37S04T0 introduction to automatic automatic transmission transaxle repair 2004

If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation.. The Automatic Transmission Curriculum consists of 8 courses addressin

automatic transmission

September 2, 2004

Ford Customer Service Division

Course 37S04T0, Slide 1

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 document 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 document cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided

in this document 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 shop manual 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 Operate the engine only in a well-ventilated area to avoid the danger

of carbon monoxide

Keep yourself and your clothing away from moving part 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 under hood 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

Course 37S04T0, Slide 3

The Automatic Transmission Curriculum consists of 8 courses addressing

automatic transmission theory of operation, diagnosis, and service Each course

in the curriculum is a “building block” for the next course in the curriculum

This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service automatic transmission systems and components The skills and knowledge gained from this curriculum will enable technicians to pursue training in other service specialty areas

The Automatic Transmission Update course is a Web-based Training (WBT)

course designed as an ongoing source of information on new

All technicians will be required to take future versions of the Automatic

Transmission Update course to remain certified

Technicians will be notified of need to take the course by electronic field

communication When technicians take the course, it sets the time clock for when they have to take the next update course

Course 37S04T0, Slide 5

The Automatic Transmission Curriculum consists of 8 courses addressing

automatic transmission theory of operation, diagnosis, and service Each course

in the curriculum is a “building block” for the next course in the curriculum

This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service automatic transmission systems and components The skills and knowledge gained from this curriculum will enable technicians to pursue training in other service specialty areas

Course 37S04T0, Slide 6

Course 37S04T0, Slide 10

All vehicles are equipped with a Vehicle Certification Label, located on the driver side door lock post For correct transmission identification, refer to the code in the space marked TR

For model, service ID level or build date information, refer to the transmission service ID tag located on the transmission case

Refer to the workshop manual procedures for proper fluid to use for a given transmission in a given vehicle

x Mercon — Ford fluid introduced in 1987 Similar to Dexron II OK for all

earlier Fords, except those requiring Type F Not interchangeable with

Mercon V, Mercon SP, or synthetic Mercon

x Mercon V — Introduced in 1997 Must not be used in earlier Fords Designed

to improve friction material stability, prevent torque converter clutch chatter and lower overall operating temperature, including shift temperature Not interchangeable with Mercon, Mercon SP, or synthetic Mercon

x Mercon SP – used in TorqShift transmission Not interchangeable with

Mercon, Mercon V, or synthetic Mercon

x Mercon Synthetic – Used in some manual transmissions

Course 37S04T0, Slide 31

Transmission Fluid Interchangeability

Merely by looking at all the fluids (MERCON, MERCON V and MERCON SP) we cannot differentiate them from each other However there are tests (not available

at the dealer level), which can run viscosity of fresh fluid and predict the category

of the fluid

Basic differences in all the MERCON fluids is viscosity

There are three different fluids in current use and all are made to a different recipe Components in different transmissions were designed to work with a specific fluid's recipe

Using the correct fluid will give known wear patterns, clutch timing/feel and seal compatibility thus we are able to easily diagnose and repair

Changing fluids means diagnostics could change Changing fluids is as

dangerous as drilling out orifices The issue is the different wear and friction coefficients The specifications for clutch material, surface finish and or facing were designed around a specific fluid

Use of MERCON SP in transmissions, which RECOMMEND MERCON or

MERCON V may result in premature gear failures, pump leakages, shift feel and other wear issues

Use of MERCON or MERCON V fluids in transmissions, which RECOMMEND MERCON SP may result in impact on shift feel and/or solenoid failures

Clutch durability would also be affected due to differences in coefficient of

Do not change fluids from what is outlined in the owner's manual unless a TSB modifies the usage – only then may a different fluid be used In this instant the fluid change is for a specific fix, for a specific application – ONLY and not to be understood or undertaken as a global change on future repairs or fluid

exchanges

Use only CLEAN automatic transmission fluid specified for a given transmission

DO NOT USE supplemental fluid additives, treatments or cleaning agents The use of these materials may affect transmission operation and result in damage to internal transmission components

Course 37S04T0, Slide 33

Contamination may swell or distort the seals

Course 37S04T0, Slide 40

A thorough diagnosis should always be the first step in automatic transmission repair Never remove a transmission from a vehicle before you are reasonably sure that you know where the problem lies It is also important not to take

shortcuts in the procedure You may find one problem, but it may not be the primary cause of the concern, often leading you to a repeat repair

x Before beginning a thorough transmission diagnosis, review the customer concern

x Does the transmission operate in all gear ranges? If yes, there is probably no mechanical failure Are the shifts early or late? If shift timing or feel is

affected, check into the hydraulic system

x Be aware that a hydraulic problem can cause a mechanical part to fail

x If you are unfamiliar with a particular transmission, you may wish to check the Diagnosis by Symptom Charts first, to “preview” what could be causing the concern

The recommended order of transmission diagnostic steps is shown in the flowchart

Course 37S04T0, Slide 43

Review the test results that lead to transmission disassembly Apply the

knowledge you have (principles of operation, power flow and hydraulic flow) in a step-by-step manner isolating a concern beginning with the symptom,

progressing to a system, a component, then to the root cause

For example, PID monitoring with a diagnostic scan tool can often point directly

to the input or output section of an electronic circuit, which can be much faster and less intrusive than proving out a circuit with a DVOM

Course 37S04T0, Slide 45

The Diagnosis by Symptom charts provide the technician with diagnostic

information, direction, and suggest possible components, using a symptom as a starting point

Select Diagnosis By Symptom from the Workshop Manual Table of Contents

The possible electrical components that could cause or contribute to the

symptom described will be shown and diagnosed first

The possible hydraulic or mechanical components that could cause or contribute

to the symptom described will be listed after the electrical components and inspected and repaired in the order listed

Course 37S04T0, Slide 47

The Diagnosis by Symptom charts provide the technician with diagnostic

information, direction, and suggest possible components, using a symptom as a starting point

Select Diagnosis By Symptom from the Workshop Manual Table of Contents

The possible electrical components that could cause or contribute to the

symptom described will be shown and diagnosed first

The possible hydraulic or mechanical components that could cause or contribute

to the symptom described will be listed after the electrical components and inspected and repaired in the order listed

Course 37S04T0, Slide 48

To properly diagnose a concern have the following publications available in DVD format:

x Powertrain Control/Emissions Diagnosis (PC/ED) manual

x TSBs and OASIS Messages

Course 37S04T0, Slide 49

The torque converter is heavy and may result in injury if it falls out of the

transmission Secure the torque converter in the transmission using the special tool, secure the torque converter in the transmission then lower the transmission from the vehicle Also use the tool to secure the transmission for installation

Do not allow the transmission to get into a nose-down position as this will cause the torque converter to move forward and disengage from the pump gear The converter housing is piloted into position by dowels in the rear of the engine block The torque converter must rest squarely against the flexplate This

indicates that the converter pilot is not binding in the engine crankshaft

Course 37S04T0, Slide 57

To maintain the initial driveshaft balance, mark the Rear driveshaft yoke and the axle pinion flange so they may be installed in their original positions

2 If equipped, remove and discard the transmission fluid in-line filter

3 To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below

x Connect the cleaner tank pressure line to the steel transmission cooler return line (consult the workshop manual to determine which line is the return line)

x Connect a tank return hose to the steel transmission cooler pressure line (consult the workshop manual to determine which line is the return line).Place the outlet end of this hose in the solvent tank reservoir

4 Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system)

5 Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line

6 Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed

7 Remove the rubber return hose from the remaining steel cooler line

Course 37S04T0, Slide 59

Normal Maintenance

NOTE: This procedure may vary from vehicle to vehicle Be sure to consult the Owners Manual, Workshop Manual, and Maintenance Guide for the vehicle you’re working on

For many vehicles, normal maintenance requires periodic automatic transmission fluid changes If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair

At this time, the torque converter, transmission cooler and tubes must be

thoroughly flushed to remove any dirt The transmission fluid needs to be

changed if evidence of fluid contamination is found When used under continuous

or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified

CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents The use of these products could cause internal transmission components

to fail; this will effect the operation of the transmission

CAUTION: Use of a fluid other than specified could result in transmission failure Refer to the vehicle certification label affixed to the LH front door lock face panel

or door pillar for the transmission code

When filling a dry transmission and torque converter, refer to General

Specifications chart in the shop manual for capacity Check the fluid level after filling

Be sure to check the workshop manual and owners manual for basic service intervals and procedures for the vehicle you’re working on

Transmission Service Schedules

Some vehicles don’t have to have the transmission fluid changed for the vehicle’s lifetime (150,000 miles) Refer the Schedule Maintenance Guide for service schedules for all vehicles

Every 15,000 miles Inspect transmission fluid level

Every 30,000 miles Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N, 4R100, 4F27E Inspect automatic transmission fluid level on all other vehicles, if equipped with dipstick

At 150,000 All transmissions, change automatic transmission/transaxle fluid and filter

Special Operating Conditions

These special operating conditions are:

x Towing or carrying heavy loads

x Extensive idling and/or driving at low-speeds for long distances

x Driving in dusty conditions

x Use of E85 fuel 50% of the time or greater (flex fuel vehicles only)

Course 37S04T0, Slide 60

Power flow is the flow of power from the engine to the drive wheels

Power flow enters the transmission via the torque converter which transfers the power to the input shaft At this point some of the power is also used to drive the fluid pump

In a RWD vehicle, power flow starts at the input shaft and is selectively directed through various hydraulic apply components and into the planetary gear set elements After the gear set, the power flow passes through other apply

components, into the output shaft and then out of the transmission

In the transaxle, power flow also enters at the torque converter At this point the transaxle uses a chain or set of gears to transfer power to the input shaft Some

of the power passes into the pump’s input shaft and drives the fluid pump Theoutput shaft transfers power to the transaxle’s final drive assembly which directs the power flow to each drive wheel