Preliminary Inspection

The following items must be checked before proceeding:

Know/Understand the Concern

In order to properly diagnose a concern, you must first understand the customer complaint or condition. Customer contact may be required in order for the technician to begin to verify the concern. You must understand the conditions as to when the concern occurs. For example:

• Hot or cold vehicle temperature
• Hot or cold ambient temperature
• Vehicle driving conditions

After understanding when and how the concern occurs, then proceed to verifying the concern.

Verification of Condition

This section provides information that must be used in both determining the actual cause of customer concerns and performing the appropriate service procedures.

NOTE: Some transmission conditions may cause engine concerns. An EPC short circuit may cause alternate firing. The torque converter clutch not disengaging will stall the engine.

The following procedures must be used when verifying the customer concerns for transmission.

Required Equipment

• Rotunda New Generation Star Tester 007-00500 or equivalent.
• Powertrain Control/Emissions Diagnosis Manual.
• Transmission Range (TR) Sensor (MLPS) Alignment Tool T93P-70010-A or equivalent.
• Rotunda Digital Volt-Ohmmeter 014-00407 or equivalent.
• Rotunda Transmission Tester 007-00085 or equivalent.
• Rotunda Transmission Range (TR) Sensor Cable "C" (MLPS Manual Lever Position Sensor Cable) 007-00086 or equivalent.
• Rotunda EEC-V 104-Pin Breakout Box 014-00950 or equivalent.

Determine Customer Concern

NOTE: Some transmission conditions may cause engine concerns. An EPC short circuit may cause alternate firing. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle usage and dependent driving conditions, paying attention to the following items:

• Hot or cold vehicle operating temperature
• Hot or cold ambient temperatures
• Type of terrain
• Vehicle loaded/unloaded
• City/highway driving

• Upshift
• Downshift
• Coasting
• Engagement
• Noise/vibration

NOTE: If noise/vibration, check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent.

Check Fluid Level and Condition

Fluid Level Check

 CAUTION: Vehicle should not be driven if fluid level is below the bottom hole.

 CAUTION: If vehicle has been operated for an extended period at high speed, in city traffic, in hot weather, or vehicle is being used to pull a trailer, the fluid has to cool approximately 30 minutes after engine has been turned off to obtain an accurate reading.

Under normal circumstances, the fluid level of the transmission must be checked during normal maintenance and changed at 48,000 km (30,000 miles), since the vehicle does not use up transmission fluid. However, if the transmission is not working properly, for instance, the transmission may slip or shift slowly, or if there is some sign of fluid leakage, the fluid level should be checked.

It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. However, if necessary, the fluid level can be checked without having to drive the vehicle to obtain a normal operating temperature if outside temperature is above 10°C (50°F).

 CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and outside temperature is above 10°C (50°F).

When checking fluid at normal operating temperature, the fluid level should be within the crosshatched area on the fluid level indicator. When the vehicle has not been driven, and outside temperature is above 10°C (50°F), the fluid level should be between the holes in the fluid level indicator.

NOTE: The fluid level indication on the fluid level indicator will be different at operating temperature and room temperature. For the correct fluid level reading on the fluid level indicator, follow the appropriate instructions stated previously.

Check fluid level as follows:

1. With transmission in PARK, engine at curb idle rpm, foot brakes applied and vehicle on level surface, move the transmission selector lever through each range. Allow time in each range to engage transmission, return to PARK, apply parking brake control (2780) and block wheels. Do not turn off the engine during the fluid level check.

2. Clean all dirt from the transmission fluid level indicator cap before removing the fluid level indicator from the fluid filler tube.

3. Pull the fluid level indicator out of the fluid filler tube, wipe it clean, and push all the way back into the tube. Make sure it is fully seated.

4. Pull the fluid level indicator out of the fluid filler tube again and check the fluid level.

   If necessary, add enough fluid through the fluid filler tube to raise the level to the correct position. Do not overfill the transmission. This will result in foaming, loss of fluid through the vent and possible transmission malfunction. If overfill occurs, excess fluid must be removed.

5. Install the fluid level indicator, making sure it is fully seated in the fluid filler tube.

   If the transmission fluid level is correctly established at 21°C-35°C (70°F-95°F), it will appear in the crosshatch area on the fluid level indicator when the transmission reaches an operating temperature of 66°C-77°C (150°F-170°F). Do not overfill or underfill.

   Underfill can result in transmission loss of engagement or slipping. This condition is most evident in cold weather or when the vehicle is parked or being driven on a hill.

   If the transmission fluid level is checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the fluid level indicator is misread. If fluid is added at this time, an overfill condition could result when the fluid reaches operating temperatures of 66°C-77°C (150°F-170°F) (fluid level indicator hot to touch).

High or Low Fluid Level

A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, and the aerated fluid may be forced from the vent.

A fluid level that is too low will affect transmission operation. Low level may indicate fluid leaks that may cause transmission damage.

Adding Fluid

 CAUTION: Use of a fluid other than MERCON® Multi-Purpose Automatic Transmission Fluid could result in transmission malfunction and/or failure.

NOTE: The fluid level indication on the fluid level indicator (7A020) will be different at operating temperature and room temperature. For the correct fluid level reading on the fluid level indicator, follow the appropriate instructions stated below.

Before adding fluid, make sure that the correct type will be used. Only use fluid that meets or exceeds the specification stamped on the fluid level indicator.

Add fluid in 0.25L (0.5-pint) increments through the filler tube to bring the level to the correct area on the dipstick. If an overfill occurs, excess fluid must be removed.

Fluid Change — Drain/Refill

Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter (7902), transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified.

Normal Maintenance

Change fluid at 48,279 km (30,000 miles).

Severe Duty/Major Overhaul

Change fluid at 33,795 km (21,000 miles).

 CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or 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 Specifications in this section for capacity. Check the fluid level.

Procedures for partial drain and refill are as follows.

1. Raise vehicle on a hoist and position suitable safety stands under vehicle. Refer to Section 00-02.

2. Place drain pan under transmission.

3. Loosen transmission pan retaining bolts and allow fluid to drain from transmission.

4. When fluid has drained to level of pan flange, remove the transmission pan retaining bolts working from the right-hand side of the transmission. Carefully lower the transmission pan and drain remaining fluid.

5. Remove the pan to case gasket and thoroughly clean the transmission pan and pan magnet.

6. Drain the torque converter by removing the torque converter drain plug.

7. Thoroughly flush torque converter, auxiliary fluid cooler (if equipped) and lines.

8. After torque converter has been drained, install new torque converter drain plug and tighten to 28-30 Nm (21-23 lb-ft).

9.  CAUTION: If installing new filter, and grommet remains in main control bore, carefully use a small screwdriver to remove it. Take care not to damage main control bore.

   NOTE: If servicing for contamination-related failure, use a new filter and grommet. Filter may be reused if no excessive contamination is present.

   Replace transmission fluid filter and grommet as required.

10. Clean and inspect transmission pan to case gasket. If OK, reuse. Install pan to case gasket on transmission pan.

11. Install pan magnet in transmission pan. Install transmission pan to transmission. Tighten fourteen retaining bolts to 12-15 Nm (9-11 lb-ft).

12. Remove safety stands and lower vehicle.

13. When filling a dry transmission and converter, start with a minimum of 6.1 liters (6.5 quarts). Refer to Specifications for capacity.

14. Fill transmission to proper level with Motorcraft MERCON ® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON® equivalent approved fluid.

Fluid Condition Check

1. Make the normal fluid check. Refer to Fluid Level Check under Verification of Condition in the Diagnosis and Testing portion of this section.

2. Observe color and odor of the fluid. It should be dark reddish, not brown or black. Odor can sometimes indicate that there is an overheating condition or clutch disc or band failure.

3. Use an absorbent white facial tissue to wipe the dipstick. Examine the stain for evidence of solids (specks of any kind) and for antifreeze signs (gum or varnish on fluid level indicator).

• If particles are present in the fluid or there is evidence of antifreeze, the transmission pan must be removed for further inspection.
• If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive solids in the transmission pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning the torque converter and transmission cooling system. It would be a waste of time to perform any further checks before cleaning and servicing the transmission.
• During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made.
• After the transmission has been serviced, all diagnosis tests and adjustments listed in the Diagnosis by Symptom Charts under Diagnosis by Symptom in the Diagnosis and Testing portion of this section must be completed to ensure the concern has been corrected.

Road Testing Vehicle

The following Shift Point Road Test and Torque Converter Operation Test provide diagnostic information concerning transmission shift controls and torque converter operation.

Shift Point Road Test

This test verifies that the shift control system is operating properly.

1. Bring engine and transmission up to normal operating temperature.

2. Operate vehicle with transmission range selector lever in D position.

3. Apply minimum throttle and observe speeds at which upshift occurs and torque converter engages. (Refer to Automatic Transmission Specification Bulletin FPS-12180-96.)

   4R70W TRANSMISSIONS — SHIFT SPEEDS — MPH^*

   Throttle Position	Range	Shift	(MPH)*
   Light Throttle	(D), D	1-2	8-12
   	(D), D	2-3	17-22
   	(D)	3-4	38-44
   	(D) - C.T.	4-3	26-23
   	(D), D - C.T.	3-2	15-12
   	(D), D - C.T.	2-1	8-6
   Wide-Open Throttle	(D), D	1-2	36-42
   	(D), D	2-3	68-75
   	(D), D	3-2	64-60
   	(D), D	2-1	33-29
   	(D)	3-4	88-92
   	(D)	4-3	80-75

   ^* May vary due to axle ratio and tire size. Refer to Automatic Transmission Specification Bulletin FPS-12180-96 for actual mph.

   C.T. = Closed Throttle.

4. With vehicle in OVERDRIVE (4th gear), press transmission control switch. Transmission should downshift to 3rd gear. Remove foot from accelerator pedal; engine braking should occur.

5. Press accelerator pedal to floor (WOT). Transmission should shift from 3rd to 2nd gear, or 3rd to 1st depending on vehicle speed. Torque converter clutch should disengage and then reapply.

6. With vehicle in (D) position above 80 km/h (50 mph) and less than half throttle, move the transmission range selector lever from (D) position to Manual 2 position and remove foot from accelerator pedal. Transmission should immediately downshift into 2nd gear. With vehicle remaining in Manual 2 position, move transmission selector into Manual 1 position, and release accelerator pedal. Transmission should downshift into 1st gear at speeds BELOW 48-56 km/h (30-35 mph).

7. If transmission fails to upshift/downshift or torque converter clutch does not apply and release, refer to Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

Torque Converter Operation Test

This test verifies that the torque converter clutch control system and the torque converter are operating properly.

1. Perform Quick Test as outlined under On-Board Diagnostics with NGS in the Diagnosis and Testing portion of this section. Check for DTCs P0741, P0743, P1741, P1742, P1743 and P1744. Refer to Pinpoint Test C for diagnosis.

2. Connect a tachometer to engine.

3. Bring engine to normal operation temperature by driving vehicle at highway speeds for approximately 15 minutes in (D) position.

4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot.

5. Engine rpm should increase when brake pedal is tapped, and decrease about 5 seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Index under Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

6. If vehicle stalls in (D) or Manual 2 at idle with vehicle at a stop, move transmission range selector lever to Manual 1 position. If vehicle stalls, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Index. Service as required. If vehicle does not stall in (D), refer to Pinpoint Tests in the Diagnosis and Testing portion of this section for PCM and Vehicle Harness Electrical Diagnosis in Pinpoint Test C.

Visual Inspection

This inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect vehicle for non-Ford-approved add-on devices such as:

• Air conditioning
• Generators
• Engine turbos
• Cellular telephones
• Cruise controls
• CB radios
• Linear boosters
• Backup alarm signals
• Computers

• These items, if not installed properly, will affect powertrain control module (PCM) (12A650) or transmission function. Pay particular attention to add-on wiring splices in the powertrain control module or transmission wiring harness, abnormal tire size or axle ratio changes.
• Leaks — refer to Leakage Inspection in the Diagnosis and Testing portion of this section.
• Proper linkage adjustments — refer to Section 07-05.

Check TSBs and OASIS

Refer to all technical service bulletins and OASIS messages which pertain to the transmission concern and follow the procedure as outlined.

Perform On-Board Diagnostics

After a road test, with the vehicle warm and before disturbing any connectors, perform the Quick Test using Rotunda New Generation STAR (NGS) Tester 007-00500 or equivalent. Refer to the Powertrain Control/Emissions Diagnosis Manual OBDII.

Refer to Diagnostics in the Diagnosis and Testing portion of this section.