEO

� Perform visual inspection and vehicle preparation as required. � Select "Vehicle and Engine Selection" menu. � Select year, engine, model with the appropriate qualifier if needed, for example, transmission or 49

state/Cal. � Select "Diagnostic Data Link" menu. � Select "Diagnostic Test Mode" menu. � Select "KOEO On-Demand Self Test." � Follow operating instructions from the NGS menu screen. � Record all DTCs displayed. � Service non-transmission DTCs first as they can directly affect the operation of the transmission.

Road test the vehicle and repeat Quick Test to verify the repair.

Quick Test 4.0 — Continuous Memory Codes

Continuous DTCs are concerns which were detected during normal vehicle operation. These codes are retained for 40 warm-up cycles.

� The cause of some continuous DTCs may have been eliminated if KOEO and/or KOER DTCs were serviced. Always retest and service any DTCs that still remain.

� If DTCs are present, go to the On-Board Diagnostic Trouble Code Description Chart in this section for service information. Erase DTC, perform the Transmission Drive Cycle Test and repeat all Quick Test procedures after completing service on the DTCs.

� If the Continuous tests passes and a concern is still present, refer to the Diagnosis By Symptom Charts , OASIS and TSBs for concern diagnosis.

Performing Continuous DTC Tests

� Select "Vehicle and Engine Selection" menu � Select year, engine, model with the appropriate qualifier if needed, for example, transmission or 49

state/Cal. � Select "Diagnostic Data Link" menu. � Select "Diagnostic Test Mode" menu. � Select "Retrieve Continuous Codes." � Follow operating instructions from the NGS menu screen. � Record all DTCs displayed. � Perform Transmission Drive Cycle Test. � Rerun Continuous DTC Test. If DTCs have returned, service as required. Road test and rerun all

DTC test procedures.

Quick Test 5.0 — Key On, Engine Running (KOER)

This test provides "hard" DTCs only.



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� Follow the menu screen instructions as they appear. � If a DTC appears after the key on engine running (KOER) test, a malfunction is present. Refer to the

DTC Code Chart for service information.

Performing KOER


state/Cal. � Select "Diagnostic Data Link" menu. � Select "Diagnostic Test Mode" menu. � Select "KOER On-Demand Self Test." � Follow operating instructions from the NGS menu screen (example: turn key on, etc.) and perform

brake on/off (BOO) and cycle the transmission control switch (TCS) on and off, if equipped, rotate steering wheel.

� Record all DTCs displayed. � Service all non-transmission DTCs first as they can directly affect the operation of the transmission.

Road test the vehicle and repeat Quick Test to verify the repair.

Special Test Modes

The following Special Test Modes may be used or required during diagnostics.

Output Test Mode

The diagnostic test mode aids is servicing output actuators associated with the PCM system. It allows the technician to energize and de-energize most of the system output actuators on command.

Performing Output Test Mode

Enter Output Test Mode with ignition key ON and the engine OFF.


state/Cal. � Select "Diagnostic Data Link" menu. � Select "Diagnostic Test Mode" menu. � Enter "Active Tests." � Enter "Output Control." � Follow operating instructions from the NGS menu screen.

PCM Reset Mode

The PCM reset mode provides a means for the NGS to command the powertrain control module to clear all DTCs. When resetting the PCM, a DTC P1000 will be set in the PCM until all OBD II system or components have been monitored during the OBDII Drive Cycle. When a PCM reset is performed the following occurs:

� DTCs cleared.



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� Freeze Frame Data cleared. � Oxygen Sensor Test Data cleared. � Status of the OBD II System Monitors reset. � DTC P1000 set.

Performing PCM Reset


state/Cal. � Select "Generic OBD II Functions" menu. � Select "Clearing ALL Codes." � Follow operating instructions from the NGS menu screen. � Perform OBD II Drive Cycle — Clear DTC P1000.

Clearing DTC P1000

In some localities it may become a legal requirement to pass an Inspection/Maintenance (I/M) test of the OBD II system. If the vehicle's powertrain system or its battery has just been serviced, the OBD II system is reset to a not ready for I/M testing condition. To prepare the vehicle for the test and to clear the DTC No. P1000, an OBD II Drive Cycle must be performed.

OBD II Drive Cycle

The following steps must be run in the order shown. If Steps 2, 3, or 4 are interrupted, repeat the step before proceeding. Any safe driving mode is acceptable between steps.

Always drive vehicle in a safe manner according to traffic conditions and obey all traffic laws.

1. Start engine and drive vehicle in typical city stop-and-go traffic for at least 10 minutes after it has reached normal operating temperature.

2. Idle vehicle for at least 45 seconds, then accelerate at part throttle to near 72 km/h (45 mph).

3. Cruise and maintain a select speed in the range of 48-64 km/h (30 to 40 mph) on a level road with throttle held steady for at least one minute.

4. Drive to accumulate at least four minutes in the range of 32-72 km/h (20 to 45 mph). If stop-and-go conditions occur, the accumulated time must be within the 32-72 km/h (20 to 45 mph) range. No wide open throttle (WOT) conditions should be encountered.

5. Decelerate and idle for at least 10 seconds.

6. Accelerate to approach 88 km/h (55 mph) at 1/2 throttle (elapsed time is about 10 seconds).

7. Cruise and maintain select speed in the range of 64-104 km/h (40 to 65 mph) on a level road with throttle held steady for at least one minute and 20 seconds.

8. OBDII Drive Cycle has been completed.



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Other NGS Features

For further information on other diagnostic testing features using the NGS or generic scan tool, refer to the Powertrain Control/Emissions Diagnosis Manual. Other diagnostic methods include the following:

� Parameter Identification (PID) Access Mode, used to monitor sensor and actuators. � Freeze Frame Data Access Mode, used to view emissions related data values from specific PIDs. � Oxygen Sensor Monitor Mode, used to monitor the O2 sensor.

Transmission Drive Cycle Test

NOTE: The Transmission Drive Cycle Test must be foll owed exactly. Malfunctions must occur four times consecutively for codes P0731, P0732, P0733 and P0734 to be set, and five times consecutively for continuous code P0743.

NOTE: When performing the Transmission Drive Cycle Test, refer to the Solenoid Application Chart for proper solenoid operation.

After performing the Quick Test, use the Transmission Drive Cycle Test for checking continuous codes.

1. Record and then erase Quick Test codes.

2. Warm engine to normal operating temperature.

3. Make sure transmission fluid level is correct.

4. With transmission in (D), moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fourth gear. Hold speed and throttle opening steady for a minimum of 15 seconds.

5. With transmission in fourth gear and maintaining steady speed and throttle opening, lightly apply and release brake pedal (2455) (to operate stoplamps). Then hold speed and throttle steady for an additional five seconds (minimum).

6. Brake to a stop and remain stopped for a minimum of 20 seconds.

7. Repeat Steps 4 through 6 at least five times.

8. Perform Quick Test and record continuous codes.

� If DTCs are present, go to the On-Board Diagnostic Trouble Code Description Chart in this section for service information. Service all non-transmission DTCs first as they can directly affect the operation of the transmission. Repeat the Quick Test and Road Test to verify the correction. Erase DTCs, perform Drive Cycle and repeat the Quick Test after completing service on the DTCs.

� If the continuous test passes and a concern is still present, refer to the Diagnosis By Symptom Charts , OASIS and TSBs for concern diagnostics.



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After On-Board Diagnostics

NOTE: The vehicle wiring harness, powertrain control module (PCM) (12A650) and non-transmission sensors may affect transmission operations. Service these concerns first.

After the On-Board Diagnostics procedures are completed, service all DTCs.

Begin with non-transmission related DTCs, then service any transmission related DTCs. Refer to the On-Board Diagnostic Trouble Code Description Chart for information on condition and symptoms. This chart will be helpful in referring to the proper manual(s) and to aid in diagnosing internal transmission concerns and external non-transmission inputs. The Pinpoint Tests are used in diagnosing electrical concerns of the transmission. Make sure that the vehicle wiring harness and the powertrain control module are diagnosed as well. The Powertrain Control/Emissions Diagnosis Manual will aid in diagnosing non-transmission electronic components.





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Before Pinpoint Tests

NOTE: Prior to entering Pinpoint Tests, refer to TSBs and OASIS messages for 4R44E concerns.

NOTE: Prior to entering Pinpoint Tests, the vehicle harness must be checked for continuity and shorts, and the powertrain control module (PCM) must be checked for any concerns. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual for diagnosis and testing of the PCM concerns.

NOTE: If any non-transmission service codes appear, service those codes first. They could affect the electrical operation of the transmission. Record and erase codes from continuous memory after repairs have been performed. After servicing any fault codes in the Quick Test, the Quick Test should be repeated.

NOTE: Check the EEC-V system wiring harness for proper connection, bent or broken pins, corrosion, loose wires, proper routing, proper seals and their condition. Check the powertrain control module (PCM) (12A650), sensors, and actuators for physical damage.

If codes appear while performing the Self Test, refer to the On-Board Diagnostic Trouble Code Description Chart for the appropriate service procedure.





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On-Board Diagnostic Trouble Code Description Chart



ON-BOARD DIAGNOSTIC TROUBLE CODE DESCRIPTION CHART

**May also be generated by some other non-electric transmission hardware system.

*Output circuit check, generated only by electrical symptoms.

Four-Digit DTC Component Description Condition Symptom Action

P0112 IAT IAT indicates 125°C (254°F) (grounded).

Voltage drop across IAT exceeds scale set for temperature 125° C (254°F).

Incorrect EPC pressure. Either high or low which will result in harsh or soft shifts.

Refer to PCED 1

P0113 IAT IAT indicates -40°C (-40°F) (open circuit).

Voltage drop across IAT exceeds scale set for temperature -40° C (-40°F).

Incorrect EPC pressure. Either high or low which will result in harsh or soft shifts.

Refer to PCED 1

P0114 IAT IAT out of on-board diagnostic range.

IAT temperature higher or lower than expected during KOEO and KOER.

Rerun on-board diagnostic at normal operating temperature.

Refer to PCED 1

P1116 ECT ECT out of on-board diagnostic range.

ECT temperature higher or lower than expected during KOEO and KOER.

Rerun on-board diagnostic at normal operating temperature.

Refer to PCED 1

P0117 ECT ECT indicates 125°C (254°F).

Voltage drop across ECT exceeds scale set for temperature 125° C (254°F) (grounded).

Torque converter clutch will always be off, resulting in reduced fuel economy.

Refer to PCED 1

P0118 ECT ECT indicates -40°C (-40°F).

Voltage drop across ECT exceeds scale set for temperature -40° C (- 40°F) (open circuit).

Torque converter clutch will always be off, resulting in reduced fuel economy.

Refer to PCED 1

P1124 TP TP voltage high/low for on-board diagnostic.

TP was not in the correct position for on-board diagnostic.

Rerun at appropriate throttle position per application.

Refer to PCED 1

P0121, P0122, P0123,

TP TP concern. PCM has detected an error. This error may cause a

Harsh engagements, firm shift feel, abnormal shift schedule, torque

Refer to PCED 1



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P1120, P1121, P1125, P1124

transmission concern.

converter clutch does not engage. Torque converter clutch cycling.

P0102, P0103, P1100, P1101

MAF MAF concerns. MAF system has a malfunction which may cause a transmission concern.

High/low EPC pressure, incorrect shift schedule. Incorrect torque converter clutch engagement scheduling. Symptoms similar to a TP failure.

Refer to PCED 1

P0300-P0306, P0320, P0340, P1351-P1364

EI EI concerns. EI system has a malfunction which may cause a transmission concern.

Harsh engagements and shifts, late WOT shifts, no torque converter clutch engagement.

Refer to PCED 1

P0500, P1500, P1501

VSS Insufficient VSS input.

PCM detected a loss of vehicle speed signal during operation.

Torque converter clutch engages, shift engagement/ disengagement (hunting) on grades.

Refer to PCED 1

P1705 DTR DTR not in PARK or NEUTRAL.

On-board diagnostic not run in PARK.

Rerun on-board diagnostic in PARK.

Refer to Pinpoint Test

D .

P1704 DTR DTR sensor failure in transition state.

DTR sensor misaligned or failed electrically.

Increase in EPC pressure.


D .

P1703 BOO Brake not actuated during on-board diagnostic KOER.

Brake not cycled during KOER.

Failed ON or not connected — torque converter clutch will not engage at less than 1/3 throttle. Failed OFF or not connected — torque converter clutch will not disengage when brake is applied.

Refer to PCED 1

P1703 BOO BOO switch circuit failed.

Brake ON circuit failure during KOEO.

Failed ON or not connected — torque converter clutch will not engage at less than 1/3 throttle. Failed OFF or not connected — torque converter clutch will not disengage when brake is applied.

Refer to PCED 1

P1460 A/C A/C clutch cycling pressure switch error.

A/C or Defrost ON condition may result from A/C clutch being ON during on-board diagnostic.

DTC set during on-board diagnostic — rerun with A/C OFF. Failed ON — EPC pressure slightly low with A/C OFF.

Refer to PCED 1

P0731** SS1, SS2, SS3 or

1st gear error. No 1st gear. Improper gear selection depending on failure or

Refer to Solenoid



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internal parts mode and manual lever position. Shift errors may also be due to other internal transmission concerns (stuck valves, damaged friction material).

On/Off Charts. Refer to

Pinpoint Test A .

P0732** SS1, SS2, SS3 or

internal parts

2nd gear error. No 2nd gear. Improper gear selection depending on failure or mode and manual lever position. Shift errors may also be due to other internal transmission concerns (stuck valves, damaged friction material).

Refer to Solenoid


Pinpoint Test A .

P0733** SS1, SS2, SS3 or

internal parts

3rd gear error. No 3rd gear. Improper gear selection depending on failure or mode and manual lever position. Shift errors may also be due to other internal transmission concerns (stuck valves, damaged friction material).

Refer to Solenoid


Pinpoint Test A .

P0734** SS1, SS2, SS3 or

internal parts

4th gear error. No 4th gear. Improper gear selection depending on failure or mode and manual lever position. Shift errors may also be due to other internal transmission concerns (stuck valves, damaged friction material).

Refer to Solenoid


Pinpoint Test A .

P0750* SS1 SS1 solenoid circuit failure.

SS1 circuit failed to provide voltage drop across solenoid. Circuit open or shorted or PCM driver failure during on-board diagnostic.

Improper gear selection depending on condition mode and manual lever position. See Solenoid On/Off charts.


A .


SS2 circuit fails to provide voltage drop across solenoid. Circuit open or shorted or PCM driver failure during on-board diagnostic.

Improper gear selection depending on condition mode and manual lever position. See Solenoid On/Off charts.


A .

— TCIL TCIL circuit failure.

TCIL circuit open or shorted.

Failed ON — Overdrive cancel mode always ON. NO flashing TCIL for EPC failure or sensor. Failed OFF — Overdrive cancel mode

Refer to PCED 1



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never indicated. NO flashing TCIL for EPC sensor failure.

P1747* EPC EPC solenoid circuit failure, shorted circuit.

Voltage through EPC solenoid is checked. An error will be noted if tolerance is exceeded.

Short Circuit — Causes minimum EPC pressure (minimum capacity) and limits engine torque (alternate firm). Zero EPC — no 2nd and 4th gear. Slips in 1st and 3rd with high torque input.


E .

P1744** TCC TCC slippage detected.

The PCM picked up an excessive amount of TCC slippage during normal vehicle operation.

TCC slippage/erratic or no torque converter clutch operation. Flash TCIL.

Refer to Diagnosis by

Symptom Index.

P1780 TCS TCS not changing states.

TCS not cycled during self test. TCS circuit open or shorted.

No (D) cancel when switch is cycled during KOER.

Rerun on-board diagnostic and cycle switch.

Refer to PCED 1

P1711 TFT TFT out of on-board diagnostic range.

Transmission not at operating temperature during on-board diagnostic.

DTC set — Vehicle cold or overheated.

Warm or cool vehicle to

normal operating

temperature. Refer to

Pinpoint Test B.

P0713 TFT -40°C (-40°F) indicated TFT sensor circuit open.

Voltage drop across TFT sensor exceeds scale set for temperature -40° C (-40°F)

Firm shift feel. Refer to Pinpoint Test

B .

P0712 TFT 157°C (315°F) indicated TFT sensor circuit grounded.

Voltage drop across TFT sensor exceeds scale set for temperature of 157° C (315°F)

Firm shift feel. Refer to Pinpoint Test

B .

P0715 TSS Insufficient input from Turbine Shaft Speed Sensor.

PCM detected a loss of TSS signal during operation.

Harsh shifts, abnormal shift schedule, no torque converter clutch activation.


F .

P0743* TCC TCC solenoid circuit failure during on-board diagnostic.

TCC solenoid circuit fails to provide voltage drop across solenoid. Circuit open or shorted or PCM drive failure during on-board diagnostic.

Short circuit — Engine stalls in second (OD, 2 range) at low idle speeds with brake applied. Open circuit — Torque converter clutch never engages.


C .

P1783 TFT Transmission Transmission fluid Increase in EPC Refer to



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overtemp condition indicated.

temperature exceeded 127°C (270° F).

pressure. Pinpoint Test B .

P0705 DTR DTR circuit failure.

DTR sensor, circuit or PCM shorted or grounded.



D .

P0708 DTR DTR circuit above maximum voltage — open.

DTR sensor, circuit or PCM indicates open.



D .

P0751 ** SS1 Shift solenoid No. 1 functional failure (California only).

Mechanical or hydraulic failure of the shift solenoid.

Improper gear selection depending on failure mode and manual lever position.

Refer to Solenoid


Pinpoint Test A .

P0756 ** SS2 Shift solenoid No. 2 functional failure (California only).



Refer to Solenoid

On/Off Chart. Refer to

Pinpoint Test A .

P1781 4x4L 4x4 low switch failure.

Switch closed or shorted during KOEO.

Early or delayed shifts. Refer to Section 07-

07A .

P1729 4x4L 4x4 low switch failure.

Circuit open/shorted.

Early or delayed shifts. Refer to Section 07-

07A .

P0761** SS3 Shift solenoid No. 3 functional failure (California).



Refer to Solenoid


Pinpoint Test A .


SS3 circuit failed to provide voltage drop across solenoid. Circuit open or shorted or PCM driver failure during on-board diagnostic.

Improper gear selection depending on condition mode and manual lever position. See Solenoid On/Off chart.


A .

P1754* CCS CCS solenoid circuit failure.

CCS circuit failed to provide voltage drop across solenoid. Circuit open or shorted or PCM driver failure during on-board diagnostic.

Failed on — no coast braking except in 4th gear. Delayed 3-2 shifts. Failed off — coast braking 2nd, 3rd. Firm 3-2 and 4-3 shifts.


G .

P1746 * EPC EPC solenoid circuit open.

Voltage through EPC solenoid is checked. Error is

Open Circuit — Causes maximum EPC pressure, harsh


E .



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noted if tolerance is exceeded.

engagements and shifts.

P1701 Transmission Reverse engagement error.

EPC pressure is low, no drop in TSS rpm, DTR indicates reverse

EPC pressure low, SS1 is off, engine lacks power.

Diagnosis by symptom.



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Rotunda Transmission Tester

Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 in Transmission Tester Kit, Rotunda Transmission Range (TR) Sensor Cable "E" 007-00111 with Digital TR Sensor Overlay 007-00131 or equivalent to diagnose electronically controlled transmissions (7003). The following instructions outline the set up and use of this tester in the Pinpoint Tests for the 4R44E. Transmission Tester





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Overlays and Adapters

1. Overlay and Cable Correctly Installed LEDs: Only LEDs with the (O) symbol will light when the overlay and cable are correctly matched.

2. Status LEDs: LED OFF when not activated by tester (solenoid not activated, open circuit or signal line short to ground).

� LED green when activated by tester and current draw is correct.



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� LED red when activated by tester and current draw is excessive (short at VPWR). � All LEDs light orange during On-Board Diagnostics.

3. Solenoid Activate Buttons: Energize respective solenoids during click testing and activate selected circuits during DRIVE mode testing.

4. Tester Mode Switch: Selects operating mode, either BENCH or DRIVE.

5. Solenoid Select/Gear Select Switch: Has three functions:

� BENCH MODE: acts as shift solenoid selector for click testing. � DRIVE MODE: acts as forward gear selector in place of vehicle's powertrain control module

(PCM) (12A650) controlled shifting. Hydraulic safety mechanisms and overrides are built into the transmission.

� OHMS CHECK: allows technician to measure ohms and to check for presence of diode on specific solenoids.

Tester Jacks

1. VPWR Pin Jacks (red): Vehicle Power (VPWR) test points for solenoid circuits.

2. Solenoid Signal Line Pin Jacks (black): Signal line test points for solenoid circuits.

3. BAT + (red) and BAT - (black) Pin Jacks: Battery reference points when measuring circuits for shorts.

4. TFT Pin Jacks: Test points for transmission fluid temperature sensor.

5. TSS Jack: Test points for TSS sensor.

LEDs and Controls

� LED turns RED when solenoid activates and OFF when solenoid deactivates. � LED turns GREEN if an activated solenoid/harness is shorted. � LED remains OFF if an activated solenoid/harness is shorted to ground or no continuity.

Instructions

The Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit or equivalent allows a technician to operate the electrical portion of the transmission independent of the vehicle electronics to determine transmission concerns. The Transmission Tester usage is divided in six steps:

� Preliminary Testing and Diagnosis � Installing the Transmission Tester � Static Testing — Engine Off � Dynamic Testing — Vehicle Running � DTR Testing � Removing Transmission Tester and Clearing DTCs

Preliminary Inspections



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1. Know and understand the customer's concern.

2. Verify the customer's concern:

� Upshift � Downshift � Coasting � Engagement

If concern involves noise or vibration, does it relate to any of the following?

� Rpm � Vehicle speed � Shift � Gear � Range � Temperature

3. Vehicle must be at normal operating temperature.

4. Check transmission fluid level and condition.

5. Check the following items:

� Vehicle modifications � Electronic add-on items � Leaks � Linkage adjustments

6. Check TSBs and OASIS for related information.

7. Perform complete On-Board Diagnostics (OBD) for both KOEO and KOER.

8. Record all DTCs.

9. Repair all non-transmission DTCs.

Installation Procedures

Installing Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit or equivalent at the transmission connector allows separation of the vehicle electronics from transmission electronics. Disconnecting normal vehicle electronics will cause firm shifts and defaults transmission to maximum line pressure.

During tester usage, additional DTCs may be set. Therefore, it is important that all codes are erased after service has been made. To verify elimination of all codes, rerun On-Board Diagnostics.

The following manuals will assist in diagnosis of electronically controlled transmissions:

� Powertrain Control/Emissions Diagnosis Manual. � Transmission Reference Manual.



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1. CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in transmission concerns.

Disconnect vehicle wiring harness at transmission connector.

2. Install appropriate overlay onto tester.

3. Turn tester solenoid select switch to the OHMS CHECK position.

4. CAUTION: Route all cables away from heat sources.

Connect appropriate interface cable to transmission tester and then to the appropriate transmission connectors.

5. CAUTION: Route gauge line away from heat sources.

Install a line pressure gauge into line pressure tap on transmission.

Static Testing — Engine Off

Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Completion of these tests prove out transmission electronics.

� Refer to appropriate Pinpoint Test based on DTCs displayed. � Use a digital volt-ohmmeter and the transmission tester to perform the Pinpoint Tests as indicated,

based on the DTCs which were displayed. � Perform repairs as indicated by the Pinpoint Tests. Always erase all codes, retest and road test

vehicle after a repair.



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Resistance/Continuity Tests — EPC Solenoid

1. Set ohmmeter to 100-200 ohm range.

2. Connect COM lead to the EPC jack.

3. Connect ohmmeter POS lead to the VPWR jack.

4. Record resistance.

5. Refer to the chart for values.

If out of specification, refer to Pinpoint Test E in this section.

Resistance/Continuity Tests — Solenoids (SS1, SS2, SS3, TCC, CCS)

1. Set ohmmeter to 100-200 ohm range.

2. Connect ohmmeter COM lead to the appropriate solenoid (shift solenoid 1 [ SS1], shift solenoid 2 [SS2], shift solenoid 3 [SS3], torque converter solenoid [ TCC], coast clutch solenoid [CCS]) jack.

3. Connect ohmmeter POS lead to the appropriate VPWR jack for the solenoid being tested.

Solenoid Resistance (Ohms)

S1 22-48

S2 22-48

S3 22-48

CCS 22-48

TCC 8.9-16.0

EPC 3.1-5.7



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5. Refer to the chart for values.

If out of specification, refer to Pinpoint Test A (SS1, SS2, SS3); Pinpoint Test C (TCC), Pinpoint Test G (CCS).

Resistance/Continuity Tests — Transmission Fluid Temperature (TFT) Sensor

1. Set ohmmeter to 1000 ohm (k) scale.

2. Connect ohmmeter COM lead to TFT jack.

3. Connect ohmmeter POS lead to + TFT jack.

4. Record resistance. Resistance will vary with temperature.

5. Refer to the following chart.

If out of specification, refer to Pinpoint Test B in this section.

Resistance/Continuity Tests — Turbine Shaft Speed (TSS) Sensor

1. Set Rotunda 73 Digital Multimeter 105-R0051 or equivalent to 200 ohms.

2. Connect multimeter COM lead to TSS jack.

3. Connect multimeter POS lead to (-) TSS jack.


Range:

� TSS 64-120 ohms

5. If resistance is out of range, refer to Pinpoint Test F in this section.

Temperature Resistance

°C °F (Ohms)

- 40 - - 20 - 40 - - 4 967k-248k

- 19 - - 1 - 3 - 31 248k-100k

0-20 32-68 100k-37k

21-40 69-104 37k-16k

41-70 105-158 16k-5k

71-90 159-194 5k-2.7k

91-110 195-230 2.7k-1.5k

110-130 231-266 1.5k-0.8k

131-150 267-302 0.8k-0.54k



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Solenoid Voltage Test

1. Slide MODE switch to BENCH position.

2. Set voltmeter to 20-volt DC range.

3. Determine solenoid to be tested and connect voltmeter leads as follows:

� If testing SS1, SS2, or SS3 solenoid, turn the SOLENOID SELECT dial to SS1, SS2, or SS3 before hooking up leads.

� Connect negative lead to solenoid jack. � Connect positive lead to VPWR jack.

4. Press solenoid activate/deactivate button and check voltage.

The LED should light, the voltage should change, and an audible click may be heard. See LED and Controls for reading LED status.

5. Observe and record values.

Dynamic Testing — Engine On

Preliminary Set Up

1. Slide MODE switch to DRIVE position.

2. Turn GEAR SELECT dial to 1.

3. Place vehicle in PARK with parking brake on.

4. Start engine.

EPC Solenoid



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CAUTION: Do not attempt to hold the electronic pressure control switch depressed (minimum line pressure) and stall the transmission (holding the vehicle with the brake while depressing the throttle with the transmission in gear). Transmission damage will result.

1. Observe line pressure. Record value. Line pressure should go to maximum. If not, refer to the Diagnosis By Symptom Index for diagnostic information or Pinpoint Test E concerning electronic pressure control solenoid.

2. Depress electronic pressure control switch. Record value. Line pressure should drop to a minimum value Record value. If not, refer to the Diagnosis by Symptom Index or Pinpoint Test E for the electronic pressure control solenoid.

Transmission Engagements

1. Verify that MODE switch is in DRIVE position.

2. Turn GEAR SELECT dial to 1.

3. Start engine.

4. Shift vehicle from PARK to REVERSE.

� Did vehicle shift into REVERSE? � Was engagement firm?

5. Depress EPC switch. Line pressure should drop to idle pressure.

While holding EPC switch down, shift vehicle from PARK to REVERSE.

� Did vehicle shift into REVERSE? � Was engagement smooth? � Shift vehicle from REVERSE to PRK. � Release EPC switch. Line pressure should rise to MAX pressure.

6. Shift vehicle from PARK to DRIVE.

� Did vehicle shift into DRIVE? � Was engagement firm?

7. Shift vehicle from DRIVE to PARK.

8. Depress EPC switch. Pressure should drop to idle pressure.

9. While holing EPC switch down, shift vehicle from PARK to DRIVE.

� Did the vehicle shift from PARK to DRIVE? � Was the engagement smooth?

10. Release EPC Switch.

Upshifts/Downshits



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NOTE: Upshifts and downshifts will be firm during this procedure. Pressure gauges may be removed. These tests should be performed on the road. If performed on the hoist, shift feel during engagement may not be possible.

LED will turn green when solenoids are activated and turn off when deactivated. Refer to the appropriate overlay for the proper status shift sequence of the shift solenoids during upshifts and downshifts.

1. Move transmission range selector lever into (D) and accelerate to 24 km/h (15 mph). By moving transmission range selector lever, shift to second gear.

� Did vehicle upshift to second gear? � Did appropriate shift solenoids activate/deactivate?

2. Accelerate to 40 km/h (25 mph) and select third gear by turning GEAR SELECT dial to 3.

� Did vehicle upshift to third gear? � Did appropriate shift solenoids activate/deactivate?

3. Accelerate to 56-72 km/h (35/45 mph) and select fourth gear by turning GEAR SELECT dial to 3.

� Did vehicle upshift to fourth gear? � Did appropriate shift solenoids activate/deactivate?

4. Reverse the order to downshift.

� Did vehicle downshift from fourth to third, third to second, and second to first?

Torque Converter Clutch (TCC) Engagement

CAUTION: Do not depress torque converter clutch sol enoid switch with transmission in gear and the vehicle at a stop. Damage to torque converter clutch may result.

NOTE: This test should be performed on the road. If performed on a hoist, torque converter clutch engagement feel may not be possible.

1. Accelerate and shift vehicle up into third gear. Hold speed steady and depress the torque converter clutch solenoid switch.

� Did the torque converter engage? � Did the engine rpm drop? � Did torque converter clutch solenoid activate? � Did TCC solenoid deactivate when switch was reused?

Coast Clutch Engagement

NOTE: This test should be performed on the road. If performed on the hoist, coast clutch engagement feel may not be possible.

1. Accelerate and shift vehicle into third gear. Depress the coast clutch solenoid switch and immediately



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back off the throttle.

� Did the coast clutch engage? Did engine braking occur? � Did the coast clutch solenoid activate?

2. Release the CCS switch.

� Did the CCS solenoid deactivate?

Turbine Shaft Speed (TSS) Sensor

NOTE: This test may be performed on the hoist or on the road.

1. Set voltmeter to 20 volts AC.

2. Connect voltmeter positive lead to +TSS.

3. Connect voltmeter negative lead to -TSS.

4. Slowly accelerate vehicle and monitor voltmeter.

� Did voltage increase with vehicle speed?

If testing of the DTR sensor is required, go to the following procedure. If testing of the DTR sensor is not required, go to the disconnecting the tester procedure in this section.

Digital Transmission Range (DTR) Sensor Testing

Introduction

The Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), TR Testing Cable "E" 007-00111 and Digital TR Sensor Overlay 007-00131 or equivalent allows a technician to test the DTR sensor independent of vehicle electronics. DTR sensor testing is divided into four steps:

1. Preliminary diagnosis and testing.

2. Installing the Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), TR Testing cable "E" (007-00111) and Digital TR Overlay or equivalent.

3. Testing the digital transmission range (DTR) sensor.

4. Testing the park/neutral, backup and optional circuits.

Preliminary Testing and Diagnosis

Before any diagnostic testing is done on a vehicle some preliminary checks must be performed. Be sure to write down any findings, especially any DTCs, for future reference.

1. Know and understand customer's concern.

2. Verify that DTR sensor is properly adjusted in NEUTRAL.



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3. Verify customer concern:

� Upshift � Downshift � Coasting � Engagement

If concern involves noise or vibration, does it relate to any of the following?

� Rpm � Vehicle speed � Shift � Gear � Range � Temperature

4. Vehicle must be at normal operating temperature.

5. Check transmission fluid level and condition.

6. Check for the following items:

� Vehicle modifications � Electronic add-on items � Leaks � Linkage adjustments

7. Check TSBs and OASIS for related information.

8. Perform complete On-Board Diagnostics (OBD) for both KOEO and KOER.

9. Record all DTCs.

10. Repair all non-transmission DTCs.

Installation Procedures

Installing the Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and TR Testing Cable "E" 007-00111 and Digital TR Sensor Overlay 007-00131 at the transmission connector allows separation of the DTR sensor electronics from the vehicle electronics.

Testing may cause additional fault codes to be set. Therefore, it is important that all DTCs are erased whenever repairs are made. To verify elimination of all codes, rerun OBD test.

The following manuals will assist in diagnosis of electronically controlled transmissions:

� Powertrain Control/Emission Diagnosis (PC/ED) Manual � Transmission Reference Manual

1. For proper DTR sensor diagnosis, follow Pinpoint Test D .

2. Disconnect vehicle harness at transmission DTR sensor.



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3. Set the two-way switch in the down position. (This switch will stay in the same position for all DTR sensor testing.)

4. Attach the Digital TR Sensor Overlay 007-00131 to the transmission tester.

Affixing the overlay will immobilize the two-way switch (set in Step 2) so it cannot be accidentally moved to an incorrect setting during testing.

5. Select and connect interface cable "E" 007-00111 to the tester and then black connector (digital) to DTR sensor.

Transmission Model Year Cable

4R44E 1997 E



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6. Set analog/digital switch on TR-E cable to digital.



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CAUTION: Route all cables away from heat sources to prevent damage to cables during testing.

Use the transmission tester extender cable when running tests with the transmission on the vehicle.

7. Turn large dial to DIGITAL TR SENSOR TEST.

8. Plug transmission tester power cable into cigar lighter socket.

All LEDs should light for a short period and then turn off. This is the Tester's internal circuit check.

CAUTION: For resistance checks, be sure that the tester selector switch is set to the TR SENSOR TEST position or damage to the ohmmeter may result.

Sensor Test



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CAUTION: Be sure that the DIGITAL 12 pin sensor cable connector (black) is used. If the wrong connection is made or the slide switch is in the wrong position, the LEDs on the TR cable will give false or no response during testing. This will cause the replacement of good parts.

1. Place transmission range selector lever into PARK.

2. Ensure that the "E" cable ANALOG/DIGITAL switch is set to DIGITAL.

3. Move the transmission range selector lever through all ranges.

4. Monitor the LEDs, located on the "E" cable, in each gear position. The LED should illuminate RED for the appropriate range selected.

5. If the LED for the applicable gear range position fails to illuminate RED or if it lights for a position other than the gear selected:

� Verify test cable connections at sensor and tester. � Verify transmission shift linkage for proper adjustment. � Verify DTR sensor for proper adjustment. � Retest.

6. If the sensor still fails to illuminate the LED RED for the selected gear range or indicates incorrect gear position, replace it.

Switch Tests — Park/Neutral, Backup Lamp and Optional Circuits

NOTE: LED lights red when circuit is closed.



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LED turns off when circuit is open.

1. Press and hold each test button while moving the transmission range selector lever to each gear position.

2. Monitor each STATUS LED:

The LED in the appropriate gear position being testing should light red.

If the LED for the applicable gear position fails to light red, or if it lights for a position other than the gear selected:

� Verify DTR alignment. Refer to the assembly procedure in this section. � Retest.

3. If the DTR sensor fails, replace it.

After testing is finished, follow the Disconnecting The Tester procedure in this section.

Disconnecting The Tester

1. CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in a transmission concern.

Disconnect transmission tester from the DTR sensor connector.

2. Reinstall vehicle wiring harness. Verify connection by pulling up on the harness.

3. Reinstall all heat shields that were previously removed.

4. Disconnect transmission tester power lead from vehicle.

5. Erase all DTCs using the procedures in the Powertrain Control/Emissions Diagnosis Manual.

6. Rerun On-Board Diagnostic Tests to receive a pass code.

7. Verify that the customer concern has been eliminated.

Digital Transmission Range (DTR) Sensor Connector



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* Ranger ** Aerostar Transmission

Pin Number Circuit EEC-V Pin Number Circuit Function

1 — — NOT USED

2 359 (GY/R) 91 Signal Return

3 199 (LB/Y) 64 TR3A

4 1144 (Y/BK) 3 TR1

5 1145 (LB/BK) 49 TR2

6 1143 (W/BK) 50 TR4

7 57 (BK) — Ground

8 463 (R/W) — Neutral Sense

9 298 (P/O) — Fused Power Feed

10 32 (R/LB) — Starter Control

11 140 (BK/PK) — Back Up

12 33 (W/PK) *

329 (PK) ** — Starter to Starter Interrupt Relay



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Pin Number Circuit Circuit Function

1 361 (R) TCC Power

2 970 (GN/W) Turbine Shaft Speed Sensor Signal

3 359 (GY/R) Sensor Signal Return (TSS)

4 923 (O/BK) Transmission Fluid Temperature Sensor

5 126 (P/Y) *

480 (P/Y) ** Torque Clutch Solenoid

6 — NOT USED

7 971 (PK/BK) Shift Solenoid No. 3

8 359 (GR/R) Sensor Signal Return (TFT)

9 924 (BR/O) Coast Clutch Solenoid

10 361 (R) Shift Solenoid Power

11 361 (R) EPC Power

12 925 (W/Y) Electronic Pressure Control Solenoid

13 — NOT USED

14 315 (P/O) Shift Solenoid No. 2

15 — NOT USED



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* Ranger ** Aerostar Internal Harness Diagram

16 237 (O/Y) Shift Solenoid No. 1

Pin Number Circuit Circuit Function

1 Black TCC Power

2 Red Turbine Shaft Speed Sensor Signal

3 White Sensor Signal Return (TSS-)

4 Red Transmission Fluid Temperature Sensor

5 Purple Torque Converter Clutch Solenoid

6 — NOT USED

7 Yellow Shift Solenoid No. 3

8 Red Sensor Signal Return (TFT-)

9 Orange Coast Clutch Solenoid

10 White Shift Solenoid Power

11 Green EPC Power

12 Blue Electronic Pressure Control Solenoid

13 — NOT USED

14 Brown Shift Solenoid No. 2

15 — NOT USED

16 Gray Shift Solenoid No. 1



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Transmission Range Sensor Internal Circuitry



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Pinpoint Tests

PINPOINT TEST A: SHIFT SOLENOIDS

Solenoid Operation Chart

The following chart shows normal solenoid operation for given operating modes.

1 O/W = TCS "ON"

Shift Solenoid Failure Mode Charts

NOTE: 2nd and 4th gear in O/D position can only be obtained with sufficient EPC pressure (i.e., no short in EPC circuit can be present).

Shift Solenoid Failure "Always Off"

Shift Solenoid failed in the OFF mode due to PCM and/or vehicle wiring concerns; solenoid electrically or mechanically stuck in the OFF mode.



SOLENOID OPERATION CHART — 4R44E


Powertrain Control Module (PCM) Gear Commanded

4R44E Solenoid States

Engine Braking SS1 SS2 SS3 CCS

P/N P/N No On Off Off Off

R R Yes 1 On Off Off O/W 1

(D)(Overdrive) 1 2 3 4

No No No No

On On Off Off

Off On Off Off

Off Off Off On

Off Off Off Off

(D) 1 1 Yes On Off Off On

2 Yes On On Off On

3 Yes Off Off Off On

Manual 2 2 Yes On On Off On

Manual 1 1 Yes On Off Off On

SS1 Always OFF:


OD 2 1



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1 When a manual pull-in occurs above a calibrated speed, the transmission will downshift from the higher gear until the vehicle speed drops below this calibrated speed.

1 When a manual pull-in occurs above a calibrated speed, the transmission will downshift from the higher gear until the vehicle speed drops below this calibrated speed. Shift Solenoid Failure "Always On"

Failed ON due to powertrain control module (PCM) (12A650) and/or vehicle wiring concerns; solenoid electrically or mechanically stuck ON.


PCM Gear Commanded Actual Gear Obtained

1 3 — 2

2 2 2 2 1

3 3 — —

4 4 — —

SS2 Always OFF:


OD 2 1


1 1 — 1

2 1 2 1

3 3 — —

4 4 — —

SS3 Always OFF:


OD 2 1


1 1 — 1

2 2 2 2 1

3 3 — —

4 3 — —

SS1 Always ON:


OD 2 1


1 1 — 1

2 2 2 2 1

3 1 — —

4 Ratio 1.86 — —



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NOTE: 2nd and 4th gear in O/D position can only be obtained with sufficient EPC pressure (i.e., no short in EPC circuit can be present).

A1 ELECTRONIC DIAGNOSTICS

� Check to make sure transmission harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding.

� Connect New Generation STAR (NGS) Tester 007-00500 or equivalent. � Perform KOEO test until continuous DTCs have been displayed. � Enter output test mode (OTM). Refer to On-Board Diagnostics with NGS as outlined. � Select the mode "ALL ON". � Push START to turn outputs "ON". � Push STOP to turn outputs "OFF".

Does vehicle enter OTM?

SS2 Always ON:


OD 2 1


1 2 — 2

2 2 2 2

3 2 — —

4 2 — —

SS3 Always ON:


OD 2 1


1 Ratio 1.86 — Ratio 1.86

2 Ratio 1.11 Ratio 1.11 Ratio 1.11 1

3 4 — —

4 4 — —

Yes No

REMAIN in OTM. GO to A2 .

PRESS START. If vehicle does not enter OTM, REFER to Powertrain Control/Emissions Diagnosis Manual for diagnosis and testing of the automatic transmission.



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A2 CHECK ELECTRICAL SIGNAL OPERATION

CAUTION: Do not pry up on connector, depress release button, then pull up on the connector.

NOTE: Refer to the schematic and chart preceding this pinpoint test.

� Disconnect transmission connector. � Using a mirror, inspect both ends of connector for damaged or pushed out pins, corrosion, loose

wires, and missing or damaged seals. � Connect Rotunda 73 Digital Multimeter 105-R0051 or equivalent positive lead to VPWR and negative

test lead to the solenoid circuit of the transmission vehicle harness connector. � Place multimeter on 20-volt scale. � While observing multimeter, press "start" and "stop" to cycle solenoid output ON and OFF.

Does the suspect solenoid output voltage change at least 0.5 volts?

A3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS


� Key OFF. � Ensure harness transmission connector is disconnected. � Disconnect powertrain control module (PCM), inspect for damage or pushed out pins, corrosion, or

loose wires. � Install Rotunda Breakout Box 014-00950 or equivalent, leave PCM disconnected. � Measure resistance between PCM test Pins 1, 27, 53 at the breakout box and the appropriate signal

pin at transmission harness connector. � Measure resistance between PCM test Pins 71/97 at the breakout box and the appropriate signal pins

at the transmission harness connector.

Is each resistance less than 5.0 ohms?

A4 CHECK SOLENOID HARNESS FOR SHORTS TO POWER AND GROUND


� Ensure Rotunda Breakout Box 014-00950 or equivalent is installed and powertrain control module disconnected.

Yes No

GO to A5 GO to A3 .

Yes No

GO to A4 . SERVICE open circuits. REMOVE breakout box. RECONNECT all components. REPEAT Quick Test.



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� Ensure transmission harness connector is disconnected. � Measure resistance between PCM signal test Pins 1, 27, 53 and the test Pins 71/97 at the breakout

box. � Measure resistance between PCM test Pins 1, 27, 53 and PCM test Pins 91 and test Pins 77, 103 at

the breakout box and chassis ground.

Is each resistance greater than 10,000 ohms?

A5 TRANSMISSION FUNCTIONAL TEST

CAUTION: Do not pry connector. Pull transmission harness connector.

� Ensure that the vehicle harness is disconnected at transmission. � Install tester to Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit)

with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit or equivalent.

� Use tests outlined in the Transmission Tester manual. � Perform Solenoid Function Test. � LED will turn green when solenoid activates and turn off when deactivated. � LED will turn red if an activated solenoid/harness is shorted to BAT+ . � LED will remain off if an activated solenoid/harness is shorted to ground or no continuity (open

circuit).

Do the solenoids (LED) activate? (LED green)

A6 TRANSMISSION DRIVE TEST

� Reconnect PCM. � Perform the Drive Test outlined in the Transmission Tester Manual.

Does the vehicle upshift when commanded by the tester?

Yes No

GO to A5 . SERVICE short circuit. REMOVE breakout box. RECONNECT all components. REPEAT Quick Test.

Yes No

GO to A6 . GO to A7 .

Yes No

REPLACE PCM. ERASE all codes and PERFORM the Transmission Drive Cycle Test as outlined in this manual. RERUN Quick Test. If the codes are still present, REFER to the Diagnosis By Symptom Routines .

GO to A7 .



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A7 CHECK RESISTANCE OF SOLENOID/HARNESS

NOTE: Refer to transmission tester for terminal locations.

� Set MODE switch to BENCH position. � Rotate GEAR SELECTOR switch to OHMS CHECK position. � Connect ohmmeter negative lead to SS1 jack and positive lead to VPWR jack on tester. This is to test

SS1. � Record resistance. Should be between 22-48 ohms. � Connect ohmmeter negative lead to SS2 jack and positive lead to VPWR jack on tester. This is to test

SS2. � Record resistance. Should be between 22-48 ohms. � Connect ohmmeter negative lead to SS3 jack and positive lead to VPWR jack on tester. This is to test

SS3. � Record resistance. Should be between 22-48 ohms.

Are all shift solenoid resistances within specifications?

A8 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND

Yes No

GO to A8 .

NOTE: Out of specifications may be caused by internal harness or solenoid concerns.

GO to A9 .



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� Check for continuity between BAT- (engine ground) and appropriate jack with an ohmmeter or other low current tester (less than 200 milliamps).

� Connection should show infinite resistance (no continuity).

Is there continuity?

Solenoid Tester Jack

SS1 SS1 VPWR

SS2 SS2 VPWR

SS3 SS3 VPWR

Yes No



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A9 INTERNAL ELECTRONIC DIAGNOSTICS

� Drain transmission fluid. � Remove transmission fluid pan. � Check that internal harness connector is fully engaged on shift solenoid assemblies. � Check that internal harness connector terminals are fully seated in connector. � Inspect connectors for damage. � Inspect wires for insulation damage.

Were checks done and was everything OK?

A10 CHECK INTERNAL HARNESS (CONTINUITY)

CAUTION: Do not probe into connector terminals.

� Disconnect internal harness from solenoid assemblies. � For SS1, connect positive lead from ohmmeter to tester jack SS1 and negative lead at appropriate

signal wire of SS1 wire connector. � Record resistance. Should be less than 0.5 ohms. � For SS2, connect positive lead from ohmmeter to tester jack SS2 and negative lead at appropriate

signal wire of the SS2 connector. � Record resistance. Should be less than 0.5 ohms. � For SS3, connect positive lead from ohmmeter to test jack SS3 and negative lead at appropriate

signal wire of the SS3 wire connector. � Record resistance. Should be less than 0.5 ohms. � For SS1, SS2, and SS3 VPWR, connect positive lead from an ohmmeter to appropriate solenoid

VPWR and negative lead to appropriate VPWR wire for SS1, SS2, or SS3. � Record resistance. Should be less than 0.5 ohms.

Is resistance less than 0.5 ohms?

GO to A9 . GO to the Shift Concerns in the Diagnosis By Symptom Index .

Yes No

GO to A10 . SERVICE as required.

Wire Colors

SS1 SS2 SS3

Signal PWR Signal PWR Signal PWR

Gray White Brown White Yellow White

Yes No

GO to A11 . REPLACE internal harness. GO to A12 .



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A11 CHECK INTERNAL HARNESS (SHORTS TO GND)

� Check for continuity between BAT- (engine ground) and appropriate wire with ohmmeter or other low current tester (less than 200 milliamps).



A12 CHECK SOLENOID RESISTANCE AT SOLENOID

� Check solenoid resistance by connecting ohmmeter at solenoid terminals. � Measure and record resistance for each solenoid (SS1, SS2, SS3).

Is resistance between 22-48 ohms?

A13 CHECK SOLENOID FOR SHORT TO GROUND

� Check for continuity between engine ground and appropriate shift solenoid terminal with ohmmeter or other low current tester (less than 200 milliamps).



Wire Colors

SS1 SS2 SS3

Signal PWR Signal PWR Signal PWR

Gray White Brown White Yellow White

Yes No

REPLACE internal harness. GO to A12 . GO to A12 .

Yes No

GO to A13 . REPLACE shift solenoid.

Solenoid Terminal

SS1 +/-

SS2 +/-

SS3 +/-

Yes No

REPLACE shift solenoid. REFER to the Diagnosis By Symptom Routines .



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PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

B1 4R44E ELECTRICAL DIAGNOSIS

� Make sure transmission harness connector is fully seated and terminals are fully engaged in connector and in good condition before proceeding.

Have items been checked?

B2 CHECK ELECTRICAL SIGNAL OPERATION

CAUTION: Do not pry up on connector. Depress release button, then pull up on the vehicle harness.


� Key OFF. � Disconnect transmission connector. � Using a mirror, inspect both ends of the connector for damaged or pushed out pins, corrosion, or

loose wires and missing or damaged seals. � Connect Rotunda 73 Digital Multimeter 105-R0051 or equivalent positive test lead to TFT circuit and

negative test lead to Signal Return (SIG RTN) circuit of transmission vehicle harness connector. � Place multimeter on 20-volt scale. � Turn key ON, engine OFF.

Is voltage between 4.75 and 5.25 volts?

B3 CHECK CONTINUITY OF TFT AND SIG RTN CIRCUITS


� Key OFF. � Ensure that the vehicle harness is disconnected at the transmission connector. � Disconnect powertrain control module (PCM). Inspect for damaged or pushed out pins, corrosion or

loose wires. � Install Rotunda Breakout Box 014-00950 or equivalent. Leave PCM disconnected.

Yes No

GO to B2 . PERFORM checks. ERASE codes. REPEAT Quick Test.

Yes No

GO to B5 . GO to B3 .



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� Measure resistance between PCM test Pin 37 at the breakout box and the appropriate signal pin at transmission harness connector.

� Measure resistance between PCM test Pin 91 at the breakout box and the appropriate signal pins at the transmission harness connector.

Are both resistances less than 5.0 ohms?

B4 CHECK TFT CIRCUIT FOR SHORT TO VPWR AND GROUND


� Key OFF. � Ensure transmission harness connector is disconnected. � Disconnect powertrain control module. Inspect for damaged or pushed out pins, corrosion or loose

wires. � Install Rotunda Breakout Box 014-00950 or equivalent. Leave powertrain control module

disconnected. � Measure resistance between PCM test signal Pin 37 and the test Pins 71/97 at the breakout box. � Measure resistance between TFT test pin 37 and chassis ground, Pins 51, 76, 77, 103 and 91.

Is the resistance greater than 10,000 ohms?

B5 CHECK RESISTANCE OF TFT SENSOR

CAUTION: Do not pry up on connector. Depress release button, then pull up on vehicle harness connector.

NOTE: Be sure tester solenoid select switch is in the OHMS CHECK position or damage to ohmmeter may result.

� Vehicle at normal operating temperature. � Disconnect vehicle harness at transmission. � Install Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with

Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit or equivalent to transmission connector.

� Set MODE switch to BENCH mode. � Rotate solenoid select switch to OHMS CHECK mode. � Connect ohmmeter negative lead to -TFT jack and positive lead to + TFT jack.

Yes No

GO to B4 . SERVICE open circuit(s). REMOVE breakout box. RECONNECT all components. ERASE all codes. REPEAT Quick Tests.

Yes No

GO to B5 . SERVICE short circuit. REMOVE breakout box. RECONNECT all components. ERASE codes. REPEAT Quick Tests.



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NOTE: While performing tests 1 and 2 observe resistances. Code P0713 is set if resistance value exceeds 869K ohms (OPEN circuit). Code P0712 is set if resistance value falls below 597 ohms (SHORT circuit).

� Perform tests 1 and 2. � Test 1: Record resistance. Should be approximately in following ranges:

� Test 2: Check for intermittent short or open. � If resistance was between 0.8k and 100k ohms, perform following test. If transmission is cold, run

transmission to warm it. If transmission is warm, allow transmission to cool. Check TFT sensor resistance again. Compare resistance with initial resistance. Resistance should decrease if transmission was heated and should increase if transmission was allowed to cool. If correct change in resistance occurs, repeat On-Board Diagnostics.

Is resistance within range?

B6 CHECK TFT SENSOR/HARNESS FOR SHORT TO GROUND

� Check for continuity between BAT- (engine ground) and appropriate jack (-TFT and +TFT), appropriate wire with ohmmeter, or other low current tester (less than 200 milliamps).



Transmission Fluid Temperature

°C °F Resistance (Ohms)

- 40 - - 20 - 40 - - 4 967k-248k

- 19 - - 1 - 3 - 31 248k-100k

0-20 32-68 100k-37k

21-40 69-104 37k-16k

41-70 105-158 16k-5k

71-90 159-194 5k-2.7k

91-110 195-230 2.7k-1.5k

111-130 231-266 1.5k-0.8k

131-150 267-302 0.8k-0.54k

Yes No

GO to B6 . REPLACE internal transmission wiring harness. CLEAR codes. RERUN Quick Test.



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B7 INTERNAL ELECTRONIC DIAGNOSTICS

� Drain transmission fluid. � Remove transmission fluid pan. � Check that internal harness connector is fully seated on TFT sensor. � Check that internal harness connector terminals are fully engaged in connector. � Inspect connector for damage.

Is everything in good condition?

PINPOINT TEST C: TORQUE CONVERTER CLUTCH (TCC) SOLENOID

C1 ELECTRONIC DIAGNOSTICS


Yes No

GO to B7 . REPLACE powertrain control module. CLEAR codes and RERUN Self Test.

Yes No

REPEAT Quick Test. If codes are present and overtemp condition exists, CHECK fluid condition. CHECK overheat condition in the Diagnosis By Symptom Routine . SERVICE as required. REPEAT Quick Test.

SERVICE as required. REPLACE internal harness.



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C2 CHECK ELECTRICAL SIGNAL OPERATION

CAUTION: Do not pry up on connector. Depress release button, then pull up on the vehicle harness.


� Disconnect transmission connector. � Using a mirror, inspect both ends of the connector for damaged or pushed out pins, corrosion, loose

wires and missing or damaged seals. � Connect Rotunda 73 Digital Multimeter 105-R0051 or equivalent positive test lead to VPWR circuit

and negative test lead to solenoid circuit of transmission vehicle harness connector. � Place multimeter on 20-volt scale. � While observing multimeter, press "start" and "stop" to cycle solenoid ON and OFF.

Does the suspected solenoid output voltage change at least 0.5 volts?

C3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS


� Turn key OFF. � Ensure transmission harness connector is disconnected. � Disconnect powertrain control module (PCM). Inspect for damaged or pushed out pins, corrosion or

loose wires. � Install Rotunda Breakout Box 014-00950 or equivalent. Leave powertrain control module

disconnected. � Measure resistance between PCM test Pin 54 at the breakout box and the appropriate signal pin at

transmission harness connector. � Measure resistance between PCM test Pins 71/97 at the breakout box and the VPWR pin at the

Yes No

REMAIN in OTM. GO to C2 .


Yes No

GO to C5 . GO to C3 .



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transmission harness connector.


C4 CHECK SOLENOID/HARNESS FOR SHORTS TO POWER AND GROUND


� Ensure Rotunda Breakout Box 014-00950 or equivalent is installed and powertrain control module is disconnected.

� Ensure transmission vehicle harness connector is disconnected. � Measure resistance between PCM signal test Pin 54 and the test Pins 71/97 at the breakout box. � Measure resistance between PCM signal test Pin 54 and test Pins 51, 76, 77, 91 and 103 at the

breakout box and chassis ground.


C5 TRANSMISSION FUNCTIONAL TEST

CAUTION: Do not pry connector. Pull on transmission harness connector.

� Disconnect vehicle harness at transmission. � Install Rotunda Tester 007-00130 (part of Rotunda Transmission Tester Kit) with Rotunda

4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit to transmission connector.

� Use tests outlined in the Transmission Tester manual. � Perform TCC Solenoid Function Test. � LED will turn green when solenoid activates and turn off when deactivated. � LED will turn red if an activated solenoid/harness is shorted to BAT+ . � LED will remain off if an activated solenoid/harness is shorted to ground or no continuity (open

circuit).

Does the TCC (LED green) activate when the tester switch is depressed?

Yes No

GO to C4 . SERVICE the open circuit(s). REMOVE the breakout box. RECONNECT all components. REPEAT Quick Test.

Yes No

GO to C5 . SERVICE the short circuit(s). REMOVE the breakout box. RECONNECT all components. REPEAT Quick Test.

Yes No

GO to C6 . GO to C7 .



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C6 TRANSMISSION DRIVE TEST

� Reconnect PCM. � Perform the Drive Test as outlined in Transmission Tester Manual. � While in 3rd gear, depress the TCC switch.

Does the TCC activate (LED green)? Does the engine rpm drop?

C7 CHECK RESISTANCE OF SOLENOID/HARNESS

Refer to Transmission Tester for terminal locations. � Set MODE switch to BENCH mode on tester. � Rotate GEAR SELECTOR switch to OHMS CHECK position. � Connect ohmmeter negative lead to TCC jack and positive lead to VPWR jack on tester. This is to

test TCC. � Record resistance. Should be between 8.9-16.0 ohms for TCC.

Is resistance within specifications?

Yes No

REPLACE PCM. ERASE all codes and PERFORM Transmission Drive Cycle Test and Torque Converter Engagement Test as outlined in this manual. RERUN Self Test. If codes are still present, REFER to the Diagnosis By Symptom Index — Torque Converter Concerns for continued diagnosis.

GO to C7 .

Yes No



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C8 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND

� Check for continuity between BAT- (engine ground) and appropriate jack with ohmmeter or other low current tester (less than 200 milliamps).



C9 INTERNAL ELECTRONIC DIAGNOSTICS

� Drain transmission fluid. � Remove transmission fluid pan. � Check that internal harness connector is fully seated on TCC solenoid.

GO to C8 .

NOTE: Internal harness or solenoid may be damaged.

GO to C9 .


TCC TCC VPWR

Yes No

GO to C9 . REFER to Diagnosis By Symptom Index in this manual to diagnose torque converter clutch concerns.



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� Check that internal harness connector terminals are fully engaged in connector. � Inspect connector for damage.

Is connector in good condition and seated properly?

C10 CHECK INTERNAL HARNESS (CONTINUITY)

NOTE: Do not probe into connector terminals.

� Disconnect internal harness from solenoid (TCC wire connector). � Connect positive lead from ohmmeter to tester TCC jack and negative lead at purple wire at TCC

connector. � Record resistance. Should be less than 0.5 ohms. � Next, connect positive lead from ohmmeter to tester VPWR jack and negative lead at black wire of

TCC connector.

Record resistance. Is resistance less than 0.5 ohms?

C11 CHECK INTERNAL HARNESS

� Check for continuity between BAT- (engine ground) and the appropriate wire with an ohmmeter or other low current tester (less than 200 milliamps).

� Connection should not show continuity (infinite).


C12 CHECK SOLENOID RESISTANCE

� Check solenoid resistance by connecting ohmmeter at terminals of TCC solenoid. � Record resistance. Should be between 8.9-16.0 ohms for TCC.

Yes No

GO to C10 . SERVICE as required.

Yes No

GO to C11 . REPLACE internal harness. GO to C12 .

Solenoid Wire Color

TCC Purple

VPWR Black

Yes No

REPLACE internal harness. GO to C12 . GO to C12 .



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Is resistance within specification?

C13 CHECK SOLENOID FOR SHORT TO GROUND

� Check for continuity between BAT- (engine ground) and appropriate terminal with ohmmeter or other low current tester (less than 200 milliamps).



PINPOINT TEST D: DIGITAL TRANSMISSION RANGE (DTR) SENSOR

Digital TR Sensor Overlay

D1 VERIFY DIGITAL TRANSMISSION RANGE SENSOR ALIGNMENT

Yes No

GO to C13 . REPLACE TCC solenoid.

Solenoid Terminal

TCC +/-

Yes No

REPLACE TCC solenoid. REFER to Diagnosis By Symptom Index in this section for torque converter clutch concerns.



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� Turn ignition switch OFF. � Place transmission range selector lever in PARK. � Check to make sure the DTR sensor harness connector is fully seated, terminals are fully engaged in

connector and in good condition before proceeding. � Apply the parking brake. � Place transmission range selector lever in OVERDRIVE. � Verify the shift linkage is adjusted in the OVERDRIVE (O/D) position. � Place transmission range selector lever in NEUTRAL. � Verify that the Digital TR Sensor Alignment Tool (T97L-70010-A) fits in the appropriate slots.

Is the DTR sensor properly adjusted?

D2 CHECK ELECTRICAL SIGNAL OPERATION

� Place transmission range selector lever in PARK.

CAUTION: Do not pry on connector. This will damage the connector and result in a transmission concern.

� Press button and pull out on DTR harness connector. � Inspect both ends of the connector for damage or pushed out pins, corrosion, loose wires and

missing or damaged seals.

Is there damage to the connector, pins or harness?

D3 CHECK ELECTRICAL SYSTEM OPERATION (DTR AND PCM)

� Turn ignition switch OFF. � Connect the New Generation STAR (NGS) tester. � Reconnect DTR connector. � Turn ignition switch ON. � Select TR PIDs TR and TR_D on the NGS tester. � Move transmission range selector lever into each gear and stop. � Observe the PIDs, TR and TR_D, while wiggling harness and tapping on sensor.

Yes No

GO to D2 .

ADJUST the DTR sensor as outlined under Assembly . PLACE transmission range selector lever into PARK and CLEAR DTCs. RERUN OBD tests.

Yes No

REPAIR as required. CLEAR DTCs and RERUN OBD tests.

If diagnosing a DTC, GO to D3 . If diagnosing a starting concern, a backup lamp concern, or 4x4 low engagement concern, GO to D8 .



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� Compare the PIDs to the chart below:

* Will read DRIVE if O/D cancel switch is ON.

Do the PIDs TR and TR_D match the above chart, and does the TR_D PID remain steady when the harness is wiggled or when the sensor is tapped upon?

D4 CHECK DIGITAL TRANSMISSION RANGE SENSOR OPERATION

� Disconnect DTR Sensor Connector. � Connect TR-E Cable (007-00111) to Transmission Tester (007-00130). � Connect TR-E Cable (007-00111) to DTR Sensor. � Place the DIGITAL TR Overlay (007-00131) onto transmission tester (007-00130). � Perform SENSOR TEST as instructed on the DTR overlay.

Does the status lamp on the tester TR-E cable match the selected gear positions?

D5 CHECK PCM HARNESS CIRCUITS FOR OPENS

NOTE: Refer to schematic diagram and illustration preceding the Pinpoint Tests.

� Turn ignition switch OFF. � Disconnect powertrain control module (PCM) connector. Inspect for damaged or pushed out pins,

corrosion or loose wires.

CAUTION: Do not pry connector. This will damage the connector and result in a

Selector Position TR TR_D

Park P/N 0000

Reverse REV 1100

Neutral NTRL 0110

Drive O/D * 1111

Man 2 MAN2 1001

Man 1 MAN1 0011

Yes No

The problem is not in the DTR sensor system. REFER to Diagnosis by Symptom for further diagnosis.

GO to D4 .

NOTE: If TR_D changes when wiggling harness or tapping on the sensor, problem may be intermittent.

Yes No

Concern is not in the DTR sensor, GO to D5 . REPLACE the DTR sensor and ADJUST as outlined. REFER to Assembly for procedures. CLEAR DTCs and RERUN OBD tests.



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transmission concern.

� Press button and pull out DTR connector. � Install 104 Pin Breakout Box (014-00950). � Measure resistance between PCM test pin 91 at the breakout box and signal return circuit pin at

vehicle harness connector pin 2. � Measure resistance between PCM test pin 3 at breakout box and TR1 circuit pin at vehicle harness

connector pin 4. � Measure resistance between PCM test pin 49 at breakout box and TR2 circuit pin at vehicle harness

connector pin 5. � Measure resistance between PCM test pin 50 at breakout box and TR4 circuit pin at vehicle harness

connector pin 6. � Measure resistance between PCM test pin 64 at breakout box and TR3A circuit pin at vehicle harness

connector pin 3.

Are all resistances less than 5 ohms?

D6 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND OR POWER

� Measure resistance between PCM test pin 91 and test pins 71/97 at breakout box. � Measure resistance between PCM test pin 3 and power/ground test pins at breakout box. � Measure resistance between PCM test pin 49 and power/ground test pins at breakout box. � Measure resistance between PCM test pin 50 and power/ground test pins at breakout box. � Measure resistance between PCM test pin 64 and power/ground test pins at breakout box.

Are all resistances greater than 10,000 ohms?

D7 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL CIRCUITS

� Measure resistance between test pin 3 and pins 49, 50 and 64 at the breakout box. � Measure the resistance between test pin 49 and pins 3, 50 and 64 at the breakout box. � Measure the resistance between test pin 50 and pins 3, 49 and 64 at the breakout box. � Measure the resistance between test pin 64 and pins 3, 49 and 50 at the breakout box.

Are all resistances greater than 10,000 ohms?

Yes No

GO to D6 . REPAIR open circuit(s). RECONNECT all components. CLEAR DTCs. RERUN OBD tests.

Yes No

GO to D7 . REPAIR short circuit(s). RECONNECT all components. CLEAR DTCs. RERUN OBD tests.

Yes No

REPLACE PCM. RECONNECT all components. CLEAR DTCs and RERUN OBD tests.

REPAIR shorts on circuits having less than 10,000 ohms between other TR/PCM input signal circuits. RECONNECT all components.



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D8 CHECK THE NON PCM INTERNAL CIRCUITS OF SENSOR

� Connect TR-E Cable (007-00111) to Transmission Tester (007-00130). � Connect TR-E Cable (007-00111) to DTR sensor. � Place the DIGITAL TR Overlay (007-00131) onto transmission tester (007-00130). � Perform SWITCH TEST as instructed on the DTR overlay.

Does the status lamp on the tester indicate RED for the correct gear position?

PINPOINT TEST E: ELECTRICAL PRESSURE CONTROL (EPC) SOLENOID

E1 ELECTRONIC DIAGNOSTICS




E2 CHECK ELECTRICAL SIGNAL OPERATION

CAUTION: Do not pry on connector. Pull up on the connector harness.

CLEAR DTCs and RERUN OBD tests.

Yes No

Concern is not in the DTR sensor. For START SYSTEM concerns, GO to Section 03-06 . For Backup Lamp concerns, GO to Section 17-01 . For Optional Circuits: 4x4 Low Neutral Sense; REFER to Powertrain Control/Emissions Diagnosis Manual and Workshop Manual Section 07-07A for diagnosis.

REPLACE DTR sensor and ADJUST as outlined. REFER to Assembly for procedures. CLEAR DTCs and RERUN OBD tests.

Yes No

REMAIN in OTM. GO to E2 .




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� Disconnect transmission connector. � Using a mirror, inspect both ends of connector for damage or pushed out pins, corrosion, loose wires,

and missing or damaged seals. � Connect a VOM positive lead to VPWR and the negative test lead to the solenoid circuit of the

transmission vehicle harness connector. � Place VOM on 20 volt scale. � While observing VOM, press "start" and "stop" to cycle solenoid output ON and OFF.

Does the suspect solenoid output voltage change at least 0.5 volt?

E3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS


� Key OFF. � Disconnect powertrain control module (PCM). Inspect for damaged or pushed out pins, corrosion, or

loose wires. � Install Rotunda Breakout Box 014-00950 or equivalent. Leave PCM disconnected. � Measure resistance between PCM test Pin 81 at the breakout box and the appropriate signal pin at

transmission harness connector. � Measure resistance between PCM test Pins 71/97 at the breakout box and the appropriate signal pins



E4 CHECK HARNESS FOR SHORT TO GROUND OR POWER


� Key OFF. � Ensure Rotunda Breakout Box 014-00950 or equivalent is installed and powertrain control module is

disconnected. � Ensure transmission connector is disconnected. � Measure resistance between PCM signal test Pin 81 and the test Pins 71/97 at the breakout box. � Measure resistance between PCM test Pin 81 and test Pins 77, 103, 76 and 91 at the breakout box

and chassis ground.


Yes No

GO to E5 . GO to E3 .

Yes No

GO to E4 . SERVICE all open circuit(s). REMOVE the breakout box. RECONNECT all components. ERASE codes and REPEAT OBD Tests.



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E5 TRANSMISSION FUNCTIONAL TEST

� Ensure that the vehicle harness is disconnected at transmission connector. � Reconnect PCM. � Install line pressure gauge at line tap on case. � Install Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with

Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit or equivalent to transmission connector.

� Set MODE switch to DRIVE mode. � Rotate GEAR SELECTOR switch to 1ST GEAR position. � Use tests outlined in the Transmission Tester manual. � Perform EPC Functional Test. � LED will turn green when solenoid activates and turn off when deactivated. � LED will turn red if activated solenoid/harness is shorted to BAT+ . � LED will remain off if activated solenoid/harness is shorted to ground or no continuity (open circuit). � Does EPC (LED green) activate when EPC switch is depressed? � Observe line pressure on gauge while depressing EPC switch (vehicle must be running).

Does line pressure drop?

E6 CHECK RESISTANCE OF SOLENOID/HARNESS

� Set MODE switch to BENCH mode on tester. � Rotate GEAR SELECTOR switch to OHMS CHECK position. � Connect ohmmeter negative lead to EPC jack and positive lead to VPWR jack on tester. This is to

test EPC solenoid and harness.

Yes No

GO to E5 . SERVICE all short circuit(s). REMOVE the breakout box. RECONNECT all components. ERASE codes and REPEAT OBD Tests.

Yes No

REPLACE powertrain control module, INSPECT power relay for damage, corrosion. SERVICE as required. REPEAT the OBD Tests.

GO to E6 .



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� Record resistance.

Is resistance between 3.10-5.7 ohms?

E7 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND


Yes No

GO to E7 .

NOTE: Internal harness or solenoid may be damaged.

GO to E8 .



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E8 INTERNAL ELECTRONIC DIAGNOSTICS

� Drain transmission fluid. � Remove transmission fluid pan. � Check that internal harness connector is fully engaged on EPC solenoid. � Check that internal harness connector terminals are fully seated in connector. � Inspect connector for damage.

Is everything engaged and in good condition?

E9 CHECK INTERNAL HARNESS (CONTINUITY)


EPC EPC VPWR

Yes No

GO to E8 . REFER to Hydraulic/Mechanical Diagnosis charts in Diagnosis By Symptom Index .

Yes No

GO to E9 . SERVICE as required.



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� Disconnect internal harness from EPC solenoid assembly. � Connect positive lead from an ohmmeter to tester EPC jack and negative lead at Blue wire at EPC

connector. � Record resistance. Should be less than 0.5 ohms. � Next, connect positive lead from an ohmmeter to tester VPWR jack and negative lead at green wire at

EPC connector. � Record resistance.

Is resistance less than 0.5 ohms?

E10 CHECK INTERNAL HARNESS (SHORTS TO GND)

� Check for continuity between BAT- (engine ground) and appropriate wire with ohmmeter or other low current tester (less than 200 milliamps).



E11 CHECK SOLENOID RESISTANCE

� Check solenoid resistance by connecting ohmmeter at EPC terminals of solenoid. � Record resistance.

Is resistance between 3.10-5.7 ohms?

E12 CHECK SOLENOID FOR SHORT TO GROUND

� Check for continuity between a good ground and each EPC terminal with ohmmeter or other low current tester (less than 200 milliamps).

Yes No

GO to E10 . REPLACE internal harness.

Solenoid Wire Color

EPC Blue - Green +

Yes No

REPLACE internal harness. GO to E11 . GO to E11 .

Yes No

GO to E12 . REPLACE EPC solenoid.

Solenoid Terminal



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PINPOINT TEST F: TURBINE SHAFT SPEED (TSS) SENSOR

F1 4R44E/4R55E ELECTRONIC DIAGNOSTICS

� Check that the transmission vehicle harness connector is fully seated, terminals are fully engaged in connector and in good condition.

Have the items above been checked?

F2 CHECK CONTINUITY OF TSS HARNESS CIRCUITS

CAUTION: Do not pry on connector. Use connector release and button.


� Key OFF. � Disconnect transmission harness connector. � Disconnect powertrain control module (PCM). Inspect for damaged or pushed out pins, corrosion, or

loose wires. � Install Rotunda Breakout Box 014-00950 or equivalent, leave powertrain control module

disconnected. � Measure resistance between PCM test Pin 84 at the breakout box and the appropriate signal pin at

the transmission harness connector. � Measure resistance between PCM test Pin 91 at the breakout box and the appropriate signal pin at

the transmission harness connector.


EPC +/-

Yes No

REPLACE EPC solenoid. REFER to Hydraulic/Mechanical Diagnosis Charts in Diagnosis By Symptom Index for diagnosis of pressure concerns.

Yes No

GO to F2 . PERFORM the checks. ERASE codes. RERUN OBD Tests.

Yes No

SERVICE open circuit(s). REMOVE breakout



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F3 CHECK TSS CIRCUITS FOR SHORT TO POWER AND GROUND

� Key OFF. � Ensure that the vehicle harness is disconnected. � Breakout box installed, powertrain control module disconnected. � Measure resistance between PCM test Pins 84, 91 and test Pins 71/97 at the breakout box. � Measure resistance between PCM signal test Pins 84, and test Pins 91, 71/97, 77, 76 and 103 at the

breakout box and chassis ground.


F4 TRANSMISSION FUNCTIONAL TEST

� Ensure that the vehicle harness is disconnected at the transmission. � Reconnect PCM. � Install Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with

Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit or equivalent.

� Connect voltmeter positive lead to +TSS and negative lead to -TSS. Set voltmeter to AC. � Perform Drive Cycle Test . Monitor voltmeter.

Does the voltage increase with an increase in vehicle speed?

F5 CHECK RESISTANCE OF SOLENOID/HARNESS

NOTE: Refer to 4R44E Transmission Tester for terminal locations.

� Rotate GEAR SELECTOR switch to OFF position. � Connect ohmmeter negative lead to TSS- jack and positive lead to TSS+ jack on tester. � Record resistance. � Resistance should be between 64-120 ohms.

Is the TSS resistance within specifications?

GO to F3 . box. RECONNECT all components. ERASE codes. RERUN OBD Tests.

Yes No

GO to F4 . SERVICE short circuit(s). REMOVE breakout box. RECONNECT all components. ERASE codes and RERUN OBD Tests.

Yes No

REPLACE powertrain control module. GO to F5 .

Yes No



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F6 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND




GO to F6 .

NOTE: Out of specification may be caused by internal harness or solenoid concerns.

GO to F6 .


TSS TSS+ TSS-

Yes No

GO to Disassembly in this section for TSS GO to Disassembly in this section for TSS



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PINPOINT TEST G: COAST CLUTCH SOLENOID

G1 ELECTRONIC DIAGNOSTICS




G2 CHECK ELECTRICAL SIGNAL OPERATION

CAUTION: Do not pry on connector. Depress release button, then pull on harness.


� Disconnect transmission connector. � Using a mirror, inspect both ends of connector for damaged or pushed out pins, corrosion, loose

wires, and missing or damaged seals. � Connect Rotunda 73 Digital Multimeter 105-R0051 or equivalent positive test lead to vehicle power

(VPWR) circuit and negative test lead to the solenoid circuit of the transmission vehicle harness connector.

� Place multimeter on 20-volt scale. � While observing volt-ohmmeter, press "start" and "stop" several times to cycle solenoid output on and

off.

Does the suspected solenoid output voltage change at least 0.5 volts?

service and hardware diagnosis. service and hardware diagnosis.

Yes No

REMAIN in OTM. GO to G2 .


Yes No

GO to G5 GO to G3 .



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G3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VEHICLE POWER HARNESS CIRCUITS


� Turn ignition switch off. � Make sure transmission harness connector is disconnected. � Disconnect powertrain control module. Inspect for damaged or pushed out pins, corrosion, or loose

wires. � Install Rotunda Breakout Box 014-00950 or equivalent, leave PCM disconnected. � Measure resistance between PCM test Pin 28 at the breakout box and the appropriate signal pin at

transmission harness connector. � Measure resistance between PCM test Pins 71/97 at the breakout box and the appropriate signal pins



G4 CHECK SOLENOID HARNESS FOR SHORTS TO POWER AND GROUND


� Key OFF. � Breakout box installed, powertrain control module disconnected. � Transmission harness connector disconnected. � Measure resistance between PCM signal test Pin 28 and test Pins 71/97 at the breakout box. � Measure resistance between PCM test Pins 28 and test Pins 77, 76, 91, 51 and 103 at the breakout

box and chassis ground.


G5 TRANSMISSION FUNCTIONAL TEST

� Reconnect PCM. � Disconnect vehicle harness at transmission. � Install Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) with

Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit or equivalent at the transmission connector.

Yes No

GO to G4 . SERVICE open circuit(s). REMOVE breakout box. RECONNECT all components. REPEAT Quick Test.

Yes No

GO to G5 . SERVICE short circuit. REMOVE breakout box. RECONNECT all components. RERUN Self Test.



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� Use tests outlined in the Transmission Tester manual. � Perform the Solenoid Function Test. � LED will turn green when solenoid activates and turn off when deactivated. � LED will turn red if activated solenoid is shorted to BAT+ . � LED will remain off if an activated solenoid is shorted to ground or no continuity.

Does the solenoid (LED) activate? (LED green)

G6 TRANSMISSION DRIVE TEST

� Perform the Drive Test as outlined in Transmission Tester Manual. � Does the CCS activate when commanded by the tester? � Does engine braking occur?

Does coast clutch engage?

G7 CHECK RESISTANCE OF SOLENOID/HARNESS

NOTE: Refer to the 4R44E/4R55E Transmission Tester for terminal locations.

� BENCH/DRIVE switch in BENCH mode. � Rotate GEAR SELECTOR switch to Ohm position. � Connect ohmmeter negative lead to CSS jack and positive lead to VPWR jack on tester. This is to

test CCS. � Record resistance. � Resistance should be between 22-48 ohms.

Is the coast clutch solenoid resistance within specification?

Yes No

GO to G6 . GO to G7 .

Yes No

REPLACE PCM. ERASE all codes and PERFORM the Transmission Drive Cycle as outlined in this section. RERUN Self Test. If symptom is still present, REFER to Diagnosis By Symptom Index to diagnose coast clutch concerns (no engine braking).

GO to G7 .



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G8 CHECK SOLENOID/HARNESS FOR SHORT TO GROUND




Yes No

GO to G8 .

NOTE: Out of specification may be caused by internal or solenoid concerns.

GO to G9 .


CCS CCS VPWR



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G9 4R44E INTERNAL ELECTRONIC DIAGNOSTICS

� Drain transmission fluid. � Remove transmission pan. � Check that the internal harness connector is fully engaged on the coast clutch solenoid assembly. � Check that the internal harness connector terminals are fully seated in the connector. � Inspect the connector for damage.

Were the checks done and was everything OK?

G10 CHECK INTERNAL 4R44E HARNESS (CONTINUITY)

� Disconnect the internal harness from the solenoid assembly. � For CCS, connect the positive lead from an ohmmeter to the tester jack CCS and the negative lead at

the orange wire of the CCS wire connector. � For CCS VPWR, connect the positive lead from an ohmmeter to the tester jack CCS VPWR and the

negative lead at the white wire of the CCS wire connector. � Record resistance. Should be less than 0.5 ohms.

Yes No

GO to G9 . GO to Service Manual Diagnosis By Symptom Index charts for diagnosis of coast clutch concerns.

Yes No

GO to G10 . SERVICE as required.



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Are the resistances less than 0.5 ohms?

G11 CHECK INTERNAL HARNESS (SHORTS TO GND)

� Check for continuity between BAT- (engine ground) and appropriate wire with an ohmmeter or other low current tester (less than 200 milliamps).



G12 CHECK SOLENOID RESISTANCE AT SOLENOID

� Check solenoid resistance by connecting an ohmmeter at the terminals of the solenoid. � Measure and record resistance for the solenoid. (CCS) � Resistance should be between 22-48 ohms.

Is resistance between 22-48 ohms?

G13 CHECK SOLENOID FOR SHORT TO GROUND

� Check for continuity between engine ground and appropriate solenoid terminal with ohmmeter or other low current tester (less than 200 milliamps).



Yes No

GO to G11 . REPLACE internal harness. GO to G12 .

Solenoid Wire Color

CCS Orange

VPWR White

Yes No

REPLACE internal harness. GO to G12 .

Yes No

GO to G13 . REPLACE CCS solenoid.

Solenoid Terminal

CCS +/-

Yes No



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REPLACE CCS solenoid.

REFER to service manual for Hydraulic/Mechanical Diagnosis Charts under Diagnosis By Symptom Index (no engine braking).



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Special Testing Procedures

Engine Idle Speed Check

Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual for diagnosis and testing of the engine idle speed.

Line Pressure Test

CAUTION: The Transmission Tester must be removed and the vehicle harness installed when verifying these pressures.

CAUTION: Perform Line Pressure Test prior to performing Stall Speed Test. If line pressure is low at stall, do not perform Stall Speed Test or further transmission damage will occur. Do not maintain wide open throttle in any gear range for more than five (5) seconds.

NOTE: Certain sensor failures may cause high EPC, FMEM (Failure Mode Effect Management) actions. Be sure that self test and electrical repairs have been performed, or test results may be incorrect.

This test verifies that the line pressure is within specifications.

1. Connect 0-2758 kPa (0-400 psi) pressure gauge to the line pressure tap.





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2. Start engine and check line pressures. Refer to the following Line Pressure Specifications No. 401 chart to determine if line pressure is within specifications.

CAUTION: Do not install Transmission Tester when verifying these pressures.

NOTE: Vehicle harness must be installed at transmission connector to verify these pressures.

3. If line pressure is not within specifications, check EPC pressure.

4. Connect Pressure Gauge to EPC pressure tap.

REFERENCE: LINE PRESSURE SPECIFICATIONS No. 401

Trans. Transmission Model/Application Range

Idle WOT Stall

EPC Line EPC Line

4R44E 2.3L Ranger R 37-47 115-145 112-134 282-350

4x2 N 21-31 77-107

(D), 2, 1 20-30 77-107 112-134 228-263

4R44E 3.0L Ranger R 46-56 143-173 112-134 282-350

4x2, 4x4 N 31-41 94-124

(D), 2, 1 20-30 71-101 112-134 228-263

4R44E 3.0L Aerostar R 47-57 153-183 112-134 282-350

4x2 N 20-30 73-103

(D), 2, 1 40-50 105-135 112-134 228-263



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5. Start engine and check EPC pressure. Refer to Reference: Line Pressure Chart in this section for specification.

6. If EPC pressure is not within specification, perform Pinpoint Test E to diagnose EPC operation. If EPC operation is OK, refer to Line Pressure Diagnosis Chart in this section for line pressure concern causes.


1 — Electronic Pressure Control (EPC)

LINE PRESSURE DIAGNOSIS CHART

Test Results Possible Source

High at Idle — All Ranges � Wiring Harnesses � EPC Boost Valve � EPC Solenoid � Main Regulator Valve

Low at Idle — All Ranges � Low Fluid Level � Fluid Inlet Filter/Seal � Main Control Body � Cross Leaks � Gaskets � Pump � Separator Plate

Low — All Forward Ranges � Forward Clutch � Main Control � O/D Servo

Low in Park Only � Valve Body

Low in Reverse Only � Separator Plate � Rear Servo Piston, Cover Seal

� Reverse Clutch � O/D Servo � Valve Body � Forward Clutch

Low in Neutral Only � Valve Body � O/D Servo



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Stall Speed Test

This test checks operation of the following items:

� Torque converter clutch � Forward clutch � Low one way clutch (OWC) assembly � Engine performance

WARNING: APPLY THE PARKING BRAKE FIRMLY WHILE PERFORMING EACH STALL TEST.

CAUTION: Always perform Line Pressure Test procedures prior to performing the Stall Speed Test. If line pressure is low at stall, do not perform Stall Speed Test or further transmission damage will occur.

NOTE: The Stall Speed Test should be performed with the engine and transmission at normal operating temperatures.

1. Connect tachometer to the engine.

2. CAUTION: After testing each of the following ranges (D), 2, 1, and R, move the transmission range selector lever to N (NEUTRAL) and run engine at 1000 rpm for about 15 seconds to allow the torque converter to cool before testing the next range.

CAUTION: Do not maintain wide open throttle in any range for more than five (5) seconds.

CAUTION: If the engine rpm recorded by the tachometer exceeds maximum specified rpm, release the accelerator pedal immediately. Clutch or band slippage is indicated.

NOTE: Prolonged use of this procedure may set Diagnostic Trouble Code P0712, P1783. After performing Stall Speed Test run OBD Test and clear DTCs from memory.

Low in Overdrive Only � Forward Clutch � O/D Servo � Valve Body

Low in Drive Only (O/D Cancelled) � Forward Clutch � O/D Servo � Valve Body

Low in 1st Position Only � Forward Clutch � Valve Body

Low in 2nd Position Only � Intermediate Servo � O/D Servo � Forward Clutch



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Press accelerator pedal to floor (WOT) in each range. Record rpm reached in each range. Stall speeds should be as follows:

If stall speeds were too high, refer to the following Stall Speed Diagnosis Chart. If stall speeds were too low, first check the engine idle speed. If engine idle is OK, remove torque converter and check the torque converter clutch for slippage.

Air Pressure Tests

A no drive condition can exist, even with correct transmission fluid pressure, because of inoperative clutches or bands. An erratic shift can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the malfunction.

When the transmission range selector lever is in a forward gear range ((D) , 2, 1), a no drive condition may be caused by an inoperative forward clutch, or an overrunning one-way clutch.

Failure to drive in R (REVERSE) could be caused by a malfunctioning reverse clutch, reverse servo, or band.

Follow the procedure to determine the location of the inoperative clutch or band by introducing air pressure into the various test plate passages.

Test Procedures

Vehicle Engine Rpm

Ranger 2.3 2610-3035

Ranger 3.0 2870-3338

Aerostar 3.0 2762-3230

STALL SPEED DIAGNOSIS CHART

Transmission Range Selector Lever Position Stall Speeds High Stall Speeds Low

(D)Overdrive, D, and 1 Overdrive One-Way Clutch, Rear One-Way Clutch

—

D, 2 and 1 Forward Clutch, O/D One-Way Clutch

—

(D)Overdrive Forward Clutch, O/D One-Way Clutch

—

(D)Overdrive, D, 2, 1 and R General Pressure Concerns, Forward Clutch, O/D One-Way Clutch

Converter One-Way Clutch or Engine Performance

R Only High/Reverse and High Clutch and Low and Reverse Band/Servo

—

2 Only Intermediate Band/Servo —

1 Only Low/Reverse Band/Servo —



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NOTE: Cover vent in test plate with a clean, lint-free shop towel to prevent spray when air is applied. Plugging vent hole during testing will result in inaccurate results.

NOTE: Use only dry regulated air pressure 276kPa (40 psi) max. A dull thud should be heard when the clutch or band applies. There should be no hissing sound when band or clutch applies.

1. Drain transmission fluid and remove transmission oil pan.

2. Remove filter and seal assembly and main control valve body.

3. Install 4R44E/4R55E Transmission Test Plate T95L-77000-AH and Transmission Test Plate Gasket T95L-77000-AH1.

4. CAUTION: Do not apply air to test the vent.

Apply air pressure to appropriate clutch port (refer to diagram). A dull thud may be heard or movement felt when clutch is applied or released. If clutch seals or check balls are leaking a hissing sound may be heard.


1 — Coast Clutch Apply

2 — Direct Clutch Apply

3 — Forward Clutch Apply

4 — Intermediate Servo Release

5 — Intermediate Servo Apply

6 — Overdrive Servo Release

7 — Overdrive Servo Apply

8 T95L-77000-AH 4R44E/4R55E Transmission Test Plate



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Test Results

If test results find that the servos do not operate, disassemble, clean and inspect them to locate the source of the concern.

If air pressure applied to the clutch passages fails to operate a clutch, or operates another clutch simultaneously, disassemble and use air pressure to check the fluid passages in the center support and clutches to detect obstructions.

— T95L-77000-AH1 Transmission Test Plate Gasket



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Leakage Inspection

CAUTION: Do not try to stop the fluid leak by increasing the torque beyond specifications. This may cause damage to the case threads.

Check the vehicle speed sensor (VSS) and the speedometer cable connection at the transmission. Replace rubber seal if necessary.

Leakage at the transmission fluid pan to case gasket often can be stopped by tightening the attaching bolts to 13-15 Nm (115-133 lb-ft). If necessary, replace the oil pan case gasket.

Check the fluid filler tube connection at the transmission case. If leakage is found here, install a new grommet.

Check fluid lines and fittings between the transmission and the cooler in the radiator tank for looseness, wear, or damage. If leakage cannot be stopped by tightening a fluid tube nut, replace the damaged parts. When fluid is found leaking between the case and cooler line fitting, check for missing or damaged O-ring, then tighten the fitting to maximum specification.

If the leak continues, replace cooler line fitting and tighten to specification. The same procedure should be followed for fluid leaks between the radiator cooler and the cooler line fittings in this section. Refer to Transmission Cooler Line Replacement for procedures.

Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the radiator is probably leaking.

The cooler can be further checked for leaks by disconnecting the lines for the cooler fittings and applying no more than 345 kPa (50 psi) air pressure to the fittings. Remove the radiator cap to relieve the pressure buildup at the exterior of the oil cooler tank. If the cooler is leaking and/or will not hold pressure, replace the cooler.

If leakage is found at the transmission range selector lever, replace the seal.

If leakage is found at the transmission internal harness connector, replace O-ring.

External Sealing

The 4R44E transmission has the following parts to prevent external fluid leakage:

� Gaskets � Lip-type seals � O-ring seals � Seal rings � Seal grommets � Thread sealant





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External Sealing


1 7A308 Shaft (Manual Valve Outer to Inner Levers)

2 7005 Case Assembly

3 7C492 Screw (Intermediate and O/D Band) Adjuster/Lock (2 Req'd)

4 7A248 Seal Ring (Fluid Pump)

5 7A103 Support and Gear Assembly (Fluid Pump)

6 E825100-S100

Nut and Seal — Hex (Intermediate and O/D Bands) Adjuster/Lock (2 Req'd)

7 7A136 Gasket (Fluid Pump)

8 7B472 Plate (Fluid Pump Adaptor)

9 7976 Housing Assembly (Converter)

10 E804595-S200

Screw and Seal Assembly, M10x33 (Attach Converter Housing to Case) (8 Req'd)

11 7A248 Seal Assembly (Converter Hub to Converter Housing) (Also in Converter Housing Assembly)



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Fluid Leakage in Torque Converter Area

In diagnosing and correcting fluid leaks in the torque converter (7902) area, use the following procedures to locate the exact cause of the leakage. Leakage at the front of the transmission, as evidenced by fluid around the converter housing, may have several sources. By careful observation it is possible to pinpoint the source

12 7902 Converter Assembly (Contains Piston Type Clutch)

13 7A194 Pan (4x4 Fluid)

14 7A191 Gasket Assembly (Fluid Pan)

15 7A194 Pan (4x2 Fluid)

16 14A624 Connector Assembly (16-Pin) (with Harness to 6 Solenoids)

17 W703015-S300

O-Ring (16-Pin Connector to Case)

18 7A160 Tube (Lube Fluid Inlet) Short (Also in Case Assembly)

19 W701203-S309M

Screw, M8x14 (Att. Fluid Pan to Case) (18 Req'd)

20 7D273 Connector Assembly — Fluid Tube (2 Req'd) (Also in Case)

21 7L493 Cover and Seal Assembly (O/D Servo)

22 E853170-S O-Ring (Servo Cover to Case) (Intermediate and O/D Servos) (2 Req'd)

23 E860343-S Ring, Retaining, 67x1.5 mm (Intermediate and O/D Servos in Case) (2 Req'd)

24 7L493 Cover and Seal Assembly (Intermediate Servo)

25 7052 Seal Assembly (Extension Housing to Slip Yoke) (Also in Extension Housing Assembly)

26 E804137-S72 Stud (Att. Extension Housing to Case)

27 7A039 Housing Assembly (4x4 Extension)

28 E800152-S72 Screw, M10x30 (Att. Extension to Case) (5 Req'd)

29 7A039 Housing Assembly (4x2 Extension)

30 7086 Gasket (Extension Housing)

31 7060 Shaft Assembly (4x2 Output)

32 7034 Vent Assembly (4x2) (Also Contained in Case Assembly)

33 E840171-S2 Pin (Reverse Band — Anchor) (2 Req'd) (Part of Case Assembly)

34 7034 Vent Assembly (4x4 Case) (Also Contained in Case Assembly)

35 E450102-S80 Plug — Pipe (Line and EPC Pressure) (Part of Case Assembly) (2 Req'd)

36 7B498 Seal Assembly (Main Control Lever) (Also in Case Assembly)

37 84280020 Spring (Retains 16-Pin Connector in Case)



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of the leak before removing the transmission from the vehicle. The paths which the fluid can take to reach the bottom of the converter housing are as follows: Torque Converter Area Leak Points

1. Fluid leaking by the torque converter impeller hub seal lip will tend to move along the converter impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip of the seal will be deposited on the inside of the converter housing only, near the outside diameter of the converter housing.

2. Fluid leakage by the outside diameter of the converter hub seal and the case will follow the same path which the leaks by the inside diameter of the seal follow.

3. Fluid leakage from the torque converter to the flywheel stud weld will appear at the outer diameter of the torque converter on the back face of the flywheel (6375), and in the converter housing only near theflywheel. If a converter-to-flywheel stud leak is suspected, remove torque converter and pressure check.

4. Fluid leakage from the pump will flow down the back of the converter housing. Leakage may be from loose or missing pump bolts, torn or damaged pump-to-case gasket and/or a worn pump bushing.

5. Engine oil leaks are sometimes improperly diagnosed as transmission pump seal leaks. The following areas of possible leakage should also be checked.

a. Leakage at the valve cover may allow engine oil to flow over the converter housing or seep down between the converter housing and block, causing oil to be present in or at the bottom of



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the converter housing. b. Oil plug leaks will allow oil to flow down the rear face of the block to the converter housing. c. Leakage at the crankshaft seal will work back to the flywheel, and then into the converter

housing.

Leak Check Test

The following procedures should be used to determine the cause of the leakage before service is made.

1. Remove the fluid level indicator (7A020) and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable amount of makeup fluid has been added or the fluid has been changed, the red color should assist in pinpointing the leak.

2. Remove the converter housing access cover. Clean off any fluid from the top and bottom of the converter housing, front of the transmission case, and rear face of the engine and pan. Clean the converter area by washing with suitable nonflammable solvent, and blow dry with compressed air.

3. Wash out converter housing and the front of the flywheel. The converter housing may be washed out using clean solvent and a squirt-type fluid can. Blow dry all washed areas with compressed air.

4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the block and top of the converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and position suitable safety stands under vehicle. Run the engine at fast idle, then at engine idle, occasionally shifting to the drive and reverse ranges to increase pressure within the transmission. Observe the front of the flywheel, back of the block (in as far as possible), and inside the converter housing and front of the transmission case. Run the engine until fluid leakage is evident and the probable source of leakage can be determined.

Leak Check Test With Black Light

Fluid soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to 0.24L (1/2 pint) of automatic transmission fluid have proven helpful in locating the source of fluid leakage. Such dyes may be used to determine whether an engine fluid or transmission fluid leak is present, or if the fluid in the transmission fluid cooler hose leaks into the engine coolant system. An ultraviolet light must be used to detect the fluorescent dye solution.



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Transmission Fluid Cooler

The following procedures will assist in diagnosing the transmission cooling system. Refer to Section 07-02 for specific transmission cooling system diagnosis and testing procedures.

Transmission Fluid Cooler Flow Test

NOTE: The transmission linkage/cable adjustment, fluid level, and line pressure must be within specification before performing this test.

1. Remove fluid level indicator (7A020) from fluid filler tube.

2. Place funnel in fluid filler tube.

3. Raise vehicle on hoist and position suitable safety stands under vehicle.

4. Remove cooler return line (rear fitting) from fitting on transmission case. Refer to removal and installation of the transmission fluid cooler line in Section 07-02 .

5. Connect one end of a hose to the cooler return line and route the other end of the hose to a point where it can be inserted into the funnel at the fluid filler tube.

6. Remove safety stands and lower vehicle. Insert end of hose into funnel.

7. Start engine and run at idle with transmission in neutral range.

8. When fluid flowing from hose is all liquid, an adequate amount of fluid should be observed (approximately 1 liter [1 quart] delivered in 30 seconds). If adequate flow is observed, test is completed.

9. If the flow is not adequate, stop engine. Disconnect hose from cooler return line and connect it to converter out line fitting (front fitting) on transmission case.

10. Repeat Steps 7 and 8. If flow is now adequate, refer to Section 07-02 for diagnosis of transmission fluid cooler (7A095). If flow is not adequate, service pump and/or converter assembly, and main control.

Transmission Fluid Cooler — Backflush/Cleaning

CAUTION: Whenever a transmission has been disassembled to replace worn or damaged parts or because the valve body sticks from foreign material, the transmission fluid cooler must be cleaned using the Rotunda Torque Converter/Fluid Cooler Cleaner 014-00028 or equivalent. Under no circumstances should torque converters be cleaned by hand agitation with solvent. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material, or band material may have been carried into the transmission cooler. These contaminants are a major cause of reoccurring transmission concerns and must be removed from the system before the transmission is put back into service.





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1. Conduct backflushing with a Rotunda Torque Converter/Transmission Fluid Cooler Cleaner 014-00028 or equivalent. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated.

2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described.

� Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line).

� Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir.

3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).

4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.

5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.

6. Remove the rubber return hose from the remaining steel cooler line.



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Transmission Fluid Cooler Tube Replacement

When fluid leakage is found at the transmission fluid cooler, the transmission fluid cooler must be replaced. Refer to Section 03-03 .

When transmission fluid cooler steel lines must be replaced, each replacement line must be fabricated from the same size inside diameter and length steel line as the original line.

Using the old line as a guide, bend the new line as required. Add the necessary fittings, and install the line.

After the fittings have been tightened, check and add fluid as necessary. Check for fluid leaks.



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Diagnosis by Symptom

The Diagnosis by Symptom Index gives the technician diagnostic information, direction and suggests possible components, using a symptom as a starting point.

The Diagnosis by Symptom Index is divided into two categories: Electrical Routines, indicated by 200 series numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

Diagnosis by Symptom Chart — Directions

1. Using the Diagnosis by Symptom Index, select the Symptom/Concern that best describes the condition.

2. Turn to the Routine indicated in the Diagnosis by Symptom Index.

3. Always begin diagnosis of a symptom by using the following:

a. Preliminary inspections b. Verification of condition c. Check the fluid level d. Perform other test procedures as directed

4. Then begin with the Electrical Routine, if indicated. Follow the reference or action required statements. Always perform the On-Board Diagnostic Tests as required. Never skip steps. Service as required. If the concern is still present after electrical diagnosis then proceed to the Hydraulic/Mechanical Routine listed.

CAUTION: Not all concerns and conditions with electrical components will set a Diagnostic Trouble Code (DTC). Be aware that the components listed may still be the cause. Verify proper function of those components prior to proceeding to the Hydraulic/Mechanical Routine listed.

5. The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could cause the concern. These components are listed in the removal sequence and by most likely concern. All components listed must be inspected to ensure proper repair.

Diagnosis by Symptom Index



Diagnosis By Symptom Index

4R44E

Routines

Electrical 1

Mechanical/ Hydraulic



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1 Perform electrical routine first.

Engagement Concerns:

� No Forward Only � No Reverse Only � Harsh Reverse Only � Harsh Forward Only � Delayed/Soft Reverse Only � Delayed/Soft Forward Only � No Forward and No Reverse � No Forward in (D) Position and No Reverse � Harsh Forward and Harsh Reverse � Delayed Forward and Delayed Reverse

201 202 203 204 205 206

207A 207B 208 209

301 302 303 304 305 306

307A 307B 308 309

Shift Concerns:

� Some/All Shifts Missing 210 310

� Timing Concern

Early/Late (Some/All) 211 311

Erratic/Hunting (Some/All) 212 312

� Feel Concerns

Soft/Slipping (Some/All) 213 313

Harsh (Some/All) 214 314

� No First Gear in Drive, Engages in a Higher Gear 215 315

� No First Gear in Manual 1st 216 316

� No Manual Second Gear 217 317

Torque Converter Clutch Operation Concerns:

� Does Not Apply � Always Applied/Stalls Vehicle � Cycling/Shudder/Chatter

240 241 242

340 341 342

Other Concerns:

� Shift Lever Efforts High � External Leaks � Poor Vehicle Performance � Poor Performance — Wrong Gear Ratio in (D) Manual 2 or

Manual 1 Position � Noise/Vibration — Forward or Reverse � Engine Will Not Crank � No Park Range � Overheating � No Engine Braking in Manual 2 � No Engine Braking in Manual 1 � No Engine Braking with (D) Canceled (2nd and 3rd Gears) � Fluid Venting or Foaming � Slips/Chatters in Manual 1st Gear � Slips/Chatters in Manual 2nd Gear � FMEM — Harsh Engagements and Shifts

251 252

253A 253B 254 255 256 257 258 259 260 261 263 264 265

351 352

353A 353B 354 355 356 357 358 359 360 361 363 364 365

Reference:

� Pressure Charts � Check Ball Locations � Band/Clutch Application Chart

— — —

401 501 601



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Diagnostic Routines

Engagement Concerns: No Forward Only

Possible Component Reference/Action

201 — ELECTRICAL ROUTINE

No Electrical Concerns

301 — HYDRAULIC/MECHANICAL ROUTINE

Fluid

� Improper level � Adjust to proper level.

Shift Linkage (Internal/External)

� Transmission shift cable and bracket damaged or misadjusted. TR sensor out of adjustment

� Inspect for damage. Readjust as required. Service all damaged components. After servicing linkage, readjust DTR sensor.

Improper Pressures

� Improper band/clutch application pressure, line pressure low

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low, check the following possible components: main control, filter/seal, pump assembly.

Filter and Seal Assembly

� Filter damaged, plugged; seal damaged, cut or missing

� Inspect for damage and replace.

Main Control Assembly

� Screw out of torque specification � Tighten to specification.

� Gaskets damaged, off location � Inspect and replace gasket.

� Separator plate damaged � Inspect for damage. Service as required.

� Forward modulator valve/EPC boost valve (207), forward engagement control valve (209), spring, damaged, missing, misassembled, stuck, bore damaged

� Inspect for damage. If damaged, replace main control. If parts are missing, replace missing parts or main control. If misassembled, reassemble properly. Do not stone, file or sand valves. This will remove the anodized finish and may result in further main control or transmission damage.

� Wrong component used in rebuild � Verify that proper components were used.

Pump Assembly

� Pump damaged, leaking � Inspect for damage. Service or replace as required.

� Screws out of torque specification � Tighten screws to specification.

Center Support Assembly

� Forward clutch support seal rings leaking

� Perform air pressure check. If OK, go to forward clutch assembly. Service as required.

Forward Clutch Assembly

� Forward clutch assembly burnt/damaged/leaking. Check ball in cylinder/leaking piston seal rings

� Perform air pressure check. Service as required.

Rear One-Way Clutch Assembly



[email protected]

� Rear one-way clutch damaged, worn � Replace rear one-way clutch and case.

Engagement Concerns: No Reverse Only





Fluid


Shift Linkages (Internal/External)

� Transmission shift cable and bracket damaged or misadjusted. DTR sensor out of adjustment

� Inspect for damage. Readjust as required. Service all damaged components. After servicing linkages, readjust DTR sensor.

Improper Pressures

� Improper band/clutch application pressures, line pressure low

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low, check the following possible components: reverse clutch.






� Gasket damaged, off location � Inspect and replace gasket.


� 1-2 shift valve (203), 2-3 shift valve (204), reverse modulator valve (205), spring damaged, missing, misassembled, stuck, bore damaged

� Inspect for damage. If damaged, replace main control. If parts are missing, replace missing parts or main control. If misassembled, reassemble properly. Do not stone, file or sand valves. This will result in further main control or transmission damage.


Pump Assembly

� Screws out of torque specification � Pump damaged, leaking

� Tighten screws to specifications. � Inspect for damage. Service as required.

Direct/Reverse Clutch/Reverse Band

� Reverse clutch assembly burnt/worn/leaking check ball in clutch piston/leaking piston seal rings, cover gasket damaged

� Perform air pressure test. � Inspect for damage. Service as required.

� Direct/reverse servo piston seal cut/leaking

� Check and replace piston seal. Check and replace low/reverse band.

Engagement Concerns: Harsh Reverse Only



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1 Can be purchased as a separate item.



Powertrain Control System

� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harness, PCM, TP, VSS, RPM, EPC, SS1 (off)

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, E. Service as required. Clear codes, road test and rerun on-board diagnostics.


Improper Pressures

� Improper band/clutch application pressures, line pressure high

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high, check the following possible components: main control.


� Screw out of torque specification

� Tighten to specification.



� EPC, SS1, solenoid stuck, damaged, O-ring damaged or out of bore

� Inspect for damage. Perform solenoid function test as listed in electrical routine. Service as required.

� Reverse modulator valves (205), pressure boost valve/main regulator valve (208), check ball B, springs, damaged, missing, misassembled, stuck, bore damaged


� Wrong components used in rebuild

� Verify that proper components were used.

Direct/Reverse Clutch Assembly

� Assembly � Seals damaged, missing � Center support hub/seal ring

damaged � Check ball damaged � Friction elements damaged or

missing

� Air check clutch assembly as outlined in this manual. � Inspect direct clutch assembly for damage. Service as

required.

Engagement Concerns: Harsh Forward Only






[email protected]


� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harness, PCM, TP, RPM, VSS, EPC

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: E. Service as required. Clear codes, road test and rerun on-board diagnostics.


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high check the following possible components: main control.






� EPC, solenoid stuck, damaged, O-ring damaged or out of bore


� Reverse modulator valves (205), forward modulator valve/EPC boost valve (207), forward engagement control valve (209), spring, damaged, missing, misassembled, stuck bore damage


� Wrong component used in rebuild



� Assembly � Air check clutch assembly as outlined in this manual.

� Plates burnt, missing; check ball missing, damaged; hub damaged

� Inspect for damage. Service as required.

Engagement Concerns: Delay/Soft Reverse








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Engine Driveline

� Looseness in the driveshaft, U-joints or engine mounts

� Service as required.

� Contamination blockage in cooler lines, in-tank radiator or auxiliary transmission oil cooler

� Perform transmission fluid cooler flow check.

Fluid


� Fluid contaminated � Inspect fluid for contamination. If contaminated, locate source of contamination. If burnt, inspect mechanical band, clutches. Service as required.




Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low, check the following possible components: main control.











� Reverse modulator valves (205), forward modulator valve/EPC boost valve (207), forward engagement control valve (209), spring damaged, missing, misassembled, stuck, bore damaged




Overdrive One-Way Clutch Assembly

� One-way clutch damaged � Determine cause of condition. Service as required.


� Direct/reverse clutch center support seal rings/ring grooves worn/damaged

� Determine cause of condition. Service as required.



[email protected]


Reverse Clutch Drum

� Rear reverse clutch drum bushing, one-way clutch damaged

� Air pressure test. Determine cause of condition. Visually inspect seal rings and pistons. Service as required.

Reverse Clutch Assembly

� Assembly � Perform air pressure check.

� Reverse clutch piston seals cut/worn


� Reverse servo piston damaged/worn


Reverse Band Assembly

� Reverse band out of adjustment or damaged

� Inspect and readjust per procedures.

� Reverse band servo piston and rod damaged


� Servo band cover gasket damaged

� Inspect gasket and replace.

Engagement Concerns: Delayed/Soft Forward







Fluid





Improper Pressures








[email protected]









� Forward modulator valve/EPC boost valve (207), forward engagement control valve (209), valve, spring, damaged, missing, misassembled, stuck, bore damaged


� Extension housing lube orifice plugged, missing





� Overdrive one-way clutch damaged

� Replace as required.


� Forward clutch piston check ball not seating/leaking

� Replace forward clutch piston. Service transmission as required.

� Forward hub seal rings damaged


� Forward clutch piston seals cut/worn

� Replace seal and service as required.

Rear One-Way Clutch

� Rear one-way clutch damaged/worn


Engagement Concerns: No Forward And No Reverse


207A — ELECTRICAL ROUTINE


307A — HYDRAULIC/MECHANICAL ROUTINE

Fluid


Improper Pressures

� Improper band/clutch application pressures, line pressure low, EPC

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible



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pressure low components: main control.







� Gasket damaged, off location

� Inspect and replace gasket.




� EPC blow-off valve, spring, damaged, missing, misassembled, stuck, bore damaged




Pump Assembly

� Screws out of torque specification

� Tighten screws to specification.

� Pump gears damaged, cracked

� Inspect for damage. If damaged, replace pump.




Engagement Concerns: No Forward In (D) Position And No Reverse


207B — ELECTRICAL ROUTINE




307B — HYDRAULIC/MECHANICAL ROUTINE

Fluid




[email protected]


Improper Pressures

� Improper band/clutch application pressures, line pressure low, EPC pressure low

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible components: main control, pump assembly.











� Forward modulator valve/EPC boost valve (207), pressure boost valve (208), EPC blow off valve, spring, damaged, missing, misassembled, stuck bore damaged




Pump Assembly



� Gears damaged, cracked � Inspect for damage. If damaged, replace pump.




Mechanical

� Mechanical damage � Check splines on turbine input shaft and overdrive carrier, overdrive one-way clutch, center shaft, forward clutch, forward carrier and output shaft.

Engagement Concerns: Harsh Forward And Reverse




� Electrical inputs/outputs, vehicle wiring harness, internal transmission wiring harness, PCM, EPC, TSS, TFT, VSS, DTR, TCC, TP

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130, Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit, Transmission Range (TR) Sensor Cable "E" (007-00111)



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and MAF and Digital TR Sensor Overlay (007-00131) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: B, C, D, E, F. Service as required, clear codes, road test and rerun on-board diagnostics.

NOTE: Refer to FMEM — Routine 265 for additional information.


Engine/Driveline

� Loose in the driveshaft, U-joints or engine mounts


� Engine idle speed too high � Check engine idle speed. Refer to the Powertrain Control/Emissions Diagnosis Manual a .

Fluid


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high, check the following possible components: main control.







� TCC, EPC, solenoid stuck, damaged, O-ring damaged or out of bore


� Forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator or valve (208), spring, damaged, missing, misassembled, stuck, bore damaged




Engagement Concerns: Delayed Soft Forward And Reverse





Fluid




[email protected]


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low, check the following possible components: main control, pump assembly.








� Forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), EPC blow-off valve, spring, damaged, missing, misassembled, stuck, bore damaged



Pump Assembly

� Screws out of torque specification � Tighten screws to specification.

� Inner gears damaged, cracked � Inspect for damage. Service as required.

Shift Concerns: Some Or All Shifts Missing




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harness, PCM, TP, RPM, DTR, VSS, SS1, SS2, SS3, TCS, TSS, EPC (no 4th or 2nd when EPC is low)

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit, Transmission Range (TR) Sensor Cable "E" (007-00111) and Digital TR Sensor Overlay (007-00131) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, D, E, F. Service as required. Clear codes, road test and rerun on-board diagnostics.


Fluid


� Fluid contaminated � Inspect fluid for contamination. If contaminated, locate



[email protected]


source of contamination. If burnt, inspect mechanical band, clutches. Service as required.




Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low, check the following possible components: main control, pump, EPC solenoid.









� SS1, SS2, SS3, EPC, solenoid stuck, damaged, O-ring damaged or out of bore


� Forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), extension housing lube orifice, check ball C damaged, spring, damaged, missing, misassembled, stuck, bore damaged




Overdrive Band

� Not adjusted properly � Readjust to proper specification.

� Piston seals damaged � Inspect for damage. Service as required.

Intermediate Band


� Servo, piston and seals damaged


For diagnosis related to a specific shift, refer to Reference/Action.

� To diagnose specific No Shift, refer to the appropriate shift routine.

No Shift 1-2, Routine 220/320 No Shift 2-3, Routine 221/321 No Shift 3-4, Routine 222/322



[email protected]


Shift Concerns: Timing — Early/Late (Some/All)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harness, PCM, TP, TFT, EPC, VSS, SS1, SS2, SS3, RPM

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, B, E. Service as required, clear codes, road test and rerun on-board diagnostics.

Other Electrical Concerns

� No power to PCM, Keep Alive Memory erased from PCM

� Inspect EEC power relay. Service as required. � Restore memory by performing drive cycle test.


Power/Engine Performance

� Poor vehicle performance � Refer to Routine No. 253A, 253B, 353A, 353B.

Other

� Tire size change � Axle ratio change � Speedometer gear change

� Refer to the specifications decal on door panel and verify that vehicle has original equipment. Changes in tire size or axle ratio will affect shift timing.

Improper Pressures

� Improper band/clutch application pressures, line pressure low (late shifts)












For diagnosis related to a specific shift or if all above are OK, refer to Reference/Action.

� To diagnose specific shift-timing concern, refer to the appropriate shift routine.

Soft/Slipping Shift 1-2, Routine 226/326 Soft/Slipping Shift 2-3, Routine 227/327 Soft/Slipping Shift 3-4, Routine 228/328 Soft/Slipping Shift 4-3, Routine 229/329



[email protected]


Shift Concerns: Timing — Erratic Hunting (Some/All)




� Electrical inputs/outputs, vehicle wiring harness, internal transmission wiring harness, PCM, TP, RPM, EPC, TFT, SS1, SS2, SS3, DTR, TCC, CCS

� Perform shift point and TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Adapter or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, B, C, D, E, G. Service as required. Clear codes, road test and rerun on-board diagnostics.


Fluid












� SS1, SS2, SS3, EPC, CCS, solenoid stuck, damaged, O-ring damaged or out of bore




Torque Converter Clutch Assembly

� Refer to converter cycling routine No. 342.

Further Diagnosis

� For further diagnosis for timing issues, refer to Reference/Action.

� For specific shift diagnosis, refer to the following application chart.



[email protected]

Shift Concerns: Feel — Soft/Slipping (Some/All)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harness, PCM, TP, RPM, EPC, TFT, MAF

� Engine — restricted air inlet

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: B, E. Service as required. Clear codes, road test and rerun on-board diagnostics.


Fluid



Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low check the following possible components: main control, filter/seal, pump assembly.




[email protected]











� Pressure boost valve/main regulator valve (208), EPC blow-off valve, extension housing lube orifice, check ball C missing, valve spring, damaged, missing, misassembled, stuck, bore damaged




Pump Assembly



Overdrive Band


� Piston seals damaged � Inspect for damage. Service as required.

Intermediate Band


� Servo, piston and seals damaged


For diagnosis related to a specific shift see Reference/Action.

� To diagnose a specific shift concern, refer to the appropriate shift routine.

Soft/Slipping Shift 1-2, Routine 226/326 Soft/Slipping Shift 2-3, Routine 227/327 Soft/Slipping Shift 3-4, Routine 228/328 Soft/Slipping Shift 4-3, Routine 229/329

Shift Concerns: Feel — Harsh (Some/All)




� Electrical inputs/outputs, vehicle wiring harness, internal transmission wiring harness, PCM, EPC, TFT, RPM, DTR, VSS, TP*, MAF*

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Adapter or equivalents to perform



[email protected]


transmission static and dynamic tests. Perform the following Pinpoint Tests: B, D, E. Service as required. Clear codes, road test and rerun on-board diagnostics.

* Also see Routine 265


Fluid


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high check the following possible components: main control.









� Forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), spring, damaged, missing, misassembled, stuck, bore damaged




Overdrive Band

� Misadjusted (tight) � Readjust to specification.

Intermediate Band

� Misadjusted (tight) � Readjust to specification.

For diagnosis related to a specific shift, refer to Reference/Action.

� For diagnosis of a specific harsh shift, refer to the appropriate shift routine.

Harsh Shift 1-2, Routine 232/332 Harsh Shift 2-3, Routine 233/333 Harsh Shift 3-4, Routine 234/334 Harsh Shift 4-3, Routine 235/335 Harsh Shift 3-2, Routine 236/336

Shift Concerns: No 1st Gear In Drive, Engages In High-Gear






[email protected]


� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS1, SS2, SS3, DTR, EPC

� Perform shift point and TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Adapter or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, D, E. Service as required. Clear codes, road test and rerun on-board diagnostics.




� Inspect for damage. Readjust as required. Service all damaged components. After servicing linkage, readjust DTR sensor.






� Separator plate damaged






Mechanical

� Clutches damaged � Refer to disassembly and assembly of transmission in this section.

For diagnosis related to a specific gear, use transmission tester to determine gear

� Refer to the following routines:

Shift 1-2, Routine 220/320 Shift 2-3, Routine 221/321 Shift 3-4, Routine 222/322

Shift Concerns: No Manual 1st Gear




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS1

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: A. Service as



[email protected]


required. Clear codes, road test and rerun on-board diagnostics.


Improper Pressures

� Improper band/clutch application (no engine braking), pressures, line pressure low

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low check the following possible components: main control.








� SS1, solenoid stuck, damaged, O-ring damaged or out of bore


� Check ball A damaged � Inspect for damage. Service as required.

Low/Reverse One-Way Clutch Assembly

� Rear one-way clutch damaged


Shift Concerns: No Manual 2nd Gear





Improper Pressures

� Improper band/clutch application pressures, line pressure high/low

� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low check the following possible components: main control.







� Check ball A damaged � Inspect for damage. Service as required.



Intermediate Band

� Intermediate band out of � Adjust intermediate band.



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adjustment

� Damaged or worn intermediate servo piston, lever, strut or internal leaks

� Perform air pressure test.

� Polished, glazed intermediate band or drum

� Replace or service as required.

Shift Concerns: No 1-2 Shift (Automatic)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TP, VSS, SS1, SS2, EPC

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, E. Service as required, clear codes, road test and rerun on-board diagnostics.


Shift Linkage (Internal/External)



Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is low check the following possible components: main control.







� SS1, SS2, EPC, solenoid stuck, damaged, O-ring damaged or out of bore


� 1-2 shift valve (203), forward modulator valve/EPC boost valve (207), spring, damaged, missing, misassembled, stuck, bore damaged






[email protected]


Intermediate Band Assembly

� Band adjustment incorrect � Inspect and readjust as required.

� Seals, piston, cover damaged


� Friction elements worn, missing, damaged, misassembled


� Return spring damaged � Inspect for damage. Service as required.

� Case bore damaged, leaking






� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TP, VSS, SS1, SS2

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: A. Service as required, clear codes, road test and rerun on-board diagnostics.








� SS1, SS2, solenoid stuck, damaged, O-ring damaged or out of bore


� 1-2 shift valve (203), 2-3 shift valve (204), spring, damaged, missing, misassembled, stuck, bore damaged

� Inspect for damage, If damaged, replace main control. If parts are missing, replace missing parts or main control. If misassembled, reassemble properly. Do not stone, file or sand valves. This will remove the anodized finish and may result in further main control or transmission damage.




� Screws not tightened to specification

� Inspect, install new and retighten to specification.

� Seal rings damaged � Inspect for damage. Service as required.

� Outside diameter of casebore or center




[email protected]


support damaged or leaking

Direct Clutch Assembly

� Assembly � Air check assembly as outlined in this manual.

� Seals, piston, cylinder damaged


� Friction elements mission or damaged


� Check ball missing, damaged






� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TP, VSS, SS3, CCS, EPC, TCS

� Perform shift point test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, E, G. Service as required, clear codes, road test and rerun on-board diagnostics.


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible components: main control.






� SS3, CCS, EPC, solenoid stuck, damaged, O-ring damaged or out of bore


� Forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), SS3 solenoid/3-4 shift valve (215), spring, damaged, missing, misassembled, stuck, bore damaged


� Wrong components used in � Verify that proper components were used.



[email protected]


rebuild

Overdrive Band Assembly


� Band friction plates burnt, missing


� Cylinder damaged, leaking seals damaged


� Piston cover seal, strut, lever damaged


Overdrive Planetary Assembly

� Damaged � Inspect for damage. Service as required.

Shift Concerns: Soft/Slipping 1-2 Only (Automatic)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TP, MAF, EPC

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: E. Service as required, clear codes, road test and rerun on-board diagnostics.








� EPC solenoid/1-2 shift valve (203), 2-3 shift valve (204), forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), EPC blow-off valve, extension housing lube orifice, spring, damaged, missing, misassembled, stuck, bore damaged




� Band adjustment incorrect � Inspect and adjust as required.

� Seals or piston, strut, lever, damaged




[email protected]


� Friction elements worn, damaged, misassembled


� Return spring wrong, damaged � Inspect for damage. Service as required.

� Case bore damaged, leaking � Inspect for damage. Service as required.





� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, EPC, TP, SS1

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, E. Service as required. Clear codes, road test and rerun on-board diagnostics.






� EPC, SS1, solenoid stuck, damaged, O-ring damaged or out of bore


� 2-3 shift valve (204), forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), extension housing tube orifice, EPC blow-off valve, spring, damaged, missing, misassembled, stuck, bore damaged




� Screw not tightened to specification

� Inspect, retighten to specification.

� Seal rings, groove damaged � Inspect for damage. Service as required.

� Outside diameter or case bore, center support, damaged or leaking



� Assembly � Air check clutch assembly as outlined in this section.

� Seals, piston, cylinder damaged � Inspect for damage. Service as required.

� Friction elements burnt, missing � Inspect for damage. Service as required.



[email protected]


� Improper quantity of plates installed

� Inspect for proper quantity. Service as required.

� Check ball missing, not seating � Inspect for damage. Service as required.

� Brake drum, intermediate band, damaged, misadjusted or incorrect

� Inspect for damage, readjust. Service as required.

Intermediate Servo

� Piston, strut, lever, cover, damaged


� Seal leaking � Inspect for damage. Service as required.

� Piston rod lever incorrect, damaged

� Inspect for correct rod, damaged. Service as required.

� Case bore damaged � Inspect bore. Service as required.

� Spring damaged � Inspect for damage. Service as required.





� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TP, EPC

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: E. Service as required, clear codes, road test and rerun on-board diagnostics.








� Forward modulator valve/EPC boost valve (207) pressure boost valve/main regulator valve (208), 3-4 shift valve (215), extension housing lube orifice, EPC blow-off valve, spring, damaged, missing, misassembled, stuck, bore damaged




� Assembly band adjustment incorrect

� Inspect and readjust as required.



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� Friction elements burnt � Inspect for damage. Service as required.

� Cylinder damaged � Inspect for damage. Service as required.

� Piston rod, lever, strut, missing or damaged


� Cover, piston seals leaking � Inspect for damage. Service as required.

� Case bore damage, leaks � Leak test.

Shift Concerns: Soft/Slipping 4-3 Downshifts



No Electrical Components


Overdrive One-Way Clutch


� Sprags missing, damaged, or worn � Inspect for damage. Service as required.

Shift Concerns: Harsh 1-2 Only (Automatic)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM

� Run on-board diagnostics. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual 1 for diagnosis and testing of the automatic transmission. Service as required. Clear codes, road test and rerun on-board diagnostics.








� 1-2 shift valve (203), spring, damaged, missing misassembled, stuck, bore damaged






� Seal or piston damaged � Inspect for damage. Service as required.



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� Friction element, lever rod, damaged or misassembled return spring


Direct Clutch

� Drum damaged, outer diameter out of specification


Shift Concerns: Harsh 2-3 Shift Only (Automatic)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, EPC, TCC, TP

� Perform TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: C, E. Service as required. Clear codes, road test and rerun on-board diagnostics.


Improper Pressures

� Improper band/clutch application pressures, line pressure low, EPC pressure low






� EPC, TCC, solenoid stuck, damaged, O-ring damaged or out of bore


� Torque converter clutch (200), forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), thermostat bypass valve/cooler limit valve (216), spring, damaged, missing, misassembled, stuck, bore damaged





� Outside diameter or case bore damaged or leaking





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� Assembly � Air check assembly as outlined in this section.

� Seals, piston or cylinder damaged � Inspect for damage. Service as required.

� Friction elements damaged, missing or improper quantity of plates were installed


� Check ball missing, not seating � Inspect for damage. Service as required.

� Intermediate brake band damaged or worn

� Inspect for damage, readjust. Service as required.

Intermediate Servo Assembly

� Piston, spring, lever, strut wrong, damaged



� Refer to routines 241/341.





� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, EPC, TCC, TP

� Perform TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: C, E. Service as required. Clear codes, road test and rerun on-board diagnostics.


Improper Pressures







� TCC, EPC, SS3, O-ring, solenoid struck, damaged, O-ring damaged or out of bore


� Torque converter clutch (200), forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), thermostat bypass valve/cooler limit valve (216), spring, damaged,




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missing, misassembled, stuck, bore damaged



� Band adjustment incorrect � Air check servo band assembly as outlined in this section.

� Friction elements burnt, missing � Inspect for damage. Service as required.

� Cylinder damaged, seals damaged � Inspect for damage. Service as required.

� Lever, strut, piston, rod wrong







� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TCC

� Perform TCC Tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Test: C. Service as required. Clear codes, road test and rerun on-board diagnostics.








� TCC, solenoid stuck, damaged, O-ring damaged or out of bore


� TCC valve (200), thermostat bypass valve/cooler limit valve (216), spring, damaged, missing misassembled, stuck, bore damage




Torque Converter Assembly




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� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS3, TCC, EPC

� Perform shift point and TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, C, E. Service as required. Clear codes, road test and rerun on-board diagnostics.






� TCC, EPC, SS3, solenoid stuck, damaged, O-ring damaged or out of bore


� Torque converter clutch (200), forward modulator valve/EPC boost valve (207), pressure boost valve/main regulator valve (208), manual low valve (212), 3-2 torque demand valve (213), thermostat bypass valve/cooler limit valve (216), spring, damaged, missing, misassembled, stuck, bore damaged


Direct Clutch Drum


Intermediate Band

� Misadjusted � Readjust band to proper specification.

Intermediate Servo Assembly

� Piston, servo, spring, damage, wrong part used in rebuild




Torque Converter Clutch Operation Concerns: No Clutch Apply






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� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, ECT, TSS, TCC

� Perform TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit) and Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: C, F. Service as required. Clear codes, road test and rerun on-board diagnostics.

NOTE: Also refer to Routine No. 265.








� Converter clutch control valve (201), thermostat bypass valve/cooler limit valve (216), spring, damaged, missing, misassembled, stuck, bore damaged


� TCC solenoid and valve (200), stuck, damaged, O-ring damaged or out of bore




Pump Assembly

� Front pump seal worn or damaged



� Retorque screws to specification.


� Torque converter internal malfunction preventing lockup, piston application

� Remove transmission. Inspect for damage. Replace torque converter if required.

Torque Converter Clutch Operation Concerns: Clutch Always Applies/Stalls Vehicle




� Low engine idle � Verify engine idle speed is within specification.

� Electrical inputs/outputs, vehicle wiring harnesses,

� Perform TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 Use Rotunda Transmission



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internal transmission wiring harnesses, PCM, TCC

Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Adapter or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Test C . Service as required. Clear codes, road test and rerun on-board diagnostics.











� TCC solenoid and valve (200), TCC control valve (201), spring, damaged, missing, misassembled, stuck, bore damaged

� Inspect for damage. If damaged, replace main control, If parts are missing, replace missing parts or main control. If misassembled, reassemble properly. Do not stone, file or sand valves. This will remove the anodized finish and result in further main control or transmission damage.




� Torque converter internal malfunction preventing lockup piston application

� Remove transmission. Inspect for damage. Replace torque converter if required.

Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TCC, DTR, BOO, TP, RPM

� Perform TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Cable "E" (007-00111) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: C, D. Service as required. Clear codes, road test and rerun on-board diagnostics.

� Speed control equipped vehicles

� Evaluate with speed control off.


Fluid



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� TCC solenoid and valve (200), converter clutch control valve (201), thermostat bypass valve/cooler limit valve (216), spring, damaged, missing, misassembled, stuck, bore damaged


Pump Assembly



� Cross leaks � Inspect for damage. Service as required.

� Front pump seal damage � Inspect for damage. Service as required.

� Seal on inner pump gear damaged



� End clearance (excessive), internal leakage, clutch material damage

� Perform end play check. Inspect and service as required.

Other Concerns: Shift Level Efforts High





Brake Shift Interlock

� System, solenoid damaged � Refer to brake section or steering column section in the service manual.




Case



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� Manual control outer lever damaged. Manual valve inner lever pin bent, damaged. Manual valve inner lever, spring rod damaged

� Manual valve lever shaft retaining pin damaged

� Adjust linkage and install manual valve lever shaft retaining pin.

Other Concerns: External Leaks





Case

� Case vent � Check the vent for free breathing. Service as required.

Seals/Gaskets

� Leakage at gaskets, seals, etc. Refer to leakage diagram for potential leak locations

� Remove all traces of lubricant on exposed surfaces of transmission. Check the vent for free breathing. Operate transmission at normal temperatures and perform fluid leakage check. Service as required.

Other Concerns: Poor Vehicle Performance


253A — ELECTRICAL ROUTINE


� Poor engine performance

� Check engine tune-up. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual 1 for diagnosis and testing of the automatic transmission.

� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS3, TCC

� Perform shift point tests on O/D with the TCS off. Refer to shift point specification if out of specifications. Run on-board diagnostic and check for shift error codes. Perform shift point and TCC tests. Re-run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Cable "E" (007-00111) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, C. Service as required. Clear codes, road test and rerun on-board diagnostics.

353A — HYDRAULIC/MECHANICAL ROUTINE








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� SS3, TCC solenoid stuck, damaged, O-ring damaged or out of bore


� SS3 and 3-4 shift valve (215), spring, damaged, missing, misassembled, stuck, bore damaged



� Verify that proper components were used


� Torque converter one-way clutch slipping

� Inspect one-way clutch. Replace torque converter.

� Incorrect TCC used in rebuild

� Inspect for correct TCC assembly. Replace as required.

Other Concerns: Poor Vehicle Performance/Wrong Gear Ratio In D, M2, M1


253B — ELECTRICAL ROUTINE


� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS3 (on)

� Perform shift point and TCC tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Cable "E" (007-00111) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Test: A. Service as required. Clear codes, road test and rerun on-board diagnostics.

353B — HYDRAULIC/MECHANICAL ROUTINE








� SS3, solenoid stuck, damaged, O-ring damaged or out of bore


� SS3 solenoid and valve (215), spring, damaged, missing,

� Inspect for damage. If damaged, replace main control. If parts are missing, replace missing parts or main control. If misassembled, reassemble properly. Do not stone, file or sand valves. This will



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misassembled, stuck, bore damaged

remove the anodized finish and result in further main control or transmission damage.



Other Concerns: Noise/Vibration — Forward Or Reverse





Fluid





Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible components: pump assembly.

Pump Assembly

� Internal leakage, cavitation � Inspect and service as required.




� One-way clutch damaged, worn, misassembled

� Service one-way clutch.


� One-way clutch damaged, worn, misassembled

� Service one-way clutch.

Other

� Transmission oil cooler lines, fill tube grounding

� Relocate transmission oil cooler lines or fill tube properly.

Gear

� Gear noise � Service planetary gear assemblies.



Other Concerns: Engine Will Not Crank



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� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, DTR sensor

� Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 for diagnosis. Use Rotunda Transmission Tester 007-00130 and Transmission Range (TR) Sensor Cable "E" 007-00111 or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Test: D. Service as required. Clear codes, road test and rerun on-board diagnostics.





Pump Assembly

� Seized � Refer to disassembly of transmission. Inspect for damage. Service or replace as required.

Flywheel


Other Concerns: No Park Range








Park Mechanism

� Park gear, parking pawl, parking pawl return spring, park or guide plate, parking pawl shaft, parking pawl actuating rod, manual lever, manual lever detent spring damaged, misassembled


� Transfer case and linkages damaged � Refer to service manual for transfer case and linkage diagnosis.

4x4 Applications

� Transfer case and linkage damaged � Refer to service manual for transfer case and linkage diagnosis.



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Other Concerns: Transmission Overheating




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TFT, TCC

� Perform shift point and TCC test. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Cable "E" (007-00111) or equivalents to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: B, C. Service as required. Clear codes, road test and rerun on-board diagnostics.


Fluid


Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible components: main control, TCC.










� Thermostat bypass valve/cooler limit valve (216), spring, damaged, missing misassembled, stuck, bore damaged





� Seized torque converter one-way clutch

� Refer to routines 240/340. � Inspect torque converter one-way clutch.

� Excessive slip detected � Replace torque converter as required. � Run on-board diagnostics.

Other

� Restriction in transmission oil cooler or tubes

� Service transmission oil cooler or tubes.



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Other Concerns: No Engine Braking In Manual 2 Position





Improper Pressures


� Check line pressure at tap. Perform line pressure and stall speed tests. Refer to pressure chart No. 401 for specifications. If pressure is high/low, check the following possible components: main control, coast clutch assembly.





� Extension housing lube orifice, check ball A and C not seating or damaged, spring, damaged, missing misassembled, stuck, bore damaged


� Wrong part used in rebuild � Service as required.

Coast Clutch Assembly

� Coast clutch damaged � Replace as required.

� Seal ring damaged � Inspect for damage. Service as required.

Intermediate Band

� Intermediate band out of adjustment

� Adjust intermediate band.

� Intermediate servo leaking � Perform air pressure test to determine if intermediate servo is leaking. Service as required.

� Glazed intermediate band � Service or replace as required.

Other Concerns: No Engine Braking In Manual 1 Position





Fluid



� Transmission shift cable and � Inspect for damage. Readjust as required. Service all



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bracket damaged or misadjusted. DTR sensor out of adjustment

damaged components. After servicing linkages, readjust DTR sensor.

Improper Pressures








� Manual low valve (212), check ball E not seating properly, spring, damaged, missing, misassembled, stuck, bore damaged


� Wrong part used in rebuild � Inspect for correct part. Service as required.


� Wrong part used in rebuild � Inspect parts. Service as required.

� Overdrive clutch damaged � Seal rings damaged


Reverse Clutch/Band

� Reverse servo or piston or gasket seal leaking

� Perform air pressure test. Check and replace piston seal as required.

� Reverse band burnt, worn or damaged


� Polished or glazed low reverse clutch band or drum

� Service or replace as required.


� Rear one-way clutch damaged � Replace as required.

Other Concerns: No Engine Braking With Overdrive Cancelled(In 2nd And 3rd)




� Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, SS3 (also no 3rd gear), CCS

� Perform shift point tests. Run on-board diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester to perform transmission static and dynamic tests. Perform the following Pinpoint Tests: A, G. Service as required. Clear codes, road test and rerun on-board diagnostics. Also check for engine braking in manual 1 and manual 2.

NOTE: No engine braking in O/D position with the TCS off, 1st



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gear is a normal function.






� SS3, CCS, solenoid stuck, damaged, O-ring damaged or out of bore


� Coast clutch solenoid and valve/converter clutch control valve (201), SS3 solenoid/3-4 shift solenoid (215), spring, damaged, missing misassembled, stuck, bore damaged





� Wrong part used in rebuild � Verify that proper components were used.

� Overdrive clutch damaged � Replace as required.


Other Concerns: Fluid Venting/Foaming





� Vent blocked or damaged � Check vent for damage or blockage. Service as required.

� Overfilled transmission � Check level and adjust as required.

� Fluid contaminated (antifreeze, water) � Check for contamination, locate source of contamination. Service as required.

� Overheating � Refer to routines 257/357.

� Filter and seal assembly damaged or misassembled

� Inspect filter and seal assembly for damage. Service as required.

Other Concerns: Slips/Chatters In Manual 1 Position







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Improper Pressures











� Dirty or sticking main control valve body

� Clean, service or replace main control valve body.


� Low/reverse one-way clutch damaged

� Replace rear one-way clutch and case.

Other Concerns: Slips/Chatters In Manual 2 Position





Improper Pressures











� Dirty or sticking main control valve body

� Clean, service or replace main control valve body.

Intermediate Band

� Intermediate band out of adjustment

� Adjust intermediate band.

� Damaged or worn intermediate servo piston,

� Perform air pressure test. Inspect for damage. Service as required.



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Main Control Body Check Ball Location No. 501

lever, strut, or internal leaks

� Polished, glazed low and intermediate band or drum

� Replace or service as required.

Other Concerns: FMEM — Harsh Engagements And Shifts




� Operating in FMEM strategy. Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, EPC, VSS, DTR, TCC, transmission overtemp (TFT), TP and MAF, shift error detected (shift solenoid, TSS, VSS and internal hardware)

� Run on-board diagnostics. Service as required. Clear codes, road test and rerun self test. Refer to Powertrain Control/Emissions Diagnosis Manual 1 . Use Rotunda Transmission Tester 007-00130 (part of Rotunda Transmission Tester Kit), Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in the Transmission Tester Kit and Transmission Range (TR) Sensor Cable "E" (007-00111) or equivalent, perform Transmission Static and Dynamic Test. Perform the following Pinpoint Test B , C, D, E, F. Service as required, clear codes, road test and rerun on-board diagnostics.


No Hydraulic/Mechanical Concerns

Pressure Chart No. 401

Trans. Transmission Model/Application Range

Idle WOT Stall

EPC Line EPC Line

4R44E 2.3L Ranger R 37-47 115-145 112-134 282-350

4x2 N 21-31 77-107

(D), 2, 1 20-30 77-107 112-134 228-263

4R44E 3.0L Ranger R 46-56 143-173 112-134 282-350

4x2, 4x4 N 31-41 94-124

(D), 2, 1 20-30 71-101 112-134 228-263

4R44E 3.0L Aerostar R 47-57 153-183 112-134 282-350

4x2 N 20-30 73-103

(D), 2, 1 40-50 105-135 112-134 228-263



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Band/Clutch Application Chart No. 601 (4R44E)



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IN-VEHICLE SERVICE

Transmission Fluid Drain and Refill

Intervals for drain and refill, due to in-vehicle service or major service operation, are as follows:

� Normal Maintenance � Not required with normal use.

� Severe Duty Maintenance � Change fluid at 80,450 km (50,000 mile) intervals using MERCON 5® XT-5-QM or equivalent.

CAUTION: Use only MERCON V® XT-5-QM Service Fluid as the use of any other fluids may result in a transmission malfunction or failure.

Maintenance Procedure

1. Loosen, then remove the transmission fluid pan-to-case screws to drain the fluid.


3. Thoroughly clean the fluid pan and the transmission case fluid pan rail surface.

4. Install new pan gasket onto pan and install fluid pan to case with screws. Tighten screws to 13-15 Nm (115-133 lb-in).

5. Add 2.8 liters (3 quarts) of MERCON V® XT-5-QM or equivalent MERCON® approved fluid into fluid filler tube.

6. Start engine. Move transmission range selector lever through all gear ranges, checking for engagements.

7. Check and adjust transmission fluid in 0.25 liter (1/2 pint) increments to proper level (cross-hatched area of fluid level indicator at normal operating temperatures).

Major Service/Overhaul

1. Loosen, then remove the transmission fluid pan screws to drain fluid.


3. Perform required internal repair and cleaning as required.

4. Thoroughly flush torque converter, cooler lines and transmission in-tank radiator cooler and auxiliary cooler (if equipped).

5. Replace with new fluid filter and O-rings assembly.





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6. Install cleaned fluid pan and new pan gasket with fluid pan-to-case screws. Tighten fluid pan-to-case screws to 13-15 Nm (115-133 lb-in).

7. Add 3.7 liters (4 quarts) of MERCON V® XT-5-QM or equivalent MERCON® approved fluid into fluid filler tube.

8. Start engine. Move the transmission range selector lever through all gear ranges, checking for engagements.

9. Check and adjust the transmission fluid level in 0.25 liter (1/2 pint) increments to the proper level (cross-hatched area of the fluid level indicator at normal operating temperatures).



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IN-VEHICLE SERVICE

Extension Housing Seal and Bushing

Removal

1. Raise vehicle on a hoist and position suitable safety stands under vehicle.

2. Remove rear driveshaft. Refer to Section 05-01 .

3. Remove output shaft and extension housing seal using Seal Remover T94P-77001-BH and Impact Slide Hammer T50T-100-A.



SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Impact Slide Hammer T50T-100-A

Extension Housing Bushing Remover T77L-7697-E

Extension Housing Bushing Replacer T77L-7697-F

Extension Housing Seal Replacer T74P-77052-A

SPECIAL SERVICE TOOLS DESIRED

Tool Number Description

Seal Remover T94P-77001-BH



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4. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not damaged.

Remove the bushing using Extension Housing Bushing Remover T77L-7697-E.



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Installation

1. Inspect the counterbore of the extension housing for burrs. If necessary, remove burrs with an oil stone.

2. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing, located 90° (3 o'clock position) from top when viewed from rear.

CAUTION: Tool will bottom when bushing is in the proper position.

NOTE: Install the extension housing bushing if it was removed.

Install the extension housing bushing using Extension Housing Bushing Replacer T77L-7697-F.



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3. Position new output shaft and extension housing seal with drain hole positioned facing downward (6

o'clock position).

4. Seat seal using Extension Housing Seal Replacer T74P-77052-A.



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5. Inspect driveshaft slip-yoke. Replace if damaged or worn.

6. Install driveshaft. Refer to Section 05-01 .

7. Remove safety stands and lower vehicle.

8. Fill the transmission to the proper level. Refer to Specifications at the end of this section.



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IN-VEHICLE SERVICE

Extension Housing Gasket

Removal

1. Raise vehicle on hoist and position suitable safety stands under vehicle.

2. Remove front (4x4 only) and rear driveshaft. Refer to Section 05-01 .

3. Remove transfer case assembly (4x4 only). Refer to Section 07-07A or Section 07-07B .

4. Remove transmission mounting pad nuts and bolts. Refer to the transmission removal procedures in this section.

5. Carefully remove wire harness locators from extension housing wire bracket.

6. Position jack under transmission and raise transmission.

7. Remove five extension housing screws, one stud and wiring bracket using a 17 mm socket.





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8. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

Carefully remove extension housing.



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9. Remove and discard extension housing gasket (7086) from extension housing and mating surfaces.

Installation

1. Clean extension housing and transmission mating surfaces. Place a light film of petroleum jelly on the extension housing gasket and position gasket on the transmission case.

2. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.

Install the parking pawl, pawl return spring and pawl shaft into the extension housing.



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3. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup.

Install the extension housing. Install the five M10 x 30 mm extension housing screws and one stud. Tighten the extension housing-to-case stud and screws to 36-52 Nm (27-39 lb-ft).



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4. On 4x4 models only, install transfer case. Refer to Section 07-07A or Section 07-07B .

5. On 4x4 models only, attach transfer case vent hose to attaching plate. Refer to Section 07-07A or Section 07-07B .

6. Install four-wheel drive connector, if equipped.

7. Install new wire harness locator into extension housing wire bracket.

8. Install transmission mounting pad nuts and bolts and tighten to 68-95 Nm (50-70 lb-ft).

9. On Ranger vehicles, install the two crossmember-to-frame through bolts and nuts and tighten to 88-115 Nm (65-85 lb-ft).

10. On Aerostar vehicles, install the two crossmember-to-frame through bolts and nuts and tighten to 37-52 Nm (28-38 lb-ft).

11. Remove universal high lift transmission jack.

12. Install front (4x4 only) and rear driveshaft. Refer to Section 05-01 .

13. Fill the transmission to the proper level. Refer to Preliminary Testing procedure in this section.



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IN-VEHICLE SERVICE

Digital Transmission Range (DTR) Sensor

Removal

1. Use a screwdriver to remove the shift cable and fitting from the transmission lever ball stud.

2. Disconnect vehicle harness connector from digital transmission range (DTR) sensor by depressing tab.

3. Remove the manual control outer lever nut and manual control outer lever.





Digital TR Sensor Alignment Tool T97L-70010-A



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4. Remove the two M6 x 25 TR sensor screws and remove the DTR sensor.

Installation

1. Install the DTR sensor on the manual lever. Install the two TR sensor screws and finger tighten. Rotate the manual lever to the neutral position (two detents rearward).



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2. Install Digital TR Sensor Alignment Tool T97L-70010-A into the three slots on the DTR sensor. Tighten the TR sensor-to-case screws to 8-11 Nm (71-97 lb-in). Remove the alignment tool.



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3. Install the manual control outer lever and manual control outer lever nut. Tighten the manual control outer lever nut to 41-54 Nm (30-40 lb-ft).



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4. Install shift cable or linkage from manual control lever (7A256). Use a screwdriver to remove the cable and fitting from the transmission lever ball stud.

5. Adjust shift cable. Refer to adjustments in Section 07-05 .

6. Reconnect vehicle harness connector to DTR sensor.



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IN-VEHICLE SERVICE

Digital Transmission Range (DTR) Sensor Adjustment

1. Use a screwdriver to remove the shift cable and fitting from the transmission lever ball stud.

2. Disconnect vehicle harness connector from digital transmission range (DTR) sensor by depressing tab.


4. Loosen the two M6 x 25 TR sensor screws.






Digital TR Sensor Alignment Tool T97L-70010-A



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7. Install shift cable or linkage from manual control lever (7A256). Use a screwdriver to remove the cable and fitting from the transmission lever ball stud.

8. Adjust shift cable. Refer to adjustments in Section 07-05 .

9. Reconnect vehicle harness connector to DTR sensor.



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IN-VEHICLE SERVICE

Fluid Pan, Gasket and Filter

Removal

1. Using a 13 mm socket, remove all M8 x 16 mm fluid pan screws, except for two in the front. Loosen two front screws only.

2. Pry the rear of the pan down and allow fluid to drain.

3. Support fluid pan and remove two remaining screws.

4. Remove fluid pan and discard old gasket.

5. Use a 10 mm socket to remove the M6 x 55 mm fluid filter assembly screw. Remove the fluid filter assembly and discard.





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Installation

1. Clean all mating surfaces, making sure they are free from debris and oil.

2. Install new fluid pan gasket on fluid pan and align holes.

3. Lube and install new O-rings onto filter assembly.

4. Install new filter onto main control assembly.

5. Make sure that both O-rings are properly installed on filter prior to installation.



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6. CAUTION: Make sure wire harness is not pinched under filter.

Install one M6 x 55 mm fluid filter assembly-to-main control assembly screw using a 10 mm socket as shown. Tighten to 8-11 Nm (71-97 lb-in).



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7. Install fluid pan and gasket onto transmission and install eighteen M8 x 16 mm fluid pan-to-case screws. Tighten to 13-15 Nm (115-133 lb-in) using a crisscross sequence.



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8. Fill the transmission to the proper level. Refer to the procedure in this section.



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IN-VEHICLE SERVICE

Solenoid Service

Removal

NOTE: Main control assembly does not need to be removed for solenoid service.

1. Remove fluid pan gasket and filter as described in this section.

2. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid brackets.

3. Disconnect the appropriate solenoid connector(s) from the solenoid(s) by carefully pulling downward and wiggling side to side.





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4. CAUTION: SS3 may pop out of its bore. This may damage the solenoid.

NOTE: Steps 4, 5 and 6 refer to SS1 and SS3 solenoids only.

Use a 10 mm socket to remove the SS1 and SS3 solenoid clamp screws. Remove the solenoid clamp.



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5. Remove SS1 and SS3 and service as required.

6. CAUTION: The TCC solenoid may pop out of its bore. The converter modulator valve may come out after the TCC solenoid has been removed. This may damage the solenoid or converter modulator valve.

NOTE: Steps 6-8 refer to TCC, CCS, SS2 and EPC solenoids only.

Remove the TCC, CCS, SS2 and EPC solenoid clamp screws.



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7. Remove the solenoid clamp.



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8. Remove solenoids and service as required.

Installation

1. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug.

Install the TCC, CCS, SS2, EPC solenoids, solenoid bracket and screws. Tighten to 6-8 Nm (53-71 lb-in).

2. Install the SS1 and SS3 solenoids, solenoid bracket and screws. Tighten to 6-8 Nm (53-71 lb-in).



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3. Carefully press down to install the solenoid connectors on the solenoids as shown.



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4. CAUTION: Excessive pressure may break the locating pins.

Install the wiring loom protector and guide. Align the pins in the holes of the solenoid clamps and gently push down.



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5. Install new fluid pan gasket and filter as described in this section.




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IN-VEHICLE SERVICE

Internal Harness Service

16-Pin Connectors

Removal

NOTE: The main control assembly does not need to be removed.

1. Remove fluid, pan, gasket and filter as described in this section. Discard gasket.

2. Disconnect the solenoid connectors from the solenoids by carefully pulling downward and wiggling side to side.

3. CAUTION: The TCC solenoid may pop out of its bore. The converter modulator valve may come out after the TCC solenoid clamp has been removed. This may damage the solenoid or converter modulator valve.





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Remove the TCC, CCS, SS2 and EPC solenoid clamp screws.

4. Remove the solenoid clamp and EPC and SS2 solenoids.



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5. CAUTION: Do not pry on other wires or damage the connector case surface.

Carefully disconnect the turbine shaft speed (TSS) sensor connector from the 16-pin case connector.



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6. CAUTION: Do not overstretch the case connector retaining spring.

Use a screwdriver to carefully remove the case connector retaining spring.



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7. CAUTION: Do not damage the connector or harness.

Carefully push down on the top of the connector until it stops. Depress the tab on the back side of the connector and push down on the connector.

8. Remove the connector and harness through the bottom of the case.



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Installation

1. Replace O-rings (W703015-S300) on connector.

2. NOTE: Make sure the tab is in the lock position.

Install the case 16-pin connector through the case until a click is heard.



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3. NOTE: Align the slot on the TSS connector with the slot on the 16-pin case connector.

Carefully install the TSS connector into the 16-pin case connector.

4. CAUTION: Do not overstretch the retaining spring.

Install the case connector retaining spring.



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5. Install SS2 and EPC solenoids.



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6. CAUTION: The solenoid bracket must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug.

Install the solenoid clamp with solenoid clamps-to-main control screws. Tighten to 6-8 Nm (53-71 lb-in).



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7. Install connectors on solenoids.

8. Install filter.

9. Install new fluid pan gasket onto pan.

10. Install pan.




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IN-VEHICLE SERVICE

Rear Servo Assembly

Removal

1. Remove fluid pan and filter as described in this section.

2. Use a 10 mm socket to remove the four M6 x 20 mm reverse servo cover screws. Remove the reverse servo cover, gasket and the reverse servo piston and rod assembly.





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3. Clean and inspect servo bore, piston and rod assembly. Service as required.

Installation

1. Install the reverse servo and rod assembly into the case.

2. Install the reverse servo cover, new gasket and the four reverse servo cover-to-case screws. Tighten cover-to-case screws in sequence as shown to 12-14 Nm (106-124 lb-in).

Item Part

Number Description

1 7D189 Piston Assembly with Rod and Retainer (Rear Band Servo)

2 7L173 Reverse Servo Cover-to-Case Gasket

3 7D036 Reverse Servo Cover

4 E800156-S Low/Reverse Servo Cover-to-Case Screw (4 Req'd)



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3. Install pan, new gasket and filter as described in this section.

4. Refill transmission.



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IN-VEHICLE SERVICE

Manual Control Lever Shaft Seal

Removal

1. Remove linkage and digital transmission range (DTR) sensor as described in this section.

2. Remove fluid pan. Filter does not need to be removed.

3. CAUTION: Do not damage the manual valve inner lever pin.

Remove the manual valve inner lever nut. Support inner manual valve lever and park rod assembly.

4. CAUTION: Do not damage the case fluid pan rail.

Use a small hammer and drift punch to tap lightly on each side of the manual control lever shaft spring pin (two or three times). This will loosen the pin prior to removal.





Shift Lever Seal Replacer T74P-77498-A



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Remove the manual control lever shaft spring pin with a narrow, sharp-edged screwdriver from the side as shown.

6. Remove the manual control lever shaft.



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7. CAUTION: Do not damage the bore.

Remove the manual control lever seal.



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Installation

1. Lubricate and install the main control lever seal using Shift Lever Seal Replacer T74P-77498-A.

2. Install the manual control lever shaft into the case.



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3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.

Align the manual control lever shaft with the manual control lever shaft spring pin. Install the retaining pin.



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4. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft.

5. CAUTION: Do not bend the manual valve inner lever pin.

Install manual valve inner lever nut and tighten to 41-54 Nm (30-44 lb-ft).



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6. CAUTION: Park pawl actuating rod must be properly installed into parking pawl and guide cup located in extension housing. Verify park linkage function.

Verify that the output shaft is locked in the PARK position.

7. Install new gasket and install pan.

8. Install DTR sensor and linkage.




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IN-VEHICLE SERVICE

Park System

Removal

1. Remove fluid pan. Remove fluid filter.

2. Remove EPC, SS2 and CCS solenoids. Remove case connector as described in this section.

3. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.

Remove the manual valve inner lever nut.

4. Remove the manual valve inner lever and parking pawl actuating rod assembly.





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5. Remove extension housing as described in this section.

6. Inspect park pawl spring and shaft. Inspect park pawl actuating rod. Service as required.

Installation

1. Install the manual valve inner lever and parking pawl actuating rod into the case. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft.



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2. CAUTION: Do not bend the manual valve inner lever pin.




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3. Install extension housing as described in this section, noting all cautions and notes.

4. Install EPC, SS2 and CCS solenoids and 16-pin case connector as described in this section.

5. Install fluid filter, fluid pan and new pan gasket with fluid pan-to-case screws. Tighten fluid pan-to-case screws to 13-15 Nm (115-133 lb-in).



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IN-VEHICLE SERVICE

Main Control Valve Body

NOTE: If a transmission has been disassembled to replace worn or damaged parts and the valves in the main control valve body (7A100) stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as Rotunda Torque Converter/Fluid Cooler Cleaner 014-00028 or equivalent.

Removal

1. Remove fluid pan.

2. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.





Valve Body Guide Pin (.235) T95L-70010-B

Valve Body Guide Pin (.248) T95L-70010-C



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3. Disconnect the six solenoid connectors from the solenoids by carefully pulling downward and wiggling side to side.



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4. Use a 10 mm socket to remove the M6 x 30 mm manual valve detent spring screw. Remove the manual valve detent spring.



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5. Use a 10 mm socket to remove the four M6 x 20 mm reverse servo cover screws. Remove the reverse servo cover, gasket and the servo piston and rod assembly.



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6. CAUTION: Support main control valve body.

Use a 10 mm socket to remove the sixteen M6 x 40 mm, four M6 x 45 mm, two M6 x 35 mm and one M6 x 30 mm main control valve body screws.



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7. Remove the main control assembly.

8. Install the guide pins into the case in the positions shown.



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9. Install new separator to case gasket.

10. NOTE: Make sure main control assembly gasket is properly aligned.

Install the main control assembly on the case. Align the manual valve with the manual valve inner lever pin as shown.



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11. Install four M6 x 45 mm screws in locations A. Finger tighten.

12. Install two M6 x 35 mm main control assembly-to-case screws in locations B. Finger tighten.

13. Install one M6 x 30 mm main control assembly-to-case screws in location C. Finger tighten.

14. Remove both valve body guide pins T95L-70010-B and T95L-70010-C.

15. Install sixteen M6 x 40 mm main control assembly-to-case screws in locations D. Finger tighten.

16. Tighten all main control assembly-to-case screws to 8-11 Nm (71-97 lb-in) in sequence shown, using a 10 mm socket.

Main Control Assembly Screws and Locations



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Refer to the tightening sequence (1R, 2R, 3R, 4R) for reverse servo cover installation also. Tightening Sequence



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17. Install the manual valve detent spring. Install the manual valve detent spring screw and tighten to 8-11 Nm (71-97 lb-in).

18. Install the reverse servo assembly into the case.



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19. Install the reverse servo and rod assembly cover, new gasket and the four servo cover-to-case screws. Tighten the screws in sequence as shown to 12-14 Nm (106-124 lb-in).

20. Carefully press down to install the solenoid connectors on the solenoid.



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22. Install filter, new gasket and fluid pan.




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IN-VEHICLE SERVICE

Intermediate and Overdrive Servos

Removal

NOTE: Procedures are the same for both O/D and intermediate servos.

1. NOTE: Catalytic converter(s) may have to be removed.

Remove heat shield, if equipped.

2. CAUTION: Servo is under spring tension. Use caution when removing.

NOTE: The J-hook must be in the appropriate hole for the servo being removed.

Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail with tool stamping facing up. Tighten the screws.

3. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.





Servo Cover Compressor T95L-77028-A

Servo Removal Tool T97T-7D021-A



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4. Carefully remove the servo cover retaining ring.



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5. CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.

6. Insert Servo Removal Tool T97T-7D021-A into case and locate on servo rod.



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7. Gently push on Servo Removal Tool T97T-7D021-A to remove front servo cover, piston and spring.

8. NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Remove the intermediate servo cover, piston and spring.



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9. Remove Servo Cover Compressor T95L-77028-A.

10. NOTE: The J-hook must be in the appropriate hole for the servo being removed.

Install Servo Cover Compressor T95L-77028-A over the overdrive servo cover at the fluid pan rail. Tighten the screws.

11. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the retaining ring.



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Remove the overdrive servo cover, piston and spring.



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18. Service as required.



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Installation

1. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur.

Install servo assembly.



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2. Carefully compress servo cover and install retaining ring.



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3. Install heat shield, if equipped.

4. Install catalytic converter if removed.



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IN-VEHICLE SERVICE

Band Adjustments

1. CAUTION: Do not allow adjustment screw to back out. Band strut could fall in transmission assembly.

CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the overdrive and intermediate band locknuts and discard, then back off the band adjusting screws.





Band Adjustment Torque Wrench Set T71P-77370-A



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2. CAUTION: Install, but do not tighten, a new locknut on the band adjusting screw. Apply petroleum jelly to the locknut seal.

CAUTION: Servos must be installed prior to band adjustment.

Install two new locknuts. Tighten the band adjusting screws using Band Adjustment Torque Wrench Set T71P-77370-A. The wrench will click at 14 Nm (10 lb-ft). Back off the band adjusting screw exactly two and one-half (2 1/2) turns for the intermediate band and two turns for the overdrive band and hold that position. Tighten the overdrive and intermediate band locknut-to-case adjusting screws to 47-61 Nm (35-45 lb-ft) using a 19 mm wrench.

Intermediate Band Adjustment



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Overdrive Band Adjustment



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REMOVAL

Transmission — 4x2 Aerostar

1. Disconnect the negative battery cable. Remove the transmission fluid level indicator.

2. Raise the vehicle and position safety stands under the vehicle.

3. Mark the relationship of the driveshaft centering flange and the rear axle companion flange.

4. Remove the four bolts retaining the driveshaft centering flange to the rear axle companion flange and disconnect the driveshaft from the rear axle. Remove the driveshaft from the vehicle.

5. Install a transmission plug in the output shaft seal.

6. Remove the transmission pan bolts and drain the transmission. Install the transmission pan, using the original gasket.

7. Disconnect the shift cable from the shift lever and from the shift cable bracket.

8. NOTE: Note the position of the ground cable at the starter bolt for installation.

Remove three starter motor bolts and position the starter aside, using mechanics wire.

9. Remove two transmission access cover bolts and the access cover from the converter housing.

10. NOTE: Mark and index one converter stud to the flexplate. The flexplate-to-converter nuts are not reuseable.

Rotate the torque converter and remove four converter-to-flexplate nuts. Discard the nuts.

11. NOTE: The transmission harness is removed from the transmission after the transmission is removed.

Disconnect the 8-pin and 16-pin connectors (for transmission sensors) at the left rear cylinder head. Disconnect the rear HO2S connector at the rear extension housing. Disconnect the right HO2S connector.

12. Remove two transmission mount nuts.

13. Support the engine.

14. Place Rotunda E4OD Transmission Jack Adapter 014-00763 or equivalent on the Transmission Jack 014-00942. Raise and secure the adapter to the transmission. Secure a safety strap to the transmission.

15. Remove the left and right crossmember bolts and nuts. Remove the crossmember. Remove the exhaust hanger bolt.

16. Remove the left and right bolts retaining the Three Way Catalytic (TWC) converters to the exhaust manifolds. Position the exhaust aside using mechanics wire.





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17. NOTE: The case connector fittings must be held in place to prevent them from moving while loosening the tube nuts.

Remove the transmission fluid cooler lines from the transmission case. Cap the transmission lines and plug the fittings at the transmission.

18. Slightly lower the transmission and remove six transmission-to-engine bolts.

19. CAUTION: Make sure the torque converter separates from the flexplate, remains seated in the transmission, and does not tip forward (so it will not fall out while lowering the transmission).

Separate transmission from the engine and flexplate. While carefully lowering the transmission and watching for obstructions, disconnect the fill tube.



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REMOVAL

Transmission — 4x2 Ranger

Removal

1. Disconnect the negative battery cable and remove the transmission fluid level indicator.

2. Remove two bolts retaining the fan shroud to the radiator.

3. Raise the vehicle and position suitable jack stands under the vehicle.

4. Mark the relationship of the driveshaft flange and the rear axle companion flange, so the driveshaft can be installed in the original position.

5. Remove two bolts and clips retaining the mid-ship bearing to the rear crossmember. Remove four bolts retaining the driveshaft flange to the rear axle companion flange. Disconnect and remove the driveshaft from the vehicle and install a plug into the extension housing.

6. Position a drain pan, remove the transmission pan bolts, and drain the fluid. Install the transmission pan, with the original gasket. Remove the drain pan.

7. Disconnect the shift cable from the transmission manual control lever and remove the cable from the cable bracket.

8. Remove the oil filter drain funnel retainers. Remove three starter motor bolts and position the starter aside, using mechanics wire. Remove the funnel.

9. Remove two torque converter access cover bolts and the access cover from the converter housing.

10. NOTE: Mark the converter stud to the flexplate. The flexplate-to-converter nuts are not reusable.

Rotate the torque converter and remove four converter-to-flexplate nuts. Discard the nuts.

11. Support the engine.

12. Install a transmission jack under the transmission. Secure the transmission to the jack.

13. Remove the transmission mount nuts. Remove the left and right crossmember bolts and nuts. Remove the crossmember.

14. Disconnect three HO2S connectors from the catalytic converter assembly.

15. Remove the bolts retaining the Y-pipe to the exhaust manifolds. Remove the converter-to-tailpipe retainers. Secure the tailpipe. Remove the converter hanger bolt and the converter assembly.

16. NOTE: The case connector fittings must be held in place while loosening the tube nuts from the cooler lines.





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Slightly lower the transmission. Remove the bolt retaining the cooler lines to the right side of the engine block. Disconnect the transmission fluid cooler lines. Cap the cooler lines and plug the fittings at the transmission.

17. Disconnect both transmission 16-pin connectors at the left rear cylinder head. Remove the transmission-to-engine bolts. Remove the fluid level indicator tube.

18. CAUTION: Make sure the torque converter separates from the flexplate and remains seated in the transmission. Do not allow the transmission to tip forward, as the converter could fall out while lowering the transmission.

Separate the transmission from the engine and carefully lower the transmission from the vehicle.



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DISASSEMBLY

Transmission

Disassembly

1. WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON THE JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.

Relocate the transmission to the top of a flat workbench.





Torque Converter Handles T81P-7902-C


Extension Housing Bushing Remover T77L-7697-E

A4LD Holding Fixture Adapter T93T-77002-AH

Bench-Mounted Holding Fixture T57L-500-B


4R44E/4R55E Transmission Test Plate T95L-77000-AH

Servo Removal Tool T97T-7D021-A



T94P-77001-BH Seal Remover



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2. NOTE: Refer to Section 07-07A , Section 07-07B , Section 07-07C or Section 07-07D for transfer case service.

If the vehicle has a transfer case, use a 13 mm socket to remove the five transfer case-to-extension housing screws. Remove the transfer case and set aside for assembly.



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3. Remove Torque Converter Holding Tool T97T-7902-A from transmission.

4. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.

Remove the torque converter using Torque Converter Handles T81P-7902-C.



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5. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.

Remove the input shaft.



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7. Remove the two M6 x 25 digital transmission range (DTR) sensor screws and remove the DTR sensor.



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8. Remove the extension housing seal using Seal Remover T94P-77001-BH and Impact Slide Hammer T50T-100-A.

9. NOTE: Remove the extension housing bushing only if service is required.



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Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gouges, scoring and wear.

Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E.

10. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

Use a 17 mm socket to remove the five M10 x 30 mm extension housing-to-transmission case screws and one (1) stud.



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11. Remove the parking pawl, parking pawl return spring and parking pawl shaft.



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12. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.

NOTE: See the special service tool section for a drawing of this optional adapter plate.

Use four M10 x 30 mm extension housing to transmission case screws to attach the adapter plate to the transmission.



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13. Attach the fixture arm assembly (part of T57L-500-B) with two 7/16 x 2-inch bolts and nuts.



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14. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Install the transmission assembly to Bench-Mounted Holding Fixture T57L-500-B. Rotate to the position shown. Place a drain pan under the assembly.



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Rotate transmission assembly so that the fluid pan is facing up.

16. CAUTION: Do not reuse the fluid pan gasket.

Use a 13 mm socket to remove the eighteen M8 x 16 mm fluid pan screws. Remove the fluid pan and fluid pan gasket. Discard the fluid pan gasket.

Fluid Pan Removal



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17. Use a 10 mm socket to remove the M6 x 55 mm fluid pan filter assembly screw. Remove and discard the fluid pan filter assembly.

Fluid Pan Filter Removal



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18. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.



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19. Disconnect the six solenoid connectors from the solenoids by carefully pulling upward and wiggling side to side.



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20. Use a 10 mm socket to remove the M6 x 30 mm manual valve detent spring screw. Remove the manual valve detent spring.



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21. Use a 10 mm socket to remove the four M6 x 20 mm reverse servo cover screws. Remove the low/reverse servo cover, gasket and piston and rod assembly.



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22. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.

NOTE: Refer to the main control disassembly and assembly in this section.

Use a 10 mm socket to remove the sixteen M6 x 40 mm, four M6 x 45 mm, two M6 x 35 mm and one M6 x 30 mm main control valve body screws.

23. Remove the main control assembly, separator plate and gaskets. Discard gaskets.

Item Part

Number Description

1 7D189 Piston Assembly with Rod and Retainer (Rear Band Servo) (Select Fit)

2 7L173 Reverse Servo-to-Case Gasket

3 7D036 Reverse Servo Cover

4 E800156-S Low/Reverse Servo Cover-to-Case Screw (4 Req'd)



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24. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the overdrive and intermediate band locknuts and discard. Back off the band adjusting screws.



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Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail with tool stamping facing up. Tighten the screws.

26. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.



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Remove the intermediate servo cover, piston and spring.



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34. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the retaining ring.



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Remove the overdrive servo cover, piston and spring.



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Rotate the transmission assembly with the converter housing facing up.

42. CAUTION: Throw the screws away. The screws are not reusable for assembly.

Use a 17 mm socket to remove the eight M10 x 33 mm converter housing-to-case screws. Discard the screws.



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43. NOTE: Rotate and lift the converter housing so that the clutch assemblies will stay in place.

Remove the converter housing and fluid pump support and gear assembly.



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44. NOTE: Refer to Converter Housing And Pump Assembly under subassemblies for service information.

Remove the No. 1 fluid pump thrust washer. Tag the No. 1 fluid pump thrust washer for identification.



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45. Remove overdrive band adjusting screw. Compress the overdrive band around the overdrive brake and coast clutch drum. Remove the overdrive band anchor strut.



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46. CAUTION: Identify which end of the overdrive band is the anchor side or the apply side.

Remove the overdrive band.



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47. Remove the overdrive brake and coast clutch drum.



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48. Remove the overdrive band apply strut.



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49. NOTE: Tag and identify the overdrive lever for assembly. The overdrive lever has a letter stamped into its side.

NOTE: The overdrive band actuating lever shaft is longer than the intermediate shaft.

Remove the overdrive band actuating lever shaft.



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50. CAUTION: Do not bend the exciter wheel.

NOTE: No. 12 thrust bearing is in this assembly.

Remove the planetary gear overdrive carrier.



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51. Remove the servo band lever and overdrive control bracket.



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52. Remove the No. 2 needle bearing if not already removed with planetary gear overdrive carrier.



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53. Remove the overdrive ring gear, overdrive one-way clutch and overdrive center shaft assembly.

54. NOTE: Tag and identify the No. 3 center shaft thrust bearing assembly for assembly.

Remove the No. 3 center shaft thrust bearing assembly.



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55. CAUTION: The center support locking nut could fall into the remaining assembly if not removed.

Use a 5 mm Allen wrench to remove the M6 x 20 mm center support capscrew.



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56. Remove the locking nut and cage from center support.



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57. CAUTION: Do not pry on other wires or damage the connector or case surface.

Carefully disconnect the turbine shaft speed (TSS) sensor connector from the 16-pin case connector.



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58. Carefully remove TSS sensor connector wires from the retaining slot on the 16-pin case connector.



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59. Use a T30 Torx® bit to remove the TSS screw.



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60. Carefully route the TSS connector and wiring into the transmission through the opening in the case. Remove the TSS.



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61. CAUTION: Do not overstretch the case connector retaining spring.

Use a screwdriver to carefully remove the case connector retaining spring.



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62. CAUTION: Do not damage the connector or harness.

Carefully push down on the top of the connector until it stops. Depress the tab on the back side of the connector and push down on the connector. Remove the connector and harness through the bottom of the case.



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63. Remove the center support retaining ring.



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64. Remove the center support by pulling evenly around the center support web.



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65. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing for assembly.

Remove the No. 4 intermediate brake drum thrust bearing.



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66. Remove the intermediate band anchor strut through the bottom of the case. Remove intermediate band adjusting screw.



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67. CAUTION: Identify which end of the intermediate band is the anchor side or the apply side.

Remove the intermediate band.



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68. Remove the intermediate band apply strut.



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69. NOTE: The intermediate band actuating lever shaft is shorter than the overdrive band actuating lever shaft.

Remove the intermediate band actuating lever shaft.



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70. NOTE: Tag and identify the intermediate band servo lever for assembly. The intermediate band servo lever has a letter stamped on its side for identification.

Remove the intermediate band servo lever.



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71. CAUTION: Make sure the lock pin on Bench-Mounted Holding Fixture T57L-500-B is secure.

Rotate the transmission so the fluid pan surface is facing up.



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72. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.

Remove the intermediate brake and direct clutch drum.



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73. NOTE: Tag and identity the No. 5 forward clutch cylinder thrust bearing for assembly.

Remove the No. 5 forward clutch cylinder thrust bearing.



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74. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the forward clutch cylinder.

Remove the forward clutch cylinder.



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75. Remove No. 6A forward ring gear hub thrust bearing assembly.



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76. Remove the forward ring gear and forward ring gear hub.



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77. Remove No. 6B forward clutch thrust washer.



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78. NOTE: Check black oxidized side during removal to ensure correct placement during

reassembly. Black oxidized side must be toward planetary assembly. The uncoated side must face up.

Remove the No. 7 forward planetary thrust bearing.

79. Remove the forward planetary assembly.



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80. Remove the input shell with forward sun gear.



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81. NOTE: Tag and identify the No. 8 thrust bearing for assembly.

Remove the No. 8 thrust bearing from the reverse planetary assembly.



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82. Remove the reverse planetary retaining ring.



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83. Remove the reverse planetary assembly.



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84. NOTE: Tag and identify for reassembly.

Remove the No. 9 reverse planetary carrier thrust bearing.



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85. Remove the output shaft sleeve.



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86. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.

Remove the output shaft retaining ring from inside the case on the output shaft.



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87. Remove the output shaft ring gear and output shaft hub.



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88. NOTE: Tag and identify the No. 10B output shaft hub thrust bearing for assembly.

Remove the No. 10B output shaft hub thrust bearing.



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89. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.

Remove the reverse brake drum and the one-way clutch assembly.



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90. Remove the reverse band.



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91. Remove the output shaft.



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92. Remove the park gear.



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93. NOTE: Tag and identify the No. 11 output shaft thrust washer for assembly.

Remove the No. 11 output shaft thrust washer.



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94. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.

Remove the manual valve inner lever nut.



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95. Remove the manual valve inner lever and parking pawl actuating rod assembly.



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Using a small hammer and drift, tap lightly on each side of the manual control lever shaft retaining pin (two or three times). This will loosen the pin prior to removal.



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Remove the manual control lever shaft retaining pin with a narrow, sharp edged screwdriver from the side as shown.



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98. Remove the manual control lever shaft.



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99. CAUTION: Do not damage the bore.

Remove the manual control lever seal.



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DISASSEMBLY/ASSEMBLY OF SUBASSEMBLIES







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1 — Valve Manual



4 — Valve — Forward Modulator

5 — Spring — Forward Modulator



8 — Valve — EPC Boost

9 — Spring — EPC Boost


11 — Sleeve — Pressure Boost Valve

12 — Valve — Pressure Boost

13 — Spring — Pressure Boost

14 — Spring — Oil Pressure Regulator

15 — Retainer — Main Regulator Spring

16 — Valve — Pressure Regulator

17 — Plug — Valve Retainer (3 Req'd)

18 — Spring — Forward Engagement

19 — Valve — Forward Engagement Control

20 7G484 Solenoid — Shift (4 Req'd)

21 — Spring — 3-2 (K.D./T.D.) (2 Req'd)

22 — Valve — 3-2 (K.D.)

23 — Spring — Manual Low (1)

24 — Valve — Manual Low (1)


26 — Valve — 3-2 (T.D.)





31 — Valve — Thermostat Bypass

32 — Valve — Thermostatic Bypass



35 — Spring — Cooler Limit

36 — Valve — Cooler Limit

37 7G136 Solenoid — Converter Clutch (PWM)



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43 — Spring — Converter Clutch (3.0L and 4.0L Only)


45 — Valve — Coast Clutch

46 — Spring — Coast Clutch


48 — Valve — 3-2 Downshifts

49 — Spring — 3-2 Downshifts

50 7G383 Solenoid — EPC (VFS)











61 — Spring — Reverse Modulation (2 Req'd)



64 7L491 Clamp — SS1/SS2

65 7L491 Clamp — SS3/CCS/EPC/TCC

66 E800155-S72 Screw — Retain Solenoid Clamps (2 Req'd)

67 7D132 I.D. Plate

68 — Body — Valve

69 7D100 Gasket — Separator Plate

70 7A008 Plate — Separator

71 E804357-S Screw — Retain Separator Plate (3 Req'd)

72 7N113 Screen — EPC Limit Circuit

73 7D376 Extension Housing Lube Orifice

74 7E368 Valve EPC Limit (Metal)

75 7E368 Valve Converter Relief (Plastic)

76 7E340 Spring — EPC Limit/Converter Relief (2 Req'd)



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Disassembly

1. CAUTION: SS3 may pop out of its bore. This may damage the solenoid.

Use a 10 mm socket to remove the SS1 and SS3 solenoid clamp screws. Remove the solenoid clamp and the solenoids.

7E195 Ball (4 Req'd)


1 7F037 Torque Converter Clutch Solenoid Assembly

2 7G484 Coast Clutch Solenoid Assembly

3 7G484 Shift Solenoid 2 Assembly

4 7H144 EPC Solenoid Assembly





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2. NOTE: The TCC solenoid may pop out of its bore.

The converter modulator valve may come out after the TCC solenoid has been removed. This may damage the solenoid or converter modulator valve.

Remove the TCC, CCS, SS2 and EPC solenoid clamp screw.



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3. Remove the solenoid clamp and the solenoids.



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4. CAUTION: Valves may come out when rotating the main control.

Carefully rotate the main control assembly so that the control valve body-to-case gasket is facing up. Remove and discard the control valve body-to-case gasket.



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5. Use a T30 Torx® bit to remove the three separator plate-to-main control screws.



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6. CAUTION: The extension housing lube orifice and relief valves may stick to the separator plate.

Remove the valve body separator plate.

7. Remove and discard the control valve body separator gasket.



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8. Carefully remove the extension housing lube orifice.



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9. Remove the electronic pressure control (EPC) limit relief valve (metal-silver color) and spring.



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10. Remove the converter relief valve (plastic-dark color) and spring.

11. Remove the EPC limit circuit screen.



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12. Remove the four check balls.



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13. CAUTION: Do not lose parts when cleaning or servicing.

Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.

14. Inspect all valve and plug bores for scores. Check all fluid passages for obstructions. Inspect the check valve for free movement. Inspect all mating surfaces for burrs or distortion. Inspect all plugs and valves for burrs or scores. Replace the control valve body if the bores are scored or if the valves are scored beyond the point of being able to be cleaned.

15. Inspect all springs for distortion. Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight in their respective bores.

16. Roll the manual valve on a flat surface to check for a bent condition.

17. Clean and inspect the EPC limit circuit screen.



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18. Clean and inspect the EPC solenoid screens.

19. Remove and replace all shift and coast clutch solenoid O-rings.

20. Clean and inspect the torque converter clutch (TCC) solenoid.



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Assembly

1. CAUTION: Make sure that the screen is properly located.

Install the EPC limit circuit screen. Push down on the EPC limit circuit screen to make sure it is fully seated.

2. Install the four check balls in proper locations as shown.



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Check Ball Installation

3. CAUTION: The springs and valves are not interchangeable.

Install the converter relief valve (plastic-dark color) and spring.



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4. CAUTION: The springs and valves are not interchangeable.

Install the EPC limit relief valve (metal-silver color) and spring.



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5. Install the extension housing lube orifice.



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6. Install and align the control valve body separator gasket.

7. Install the valve body separator plate. Install the three (3) separating plate-to-main control screws fingertight.



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8. Install the alignment pins in the locations shown.

9. Tighten the separator plate-to-main control screws to 6-8 Nm (53-71 lb-in).



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10. NOTE: Apply petroleum jelly on the separator surface to hold the gasket in place.

Install the control valve body-to-case gasket.



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11. Remove the alignment pins.

12. Rotate the main control so that the separator plate is facing down.

13. CAUTION: The shift and coast clutch solenoid terminals must face upward.

NOTE: The shift and CCS solenoids are interchangeable.

NOTE: If the TCC valve came out, use caution when installing the TCC solenoid.

Install the solenoids.



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14. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug.

Install the solenoid clamp. Tighten the solenoid clamp screw to 6-8 Nm (53-71 lb-in).



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15. Install shift solenoids 1 and 3.



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16. Install the solenoid clamp. Tighten the clamp screw to 6-8 Nm (53-71 lb-in).



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Converter Housing and Fluid Pump

Converter Housing and Fluid Pump





Converter Housing Seal Replacer T97T-77000-A



TOOL-1175-AC Seal Remover


1 W701429-S309M

Fluid Pump-to-Converter Housing Screws (6 Req'd)

2 7D014 No. 1 Fluid Pump Input Thrust Washer

3 7A103 Fluid Pump Support and Gear Assembly



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Disassembly

1. Remove and discard the fluid pump gasket.

2. Remove and discard the fluid pump square cut seal ring.

4 W701431-S300 Fluid Pump Shaft-to-Inner Gear O-Ring

5 7L323 Fluid Pump Support Seal Ring

6 7A136 Fluid Pump Gasket

7 7B472 Fluid Pump Adapter Plate

8 7976 Converter Housing Assembly

9 E804595-S200 Converter Housing-to-Case Screw and Seal Assembly (8 Req'd)

10 7A248 Converter Hub-to-Converter Housing Seal Assembly



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3. Remove the fluid pump support seal ring.



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4. Use a Torx® 40 wrench to remove the six M8 x 35 mm front pump-to-converter housing screws.

Remove the fluid pump support and gear and the fluid pump adapter plate.

5. NOTE: The pump gears are part of the pump assembly and are not serviced separately.

NOTE: A rough casting on the pump surface crescent is not a flaw.

Remove the pump gears.



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6. Remove the drive gear O-ring and discard.



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7. Inspect the pump gears for scoring and cracks. Replace pump assembly if damaged.

8. NOTE: Fluid pump-to-converter housing bushing is not serviced separately. If service is required, the converter housing assembly must be replaced.

Inspect the fluid pump to converter housing bushing and converter hub to converter housing seal. Replace converter housing assembly if necessary.

9. Remove and discard the converter hub-to-converter housing seal using Seal Remover TOOL-1175-AC or equivalent from the converter housing as shown.



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10. Clean and inspect the front and rear input shaft support bushings. If bushings are worn, scored or damaged, replace the fluid pump support and gear assembly. Inspect the pump gear pockets for scoring and wear. Replace if necessary.



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11. Inspect the mating surfaces of the pump body and case for burrs.

Inspect the drive and driven gear bearing surface for scores and check the gear teeth for burrs.

Inspect the fluid pump seal for cuts or nicks. Inspect the pump bushing for scoring.

Check the fluid passages for obstruction.

If any parts are found to be damaged or worn, replace the pump as an assembly. Minor burrs and scores may be removed with a crocus cloth.

Assembly

1. NOTE: Check and make sure that the garter spring has not popped off of the converter hub-to-converter housing seal.

Install new converter hub to housing seal onto Converter Housing Seal Replacer T97T-77000-A.



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2. CAUTION: Place the converter housing on a block of wood or equivalent to protect the converter hydraulic passages on the back side.

Install a new converter hub-to-converter housing seal until it bottoms in housing using Converter Housing Seal Replacer T97T-77000-A.



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Coast Clutch

Overdrive Brake and Coast Clutch Drum Assembly





Clutch Spring Compressor T65L-77515-A

Coast Clutch Outer Seal Sizing Tool T95L-70010-D


1 E860126-S/129-S


2 7B066 Coast Clutch Pressure Plate

3 7B164 Coast Clutch Internal Plate — Friction (2 Req'd)

4 7B442 Coast Clutch External Plate — Steel (2 Req'd)


6 7A527 Coast Clutch Piston Spring Retainer

7 7A480 Coast Clutch Piston Springs (20 Req'd)

8 7A258 Coast Clutch Piston

9 7D548 Coast Clutch Piston Outer Seal Ring



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Disassembly

1. CAUTION: This is a select fit ring. See assembly procedure if the ring or clutch plate pack is replaced.

Remove the retaining ring and coast clutch pressure plate from the overdrive brake and coast clutch drum.

2. CAUTION: Coast clutch friction plates are directional. Note direction of grooves for installation.

CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

Remove the coast clutch pack. Inspect for wear, damage or overheating. Replace as necessary.

10 7D404 Coast Clutch Piston Inner Seal Ring




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3. WARNING: USE CAUTION WHEN RELEASING TOOL PRESSURE ON THE REAR CLUTCH PISTON SPRINGS.

CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.

Compress the clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring.



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4. Remove the clutch piston spring retainer and 20 clutch piston springs.



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5. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR, AND MAKE SURE DRUM IS FACING DOWN AS SHOWN.

Remove the coast clutch piston by using air pressure. Apply air pressure to one hole on the inside diameter of the overdrive brake and coast clutch drum while blocking the other hole with a finger.



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6. Remove the coast clutch piston inner and outer seal. Clean and replace as necessary.



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Assembly

1. CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent roll over of the lip seal.

Install new coast clutch piston inner and outer seal on the coast clutch piston.



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2. CAUTION: Lubricate the coast clutch piston inner and outer seal.

Carefully press the coast clutch piston into Coast Clutch Outer Seal Sizing Tool T95L-70010-D.



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3. Inspect the drum band surface, bushing, and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.

4. Inspect the clutch piston bore and the piston and the piston inner and outer bearing surfaces for scores.

5. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.

6. Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Replace all plates that are badly scored, worn or do not fit freely in the hub serrations.

7. Inspect the clutch pressure plate for scores on the clutch plate surface. Check the clutch release spring(s) for distortion.

8. Make sure the check ball is free and clear of debris prior to installing piston. The check ball is located in the overdrive brake and coast clutch drum.



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9. Carefully remove the coast clutch piston from Coast Clutch Outer Seal Sizing Tool T95L-70010-D.



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10. CAUTION: Care must be taken to prevent damage to the seals during installation.

Carefully install the coast clutch piston into the overdrive brake and coast clutch drum.

11. Install the 20 coast clutch piston springs and coast clutch piston spring retainer onto the coast clutch piston.

12. CAUTION: Do not fully compress the clutch spring compressor or damage to the coast clutch piston spring retainer may occur.

Compress the coast clutch piston springs with Clutch Spring Compressor T65L-77515-A. Install the retaining ring. Release the load on the springs applied by the tool. Remove the tool.

13. CAUTION: Friction plates are directional and must be installed with grooves clockwise (I.D. to O.D.). The word "TOP" should face up.


NOTE: When installing friction plate, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise.



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Install the two steel clutch plates and two friction clutch plates in alternating order, starting with a steel plate first.

14. CAUTION: The retaining ring is select fit.

Install the coast clutch pressure plate. Install the original retaining ring on top of the clutch pressure plate.



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15. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE DRUM IS FACING DOWN AS SHOWN.

NOTE: The coast clutch piston must apply with air pressure and release when the air is removed.

Air check the assembly. Apply air to one hole on the inside diameter of the overdrive brake and coast clutch drum while blocking the other hole with a finger.



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16. Check the free play of the clutch pack. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and the pressure plate. Specification: 1.3 to 2.0 mm (.051 to .079 inch).

If the reading is not within specification, remove the retaining ring and check the thickness. Replace it with a ring that will correct free play. Verify with a feeler gauge.



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COAST CLUTCH

Part Number

Thickness Diameter

mm Inches mm Inches

E860126-S 1.37 .0539 130.1 5.122

E860127-S 1.73 .0681 130.1 5.122

E860128-S 2.08 .0819 130.1 5.122

E860129-S 2.44 .0961 130.1 5.122



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Intermediate Brake and Direct Clutch Drum Assembly

Intermediate Brake and Direct Clutch Drum Assembly






Direct Clutch Outer Seal Sizing Tool T95L-70010-E


1 E860126-S/129-S


2 7B066 Direct Clutch Pressure Plate

3 7B164 Direct Clutch Internal Plate — Friction

4 7B442 Direct Clutch External Plate — Steel


6 7A527 Direct Clutch Piston Spring Retainer (8 Tabs)

7 7A480 Direct Clutch Piston Springs (20 Req'd)

8 7A258 Direct Clutch Piston

9 7A548 Direct Clutch Piston Outer Seal Ring



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Disassembly

1. CAUTION: The retaining ring is a select fit ring. See assembly procedure if the ring or clutch pack is replaced.

Remove the retaining ring and direct clutch pressure plate.



Remove the direct clutch pack. Inspect for wear, damage or overheating. Replace the steel or friction plates as necessary.

10 7D404 Direct Clutch Piston Inner Seal Ring




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3. WARNING: AFTER REMOVING THE RETAINING RING, USE CARE WHEN RELEASING THE PRESSURE ON THE SPRINGS.

CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.

Compress the direct clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring. Remove the tool.



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4. Remove the direct clutch piston spring retainer and 20 direct clutch piston springs.

5. WARNING: DO NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING



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COMPRESSED AIR. MAKE SURE DRUM IS FACING DOWN AS SHOWN.

Remove the direct clutch piston using compressed air. Apply air pressure to one hole on the inside diameter of the intermediate brake and direct clutch drum while blocking the other hole with a finger.

6. Remove the direct clutch piston inner and outer seals. Clean and replace as necessary.



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Assembly

1. CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

Install new direct clutch piston inner and outer seals on the direct clutch piston.



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2. CAUTION: Lubricate the direct clutch piston inner and outer seals with MERCON V® XT-5-QM transmission fluid.

Carefully press the direct clutch piston into Direct Clutch Outer Seal Sizing Tool T95L-70010-E.



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3. Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.

4. Inspect the clutch piston bore and the piston and the piston inner and outer bearing surfaces for scores.

5. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.


7. Inspect the direct clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release springs for distortion.

8. Make sure the check ball is free and clear of debris prior to installing piston. The check ball is located in the intermediate brake and direct clutch drum assembly.



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9. Carefully remove the direct clutch piston from Direct Clutch Outer Seal Sizing Tool T95L-70010-E.



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10. CAUTION: Care must be taken to prevent damage to the seals during installation.

Carefully install the clutch piston into the intermediate brake and direct clutch drum.



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11. Install the direct clutch piston spring retainer and 20 direct clutch piston springs.

12. CAUTION: Do not fully compress the clutch spring compressor damage to the spring retainer may occur.

Compress the direct clutch piston springs with Clutch Spring Compressor T65L-77515-A. Install the retaining ring. Remove the tool.



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CAUTION: The number of plates is model dependent. See Specifications at the end of this section. If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

NOTE: When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise.

Install the steel clutch plates and friction clutch plates in alternating order, starting with a steel plate and finishing with a friction plate.



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CLUTCH PACK

Steel Friction

4 4



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14. CAUTION: The retaining ring is a select fit.

Install the direct clutch pressure plate and original retaining ring on the clutch stack.



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15. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE DRUM IS FACING DOWN AS SHOWN.

NOTE: The direct clutch piston must apply with air pressure and release when the air is removed.

Air check the assembly. Apply air to one hole on the inside diameter of the intermediate brake and direct clutch drum while blocking the other hole with a finger.



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16. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and the clutch pressure plate. Specification: 1.3 to 2.0 mm (0.051 to 0.079 inch).

If the reading is not within specification, remove the retaining ring and check thickness. Replace with a ring that will correct free play, and verify with a feeler gauge.

DIRECT CLUTCH

Thickness Diameter



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Part Number mm Inches mm Inches

E860126-S 1.37 .0539 130.1 5.122

E860127-S 1.73 .0681 130.1 5.122

E860128-S 2.08 .0819 130.1 5.122

E860129-S 2.44 .0961 130.1 5.122



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Forward Clutch







Lip Seal Protector T74P-77548-A

Lip Seal Protector T74P-77548-B


1 E860115-S/118-S Retaining Ring (Select Fit)



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Disassembly

1. CAUTION: The retaining ring is a select fit ring. See assembly procedure if the retaining ring or clutch pack is replaced.

CAUTION: If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

Remove the retaining ring and forward clutch pressure plate.

2 7B066 Forward Clutch Pressure Plate

3 7B164 Forward Clutch Internal Plate — Friction

4 7B442 Forward Clutch External Plate — Steel

5 7B070 Forward Clutch Cushion Spring


7 7A527 Forward Clutch Piston Spring Retainer

8 7A480 Forward Clutch Piston Springs (15 Req'd)

9 7A262 Forward Clutch Piston Assembly

10 7A548 Forward Clutch Piston Outer Seal Ring

11 7A548 Forward Clutch Piston Inner Seal Ring





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2. CAUTION: Friction plates are directional and must be installed with grooves counterclockwise (I.D. to O.D.). The word "TOP" should face up.

Remove the forward clutch pack. Inspect for wear, damage or overheating. Replace as necessary.

3. CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.

Compress the forward clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring.



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4. WARNING: CAREFULLY RELEASE THE TOOL PRESSURE ON THE FORWARD CLUTCH PISTON SPRINGS AND REMOVE THE TOOL.

Remove the clutch spring compressor from the forward clutch cylinder.

5. Remove the forward clutch piston spring retainer and 15 forward clutch piston springs. Remove the rubber forward clutch cushion spring. Replace as necessary.



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6. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE CYLINDER IS FACING DOWN AS SHOWN.

NOTE: This is the middle-sized port.

Use the center support to remove the forward clutch piston. Install the center support on the forward clutch cylinder. Apply air pressure to the far left port in the center support as shown.



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7. Remove the forward clutch piston inner and outer seals. Clean and replace as necessary.



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8. Inspect the forward clutch cylinder thrust surfaces, piston bore and clutch plate serration for scores or

burrs. Minor scores or burrs may be removed with a crocus cloth. Replace the forward clutch cylinder if it is badly scored or damaged.

9. Check the fluid passages in the forward clutch cylinder for obstructions. Clean out all passages. Inspect the forward clutch piston for scores and replace if necessary. Inspect the piston check ball for freedom of movement and proper seating.

10. Check the clutch release springs for distortion and cracks. Replace the springs if they are distorted or cracked.

11. Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surface. Replace all parts that are deeply scored.

12. Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.

13. Check clutch hub thrust surfaces for scores and clutch hub splines for wear.

14. NOTE: The check ball is located in the piston.

Make sure the check ball is free and clear of debris prior to installing the forward clutch piston.

15. Inspect bearing and seal rings for damage.



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Assembly

1. CAUTION: If there is evidence of clutch plate burning, replace the forward clutch cushion spring.

Install new forward clutch piston inner and outer seals on the forward clutch piston. Install the forward clutch cushion spring.



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2. To prevent damage to the forward clutch piston outer seal, install Lip Seal Protector T74P-77548-B. To prevent damage to the forward clutch piston inner seal install Lip Seal Protector T74P-77548-A into forward clutch cylinder.



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3. CAUTION: Care must be taken to prevent damage to the seals.

NOTE: Apply petroleum jelly to the inner and outer seals.

Carefully install the forward clutch piston into the forward clutch cylinder.

4. Carefully remove Lip Seal Protector T74P-77548-A and Lip Seal Protector T74P-77548-B from the forward clutch cylinder.

5. Install the 15 forward clutch piston springs and forward clutch piston spring retainer.



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6. CAUTION: Do not fully compress the clutch spring compressor or damage to the forward clutch piston spring retainer may occur.

Compress the clutch piston springs with Clutch Spring Compressor T65L-77515-A and install the retaining ring. Release the load on the forward clutch piston springs and remove the tool.



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7. CAUTION: Friction plates are directional and must be installed with grooves counterclockwise (I.D. to O.D.). The word "TOP" should face up.

CAUTION: If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.

NOTE: When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise.

Install the steel clutch plates and friction clutch plates in alternating order, starting with a steel plate and finishing with a friction plate.



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8. CAUTION: The retaining ring is a select fit.

Install the forward clutch pressure plate on the clutch pack. Install the original retaining ring.

CLUTCH PACK

Steel Friction

5 5



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9. WARNING: DO NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE DRUM IS FACING DOWN AS SHOWN.

NOTE: The forward clutch piston must apply with air pressure and release when the air is removed.

Install the center support on the forward clutch cylinder. Apply air pressure to the far left port in the center support as shown.

10. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and



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the clutch pressure plate. Specification: 1.4 to 2.1 mm (.055 to .083 inch). If the reading is not within specifications, remove the retaining ring and check the thickness. Replace the retaining ring with one that will provide correct free play. Verify free play with a feeler gauge.

FORWARD CLUTCH CYLINDER

Part Number

Thickness Diameter

mm Inches mm Inches

E860115-S 1.37 .0539 125.1 4.925

E860116-S 1.73 .0681 125.1 4.925

E860117-S 2.08 .0819 125.1 4.925

E860118-S 2.44 .0961 125.1 4.925



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Forward Geartrain Assembly

Assembly

1. Install the No. 5 forward clutch cylinder thrust bearing on the forward clutch cylinder assembly. Use petroleum jelly to hold the bearing in place.



Item Part

Number Description

1 — Intermediate Brake and Direct Clutch Drum Assembly


3 — Forward Clutch Cylinder Assembly

4 7D234 No. 6A Forward Ring Gear Hub Thrust Bearing Assembly

5 7D090 No. 6B Forward Clutch Thrust Washer

6 7D392 Forward Ring Gear

7 7F374 No. 7 Forward Planetary Thrust Bearing Assembly

8 7A398 Forward Planetary Assembly

9 7D064 Input Shell




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2. Install the forward clutch cylinder assembly into the intermediate brake and direct clutch drum assembly as shown.

3. Install the No. 6A forward ring gear hub thrust bearing into the forward clutch cylinder with tabs facing up as shown.



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4. NOTE: Use petroleum jelly to hold the washer in place.

Install the No. 6B forward clutch thrust washer into the forward ring gear hub.



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5. NOTE: Make sure the No. 6A bearing and No. 6B forward clutch thrust washer assembly are inside the forward ring gear.

Install the forward ring gear and forward clutch thrust washer into the forward clutch cylinder assembly as shown.



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6. CAUTION: Black oxidized color of thrust bearing must face up toward planetary assembly.

Install the No. 7 forward planetary thrust bearing into the forward ring gear as shown.



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7. NOTE: All service replacements are 6 pinion only.

Install the forward planetary assembly into the forward ring gear as shown.

8. NOTE: If sun gear, retaining rings or input shell require service, perform steps a-e.

Inspect the drum gear, bushing and washer for scoring, wear or damage. Replace as required.

a. Remove rear retaining ring and sun gear from input shell.



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b. Remove front retaining ring from sun gear.

c. Install new retaining ring onto sun gear.



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d. Install forward sun gear into input shell.

e. Install new rear retaining ring onto sun gear.



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9. NOTE: Make sure the forward sun gear aligns with the forward planetary assembly. Make sure the input shell aligns with the intermediate brake and direct clutch drum assembly as shown.

Install the input shell with forward sun gear assembly as shown.



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Overdrive Planetary and One-Way Clutch Assembly

Overdrive Planetary and One-Way Clutch Assembly

Disassembly

1. Remove the overdrive center shaft retaining ring from the overdrive ring gear.




1 W702037-S Retaining Ring

2 7A658 Overdrive Center Shaft Assembly

3 7653 Overdrive Ring Gear

4 7L495 No. 2 Overdrive Planetary Thrust Bearing

5 7B446 Overdrive Planetary Gear Carrier Assembly

6 7D063 Overdrive Sun Gear Assembly

7 7660 Coast Clutch Adapter



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2. Remove the overdrive center shaft from the overdrive ring gear.



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3. CAUTION: Do not remove the overdrive one-way clutch. Damage to the clutch may occur if it is removed.

NOTE: The overdrive one-way clutch is serviced with the overdrive center shaft.

Clean and inspect the overdrive one-way clutch and overdrive center shaft assembly. Check for cracks in the roller cage and wear on the roller clutch. Inspect the press fit of the one-way roller clutch to the overdrive center shaft.

Inspect the rollers and springs for excessive wear or damage.

Inspect the spring and roller cage for bent or damaged spring retainers.

4. Temporarily insert the overdrive planetary gear carrier assembly into the one-way clutch rollers for verification of the one-way clutch. The planetary must rotate counterclockwise and hold clockwise as shown. Remove the overdrive planetary gear carrier assembly.



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Assembly

1. Install the overdrive center shaft and overdrive one-way clutch into the overdrive ring gear.



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2. Install the center shaft retaining ring.



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3. CAUTION: Planetary's must be replaced. Do not restake.

NOTE: Individual parts of the planetary carriers are not serviceable.

Check the pins and shafts in the planetary assemblies for loose fit and/or complete disengagement. Use a new planetary assembly if either condition exists. Before installing a planetary assembly, the shaft retaining pins should be checked for adequate staking.

Inspect the pinion gears for damaged or excessively worn teeth.

Check for free rotation of the pinion gears.

Inspect the overdrive one-way clutch inner race for scoring.

Check pinion bearing and gears.

Inspect the inner and outer races for scored or damaged surface areas where the rollers contact the races.

Inspect the needle bearing on the nose of the overdrive planetary gear carrier assembly.

4. Remove and inspect the No.2 planetary thrust bearing.



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5. Remove coast clutch to O/D carrier adapter and O/D sun gear.



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6. Inspect the No. 12 needle bearing inside the overdrive planetary gear carrier.



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7. NOTE: Use petroleum jelly to hold the No. 2 overdrive planetary thrust bearing in place.

Install the No. 2 overdrive planetary thrust bearing between the overdrive center shaft face and the overdrive planetary gear carrier assembly.



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8. Install the overdrive planetary gear carrier into the overdrive center shaft and overdrive ring gear.



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9. CAUTION: Use care not to bend or damage the exciter wheel.

CAUTION: Before installing the overdrive sun gear into the overdrive planetary gear carrier, make sure the No. 12 sun gear thrust bearing race is aligned with the needle bearing inside the overdrive planetary gear carrier. The overdrive sun gear will not seat properly if the No. 12 sun gear thrust bearing race is not aligned in the center of the overdrive sun gear.

Install the overdrive sun gear into the overdrive planetary gear carrier.



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10. Install the coast clutch adapter on the overdrive sun gear.



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Center Support

Inspection

1. Inspect center support for damage. If damaged, replace center support assembly.





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2. Inspect seal rings for damage. If damaged, replace center support.



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3. Inspect thrust surface for wear, scoring or damage. Inspect forward clutch sealing surface for scoring

or damage. Inspect hydraulic passages for damage or restrictions.



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Low/Reverse Brake Drum

Low/Reverse Brake Drum Assembly





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Inspection

1. NOTE: The rear one-way clutch is part of the low/reverse drum assembly.

Inspect rollers, sprags, and reverse drum for damage. If damaged, replace drum assembly.



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Output Shaft Ring Gear and Hub Assembly

Output Shaft Ring Gear and Hub Assembly

Disassembly

1. Inspect the ring gear, hub, No. 10B needle bearing and No. 10A bearing race assembly for damage. If service is required, use the following procedures.

2. Remove No. 10B needle bearing, if not already removed.




1 7A153 Output Shaft Ring Gear

2 7D164 Output Shaft Hub


4 7M150 No. 10A Bearing Race Assembly

5 7M150 No. 10B Needle Bearing



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3. Remove No. 10A bearing race assembly.

4. Separate ring gear from hub by removing retaining ring.



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Assembly

1. Install output shaft hub into ring. Install retaining ring.

2. Install No. 10A bearing race assembly onto outshaft hub. Press on-snap fit.



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3. Use petroleum jelly and install No. 10B needle bearing onto output shaft ring gear and hub assembly.



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Torque Converter Service Procedures

Cleaning/Inspection

When internal wear or damage has occurred in the transmission, metal particles, clutch plate material, or band material may have been carried into the torque converter. These contaminates are a major cause of recurring transmission troubles and MUST be removed from the system before the transmission is put back into the vehicle.

Whenever a transmission has been disassembled to replace worn or damaged parts, or because the valve body sticks repeatedly from foreign material, the torque converter MUST be cleaned using a mechanical agitated cleaner, such as Rotunda Torque Converter/Transmission Oil Cooler Cleaner 014-00028 or equivalent.

Torque Converter Flushing

NOTE: Mineral spirits used to clean the torque converter must be fresh, non-chlorinated and non-halogenated.

Following the instructions included with the Torque Converter/Transmission Oil Cooler Cleaner 014-00028, flush out the converter.

After flushing the torque converter, follow these steps:

� Thoroughly drain the remaining solvent through the impeller hub. � Add 1.9L (2.0 quarts) of clean MERCON V® Automatic Transmission Fluid into fluid filler tube. � Agitate the solution inside the torque converter by hand. � Thoroughly drain the torque converter through the impeller hub.

Torque Converter Leak Check

1. Clean the outside surface of the torque converter.

2. Install Torque Converter Leak Check Tool and Gasket 014-R1075 into converter hub.





Torque Converter Leak Check Tool and Gasket 014-R1075



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3. Install torque converter with installed Torque Converter Leak Check Tool and Gasket 014-R1075 into press.



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4. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS.

Secure press. Apply enough force from press to seal tool into torque converter.

5. NOTE: Use clean dry shop air.

Apply air pressure 80 psi (MAX) to valve on Torque Converter Leak Check Tool and Gasket 014-R1075.



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6. With air pressure applied to valve, inspect for leaks at studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter.



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7. Release pressure and then slowly release press. Remove air hose.



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8. Rotate torque converter and tool then reinstall into press with tool up.

9. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS.

Secure press. Apply enough force from press to seal tool into torque converter.

10. NOTE: Use clean dry shop air.

Apply air pressure 80 psi (MAX) to valve on leak check tool.



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11. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter.



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12. Remove air hose. Release pressure and then slowly release press. Remove the converter. Remove the tool.



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Stator to Impeller Interference Check

1. Install the fluid pump support into torque converter. Engage the splines of the one-way clutch inner

race with the mating splines of the stator support.



End Play Checking Tool T80L-7902-A



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2. Rotate the torque converter both clockwise and counterclockwise. The fluid pump support should rotate freely without any signs of interference or scraping within the torque converter.

If there is an indication of scraping, the trailing edges of the stator blades may be interfering with the leading edges of the impeller blades. In such cases, replace the torque converter.



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Torque Converter End Play Check

1. Install End Play Checking Tool T80L-7902-A into the converter turbine hub until it bottoms.

2. Expand the sleeve in the turbine spline by tightening the threaded inner post until the tool is securely locked in the spline.



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3. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent to End Play Checking Tool T80L-7902-A. Position the indicator button on the converter impeller housing and set the dial face to zero (0).



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4. Lift the tool upwards as far as it will go and note the indicator reading. The indicator reading is the total end play which the turbine and stator share. Replace the torque converter if the total end play exceeds the specifications.

5. Loosen the threaded inner post to remove the tool from the torque converter (7902).

CONVERTER END PLAY

New or Rebuilt Converter Used Converter

mm Inch mm Inch

0.58 Max. 0.023 Max. 1.27 Max. 0.050 Max.



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ASSEMBLY

Transmission

1. Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for

burrs. Check the vent for obstructions and check all fluid passages for obstructions and leakage.

2. Inspect case bearing for damage. If damaged, replace bearing. Refer to steps a-d.





Bench-Mounted Holding Fixture T57L-500-B

Shift Lever Seal Replacer T74P-77498-A

Gauge Bar T93T-77003-AH

Front Pump Alignment Set T74P-77103-X

Band Adjustment Torque Wrench Set T71P-77370-A

Servo Rod Selecting Gauge T74P-77190-A

Extension Housing Bushing Replacer T77L-7697-F

Extension Housing Seal Replacer T74P-77052-A

TR Sensor Alignment Tool T97L-70010-A

Drive Handle T80T-4000-W

Case Bearing Installation Tool T97T-77110-A

Bearing Cup Puller T77F-1102-A


Turbine Shaft Speed Sensor Gauge T95L-70010-F

Valve Body Guide Pin (.235) T95L-70010-B

Valve Body Guide Pin (.248) T95L-70010-C

Torque Converter Handles T81P-7902-C


Converter Guide Pins T95L-7902-A



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a. Install Bearing Cup Puller T77F-1102-A with Impact Slide Hammer T50T-100-A onto case bearing. Remove bearing.



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b. Inspect case bore for nicks and burrs. Remove with oil stone prior to installation of new bearing.

c. Install Drive Handle T80T-4000-W into Case Bearing Installation Tool T97T-77110-A. Install



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new bearing on Case Bearing Installation Tool T97T-77110-A. Make sure bearing seal ring is facing Drive Handle T80T-4000-W.

d. Using a hammer, tap bearing into place with Case Bearing Installation Tool T97T-77110-A.



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3. Check all parking linkage for wear or damage.

4. Inspect all case threads for damage.



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5. Inspect the extension housing for cracks. Inspect the gasket surfaces for burrs or warpage.



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6. Inspect the bushing for scores or wear. Replace if required.

7. Inspect the rear seal for hardness, cracks or wear. If the seal shows wear or deterioration, replace the seal.

8. Inspect the seal counterbore and remove all burrs and scores with a crocus cloth.

9. NOTE: Bench-Mounted Holding Fixture T57L-500-B should still be attached to the adapter plate. If it is not, reattach the fixture arm at this time.

Reattach the adapter plate to the extension housing face using four M10 x 30 mm screws.


Install the transmission case in the Bench-Mounted Holding Fixture T57L-500-B and rotate so the transmission fluid pan rail is facing up.



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11. Lubricate and install the main control lever seal using Shift Lever Seal Replacer T74P-77498-A.



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12. Assemble the manual valve inner lever and parking pawl actuating rod as shown.

13. Install the manual control lever shaft into the case.



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14. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.

Align the manual control lever shaft with the manual control lever shaft retaining pin. Install the retaining pin.



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15. Install the manual valve inner lever and parking pawl actuating rod into the case. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft.

16. CAUTION: To avoid damage, do not allow wrench to strike the manual valve inner lever pin.




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17. CAUTION: The tabs on the No. 11 output shaft thrust washer point into the case. Ensure that the thrust washer is properly seated.

Apply petroleum jelly to the No. 11 output shaft thrust washer and install into the rear of the case bore.



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18. Install the park gear into the rear case bore.



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19. Rotating the reverse brake drum assembly clockwise and install into case.



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20. If not already installed, use petroleum jelly to install No. 10B thrust bearing onto output shaft hub.

21. Install the output shaft through the output shaft park gear.



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22. Install the output shaft ring gear and output shaft hub assembly.



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23. CAUTION: Always use a new retaining ring.

Install a new output shaft retaining ring in the output shaft retaining ring groove.



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24. NOTE: Use petroleum jelly to hold the sleeve in place.

Install the output shaft sleeve with cone facing up.



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25. NOTE: Use petroleum jelly to hold the needle bearings in place.

Position the No. 8 reverse planetary carrier needle bearing on the front face of the reverse planetary. Position the No. 9 reverse planetary carrier needle bearing on the rear face of the reverse planetary.

No. 8 and 9 Reverse Planetary Carrier Needle Bearing Position



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26. CAUTION: Make sure the needle bearings stay in place.

Install the reverse planetary assembly, with No. 8 and No. 9 reverse planetary carrier needle bearings, into the output shaft ring gear.

Reverse Planetary Assembly Installation



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27. PULL THE REVERSE BRAKE DRUM FORWARD and install the retaining ring into reverse brake drum groove. This will hold the reverse planetary assembly in place.



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28. CAUTION: Make sure band is resting on the two anchor pins in the case.

Install the reverse band over the reverse brake drum.



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29. Install the reverse band servo piston and rod temporarily to hold the reverse clutch band in position.



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30. Install the previously assembled forward geartrain assembly.



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Rotate the transmission assembly so that the converter housing gasket surface is facing up.

32. Place Gage Bar T93T-77003-AH on the case shoulder of the number four intermediate brake drum thrust surface. Set the mircometer on top of the gage bar as shown.

33. Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading as dimension "A."



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34. Place the micrometer on the opposite side and extend the mircometer probe until it contacts the intermediate brake drum thrust surface. Record the reading as dimension "B."

35. Add the dimensions "A" and "B," divide the total of "A" and "B" by two. Subtract the gage bar thickness (17.18 mm [0.700 in]). This is dimension "C."

36. Place Gage Bar T93T-77003-AH across the center support. Place micrometer on top of the gage bar as shown. Extend the micrometer probe until it contacts the center support thrust bearing surface.



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Record the reading as dimension "D."

37. Place the micrometer on the opposite side of Gage Bar T93T-77003-AH and extend the micrometer until it contacts the center support thrust bearing surface. Record the dimension as "F."

38. Add dimensions "D" and "F" and divide the total of "D" and "F" by two, then subtract the Gage Bar thickness (17.18 mm [0.700 in]). The resulting dimension is "G."

39. Add dimensions "G" and "C." This total is dimension "J." Use the chart below and dimension "J" to choose the proper number four thrust bearing. Reference end play is 0.21-0.51 mm (0.008-0.020 in).

40. Install the intermediate servo actuating lever as shown.

Dimension "J" Service Part

Number Bearing Thickness Identification

Notches

3.01-3.15 mm (0.119-0.124 in)

F77Z-7D014-GA 2.65-2.80 mm (0.104-0.110 in)

None

3.17-3.34 mm (0.125-0.132 in)

F77Z-7D014-HA 2.80-2.95 mm (0.110-0.116 in)

One

3.36-3.54 mm (0.133-0.140 in)

F77Z-7D014-KA 3.00-3.15 mm (0.118-0.124 in)

Two

3.57-3.71 mm (0.141-0.147 in)

F77Z-7D014-LA 3.20-3.35 mm (0.126-0.132 in)

Three



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41. NOTE: The intermediate band actuating lever shaft is shorter than the overdrive shaft.

Install the intermediate band actuating lever shaft through the intermediate servo lever.



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42. Install the intermediate band apply strut on the intermediate servo lever.



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43. NOTE: Make sure the apply strut is aligned with the band notch.

Install the intermediate band.



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44. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.

NOTE: The overdrive and intermediate band anchor struts are the same.

Install the intermediate band anchor strut and intermediate band adjusting screw.



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45. NOTE: Use petroleum jelly to hold the No. 4 intermediate brake drum thrust bearing in place.

Install the correctly selected No. 4 intermediate brake drum thrust bearing over the center support as shown.



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46. CAUTION: Do not apply pressure to the rear planetary support while installing. Damage to the sealing rings may result. Make sure the rear planetary support is seated.

Position the center support into the reverse clutch drum. Use the input shaft as an aid to seat the center support. Gently wiggle the input shaft from side to side until the center support is seated against the case shoulder. Remove the input shaft.



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47. CAUTION: Install the retaining ring in the transmission case groove with the tapered side facing up.

CAUTION: The retaining ring must be installed so the notch opening is not obstructed by the center support retaining ring. This will prevent damage to the turbine shaft speed (TSS) sensor wires.

Install the center support retaining ring in the transmission case groove.



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48. Ensure that the nut and cage assembly is in place.



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49. Use a 5 mm Allen wrench to install the M6 x 20 mm center support-to-case capscrew into the nut and cage assembly as shown. Tighten the center support-to-case capscrew to 9-13 Nm (80-115 lb-in).



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50. CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.

Route the TSS sensor connector and wiring harness through the opening in the case.



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51. Install the turbine shaft speed (TSS) sensor on the center support. Use a T30 Torx® Socket to install the TSS screw. Tighten the TSS sensor-to-center support screw to 8-11 Nm (71-97 lb-in).



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52. CAUTION: Use only the No. 3 center shaft thrust bearing assembly.

NOTE: No. 3 center shaft thrust bearing assembly has no notches on the outer race.

Install the No. 3 center shaft thrust bearing assembly.



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53. CAUTION: Do not bend the trigger wheel.

Install the planetary gear overdrive carrier, overdrive ring gear, overdrive one-way clutch and overdrive center shaft assembly.



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54. NOTE: Perform TSS air gap clearance check. This step and the next two steps describe the procedures for checking the turbine shaft speed (TSS) sensor air gap clearance.

Place the thin blade of Turbine Shaft Speed Sensor Gauge T95L-70010-F over the turbine shaft speed (TSS) sensor as shown. Rotate the trigger wheel. The trigger wheel window should pass over the thin blade of the TSS gauge. If it doesn't, the planetary gear overdrive carrier and trigger wheel must be replaced.



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55. Place the thick blade of Turbine Shaft Speed Sensor Gauge over the turbine shaft speed (TSS) sensor as shown. Rotate the trigger wheel. The trigger wheel window should not pass over the thick blade of the TSS gauge. If it does, the planetary gear overdrive carrier and trigger wheel must be replaced.



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56. Repeat the previous two steps for the remaining trigger wheel windows.

57. Align the clutch plates and front adapter gear and install the overdrive brake and coast clutch drum assembly.



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58. Install the overdrive band lever-to-case bracket and overdrive band servo lever as shown.



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59. NOTE: The overdrive band actuating lever shaft is longer than the intermediate band actuating lever shaft.

Install the overdrive band actuating lever shaft through the overdrive band lever to case bracket and overdrive band servo actuating lever.



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60. Install the overdrive band apply strut.



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61. NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.

Install the overdrive band assembly over the overdrive brake and coast clutch drum.



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62. NOTE: Use the band adjusting screw as a temporary alignment guide.

Install the overdrive band anchor strut.



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63. Install the overdrive band adjusting screw.



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64. Perform the front end play check procedure as follows:

a. CAUTION: Be sure the pump body is seated against the washer and overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

Use petroleum jelly to hold any No. 1 fluid pump thrust washer on the rear of the pump. The washer tabs go into the pump face. Place the pump into position in the case.



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b. CAUTION: The gauge bar must rest on the gasket surface.

Place Gauge Bar T93T-77003-AH across the case as shown. c. Place a micrometer on the gauge bar and extend the probe until it contacts the pump surface. d. Read the micrometer and subtract the thickness of the gauge bar (17.78 mm [ 0.700 inch]).

Record this as dimension "A." e. Move the gauge bar to the opposite side of the case. f. Repeat Steps c and d and record this measurement as dimension "B." g. Add dimensions "A" and "B" together and divide by 2. This is the front end clearance,

dimension "C."



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h. CAUTION: If the average is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.

NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 in).

NOTE: The tabs on the washer go into the pump face.

Remove the pump and install the correct No. 1 thrust washer. Use petroleum jelly to hold the washer in place. TRANSMISSION END CLEARANCE

Dimension "C" Identification:

Color Service Part

Number Washer Thickness

Front No. 1 (All Engines) 0.18-0.70 mm (0.007-0.028 in.) Without Gasket

White Green Red

Beige Black Yellow

97GT-7D014-TA 97GT-7D014-MA 97GT-7D014-NA 97GT-7D014-PA 97GT-7D014-RA 97GT-7D014-SA

1.55-1.60 mm (0.061-0.063 in.) 1.75-1.80 mm (0.069-0.071 in.) 1.85-1.90 mm (0.073-0.075 in.)



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i. NOTE: Front end clearance specification is 0.18-0.70 mm (0.007-0.028 in).

Verify front end clearance is correct; repeat steps a-g.

65. Install a new drive gear O-ring.

66. Lubricate Fluid Pump Seal Sizing Tool T95L-70010-G to seat drive gear O-ring.

67. Install Fluid Pump Seal Sizing Tool into pump drive gear to seat drive gear O-ring into groove.

1.95-2.00 mm (0.077-0.079 in.) 2.05-2.10 mm (0.081-0.083 in.) 2.15-2.20 mm (0.085-0.087 in.)



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68. Remove Fluid Pump Seal Sizing Tool.

69. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.

Position the two pump gears into the pump housing. Apply a lubricant to the pump gears to prevent scoring at initial start-up.



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70. CAUTION: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.



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71. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.

NOTE: The notch on the outside of the fluid pump adapter plate will be at the nine o'clock position, relative to the converter housing.

Turn the converter housing face down on the bench. Hold the fluid pump adapter plate against the front pump support and gear to keep the pump gears in place. Turn the pump and adapter plate over and place on the converter housing.



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72. Install the six M8 x 35 mm Torx® head front pump support and gear screws fingertight only.



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73. CAUTION: Fluid Pump Alignment Set T74P-77103-X must be used to properly align the front pump support and gear to the fluid pump adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Select the gauge that will be the snuggest fit when placed over the fluid pump support and gear.

74. Thread the gauge into Pump Alignment Handle T74P-77103-H (Part of T74P-77103-X, Fluid Pump Alignment Set). Slide the tool over the front pump support and gear until it bottoms out in the pump gear pocket. This centers the pump to the converter housing.



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75. Use a Torx® 40 socket wrench to tighten the six M8 x 35 mm fluid pump support and gear-to-converter housing screws. Tighten the fluid pump support and gear-to-converter housing screws in a star pattern to 22-28 Nm (16-21 lb-ft). Remove the Pump Alignment Handle.



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76. Install a new fluid pump seal ring.



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77. NOTE: Make sure the fluid pump seal ring is installed on the converter housing and pump assembly.

Place a new fluid pump gasket on the fluid pump adapter plate as shown. Use petroleum jelly to hold the fluid pump gasket in place.



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78. Install the correct No. 1 fluid pump thrust washer on the fluid pump support and gear. Use petroleum jelly to hold the washer in place.



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79. NOTE: Verify correct seal installation. Be sure seal grooves are clean and free of burrs.

Turn the converter housing over and install the front pump support seal ring.



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80. NOTE: The splines on the input shaft are not the same length. The shorter splines go into the assembly.

Install the input shaft as a guide for the converter housing and fluid pump support and gear assembly. Install the Converter Guide Pins T95L-7902-A as shown.



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81. Install the converter housing and fluid pump support and gear assembly (with the fluid pump gasket) and the No. 1 fluid pump thrust washer to the case.



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82. NOTE: Lubricate O-rings on converter housing screws.

Remove Converter Guide Pins and use a 17 mm socket wrench to install the eight new M10 x 33 mm converter housing-to-case screws. Tighten the converter housing-to-case screws in a star pattern to 36-52 Nm (27-39 lb-ft).



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83. Remove input shaft.


Rotate the transmission assembly so the fluid pan rail is facing up.

85. CAUTION: Do not damage the overdrive servo cover to case O-ring during installation. Do not press the overdrive servo cover and O-ring past the relief hole in the case. O-ring damage may occur.



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Install the overdrive servo piston spring, servo piston and rod assembly, servo cover to case O-ring with servo cover.


1 7D021 Overdrive Servo Piston and Rod Assembly

2 7D027 Overdrive Servo Cover and Seal Assembly

3 7D040 Overdrive Servo O-Ring

4 7D028 Overdrive Servo Piston Spring

5 — Relief Hole (Part of 7005)



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86. NOTE: The J-hook must be in the appropriate hole for the servo being removed, and tool number should be facing up.


87. Use a 1/2-inch wrench to tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.



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88. Carefully install the servo cover retaining ring.



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91. CAUTION: Do not damage the intermediate servo cover to case O-ring during installation. Do not press the intermediate servo cover and seal assembly and O-ring past the relief hole in the case. O-ring damage may occur.

Install the intermediate servo piston spring, servo piston and rod assembly, servo cover to case O-ring with servo cover assembly with O-ring.



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1 — Relief Hole (Part of 7005)

2 7D028 Intermediate Servo Piston Spring

3 7D027 Intermediate Servo Cover and Seal Assembly

4 7D040 Intermediate Servo O-Ring

5 7D021 Intermediate Servo Piston and Rod Assembly



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92. NOTE: The J-hook must be in the appropriate hole for the servo being removed, and tool number should be facing up.

Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail. Tighten the screws.

93. Use a 1/2-inch wrench to tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.



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94. Carefully install the intermediate servo cover retaining ring.



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Carefully back off the nut on the J-hook until the servo piston spring is unloaded.



CAUTION: The overdrive servo must be installed prior to band adjustment.

Install new locknut. Tighten the overdrive band adjusting screw using Band Adjustment Torque Wrench Set T71P-77370-A. The wrench will click at 14 Nm (10 lb-ft). Back off the band adjusting screw exactly two (2) turns and hold that position. Tighten the overdrive band locknut to 47-61 Nm (35-45 lb-ft) using a 19 mm wrench.



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CAUTION: Intermediate servo must be installed prior to band adjustment.

Install new locknut. Tighten the intermediate band adjusting screw using Band Adjustment Torque Wrench Set T71P-77370-A. The wrench will click at 14 Nm (10 lb-ft). Back off the band adjusting screw exactly two and one-half (2 1/2) turns and hold that position. Tighten the intermediate band locknut to 47-61 Nm (35-45 lb-ft) using a 19 mm wrench.



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99. NOTE: Make sure the tab is in the lock position.

Inspect O-rings (W703015-S300) for damage. Replace if damaged. Lubricate and install the 16-pin connector assembly through the case until a click is heard.



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100. CAUTION: Do not overstretch the 16-pin connector assembly retaining spring.

Install the 16-pin connector assembly retaining spring.



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101. NOTE: Align the slot on the turbine shaft speed (TSS) sensor connector with the slot on the 16-pin connector assembly.

Carefully install the TSS sensor connector into the 16-pin connector assembly.



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102. Carefully insert TSS sensor connector wires into the retaining slot on the 16-pin case connector.



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103. Install the valve body guide pins into the case in the positions shown.



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104. NOTE: Ensure main control assembly gasket is properly aligned.

Install the main control assembly on the case. Align the manual valve with the manual valve inner lever pin as shown.



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105. Install four M6 x 45 mm main control assembly-to-case screws in location A. Fingertighten.

Main Control Assembly Screws and Locations



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106. Install two M6 x 35 mm main control assembly-to-case screws in location B. Fingertighten.

107. Install one M6 x 30 mm main control assembly-to-case screw in location C. Fingertighten.

108. Remove both Valve Body Guide pins T95L-70010-B and T95L-70010-C.



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109. Install sixteen M6 x 40 mm main control assembly-to-case screws in location D. Fingertighten.

110. Tighten all main control assembly-to-case screws including reverse servo cover sequence (1R, 2R, 3R and 4R), to 8-11 Nm (71-97 lb-in) in sequence shown, using a 10 mm socket wrench.

Tightening Sequence

111. Install the manual valve detent spring. Install the manual valve detent spring screw in location A. Tighten the manual valve detent spring screw to 8-11 Nm (71-97 lb-in).



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112. NOTE: Perform Steps 105 through 112 only if rear reverse servo piston and rod is to be checked.

Remove the reverse servo piston and rod from the case.

113. NOTE: An A4LD Reverse Servo Return Spring D4ZZ-7D031-A is to be used only as a test spring.

Install the reverse servo piston and rod into the servo bore along with a D4ZZ-7D031-A reverse servo return spring.

114. Install a new reverse servo separator plate cover gasket. Install Servo Rod Selecting Gauge T74P-77190-A and tighten with the three screws.

115. Tighten the servo gauge adjusting screw to 4 Nm (35.5 lb-in).

116. Install Dial Indicator with Bracketry TOOL-4201-C or equivalent on the transmission case. Position the indicator on the piston pad. Set the dial indicator to zero.



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117. NOTE: If the piston travel in this step is 3-5.6 mm (0.120-0.220 inch), it is within specification. If the piston travel is greater than 5.6 mm (0.220 inch), use the next longer piston and rod. If the piston travel is less than 3 mm (0.120 inch), use the next shorter piston and rod.

Back out the servo gauge adjusting screw until it bottoms out on the tool. Record the distance the servo piston traveled.

118. CAUTION: Make sure the test spring is removed after this step.

Use the above procedure to check the piston travel with the newly selected reverse band servo piston and rod (if required) to make sure that the piston travel is 3-5.6 mm (0.120-0.220 inch).

Remove the servo gauge and the reverse band servo return spring.

NOTE: Grooves are located on reverse servo rod.



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119. CAUTION: The reverse servo test spring must be removed.

Install the reverse servo cover and the four reverse servo cover-to-case screws. Tighten the reverse servo cover-to-case screws to 12-14 Nm (106-124 lb-in) in the sequence shown.

120. Carefully press down to install the solenoid connectors on the solenoids as shown.

Length — mm Length — Inches I.D.

54/53 2.112/2.085 1 Groove

51/50 2.014/1.986 No Groove

49/48 1.915/1.888 2 Grooves



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122. Ensure that both O-rings are properly installed onto filter prior to installation.



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123. CAUTION: Lubricate the fluid filter O-rings with MERCON V® XT-5-QM approved fluid, or they may be damaged.

Lubricate and install new O-rings onto filter assembly. Install a new fluid filter assembly into the main control assembly. Install one "E" length M6 x 55 fluid filter assembly-to-main control assembly screw and tighten to 8-11 Nm (71-97 lb-in).

124. Install Rotunda Transmission Tester 007-00130 on the transmission 16-pin case connector.



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125. Use Rotunda Transmission Tester 007-00130 and the 4R44E/4R55E Cable/Overlay 007-00106 to perform the solenoid static function check bench testing procedures. Refer to Diagnosis and Testing in this section. This procedure will verify the electrical function of all solenoids prior to installing the fluid pan.

126. Depress the lock tab and remove the transmission tester.



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127. Position a new fluid pan gasket on the case fluid pan rail.



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128. Install the fluid pan on top of the gasket. Use a 13 mm socket wrench to install the eighteen M8 x 16 mm fluid pan-to-case screws. Tighten the fluid pan-to-case screws to 13-15 Nm (115-133 lb-in).



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129. Remove the transmission from the bench fixture pivot. Place the transmission on a flat surface. Remove the fixture and adapter plate.



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130. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup.

NOTE: Use petroleum jelly to hold the gasket in place.

NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.

Install a new extension housing gasket on the case.

131. Install the parking pawl, pawl return spring and pawl shaft into the extension housing.



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132. Install the extension housing. Install the five M10 x 30 mm extension housing-to-case screws and one stud. Tighten the extension housing-to-case screws and stud to 36-52 Nm (27-39 lb-ft).



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133. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.

CAUTION: Tool will bottom when bushing is in the proper position.

NOTE: The lube hole should be located at the 3 o'clock position with view extension from the rear.

NOTE: Install the extension housing bushing only if it was removed in disassembly.

Install the extension housing bushing using Extension Housing Bushing Replacer T77L-7697-F.



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134. Position the extension housing seal drain hole at the 6 o'clock (down) position and install the extension housing seal using Extension Housing Seal Replacer T74P-77052-A.

135. Install the digital transmission range (DTR) sensor on the manual lever. Install the two TR sensor screws and finger tighten. Rotate the manual lever to the neutral position (two detents rearward).



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138. CAUTION: The splines are not the same on both ends. The shaft end with the shorter splines goes into the front pump support and gear.

Install the input shaft into the front pump support and gear.



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139. Insert Fluid Pump Seal Sizing Tool T95L-70010-G into pump drive gear to make sure the drive gear O-ring is properly seated prior to installing the torque converter. Remove tool.



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140. WARNING: THE TORQUE CONVERTER CAN FALL OUT IF THE TRANSMISSION IS TIPPED.

CAUTION: Do not damage the pump drive gear O-ring when installing the torque converter.

CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Lightly lubricate the converter hub with MERCON V® XT-5-QM transmission fluid.



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141. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.

Use Torque Converter Handles T81P-7902-C to install the torque converter by pushing and rotating.



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142. NOTE: dimension "A" should be 10.23-14.43 mm (0.43-0.56 inch).

Check dimension "A."



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143. Prior to installation of the transmission assembly, the torque converter pilot hub must be properly lubricated. Use Ford Multi Purpose Grease (D0AZ-19584-AA, specification ESA-M1C45-A).



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144. Before installing transmission, make sure that the transmission cooling system (line and cooler[s])

have been thoroughly flushed. Use the procedure found in this section. If contamination cannot be removed, or proper flow cannot be obtained, replace cooler and/or lines.

145. Install Torque Converter Holding Tool T97T-7902-A onto the case using standard bolt and nut to prevent converter from falling forward when moving to jackstand and to vehicle.



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INSTALLATION

Transmission — 4x2 Aerostar

1. Install transmission and tighten bolts to 44-60 N-m (32-44 lb-ft).

2. CAUTION: Use care not to bend or otherwise damage the cooler lines.

NOTE: The case connector fitting must be held in place to prevent it from moving while tightening the tube nut.

Remove the caps from the lines and fittings. Securely install the transmission cooler lines to the transmission fittings.

3. Install new torque converter nuts and tighten them to 34-46 Nm (25-34 lb-ft).

4. Position the dual TWC converter assembly to the exhaust manifolds. Install four bolts and tighten them to 34-46 Nm (25-34 lb-ft).

5. Install the exhaust hanger to the transmission mount. Tighten the retainer to 20-27 Nm (15-20 lb-ft).

6. Raise the transmission, position the crossmember, and install through bolts and nuts. Tighten the retainers to 37-52 Nm (27-38 lb-ft).

7. Lower the transmission onto the crossmember. Remove the transmission jack adapter plate from the transmission. Lower and remove the jack.

8. Install the nuts to the transmission support insulator. Tighten the nuts to 85-118 Nm (63-87 lb-ft).

9. Reconnect the 8-pin and 16-pin connectors at the left rear cylinder head, reconnect the HO2S, and install the shift indicator cable to the bracket and lever.

10. Position the transmission access cover and install the two transmission access cover screws. Tighten them to 16-22 Nm (12-16 lb-ft).

11. Position the starter motor and ground wire. Install the bolts and tighten them to 22-28 Nm (16-21 lb-ft).

12. Lightly coat the slip yoke with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent.

13. Remove the plug and install the driveshaft. Rotate the driveshaft and align it with the index mark made during removal. Install the bolts and tighten them to 83-118 Nm (61-87 lb-ft).

14. Remove the safety stands.

15. Lower the vehicle.

16. Connect the negative battery cable.





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17. Fill the transmission to the proper level with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent and install the indicator.

18. NOTE: A weight of 1.4kg (3 lb) must be hung on the gearshift lever to verify the lever is located firmly on the DRIVE or the OVERDRIVE detent.

From inside the vehicle, place the gearshift lever in the DRIVE or the OVERDRIVE position.

19. Raise the vehicle.

20. Remove the shift cable from the transmission lever ball stud. Pull the lock tab down on the shift cable body. Position the gearshift lever in the DRIVE position (three detents from the front-most lever position, with the first position counted as one). Connect the cable end fitting to the transmission lever ball stud. Push up on the lock tab to lock the cable in the correctly adjusted position.


22. Remove the 1.4kg (3 lb) weight from the gearshift lever. After making the adjustment, check for park engagement. Check the gearshift lever in all detent positions with the engine running to verify correct detent/transmission actions. Readjust if necessary.



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INSTALLATION

Transmission—4x2 Ranger

Installation

1. Position the torque converter to the transmission. Align the converter to the front pump by rotating the converter and pushing it inward until full engagement is made. Lightly lubricate the converter pilot hub using Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.

2. NOTE: The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the crankshaft.

Position the transmission under the vehicle. Raise the transmission into position. Do not allow the torque converter drive flats to disengage the pump gear. Rotate the converter to align the studs with the flexplate mounting holes. Position the transmission to the engine.

3. NOTE: The top right transmission-to-engine bolt, retaining the fluid level indicator tube and harness bracket, must be installed after the other transmission-to-engine bolts have been installed and tightend.

Install the connector bracket, fluid level indicator tube, and six transmission-to-engine bolts. Tighten the bolts to 44-60 Nm (32-44 lb-ft). Connect the 16-pin harness connectors.

4. Remove the engine support.

5. CAUTION: Use care not to bend or otherwise damage the cooler lines. The case connector fitting must be held in place to prevent it from moving while tightening the tube nut.

Remove the caps from the lines and fittings. Install the transmission cooler lines. Tighten the fittings to 35-43 Nm (26-32 lb-ft). Securely install the bolt retaining the cooler line bracket to the engine block.

6. Install new torque converter nuts. Tighten the nuts to 34-46 Nm (25-34 lb-ft).

7. Install the torque converter access cover. Securely install two access cover bolts.

8. Raise the transmission and position the Y-pipe to the exhaust manifolds. Loosely install the hanger bracket bolt. Install the converter-to-tailpipe flange bolts and the Y-pipe-to-manifold bolts. Tighten the bolts to 34-46 Nm (25-34 lb-ft).

9. Install the exhaust hanger at the transmission support insulator. Tighten the retainer to 20-27 Nm (15-20 lb-ft).

10. Position the crossmember. Install the bolts and nuts. Tighten the retainers to 37-52 Nm (27-38 lb-ft).

11. Lower the transmission guiding support insulator studs into the crossmember. Install the transmission support insulator nuts. Tighten the nuts to 85-118 Nm (63-87 lb-ft).





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12. Lower and remove the transmission jack from under the vehicle.

13. Connect the HO2S connectors and install the shift cable to the shift cable bracket. Connect the shift cable to the manual control lever.

14. Install the oil filter funnel and the starter motor. Install the bolts and tighten them to 22-28 Nm (16-21 lb-ft). Securely install the oil filter funnel bolt and nut.

15. Lightly coat the slip yoke with Premium Long-life Grease XG-1-C (or -K, or equivalent meeting Ford specification ESA-M1C75-B).

16. Remove the extension housing plug and install the driveshaft. Rotate the driveshaft and align it to the index mark made during removal. Install the bolts and tighten them to 83-118 Nm (61-87 lb-ft). Install two midship bearing clips and bolts. Tighten the retainers to 37-50 Nm (27-37 lb-ft).

17. Remove the jack stands.


19. From inside the vehicle, place the gearshift lever in the DRIVE or OVERDRIVE position. Hang a weight of 1.4 kg (3 lb) on the gearshift lever to verify the lever is located firmly on the D or OVERDRIVE detent.

20. Raise the vehicle.

21. Remove the shift cable from the transmission lever ball stud. Pull down on the lock tab on the shift cable body. Position the gearshift lever in the DRIVE position. (This is three detents from the frontmost lever position, with the first position counted as one). Connect the cable end fitting to the transmission lever ball stud. Push up on the lock tab and lock the cable in the correctly adjusted position.


23. Install the fan shroud-to-radiator bolts. Tighten the bolts to 6-8 Nm (53-71 lb-in).

24. Connect the negative battery cable.

25. Fill the transmission to the proper level with Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON® specification and install the fluid level indicator.

26. Check the operation of the transmission.

27. Remove the three-pound weight from the gearshift lever. After making the adjustment, check for park engagement. Check the gearshift lever in all detent positions with the engine running, to verify correct detent/transmission actions. Readjust if necessary.



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INSTALLATION

Transmission — 4x4

1. WARNING: SECURE THE TRANSMISSION TO THE TRANSMISSION JACK WITH A SAFETY CHAIN.

Position the transmission on a transmission jack.

2. Raise the transmission jack and position the transmission to engine.

3. Remove Torque Converter Holding Tool T97T-7902-A.

4. Position the transmission to the engine and align the converter stud-to-flex plate index mark made at removal.

5. Install the four converter housing-to-engine screws. Tighten to 40-55 Nm (30-41 lb-ft) on the 2.3L. On the 3.0L, tighten to 40-55 Nm (30-41 lb-ft).

6. CAUTION: Use care not to bend or otherwise damage the cooler lines.

Remove the plugs and install the transmission cooler lines. Tighten the transmission cooler lines tube nuts to 24-31 Nm (18-23 lb-ft).

7. Install the two lower converter housing-to-engine screws. Tighten to 40-55 Nm (30-41 lb-ft) on the 2.3L. On the 3.0L, tighten to 40-55 Nm (30-41 lb-ft).

8. Install the fluid filler tube into the lube fluid inlet short tube.

9. Install the two upper converter housing-to-engine screws. Tighten to 40-55 Nm (30-41 lb-ft) on the 2.3L. Tighten to 40-55 Nm (30-41 lb-ft) on the 3.0L.

10. Install the transfer case. Refer to Section 07-07A , Section 07-07B , Section 07-07C or Section 07-07D .

11. Install the transfer case vent bracket. Tighten the transfer case vent bracket screws to 34-46 Nm (25-34 lb-ft).

12. Install the five transfer case-to-extension housing bolts. Tighten to 34-48 Nm (25-35 lb-ft).

13. On 3.0L, install the catalytic converter and crossover pipe nuts using 15 mm socket wrench. Tighten the nuts to 24-34 Nm (18-25 lb-ft).

14. On 3.0L, install the catalytic converter-to-exhaust bolts. Tighten to 24-34 Nm (18-25 lb-ft).

15. Install the rear engine mount. Refer to Section 02-03 .

16. On Aerostar vehicles, install the two crossmember-to-frame through nuts and bolts. Tighten to 37-52 Nm (28-38 lb-ft).





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17. On Aerostar vehicles, install the engine support-to-crossmember screws. Tighten to 98-132 Nm (73-97 lb-ft).

18. On Ranger vehicles, install the two crossmember-to-frame through nuts and bolts. Tighten to 88-115 Nm (65-85 lb-ft).

19. On Ranger vehicles, install the engine support-to-crossmember nuts. Tighten to 88-115 Nm (65-85 lb-ft).

20. Install the two rear engine support-to-crossmember nuts. Tighten to 85-118 Nm (63-87 lb-ft).

21. Connect the transfer case electrical connectors.

22. Install the front axle driveshaft. Refer to Section 05-03A , Section 05-03B or Section 05-03C .

23. Install the transfer case skid plate. Tighten the skid plate screws to 22-28 Nm (16-21 lb-ft).

24. Connect the 16-pin transmission electrical connector and the digital transmission range (DTR) sensor connector.

25. Install the transmission shift cable into the cable bracket.

26. Install the transmission shift bellcrank on the ball stud lever.

27. Connect the transmission shift cable to the transmission manual control lever.

28. Adjust shift cable; refer to cable adjustment.

29. Install the vehicle speed sensor (VSS) (if equipped) into the transfer case.

30. Align the index mark made at removal and install the rear driveshaft. Refer to Section 05-01 .

31. CAUTION: Never turn the engine counterclockwise (as viewed from the front).

CAUTION: Use new flexplate-to-converter nuts.

Install the four new flexplate-to-converter nuts, using a 22 mm socket wrench and breaker bar on the crankshaft pulley to turn the engine into position. Tighten the flexplate-to-converter nuts to 30-40 Nm (22-30 lb-ft).

32. Install the starter motor. Refer to Section 03-06 .

33. For 3.0L, install the transmission access cover and screws. Tighten the bolts to 16-22 Nm (12-16 lb-ft).


35. Fill the transmission fluid with MERCON V® XT-5-QM to the proper level. Refer to procedure in this section.

36. Install the fluid level indicator.



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37. Install the battery ground cable.



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CLEANING AND INSPECTION

Transmission Fluid Lines

When one or more of the fluid cooler steel tubes must be replaced, each replacement tube must be fabricated from the same size steel tubing as the original line.

Using the old tube as a guide, bend the new tube as required. Add the necessary fittings and install the tube. Make sure the tube has adequate clearance to the other components, especially the exhaust system and parts having sharp edges.

After the fittings have been tightened, add fluid as needed and check for fluid leaks.





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Transmission

It is important to completely clean all transmission components including the converter, fluid cooler, cooler lines, main control valve body, all clutches and check balls after any transmission servicing that generates contamination. These contaminants are a major cause for recurring transmission troubles and must be removed from the system before the transmission is put back into service. The cleaning of debris from the coast, direct/reverse, and the forward clutch check balls is often omitted. This omission can lead to a repeat servicing of the transmission.

Clean the parts with a suitable solvent and use moisture-free air to dry off all the parts and clean out fluid passages.

CAUTION: Do not use mineral spirits or oil based solvent.

The composition clutch plates, bands, and synthetic seals should not be cleaned in a vapor degreaser or any type of detergent solution.

To clean these parts, wipe them off with a lint-free cloth. New clutch plates or bands should be soaked in transmission fluid specified for that transmission type for 30 minutes before being assembled.





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1. Clean all parts thoroughly in clean solvent and blow dry with moisture-free compressed air.

2. Inspect all valve and plug bores for scores. Check all fluid passages for obstructions. Inspect the check valve for free movement. Inspect all mating surfaces for burrs or distortion. Inspect all plugs and valves for burrs or scores. Replace the control valve body if the bores or valve are scored beyond the point of being cleanable.

3. CAUTION: Do not sand, stone or polish valves and bores. This removes the anodizing treatment and destroys them.

Inspect all springs for distortion. Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight into their respective bores.

4. Roll the manual valve on a flat surface to check for a bent condition.





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Overdrive and Intermediate Servos

NOTE: Identify servo covers, pistons, and springs with a tag.

1. Inspect the servo bore for cracks and the servo piston for damage (the rubber sealing surfaces should be pliable). Inspect the piston bore, servo piston bore and servo piston stem for scores. Check the fluid passages for obstructions. Replace damaged seals.

2. Check the servo springs, servo band strut(s) and apply levers for distortion and wear.

3. Inspect the cover seal and gasket cover sealing surface for damage.

4. Inspect the band lining for excessive wear and for proper bonding to the metal band.





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Low-Reverse Servo and Band

1. Inspect the bore for scores.

2. Check the fluid passages for obstructions.

3. Inspect the band for distortion. Inspect the band ends for cracks.

4. Inspect the servo for distortion.

5. Inspect the band lining for excessive wear and for proper bonding to the metal band.

6. Replace the cover seal if damaged.

7. Replace the piston seals if damaged.





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Extension Housing

1. Inspect the housing for cracks. Inspect the gasket surface for burrs or warpage.

2. Inspect the bushing for scores or wear. Inspect slip yoke for damage. Replace if required.

3. Inspect the rear seal for hardness, cracks or wear. Replace if required.

4. Inspect the seal counterbore and remove all burrs and scores with a crocus cloth.





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Pump

1. Inspect the mating surfaces of the pump body and case for burrs.

2. Inspect the drive and driven gear bearing surfaces for scores. Check the gear teeth for burrs.

3. Inspect the inner pump gear O-ring for damage.

4. Inspect the front pump seal for cuts or nicks. Inspect the pump bushing for scoring.

5. Check all fluid passages for obstruction.

6. If any parts are found damaged or worn, replace the pump as an assembly. Minor burrs and scores may be removed with a crocus cloth.





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Direct/Reverse and Coast Clutches

1. Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.

2. Inspect the clutch piston bore and piston inner and outer bearing surfaces for scores.

3. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstruction.


5. Inspect the clutch pressure plate for scoring and binding on the clutch plate surface. Check the clutch release spring for distortion pressure.

6. The clutch cylinders have check balls. Inspect the check balls for freedom of movement and proper seating.

7. Inspect the friction plates for proper installation (direction).





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Forward Clutch

1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serration for scores or burrs. Minor scores and burrs may be removed with a crocus cloth. Replace the clutch cylinder if it is badly scored or damaged.

2. Check the fluid passages in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and replace if necessary. Inspect the piston check ball for freedom of movement and proper seating.

3. Check the clutch release springs for distortion and cracks. Replace the springs if they are distorted or cracked.

4. Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored surfaces. Replace all parts that are deeply scored.

5. Check all clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.

6. Check the clutch hub thrust surfaces for scores. Check the clutch hub splines for wear.





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Input Shaft

Check the input shaft for damaged or worn splines. Replace the shaft if the splines are excessively worn. Inspect the bushings in the stator support for scores.





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Overdrive One-Way Clutch and Rear One-Way Clutch

1. Inspect the outer and inner races for scores or damaged surface areas where the rollers contact the races.

2. Inspect the rollers and springs for excessive wear or damage.





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Converter and Fluid Cooler

When wear or internal damage has occurred in the transmission, metal particles, clutch plate material, or band material may have been carried into the converter and fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into service.

Whenever a transmission has been disassembled to replace worn or damaged parts, or because the valve body sticks from foreign material, the converter, fluid cooler and cooler lines must be cleaned and flushed. Rotunda Torque Converter/Transmission Oil Cooler Cleaner 014-00028 or equivalent can be used. Under no circumstances should an attempt be made to clean the torque converter by hand agitation with solvent.

The lack of a drain plug in the torque converter increases the amount of residual flushing solvent in the torque converter after cleaning. This retained solvent is not acceptable and a method of diluting is required. The following procedure is to be used after the removal of the torque converter from the cleaning equipment.

1. Thoroughly drain the remaining solvent through the converter hub.

2. Add 1.9L (2.0 quarts) of clean MERCON V® XT-5-QM transmission fluid to the converter. Agitate by hand.

3. Thoroughly drain the solution through the converter hub.





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Pinion Carriers

Individual parts of the planetary carriers are not serviceable.

1. Check the pins and shafts in the planetary assemblies for loose fit and/or complete disengagement. Use a new planetary assembly if either condition exists. Before installing a planetary assembly, the shaft retaining pins should be checked for adequate staking. Do not restake the planetary pinion. If necessary, replace the planetary assembly.

2. Inspect the pinion gears for damaged or excessively worn teeth.

3. Check for free rotation of the pinion gears.





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Stator Support

1. Inspect the stator support splines for burrs and wear.

2. Check the oil ring grooves in the stator support for nicks, burrs or damaged edges.

3. Check the front and rear bushings of the stator support for wear or scoring.

4. Check front pump support seal and groove.

5. Check the seal rings for damage.

6. Check bearings for damage.





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Case

Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the vent for obstructions, and check all fluid passages for obstructions and leakage.

Inspect the case bearing for scores. Check all parking linkage parts for wear or damage.

Inspect the case threads for damage.





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Case Thread Repair Procedures

If a transmission case thread is damaged, service kits may be purchased from local jobbers. To service a damaged thread, the following procedure should be carefully followed.

1. Drill out the damaged threads, using the same drill size as the thread outside diameter. For example, use a 5/16-inch drill for a 5/16-18-inch thread.

2. Select the proper special tap and tap the drilled hole. The tap is marked for the size of the thread being repaired. The special tap marked 5/16-18 inch will not cut the same thread as a standard 5/16-18-inch tap. It does cut a thread large enough to accommodate the insert, and after the insert is installed, the original thread size is restored.

3. Select the proper coil inserting tool. These tools are marked with the thread size being repaired. Place the insert on the tool and adjust the sleeve to the length of the insert being used. Press the insert against the face of the tapped hole. Turn the tool clockwise and wind the insert into the hole until the insert is one-half turn below the face.

4. Working through the insert, bend the insert tang straight up and down until it breaks off at the notch.

5. Improperly installed inserts can be removed with the extractor tool. Place the extractor tool in the insert with the blade resting against the top coil one-quarter to one-half turn away from the end of the coil. Tap the tool sharply with a hammer until the blade cuts into the insert. Exert downward pressure on the tool and turn it counterclockwise until the insert is removed.





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SPECIFICATIONS

SPECIFICATIONS

1 Approximate dry capacity, includes cooler and lines. Fluid level indicator should be used to determine actual fluid requirements and fluid specification. Check level at normal operating temperature. DO NOT OVERFILL. If it is necessary to add or replace fluid, use only fluid which has been certified by the supplier as meeting one of the Ford Motor Company specifications shown.

Note: Use Motorcraft MERCON V® or fluid meeting Ford specification XT-5-QM.



Fluid Capacity

Vehicle Engine

Approximate Refill Capacity 1

Liters U.S. Quarts

Aerostar, Ranger — 4R44E (4x2) 2.3L, 3.0L 9.0 9.5

Aerostar, Ranger — 4R44E (4x4) 2.3L, 3.0L 9.3 9.8

Torque Specifications

Description Nm Lb-Ft Lb-In

Extension Housing-to-Case Screws and Stud 36-52 27-39 —

Transmission Mounting Pad Nuts and Bolts 68-95 50-70 —

Transmission Range Sensor-to-Case 8-11 — 71-97

Manual Control Outer Lever Nut 41-54 30-40 —

Fluid Pan-to-Case Screws 13-15 — 115-133

Solenoid Clamps-to-Main Control Screws 6-8 — 53-71

Reverse Servo Cover-to-Case Bolts 12-14 — 106-124

Manual Valve Inner Lever Nut 41-54 30-40 —

Main Control Assembly-to-Case Screws 8-11 — 71-97

Manual Valve Detent Spring Screw 8-11 — 71-97

Overdrive Band Locknut-to-Case Adjusting Screw 47-61 35-45 —

Intermediate Band Locknut-to-Case Adjusting Screw 47-61 35-45 —

Center Support-to-Case Capscrew 9-13 — 80-115

Turbine Shaft Speed (TSS) Sensor-to-Center Support Screw 8-11 — 71-97

Fluid Pump Support and Gear-to-Converter Housing Bolts 22-28 16-21 —

Converter Housing-to-Case Screw 36-52 27-39 —

Fluid Filter Assembly-to-Main Control Assembly Screw 8-11 — 71-97

Converter Housing-to-Engine Bolts (2.3L) 40-55 30-41 —



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Converter Housing-to-Engine Bolts (3.0L) 40-55 30-41 —

Converter Housing Access Cover to Engine Oil Pan (2.3L) 2.3-3.3 — 20-29

Catalytic Converter-to-Crossover Pipe Nuts 34-46 25-34 —

Catalytic Converter-to-Exhaust Pipe Nuts and Bolts 34-46 25-34 —

Engine Support-to-Crossmember Bolts (Aerostar) 98-132 73-97 —

Engine Support-to-Crossmember Nuts (Ranger) 88-115 65-85 —

Rear Engine Support-to-Crossmember Nuts 85-118 63-87 —

Crossmember-to-Frame Through Bolts and Nuts (Aerostar) 37-52 28-38 —

Crossmember-to-Frame Through Bolts and Nuts (Ranger) 88-115 65-85 —

Transmission Cooler Lines Case Connectors 35-43 26-32 —

Transmission Fluid Cooler Line Nut to Case Converter 24-31 18-23 —

Flexplate-to-Converter Nuts 30-40 22-30 —

Transmission Access Cover Screws (3.0L) 16-22 12-16 —

Transfer Case Vent Bracket Bolts 34-46 25-34 —

Transfer Case-to-Extension Housing Bolts 34-48 25-35 —

Catalytic Converter and Crossover Pipe Nuts (3.0L) 24-34 18-25 —

Catalytic Converter-to-Exhaust Bolts (3.0L) 24-34 18-25 —

Transfer Case Skid Plate Bolts 22-28 16-21 —

Separator Plate-to-Main Control Screws 6-8 — 53-71

Pressure Plug-to-Case 10-15 — 89-133

Servo Gauge Adjusting Screw 4 — 35.5

End Play Specifications — Selective Thrust Washer (Nylon)

Transmission End Play Dimension "C"

Selective Thrust Washer (Nylon) Identification:

Color Part Number Thickness

Front No. 1 (All Engines) 0.18-0.70 mm (0.007-0.028 In.) Without Gasket

97GT-7D014-TA

97GT-7D014-MA

97GT-7D014-NA

97GT-7D014-PA

97GT-7D014-RA

97GT-7D014-SA

1.55-1.60 mm (0.061-0.063 In.)

1.75-1.80 mm (0.069-0.071 In.)

1.85-1.90 mm (0.073-0.075 In.)

1.95-2.00 mm (0.077-0.079 In.)

2.05-2.10 mm (0.081-0.083 In.)

2.15-2.20 mm (0.085-0.087 In.)

White Green Red

Beige Black Yellow

End Play Specifications — Selective Needle Bearings

Transmission End Play Dimension "C"

Selective Needle Bearings Identification:

Notches Part Number Thickness



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1.67-1.85 mm (0.066-0.073 In.) 1.86-2.04 mm (0.073-0.080 In.) 2.05-2.23 mm (0.081-0.088 In.) 2.25-2.43 mm (0.089-0.096 In.) Rear No. 4 Reference End Play 0.21-0.51 mm (0.008-0.020 In.)

97GT-7D014-GA

97GT-7D014-HA

97GT-7D014-KA

97GT-7D014-LA

2.65-2.80 mm (0.104-0.110 In.)

2.80-2.95 mm (0.110-0.116 In.)

3.00-3.15 mm (0.118-0.124 In.)

3.20-3.35 mm (0.126-0.132 In.)

0 1 2 3

Torque Converter End Play

Transmission Model

Converter End Play

New or Rebuilt Converter Used Converter

mm Inch mm Inch

4R44E 0.58 Max. 0.023 Max. 1.27 Max. 0.050 Max.

Selective Snap Rings

Coast and Reverse Clutch Drum Forward Clutch Cylinder

Part Number

Thickness Diameter

Part Number

Thickness Diameter

mm Inches mm Inches mm Inches mm Inches

E 860126-S 1.37 .0539 130.1 5.122 E 860115-S 1.37 .0539 125.1 4.925

E 860127-S 1.73 .0681 130.1 5.122 E 860116-S 1.73 .0681 125.1 4.925

E 860128-S 2.08 .0819 130.1 5.122 E 860117-S 2.08 .0819 125.1 4.925

E 860129-S 2.44 .0961 130.1 5.122 E 860118-S 2.44 .0961 125.1 4.925

Band Adjustment And Torque Chart

Description Number of Turns to Back Off

Locknut Screw

Nm Lb-Ft Nm Lb-Ft

Intermediate Band 2.5 47-61 35-45 14 10

Overdrive Band 2.0 47-61 35-45 14 10

Clutch Plate Usage And Clearance Specifications

Clutch Steel Friction Clearance

Selective Snap Rings

Part Number Thickness

Forward Clutch

2.3L/3.0L 5 5 0.055-0.083 E 860115-S E 860116-S E 860117-S E 860118-S

1.37 mm (0.0539 In.)

1.73 mm (0.0681 In.)

2.08 mm (0.0819 In.)



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2.44 mm (0.0961 In.)

Direct/Reverse Clutch

2.3L/3.0L 4 4 0.051-0.079 E 860126-S E 860127-S E 860128-S E 860129-S

1.37 mm (0.0539 In.)

1.73 mm (0.0681 In.)

2.08 mm (0.0819 In.)

2.44 mm (0.0961 In.)

Coast Clutch

All Engines 2 2 0.051-0.079 E 860126-S E 860127-S E 860128-S E 860129-S

1.37 mm (0.0539 In.)

1.73 mm (0.0681 In.)

2.08 mm (0.0819 In.)

2.44 mm (0.0961 In.)

4R44E Service Identification Model Chart

7000 Prefix and Suffix

Speedo Drive Teeth

C=Column F=Floor

Engine Displacement

Vehicle Application

Vehicle Applications (600 Nm)

97GT-EBA 6T C 3.0L Ranger (4x2)

97GT-GBA 6T C 2.3L Ranger (4x2)

97GT-MBA 6T C 3.0L Aerostar (4x2) Van

97GT-NBA 6T C 3.0L Aerostar (4x4) Wagon

97GT-FBA — C 3.0L Ranger (4x4)



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Transmission Description - visualbits.netvisualbits.net/Car Stuff/Ford Ranger 1993-1999/07...

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