2011 FORD KUGA Select shift module

307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
.
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Description
Item
ABS (anti-lock brake system)
5
Speed control
6
Select-shift switch module
7
PCM
8
Selector lever lock
9
PWM solenoid valve – shift pressure (SLS)
10
PWM solenoid valve for main line pressure
(SLT)
11
PWM- solenoid valve – TCC (SLU)
12Description
Item
Shift solenoid S1 (open when dormant)
13
Shift solenoid S2 (closed when dormant)
14
Shift solenoid S3 (closed when dormant)
15
Shift solenoid S4 (open when dormant)
16
Shift solenoid S5 (closed when dormant)
17
The TSS sensor
18
The OSS sensor
19
The TFT sensor
20
TR sensor in TCM
21
Knowing and Understanding Customer
Concerns
Knowing and understanding customer concerns is
necessary in order to perform diagnosis.
First of all, ask the customer under which operating
conditions the problem occurs. If possible, try to
reproduce the concern by road testing the vehicle
with the customer.
You should be familiar with the following operating
conditions:
• Engine operating state
– Cold, warm-up phase, or at operatingtemperature
• Ambient temperature – Below 0 °C (32 °F), 0 to 20 °C (32 to 68 °F),or above 20 °C (68 °F)
• Road conditions – Good, poor, or off-road
• Vehicle load status – Unloaded, loaded, or fully loaded
• Transaxle status in manual mode – Upshift, downshift, overrun or acceleration
Testing Possible Causes of Transmission
Control Faults
Before performing a symptom-based diagnosis,
first carry out checks to eliminate various other
potential causes of the fault.
These situations include:
• Battery state of charge
• Defective fuses • Loose or corroded cables or electrical
connectors
• Ground connections to the transmission
• Retrofitted add-on units which are not approved by Ford, such as air conditioning, car telephone,
cruise control
• Unapproved tire sizes
• Incorrect tire size programmed with IDS (Integrated Diagnostic System)
• Engine tuning
IDS Diagnosis
NOTE: Customer concerns relating to the transaxle
can also be caused by engine-related faults.
The transmission control system of the AW55 is
closely linked to the engine management system.
Faults in the engine management system may
affect the transmission control system.
Before repairing the transaxle, it should be ensured
that the fault is not caused by the engine
management system or other non-transaxle
components.
The diagnosis can be performed on the AW55 with
the aid of von IDS.
visual inspection
A thorough visual inspection of the transaxle is
necessary for successful diagnosis.
A visual inspection is made of the following
components:
• Connectors and plug connections
• Ease of operation of the selector lever
G1163604en2008.50 Kuga8/2011
307-01- 14
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 14
DESCRIPTION AND OPERATION
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Transmission Description – System Operation and ComponentDescription
System Operation
E112576
The AW55 5-gear automatic transaxle is a fully
automatic, electronically controlled automatic
transaxle. The fifth gear is an overdrive which
saves fuel.
The maximum input torque is 330 Nm.
Gear changes are controlled by an
electro-hydraulic system.
The gear ratios are achieved by means of a
combined planetary gear set and a Simpson set.
Three multi-plate clutches, four multi-plate brakes
and one band brake as well as two one-way
clutches control the various ratios.
The clutches and brakes are hydraulically operated
by electrically actuated solenoid valves. The valves
are actuated by the TCM depending on the driving
conditions and the driver's requirements.
The TCC is activated in gears 3, 4 and 5. The TCC
is driven in interlock mode and in slip mode. Defined slip achieves a smooth and therefore
comfortable clutch engagement of the TCC.
Control of slip mode depends on the engine speed,
accelerator pedal position and vehicle speed
signals provided by the ECM (engine control
module). This controls the rate of slip by comparing
the engine speed and the turbine shaft speed.
The TSS sensor and the OSS sensor use the Hall
effect principle. The TCM can regulate the slip in
the torque converter by comparing the engine
speed with the transmission speed.
All parameters for actuating the clutches and the
TCC are determined by the TCM as a function of
the operating parameters. The automatic transaxle
features a self-learning strategy.
The fundamental parameters for gear shifting are
the accelerator pedal position and the vehicle
speed.
Gear selection can either be performed
automatically or in select-shift mode. The selected
G1163605en2008.50 Kuga8/2011
307-01-
21
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 21
DESCRIPTION AND OPERATION
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E125524
Description
Item
Electronic Control System
A
Hydraulic Control System
BDescription
Item
Select-shift switch module
1
CAN (controller area network) bus input
signals
2
G1163605en2008.50 Kuga8/2011
307-01-
23
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 23
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112322
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only
controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts thevarious transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Transmission range chosen (TR sensor).
• Type of driving mode chosen
(normal/sport/select-shift).
• Transmission input shaft speed (TSS sensor).
• Transmission output shaft speed (OSS sensor).
• Transmission fluid temperature (TFT sensor).
• The engine speed and the torque as well as the throttle plate opening - from the PCM via the
CAN data bus.
• Actuation of the accelerator pedal - from the PCM via the CAN data bus.
• Coolant temperature - from the PCM via the CAN data bus.
• Vehicle speed - from the ABS via the CAN data bus.
• Actuation of the brake pedal - from the ABS via the CAN data bus.
Pin assignment for TCM connector 'A' (connection to vehicle)
11
E125669
Description
Item
Battery (+)
1
not assigned
2Description
Item
not assigned
3
not assigned
4
G1163605en2008.50 Kuga8/2011
307-01- 26
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 26
DESCRIPTION AND OPERATION
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Description
Item
Starter motor inhibitor signal to the PCM
5
CAN (low)
6
LIN (local interconnect network)
7
CAN (high)
8
GND (ground)
9
not assigned
10Description
Item
Battery (+) via ignition switch
11
not assigned
12
Selector lever lock
13
not assigned
14
not assigned
15
Voltage supply for select-shift switch
module
16
Pin assignment for TCM connector 'B' (connection to transaxle)
E125670
Description
Item
OSS(–)
1
OSS(+)
2Description
Item
TSS(+)
3
TSS(–)
4
Pin assignment for TCM connector 'C'
(connection to transaxle)
G1163605en2008.50 Kuga8/2011
307-01- 27
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 27
DESCRIPTION AND OPERATION
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21
22 20 19
15 14 13
161718 12
876
9
10
11 5
3
42121
22 20 19
15 14 13
161718 12
876
9
10
11 5
3
421
E125671
Description
Item
Shift solenoid valve S1 (+)
1
Shift solenoid valve (S2) (+)
2
PWM solenoid valve – main line pressure
(SLT) (+)
3
not assigned
4
not assigned
5
PWM solenoid valve – main pressure line
(SLT) (–)
6
PWM solendoid valve – TCC (SLU) (–)
7
not assigned
8
PWM solenoid valve – TCC (SLU) (+)
9
PWM solenoid valve – shift pressure (SLS)
(–)
10Description
Item
not assigned
11
not assigned
12
TFT sensor (–)
13
TFT sensor (+)
14
not assigned
15
PWM solenoid valve – shift pressure (SLS)
(+)
16
Shift solenoid valve (S3) (+)
17
not assigned
18
not assigned
19
not assigned
20
Shift solenoid valve (S5) (+)
21
Shift solenoid valve (S4) (+)
22
Operation
Depending on the input signals, the TCM mounted
on the transmission actuates the solenoid valves
in the valve body. The TCM calculates and stores
adaptive data, fault codes and values for diagnosis.
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts the
various transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
G1163605en2008.50 Kuga8/2011
307-01-
28
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 28
DESCRIPTION AND OPERATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Selected transmission range (TR sensor)
• Selected driving mode (normal/sport/select-shift)
• Transmission input shaft speed (TSS sensor)
• Transmission output shaft speed (OSS sensor)
• Transmission fluid temperature (TFT sensor)
• The engine speed and the torque as well as thethrottle plate opening - from the PCM via the
CAN databus
• Actuation of accelerator – from the PCM via the CAN databus
• The coolant temperature – from the PCM via the CAN databus
• Road speed – from the ABS module via the CAN databus
• Actuation of brake pedal – from the PCM via the CAN databus
Gearshift control
Adaptation
The TCM monitors every shift operation in all
driving conditions to make even and smooth gear
shifts possible. This is done by the control module,
which either lowers or increases the hydraulic line
pressure during gearshifts.
The changed pressure values are stored in the
control module memory after the engine is switched
off and retrieved during engine starting. This
improves the shift comfort and extends the service
life.
Full adaptability occurs when the following criteria
are met:
• Throttle plate opening is constant.
• Transmission fluid temperature between 65 °Cand 110 °C.
Shifting from 'P' to another transmission
range
To be able to move the selector lever from 'P' into
another transmission range, the ignition must be
switched on and the brake pedal pressed (stoplamp
switch on). The TCM detects the position of the
brake pedal via the CAN data bus and the engaged
transmission range from the TR sensor. Based on this information, the TCM transmits a
signal to the select-shift switch module. This
activates the brake shift interlock actuator in the
selector lever assembly.
When the brake shift interlock actuator is activated,
the locking pin is retracted so that another
transmission range can be selected.
The brake shift interlock actuator is deactivated
when the ignition is switched off. It is mechanically
locked when the gear selector lever is in 'P'.
Automatic transmission, selector lever in
position "D".
The TCM adapts the shift points to match the
driving conditions. Normally the TCM is in adaptive
mode and gear changes take place adapted to the
driving conditions. If special driving conditions are
detected, the TCM switches to predefined
characteristics.
When driving with normal acceleration, the TCM
uses a preset shift program which is optimized for
economical driving.
This shift program is suitable for "normal" driving
and delivers early upward changes and torque
converter lockup. Furthermore, the transmission
fluid pressure is adapted to make smooth
engagement of the gears possible.
Sport mode, selector lever in position "S"
The transmission switches from automatic
operation into sport mode. In this mode the TCM
switches to another set of characteristic curves.
These characteristic curves for control of the gear
changes are adapted to sporting calculations (e.g.
gear change at higher engine speed).
In the sport mode shift program the shift points are
set so that good performance is offered. Changing
down occurs at lower engine speeds.
Manual gear changes (select-shift mode) can be
made in sport mode by moving the selector lever
in the (+) or (-) direction.
Changing gear in select-shift mode
If you move the selector lever to 'S', the automatic
transaxle remains hydraulically in 'D' position. If
you move the gear selector lever forwards (-), the
G1163605en2008.50 Kuga8/2011
307-01-
29
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 29
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL