30N12T0 CVT diagnosis and service 2004

• The variators, which are controlled by fluid pressure, change the path of the chain moving over the pulleys to vary the pulley speed ratio, which provides the output to the differentia

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Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,

as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful

in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• Set the parking brake when working on the vehicle If you

have an automatic transmission, set it in PARK unless

instructed otherwise for a specific service operation If

you have a manual transmission it should be in

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• Operate the engine only in a well-ventilated area to avoid

the danger of carbon monoxide.

• Keep yourself and your clothing away from moving parts

when the engine is running, especially the fan and belts.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head.

• Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual

is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice.

WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing

the asbestos dust can cause asbestosis and cancer.

Breathing asbestos dust is harmful to your health.

Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing.

Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag.

If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area.

Technical Support Operations Ford Customer Service Division

Mission Statement:

All dealership personnel will treat every customer as a potential lifetime

purchaser, communicating a professional image which embraces honesty and concern for customer wants and needs.

5. Provide me with a clear and thorough explanation of the service performed.

6. Call me within a reasonable amount

of time after my service visit to ensure that I'm completely satisfied.

7. Be responsive to questions or concerns I bring to your attention.

1. Make it convenient to have my

vehicle serviced at your

dealership.

2. The Service Advisor should

demonstrate a genuine concern

for my service needs.

3. Fix it right the first time.

4. Complete servicing my vehicle in a

timely and professional manner

Expectation 3

“Fix It Right the First Time, on Time.”

Both service advisors and technicians are important players when it comes to

— Web-Based Training — Web-Based Training

— Fordstar Broadcasts — Fordstar Broadcasts

— Ford Multimedia Training (FMT) — Instructor-Led

— Instructor-Led

The Benefits

The successful implementation of standards means

— Satisfied customers

— Repeat vehicle sales

— Repeat service sales

— Recognition that Ford and Lincoln/Mercury technicians are

“the Best in the Business”

Customer Expectations: Service

Objectives Intro-1 Ford Continuously Variable Transaxle (CVT) New Model Instructor-Led Course Description Intro-2 Course Terminal Objectives Intro-2 Audience Intro-2 Course Prerequisites Intro-2 Evaluation Intro-3 Student Guide Intro-3

LESSON 1: CVT COMPONENTS AND OPERATION

Objectives 1 - 1 What is a Continuously Variable Transaxle (CVT) 1 - 2 Variator Operation 1 - 3

TRANSAXLE CONTROL SYSTEM 1 - 5

CVT MECHANICAL COMPONENTS 1 - 8 Fluid Pump 1 - 9 Planetary Gearset 1 - 10 Clutches 1 - 11 Output Gear and Differential 1 - 12 Parking Pawl 1 - 13

TRANSAXLE OPERATION 1 - 14 Powerflow in Forward 1 - 14 Powerflow in Reverse 1 - 15 Planetary Gearset Operation 1 - 16

Workstation 1 1 - 18 Workstation 2 1 - 19 Workstation 3 1 - 21 Workstation 4 1 - 22

LESSON 2: CVT DIAGNOSIS AND SERVICE

Objectives 2 - 1 Introduction to CVT Diagnosis and Service 2 - 2 CVT inputs and outputs 2 - 3 Description of Inputs and Outputs 2 - 4 CVT Operational Strategies 2 - 7 CVT Diagnosis 2 - 8 CVT Disassembly and Assembly 2 - 9

Demonstration Worksheets 2 - 10

Workstation 1 2 - 16 Workstation 2 2 - 17 Workstation 3 2 - 18 Workstation 4 2 - 20

GLOSSARY Glossary - 1

TOOL LIST Tool - 1

ROTUNDA ORDER FORM

z Introduce the Students to the course

z Explain Course Objectives

z Describe Course Prerequisites

z Explain Course Evaluation Standards

INTRODUCTION

Ford Continuously Variable Transaxle (CVT) New Model Course Description

The Continuously Variable Transaxle (CVT) New Model instructor-led course is a two-daycourse facilitated by an instructor This course is designed to provide hands-on opportunitiesfor Ford Service Technicians to learn and improve their skills with respect to utilizing tools andequipment and to apply knowledge learned in both this course and in the previous

FORDSTAR Five Hundred, Freestyle, and Mercury Montego New Model Course

Course Terminal Objectives

After successfully completing this course, a technician will be able to:

Audience

This course is designed and intended for Ford Motor Company Dealership Service

Technicians who have completed the Ford Automatic Transmission Curriculum and its

prerequistites

Course Prerequisites

A technician taking this course should have the following prerequisite skills, knowledge, and/orexperience:

30N27F0

Hands-on skills and course related knowledge is evaluated on the afternoon of the second day

z Hands-on evaluations will be conducted with exercises in:

– CVT system diagnosis

– CVT system service

– Service publication WEB/DVD navigation

– CVT special tool usage

In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-onexercises AND you must answer at least 80% of the written post test questions correctly

CONTENTS OBJECTIVES

LESSON 1: CVT COMPONENTS AND OPERATION

z Upon completion of this lesson the

student will be able to:

– Explain the function of the CVT

– Describe the components of the CVT

– Identify the operation of CVT

components

– Explain the powerflow of the CVT

z What is a Continuously Variable Transaxle

The continuously variable transaxle (CVT) in the new Ford Five Hundred, Freestyle and cury Montego offers many times more gear ratios than any conventional automatic transaxle.Conventional transaxles use planetary gearsets to change discrete ratios Changing ratios

Mer-increases vehicle speed

The CVT uses two cone shaped, pressure controlled variators

• These variators act as pulleys with a heavy duty chain that connects them

• The variators, which are controlled by fluid pressure, change the path of the chain moving

over the pulleys to vary the pulley speed ratio, which provides the output to the differential

• The portion of the variators (pulleys) that the chain runs over varies in diameter

• The chain path around the variators change based upon driver demands and driving

conditions as monitored by the Transaxle Control Module (TCM)

• The TCM, through the main control valve body, controls fluid pressure to the variators (thecombination of the TCM and main control valve body are known as the mechatronic)

• The changing path of the chain around the variators produces the change in ratios as

planetary gearsets do in conventional transaxles

The obvious benefit is smoothness because there is no shifting CVTs are also more efficientand thus save about 4 percent to 8 percent in fuel versus the traditional four-speed automatic.Ratio changes take place smoothly – the “feel” of the transaxle changing gear ratios is excel-lent

WHAT IS A CONTINUOUSLY VARIABLE TRANSAXLE (CVT)

CVT

The CVT permits the engine to always operate at its most efficient speeds.

• There are no discrete gear shifts and no interruptions in acceleration Instead optimum use isalways made of the engines potential to transmit its full torque to the drive wheels

• There is an infinite number of intermediate gear ratios, so that the optimum engine operatingpoint can always be found Acceleration is also continuous

• The mechanical section of the CVT contains 2 pressure controlled variator assemblies and asingle dual pinion planetary gearset

Variators

• The variators function as variable speed pulleys The chain wraps around the pulleys (bothvariators) like a “V” belt

• The fluid pressure controlled variators change the path of the chain moving over the pulleys

to vary the variator speed ratio

• They provide the input-to-output ratio of the transaxle like a step ratio using fixed planetaryratios

• The primary (input) variator (pulley) receives input torque from the torque converter turbine

• The secondary variator (output) is driven by the chain and transmits torque to the differential

• The variator speed ratios are controlled by pulley pressure on the chain

• This causes the chain path over the pulleys to change radius over the pulleys providing theratios from lowest to highest

VARIATOR OPERATION

CVT Variators and Chain

Item Description Item Description

1

2

3 Chain

Secondary Variator (Pulley)

Primary Variator (Pulley)

3

12

On the primary variator, one half of the variator is fixed to the input shaft, while the other can

be moved along the shaft by a hydraulic piston

• One half of the secondary variator on the output shaft is also fixed in place and the other halfmoves along the shaft by a hydraulic piston

• The piston cylinders of each variator are linked by a fluid line

• If pressure is applied to a moveable half of one variator in a given direction, the other

movable half on the other variator must then move in the opposite direction

• Depending on the torque, the chain is pressed against the variator halves at a controlled

level that reliably prevents the chain from slipping

• The working pressure to regulate the variator ratio and the chain contact pressure is

generated by a hydraulic pump and controlled by a hydraulic circuit with precision valves

which are actuated by the electronic system

Hydraulic Operation

Variator Operation (continued)

Fluid Pressure between Variators

Item Description Item Description

1

2

3 4

3

The mechatronic assembly is located in the fluid pan The assembly contains:

• The hydraulic main control valve body which uses 11 valves for pressure control

• 5 pressure control solenoids

• The transaxle control module (TCM)

– Speed sensors (internal)

– Pressure sensors

– Primary variator (input)

– Secondary variator (output)

CAUTION: Do not touch the electrical connector pins Electrostatic charge may occur and will cause damage to the mechatronic unit.

TRANSAXLE CONTROL SYSTEM

Mechatronics

Main control valve body - The valve body controls the system hydraulic pressure and variator

pressure

Pressure control (PC) solenoids - The 5 pressure control solenoids are variable force

solenoids (VFS)

• Main system control pressure (PCA solenoid)

• Torque converter clutch operation (TCC or PCE solenoid)

• Primary pulley pressure (PCB solenoid)

• Secondary pulley pressure (PCC solenoid)

• Forward and reverse clutch apply pressure (PCD solenoid)

TRANSAXLE CONTROL SYSTEM (continued)

Hydraulic Main Control Valve Body

Transaxle control module (TCM) - The TCM controls transaxle function It is the transaxle to

vehicle system interface

• Additionally, it supplies the signal to the PCM for starter interlock

• Diagnostic Trouble Codes (DTCs) that are transaxle related are supplied to the PCM from theTCM

• The Transaxle Fluid Temperature (TFT) sensor is mounted within the TCM and cannot beseen

3 Pressure Control Solenoids

Note: The Mechatronic can only be serviced as a complete assembly.

TRANSAXLE CONTROL SYSTEM (continued)

Manual Valve and Transaxle Range Sensor Location

• The CVT has a unique manual control valve that is separate from the hydraulic valve body

• Additionally, the Transaxle Range Sensor (TRS) is a hall effect type sensor that provides theTCM with shift lever position information

2

Item Description Item Description

1 Manual Valve 2 Transmission Range Sensor (TRS)

1

CVT MECHANICAL COMPONENTS

Schematic View of CVT (As viewed from the top looking down)

This section will look at the components that make up the CVT

Item Description Item Description

Reverse Clutch

Mechatronics

Forward Clutch

Primary Variator Assembly (Input)

Secondary Variator Assembly (Output) Chain

Differential Torque Converter

The CVT fluid pump is a high-pressure, radial-piston pump.

• There are eight pistons located radially around the circumference at uniform intervals

• The pump is driven directly from the engine via the outer housing of the torque converter andsupplies the transaxle with both lubricating fluid and hydraulic pressure

• The torque converter is supported inside the converter hub

• The pump draws in fluid from the fluid pan via a fluid pan (suction) filter and discharges thefluid at high pressure to the main regulator valve in the main control valve body At this valvethe main (system) pressure is regulated and excess fluid is returned to the suction side ofthe pump

WARNING: THE FLUID PUMP MUST NEVER BE DISASSEMBLED THE PISTONS ARE UNDER VERY HIGH SPRING TENSION AND MAY RELEASE WITH ENOUGH ENERGY TO CAUSE INJURY.

Pump Housing

Pistons (8)

Springs (8) Pump Eccentric

3

2

4

The CVT uses a unique dual pinion planetary gearset to allow both forward and reverse gearrange.

• Planetary operation is controlled conventionally using two clutch packs, forward and reverse

PLANETARY GEARSET

CVT Planetary Gearset

4

35

Item Description Item Description

1

2

3

4 5 6

Speed Sensor Pulse Wheel

Planet Carrier

Location for Sun Gear (not shown)

Input (Turbine) Shaft Ring Gear

Reverse Clutch Carrier

1

26

The CVT uses conventional multiplate disc clutches to establish only forward and reverserange.

• The clutch packs function the same as any clutch pack used in modern transaxle

CLUTCHES

Cutaway of Clutches

Item Description Item Description

21

3

4

The CVT uses a conventional helical gear type differential

• As with all transaxles they are integrated into the transaxle housing

• Torque is transmitted from the spur gear, which is connected to the secondary variator,

through the side gear, and then to the differential

There are 3 differential gear ratios available, depending on vehicle configuration

Side Gear

Differential

PARKING PAWL

Parking Pawl

Item Description Item Description

As with all automatic transmissions, the CVT has a parking pawl to prevent the vehicle fromrolling when parked

• When the shift lever is moved to PARK position the park pawl engages the parking gearwhich is located on the secondary variator assembly

• This eliminates secondary variator movement and prevents the vehicle wheels from rolling

1

2

3 4

Detent Spring

Detent Disk

Linkage Rod Parking Pawl

21

3

4

Powerflow for the CVT is very straight forward.

• Torque from the engine is transmitted to the torque converter, which in turn drives the inputshaft

• The input shaft is connected to and drives the planet carrier

• In forward, the forward clutch is applied, which locks the input shaft to the primary variator

• The primary variator drives the secondary (output) variator via the chain

• The secondary variator is connected to the output gear, which in turn drives the differential

Differential

Side Gear and Shaft Assembly

Secondary Variator Assembly

Chain

Primary Variator Assembly

Forward Clutch Input Shaft Torque Converter Spur Gear

57

10

6

Powerflow for the CVT in reverse is as follows.

• Torque from the engine is transmitted to the torque converter, which in turn drives the inputshaft

• The input shaft is connected to and drives the planet carrier

• In reverse, the reverse clutch is applied, which locks the ring gear to the case, causing thesun gear to reverse direction

• The sun gear is fixed to, and drives the primary (input) variator

• The primary variator drives the secondary (output) variator via the chain

• The secondary variator is connected to the output gear, which in turn drives the differential

57

Differential

Side Gear and Shaft Assembly

Secondary Variator Assembly

Chain

Primary Variator Assembly

Forward Clutch Input Shaft Torque Converter Spur Gear

Planet Carrier

PLANETARY GEAR OPERATION

The function of the planetary gearset in the CVT is not to provide gear ratios (although due toplanetary action there is reduction in Reverse), but only to change variator rotation direction.Planetary operation is as follows:

Drive

• In Drive/Low, the input shaft is connected to, and drives, the planet carrier.

• The forward clutch is applied, which locks the planet carrier to the primary variator (which issplined to both the sun gear and forward clutch drum)

Reverse

• In Reverse, the reverse clutch is applied, which locks the ring gear to the case.

• The input shaft is connected to, and drives, the planet carrier

• The pinions of the carrier drive the sun gear in reverse direction

• The sun gear is fixed to, and drives the primary (input) variator

Item Description Item Description

1

2

3 Sun Gear (Output)

Carrier Pinions (Input)

Ring Gear (Held)

1

2

3

22

Planetary Gearset in Reverse

CONTENTS OBJECTIVES

z Upon completion of this activity the

student will be able to:

– Identify CVT components and

operation

– Explain CVT special service tools

and their function

– Describe and identify CVT

WORKSTATION 1 CVT COMPONENT IDENTIFICATION AND FUNCTION

STUDENT ANSWER SHEET

A. Receives input torque from the torque converterturbine

B Is driven by the chain and transmits torque to the differential.

C. Is pressed against the variator halves at a trolled level.

con-D Controls transaxle operation.

E. Controls the system hydraulic pressure and tor pressure.

shift lever position information

G. Has eight pistons located radially around thecircumference at uniform intervals.

H. Is controlled conventionally using clutch packs.

I. When applied it locks the ring gear to the case

J. When applied it locks the carrier to the sun gear

Directions: Go to Workstation 1 Locate the CVT component that performs the COMPONENT

FUNCTION listed in the right hand column Next, write the name of the component in the

center COMPONENT NAME column Then write the number on the tag that is attached to thatcomponent in the TAG column on the left

END OF WORKSHEET, RETURN THE WORKSTATION TO THE CONDITION IN WHICH YOU FOUND IT

WORKSTATION 2 CVT PIDS STUDENT ANSWER SHEET

Directions: Go to Workstation 2 Use the WDS and service publications to answer the

ques-tions below

1 View the file stored in the WDS memory Select the Datalogger menu and view the PIDSshown Write the function of each PID shown in the center column and list the parametervalue displayed (voltage, resistance, percentage etc.)

6 With no DTCs present, which Diagnosis by Symptom routine would you follow to diagnose atorque converter chatter concern?

5 What is the description of PID SSPC_E?

Use the workshop manual to answer questions 5-9

2 What is the variator commanded ratio at 5 seconds into the recording?

3 What is variator measured ratios at 5 seconds into the recording?

4 Why do you think there is a difference between the two ratios?

WORKSHEET CONTINUED ON NEXT PAGE

WORKSTATION 2 CVT PIDS AND SERVICE INFORMATION (CONTINUED)

STUDENT ANSWER SHEET

8 During assembly of the CVT you are preparing to set differential preload To perform thisaction you must place spacers between the case and the torque converter housing What isthe tool number of these spacers?

9 While doing an In-vehicle Repair on the side shaft gear assembly, what is the tool number

of the seal installer that must be used to install the side shaft gear assembly dust cover?

7 You are performing an In-vehicle Repair on the primary variator cover What special servicetool do you use to install new square cut seals onto the primary cover feed tube?

END OF WORKSHEET, RETURN THE WORKSTATION TO THE CONDITION IN WHICH YOU FOUND IT

WORKSTATION 3 CVT SPECIAL SERVICE TOOL IDENTIFICATION

STUDENT ANSWER SHEET Directions: Go to Workstation 3 Read the tool function listed Use the service publications to

find the tool that performs that function, then note it’s name and tool number in the appropriatecolumn

END OF WORKSHEET, RETURN THE WORKSTATION TO THE CONDITION IN WHICH YOU FOUND IT

Compresses secondary variator

Allows removal of the chain from the variators

Installs the pump cover seal on the pump

Tools that align the CVT pump

Installs front pump seal

Allows input shaft end play to be measured

Enables variator nut removal

Mounts between differential and torque

converter housing and measures correct

shim thickness for setting preload