Automated IB5 Manual Transaxle - Diagnosis

Curriculum Training
Automated Gearshift System
Automated iB5 Manual Transaxle - Diagnosis
Technical Service Training CG 8135/S en 06/2004

TC3083002H
To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time
of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice
is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers.
No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic,
mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke Aktiengesellschaft.
No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as
complete and accurate as possible.
Copyright ©2004
FORD-WERKE AKTIENGESELLSCHAFT
Service training programs D-F/GT-1
Printed in Germany - rewi druckhaus, Wissen -
Printed on environmentally friendly chlorine-free paper. (GB)
Preface
An automated manual transaxle has been available as an option both for the Fiesta and for the Fusion since Model
Year 2003.25. It is available in conjunction with the 1.4L Duratec 16V (Sigma) petrol engine and with the 1.4L
Duratorq TDCi (DV) diesel engine.
The transmission is a slightly modified iB5 manual transaxle , which can be shifted both automatically and manually
by the driver.
The driver request is acquired via an electronic selector lever and relayed to the TCM (Transmission Control
Module).
The TCM controls both the clutch engaging and disengaging operations as well as the shifting of the individual
gears.
The clutch pedal and the shift and selector cables are no longer required. Instead the system features a clutch actuator
and a shift actuator.
The training course "Automated iB5 Manual Transaxle - Diagnosis, TC30830001H" has been developed to provide
the technician with the necessary knowledge for performing a correct diagnosis and a successful repair.
The training course includes the following Student Information publications:
• Product launch "2003.25 Fiesta - Automated iB5 Transaxle ", CG 8009/S

• Curriculum Training "Automated iB5 Manual Transaxle - Diagnosis", CG 8135/S
This Student Information describes the transmission control and provides important information about the initial
checks and the diagnosis of the transmission.
Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only. Repairs
and adjustments MUST always be carried out according to the instructions and specifications in the workshop
literature. Please make full use of the training offered by Ford Technical Training Courses to gain extensive
knowledge of both theory and practice.
Service Training (G410890) 1

Table of Contents
PAGE
Preface.............................................................................................................................. 1
Lesson 1 – Initial Checks
Objectives.................................................................................................................................................... 5
Customer concerns..................................................................................................................................... 6
Knowing and understanding customer concerns............................................................................................................. 6
Testing possible causes of transmission control faults.................................................................................................... 6
Test questions.............................................................................................................................................. 7
Lesson 2 – Transmission Control
Objectives.................................................................................................................................................... 9
Overview......................................................................................................................................................................... 10
Regulating and control strategies.................................................................................................................................... 11
Signal transfer via the CAN data bus.............................................................................................................................. 15
Test questions.............................................................................................................................................. 20
Lesson 3 – Diagnostic Hints
Objectives.................................................................................................................................................... 23
TCM................................................................................................................................................................................ 24
Data transfer............................................................................................................................................... 26
CAN data bus.................................................................................................................................................................. 26
Sensors......................................................................................................................................................... 27
Clutch actuator distance sensor....................................................................................................................................... 27
Selector motor distance sensor and shift motor distance sensor..................................................................................... 27
APP sensor...................................................................................................................................................................... 29
2 Service Training
Table of Contents
IAT sensor....................................................................................................................................................................... 30
ECT sensor...................................................................................................................................................................... 30
CKP sensor...................................................................................................................................................................... 31
BPP switch and stoplamp switch.................................................................................................................................... 31
Driver's door ajar switch................................................................................................................................................. 33
Wheel speed sensors....................................................................................................................................................... 34
Electronic selector lever.................................................................................................................................................. 35
Parking brake switch....................................................................................................................................................... 36
Actuators..................................................................................................................................................... 37
Clutch actuator................................................................................................................................................................ 37
Selector motor and shift motor in the shift actuator........................................................................................................ 39
Datalogger................................................................................................................................................... 41
Signals in the Datalogger................................................................................................................................................ 41
Fault finding based on symptom............................................................................................................... 50
Notes and Tips................................................................................................................................................................. 50
Evaluation of datalogger values................................................................................................................ 54
Concern: gearshift problems........................................................................................................................................... 54
Concern: clutch slip........................................................................................................................................................ 55
Test questions.............................................................................................................................................. 56
Answers to the test questions......................................................................................... 59
List of Abbreviations....................................................................................................... 60
Service Training 3
Notes
Lesson 1 – Initial Checks Objectives
On completing this lesson, you will be able to

• establish the customer concern and the operating conditions under which the concern arises by carefully
questioning the customer.
• check the vehicle for possible external causes of transmission control faults.

Customer concerns Lesson 1 – Initial Checks
Knowing and understanding customer First of all, ask the customer under which operating
concerns conditions the problem occurs.
If possible, try to reproduce the customer concern by

Before attempting a diagnosis, it is first necessary to
road testing the vehicle with the customer.
know and understand the customer concern.
You should be familiar with the following operating
conditions:
Cold Warm-up phase Operating temperature
Engine operating state
Below 0 °C 0 to 20 °C Above 20 °C
Ambient temperature
Good Poor Off-road
Road conditions
Unladen Laden Fully laden
Vehicle load status
Shifting up Shifting down Coasting Shifting in manual

mode
Transmission shift status
• installation of additional aftermarket equipment

Testing possible causes of transmission which is not approved by Ford, e.g. air conditioning,
control faults car telephone, cruise control system,
• unapproved tyre sizes,
NOTE: Customer concerns relating to the automated • tyre size incorrectly programmed using WDS (
manual transaxle may also be caused by engine faults. Worldwide Diagnostic System),
Before performing a comprehensive diagnosis of the • engine tuning.
transmission, first carry out checks to eliminate various
other potential causes of the fault. These include:
• battery state of charge,
• defective fuses,
• loose or corroded cables or electrical connectors,
• faulty ground connections on the transmission,
6 (G410891) Service Training

Lesson 1 – Initial Checks Test questions
Tick the correct answer or fill in the gaps.
1. Which engine operating state is not relevant to a possible customer concern regarding the transmission?
a. Engine is cold.
b. Engine is in warm-up phase.
c. Engine is at operating temperature.
d. The engine judders while driving.
2. Which fault source is not responsible for a customer's concern regarding the transmission?
a. Loose or defective cables or electrical connectors
b. Battery state of charge
c. Wind noise
d. Unapproved tyre sizes

Notes
Lesson 2 – Transmission Control Objectives

• identify the components of the transmission control system;
• describe the various regulation and control strategies of the transmission control.
• describe the data exchange over the CAN data bus regarding the transmission control.

Overview
3
4
16
1
9
10
17
18
11
12
2
6
13
14 15
E52674

1 TCM 10 Distance sensor in the shift motor

2 DLC (Data Link Connector) 11 BPP (Brake Pedal Position) switch and stoplamp
3 PCM (Powertrain Control Module) (illustrated switch
for 1.4L Duratec 16V (Sigma)) 12 Driver's door ajar switch
4 ABS (Anti-lock Brake System) control module 13 Power supply relay
5 Instrument cluster 14 Ignition switch
6 GEM (Generic Electronic Module) 15 Battery
7 Electronic selector lever 16 Clutch actuator
8 Distance sensor in the clutch actuator 17 Selector motor
9 Distance sensor in the selector motor 18 Shift motor
Regulating and control strategies Adaption - clutch take-up point
Park NOTE: The clutch take-up point is factory-programmed

and stored in a non-volatile memory of the TCM. When
When stopping the engine, the clutch actuator is actuated replacing the clutch actuator with integrated TCM, the
and the clutch engaged. clutch take-up point including the transmission geometry
The selector lever must be in position D or R when the data must be reprogrammed using WDS.
engine is stopped to prevent the vehicle from rolling The term 'clutch take-up point' describes the point at
away. which the pressure plate and the clutch plate contact
and transmit a low torque (approx. 4 Nm).
Engine start release The TCM needs this information to be able to always
engage the clutch in the best possible way, i.e. smoothly
It is only permitted to start the engine when the PCM
without judder and without excessive slip.
receives a start release from the TCM via the CAN
(Controller Area Network) data bus. Adaption of the clutch take-up point is performed
repeatedly during driving with the engine idling, with
The following conditions must be satisfied for this to
a gear engaged and with the brake depressed.
happen:
In addition, while shifting the instantaneous clutch
• Transmission in neutral (signals from distance
take-up point is checked by the TCM and adapted if
sensors of shift motor and selector motor),
necessary.
• Selector lever in N position,
This means that the various tolerances in the clutch
• Brake pedal actuated.
operating mechanism, which arise for example due to
variations in operating temperatures, are continuously
adapted and optimized for the current operating
conditions.

Creep A Torque
B Time
The transmission control provides a creep function
similar to that of an automatic transmission when the 1 Declutching duration
selector lever is in the D or R position and the brake 2 Shift request signal
and accelerator are not pressed.
3 Clutch transmission capability
The creep function means that when first gear or reverse 4 Engine torque
gear is engaged the clutch is partially engaged (i.e. with
slip) and a noticeable amount of torque is transmitted. The clutch is only actuated as far as is required by the
current torque which is to be transmitted.
The creep quality depends greatly on the smoothness
of the engine idling. The instantaneous clutch transmission capability
required is calculated using the engine torque, the engine
The creep function is suspended if there is not enough
speed and the wheel speed.
torque available to move the vehicle (e.g. when climbing
hills) or if the torque signal transmitted by the PCM is The advantage of torque tracking is that the time from
not precise enough. actuating the clutch to shifting can be considerably
reduced.
Stalling of the engine is prevented in all cases.
Another advantage of torque tracking is that the clutch
NOTE: If the engine does stall then this indicates a
can temporarily slip whenever there are torque peaks.
fault. The cause of a fault may be either a problem in
the engine management or a problem with the This effect places no particular strain on the clutch
transmission control. because there is only a small difference in rotational
speeds at this point. However, it offers the advantage
If the driver's door is open when the creep function is
of smoother ride comfort, as any judder in the
active, a warning sounds and the current gear flashes
powertrain is absorbed by the clutch slip.
on the instrument cluster display.
The creep function is deactivated when the parking

Clutch overheating protection
brake is applied.
In order to protect the clutch against overheating, it is
Torque tracking necessary to determine the current clutch temperature.
A separate temperature sensor is not installed for

1 determining the clutch temperature. It is calculated
instead by the TCM.
A 2 For this purpose, the TCM utilizes the following factors:

3
• Ambient temperature (IAT (Intake Air Temperature)
sensor),
4
0 • Engine temperature (ECT (Engine Coolant
Temperature) sensor),
0
B • Time since engine start,
E38599
• Previous clutch slip,

• Torque to be transmitted. In principle, it is possible to pull away in 1st gear and

in reverse gear.
The calculation model for the clutch temperature takes
into consideration the characteristic temperature In manual driving mode, it is also possible with
capacities of the components very precisely. petrol-engine vehicles to pull away in 2nd gear (also
planned in future for vehicles with diesel engines).
Using the calculated clutch temperature, the TCM is
able to record defects, permit warnings and change the To prevent pulling away unintentionally, the selected
control strategy in the event that the clutch temperature gear is only actually engaged when the brake is pressed
is too high. on changing from the N to the D or R position.
If the driver attempts to hold the vehicle with clutch slip In addition, neither is a gear engaged when the
(e.g. when climbing a hill), then this will result in a risk accelerator pedal is not actuated within about 26 seconds
of the clutch overheating. after the selector lever is shifted (from N to D or R
position).
In situations like this the transmission control
deliberately encourages judder by varying the amount If the vehicle is already rolling, the corresponding gear
of clutch torque to be transmitted (more or less clutch is automatically engaged when the transmission control
slip). shifts from the N to D or A position in both driving
modes, depending on the vehicle speed.
This warns the driver about the imminent risk of
overheating.
The driver will then either release the accelerator (and Detection of driving resistance
thus the clutch) or even press it (thus permitting slip-free
The TCM calculates an expected vehicle acceleration
engagement of the clutch).
based on the current engine operating state and gear.
If the driver does not respond to the juddering, this may
This calculated vehicle acceleration is compared with
result in the clutch plate being destroyed.
the actual acceleration.
While driving, the torque tracking and the creep function
If the actual acceleration is greater than that expected,
are deactivated above a specific temperature to protect
the transmission control detects downhill driving and
the clutch from overheating.
switches to a corresponding shifting characteristic map
In other words, the clutch in this case is always with the aim of better utilizing the engine braking.
completely disengaged or completely engaged.
For this purpose, up-shifting only occurs at higher
engine speeds.
Pulling away
By additionally operating the brake pedal, it is possible
to shift down to assist the engine.
CAUTION: It is possible to depress both the
accelerator pedal and the brake pedal at the If the actual acceleration is less than that expected, the
same time. If this happens then the clutch is transmission control detects uphill driving and switches
subjected to severe strain and may be destroyed. to a corresponding shifting characteristic map with the
aim of optimizing the transition to the next higher gear
NOTE: The driver controls pulling away with the
and preventing frequent shifting back and forth between
accelerator pedal alone.
the gears.

For this purpose, up-shifting only occurs at higher • brake pedal actuated.
engine speeds. An exception is the rapid switching between the
positions D " N " R and R " N " D, to jolt free in snow,
Fast-off detection for example.
In this case, the transmission control recognizes shifting

When quickly releasing the accelerator pedal, a Fast-off
to the R position even without the intermediate actuation
situation is detected.
of the brake.
In this case the system suppresses an immediate upshift
If the switch between the positions is briefly interrupted,
to the next higher gear in order to give the driver a more
actuation of the brake pedal is again necessary for
direct driving experience and to maximize the benefits
shifting.
of engine braking.
Kick-down
Cornering detection
The transmission control features a kick-down function.
NOTE: The cornering detection for diesel and petrol
If the APP (Accelerator Pedal Position) sensor detects
engines has been discontinued since MY 10/03.
a pedal position of greater than 90 % then kick-down
The transmission control detects corners by comparing is detected. Depending on the current driving situation,
the wheel speed sensor signals for the two rear wheels. one or more gears are downshifted if the engine speed
Depending on the difference in speed detected, permits.
up-shifting is avoiding when cornering to prevent load The driver is made aware of the kick-down point by a
change responses at the limits of stability. resistance at the accelerator pedal. No separate sensor
When an emergency spare wheel has been fitted, the is installed.
transmission control constantly detects cornering. As a
result, the transmission does not shift to higher than the Manual driving mode
3rd gear in automatic mode.
In manual driving mode the driver can decide when to
In manual mode, however, all gears can be selected.
change gear.
The transmission control, however, checks before the

Selecting the reverse gear
gear is shifted whether the engine speed will be too high
For safety reasons, the reverse gear may not be selected or too low after the shift.
by unintentionally engaging the selector lever position The system also changes gear automatically in manual
R. driving mode if the engine speed becomes too low for
Therefore reverse gear will only be engaged under the the selected gear (when the vehicle is decelerating).
following conditions: If the driver operates the selector lever several times in
• electronic selector lever in R position, quick succession then the target gear is engaged without
• road speed less than 2 km/h, the intermediate gears being engaged.
• delay, to ensure that the rotational speed differences
of the cog wheels are not too high,

If the expected engine speed (too high or too low) NOTE: For the TCM to disengage the clutch and shift
prevents the target gear from being selected, the to neutral, there must be battery voltage at the TCM.
transmission control switches to the next possible gear. If the engine is not running, the following prerequisites
It is possible to switch between automatic and manual must be met to shift to neutral:
driving mode at any time while driving. • Ignition lock position II,
• Brake pedal actuated,
Towing • Selector lever position N.
It is possible to tow the vehicle if the transmission is in

neutral.
Signal transfer via the CAN data bus.
1 2 3 5
4
6
8 9 10
7
13 11
12
E52535

1 CKP (Crankshaft Position) sensor 6 Wheel speed sensors (x 4)

2 MAF (Mass Air Flow) sensor or MAPT 7 TCM (integrated into clutch actuator)
(Manifold Absolute Pressure and Temperature) 8 PCM (shown for 1.4L Duratec 16V (Sigma))
sensor (depending on engine variant, the 1.6L
9 ABS control module
Duratorq TDCi (DV) diesel is shown)
10 Electronic selector lever
3 ECT sensor
11 DLC
4 BPP switch and stoplamp switch
12 Parking brake switch
5 APP sensor
13 Instrument cluster
Engine start release This signal is transferred via the CAN data bus to the
TCM.
The PCM receives an engine start release signal from
This signal is used by the TCM for the following
the TCM if the transmission and the selector lever are
functions:
in neutral and the brake pedal is actuated.
• Establishing the shift points,
• Torque tracking,
Engine speed
• Creep function,
The engine speed is detected by the CKP sensor and • Calculation of the clutch temperature,
transmitted to the PCM.
• Rolling resistance detection.
The engine speed is transferred from the PCM via the
CAN data bus to the TCM.
Engine control while shifting
functions: Before the TCM disengages the clutch, it sends a torque
reduction signal to the PCM.
• Engaging and releasing the clutch,
• Clutch take-up point adaption, After the PCM has reduced the engine torque, the TCM
disengages the clutch, shifts out of the selected gear and
into the target gear and engages the clutch again.
• Creep function,
Then the TCM sends a torque increase signal to the
• Calculation of the clutch temperature,
PCM.
• Triggering the shifting operation in manual driving
mode (downshifting), The PCM then increases the engine torque up to the
value instantaneously being transmitted by the APP
• Determining the target gear.
sensor.
This control prevents the engine from revving while the

Engine torque
clutch is disengaged, even if the driver does not release
The PCM determines the engine torque that is currently the accelerator pedal.
available to the clutch.

Wheel speed signals The current selector lever position or the current selector
lever operation is detected by the electronic selector
The wheel speed sensors provide the ABS control lever by means of six Hall sensors with integrated
module with the wheel speed separately for each wheel. electronic circuitry and is transmitted via the CAN data
These wheel speeds are transferred to the TCM via the bus to the TCM.
CAN data bus. The TCM uses the current selector lever position or the
This signal is used by the TCM for the following current selector lever operation for automatic or manual
functions: driving mode.
• Establishing the road speed,
• Establishing the vehicle acceleration, Brake actuation signal
• Recognizing wheel spin,
The PCM receives a signal regarding brake operation
• Engaging and releasing the clutch, from both the BPP switch and the stoplamp switch. Both
• Clutch take-up point adaption, signals are transferred via the CAN data bus to the TCM.
• Torque tracking, The signal of the stop lamp switch is also sent directly
• Creep function, to the TCM (hard-wired).
• Calculation of the clutch temperature, This signal is used by the TCM for the following
• Rolling resistance detection, functions:
• Cornering detection. • Engine start release,
• Downshifting for downhill driving,
Selector lever position and operation • Selecting reverse gear,
• Driver recognition when pulling away for shifting
gear,
1
• Creep function.
Parking brake actuation signal
The signal from the parking brake switch is detected by

the instrument cluster and transferred via the CAN data
2
bus to the TCM.
E38718
The signal for switching off the creep function is used
Printed circuit board in the electronic selector lever by the TCM when the parking brake is actuated.
1 Hall sensors
Pulling away on a hill with the parking brake applied
2 Printed circuit board is possible, if the accelerator pedal is pressed in addition
to the parking brake being applied.

Gear selection indicator If the gear selection indicator flashes (and an audible
warning is given at the same time), the driver is being
warned that the creep function is active and the driver
door is open.
If the gear selection indicator flashes while driving and

the powertrain warning indicator comes on at the same
A time, then this indicates a fault in the transmission
control.
If "- -" is displayed while driving and the powertrain

warning indicator comes on, there is a communication
fault with the TCM.
Actuation of the powertrain warning indicator
E38686
A Automatic driving mode - 2nd gear

E38687
B Manual driving mode - 2nd gear
The TCM transmits the information regarding the gear The powertrain warning indicator is actuated by the
currently selected and the current driving mode instrument cluster in the event of a serious fault with
(automatic or manual) over the CAN data bus to the the transmission. The actuation information is received
instrument cluster. by the instrument cluster from the TCM.
The current gear and the automatic driving mode (Auto)

is displayed for the driver in the instrument cluster.
During a gearshift the last engaged gear remains

displayed until the gearshift is complete.
If the gear selection indicator flashes while the vehicle

is stationary, then this means that the selected gear has
not yet been engaged, as not all of the required
conditions (e. g. R selected, brake pedal not yet actuated)
are satisfied.

Warning tone request
E38701
GEM
The TCM transmits a request for a warning tone to the
instrument cluster if the following conditions are met:
• Engine running,
• Transmission control system in creep mode,
• The driver's door is open.
The instrument cluster passes on the warning tone

request to the GEM. The GEM generates the warning
tone.

Test questions Lesson 2 – Transmission Control
1. The TCM only transmits the engine start release signal when certain prerequisites are met: Which of
these are NOT prerequisites?
a. Transmission in neutral.
b. Selector lever in N position.
c. Brake pedal actuated.
d. Parking brake applied.
2. Which component is not part of the automated gearshift mechanism?
a. TCM
b. Stop lamp switch
c. Electronic selector lever
d. VSS (Vehicle Speed Sensor)
3. It is not possible for the engine to stall if the automated iB5 manual transaxle is operating without faults.
a. True
b. False
4. Pulling away always takes place in 1st gear.
a. True
b. False
5. The parking brake actuation signal:
a. is not required by the TCM.
b. is detected directly by the TCM.
c. is used to switch off the creep function when the parking brake is actuated.
d. is used to prevent pulling away when the parking brake is actuated.

Lesson 2 – Transmission Control Test questions
6. Which component of the automated gearshift mechanism is not connected to the CAN data bus?
a. PCM
b. Instrument cluster
c. Wheel speed sensors
d. ABS control module
7. When the engine is stopped, the 1st gear is automatically engaged and the clutch engaged so that the
vehicle cannot roll away.
a. True
b. False
8. It is possible to jump over gears in manual driving mode by repeatedly operating the electronic selector
lever.
a. True
b. False
9. What must be remembered when towing a vehicle with an automated iB5 manual transaxle ?
a. A vehicle with automated iB5 manual transaxle must never be towed.
b. When towing, there must be a battery voltage at the TCM.
c. The transmission must be in neutral
d. The vehicle can only be towed in the reverse gear.
10. Under which driving conditions does the transmission control trigger an audible warning?
a. If the vehicle is traveling too fast.
b. If the transmission temperature is too hot.
c. If the transmission is in creep mode and the driver door is open.
d. If the reverse gear is engaged.

Notes
Lesson 3 – Diagnostic Hints Objectives

• explain how the components of the automated gearshift mechanism work.
• show the component location of the automated gearshift mechanism.
• explain the effects of a component signal failure.
• demonstrate the schematic power supply of the individual components using schematic circuit diagrams.
• explain the signals of the automated gearshift mechanism in the datalogger.
• diagnose the system of the automated gearshift mechanism with the aid of a fault finding chart.
• explain how specific customer concerns can be diagnosed using the datalogger.

TCM The transmission control then controls the complete

sequence of a shift operation:
• Reducing the engine torque,
• Disengaging the clutch,
• Selecting the target gear,
• Synchronization,
• Engaging the target gear,
• Engaging the clutch,
• Increasing the engine torque.
The transmission control must perform the gearshifts

so that they do not impair the durability of the
transmission.
Effects of failure
If the TCM fails:

• a trouble code is set.
• the powertrain warning indicator in the instrument
cluster comes on.
E38597 • the engaged gear is retained. Shifting is no longer
possible.
Installation position • the position of the clutch actuator is no longer

changed (shut down).
The TCM is integrated into the clutch actuator. If the clutch overheats:
The assembly is located in the engine compartment in • there is no longer any torque tracking.
front of the transmission and is attached to the left-hand • the creep function is suppressed.
front longitudinal member.
The TCM is connected to the vehicle wiring harness by Diagnosis using WDS
two coded connectors.
Task and function
The TCM is responsible for detecting the incoming

signals from the individual sensors and control modules.
It must then evaluate these signals and perform the
necessary gearshifts.
E47353

The transmission control can be diagnosed using WDS

via the DLC.
The DLC is located in the passenger compartment

underneath the steering wheel.
The TCM can be reprogrammed using WDS if

recalibration becomes necessary.

Data transfer Lesson 3 – Diagnostic Hints
CAN data bus A ABS module

B PCM
Tasks and function
C TCM
The CAN data bus is a multi-master bus system. D DLC
Connected to it are control modules and sensors.
E Electronic selector lever
The benefits of the CAN data bus is that each bus
F Instrument cluster
participant (control modules and sensors) can send their
54 Line for CAN data bus high 1
own data on the data bus. The participants decide on
the data that they need, read it out and process it further. 56 Line for CAN data bus low 2
This results in faster data processing. 61 Line for CAN data bus high 2
The terminating resistors in the Fiesta/Fusion are located 63 Line for CAN data bus low 2
in the PCM and also in the instrument cluster.
In the TCM the CAN data bus is looped via a bridge.
Consequences of signal failure
In the event of a general CAN data bus fault:

cluster comes on.
• the engaged gear is retained. Shifting is no longer
possible.
• the position of the clutch actuator is no longer
A 61 63
C
54 56
F
E
D
E52121

Lesson 3 – Diagnostic Hints Sensors
Clutch actuator distance sensor Task and function
The rotational angle movement of the worm gear is first

2 3
converted into a straight-line movement of the ferrite
4 core via the connecting bolt.
It is designed as a solenoid plunger sensor.

1
The movement of the ferrite core is detected by the
multi-chamber coil of the distance sensor and passed
on to the TCM as a signal.
With the distance signal of the clutch actuator, the TCM

5
can determine the exact position of the clutch and thus
implement the engagement and disengagement of the
clutch, as well as the torque tracking and the creep
function of the clutch.

6
In the event that the clutch actuator distance sensor fails:

E38601
cluster comes on.
Schematic diagram • the engaged gear is retained. Shifting is no longer
1 Clutch actuator worm gear possible.
2 Plastic surround molding with gate guide • the position of the clutch actuator is no longer
3 Ferrite core changed (shut down).
4 Multi-chamber coil
5 Measurement tap
Selector motor distance sensor and shift
motor distance sensor
6 Connecting bolt to the clutch actuator worm gear
Installation position
The clutch actuator distance sensor is integrated into 2
the clutch actuator.

1
E38602

Sensors Lesson 3 – Diagnostic Hints
Schematic diagram
1 Electric motor shaft A
2 1st Hall sensor

3 2nd Hall sensor
N North pole magnetic field
S South pole magnetic field
B
The distance sensors of the selector motor and shift

motor are integrated into the motors.
C
E52119
Task and function
A Shift motor
The TCM needs the signals to be able to carry out the B TCM
selection and shift processes precisely.
C Selector motor
The electric motors are each equipped with ten pairs of 106 Selector motor distance sensor signal
magnetic poles.
107 Selector motor direction signal
Two Hall sensors with integrated electronic circuitry
108 Shift motor distance sensor signal
are arranged above each of these pairs of poles.
109 Shift motor direction signal
The integrated electronic circuitry of the Hall sensors
120 Selector motor distance sensor ground
is capable of using the signals from the two Hall sensors
to determine the rotational speed, the rotary angle and 121 Shift motor distance sensor ground
the direction of rotation of each electric motor.
If there is a signal failure of the distance sensors:

cluster comes on.
• further upshifting or downshifting is no longer
possible (freeze gear).
• when shifting to the N position the clutch is
disengaged and taken out of gear.

APP sensor A mechanical kick-down function is integrated into the

accelerator pedal. At an accelerator pedal position of
approx. 90 %, the driver notices the kick-down function
through a threshold implemented by a spring.
If one of the two sensor signals in the PCM fails:

• the rotational speed of the engine is restricted (diesel
engine).
• the engine torque (petrol engine) is restricted.
If there is an inaccurate sensor signal received via the
CAN data bus in the TCM:
• the TCM interrupts the torque tracking of the clutch.
If both sensor signals fail:

cluster comes on.
E30985
possible.
The APP sensor is located in the vehicle's accelerator changed (shut down).
pedal as an integral component.
A
Task and function
The movement of the accelerator pedal is determined

using sensors. For safety reasons, two sensors are
installed in the accelerator pedal. B
The signal from the APP sensor is transferred to the

PCM where it is relayed over the CAN data bus to the
TCM.
C
Potentiometers are used as APP sensors.
E52534
A TCM

B PCM sensor ECT sensor

C APP sensor
61 Line for CAN data bus high
63 Line for CAN data bus low
IAT sensor
E30976
ECT sensor (1.4L Duratorq TDCi (DV) diesel)
The ECT sensor is located in the engine's cooling circuit

E30974 system.
MAF sensor (1.4L Duratorq TDCi (DV) diesel))
Task and function
With the aid of the ECT sensor, the transmission control
The IAT sensor in the 1.4L Duratorq TDCi (DV) diesel calculates the clutch temperature.
engine is integrated into the MAF sensor. Consequences of signal failure
In the petrol engine variant, the IAT sensor is integrated If the ECT sensor fails:
into the MAPT sensor. • a trouble code is set.
• the creep function is no longer executed.
Task and function • the torque tracking of the clutch is suppressed.
With the aid of the IAT sensor, the transmission control • the powertrain warning indicator in the instrument
calculates the clutch temperature. cluster does not comes on.
If the IAT sensor fails:

• the torque tracking of the clutch is suppressed.
cluster does not comes on.

CKP sensor If the engine speed signal (CAN data bus signal) in the
TCM fails:
cluster comes on.
possible.
E30978
BPP switch and stoplamp switch
CKP sensor (1.4L Duratorq TDCi (DV) diesel)
The CKP sensor is located on the oil pump housing,

behind the crankshaft timing belt pulley.
In the petrol engine, the signal is picked up at the 1
flywheel.
Task and function
The CKP sensor is an inductive transducer and acquires

the engine speed. 2
functions:
• Engaging and releasing the clutch,
• Clutch take-up point adaption,
• Creep function,
E38603
• Clutch overheating protection,
• Determining the target gear. 1 BPP switch
2 Stop lamp switch

In the event that the CKP sensor fails:
• the engine stops. The BPP switch and the stoplamp switch are located on
the brake pedal.

Task and function • the engine start, if the vehicle was parked in the D
or R position, is only possible if within three seconds
For safety reasons, the TCM receives two signals after switching the ignition on it is shifted to the N
regarding the brake pedal position. position and started.
The stoplamp switch switches on the stoplamps when If the signal from the stoplamp switch and BPP switch
the foot brake is actuated and relays the signal to the fails:
PCM and to the TCM. • there is no engine start release.
The BPP switch opens at the same moment as the • a trouble code is set.
stoplamp switch closes, and in doing so interrupts a • the powertrain warning indicator in the instrument
ground connection to the PCM. cluster comes on.
The signal from the BPP switch is transmitted from the • the creep function is no longer executed.
PCM over the CAN data bus to the TCM. • shifting of the reverse gear is not possible.
The TCM requires the brake pedal actuation
information: A
• for the engine start release,

• for downshifting for downhill driving, B
• for shifting the forward and reverse gear when
pulling away,
• for switching off the creep function,
• for the clutch take-up point adaption. C
NOTE: Even an incorrectly adjusted stoplamp switch D

or BPP switch can result in difficulties.
If the stoplamp switch signal fails:

• the creep function is executed, although the brake is
actuated. E
• if the vehicle was parked in the D or R position,
engine start is only possible if within three seconds
E52069
after switching the ignition on it is shifted to the N
A Fuse
position and started.
• pulling away is only possible by pressing the B Stop lamp switch
accelerator pedal (not by pressing and releasing the C TCM
brake pedal). D PCM
If the signal from the BPP switch fails:
E BPP switch
• there is no clutch take-up point adaption.
52 Stop lamp switch signal
• the rolling resistance recognition is interrupted.

61 Line for CAN data bus high Consequences of signal failure

If the driver's door ajar switch fails:
• no trouble code is set.
Driver's door ajar switch • the powertrain warning indicator in the instrument
• no audible warning is generated when the driver's
door is open and a gear is engaged.
If the driver's door ajar switch interrupts the ground
even when the door is closed:
• the warning tone is given even when the engine is
running, the door is closed and in creep mode.
A
E38604
The door ajar switch is located in the door lock of the

driver's door.
Task and function

B
The transmission control uses the signal from the driver's
door ajar switch to warn the driver if the engine is
running, the transmission is in creep mode and the E52118
driver's door is open. A TCM

When the door is closed, a ground signal is transmitted B Door ajar switches
to the TCM. 59 Signal input
When the door is opened this ground connection is
interrupted.
The TCM transfers the warning tone request to the

instrument cluster over the CAN data bus. The
instrument cluster forwards this request on to the GEM
and a warning tone is generated by the GEM.

Wheel speed sensors If two or more wheel speed sensors fail:

• further upshifting or downshifting is no longer
disengaged and taken out of gear.
54 56
E52529
B
Task and function
The wheel speed sensors are active Hall sensors that

acquire the corresponding wheel speed and transmit the
signal to the ABS control module. The ABS control
module transmits the signals over the CAN data bus to
the TCM. 4 3 2 1
E52122
The signals are used by the TCM for the following
functions: A TCM
• Cornering detection (signal of rear sensors), B ABS control module
• Determination of road speed (signal of front and rear 1 Right-hand rear wheel speed sensor
sensors), 2 Left-hand rear wheel speed sensor
3 Right-hand front wheel speed sensor
• Recognizing clutch slip,
4 Left-hand front wheel speed sensor
• Detection of drive wheels spinning (signal of front
sensors).
Effects of failure
If one wheel speed sensor fails:

• the torque tracking of the clutch is disabled.
• a trouble code is set,
cluster comes on.

Electronic selector lever If the power supply via terminal 30 fails, the electronic
selector lever is supplied with power via terminal 15
without a fault message and without a trouble code being
set.
54 56
C
E52531
A CJB (Central Junction Box)

E52530 B Selector lever
C TCM
Task and function 56 Line for CAN data bus low
The current selector lever position or the current selector

lever operation is detected via Hall sensors, evaluated
by the internal electronics and made available to the
TCM via the CAN data bus.
If the power supply via terminal 15 fails, if the ground

fails and if the CAN data bus fails:
• the rolling resistance recognition is interrupted.
• a manual transmission mode is no longer permitted.
• the transmission is shifted to neutral at below 5 km/h.
It is then no longer possible to continue driving.

Parking brake switch

A B
54 56
E52532
E52675
A TCM
B GEM
C Parking brake switch
Task and function
D Instrument cluster
A creep function is provided, as in automatic 54 Line for CAN data bus high
transmissions. The creep function is activated when the
selector lever is in the D or R position and the
accelerator and the brake pedal are not actuated.
The transmission's creep function is interrupted by

operating the parking brake.
If there is a signal failure:

• no trouble code is set.
• the torque tracking of the clutch is suppressed.
If there is a signal failure of the ground at the switch:
• the creep function is not deactivated by operating
the parking brake.

Lesson 3 – Diagnostic Hints Actuators
Clutch actuator
4
5
10
12
11
E38533
1 DC motor 7 Compensation spring

2 Integral TCM 8 Piston rod
3 Drive worm gear 9 Replenishing connection (from brake fluid
4 Worm gear reservoir)
5 Piston rod connecting bolt 10 Clutch master cylinder piston
6 Distance sensor 11 Clutch master cylinder

Actuators Lesson 3 – Diagnostic Hints
12 High-pressure connection (to the clutch slave cylinder)
Installation position The pressure is passed on via the high-pressure line to

the clutch slave cylinder in the transmission and the
The clutch actuator with integrated TCM is located in currently requested clutch position is adopted.
the engine compartment in front of the transmission and
Brake fluid is used as the hydraulic fluid.
is secured on the left-hand front longitudinal member.

Task and function
If the clutch actuator fails:
The TCM actuates the DC motor in the clutch actuator
if required. • a trouble code is set.
The DC motor drives the worm gear via the drive worm
cluster comes on.
gear.
The worm gearing is a self-locking device, as a result
possible.
of which the clutch master cylinder piston will remain
naturally in any position without any energy being
required to keep it there.
If the clutch actuator overheats:
The worm gear is connected to the piston rod via the
piston rod connecting bolt.
• there is no longer any torque tracking.
Pressure is built up in the clutch master cylinder via the
• the transmission no longer shifts to the 5th gear.
piston rod and the piston.
• the shift points are changed.

Lesson 3 – Diagnostic Hints Actuators
Selector motor and shift motor in the shift actuator
3
B
4
A
E38531
1 Selector motor 4 Selector shaft (in the transmission)

2 Shift motor A Selection movement
3 Support frame B Shift movement

Actuators Lesson 3 – Diagnostic Hints
Installation position • further upshifting or downshifting is no longer

The selector and shift motors are attached in the shift
actuator to a carrier plate on the transmission and are
disengaged and taken out of gear (if possible).
connected to the gearshift shaft of the transmission via
joints.
A
Task and function
The selector motor is actuated by the TCM to select the

corresponding shift alley.
B
The shift motor is actuated by the TCM to shift the
corresponding gear.
For this purpose the two motors are mechanically

connected to the selector shaft of the transmission via
relay levers and connecting linkage.
C
Both motors act via a worm gear to allow the forces E52119
which are required for the gearshift operation to be
A Shift motor
applied.
B TCM
The gearing of the shift motor also has an additional
elastic module which has the task of making the C Selector motor
gearshift as smooth and judder-free as possible and is 114 PWM (Pulse Width Modulation) signal (-) to the
also designed to keep the gearshift time as short as selector motor
possible. 115 PWM signal (-) to the shift motor
Both electric motors are DC motors with two Hall 116 PWM signal (+) to the shift motor
sensors and integrated electronic circuitry each.
117 PWM signal (+) to the selector motor
The electrical actuation is carried out by the TCM by 118 Shift motor power supply
pulse width modulation.
119 Selector motor power supply
The motors are connected to the wiring harness via
coded connectors to prevent any confusion.
If there is a signal failure of one or both motors:

cluster comes on.

Lesson 3 – Diagnostic Hints Datalogger
Signals in the Datalogger
E52120

Datalogger Lesson 3 – Diagnostic Hints
System signal group

Datalogger Signal Description Target values/comments
DTC_TCM Number of trouble codes stored 0 to 10 trouble codes
ABS_STAT ABS control INACTIVE: currently no ABS

control
ACTIVE: current ABS control
ACSW Air-conditioning system INACTIVE: A/C magnetic clutch

open
ACTIVE: A/C magnetic clutch
closed
DR_DOOR_SW Front door ajar switch Closed: driver's door closed

Open: driver's door open
IGN_SW Ignition lock ON: IGN On

OFF: IGN Off
KickDown Throttle valve in kick-down position INACTIVE: throttle valve position

less than 85 degrees
ACTIVE: throttle valve position
greater than 85 degrees
VPWR Voltage at control module Vehicle on-board voltage
TP Throttle position Display in degrees (closed throttle

valve: 0 degrees; fully open throttle
valve: 90 degrees)
APP Accelerator-pedal position Display in degrees (accelerator pedal

not actuated: 0 degrees; fully actuated
accelerator pedal: 90 degrees)

Engine signal group

RPM_TCM Engine speed Current engine speed
ENG_IDLE Target idle speed Engine at operating temperature, A/

C system switched off: approx. 850
rpm
Engine at operating temperature, A/
C system switched on: approx. 950
rpm
ENG_TORQ Current engine load Idle: 0 to 5 Nm

While driving: 0 to 120 Nm
IDLE_SW Accelerator pedal position: not actu- ON: accelerator pedal not actuated
ated OFF: accelerator pedal actuated
START_REQ Ignition lock position III (start) ON: ignition lock position III
OFF: no ignition lock position III
START_RLY Engine start release ON: ignition lock position II or III,

brake pedal actuated, selector lever
in N position
OFF: not all conditions given for ON
are met
IGN_CAN Ignition lock position II on the CAN ON: IGN On

data bus OFF: IGN Off
ABS wheel speed sensors signal group

WSPDFL Left-hand front wheel speed sensor Wheel speed between 0 and 2000
rpm
WSPDFR Right-hand front wheel speed sensor Wheel speed between 0 and 2000
rpm
WSPDRL Left-hand rear wheel speed sensor Wheel speed between 0 and 2000
rpm
WSPDRR Right-hand rear wheel speed sensor Wheel speed between 0 and 2000
rpm

Brake signal group

BCAOC BPP switch on CAN data bus ON: brake pedal actuated
OFF: brake pedal not actuated or only
slightly actuated
BCBHW Stop lamp switch ON: brake pedal slightly actuated or

actuated
OFF: brake pedal not actuated
BCBOC Stop lamp switch on CAN data bus ON: brake pedal slightly actuated or
actuated
OFF: brake pedal not actuated
HANDBRAKE Parking brake switch ON: parking brake applied

OFF: parking brake not applied
FOOTBRAKE Brake pedal position Brake status on CAN data bus sent
by the TCM
ACTIVE: brake actuated
INACTIVE: brake not actuated
Clutch signal group

TCHPT_LT Long-term adaption value of clutch Basic programming: 11 mm

take-up point Tolerance range: 7.5 to 14.9 mm
TCHPT_MT Medium-term adaption value of Basic programming: 11 mm

clutch take-up point Tolerance range: 7.5 to 14.9 mm
TCHPT_ST Short-term adaption value of clutch Basic programming: 11 mm

take-up point Tolerance range: 7.5 to 14.9 mm
FRIC1 Clutch coefficient of friction 1 Basic programming: 270

Tolerance range: 100 to 650


FRIC_GEN General clutch coefficient of friction Basic programming: 270


CLTCHSETPNT Current clutch position Selector lever position N and engine

running: approx. 16 mm (clutch
disengaged)
Selector lever position D and engine
running: 10 to 15 mm
Driving slowly: approx. 10 mm
(clutch engaged)
CLTCH_SLIP Slipping clutch Selector lever position D, engine

running, vehicle stationary: 720 rpm
to 780 rpm
Driving constantly: 0 rpm to 20 rpm
(tolerance range because calculated
value from engine speed and wheel
speeds)
While shifting, clutch slip up to 2300
rpm is displayed
CLTCH_TEMP Clutch temperature Engine at operating temperature,

vehicle not being driven: approx. 65
°C
Vehicle being driven, engine idling:
approx. 150 °C
Electronic selector lever signal group

GRSEL Engaged gear N, R, 1, 2, 3, 4, 5
TIP+ Selector lever position Select Shift ON: selector lever in position Select
(+) Shift (+)
OFF: selector lever not in position
Select Shift (+)
TIP- Selector lever position Select Shift ON: selector lever in position Select
(-) Shift (-)
OFF: selector lever not in position
Select Shift (-)
REVERSE Selector lever position "R" ON: selector lever in R position

OFF: selector lever not in R position

MANUAL_ASM Manual driving mode ACTIVE: manual driving mode

selected
INACTIVE: automatic driving mode
selected
NEUTRAL Selector lever position "N" ON: selector lever in N position

OFF: selector lever not in N position
GLP_D Selector lever position A ON: selector lever in A position

OFF: selector lever not in A position
Shift actuator signal group

SHFTMTR_ACT Current position of shift motor Data in mm
SHFTMTR_REQ Requested position of shift motor Data in mm
TRANS_GEAR Engaged gear N, R, 1, 2, 3, 4, 5
REFPOS_SHFT Reference position of shift motor -1 mm
REFPOS_SEL Reference position of selector motor -18 mm
PWR-AMP Shift actuator power output stage

D
A
E53730
A Zero position C SYNC_POS1

B SEL_POS1 D SHFT_POS1
The last shift operation is divided into the movement:

NOTE: The diagram shows the learned gear positions
signal group. a. Approaching the synchronization point
SYNC_POS1.
The diagram represents the shift positions of the
transmission from 1st gear to reverse gear. b. Approaching the end position SHFT_POS1.
When 1st gear is engaged, the transmission control Depending on the position of the gears, the sign in front
moves the gearshift shaft from the zero position A to of the actuated specified values changes.
the learned position SEL_POS1.

Learned gear positions signal group

SEL_POS1 Selector motor position for 1st gear Default setting: -18 mm
Tolerance range: ± 3 mm
SEL_POS2 Selector motor position for 2nd gear Default setting: -18 mm
SEL_POS3 Selector motor position for 3rd gear Default setting: 0 mm

SEL_POS4 Selector motor position for 4th gear Default setting: 0 mm

SEL_POS5 Selector motor position for 5th gear Default setting: 19 mm

SEL_POS-R Selector motor position for reverse Default setting: 19 mm

gear Tolerance range: ± 3 mm
SHFT_POS1 Shift motor position for 1st gear Default setting: 10 mm
SHFT_POS2 Shift motor position for 2nd gear Default setting: -10 mm
SHFT_POS3 Shift motor position for 3rd gear Default setting: 10 mm
SHFT_POS4 Shift motor position for 4th gear Default setting: -10 mm
SHFT_POS5 Shift motor position for 5th gear Default setting: 10 mm
SHFT_POS-R Shift motor position for reverse gear Default setting: -10 mm
SYNC_POS1 Synchronizer device contact point for Default setting: 4 mm ± 1.5 mm

1st gear
SYNC_POS2 Synchronizer device contact point for Default setting: -4 mm ± 1.5 mm

2nd gear

3rd gear
SYNC_POS4 Synchronizer device contact point for Default setting: -4 mm ± 1.5 mm

4th gear

5th gear
NOTE:

The datalogger signals listed below are not relevant to

a service diagnosis (data is only required during
production):
• SEL_TRVL1
• SEL_TRVL2
• SEL_TRVL3
• SEL_TRVL4
• SEL_TRVL5
• SEL_TRVL-R
• L_CTP1 (learned clutch take-up point 1 during
initialization)
initialization)
initialization)
• L_ENDPOS1 (learned transmission position for 1st
gear during initialization)
• L_ENDPOS2 (learned transmission position for 2nd
• L_ENDPOS3 (learned transmission position for 3rd
• L_ENDPOS4 (learned transmission position for 4th
• L_ENDPOS5 (learned transmission position for 5th
• L_ENDPOS-R (learned transmission position for
reverse gear during initialization)
• L_SYNCPOS1 (learned synchronizer device contact
point for 1st gear during initialization)
point for 2nd gear during initialization)
point for 3rd gear during initialization)
point for 4th gear during initialization)
point for 5th gear during initialization)

Fault finding based on symptom Lesson 3 – Diagnostic Hints
Notes and Tips
Engine does not start
Check Comments /measures if signal is not correct
In the datalogger select "START-RLY", move selector Check battery, starter, starter relay, immobilizer, PCM.
lever to N position, actuate brake pedal and turn ignition
lock to position II or III.
In the datalogger check the signals from the brake pedal Check components, adjustment and wiring circuits.
position switch "BCAOC" and stoplamp switches
"BCBHW" and "BCBOC".
In the datalogger, check the signal of the electronic Query trouble codes and replace the selector lever if
selector lever for the "NEUTRAL" position. necessary.
In the datalogger select "START-RLY", move selector If all the above-mentioned fault sources are ruled out,
lever to N position, actuate brake pedal and turn ignition the TCM must be replaced.

Lesson 3 – Diagnostic Hints Fault finding based on symptom
No transmitted drive
In the datalogger select "START-RLY", move selector

lever to N position, actuate brake pedal and turn ignition
position switch "BCAOC" and stoplamp switches
"BCBHW" and "BCBOC".
Check whether the gear selection indicator in the From the clutch position in the datalogger it can be
instrument cluster displays "1". determined whether the clutch is engaged (10 to 15 mm)
The gear selection indicator must not be flashing. or disengaged (16 mm).
In the datalogger, call up "CLTCHSETPNT" and Check hydraulic lines for leaks and check filling level.
determine clutch position. The gear may not be engaged because the clutch remains
engaged.
Perform entire initialization process including clutch
bleeding using WDS.
Read out fault memory and address any trouble codes.

Then delete trouble codes.
Check clutch and clutch slave cylinder. Renew the clutch and clutch slave cylinder if necessary.
Check transmission function. Renew the transmission if necessary.
Check TCM. Renew TCM if necessary.

Fault finding based on symptom Lesson 3 – Diagnostic Hints
No creep function
position switch "BCAOC" and stoplamp switches Above a clutch temperature of approx. 200 °C, the creep
"BCBHW" and "BCBOC". function is reduced, above approx. 300 °C the TCM
In the datalogger, check the signal of the idle position switches off the creep function to protect the components.
"IDLE-SW".
In the datalogger, check the signal of the handbrake
"HANDBRAKE".
In the datalogger, check the signal of the clutch temper-
ature "CLTCH-TEMP".
Actuate brake pedal, move selector lever to D position. The two signals must match.
In the datalogger check the signals from the actual gear If the signals do not match, read out fault memory and
"TRANS-GEAR" and the selected gear "GRSEL". address any trouble codes.

bleeding using WDS.
Perform test drive. For this purpose, first check the signal Renew the clutch and clutch slave cylinder if necessary.
of the clutch temperature "CLTCH-TEMP" in the data-
logger. The value at the start of the test drive must not
be higher than 100 °C.
Pull away at least five times with wide-open-throttle and
shift through all gears.

Check creep function.

Lesson 3 – Diagnostic Hints Fault finding based on symptom
Engine stalls when vehicle stops
Check hydraulic lines for leaks and check filling level.


bleeding using WDS.
Perform test drive. For this purpose, first check the signal
of the clutch temperature "CLTCH-TEMP" in the data-
logger. The value at the start of the test drive must not
be higher than 100 °C.
Pull away at least five times with wide-open-throttle and
shift through all gears.
No communication with WDS
If during diagnosis using WDS communication cannot

be established with the TCM, this may be caused by
one of the following:
• no power supply or inadequate power supply of
battery (check power supply),
• ignition is not switched on,
• connecting cable of data link connector faulty (check
cable or diagnostic lead),
• problems with the WDS software (check WDS
software, perform WDS self-test),
• power supply at the TCM faulty (check power supply
and ground supply at the TCM),
• TCM defective (check communication with other
control modules).

Evaluation of datalogger values Lesson 3 – Diagnostic Hints
Concern: gearshift problems
E52067
A actual position of shift motor B requested position of shift motor
Gearshift problems may be caused by the following: shift motor requested by the module. If there are no
• mechanical resistance in the transmission (defective mechanical faults in the transmission, the actual path
synchronization) or in the gear shift linkage. of the shift motor is synchronous.
• a malfunction of the automated gearshift mechanism. In the event of a mechanical fault in the transmission,
the path shown in display zone A will differ from that
With the aid of the datalogger, the set point and actual
in display zone B.
values of the shifting process can be compared. The
diagram in the display zone (B) shows the path of the

Lesson 3 – Diagnostic Hints Evaluation of datalogger values
Concern: clutch slip
1011
0101
2500
A
0
15 12.5 10 7.5 5 2.5 0
E52065
A Time axis B Clutch slip in rpm
The torque tracking of the automated gearshift

mechanism permits controlled clutch slippage. The slip
can be checked using the datalogger value
"CLUTCH_SLIP".
With rapid acceleration, a slip of up to 20 rpm is normal.

Values much higher than this indicate a defective clutch.

Test questions Lesson 3 – Diagnostic Hints
1. What is the function of the CAN data bus?
a. It increases engine performance.
b. Data exchange takes place faster.
c. The CAN data bus only controls the engine management.
d. The CAN data bus has no effect on the automated gearshift mechanism.
2. The selector motor distance sensor is located:
a. in the shift actuator.
b. in the clutch actuator.
c. in the TCM.
d. in the electronic selector lever.
3. Using which datalogger signals can the actual position and the requested function of the shift motor be
compared?
a. SHFT_POS1 and SHFT_POS2
b. SHFTMTR_ACT and SHFTMTR_REQ
c. SYNC_POS1 and SYNC_POS2
d. This function is not available in the datalogger.
4. If just one of the two brake switches fails (stop lamp switch and BPP switch), the engine can no longer
be started.
a. True
b. False
5. Using which datalogger signal can the engine start release be checked?
a. IGN_SW
b. START_REQ
c. START_RLY
d. IGN_CAN

Lesson 3 – Diagnostic Hints Test questions
6. How is the temperature of the clutch is determined?
a. The temperature is determined using the clutch temperature sensor.
b. The ECT sensor determines the clutch temperature.
c. The clutch temperature is calculated with the aid of the ECT sensor and the IAT sensor by the TCM.
d. The clutch temperature is of no significance and is not determined.
7. Using which datalogger signal can a worn clutch be checked?
a. CLTCH_SLIP
b. FRIC1
c. CLTCH_TEMP
d. CLTCHSETPNT
8. Using which datalogger signal can the kick-down function be checked?
a. KickDown
b. TP
c. AP
d. RPM_TCM
9. In the datalogger it is possible to check the signal of the handbrake switch by calling up HANDBRAKE.
With which customer concern should you call up this signal?
a. Engine does not start.
b. No transmitted drive
c. No creep function
d. Engine stalls when vehicle stops.

Test questions Lesson 3 – Diagnostic Hints
10. In the datalogger it is possible to check the signals of the electronic selector lever. Which signal must be
called to test the selector lever position A?
a. TIP+
b. TIP-
c. MANUAL_ASM
d. GLP_D

Answers to the test questions
Lesson 1 – Initial Checks
1. d
2. c
1. d
2. d
3. a
4. b
5. c
6. c
7. b
8. a
9. c
10. c
1. b
2. a
3. b
4. b
5. c
6. c
7. a
8. a
9. c
10. d
Service Training 59
List of Abbreviations
ABS Anti-lock Brake System
APP Accelerator Pedal Position
BPP Brake Pedal Position
CAN Controller Area Network
CJB Central Junction Box
CKP Crankshaft Position
DLC Data Link Connector
ECT Engine Coolant Temperature
GEM Generic Electronic Module
IAT Intake Air Temperature
MAF Mass Air Flow
MAPT Manifold Absolute Pressure And

Temperature
PCM Powertrain Control Module
PWM Pulse Width Modulation
TCM Transmission Control Module
VSS Vehicle Speed Sensor
WDS Worldwide Diagnostic System
60 Service Training

Automated IB5 Manual Transaxle - Diagnosis

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Curriculum Training

Automated Gearshift System

Automated iB5 Manual Transaxle - Diagnosis

Technical Service Training CG 8135/S en 06/2004

The training course includes the following Student Information publications:

• Product launch "2003.25 Fiesta - Automated iB5 Transaxle ", CG 8009/S

Service Training (G410890) 1

Lesson 1 – Initial Checks

Knowing and understanding customer concerns............................................................................................................. 6

Testing possible causes of transmission control faults.................................................................................................... 6

Lesson 2 – Transmission Control

Regulating and control strategies.................................................................................................................................... 11

Signal transfer via the CAN data bus.............................................................................................................................. 15

Lesson 3 – Diagnostic Hints

CAN data bus.................................................................................................................................................................. 26

Clutch actuator distance sensor....................................................................................................................................... 27

Selector motor distance sensor and shift motor distance sensor..................................................................................... 27

BPP switch and stoplamp switch.................................................................................................................................... 31

Driver's door ajar switch................................................................................................................................................. 33

Wheel speed sensors....................................................................................................................................................... 34

Electronic selector lever.................................................................................................................................................. 35

Parking brake switch....................................................................................................................................................... 36

Selector motor and shift motor in the shift actuator........................................................................................................ 39

Signals in the Datalogger................................................................................................................................................ 41

Fault finding based on symptom............................................................................................................... 50

Notes and Tips................................................................................................................................................................. 50

Evaluation of datalogger values................................................................................................................ 54

Concern: gearshift problems........................................................................................................................................... 54

Concern: clutch slip........................................................................................................................................................ 55

Answers to the test questions......................................................................................... 59

On completing this lesson, you will be able to

Service Training (G410892) 5

If possible, try to reproduce the customer concern by

Cold Warm-up phase Operating temperature

Engine operating state

Good Poor Off-road

Unladen Laden Fully laden

Vehicle load status

Shifting up Shifting down Coasting Shifting in manual

Transmission shift status

• installation of additional aftermarket equipment

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Tick the correct answer or fill in the gaps.

b. Engine is in warm-up phase.

c. Engine is at operating temperature.

d. The engine judders while driving.

a. Loose or defective cables or electrical connectors

b. Battery state of charge

d. Unapproved tyre sizes

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On completing this lesson, you will be able to

Service Training (G410894) 9

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1 TCM 10 Distance sensor in the shift motor

Regulating and control strategies Adaption - clutch take-up point

Park NOTE: The clutch take-up point is factory-programmed

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The creep function is deactivated when the parking

A separate temperature sensor is not installed for

A 2 For this purpose, the TCM utilizes the following factors:

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• Torque to be transmitted. In principle, it is possible to pull away in 1st gear and

Service Training (G410893) 13

In this case, the transmission control recognizes shifting