2011 FORD KUGA Automatic transmission

Output signals
Hard wired
• Item 8: PCM– Start inhibitor. Supplies the PCM with a signalthat indicates whether the engine can be
started or not.
• Item 9: Selector lever module (select-shift module)
– Controls the solenoid switch in the selectorlever unit.
• Position 10: PWM solenoid valve – shift pressure (SLS)
– Matches the line pressure to a shift pressureand is activated for certain gears.
• Position 11: PWM solenoid valve – main line pressure (SLT)
– Adjusts the linear line pressure for gearchanges without jolts.
• Position 12: PWM- solenoid valve – TCC (SLU) – Matches the line pressure to a torqueconverter lock-up pressure. Is also used for
certain gearshifts.
• Items 13 - 17: Shift solenoids S1 – S5 – The TCM checks which gear is engaged asthe solenoids become active in different
patterns.
Via the LIN data bus
• Item 7: Selector lever module (select-shift module)
– The TCM transmits a signal to the selectorlever module which activates the LED (light
emitting diode) in the selector mechanism
assembly according to the selector lever
position. Via the CAN data bus
• Item 2: GEM
– The selector lever module transmits a signalvia the TCM, which indicates that the selector
lever is locked in position P. The GEM uses
this information to control the ignition switch
key inhibit function.
– The TCM transmits a signal via the GEM to activate the back-up lamps.
• Item 3: Instrument Cluster – Current selector lever position. Used toindicate the selector lever position in the
instrument cluster.
– Check the warning lamps via the GEM. In the event of a fault, the general warning lamp
lights.
– Text messages in the instrument cluster via the GEM. The driver receives various
malfunction messages from the TCM.
– The TCM transmits signals on the CAN data bus to the PCM so that the MIL lights up in
the event of emissions-related faults.
• Item 4: PCM – Transmission fluid temperature, used tocompensate for increased loads at low fluid
temperatures.
– Gear selected, used by the engine so that it can compensate for different loads.
– Torque converter lockup, used by the engine so that it can compensate for different loads.
– Next gear planned by the TCM, used by the engine to compensate for different loads.
– Requirement for a reduced engine torque during gear shifts, the engine reduces the
engine torque during gear shifts.
– Torque limiting requirement, the engine limits the engine torque according to the gear
engaged.
• Item 5: ABS module – Current gear, used to transmit a signal, notfor shift control.
– Vehicle speed, used as reserve.
Control valve assembly
G1163605en2008.50 Kuga8/2011
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 45
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E125595
2
3
4
5678
1
Description
Item
PWM solenoid valve for main line pressure
(SLT)
1
PWM- solenoid valve – TCC (SLU)
2
PWM solenoid valve – shift pressure (SLS)
3
Shift solenoid S4
4Description
Item
Shift solenoid S3
5
Shift solenoid S1
6
Shift solenoid S5
7
Shift solenoid S2
8
The hydraulic pressure is distributed to the
individual clutches and brakes in the valve body.
The hydraulic paths and the hydraulic pressure are
controlled electronically via three PWM solenoid
valves and five shift solenoid valves.
The shift solenoid valves S1-S5 are either in the
'open' or 'closed' state.
The control valves (SLT and SLS) regulate the
hydraulic pressure in accordance with the duty
cycle of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes. The control valve (SLU) regulates the hydraulic
pressure in accordance with the duty cycle of the
electrical PWM signal. It controls the torque
converter clutch. The PWM control achieves
smooth engagement of the gears.
The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, the gears are shifted and
the torque converter lockup is activated at low
engines speeds in order to reduce the fuel
consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163605en2008.50 Kuga8/2011
307-01-
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 46
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Function of the shift solenoid valves in the gears and when shifting gears
S5
S4
S3
S2
S1
Gear
–
–
–
–
–
Park
0
–
0
–
–
R (V<=7)
–
–
–
–
0
R (V>7)
–
–
–
–
–
N
–
–
0
0
0
1
–
–
0
–
–
1<=>2
–
–
0
–
–
2
0
0
0
–
–
2<=>3
–
0
0
–
–
3
0
0
–
–
–
3<=>4
–
0
–
–
–
4
–
0
–
0
–
4<=>5
–
0
–
0
–
5
• V= Road speed in km/h
• 0= Actuated
• –= Not actuated
• x<=>x = Gear change "up/down"
Shift solenoids S1 - S5
E112324
1
2
4
5
3
Description
Item
Shift solenoid S1
1
Shift solenoid S4
2
Shift solenoid S3
3
Description
Item
Shift solenoid S5
4
Shift solenoid S2
5
Shift solenoids S1, S2, S3, S4 and S5 are located
in the control valve assembly on the front of the
transmission.
Function
The shift solenoid valves are actuated by the TCM
TCM. The shift solenoid valves S1 and S4 are fully
open when de-energized. The shift solenoid valves
S2, S3, and S5 are fully closed when de-energized.
They control gearshifting, while the TCM decides
which gear should be engaged by activating the
shift solenoid valves in different combinations.
Consequences of signal failure
G1163605en2008.50 Kuga8/2011
307-01- 47
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 47
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5252
E125820
12345
6
Description
Item
Shift solenoid S1
1
Shift solenoid S2
2
Shift solenoid S3
3
Shift solenoid S4
4
Shift solenoid S5
5
TCM connector 'C'
6
If a shift solenoid valve fails, the MIL is activated
and the vehicle can be driven in the appropriate
emergency mode.
Failure of the shift solenoids
Emergency function
MIL
Reason
Component
Emergency Mode 1
On
Short B+ / open circuit
Shift solenoid S1
No 1st gear / no N-D
control
Short B-
Emergency Mode 1
On
Short B+ / open circuit
Shift solenoid S2
No 1st or 5th gear
Short B-
Emergency Mode 2
On
Short B+ / open circuit
Shift solenoid S3
Emergency Mode 4
Short B-
Emergency Mode 1
On
Short B+ / open circuit
Shift solenoid S4
Short B- Emergency Mode 1
On
Short B+ / open circuit
Shift solenoid S5
Short B-
G1163605en2008.50 Kuga8/2011
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
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PWM- solenoid valve – TCC (SLU)
E112325
Installation position
The PWM solenoid valve for the TCC (SLU) is
located in the valve body on the front of the
transaxle.
Function
00.2 1.0 0.80.60.4
0
0.2 1.0
0.80.60.4
0
0.2 1.0
0.80.60.40
0.2 1.0 0.80.60.4
E125965
1
2
Description
Item
Hydraulic pressure
1
Average current (A)
2
The valve actuates the torque converter clutch as
well as the reverse gear brake (B3) and 2nd - 5th
gear brake (B2). The PWM control achieves
smooth engagement of the gears. The two brakes
are actuated in 1st and 2nd gear to guarantee
engine braking.
The valve also actuates the torque converter in
such a way that is works in three positions: 'open',
'controlled looping (slip lock-up mode)', and 'locked
(full lock-up mode)'. The hydraulic function of the
valve is linear.
In lockup mode the TCC is closed. The impeller
and the turbine of the torque converter are friction
locked. The engine torque acts directly on the
transmission input shaft. Fuel consumption is
reduced due to a reduction in the torque converter
pump losses.
In slip lock-up mode, slip in the TCC is permitted
in order to improve driving comfort. The hydraulic
pressure acting on the TCM varies in accordance
with the duty signal of the actuation signal
generated by the PWM for the TCC solenoid valve
for the TCC (SLU). The temperature of the
transmission fluid increases in slip mode.
Consequences of signal failure
G1163605en2008.50 Kuga8/2011
307-01- 49
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 49
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E125966
97
2
1
Description
Item
PWM- solenoid valve – TCC (SLU)
1
TCM connector 'C'
2
If the PWM solenoid valve for the TCC (SLU) fails,
the MIL is activated and the vehicle can be driven
in emergency mode 1.
PWM solenoid valve – shift pressure (SLS)
E112326
Installation position
The PWM solenoid valve for shift pressure (SLS)
is located in the valve body on the front of the
transaxle.
Function
0 0.2 1.00.80.60.4
0
0.2 1.00.80.60.4
0
0.2 1.00.80.60.40
0.2 1.00.80.60.4
E125990
1
2
G1163605en2008.50 Kuga8/2011
307-01- 50
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 50
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Description
Item
Hydraulic pressure
1
Average current (A)
2
The valve directly actuates the multi-plate brake
(B1) in 2nd - 4th gear as well as the clutch (C2) in
5th and reverse gear. The PWM control achieves
smooth engagement of the gears.
The hydraulic function of the valve is linear. The
hydraulic valve is controlled by means of the
varying current resulting from the current duty
cycle. The system pressure is low with a high duty
cycle, i.e. with high current intensity (approx. 1 A),
and vice versa.
Consequences of signal failure
E125991
2
1
Description
Item
PWM solenoid valve – shift pressure (SLS)
1
TCM connector 'C'
2
The shift pressure increases to the maximum value
in the event of interruptions, which leads to hard
gearshifts when shifting to another gear. The valve
is then fully open. If the PWM solenoid valve for shift pressure (SLS)
fails, the MIL is activated and the vehicle can be
driven in emergency mode 3.
PWM solenoid valve for main line pressure
(SLT)
E112327
Installation position
The PWM solenoid valve – main line pressure
(SLT) is located in the control valve assembly on
the front of the transmission.
Function
G1163605en2008.50 Kuga8/2011
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
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00.2 1.0 0.80.60.4
0
0.2 1.0
0.80.60.40
0.2 1.0 0.80.60.40
0.2 1.0 0.80.60.4
E125990
1
2
Description
Item
Hydraulic pressure
1
Average current (A)
2
The PWM solenoid valve for main line pressure
(SLT) is actuated proportionally by the TCM.
The TCM evaluates the accelerator pedal position
and the current engine torque.
The main line pressure is adapted proportionally
by the TCM via the PWM solenoid valve. This
measure enables judder-free gearshifts.
The PWM solenoid valve is open when
de-energized. In the case of faults and failure of
the control system, the PWM solenoid valve
remains fully open. The maximum main line
pressure is applied.
Consequences of signal failure
E125992
2
1
Description
Item
PWM solenoid valve for main line pressure
(SLT)
1
TCM connector 'C'
2
The system pressure increases to the maximum
value in the event of interruptions, which leads to
hard gearshifts when shifting to another gear. The
valve is then fully open.
If the PWM solenoid valve – main line pressure
(SLT) fails, the MIL is activated and the vehicle can
be driven in emergency mode 1.
TCC
Installation position
The TCC is an integral component of the torque
converter.
Operation
The TCM controls the PWM via the TCC solenoid
valve for the TCC (SLU). Based on the signals for
engine speed and accelerator pedal position as
G1163605en2008.50 Kuga8/2011
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
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