2003 FORD MUSTANG air condition

Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin
condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or
install a new connector as required.
Shift Solenoids Pre-Diagnosis
Use the following shift solenoid operation information when carrying out Pinpoint Test A.
a 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.
EC = Electronically controlled.
HD = Hydraulically disabled.
Shift Solenoid Failure Mode Chart "Always Off"
Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or
hydraulically stuck off. Solenoid Operation Chart Gear Lever Position PCM Commanded Gear Solenoids
SSA SSB TCC
P/R/N 1 ON OFF HD
(D) 1 ON OFF HD
(D) 2 OFF OFF EC
(D) 3 OFF ON EC
(D) 4 ON ON EC
(D)
w/OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Manual 2 2 OFF OFF EC
Manual 1 1 ON OFF HD
1
a 2 OFF OFF EC
SSA ALWAYS OFF: Gear Lever Position
(D) 2 1
PCM Gear
Commanded Actual Gear
Obtained
1 2 2 2
2 2 2 2
3 3
2
a 2
a 4 3
2
a 2
a Klj . 2 ba
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NOTE:
Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests. A1 ELECTRONIC DIAGNOSTICS
z
Select PARK.
z Key in OFF position.
z Check to make sure the transmission harness connector
is fully seated, pins are fully engaged in connector and
in good condition before proceeding.
z Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: Diagnostic Data Link.
z Enter the following diagnostic mode on the diagnostic
tool: PCM.
z Enter the following diagnostic mode on the diagnostic
tool: Active Command Modes.
z Enter the following diagnostic mode on the diagnostic
tool: Output State Control (OSC).
z Enter the following diagnostic mode on the diagnostic
tool: Trans- Bench Mode.
z Does vehicle enter Trans- Bench Mode? Yes
GO to
A2 .
No
REPEAT procedure to enter
Trans-Bench Mode. If vehicle
did not enter Trans- Bench
Mode, REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
of PCM. A2 WIGGLE TEST
z
Select PIDs to be monitored.
z Select "ON" to turn suspect solenoid on.
z Press "SEND".
z Wiggle all wiring and connectors to the transmission.
Monitor the Solenoid State for changes.
z Select "OFF" to turn solenoid off.
z Press "SEND".
z Does the suspect solenoid(s) fault state change? PID Command PID Actual
SSA SS1F
SSB SS2F
TCC TCCF Yes
REPAIR open or short in the
vehicle harness or connector.
No
GO to
A3 .
A3 SOLENOID FUNCTIONAL CHECK
z
Monitor each solenoid state.
z Turn each solenoid ON and OFF.
z Does the solenoid turn ON and OFF when
commanded and can solenoid activation be heard? Yes
GO to
A4 .
No
GO to A5 .
A4 OSC TRANS-
DRIVE MODE (GR_CM OR TCC) z
Carry out OSC Trans- Drive Mode.
z Select GR_CM for Shift Solenoids or follow procedures
for GR_CM as listed.
z Select TCC for Torque Converter Clutch Solenoid.
Follow procedures of TCC in Drive Mode as listed.
z Does the transmission upshift and downshift or
torque converter engage/disengage when
commanded? Yes
CLEAR all DTCs. ROAD TEST
to verify if concern is still
present. If concern is still
present, REFER to
Diagnosis By Symptom in this section to
diagnose shift or torque
converter concern.
No
GO to A5 .
A5 CHECK FOR BATTERY VOLTAGE
z
Remove transmission fluid pan. Yes Klj . 4 ba
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C1 VERIFY DIAGNOSTIC TROUBLE CODES
z
Select PARK.
z Key in OFF position.
z NOTE: DTC codes P0705 and P0708 cannot be set by
an incorrectly adjusted digital TR sensor.
z Carry out on board diagnostic test.
z Are only DTC codes P0705, P0708 present? Yes
GO to
C4 .
No
GO to C2 .
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR
ALIGNMENT z
Check to make sure the digital TR sensor harness
connector is fully seated, pins are fully engaged in
connector and in good condition before proceeding.
z Apply the parking brake.
z Select NEUTRAL.
z Disconnect the shift cable/linkage from the manual lever.
z Verify that the digital TR Sensor Alignment Tool fits in
the appropriate slots.
z Is the digital TR sensor adjustment OK? Yes
GO to
C3 .
No
ADJUST the digital TR sensor.
PLACE transmission range
selector lever in P and CLEAR
DTCs. REPEAT OBD Tests.GO
to C3 .
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
z
Place the manual lever in the overdrive position.
z Select DRIVE.
z Reconnect the shift cable/linkage.
z Verify that the shift cable/linkage is adjusted OK. Refer
to Section 307 - 05 .
z Is the shift cable/linkage adjusted OK? Yes
GO to
C4 .
No
ADJUST the shift cable/linkage.
REFER to Section 307 - 05 .
C4 CHECK ELECTRICAL SIGNAL OPERATION
z
Select PARK.
z Disconnect: Digital TR Sensor.
z CAUTION: Do not pry on connector. This will
damage the connector and result in a transmission
concern.
z Press the button and pull out on the digital TR harness
connector.
z Inspect both ends of the connector for damage or
pushed- out pins, corrosion, loose wires and missing or
damaged seals.
z Are the connector, pins and harness damaged? Yes
REPAIR as required. CLEAR
DTCs and REPEAT OBD
Tests.
No
If diagnosing a DTC, GO to
C5
.
If diagnosing a starting concern
or a reversing lamp concern,
GO to C10 .
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL
TR AND PCM) z
Key in OFF position.
z Connect the diagnostic tool.
z Connect: Digital TR Sensor.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: TR PIDS TR, TR_D, TR_V.
z Move transmission range selector lever into each gear
and stop.
z Observe any of the following PIDs, TR and TR_D, TR_V
(vehicle dependent) while wiggling harness, tapping on
sensor, or driving the vehicle. Use PIDs TR, and TR_D
for DTCs P0705, P1704, and P1705. Use PIDs TR, and
TR_V for DTC P0708.
z Compare the PIDs to the Digital Transmission Range
(TR) Sensor Diagnosis Chart.
z Do the PIDs TR, TR_D and TR_V match the Digital
Transmission Range (TR) Sensor Diagnosis chart,
and does the TR_D PID remain steady when the Yes
The problem is not in the digital
TR sensor system. REFER to
Diagnosis By Symptom
in this
section for further diagnosis.
No
If TR_D changes when wiggling
harness, tapping on the sensor,
or driving the vehicle, the
problem may be intermittent.
GO to C6 . Klj . 10 ba
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PINPOINT TEST D: ELECTRICAL PRESSURE CONTROL (EPC)
SOLENOID z
Are all the resistances greater than 10,000 ohms? C10 CHECK THE NON-
PCM INTERNAL CIRCUITS OF
SENSOR z
Connect: TRS- E Cable to Transmission.
z Connect: TRS- E Cable to Digital TR Sensor.
z Place the Digital TR Overlay onto Transmission Tester.
z Carry out Switch Test as instructed on the Digital TR
Overlay.
z Does the status lamp on the tester indicate RED for
the correct gear position? Yes
Concern is not in the digital TR
sensor. For starting system
concerns, REFER to
Section 303 - 06 . For reversing lamp
concerns, REFER to Section 417 - 01 . For optional circuits,
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis.
No
INSTALL a new digital TR
sensor. CLEAR DTCs.
REPEAT OBD Tests. Test Step Result / Action to Take
NOTE:
Refer to the Transmission Internal Harness illustration preceding these pinpoint tests. NOTE:
Read and record all DTCs. All digital TR Sensor and VSS DTCs must be repaired before
entering Output State Control (OSC). D1 ELECTRONIC DIAGNOSTICS
z
Key in OFF position.
z Select PARK.
z Check to make sure the transmission harness connector
is fully seated, pins are fully engaged in the connector and
in good condition before proceeding.
z Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
Diagnostic Data Link.
z Enter the following diagnostic mode on the diagnostic tool:
PCM.
z Enter the following diagnostic mode on the diagnostic tool:
Active Command Modes.
z Enter the following diagnostic mode on the diagnostic tool:
Output State Control (OSC).
z Enter the following diagnostic mode on the diagnostic tool:
Trans- Bench Mode.
z Does the vehicle enter the Trans- Bench Mode? Yes
GO to
D2 .
No
REPEAT procedure to
ENTER Trans-Bench Mode. If
vehicle did not enter OSC,
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
of PCM. Klj . 17 ba
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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.
Follow the procedure to determine the location of the inoperative clutch or band by introducing air
pressure into the various test plate passages.
NOTE: Use only dry, regulated 276 kPa (40 psi) maximum air pressure.
Apply air to the appropriate passage(s). A dull thud should be felt or heard or movement could be
observed when the clutch component applies. There should be no hissing sound when the component
is applied.
Cover the vent hole in the test plate with a clean, lint- free shop towel to prevent spray when the air is
applied. Plugging the vent hole during testing will result in inaccurate results.
1. Drain transmission fluid and remove the transmission fluid pan.
2. Remove the main control valve body.
3. Install transmission test plate and gasket. Tighten bolts to 10 Nm (89 lb- in).
4. NOTE: Do not apply air to the test plate vent hole.
Apply air to the appropriate clutch port (refer to the Transmission Air Test Plate illustration). A
dull thud may be heard or movement felt when the component is applied or released. If clutch
seals or check balls are leaking a hissing sound may be heard.
If 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 clutches
simultaneously, inspect the fluid passages in the case.
If air pressure applied to the accumulator fails to operate an accumulator, remove and inspect case
passages and piston.
Clutch Pressure Test
The Clutch Pressure Test will diagnose a low- pressure condition or leakage in a clutch circuit. A
difference of 103 kPa (15 psi) or more between the clutch pressure and line pressure will prevent a
normal shift.
1. CAUTION: Pressure gauges affect the shift quality of the transmission. Care must
be taken not to accelerate or decelerate rapidly. Possible transmission failure can result.
Attach 0- 2068 kPa (0- 300 psi) pressure gauges to the line pressure tap and the appropriate
clutch pressure tap according to Band and Clutch Application Chart A&B. Gauges must be
accurate enough to distinguish a 103 kPa (15 psi) difference. (If this test is done in conjunction
with a control pressure test, pressure gauges will be attached to all pressure taps.) Have
sufficient flexible hose available to read the gauges in the vehicle.
2. Drive the vehicle. When pressure is applied to the clutch, note the difference between the line pressure gauge and the corresponding clutch pressure gauge.
3. If the difference in pressures is less than 103 kPa (15 psi), the corresponding clutch circuit does not have a pressure loss. The gauges on the line pressure tap and appropriate clutch pressure
tap can be switched to confirm that gauge calibration differences are not the cause. Klj . 6 ba
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The Diagnosis by Symptom charts give the technician diagnostic information, direction, and suggest
possible components, using a symptom as a starting point.
The Diagnosis by Symptom charts are 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 Concern/Symptom that best describes the condition.
2. Refer to the routine indicated in the Diagnosis by Symptom Index.
3. Always begin diagnosis of a symptom with:
a. preliminary inspections.
b. verifications of condition. c. checking the fluid levels.
d. carrying out other test procedures as directed.
4. NOTE: 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 correct function
of these components prior to proceeding to the Hydraulic/Mechanical Routine listed.
Begin with the Electrical Routine, if indicated. Follow the reference or action required
statements. Always carry out the on- board diagnostic tests as required. Never skip steps.
Repair as required. If the concern is still present after electrical diagnosis, then proceed 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
probable cause. All components listed must be inspected to ensure correct repair. 105-
R0057 or equivalent UV Leak Detector Kit
164-
R0756 or equivalent
Diagnosis by Symptom Index Title Routines
Electrical
a Hydraulic/
Mechanical Klj . 2 ba
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Condition.
Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify the digital
transmission range (TR) sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Incorrect Pressures
·
Low forward clutch
pressure, low line
pressure ·
Check pressure at line and forward clutch tap. Refer to Line Pressure
Chart for specification. If pressures are low, check the following
components: oil filter and seal assembly, main controls, pump
assembly, forward clutch assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
3- 4 shift valve, main
regulator valve, manual
valve — stuck,
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect gaskets for damage and install a new gasket. ·
2- 3 accumulator and
seals damaged ·
Inspect piston, seals and bore for damage. Repair as required. ·
Pressure regulator
valve ·
Inspect the diameter for wear. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross
leaks/ball missing or
leaking, plugged hole ·
Inspect for porosity and leaks. Repair as required. ·
No. 3 and No. 4 seal
rings damaged ·
Inspect seals for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Forward Clutch
Assembly
·
Seals, piston damaged ·
Inspect seals for damage. Repair as required. ·
Check balls damaged,
missing, mislocated,
not seating correctly ·
Inspect for mislocation, poor seating, damage. Install a new cylinder
as required. ·
Friction elements
damaged or worn ·
Check for abnormal wear, damage. Repair as required. One-
Way Clutch
Assembly (Planetary) ·
Worn, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. Output Shaft Klj . 4 ba
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·
Damaged ·
Inspect for damage. Install new components as required.
Engagement Concern: No Reverse Possible Component Reference/Action
202 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 302 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. Incorrect Pressures
·
Low reverse clutch
pressure, low reverse band
pressure, low line pressure ·
Check pressure at line pressure tap; refer to Line Pressure Chart
for specifications. If pressures are low, check the following
components: oil filter and seal assembly, main controls, reverse
servo, pump assembly, reverse clutch assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. Main Controls
·
No. 6 shuttle ball, manual
valve, main regulator valve,
1- 2 accumulator seals
stuck or damaged ·
Inspect for damage. Repair as required. ·
Loose bolts ·
Tighten bolts to specifications. ·
Gasket damaged ·
Inspect for damage and install a new gasket. Low/Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring
damaged ·
Anchor pins (case)
damaged Pump Assembly
·
Loose bolts ·
Tighten bolts to specifications. ·
Porosity/cross leaks/ball
missing or leaking, plugged
hole ·
Inspect pump assembly. Install new as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 1 and 2 seal rings
damaged ·
Inspect for damage. Repair as required. Reverse Clutch Assembly Klj . 5 ba
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