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Transmission Control Systems: Testing and Inspection Diagnostic Strategy
Diagnostic Strategy Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method of diagnosis. One of the most important things to remember is that there is a definite procedure to follow. NOTE: Do not take any shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. To correctly diagnose a concern, have the following publications available: - TSBs - Wiring Diagram Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.

Preliminary Inspection - Know and understand the customer's concern. - Verify the concern by operating the vehicle. - Check the fluid levels and condition. - Check for non-factory add-on items. - Check shift linkages for correct adjustment. - Check TSBs regarding the concern. Diagnostics Carry out on-board diagnostic procedures Key On Engine Off (KOEO) and Key On Engine Running (KOER). - Record all Diagnostic Trouble Codes (DTCs). - Repair all non-transmission codes first. - Repair all transmission codes second. - Erase all continuous codes and attempt to repeat them, - Repair all continuous codes. - If only pass codes are obtained, proceed to Diagnosis By Symptom for additional information and diagnosis. See: Diagnosis By Symptom Follow the diagnostic sequence to diagnose and repair the concern the first time.

Diagnostic Flow Chart
Diagnostic Flow Chart

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Part 2 of 2

Preliminary Inspection
Preliminary Inspection The following items must be checked prior to beginning the diagnostic procedures: Know and Understand the Concern In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer contact may be necessary in order to begin to verify the concern. Understand the condition as to when the concern occurs, for example: - hot or cold vehicle temperature. - hot or cold ambient temperature. - vehicle driving conditions. - vehicle loaded/unloaded.

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After understanding when and how the concern Occurs, proceed to verify the concern. Verification of Condition The following procedures must be used when verifying customer concerns for the engine. Determine Customer Concern NOTE: Some transmission conditions can cause engine concerns. An electronic pressure control short circuit can cause engine misfiring. The torque converter clutch not disengaging will stall the engine. Determine customer concerns relative to vehicle use 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 - check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent, or temperature dependent.

Visual Inspection
Visual Inspection This inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as: - electronic add-on items: - air conditioning - generator (alternator) - engine turbo - cellular telephone - cruise control - CB radio - linear booster - backup alarm signal - computer Vehicle modification: These items, if not installed correctly, will affect the Powertrain Control Module (PCM), or transmission function. Pay particular attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire size, or axle ratio changes. - Leaks. - Correct linkage adjustments.

Shift Linkage Check Check for a misadjustment in shift linkage by matching the detents in the transmission range selector lever with those in the transmission. If they match, the misadjustment is in the indicator. Do not adjust the shift linkage. Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating if the linkage is not correctly adjusted.

Carry Out On-Board Diagnostics (KOEO, KOER) After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using New Generation Star (NGS) Tester.

Shift Point Road Test
Road Testing Vehicle NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws. NOTE: When the battery has been disconnected, or a new battery installed certain transmission operating parameters may be lost. The Powertrain Control Module (PCM) must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. The Shift Point Road Test and Torque Converter Clutch Operation Test provide diagnostic information on transmission shift controls and torque converter operation. Refer to Component Tests for Torque Converter Diagnosis. See: Component Tests

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Shift Point Road Test This test verifies that the shift control system is operating correctly. 1. Bring engine and transmission up to normal operating temperature. 2. Operate the vehicle with the selector lever in the (D) position. 3. Apply minimum throttle and observe the speeds at which upshift occurs and torque converter engages. Refer to the following Shift Speeds chart. 4. Stop the vehicle. Depress Transmission Control Switch (TCS) to activate D range. Repeat Step 3. Transmission will make all upshifts except 4-5, and torque converter clutch apply should occur above 46 km/h (29 mph). 5. Press the accelerator pedal to the floor, Wide Open Throttle (WOT). The transmission should shift from third to second, or third to first, depending on vehicle speed, and torque converter clutch should release. 6. With vehicle speed above 48 km/h (30 mph), move the transmission range selector lever from D position to first position and release the accelerator pedal. The transmission should immediately downshift to third gear. When vehicle speed drops below 32 km/h (20 mph), the transmission should downshift into first gear. 7. If transmission fails to upshift/downshift or torque converter clutch does not apply/release, refer to Diagnosis By Symptom for possible causes. Shift Speeds

CAUTION: Always obey local traffic laws. Do not exceed posted limits.

After On-Board Diagnostics
After On-Board Diagnostics NOTE: The vehicle wiring harness, Powertrain Control Module (PCM) and non-transmission sensors may affect transmission operations. Repair these concerns first. After the on-board diagnostic procedures are completed, repair all DTCs. Begin with non-transmission related DTCs, then repair any transmission related DTCs. Refer to the Diagnostic Trouble Code Charts for information on condition and symptoms. This chart will be helpful in referring to the correct aids in diagnosing internal transmission concerns and external non-transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns. Make sure that the vehicle wiring harness and the PCM are diagnosed as well.

Wiggle Test Information For Open/Shorts
Wiggle Test Information for Open/Shorts A. TR4, TR3A, TR2, and TR 1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TR-D).

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B. TR4, TR3A, TR2, and TR 1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TR-D, unplug the TR and see if the short goes away. If the short is still present unplug the transaxle harness and see if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness.

With Manufacturer's Scan Tool (WDS or NGS Tester)
Diagnostics

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Special Tool(s) Diagnosing electronically controlled automatic transmissions is simplified using the following procedures. It is important to remember that there is a definite procedure to follow. Do not take shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair the concern the first time. On-Board Diagnostics with NGS NOTE: For detailed instruction and other diagnostic methods using the NGS, refer to the NGS tester. These quick tests should be used to diagnose the Powertrain Control Module (PCM) and should be carried out in order. - Quick Test 1.0 - Visual Inspection - Quick Test 2.0 - Set Up - Quick Test 3.0 - Key On, Engine Off - Quick Test 4.0 - Continuous Memory - Quick Test 5.0 - Key On, Engine Running - Special Test Mode - Wiggle Test Mode - Output Test Mode

2002 Ford Truck Explorer 4WD V6-4.0L VIN E - PCM Reset Mode - Clearing DTCs - OBD II Drive Cycle - Other NGS Features Other diagnostic methods include the following: - Parameter Identification (PID) Access Mode - Freeze Frame Data Access Mode - Oxygen Sensor Monitor Mode

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Without A Scan Tool
Ford does not provide procedures to display or clear codes without the use of a scan tool.

With Manufacturer's Scan Tool (WDS or NGS Tester)
Diagnostics

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Special Tool(s) Diagnosing electronically controlled automatic transmissions is simplified using the following procedures. It is important to remember that there is a definite procedure to follow. Do not take shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair the concern the first time. On-Board Diagnostics with NGS NOTE: For detailed instruction and other diagnostic methods using the NGS, refer to the NGS tester. These quick tests should be used to diagnose the Powertrain Control Module (PCM) and should be carried out in order. - Quick Test 1.0 - Visual Inspection - Quick Test 2.0 - Set Up - Quick Test 3.0 - Key On, Engine Off - Quick Test 4.0 - Continuous Memory - Quick Test 5.0 - Key On, Engine Running - Special Test Mode - Wiggle Test Mode - Output Test Mode

2002 Ford Truck Explorer 4WD V6-4.0L VIN E - PCM Reset Mode - Clearing DTCs - OBD II Drive Cycle - Other NGS Features Other diagnostic methods include the following: - Parameter Identification (PID) Access Mode - Freeze Frame Data Access Mode - Oxygen Sensor Monitor Mode

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Without A Scan Tool
Ford does not provide procedures to display or clear codes without the use of a scan tool.

Trouble Code Descriptions
Diagnostic Trouble Code Charts

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Part 10 of 10

Rotunda Transmission Tester
Rotunda Transmission Tester The Rotunda Transmission Tester is used to diagnose electronically controlled transmissions and is used in conjunction with the pinpoint tests. The tests should be carried out in order. Installing the Rotunda Transmission Tester allows separation of the vehicle electronics from transmission electronics. - Digital Transmission Range (TR) Sensor Testing - Resistance/Continuity Test - Switch Test - PARK/NEUTRAL, Backup Lamp, and Optional Circuits

Before Pinpoint Tests
Before Pinpoint Tests NOTE: Prior to entering pinpoint tests, check the Powertrain Control Module (PCM) wiring harness for correct connections, bent or broken pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and actuators for damage. NOTE: If a concern still exists after electrical diagnosis, refer to Diagnosis By Symptom. If DTCs appear while carrying out the on-board diagnostics, refer to the Diagnostic Trouble Code Charts for the appropriate repair procedure. Prior to entering pinpoint tests, refer to any TSBs for transmission concerns.

General Information
Pinpoint Tests -Osc Equipped Vehicles

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Special Tool(s) Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary.

Shift Solenoid Pre-Diagnosis
Shift Solenoid Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A.

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Solenoid Operation Chart Shift Solenoid Failure Mode Chart Failed ON or OFF due to Powertrain Control Module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck on or off.

SSA, SSB

SSA, SSB

SSA, SSB

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SSc,SSD

PC A,PC B,PC C

Transmission Connector Layouts
Transmission Connector Layouts

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Transmission Vehicle Harness Connector

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Digital Transmission Range (TR) Sensor Vehicle Harness Connector

Turbine Shaft Speed (TSS) Sensor Harness Connector

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Output Shaft Speed (OSS) Sensor Harness Connector

Intermediate Shaft Speed (ISS) Sensor Harness Connector

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Digital Transmission Range (TR) Sensor Diagnosis Chart

Test A: Shift and Torque Converter Clutch Solenoids
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS

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Test A1

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Test A2-A3

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Test A3-A5

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Test A5

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Test A6

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Test A7-A8 NOTE: Refer to the Transmission Vehicle Harness Connector illustration. NOTE: Refer to the Internal Harness Diagram illustration. NOTE: Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired before entering Output State Control (OSC).

Test B: Transmission Fluid Temperature (TFT) Sensor
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

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Test B1

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Test B2-B3

Test B3

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Test B4 NOTE: Refer to the Transmission Vehicle Harness Connector illustration.

Test C: Digital Transmission Range (TR) Sensor
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR

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Test C1-C2

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Test C2-C3

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Test C4-C5

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Test C5-C6

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Test C7

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Test C7

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Test C8

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Test C8-C9

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Test C9

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Test C10

NOTE: Refer to the Digital Transmission Range (TR) Sensor Connector illustration and Digital Transmission Range (TR) Sensor Diagnosis Chart.

Test D: Pressure Control (PC) Solenoids (PCA, PCB, PCC)
PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC)

Test D1

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Test D1-D2

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Test D2-D3

Test D3

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Test D4

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Test D4-D6 NOTE: Refer to the Transmission Vehicle Harness Connector illustration. NOTE: Read and record all DTCs. All digital TR Sensor and VSS DTCs must be repaired before entering Output State Control (OSC).

Test E: Turbine Shaft Speed (TSS), Intermediate Shaft Speed (ISS), And Output Shaft Speed (OSS) Sensors
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED (ISS), AND OUTPUT SHAFT SPEED (OSS) SENSORS

Test E1

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Test E1-E2

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Test E3-E4

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Test E4

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Test E4-E5

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Test E5-E6

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Test E6-E7 NOTE: Refer to the Turbine Shaft Speed (TSS), Intermediate Shaft Speed (ISS), and Output Shaft Speed (OSS) sensor connector illustrations.

Test F: Solenoid Mechanical Failure
PINPOINT TEST F: SOLENOID MECHANICAL FAILURE

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Test F1-F2

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Test F3 NOTE: Repair all other DTCs before repairing the following DTCs: P1714, P1715, P1716, P1717, P1740.

Component Tests
Torque Converter Diagnosis Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer Concern. 3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test. 4. Carry out Diagnostic Procedures. - Run on-board diagnostics. See On-Board Diagnostics with NGS. - Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. - Carry out the Line Pressure Test. - Carry out the Stall Speed Test. - Carry out the Diagnosis by Symptom Index. Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as necessary before servicing the torque converter. Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out the Quick Test. See On-Board Diagnostics with NGS. Check for DTCs. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes (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. The engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in Diagnosis By Symptom. 6. If the vehicle stalls in (D) or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Diagnosis By Symptom, Torque Converter Operation Concerns. Repair as necessary. If the vehicle does not stall in (D), refer to Diagnosis By Symptom.

General Information

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Special Tool(s) The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portion of the transmission.

Line Pressure Test
Line Pressure Test CAUTION: Carry out Line Pressure Test prior to carrying out Stall Speed Test. If line pressure is low at stall, do not carry out the Stall Speed Test or further transmission damage will occur. Do not maintain wide open throttle in any gear range for more than five seconds. NOTE: Certain sensor failures may cause high PC, FMEM (Failure Mode Effect Management) actions. Be sure that self test and electrical repairs have been carried out, or test results may be incorrect. NOTE: The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off while verifying the output from the other solenoid. The second pressure tap is used to verify the Output from the PC C solenoid. This test verifies that the line pressure is within specifications.

1. Connect pressure gauge to the line pressure tap.

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2. Start engine and check line pressures. Refer to the following Line Pressure Chart to determine if line pressure is within specifications. 3. If line pressure is not within specifications, check PC C pressure.

4. Connect Pressure Gauge to PC C pressure tap. 5. Start engine and check PC C pressure. 6. If PC C pressure is not within specification, carry out Pinpoint Test D to diagnose PC C operation. If PC C operation is OK, refer to Line Pressure Diagnosis Chart for line pressure concern causes.

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Line Pressure Diagnosis Chart

Stall Speed Test
Stall Speed Test This test checks operation of the following items: - torque converter clutch - forward clutch - Low-One Way Clutch (OWC) assembly - engine performance - overdrive one-way clutch assembly WARNING: Apply the parking brake firmly while carrying out each stall test. CAUTION: Always carry out the Line Pressure Test procedures prior to carrying out the Stall Speed Test. If line pressure is low at stall, do not carry out the Stall Speed Test or further transmission damage will occur. NOTE: The Stall Speed Test should be carried out with the engine and transmission at normal operating temperatures.

2002 Ford Truck Explorer 4WD V6-4.0L VIN E 1. Connect tachometer to the engine.

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2. CAUTION: After testing each of the following rangesE), D, 3,2, 1, and R, move the transmission range selector lever to N (NEUTRAL) and run the engine at 1,000 rpm for about 15 seconds to allow the torque converter to cool before testing the next range. CAUTION: Do not maintain wide open throttle in any range for more than five (5) seconds. CAUTION: If the engine rpm recorded by the tachometer exceeds maximum specified rpm, release the accelerator pedal immediately. Clutch or band slippage is indicated. NOTE: Prolonged use of this procedure may set Diagnostic Trouble Code P0712, P1783. After Carrying out Stall Speed Test run 0131) Test and clear DTCs from memory. Press accelerator pedal to floor (WOT) in each range. Record rpm reached in each range. Stall speeds should be as follows:

5R55W/S Stall Speed Chart If stall speeds were too high, refer to the following Stall Speed Diagnosis Chart. If stall speeds were too low, first check the engine idle speed. If engine idle is OK, remove torque converter and check the torque converter one-way clutch for slippage.

Stall Speed Diagnosis Chart

Air Pressure Tests
Air Pressure Tests

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A no-drive condition can exist even with correct transmission fluid pressure because of inoperative clutches or bands. An erratic shift can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the failure. Follow the procedure to determine the location of the inoperative clutch or band by introducing air pressure into the various test plate passages. NOTE: Use only dry, regulated (276 kPa maximum) air pressure. Apply air to the appropriate passage(s). A dull thud should be felt or heard or movement could be observed when the component applies. There should be no hissing sound when the component is fully applied. NOTE: Cover the vent hole in the test plate with a clean, lint-free shop towel to prevent spray when the air is applied. Plugging the vent hole during testing will result in inaccurate results. 1. Drain transmission fluid and remove the transmission fluid pan. 2. Remove the main control valve body. 3. Install the Transmission Test Plate and gasket. Tighten bolts to 10 Nm (89 inch lbs.). 4. NOTE: Do not apply air to the test plate vent hole. Apply air to the appropriate clutch port (refer to diagram). A dull thud may be heard or movement felt when the component is applied or released. If clutch seals or check balls are leaking a hissing sound may be heard. If test results find that the servos do not operate, disassemble, clean and inspect them to locate the source of the concern. If air pressure applied to the clutch passages fails to operate a clutch, or operates another clutch simultaneously, disassemble and use air pressure to check the fluid passages in the center support and clutches to detect obstructions.

Scan Tool Testing
Output State Control (OSC) Mode Output State Control (OSC) allows the technician to take control of certain parameters to function the transmission. For example, OSC allows the technician to shift the transmission only when commanding a gear change. If the technician commands first gear in OSC, the transmission will remain in first gear until the technician commands the next gear. For another example, the technician can command a shift solenoid to turn on or off when carrying out an electrical circuit check. OSC has two modes of operation for transmission, the BENCH MODE and the DRIVE MODE. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC. NOTE: To operate OSC the digital Transmission Range (TR) sensor and the Vehicle Speed Sensor (VSS) must be operational. No Diagnostic Trouble Codes (DTCs) related to the digital TR sensor or the VSS can be present. - The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to vehicle requirements for each individual test. - If the vehicle requirements are NOT MET when SENDING the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted. - If after a sent value is substituted and the vehicle requirements are no longer met, the PCM will cancel the OSC value and resume normal operation. No error message will be sent. - The OSC value may be sent anytime to cancel OSC.

Output State Control (OSC) Procedures

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Carry out visual inspection and vehicle preparation as necessary. Select "Vehicle and Engine Selection" menu. Select appropriate vehicle and engine. Select "Diagnostic Data Link." Select " Powertrain Control Module." Select "Diagnostic Test Mode." Select "KOEO On-Demand Self Test and KOER On-Demand Self Tests." Carry out test and record DTCs. Repair all NON-Transmission DTCs. Repair all VSS and digital TR sensor DTCs. Make sure that VSS/digital TR sensors are functional. Select "Active Command Modes." Select "Output State Control." Select "Trans - Bench Mode or Trans - Drive Mode."

OSC -Transmission Bench Modes The following Transmission Bench Modes may be used as necessary during diagnostics.

SSA, SSB, SSC, SSD and TCC in BENCH MODE CAUTION: The parking brake must be set prior to carrying out this procedure. The BENCH MODE allows the technician to carry out electrical circuit checks on the following components: - SSA - Activates SS A OFF or ON. - SSB - Activates SS B OFF or ON. - SSC - Activates SS C OFF or ON. - SSD - Activates SS D OFF or ON. - TCC - Activates TCC OFF or ON. OSC "SSA, SSB, SSC, SSD, TCC" BENCH MODE Operates ONLY when: - VSS and digital TR sensor are operational. - No VSS and digital TR sensor DTCs. - Transmission range selector lever in P or N. - Key ON. - Engine OFF. OSC Command Values turns solenoid OFF. turns solenoid ON. cancels OSC value sent. sends the values to PCM. BENCH MODE Procedure for SSA, SSB, SSC, SSD, and TCC Follow operating instructions from the NGS menu screen: - Select "Output State Control." - Select "Trans - Bench Mode." - Select " PIDs " to be monitored. - Monitor all selected PlDs during test. - Select "Parameters - SSA, SSB, SSC, SSD, or TCC. " - Select "ON" to turn solenoid ON. - Press "SEND" to send command ON. - Select "OFF" to turn solenoid OFF. - Press "SEND" to send command OFF. - Select "XXX" to cancel at any time. - Press "SEND."

PCA, PCB, PCC in BENCH MODE CAUTION: The parking brake must be set prior to carrying out this procedure. The BENCH MODE is also used to test the functionality of the transmission electronic pressure control. During BENCH MODE, the PCx solenoids can be commanded in increments of 15 psi from 0 to 90 psi and 90 to 0 psi. The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off while verifying the output from the other solenoid. The second pressure tap is used to verify the output from the PC C solenoid. The OSC functions for the parameter PCx allows the technician to choose the following options: PCx - Activates PCx to selected values. - sets PCx pressure to 00 psi. - sets PCx pressure to 15 psi. - sets PCx pressure to 30 psi. - sets PCx pressure to 45 psi.

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- sets PCx pressure to 60 psi. - sets PCx pressure to 75 psi. - sets PCx pressure to 90 psi. OSC -PCx- Bench Mode should ONLY be operated to check PRESSURE FUNCTIONALITY using an installed pressure gauge (300 psi) when: - VSS and digital TR sensor are operational. - No VSS and digital TR sensor DTCs. - Transmission range selector lever in P or N. - Pressure gauge installed. - Key ON. - Engine ON. - Engine rpm at least 1500. OSC "PCx" Bench Mode should ONLY be operated to complete PCx SOLENOID CIRCUIT PINPOINT TESTS when: - VSS and Digital TR Sensor are operational. - No VSS and Digital TR Sensor DTCs are present. - Transmission range selector lever is in "P" or "N". - Key "ON". - Engine "OFF". OSC Command Values sets PCx pressure to 00 psi. sets PCx pressure to 15 psi. sets PCx pressure to 30 psi. sets PCx pressure to 45 psi. sets PCx pressure to 60 psi. sets PCx pressure to 75 psi. sets PCx pressure to 90 psi. cancels OSC value sent. sends the values to PCM. BENCH MODE Procedure for PCx Following operating instructions from the NGS menu screen: - Select "Output State Control." - Select "Trans - Bench Mode." - Select "PIDs" to be monitored. - Monitor all selected PIDs during test. - Select "Parameters - PCx. - Select Value " 0 - 90 psi." - Press "SEND" to send command. - Select "XXX" to cancel at any time. - Press "SEND." OSC -Transmission DRIVE MODES The DRIVE MODE allows control of three transmission parameters. Each mode/parameter has a unique set of vehicle operating requirements that the technician must meet before being allowed to operate OSC. The recommended procedure, when using the DRIVE MODE, is to control one parameter at a time. The DRIVE MODE allows the technician to carry out the following functions on the transmission: - GEAR - allows upshifts or downshifts. - TCC - engages or disengages the torque converter clutch. - FIRM_SFT - Commands a higher control pressure during upshift. The Pressure Control (PCx) solenoids for this transmission are not directly controlled during DRIVE MODE testing. Pressures may be raised during an upshift via the harsh shift control channel (FIRM-SF-r)

GEAR in DRIVE MODE This OSC function is used to test the transmission shift functions. The OSC functions for the GEAR parameter allow the technician to choose the following options: PCM selects 1st gear. PCM selects 2nd gear. PCM selects 3rd gear. PCM selects 4th gear. PCM selects 5th gear. OSC "GEAR" Mode operates ONLY when: - VSS and digital TR sensor are operational. - No VSS and digital TR sensor DTCs. - Engine ON. - TCC "OFF" (TCC cannot be engaged) - Transmission range selector lever in 0. - Vehicle speed is greater than 3 km/h (2 mph). OSC Command Values - PCM selects 1st gear. - PCM selects 2nd gear. - PCM selects 3rd gear. - PCM selects 4th gear. - PCM selects 5th gear. - cancels OSC value sent. - sends the values to PCM. DRIVE MODE Procedure for GEAR Follow operating instructions from the NGS menu screen.

2002 Ford Truck Explorer 4WD V6-4.0L VIN E Select "Output State Control." Select "Trans - DRIVE MODE." Select "PIDs" to be monitored. Monitor all selected PIDs during test. Select "Parameters - GEAR." Select Value " 1-5" Press "SEND" to send command. Re-Select Value "1-5" Press "SEND" to send command. Select "XXX" to cancel at any time. Press "SEND."

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TCC in DRIVE MODE This OSC function is used to test whether the torque converter clutch is engaging and disengaging correctly. The OSC functions for the TCC parameter allows the technician to choose the following: - TCC - activates TCC OFF and ON. - turns TCC solenoid ON. - turns TCC solenoid OFF. OSC "TCC OFF" DRIVE MODE operates ONLY when: - VSS and digital TR sensors are operational. - No VSS and digital TR sensor DTCs present. - Engine ON. - Transmission range selector lever in 0. - Vehicle speed is greater than 3 km/h (2 mph). OSC -TCC ON" DRIVE MODE operates ONLY when: - VSS and digital TR sensors are operational. - No VSS and digital TR sensor DTCs present. - Engine ON. - Transmission range selector lever in 0. - Vehicle speed is greater than 3 km/h (2 mph). - Transmission in 2nd gear or higher. - TFIF is between 33 - 153°C (60 - 275°F). - Brake not applied "OFF" below 32 km/h (20 mph). - Maintain steady speed. OSC Command Values turns TCC OFF. - turns TCC ON. - cancels OSC value sent. - sends the values to PCM. Drive Mode Procedures for TCC Follow operating instructions from the NGS menu screen. - Select "Output State Control." - Select "Trans - Drive Mode." - Select "PIDs" to be monitored. - Monitor all selected PIDs during test. - Select "Parameters - TCC. " - Select "ON" to turn solenoid ON. - Press "SEND" to send command ON. - Select "OFF" to turn solenoid OFF. - Press "SEND" to send command OFF. - Select " XXX- to cancel at anytime. - Press "SEND." FIRM-SFT in DRIVE MODE This OSC function is used to raise pressure during an upshift to determine whether the pressure control system is functioning correctly. Harsher shifts indicate that the pressure control system works at higher pressure. The best test for isolating pressure control system problems is to carry out the PCA, PCB, PCC in BENCH MODE using a hydraulic pressure gauge. The OSC functions for the parameter FIRM-SFT allows the technician to choose the following options: FIRM_SFT - activates the harsh shift channel. - sets control pressure higher for all upshifts (determined by the PCM) - sets control pressure to normal for all upshifts (determined by the PCM) - cancel OSC for FIRM-SFT OSC "FIRML-SFT" DRIVE MODE operates ONLY when: - VSS and digital TR sensor are operational. - No VSS and digital TR sensor DTCs.

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- Transmission range selector lever in O/D. - Pressure gauge installed (optional). - Key ON. - Engine ON. - Vehicle speed greater than 3 km/h (2 mph). - TCC is OFF (TCC is not engaged)OSC Command Values - sets control pressure high for all upshifts (determined by the PCM) - sets control pressure to normal for all upshifts (determined by the PCM) - cancel OSC for FIRM-SFT - sends the values to the PCM DRIVE MODE Procedure for FIRM-SFT Follow operating instructions from the NGS menu screen. - Select "Output State Control." - Select "Trans - Drive Mode." - Select "PIDs" to be monitored. - Monitor all selected PIDs during test. - Select "Parameters - FIRM-SFIF. - Press "SEND" to send command. - Select "XXX" to cancel at any time. - Press "SEND." Using Output State Control (OSC) and Accessing PIDs

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To confirm that the OSC value was sent by the NGS and the PCM has accepted the OSC substitution, a corresponding PID for each OSC parameter must be monitored. Additional PIDs should be monitored to help the technician adequately diagnose the transmission. The following is a list of OSC parameters and their corresponding PID: To confirm that the OSC substitution occurred, SEND the OSC value and monitor the corresponding PID value. If no ERROR MESSAGE was received and the value of the corresponding PID is the same as the value sent from OSC, then the OSC substitution was successful.

Index Directions

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Special Tool(s) The Diagnosis by Symptom Index gives the technician diagnostic information, direction, and suggest possible components, using a symptom as a starting point.

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The Diagnosis by Symptom Index is divided into two categories: Electrical Routines, indicated by 200 series numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described. Diagnosis by Symptom Index - Directions 1. Using the Symptom Index, select the Concern/Symptom that best describes the condition. 2. Refer to the routine indicated in the Diagnosis by Symptom Index. 3. Always begin diagnosis of a symptom with: a. Preliminary inspections. b. Verifications of condition. c. Checking the fluid levels. d. Carrying out other test procedures as directed. 4. NOTE: Not all concerns and conditions with electrical components will set a Diagnostic Trouble Code (DTC). Be aware that the components listed may still be the cause. Verify correct function of these components prior to proceeding to the Hydraulic/Mechanical Routine listed. Begin with the Electrical Routine, if indicated. Follow the reference or action statements. Always carry out the on-board diagnostic tests as necessary. Never skip steps. Repair as necessary. If the concern is still present after electrical diagnosis, then proceed to the Hydraulic/Mechanical Routine listed. 5. The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could cause the concern. These components are listed in the removal sequence and by most probable cause. All components listed must be inspected to ensure correct repair.

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Monitors, Trips and/or Drive Cycles
Transmission Drive Cycle Test NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws. NOTE: The Transmission Drive Cycle Test must be followed exactly. Transmission failure must occur four times consecutively for shift error DTC code to be set, and five times consecutively for continuous torque converter clutch code to set. NOTE: When carrying out the Transmission Drive Cycle Test, use the Solenoid Operation Chart for proper solenoid operation. Refer to Pinpoint Tests OSC Equipped Vehicles. After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous codes. 1. Record and then erase Quick Test codes. 2. Warm engine to normal operating temperature. 3. Make sure transmission fluid level is correct. 4. With transmission in D position, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fifth gear. Hold speed and throttle open steady for a minimum of 15 seconds. 5. With transmission in fifth gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stoplamps. Then hold speed and throttle steady for a minimum of five seconds. 6. Brake to a stop and remain stopped for a minimum of 20 seconds. 7. Repeat steps 4 through 6 at least five times. 8. Carry out Quick Test and record continuous DTCs.