2003 FORD MUSTANG check transmission fluid

D2 SOLENOID FUNCTIONAL TEST
z
Install 2,060 kPa (300 psi) pressure gauge into EPC tap.
z Monitor pressure gauge.
z Enter the following diagnostic mode on the diagnostic tool:
Parameter; EPC.
z Select value - 15, 30, 45, 60, 70 or 90 psi.
z Press "SEND".
z Select another value "0- 90 psi".
z Press "SEND".
z Enter the following diagnostic mode on the diagnostic tool:
XXX.
z Press "SEND".
z Does the pressure reading match the commanded
pressure? Yes
CLEAR DTCs. REPEAT OBD
Tests.
No
GO to
D3 .
D3 CHECK FOR BATTERY VOLTAGE
z
Remove transmission fluid pan.
z Visually inspect the lead frame connectors for damage.
z Key in ON position.
z Measure the voltage with positive lead to VPWR solenoid
pin and negative lead to a good ground.
z Is voltage greater than 10 volts? Yes
GO to
D4 .
No
REPAIR the circuit. CLEAR
the DTCs. REPEAT the OBD
Tests. D4 ELECTRICAL SIGNAL CHECK
z
Measure the voltage with positive lead connected to
VPWR solenoid pin and connect negative lead to the
signal pin of the EPC solenoid.
z Turn the solenoids ON and OFF, while monitoring the
voltage reading, solenoid state on the scan tool (ON and
OFF), listen for the solenoid to activate (click).
z Enter the following diagnostic mode on the diagnostic tool:
Trans- Bench Mode.
z Enter the following diagnostic mode on the diagnostic tool:
Parameter EPC.
z Select a value "0- 90 psi".
z Press "SEND".
z Select another value "0- 90 psi".
z Press "SEND".
z Enter the following diagnostic mode on the diagnostic tool: Yes
GO to
D5 .
No
CHECK for open or short
circuit in harness or PCM. Klj . 18 ba
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Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 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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DIAGNOSIS AND TESTING
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 fluid filler tube connection at the transmission case. If leakage is found here, install a new
grommet.
Check the VSS plug or VSS sensor O-ring (model dependent). If leakage is found install a new O- ring.
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, install new
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, install a new 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 Section 307 - 02 .
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, install a new cooler.
If leakage is found at the transmission range selector lever, install a new seal.
If leakage is found at the transmission internal harness connector, install a new O- ring. 4R70W External Sealing SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator 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 torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 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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·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check ball missing or
damaged ·
Friction elements damaged
or worn Low/Reverse Band
·
Band, servo, anchor pins
damaged or worn ·
Inspect for damage. Repair as required.
Engagement Concern: Harsh Reverse Possible Component Reference/Action
203 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, TFT sensor, EPC
solenoid ·
Carry out Self-Test; refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Carry out engagement test, EPC test
and Go To Pinpoint Test B or
Go To Pinpoint Test D . Check idle
speed. Repair as required. Clear DTCs, road test and repeat Self-
Test. 303 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Engine Driveline
·
Looseness in the
driveshaft, U- joints or the
engine mounts ·
Repair as required. 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
·
High line pressure, high
EPC pressure ·
Check pressure at line and EPC pressure taps; refer to Line
Pressure Chart for specifications. If high, check the following
components: main controls, oil filter and seal assembly. Fluid Filter and Seal
Assembly
·
Plugged or damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
No. 6 shuttle ball, No. 5
check ball, manual valve,
main regulator valve stuck,
damaged or missing ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. Klj . 6 ba
312003 Mustang Workshop Manual
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