37S05T0 front wheel drive automatic transaxle repair 2004

It has the following major components: x case with chain cover x chain drive x two friction bands: overdrive, coast x five friction clutches: forward, direct, intermediate, reverse, low-

automatic transmission

front-wheel drive automatic transaxle

repair

student reference book

COURSE CODE: 37S05T0 ORDER NUMBER: FCS-13882-REF

September 2, 2004

Ford Customer Service Division

Course 37S05T0, 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 37S05T0, 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 37S05T0, 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 37S05T0, Slide 6

Course 37S05T0, Slide 10

In a typical 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 The output shaft transfers power to the transaxle’s final drive assembly which directs the power flow to each drive wheel

Course 37S05T0, Slide 28

The 4F50N/AX4N automatic transaxle is a four-speed unit with electronic shift control It is designed for operation in a transverse power train for front-wheel drive vehicles It has the following major components:

x case with chain cover

x chain drive

x two friction bands: overdrive, coast

x five friction clutches: forward, direct, intermediate, reverse, low-intermediate (AX4S – low intermediate clutch not present)

x three one-way clutches: low, direct, low-intermediate (AX4S – low

intermediate one-way clutch not present)

x a front and rear simple planetary gear set

x final drive planetary gear set

Non-synchronized – one hydraulic event in a single shift (apply or release), for example on the AX4N the low/intermediate clutch remains applied for all forward gears but has no effect on some gears.

x clutch and damper assembly

The standard torque converter components operate as follows:

x Rotation of the converter housing and impeller set the fluid in motion

x The turbine reacts to the fluid motion from the impeller, transferring rotation to the gear train through the input shaft

x The stator (also called reactor) redirects fluid going back into the impeller, providing for torque multiplication

x The clutch and damper assembly dampens power train torsional vibration and provides a direct mechanical connection for improved efficiency

x Power is transmitted from the torque converter to the planetary gear sets and other components through the input shaft.

Course 37S05T0, Slide 30

The hydraulic system has a main control assembly The pump assembly, hydraulic control valves and electro-hydraulic actuators are located in the main control

Gaskets are used for the separator plate between the pump body and valve body The separator plate between the valve body and chain cover has integral gaskets

Course 37S05T0, Slide 31

The gear train consists of:

x planetary gear sets

x apply components

x final drive gear set

x differential

Planetary Gear Set

The transaxle has two planetary gear sets to provide operation in reverse and four forward speeds

The gear sets are comprised of the following components:

x front sun gear (part of the front sun gear and shell assembly)

x front carrier

x rear ring gear

x front ring gear and rear carrier

x rear sun gear

The sun gear is splined to the front ring gear and rear carrier of the planetary gear sets The sun gear acts as the driving member and the carrier as the driven member The ring gear is held stationary inside the case using lugged teeth

Turbine Shaft

The turbine shaft is splined to both the torque converter stator and the drive sprocket This allows input torque to be transmitted from the torque converter to the drive chain and driven sprocket

Output Shaft

The output shaft is splined to one of the differential side gears on one end, supported by the driven sprocket and driven sprocket support on the other end This allows power flow through the differential for even output torque to the drive axles

Drive Chain and Sprockets

A chain drive transfers torque from the torque converter turbine to the planetary gear sets The chain drive is composed of the following components:

components

Final Drive Gear Set

The final drive consists of a planetary gear set that transfers and multiplies torque from the planetary gear sets to the differential

The final drive consists of the following components:

The differential assembly consists of the following components:

x differential case (part of the final drive carrier)

x two pinion gears supported by a pinion shaft

x two side gears supported by the differential case and half shafts

Course 37S05T0, Slide 32

The 4F27E was introduced with the 2000 Focus It is a fully automatic,

electronically controlled four-speed transmission designed for front-wheel-drive vehicles The designation 4F27E means:

x 4 — 4-four-speed transmission

x F — front wheel drive

x 27 — originally designed for maximum input torque after torque converter:

365 Nm (270 lb-ft)

x E — fully electronic control

The individual ratios are achieved through two planetary gear sets, connected one behind the other

The individual components of the planetary gear sets are driven or held by means of four multi-plate clutches, a band and a roller one-way clutch

Torque is transmitted to the final drive assembly through an intermediate gear stage.

The electrical and hydraulic functions are carried out by an EEC V Powertrain Control Module (PCM)

The manual selector lever gives the driver a choice of "P", "R", "N", "1", "2" and

"D"

In drive range "D" it is also possible to operate an O/D switch on the manual selector lever to prevent the transmission from shifting into fourth gear or, if already in fourth, shifting down to third gear

To minimize fuel consumption, the torque converter clutch is applied by the PCM

in 3rd and 4th gears depending on the throttle position and vehicle speed

The transmission has Electronic Synchronous Shift Control (ESSC), which

guarantees extremely smooth gear shifting over the entire life of the

transmission

A hydraulic emergency operating program maintains limited operation in the event of failure of important electrical components Default is 3rd gear

The transmission can be tested using a scan tool through the Data Link

Connector (DLC) in the passenger compartment

x clutch and damper assembly

The standard torque converter components operate as follows:

x Rotation of the converter housing and impeller set the fluid in motion

x The turbine reacts to the fluid motion from the impeller, transferring rotation to the gear train through the input shaft

x The stator/reactor redirects fluid going back into the impeller, providing for torque multiplication

x The clutch and damper assembly dampens power train torsional vibration and provides a direct mechanical connection for improved efficiency

x Power is transmitted from the torque converter to the planetary gear sets and other components through the input shaft

x two shift solenoids (on/off)

x one main regulating solenoid (variable force solenoid- EPC)

The individual clutches and bands are supplied pressure from the PWM solenoid valves and the shift solenoid (on/off) valves These valves allow direct actuation

of clutches and bands to ensure extremely smooth gear shifting through precise pressure regulation

The shift solenoid (on/off) valves switch the hydraulic path to the clutches and bands, reducing the number of required modulating valves

The main regulating valve (variable force solenoid) ensures that sufficient

hydraulic pressure is available in all operating conditions

PWM solenoid 1-3

PWM solenoids 1, 2 and 3 control the pressure to the bands and clutches

Shift solenoid (on/off) 1 and 2

The shift solenoids (on/off) switch the different oil passages in the valve body to direct the pressure to the individual clutches and bands

Main regulating solenoid

The main regulating solenoid controls the required main line pressure (based on engine load) for the individual transmission ranges

Electronic Synchronous Shift Control (ESSC)

ESSC monitors shift operations to adapt to the wear in the shift elements over the life of the transmission This is possible since the shift elements are actuated

by modulated valves

If the PCM detects a deviation from the stored values for the shift time and synchronization of the shift operation, the pressure buildup or reduction is

adapted accordingly

Course 37S05T0, Slide 35

The final drive input gear is splined to the planet carrier of the front planetary gear set and drives the transfer shaft input gear of the intermediate gear stage The transfer shaft output gear of the intermediate gear stage drives the final drive assembly

Torque is transmitted to the half shafts through the final drive assembly

The differential allows the half shafts and wheels to rotate at different speeds during cornering

The intermediate gear stage is designed such that final drive ratio can be

adapted for different vehicle applications

Course 37S05T0, Slide 36

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 37S05T0, Slide 37

When internal wear or damage has occurred in the transaxle, metal particles, clutch plate material, or band material may have been carried into the torque converter and transaxle fluid cooler These contaminants are a major cause of recurring transaxle troubles and must be removed from the system before the transaxle is put back into use

Course 37S05T0, Slide 41

Course 37S05T0, Slide 1

Course 37S05T0, Slide 10

Course 37S05T0, Slide 1

Course 37S05T0, Slide 10