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Download this manual See also: Owner's Manual
2002 F-150 Workshop Manual
SECTION 307-01A: Automatic Transmission — 4R100
DIAGNOSIS AND TESTING
Diagnostics
Special Tool(s)
UV Leak Detector Kit
164-R0756 or equivalent
Transmission Fluid Pressure Gauge
307-004 (T57L-77820-A)
73 III Automotive Meter
105-R0057 or equivalent
E4OD Transmission Cable
418-F037 (007-00107) or equivalent
Breakout Box, EEC-V Control System
418-049 (T94L-50-EEC-V) 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
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
MLP-TR Cable
418-F107 (007-00111) or equivalent
Trans Tester TR/MLP Overlay and Manual
007-00131 or equivalent
Diagnosing an electronically controlled automatic transmission is simplified by using the following procedures. One of the most important things to remember is that
there is a definite procedure to follow. DO NOT TAKE SHORTCUTS OR ASSUME THAT CRITICAL CHECKS OR ADJUSTMENTS HAVE ALREADY BEEN MADE.
Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair
the concern the first time.
On-Board Diagnostics with Diagnostic Tool
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS21/~MUS~LEN/19/S...
Page 1 of 33
2002 F-150 Workshop Manual
Procedure revision date: 06/20/2001
9/17/2010
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Summary of Contents for Ford F-150 2002
- Page 1 2002 F-150 Workshop Manual Page 1 of 33 SECTION 307-01A: Automatic Transmission — 4R100 2002 F-150 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 06/20/2001 Diagnostics Special Tool(s) UV Leak Detector Kit 164-R0756 or equivalent Transmission Fluid Pressure Gauge 307-004 (T57L-77820-A) 73 III Automotive Meter 105-R0057 or equivalent E4OD Transmission Cable...
- Page 2 2002 F-150 Workshop Manual Page 2 of 33 NOTE: For detailed instruction and other diagnostic methods using the scan tool, refer to the NGS Tester Manual and the Powertrain Control/Emissions Diagnosis (PC/ED) manual . These quick tests should be used to diagnose the powertrain control module (PCM) and should be carried out in order. Quick Test 1.0-Visual Inspection Quick Test 2.0-Set Up Quick Test 3.0-Key On, Engine Off (KOEO)
- Page 3 2002 F-150 Workshop Manual Page 3 of 33 manual. NOTE: If a concern still exists after electrical diagnosis have been carried out , refer to Diagnosis By Symptom in this section. If DTCs appear while carrying out the on-board diagnostics, refer to the Diagnostic Trouble Code Chart for the appropriate procedure. Prior to entering pinpoint tests, refer to any TSBs and OASIS messages for transmission concerns.
- Page 4 2002 F-150 Workshop Manual Page 4 of 33 valves or damaged friction material. May flash TCIL. SSA, SSB or 3-4 shift error. Engine rpm drop not detected Incorrect gear selection depending on GO to Pinpoint Test P0783 Internal when 3-4 shift was commanded by failure mode and transmission range Transmission PCM.
- Page 5 2002 F-150 Workshop Manual Page 5 of 33 Control/Emissions Diagnosis (PC/ED) manual. P0730 BPP switch circuit BPP circuit failure. Failed off — TCC will not disengage when Refer to the Powertrain failed. brake is applied. Control/Emissions Diagnosis (PC/ED) manual. Shift solenoid circuit SSA circuit failed to provide Incorrect gear selection depending on GO to Pinpoint Test...
- Page 6 2002 F-150 Workshop Manual Page 6 of 33 P0717 Insufficient Input. PCM has detected an intermittent Harsh shifts, or erratic shifts. Set DTC, GO to Pinpoint Test TSS signal. May flash TCIL. P0718 TSS Signal Noisy. PCM has detected a noisy TSS Harsh shifts, or erratic shifts.
- Page 7 2002 F-150 Workshop Manual Page 7 of 33 Pin Number Circuit Function PCM Pin Not Used — SIG RTN TR3A Not Used — Not Used — FSD PWR FD — STR Control — Back Up — STR to INT — Turbine Shaft Speed Sensor (TSS) Harness Connector Pin Number Circuit Circuit Function...
- Page 8 2002 F-150 Workshop Manual Page 8 of 33 PARK 0.0 Volts In Between 1.3 - 1.8 Volts REVERSE 1.3 - 1.8 Volts In Between 1.3 - 1.8 Volts NEUTRAL NTRL 1.3 - 1.8 Volts In Between 1.3 - 1.8 Volts OVERDRIVE 1.3 - 1.8 Volts In Between...
- Page 9 2002 F-150 Workshop Manual Page 9 of 33 Commanded Obtained Gear Lever Position SSB ALWAYS OFF: PCM Gear Actual Gear Commanded Obtained Shift Solenoid Failure Mode Chart "Always On" Failed on due to powertrain control module (PCM) or vehicle wiring concerns, electrically or hydraulically stuck off. Gear Lever Position SSA ALWAYS ON: PCM Gear...
- Page 10 2002 F-150 Workshop Manual Page 10 of 33 Diagnostic Data Link Active Command Modes Output State Control (OSC) Trans-Bench Mode Does vehicle enter Trans-Bench Mode? REMAIN in Trans-Bench Mode. GO to REPEAT procedure to enter Trans-Bench Mode. If vehicle did not enter Trans-Bench Mode, REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis of PCM or NGS.
- Page 11 2002 F-150 Workshop Manual Page 11 of 33 GO to A4. GO to A5. A4 OSC TRANS-DRIVE MODE (GEAR OR TCC) Carry out OSC Transmission Drive Mode. Select GEAR for shift solenoids or follow procedures for GEAR as listed in this section. Select TCC for Torque Converter Clutch Solenoid.
- Page 12 2002 F-150 Workshop Manual Page 12 of 33 Select "ON". Press "SEND". Measure the voltage while cycling the solenoids ON and OFF. Listen for the solenoid to activate (click). Select "OFF", press "SEND". Does the voltage change? GO to A7. REPAIR the circuit.
- Page 13 2002 F-150 Workshop Manual Page 13 of 33 Check to make sure the transmission harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding. Select Diagnostic Data Link. Select PCM. Select PID/Data Monitor and Record. PIDs;...
- Page 14 2002 F-150 Workshop Manual Page 14 of 33 GO to B4. REPAIR the circuit. TEST the system for normal operation. B4 CHECK RESISTANCE OF TFT SENSOR Measure the resistance between pins 7 and 8 at the solenoid body connector. Record the resistance. Resistance should be approximately in the following ranges: Transmission Fluid Temperature °...
- Page 15 2002 F-150 Workshop Manual Page 15 of 33 Check to make sure the digital TR sensor harness connector is fully seated, terminals are fully engaged in connector and in good condition before proceeding. Apply the parking brake. Disconnect the shift cable/linkage from the manual lever. Verify that the TR Sensor Alignment Gauge fits in the appropriate slots.
- Page 16 2002 F-150 Workshop Manual Page 16 of 33 Digital TR Sensor TR PIDS TR_D, TR_V Move transmission range selector lever into each gear and stop. Observe the PIDs, TR_D, and TR_V (vehicle-dependent) while wiggling harness, tapping on sensor, or driving the vehicle. Use PIDs TR_D for DTCs P0705, P1704, and P1705. Use PIDs TR_V for DTC P0708.
- Page 17 2002 F-150 Workshop Manual Page 17 of 33 Install the EEC V Control System Breakout Box. CAUTION: Do not pry the connector. This will damage the connector and result in a transmission concern. Disconnect the digital TR sensor connector. Digital TR Sensor Measure the resistance between the TR sensor connector pin 2 harness side and the EEC V Control System Breakout Box pin 91.
- Page 18 2002 F-150 Workshop Manual Page 18 of 33 Are the resistances less than 5 ohms? GO to C8. REPAIR the circuits. TEST the system for normal operation. C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND OR POWER Measure the resistance between EEC V Control System Breakout Box pin 91 and TR sensor connector pin 10 and 12 harness side.
- Page 19 2002 F-150 Workshop Manual Page 19 of 33 Are the resistances greater than 10,000 ohms? GO to C9. REPAIR the circuits. TEST the system for normal operation. CLEAR DTCs. RERUN OBD Tests. C9 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL CIRCUITS Measure the resistance between EEC V Control System Breakout Box pins 64 and pins 34, 49, and 50.
- Page 20 2002 F-150 Workshop Manual Page 20 of 33 INSTALL a new PCM. TEST the system for normal operation. REPAIR the circuit. TEST the system for normal operation. C10 CHECK THE NON-PCM INTERNAL CIRCUITS OF SENSOR TRS-E Cable to Transmission TRS-E Cable to Digital TR Sensor Place the Digital TR Overlay onto Transmission Tester.
- Page 21 2002 F-150 Workshop Manual Page 21 of 33 Active Command Modes Output State Control (OSC) Trans-Bench Mode Does the vehicle enter the Trans-Bench Mode? REMAIN in Trans-Bench Mode. GO to REPEAT procedure to ENTER Trans-Bench Mode. If vehicle did not enter OSC, REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis of PCM or NGS.
- Page 22 2002 F-150 Workshop Manual Page 22 of 33 Is the voltage greater than 10 volts? GO to D4. REPAIR the circuit. TEST the system for normal operation. D4 ELECTRICAL SIGNAL CHECK Leave the positive lead connected to pin 11 and connect the negative lead to pin 12 harness side.
- Page 23 2002 F-150 Workshop Manual Page 23 of 33 Is the resistance within specifications? GO to D6. INSTALL a new solenoid body assembly. D6 CHECK SOLENOID FOR SHORT TO GROUND Measure and record the resistance between the EPC solenoid pins 11, 12 and ground. Is the resistance less than 10,000 ohms? INSTALL a new solenoid body assembly.
- Page 24 2002 F-150 Workshop Manual Page 24 of 33 Does vehicle enter PID/Data Monitor and Record? REMAIN in PID/Data. GO to REPEAT procedure to ENTER PID. If vehicle did not enter PID, REFER to thePowertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis of PCM or NGS. E2 DRIVE CYCLE TEST While monitoring the appropriate sensor PID, drive the vehicle so that the transmission upshifts and downshifts through all gears.
- Page 25 2002 F-150 Workshop Manual Page 25 of 33 and the appropriate sensor connector pin 1 harness side. For OSS, measure the resistance between pin 84 at the EEC V Control System Breakout Box and the appropriate connector sensor pin 1 harness side. Are all resistances less than 5 ohms? GO to E5.
- Page 26 2002 F-150 Workshop Manual Page 26 of 33 Record the resistance. Resistance should be between 781 and 1,979 ohms. Is the resistance within specification for the appropriate sensor? GO to E7. INSTALL a new sensor. E7 CHECK SENSORS FOR SHORT TO GROUND Measure the resistance between pin 1 and 2 of each sensor and ground.
- Page 27 2002 F-150 Workshop Manual Page 27 of 33 INSTALL a new solenoid and/or body. REFER to Diagnostic Trouble Code Charts in this section for code description. GO to F2 TRANSMISSION DRIVE CYCLE TEST Carry out transmission drive cycle test; refer to Transmission Drive Cycle Test in this section. Does the vehicle upshift and downshift OK? GO to F3.
- Page 28 2002 F-150 Workshop Manual Page 28 of 33 3. If the line pressure is not within specifications, carry out On-Board Diagnostics and GO to Pinpoint Test D, air pressure check, and clean, inspect and install a new main control system or pump as required. Line Pressure Chart Line Pressure —...
- Page 29 2002 F-150 Workshop Manual Page 29 of 33 Stall Speed Diagnosis Chart Range Possible Source Forward Clutch Overdrive One-Way Clutch Low One-Way Clutch Direct Clutch Overdrive One-Way Clutch Coast Clutch Reverse Clutch Forward Clutch Overdrive One-Way Clutch and Coast Clutch Intermediate Clutch Intermediate One-Way Clutch Band...
- Page 30 2002 F-150 Workshop Manual Page 30 of 33 3. Drive the vehicle through 8 to 10 cycles of 1/2 throttle, 1-2 upshifts to elevate the transmission temperature. Then proceed as follows: Park the vehicle on level ground. Allow the vehicle to sit for 30-60 minutes. Check and note the fluid level on the fluid level indicator with the engine off, in PARK.
- Page 31 2002 F-150 Workshop Manual Page 31 of 33 Item Part Number Description 7902 Torque converter assembly 7A248 Front pump seal 7A248 Front pump seal square-cut OD seal N805260-S Bolt and washer assembly 7G379 Washer 7A136 Pump gasket 7A020 Fluid level indicator 7A228 Fluid filler tube assembly 391308-S...
- Page 32 2002 F-150 Workshop Manual Page 32 of 33 If leakage is found by the solenoid body connector, refer to Main Control Valve Body — Accumulator Body, Solenoid Body in this section. Check the transmission sealing washers on the cooler bypass valve (CBV), fluid filler tube connection at the transmission case. If leakage is found, install a new short fluid inlet tube.
- Page 33 2002 F-150 Workshop Manual Page 33 of 33 housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, then at engine idle, occasionally shifting to the OVERDRIVE and REVERSE ranges to increase pressure within the transmission. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and inside the torque converter housing and front of the case.
