F4A42/F4A51 Operation, Diagnosis and Repair F4A42/F4A51 Operation, Diagnosis and Repair F4A42/F4A51 Operation, Diagnosis and Repair TABLE OF CONTENTS INTRODUCTION AND OBJECTIVES ................................................................... 1 F4A42 AND F4A51 AUTOMATIC TRANSAXLE OVERVIEW.................................. 2 ACRONYMS ...................................................................................................... 4 GENERAL DESCRIPTION ................................................................................... 5 MODULE 1 F4A42/F4A51 TRANSAXLE IDENTIFICATION................................. 7 IDENTIFICATION................................................................................................ 7 MODEL DESIGNATION....................................................................................... 7 AUTOMATIC TRANSMISSION FLUID .................................................................. 9 ACTIVITY 1.1 TRANSAXLE IDENTIFICATION ................................................. 10 MODULE 2 MECHANICAL COMPONENTS ........................................................ 11 MECHANICAL COMPONENTS .......................................................................... 11 TRANSAXLE CASE ........................................................................................... 11 TORQUE CONVERTER ..................................................................................... 13 MANUAL CONTROL LEVER.............................................................................. 14 VALVE BODY LOCATION.................................................................................. 15 ACCUMULATORS ............................................................................................. 18 ACCUMULATOR SPRINGS................................................................................ 18 ACTIVITY 2.1 VALVE BODY REMOVAL ........................................................... 19 TASK ONE: VALVE BODY REMOVAL................................................................ 19 TASK TWO: STRAINER AND 2ND BRAKE SEAL REMOVAL ................................ 20 TASK THREE: ACCUMULATOR REMOVAL ....................................................... 21 TASK FOUR: MANUAL LEVER REMOVAL ........................................................ 21 SPEEDOMETER GEAR (2001 MODEL YEAR WITH VSS) ................................... 22 OIL PUMP......................................................................................................... 23 OIL FILTER ...................................................................................................... 24 ACTIVITY 2.2 TRANSAXLE DISASSEMBLY ...................................................... 25 TASK ONE: CASE SEPARATION ....................................................................... 25 TASK TWO: OIL FILTER, OIL PUMP AND INPUT SHAFT REMOVAL................... 25 TASK THREE: CLUTCH AND GEARTRAIN REMOVAL ....................................... 26 TASK FOUR: OUTPUT SHAFT REMOVAL.......................................................... 27 CLUTCHES ...................................................................................................... 30 Underdrive Clutch 30 Reverse Clutch and Overdrive Clutch 32 Balance Pistons 34 BRAKES (HOLDING CLUTCHES) ...................................................................... 35 Low/Reverse Brake 35 Second Brake 36 One-Way Clutch 37 PLANETARY GEAR SETS .................................................................................. 38 DIFFERENTIAL................................................................................................. 39 Transfer Drive Gear 40 Output Shaft/Transfer Driven Gear 41 MODULE 3 POWERFLOW ................................................................................ 42 i F4A42/F4A51 Operation, Diagnosis and Repair PARK AND NEUTRAL........................................................................................42 REVERSE .........................................................................................................43 FIRST GEAR .....................................................................................................44 SECOND GEAR ................................................................................................45 THIRD GEAR ....................................................................................................46 FOURTH GEAR.................................................................................................47 ACTIVITY 3.1 PLANETARY CARRIER...............................................................48 CLUTCH AND GEARTRAIN ...............................................................................49 ACTIVITY 3.2 GEAR RATIOS ...........................................................................50 ACTIVITY 3.3 TRANSAXLE ASSEMBLY ............................................................51 TASK ONE: TRANSFER GEAR INSTALLATION...................................................51 TASK TWO: L/R AND 2ND BRAKE SET-UP.........................................................51 TASK THREE: OUTPUT SHAFT INSTALLATION AND SETUP .............................53 TASK FOUR: PARKING PAWL INSTALLATION ..................................................54 TASK FIVE: PLANETARY CARRIER INSTALLATION ...........................................54 TASK SIX: UNDERDRIVE AND OVERDRIVE/REVERSE CLUTCH SETUP ..........55 TASK SEVEN: OIL PUMP INSTALLATION ..........................................................56 TASK EIGHT: CONVERTER HOUSING INSTALLATION ......................................56 MODULE 4 VALVE BODY/HYDRAULIC CONTROL SYSTEM...............................58 CHECK BALLS..................................................................................................60 PRESSURE CONTROL VALVES AND SOLENOID VALVES .................................62 Operation 62 REGULATOR VALVE.........................................................................................63 TORQUE CONVERTER PRESSURE CONTROL VALVE.......................................64 DAMPER CLUTCH CONTROL VALVE AND DAMPER CLUTCH SOLENOID VALVE .........................................................................................................................66 Operation 66 HYDRAULIC OPERATION..................................................................................68 Park and Neutral 68 Reverse 70 First Gear 72 Second Gear 74 Third Gear 76 Fourth Gear 78 MANUAL VALVE ...............................................................................................80 Operation (P/N) 80 Operation (R) 82 Operation (D) 84 SWITCH VALVE ................................................................................................86 FAIL-SAFE VALVE A .........................................................................................90 FAIL-SAFE VALVE B.........................................................................................90 ACTIVITY 4.1 VALVE BODY DISASSEMBLY......................................................91 ACTIVITY 4.2 HYDRAULIC OPERATION ...........................................................92 MODULE 5 ELECTRONIC CONTROL SYSTEM...................................................97 ELECTRONIC COMPONENTS ...........................................................................97 ii F4A42/F4A51 Operation, Diagnosis and Repair POWERTRAIN CONTROL MODULE (PCM) ........................................................ 98 PCM CONNECTOR ........................................................................................... 99 SYSTEM CONSTRUCTION DIAGRAM.............................................................. 100 SENSORS AND ACTUATORS .......................................................................... 101 INPUT SHAFT SPEED SENSOR/OUTPUT SHAFT SPEED SENSOR ................. 102 Circuit Operation 103 Vehicle Speed Signal 103 ACTIVITY 5.1 INPUT SHAFT AND OUTPUT SHAFT SPEED SENSORS ............. 104 CRANKSHAFT POSITION (CKP) SENSOR ........................................................ 106 Circuit Operation 106 ACTIVITY 5.2 CRANKSHAFT POSITION SENSOR........................................... 107 THROTTLE POSITION SENSOR ...................................................................... 108 Circuit Operation 108 Throttle Position Sensor Adjustment 108 ACTIVITY 5.3 THROTTLE POSITION SENSOR ............................................... 110 TPS WIRE COLOR 110 VOLTAGE READING 110 ATF TEMPERATURE SENSOR ........................................................................ 112 Circuit Operation 112 ATF TEMPERATURE CONTROL...................................................................... 113 ACTIVITY 5.4 AUTOMATIC TRANSAXLE FLUID TEMPERATURE SENSOR...... 114 Park/Neutral Position Switch 115 Circuit Operation 115 ACTIVITY 5.5 TRANSAXLE RANGE SWITCH/PARK/ NEUTRAL POSITION SWITCH (INHIBIT SWITCH) CONTINUITY CHECK .......................................... 116 TRANSAXLE CONTROL .................................................................................. 118 ACTIVITY 5.6 PARK/NEUTRAL POSITION SWITCH AND CONTROL CABLE ADJUSTMENT............................................................................................... 119 A/C DUAL PRESSURE SWITCH...................................................................... 120 Circuit Operation 120 STOPLIGHT SWITCH ...................................................................................... 120 Circuit Operation 121 AUTO-CRUISE CONTROL..............................................................................