Ford Mustang (1999-2004) Service Manual: Diagnosis By Symptom

Special Tool(s)

Transmission Fluid Pressure Gauge 307-004 (T57L-77820-A)
Air Test Plate, Transmission 307-246 (T92P-7006-A)
Breakout Box, EEC-V Control System 418-049 (T94L-50-EEC-V) or equivalent
MLP-TR Cable 418-F107 (007-00111) or equivalent
Worldwide Diagnostic System (WDS) 418-F224 New Generation STAR (NGS) Tester 418-F052 or equivalent scan tool
Transmission Tester 307-F016 (007-00130) or equivalent
Trans Tester TR/MLP Overlay and Manual 007-00131 or equivalent
73 III Automotive Meter 105-R0057 or equivalent
UV Leak Detector Kit 164-R0756 or equivalent

The Diagnosis by Symptom charts give the technician diagnostic information, direction, and suggest possible components, using a symptom as a starting point.

The Diagnosis by Symptom charts are 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 Chart Directions

1. Using the Diagnosis by 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 required statements. Always carry out the on-board diagnostic tests as required. Never skip steps.

Repair as required. 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.

Diagnosis by Symptom Index

Diagnosis by Symptom Index

Diagnosis by Symptom Index

a - Carry out electrical routine first.

Diagnostic Routines

Engagement Concern: No Forward

Possible Component Reference/Action
201 - ELECTRICAL ROUTINE
 No Electrical Concerns  
301 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.

 Inspect as under Fluid Condition Check; refer to Verification of Condition.

 Condition
Shift Linkage  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify the digital transmission range (TR) sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
 Damaged or incorrectly adjusted
Incorrect Pressures  Check pressure at line and forward clutch tap. Refer to Line Pressure Chart for specification. If pressures are low, check the following components: oil filter and seal assembly, main controls, pump assembly, forward clutch assembly.
 Low forward clutch pressure, low line pressure
Fluid Filter and Seal Assembly  
 Plugged, damaged  Install a new filter and seal assembly.
 Filter seal damaged
Main Controls  
 3-4 shift valve, main regulator valve, manual valve - stuck, damaged  Inspect for damage. Repair as required.
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Gaskets damaged  Inspect gaskets for damage and install a new gasket.
 2-3 accumulator and seals damaged  Inspect piston, seals and bore for damage. Repair as required.

 Inspect the diameter for wear.

 Pressure regulator valve
Pump Assembly  
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Porosity/cross leaks/ball missing or leaking, plugged hole  Inspect for porosity and leaks. Repair as required.
 No. 3 and No. 4 seal rings damaged  Inspect seals for damage. Repair as required.

 Inspect for damage and install a new gasket.

 Gaskets damaged
Forward Clutch Assembly  
 Seals, piston damaged  Inspect seals for damage. Repair as required.
 Check balls damaged, missing, mislocated, not seating correctly  Inspect for mislocation, poor seating, damage. Install a new cylinder as required.

 Check for abnormal wear, damage. Repair as required.

 Friction elements damaged or worn
One-Way Clutch Assembly (Planetary)  Inspect for damage. Repair as required.
 Worn, damaged or assembled incorrectly
Output Shaft  Inspect for damage. Install new components as required.
 Damaged

Engagement Concern: No Reverse

Possible Component Reference/Action
202 - ELECTRICAL ROUTINE
 No Electrical Concerns  
302 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.

 Inspect as under Fluid Condition Check; refer to Verification of Condition.

 Condition
Shift Linkage  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify the digital transmission range (TR) sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
 Damaged or incorrectly adjusted
Incorrect Pressures  Check pressure at line and forward clutch tap. Refer to Line Pressure Chart for specification. If pressures are low, check the following components: oil filter and seal assembly, main controls, pump assembly, forward clutch assembly.
 Low forward clutch pressure, low line pressure
Fluid Filter and Seal Assembly  
 Plugged, damaged  Install a new filter and seal assembly.
Main Controls  
 No. 6 shuttle ball, manual valve, main regulator valve, 1-2 accumulator seals stuck or damaged  Inspect for damage. Repair as required.
 Loose bolts  Tighten bolts to specifications.

 Inspect gaskets for damage and install a new gasket.

 Gasket damaged
Low/Reverse Servo  
 Seals (piston and cover) damaged  Inspect for damage. Repair as required.
 Servo cover retaining ring damaged  
 Anchor pins (case) damaged
Pump Assembly  
 Loose bolts  Tighten bolts to specifications.
 Porosity/cross leaks/ball missing or leaking, plugged hole  Inspect for porosity and leaks. Repair as required.
 No. 1 and No. 2 seal rings damaged  Inspect seals for damage. Repair as required.

 Inspect for damage and install a new gasket.

 Gaskets damaged
Reverse Clutch Assembly  
 Seals, piston damaged  Inspect seals for damage. Repair as required.
 Check ball missing or damaged  
 Friction elements damaged or worn
Low/Reverse Band  Inspect for damage. Repair as required.
 Band, servo, anchor pins damaged or worn

Engagement Concern: Harsh Reverse

Possible Component Reference/Action
203 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test; refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Carry out engagement test, EPC test and Go To Pinpoint Test B or Go To Pinpoint Test D . Check idle speed. Repair as required. Clear DTCs, road test and repeat Self- Test.
 Electrical inputs/outputs, vehicle wiring harnesses, PCM, TFT sensor, EPC solenoid
303 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Engine Driveline  
 Looseness in the driveshaft, U-joints or the engine mounts  Repair as required.
Shift Linkage  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify the digital transmission range (TR) sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
 Damaged or incorrectly adjusted
Incorrect Pressures  Check pressure at line and forward clutch tap. Refer to Line Pressure Chart for specification. If pressures are low, check the following components: oil filter and seal assembly, main controls, pump assembly, forward clutch assembly.
 High line pressure, high EPC pressure
Fluid Filter and Seal Assembly  
 Plugged, damaged  Install a new filter and seal assembly.
 Filter seal damaged
Main Controls  
 No. 6 shuttle ball, No. 5 check ball, manual valve, main regulator valve stuck, damaged or missing  Inspect for damage. Repair as required.
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Gaskets damaged  Inspect gaskets for damage and install a new gasket.

 Inspect for damage, contamination. Carry out EPC test in Routine No. 203. Repair as required.

 EPC solenoid stuck or damaged
Low Reverse Servo  
 Seals (piston and cover) damaged  Inspect for damage. Repair as required.
 Servo cover retaining ring assembled incorrectly  
 Anchor pins (case) damaged
Pump Assembly  
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Porosity/cross leaks  Inspect pump assembly. Install new as required.
 No. 1 and No. 2 seal rings damaged  Inspect seals for damage. Repair as required.

 Inspect for damage and install a new gasket.

 Gaskets damaged
Reverse Clutch Assembly  
 Seals, piston damaged  Inspect seals for damage. Repair as required.
 Check ball missing or damaged  
 Friction elements damaged or worn
Low Reverse Band  Inspect for damage. Repair as required.
 Band, servo, anchor pin damaged or worn

Engagement Concern: Harsh Forward

Possible Component Reference/Action
204 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test; refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Carry out engagement test, EPC test and Go To Pinpoint Test B or Go To Pinpoint Test D . Check idle speed. Repair as required. Clear DTCs, road test and repeat Self- Test.
 Electrical inputs/outputs, vehicle wiring harnesses, PCM, TFT sensor, EPC solenoid
304 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Engine Driveline  
 Looseness in the driveshaft, U-joints or the engine mounts  Repair as required.
Incorrect Pressures  Check pressure at line and forward clutch tap. Refer to Line Pressure Chart for specification. If pressures are low, check the following components: oil filter and seal assembly, main controls, pump assembly, forward clutch assembly.
 High forward clutch pressure, high line pressure, high EPC pressure
Main Controls  
 Main regulator valve stuck, damaged  Inspect and repair as required.
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Gaskets damaged  Inspect gaskets for damage and install a new gasket.

 Inspect for damage, contamination. Carry out EPC test in Routine No. 204. Repair as required.

 EPC solenoid stuck or damaged
Case  
 2-3 accumulator seal/retainer stuck, damaged  Inspect for damage. Repair as required.
Pump Assembly  
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Porosity/cross leaks  Inspect pump assembly. Install new as required.
 Gaskets damaged  Inspect for porosity/leaks. Install a new pump as required.

 Inspect for damage and install a new gasket.

Forward Clutch Assembly  
 Check ball missing or damaged  Inspect for mislocation, poor seating, damage. Install a new forward clutch cylinder.
 Friction elements damaged or worn  Inspect for damage. Repair as required.
 Forward clutch wave spring damaged  Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Forward clutch return spring damaged

Engagement Concern: Delayed/Soft Reverse

Possible Component Reference/Action
205 - ELECTRICAL ROUTINE
   No Electrical Concerns
305 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.

 Inspect condition of fluid.

 Condition
Shift Linkage  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify the digital transmission range (TR) sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
 Damaged or incorrectly adjusted
Incorrect Pressures  Check pressure at line tap; refer to Line Pressure Chart for specifications. If pressures are low, check the following components: main controls, pump assembly, reverse clutch assembly, reverse servo.
 Low reverse clutch pressure, low reverse band pressure, low line pressure
Fluid Filter and Seal Assembly  
 Plugged, damaged  Install a new filter and seal assembly.

 Filter seal damaged

 
Main Controls  
 No. 6 shuttle ball, manual valve, main regulator valve stuck or damaged  Inspect for damage. Repair as required.
 Bolts not tightened to specifications  Tighten bolts to specifications.

 Inspect for damage and install a new gasket.

 Gaskets damaged
Case  Inspect for damage. Repair as required.
 1-2 accumulator seals stuck or damaged
Low Reverse Servo  
 Seals (piston and cover) damaged  Inspect for damage. Repair as required.
 Servo cover retaining ring assembled incorrectly
Pump Assembly  
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Porosity/cross leaks/ball missing or leaking  Inspect pump assembly. Install new as required.
 No. 1 and No. 2 seal rings damaged  Inspect seals for damage. Repair as required.

 Inspect for damage and install a new gasket.

 Gaskets damaged
Reverse Clutch Assembly  
 Seals, piston damaged  Inspect seals for damage. Repair as required.
 Check ball missing or damaged  
 Friction elements damaged or worn
Low Reverse Band  Inspect for damage. Repair as required.
 Damaged, worn

Engagement Concern: Delayed/Soft Forward

Possible Component Reference/Action
206 - ELECTRICAL ROUTINE
   No Electrical Concerns
306 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.

 Inspect condition of fluid.

 Condition
Shift Linkage  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify the digital transmission range (TR) sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
 Damaged or incorrectly adjusted
Incorrect Pressures  Check pressure at line, forward clutch and EPC taps; refer to Line Pressure Chart for specifications. If pressures are low, check the following components: oil filter and seal assembly, main controls and pump assembly.
Low forward clutch pressure, low line pressure, low EPC pressure
Fluid Filter and Seal Assembly  
 Plugged, damaged  Install a new filter and seal assembly.

 

 Filter seal damaged
Main Controls  
 3-4 shift valve, main regulator valve stuck or damaged  Inspect and repair as required.
 Bolts not tightened to specifications  Tighten bolts to specifications.

 Inspect for damage and repair as required.

 Gaskets damaged
Case  Inspect for damage. Repair as required.
 2-3 or 1-2 accumulator, bore damaged or stuck
Low Reverse Servo  
 Seals (piston and cover) damaged  Inspect for damage. Repair as required.
 Servo cover retaining ring assembled incorrectly
Pump Assembly  
 Bolts not tightened to specifications  Tighten bolts to specifications.
 Porosity/cross leaks  Inspect pump assembly. Repair as required.
 No. 3 and No. 4 seal rings damaged  Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Gaskets damaged
Forward Clutch Assembly  
 Seals, piston damaged  Inspect for damage. Repair as required
 Check ball missing or damaged  Inspect for mislocation, poor seating, damage. Install a new cylinder as required.

 Check for damage. Repair as required.

 Friction elements damaged or worn

Shift Concerns: Some/All Shifts Missing

Possible Component Reference/Action
210 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test; refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test A , Go To Pinpoint Test C or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.
 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, output shaft speed (OSS) sensor, digital TR sensor
303 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Shift Linkage, Digital TR Sensor  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted. Adjust the digital TR sensor as necessary.

 Refer to the following shift routine(s) for further diagnosis:

  • Shift 1-2, Routine 220/320
  • Shift 2-3, Routine 221/321
  • Shift 3-4, Routine 222/322
  • Shift 4-3, Routine 223/323
  • Shift 3-2, Routine 224/324
  • Shift 2-1, Routine 225/325
 Damaged or incorrectly adjusted

Shift Concerns: Timing Concerns - Early/Late

Possible Component Reference/Action
211 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test A , Go To Pinpoint Test C or Go To Pinpoint Test E . Repair as required.

Clear DTCs, road test and repeat Self-Test.

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, EPC solenoid, TFT sensor, OSS
311 - HYDRAULIC/MECHANICAL ROUTINE
Other  
 Tire size change, axle ratio change  Verify vehicle has original equipment. Refer to Certification Label and Safety Standard Certification Label. Changes in tire size or axle ratio will affect shift timing.
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Powertrain Control System  
 Engine driveability concerns  Refer to Routine 253.
Incorrect Pressures  Check pressure at line and EPC taps; refer to Line Pressure Chart for specifications. If not OK, check the main controls. If OK, refer to the shift routine(s) for further diagnosis:
  • Shift 1-2, Routine 320
  • Shift 2-3, Routine 321
  • Shift 3-4, Routine 322
  • Shift 4-3, Routine 323
  • Shift 3-2, Routine 324
  • Shift 2-1, Routine 325
 Line pressure, EPC pressure
Main Controls  
 EPC solenoid, stuck or damaged hydraulically or mechanically  Inspect for damage, contamination. Carry out EPC tests in Routine No. 211. Repair as required.
 Valves, accumulators, seals stuck or damaged or assembled incorrectly  Inspect for damage. Repair as required.
 Gaskets damaged  Inspect for damage and install a new gasket.

 Clean or install a new screen.

 Solenoid screen blocked or damaged

Shift Concerns: Timing Concerns - Erratic/Hunting

Possible Component Reference/Action
212 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis. Go To Pinpoint Test A , Go To Pinpoint Test C or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.
 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, torque converter clutch (TCC) solenoid, digital TR sensor, output shaft speed (OSS)
312 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.

 Inspect condition of fluid.

 Condition
Main Controls  
 Valves, accumulators, seals, assembled wrong, stuck or damaged  Inspect for damage. Repair as required.
 Solenoid screen blocked or damaged  Inspect gaskets for damage and install a new gasket.

 Clean or install a new screen.

 Gaskets damaged
Torque Converter Clutch  Refer to Torque Converter Operation Concerns: Cycling/Shudder/Chatter Hydraulic/Mechanical Routine 342.
 Torque converter
Specific Shifts  Refer to the following shift routine(s) for further diagnosis:
  • Shift 1-2, Routine 320
  • Shift 2-3, Routine 321
  • Shift 3-4, Routine 322
  • Shift 4-3, Routine 323
  • Shift 3-2, Routine 324
  • Shift 2-1, Routine 325
 

Shift Concerns: Feel - Soft/Slipping

Possible Component Reference/Action
213 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test D or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.

 Refer to Routine 253.

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, EPC solenoid, OSS
 Engine driveability concerns
313 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Incorrect Pressures  Check pressures at line and EPC taps; refer to Line Pressure Chart for specifications. If pressures are low or all shifts are soft/slipping, go to main controls. If pressures are OK and a specific shift is soft/slipping, refer to the following routine(s) for further diagnosis:
  • Shift 1-2, Routine 320
  • Shift 2-3, Routine 321
  • Shift 3-4, Routine 322
  • Shift 4-3, Routine 323
  • Shift 3-2, Routine 324
  • Shift 2-1, Routine 325
 Low line pressure, low EPC pressure
Main Controls  
 Main regulator valve, overdrive servo regulator valve stuck, damaged or assembled incorrectly  

 Inspect for damage. Repair as required.

 Inspect for damage and contamination. Carry out EPC tests in Routine 213. Repair as required.

 EPC solenoid stuck or damaged
Case  
 1-2 accumulator stuck or damaged  Inspect for damage. Repair as required.
Filter and Seal Assembly  

 Inspect for damage. Install a new filter as required.

 Inspect for damage. Repair as required.

 Filter plugged, damaged
 Seal damaged or cut

Shift Concerns: Feel - Harsh

Possible Component Reference/Action
214 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test D or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.

 Refer to Routine 253.

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, EPC solenoid, OSS
 Engine driveability concerns
314 - HYDRAULIC/MECHANICAL ROUTINE
Fluid  
 Incorrect level  Adjust fluid to correct level.
 Condition  Inspect condition of fluid.
Incorrect Pressures  Check pressures at line and EPC taps; refer to Line Pressure Chart for specifications. If pressures are low or all shifts are soft/slipping, go to main controls. If pressures are OK and a specific shift is soft/slipping, refer to the following routine(s) for further diagnosis:
  • Shift 1-2, Routine 320
  • Shift 2-3, Routine 321
  • Shift 3-4, Routine 322
  • Shift 4-3, Routine 323
  • Shift 3-2, Routine 324
  • Shift 2-1, Routine 325
 High line pressure, high EPC pressure
Main Controls  
 Main regulator valve, overdrive servo regulator valve stuck, damaged or assembled incorrectly  Inspect for damage. Repair as required.

 

 Inspect for damage or contamination. Carry out EPC tests in Routine 214. Repair as required.

 EPC solenoid stuck or damaged

Shift Concerns: No 1st Gear, Engages In Higher Gear

Possible Component Reference/Action
215 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test A or Go To Pinpoint Test C . Repair as required. Clear DTCs, road test and repeat Self-Test.
 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, digital transmission range TR sensor
315 - HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage, Digital TR Sensor  
 Damaged or incorrectly adjusted  Inspect and repair as required. Verify transmission shift cable adjustment. Refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted.
Incorrect Pressures  

 Check for which pressures are on and refer to Band/Clutch Application Chart 601 and corresponding routines.

  • 324, 301
  • 325, 301
  • 323, 324, 325, 301
  • 324
  • 325
  • 323, 324, 325
  • Refer to appropriate mechanical diagnosis.
 Low reverse clutch pressure, low reverse band pressure, low line pressure
  • Forward Off, Intermediate Off, Direct X
  • Forward Off, Intermediate X, Direct Off
  • Forward Off, Intermediate X, Direct X
  • Forward X, Intermediate Off, Direct X
  • Forward X, Intermediate X, Direct Off
  • Forward X, Intermediate X, Direct X
  • Forward X, Intermediate Off, Direct Off
Mechanical  
 Bands, clutches or seals damaged or worn  Refer to Transmission Disassembly and Assembly.

X = pressure applied

Shift Concerns: No Manual 1st Gear

Possible Component Reference/Action
216 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test A or Go To Pinpoint Test C . Repair as required. Clear DTCs, road test and repeat Self-Test.

 

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, digital TR sensor
316 - HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage, Cable, Digital TR Sensor  
 Damaged or incorrectly adjusted  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
Incorrect Pressures  Check pressure at line and EPC pressure taps; refer to Line Pressure Chart for specifications. If pressures are low, check the following components: oil filter and seal assembly, main controls, reverse clutch assembly and reverse servo assembly.
 Low reverse clutch pressure, low reverse band pressure, low line pressure, low EPC pressure
Main Controls  
 No. 6 shuttle ball, manual valve, main regulator valve, low servo modulator valve stuck, damaged or assembled incorrectly  Inspect for damage. Repair as required.

 

 Tighten bolts to specifications.

 Bolts not tightened to specifications
Fluid Filter and Seal Assembly  
 Plugged or damaged  Install a new filter and seal assembly.
Low Reverse Servo  

 Inspect for damage. Repair as required.

 

 Seals (piston and cover) damaged

Shift Concerns: No Manual 2nd Gear

Possible Component Reference/Action
217 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test A or Go To Pinpoint Test C . Repair as required. Clear DTCs, road test and repeat Self-Test.

 

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, shift solenoids, digital TR sensor
317 - HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage, Cable, Digital TR Sensor  
 Damaged or incorrectly adjusted  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
Main Controls  
 3-4 shift valve, 1-2 and 2-3 shift valve, 3-4 capacity modulator valve stuck, damaged or assembled incorrectly  Inspect for damage. Repair as required.

 

 Tighten bolts to specifications.

 Bolts not tightened to specifications

Shift Concerns: 1-2 Shift (Automatic)

Possible Component Reference/Action
220 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test D or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.

 Refer to Routine 253.

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, EPC solenoid, OSS
 Engine driveability concerns
320 - HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage, Digital TR Sensor  
 Damaged or incorrectly adjusted  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
Incorrect Pressures  Check pressure at line and intermediate clutch taps; see the line pressure chart for specifications. If not OK, check the main controls.
 Intermediate clutch pressure, line pressure
Main Controls  
 1-2 shift valve, stuck or damaged  Inspect for damage. Repair as required.

 Tighten bolts to specification.

 Bolts not tightened to specifications
 Shift solenoid SSA malfunction  Activate solenoid using scan tool. If solenoid operation cannot be felt when placing hand on solenoid, install a new solenoid. Inspect O-rings for damage. Repair as required.
 Gasket damaged  Inspect for damage and install a new gasket.

 Inspect for damage. Repair as required.

 No. 8 ball not seating
Case  
 1-2 accumulator stuck or damaged  Inspect for damage. Repair as required.
Pump  

 Inspect for porosity/leaks, balls missing. Install a new pump as required.

 Inspect for damage and install a new gasket.

 Porosity/cross leaks, balls missing, damaged or leaking
 Gasket damaged
Intermediate Clutch Assembly  

 Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Seals damaged
 Piston damaged

 Friction elements damaged or worn

Intermediate One-Way Clutch Assembly  Inspect for damage. Repair as required.
 Not holding or damaged
Planetary One-Way Clutch Assembly
 Not overrunning or damaged  Inspect for damage. Repair as required.
1-2 Accumulator  

 Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Damaged accumulator piston
 Springs damaged or broken
 Case bore scored  Inspect for damage. Repair as required.

Shift Concerns: 2-3 Shift (Automatic)

Possible Component Reference/Action
221 - ELECTRICAL ROUTINE
Powertrain Control System  Carry out Self-Test. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the Powertrain Control System. Go To Pinpoint Test D or Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and repeat Self-Test.

 Refer to Routine 253.

 Electrical inputs/outputs, vehicle wiring harnesses, PCM, EPC solenoid, OSS
 Engine driveability concerns
321 - HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage, Digital TR Sensor  
 Damaged or incorrectly adjusted  Inspect and repair as required. Verify transmission shift cable adjustment; refer to Section. Adjust transmission shift cable as necessary. After repairing transmission shift cable, verify that the digital TR sensor is correctly adjusted. Adjust the digital TR sensor as necessary.
Incorrect Pressures  Check pressure at line and intermediate clutch taps; see the line pressure chart for specifications. If not OK, check the main controls.
 Intermediate clutch pressure, line pressure
Main Controls  
 2-3 shift valve, check ball No.

9 or No. 3, solenoid pressure regulator valve, damaged or assembled incorrectly

 Inspect for damage. Repair as required.

 

 Tighten bolts to specification.

 Bolts not tightened to specifications
 Shift solenoid SSB malfunction  Activate solenoid using scan tool. If solenoid operation cannot be felt when placing hand on solenoid, install a new solenoid.

Inspect O-rings for damage. Repair as required.

 Gasket damaged  Inspect for damage and install a new gasket.

 Inspect for damage. Repair as required.

 Output shaft seals damaged or cup plug leaking or missing
Case  
 Output shaft rear seals leaking or damaged  Inspect for damage. Repair as required. Inspect case for damaged seal area. If damaged, install a new case.
Intermediate One-Way Clutch Assembly  Inspect for damage. Repair as required.
 Not overrunning or damaged
Output Shaft
 Seal rings damaged  Inspect for damage. Repair as required.
 Cup plug damaged or missing
Direct Clutch Assembly  

 Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Seals or piston damaged
 Friction elements worn or damaged
 Check ball not seating  Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Return spring assembly damaged
2-3 Accumulator  

 Inspect for damage. Repair as required.

 Inspect for damage. Repair as required.

 Damaged accumulator piston
 Springs damaged or broken
 Case bore scored  Inspect for damage. Repair as required.

Shift Concerns: 3-4 Shift (Automatic)

Shift Concerns: 3-4 Shift (Automatic)

Shift Concerns: 3-4 Shift (Automatic)

Shift Concerns: 4-3 Shift (Automatic)

Shift Concerns: 4-3 Shift (Automatic)

Shift Concerns: 4-3 Shift (Automatic)

Shift Concerns: 3-2 Shift (Automatic)

Shift Concerns: 3-2 Shift (Automatic)

Shift Concerns: 3-2 Shift (Automatic)

Shift Concerns: 2-1 Shift (Automatic)

Shift Concerns: 2-1 Shift (Automatic)

Shift Concerns: 2-1 Shift (Automatic)

Torque Converter Clutch Operation Concerns: No Apply

Torque Converter Clutch Operation Concerns: No Apply

Torque Converter Clutch Operation Concerns: No Apply

Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle

Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle

Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle

Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter

Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter

Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position

Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position

Other Concerns: Shift Lever Efforts High

Other Concerns: Shift Lever Efforts High

Other Concerns: Shift Lever Efforts High

Other Concerns: External Leaks

Other Concerns: External Leaks

Other Concerns: Poor Vehicle Performance

Other Concerns: Poor Vehicle Performance

Other Concerns: Poor Vehicle Performance

Other Concerns: Noise/Vibration - Forward Or Reverse

Other Concerns: Noise/Vibration - Forward Or Reverse

Other Concerns: Noise/Vibration - Forward Or Reverse

Other Concerns: Engine Will Not Crank

Other Concerns: Engine Will Not Crank

Other Concerns: No Park (P) Range

Other Concerns: No Park (P) Range

Other Concerns: No Park (P) Range

Other Concerns: Overheating

Other Concerns: Overheating

    Transmission Fluid Cooler
    CAUTION: Whenever a transmission has been disassembled to install new parts, the cooler bypass valve (CBV), all transmission fluid coolers (in tank and auxiliary) and transmission fluid cooler l ...

    Transmission Fluid Cooler - Backflushing and Cleaning
    1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the oper ...

    Other materials:

    Safety precautions
    WARNING: Do not overfill the fuel tank. The pressure in an overfilled tank may cause leakage and lead to fuel spray and fire. WARNING: The fuel system may be under pressure. If you hear a hissing sound near the fuel filler inlet, do not refuel until the sound ...

    Crankshaft Runout
    Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the Dial Indicator Gauge with Holding Fixtur ...

    Shield
    Removal 1. Remove the brake disc (1125). For additional information, refer to Disc in this section. 2. Remove the brake disc shield (2K004). 1. Drill out three brake disc shield rivets. 2. Remove the brake disc shield. Installation 1. I ...