Before Pinpoint Tests
Rotunda Transmission TesterFord DOES NOT provide procedures to perform the testing and/or diagnosis without the Rotunda Transmission Tester/Tester Kit.
Use Rotunda Transmission Tester 00700085D (part of Rotunda Transmission Tester Kit 007-0085D) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 in Transmission Tester Kit 0070085D or equivalent to diagnose electronically controlled transmissions (7003). The following instructions outline the set up and use of this tester in the Pinpoint Tests for the 4R44E/4R55E.
Overlays and Adapters
Transmission Tester:
1. Overlay and Cable Correctly Installed LEDs:
Only LEDs with the (O) symbol will light when the overlay and cable are correctly matched.
2. Status LEDs: LED OFF when not activated by tester (solenoid not activated, Open circuit or signal line short to ground).
- LED green when activated by tester and current draw is correct.
- LED red when activated by tester and current draw is excessive (short at VPWR).
- All LEDs light orange during On-Board Diagnostics.
3. Solenoid Activate Buttons: Energize respective solenoids during click testing and activate selected circuits during DRIVE mode testing.
4. Tester Mode Switch: Selects operating mode, either BENCH or DRIVE.
5. Solenoid Select/Gear Select Switch: Has three functions:
- BENCH MODE: acts as shift solenoid selector for click testing.
- DRIVE MODE: acts as forward gear selector in place of vehicle's powertrain control module (PCMX12A650) controlled shifting. Hydraulic safety mechanisms and overrides are built into the transmission.
- OHMS CHECK: allows technician to measure ohms and to check for presence of diode on specific solenoids.
Tester Jacks
1. VPWR Pin Jacks (red): Vehicle Power (VPWR) test points for solenoid circuits.
2. Solenoid Signal Line Pin Jacks (black): Signal line test points for solenoid circuits.
3. BAT + (red) and BAT - (black) Pin Jacks: Battery reference points when measuring circuits for shorts.
4. TFT Pin Jacks: Test points for transmission fluid temperature sensor.
5. TSS Jack: Test points for TSS sensor.
LEDs and Controls
- LED turns GREEN when solenoid activates and OFF when solenoid deactivates.
- LED turns RED if an activated solenoid/harness is shorted.
- LED remains OFF if an activated solenoid/harness is shorted to ground or no continuity.
Instructions
The Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester Kit 007-0085D) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit 007-0085D or equivalent allows a technician to operate the electrical portion of the transmission independent of the vehicle electronics to determine transmission concerns. The Transmission Tester usage is divided in six steps:
1. Preliminary Testing and Diagnosis
2. Installing the Transmission Tester
3. Static Testing - Engine Off
4. Dynamic Testing - Vehicle Running
5. TR/MLP Testing
6. Removing Transmission Tester and Clearing DTCs
Preliminary Inspections
1. Know and understand the customer's concern.
2. Verify the customer's concern:
- Upshift
- Downshift
- Coasting
- Engagement
If concern involves noise or vibration, does it relate to any of the following?
- Rpm
- Vehicle speed
- Shift
- Gear
- Range
- Temperature
3. Vehicle must be at normal operating temperature.
4. Check transmission fluid level and condition.
5. Check for the following items:
- Vehicle modifications
- Electronic add-on items:
- Leaks
- Linkage adjustments
6. Check TSBs and OASIS for related information.
7. Perform complete On-Board Diagnostics (OBD) for both KOEO and KOER.
8. Record all DTCs.
9. Repair all non-transmission DTCs. Installation Procedures Installing Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester Kit 007-0085D) with Rotunda 4R44E/4R55E Overlay/Cable 007-00106 included in Transmission Tester Kit 007-0085D or equivalent at the transmission connector allows separation of the vehicle electronics from transmission electronics. Disconnecting normal vehicle electronics will cause firm shifts and defaults transmission to maximum line pressure.
During tester usage, additional DTCs may be set. Therefore, it is important that all codes are erased after service has been made. To verify elimination of all codes rerun On-Board Diagnostics.
1. CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in transmission concerns. Disconnect vehicle wiring harness at transmission connector.
2. Install appropriate overlay onto tester.
3. Turn tester solenoid select switch to the OHMS CHECK position.
4. CAUTION: Route all cables away from heat sources.
Connect appropriate interface cable to transmission tester and then to the appropriate transmission connectors.
5. CAUTION: Route gauge line away from heat sources.
Install a line pressure gauge into line pressure tap on transmission.
Static Testing - Engine Off
Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Completion of these tests prove out transmission electronics.
Refer to appropriate Pinpoint Test based on DTCs displayed. Use a digital volt-ohmmeter and the transmission tester to perform the Pinpoint Tests as indicated, based on the DTCs which were displayed. Perform repairs as indicated by the Pinpoint Tests. Always erase all codes, retest and road test vehicle after a repair.
Resistance/Continuity Tests - EPC Solenoid
1. Set ohmmeter to 100-200 ohm range.
2. Connect COM lead to the EPC jack.
3. Connect ohmmeter POS lead to the VPWR jack.
4. Record resistance.
Solenoid Resistance Chart:
5. Refer to the chart for values. If out of specification, refer to Pinpoint Test E. E: Electronic Pressure Control (EPC) Solenoid
Resistance/Continuity Tests - Solenoids (SS1, SS2, SS3, TCC, CCS)
1. Set ohmmeter to 100-200 ohm range.
2. Connect ohmmeter COM lead to the appropriate solenoid (shift solenoid 1 (SS1), shift solenoid 2 (SS2), shift solenoid 3 (SS3), torque converter solenoid [TCC], coast clutch solenoid (CCS) jack.
3. Connect ohmmeter POS lead to the appropriate VPWR jack for the solenoid being tested.
4. Record resistance.
5. Refer to the chart for values. If out of specification, refer to Pinpoint Test A (SS1, SS2, SS3); Pinpoint Test C (TCC), Pinpoint Test G (CCS). G: Coast Clutch Solenoid (CCS)
Resistance/Continuity Tests - Transmission Fluid Temperature (TFT) Sensor
1. Set ohmmeter to 1000 ohm (k) scale.
2. Connect ohmmeter COM lead to TFT jack.
3. Connect ohmmeter P0S lead to + TFT jack.
4. Record resistance. Resistance will vary with temperature.
TFT Sensor Resistance Chart:
5. Refer to the chart. If out of specification, refer to Pinpoint Test B in this section. B: Transmission Fluid/Oil Temperature (TFT/TOT) Sensor
Resistance/Continuity Tests - Turbine Shaft Speed (TSS) Sensor
1. Set Rotunda 73 Digital Multimeter 105R0051 or equivalent to 200 ohms.
2. Connect multimeter COM lead to TSS jack.
3. Connect multimeter P0S lead to (-) TSS jack.
4. Record resistance.
Range TSS 64-120 ohms
5. If resistance is out of range, refer to Pinpoint Test F in this section. F: Turbine/Transmission Shaft Speed (TSS) Sensor
Solenoid Voltage Test
1. Slide MODE switch to BENCH position.
2. Set voltmeter to 20-volt DC range.
3. Determine solenoid to be tested and connect voltmeter leads as follows:
a. If testing SS1, SS2, or SS3 solenoid, turn the SOLENOID SELECT dial to SS1,SS2, or SS3 BEFORE hooking up leads.
b. Connect negative lead to solenoid jack.
c. Connect positive lead to VPWR jack.
4. Press solenoid activate/deactivate button and check voltage.
The LED should light, the voltage should change, and an audible click may be heard. See "LED and Controls" for reading LED status.
5. Observe and record values.
Dynamic Testing - Engine On
Preliminary Set-Up
1. Slide MODE switch to DRIVE position.
2. Turn GEAR SELECT dial to 1.
3. Place vehicle in PARK with parking brake on.
4. Start engine.
EPC Solenoid
CAUTION: Do not attempt to hold the electronic pressure control switch depressed (minimum line pressure) and stall the transmission (holding the vehicle with the brake while depressing the throttle with the transmission in gear). Transmission damage will result.
1. Observe line pressure. Record value. Line pressure should go to maximum. If not, refer to the Diagnosis by Symptom Index for diagnostic information or Pinpoint Test E concerning electronic pressure control solenoid.
2. Depress electronic pressure control switch. Record value. Line pressure should drop to a minimum value. Record value. If not, refer to the Diagnosis by Symptom Index or Pinpoint Test E for the electronic pressure control solenoid.
Transmission Engagements
1. Verify that MODE switch is in DRIVE position.
2. Turn GEAR SELECT dial to 1.
3. Start engine.
4. Shift vehicle from PARK to REVERSE.
- Did vehicle shift into REVERSE?
- Was engagement firm?
5. Depress EPC switch. Line pressure should drop to idle pressure. While holding EPC switch down, shift vehicle from PARK to REVERSE.
- Did vehicle shift into REVERSE?
- Was engagement smooth?
- Shift vehicle from REVERSE to PARK.
- Release EPC switch. Line pressure should rise to MAX pressure.
6. Shift vehicle from PARK to DRIVE.
- Did vehicle shift into DRIVE?
- Was engagement firm?
7. Shift vehicle from DRIVE to PARK.
8. Depress EPC switch. Pressure should drop to idle pressure.
9. While holding EPC switch down, shift vehicle from PARK to DRIVE.
- Did the vehicle shift from PARK to DRIVE?
- 10. Release EPC Switch.
Upshifts/Downshifts
NOTE: Upshifts and downshifts will be firm during this procedure. Pressure gauges may be removed. These tests should be performed on the road. If performed on the hoist, shift feel during engagement may not be possible.
LEDs will turn green when solenoids are activated and turn off when deactivated. Refer to the appropriate overlay for the proper status shift sequence of the shift solenoids during upshifts and downshifts.
1. Move transmission range selector lever into (D) and accelerate to 24 km/h (15 mph). By moving transmission range selector lever, shift to second gear.
- Did vehicle upshift to second gear?
- Did appropriate shift solenoids activate/deactivate?
2. Accelerate to 40km/h (25 mph) and select third gear by turning GEAR SELECT dial to 3.
- Did vehicle upshift to third gear?
- Did appropriate shift solenoids activate/deactivate?
3. Accelerate to 56-72km/h (35/45mph) and select fourth gear by turning GEAR SELECT dial to3.
- Did vehicle upshift to fourth gear?
- Did appropriate shift solenoids activate / deactivate?
4. Reverse the order to downshift.
- Did vehicle downshift from fourth to third, third to second, and second to first?
Torque Converter Clutch (TCC) Engagement
CAUTION: Do not depress torque converter clutch solenoid switch with transmission in gear and the vehicle at a stop. Damage to torque converter clutch may result.
NOTE: This test should be performed on the road. If performed on a hoist, torque converter clutch engagement feel may not be possible.
1. Accelerate and shift vehicle up into third gear. Hold speed steady and depress the torque converter clutch solenoid switch.
- Did the torque converter engage?
- Did the engine rpm drop?
- Did torque converter clutch solenoid activate?
- Did TCC solenoid deactivate when switch was reused?
Coast Clutch Engagement
NOTE: This test should be performed on the road. If performed on the hoist, coast clutch engagement feel may not be possible.
1. Accelerate and shift vehicle into third gear. Depress the coast clutch solenoid switch and immediately back off the throttle.
- Did the coast clutch engage? Did engine braking occur?
- Did the coast clutch solenoid activate?
2. Release the CCS switch.
- Did the CCS solenoid deactivate?
Turbine Shaft Speed (TSS) Sensor
NOTE: This test may be performed on the hoist or on the road.
1. Set voltmeter to 20 volts AC.
2. Connect voltmeter positive lead to +TSS.
3. Connect voltmeter negative lead to -TSS.
4. Slowly accelerate vehicle and monitor voltmeter.
- Did voltage increase with vehicle speed?
If testing of the TR/MLP sensor is required, go to the following procedure. If testing of the TR I MLP sensor is not required, go to the disconnecting the tester procedure in this section.
Transmission Range (TR) Sensor Testing Introduction
The Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester Kit 007-0085D) or equivalent allows a technician to test the TR sensor independent of vehicle electronics. TR sensor testing is divided into four steps:
1. Preliminary diagnosis and testing.
2. Installing the Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester Kit 007-0085D) or equivalent.
3. Testing the transmission range (TR) sensor.
4. Testing the park/neutral, backup and optional circuits.
Preliminary Testing and Diagnosis
Before any diagnostic testing is done on a vehicle some preliminary checks must be performed. Be sure to write down any findings, especially any DTCs, for future reference.
1. Know and understand customer's concern.
2. Verify that TR/MLP sensor is properly adjusted in NEUTRAL.
3. Verify customer concern:
a. Upshift
b. Downshift
c. Coasting
d. Engagement
4. If concern involves noise or vibration, does it relate to any of the following?
a. Rpm
b. Vehicle speed
c. Shift
d. Gear
e. Range
f. Temperature
5. Vehicle must be at normal operating temperature.
6. Check transmission fluid level and condition.
7. Check for the following items:
- Vehicle modifications
- Electronic add-on items
- Leaks
- Linkage adjustments
8. Check TSBs and OASIS for related information.
9. Perform complete On-Board Diagnostics (OBD) for both KOEO and KOER.
10. Record all DTCs.
11. Repair all non-transmission DTCs.
Installation Procedures
Installing the Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester Kit 007-0085D) at the transmission connector allows separation of the TR I MLP sensor electronics from the vehicle electronics.
Testing may cause additional fault codes to be set. Therefore, it is important that all DTCs are erased whenever repairs are made. To verify elimination of all codes, rerun OBD test.
The following manuals will assist in diagnosis of electronically controlled transmissions:
Powertrain Control/Emission Diagnosis (PC/ED) Manual
Transmission Reference Manual
1. Disconnect vehicle harness at transmission TR sensor.
2. Set the two-way switch in the down position. (This switch will stay in the same position for all TR sensor testing.)
3. Attach the TR I MLP sensor overlay to the transmission tester.
Affixing the overlay will immobilize the two-way switch (set in Step 2) so it cannot be accidentally moved to an incorrect setting during testing.
4. Select and connect interface cable C to the tester and then to TR connector.
CAUTION: Route all cables away from heat sources to prevent damage to cables during testing.
Use the transmission tester extender cable when running tests with the transmission on the vehicle.
5. Turn large dial to TR/MLP SENSOR TEST.
6. Plug transmission tester power cable into cigar lighter socket.
All LEDs should light for a short period and then turn off. This is the Tester's internal circuit check.
CAUTION: For resistance checks, be sure that the tester selector switch is set to the TR SENSOR TEST position or damage to the ohmmeter may result.
Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Completion of these tests prove out the TR sensor electronically.
Resistance/Continuity Tests
1. Use a digital volt-ohmmeter and Rotunda Transmission Tester 007-00085 (part of Rotunda Transmission Tester kit 007-0085D) or equivalent and Transmission Range (TR) Sensor Cable "C" ("MLPS" Manual Lever Position Sensor Cable) 007-0086A or equivalent to perform Pinpoint Test D based on the DTCs that were displayed.
2. Perform services as indicated by the pinpoint tests. Always retest and road test vehicle after any service.
3. Set ohmmeter to 20k ohms range.
4. Connect ohmmeter COM jack to the SIGRTN jack.
5. Connect ohmmeter POS jack to the TR/MLP jack. LED turns OFF when circuit is open.
6. Move transmission range selector lever into each gear position. Record resistance at each position.
7. Refer to the chart for values.
8. If out of range, refer to Pinpoint Test D.
TR Sensor Resistance Chart:
Pinpoint Tests
NOTE: Prior to entering pinpoint tests, refer to any Technical Service Bulletins and OASIS messages for 4R44E/4R55E transmission concerns.
NOTE: Prior to entering pinpoint tests, the vehicle harness must be checked for continuity and shorts and the powertrain control module (PCM)( 1 2A650) must be checked for any concerns. Refer to Section 4A in the Powertrain Control/Emissions Diagnosis Manual8 for diagnosis and testing of the automatic transmission.
NOTE: If any non-transmission DTCs appear, service those codes first. They could affect the electrical operation of the transmission. Record and erase codes from continuous memory after service has been performed. After servicing any DTCs in the Quick Test, the Quick Test should be repeated.
NOTE: Check powertrain control module wiring harness for proper connections, bent or broken pins, corrosion, loose wires, proper routing, proper seals and their condition. Check the powertrain control module sensors and actuators for physical damage.
If DTCs are present while performing the On-Board Diagnostic, refer to On-Board Diagnostic Trouble Code Description Chart for the appropriate service procedure.