Chrysler 2005 Sebring User manual

We l c o m e
2005 JR Sebring/Stratus Sedan and Se bring Conve rtible
Te c h n i c a l Pu bl i c a t i o n s
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Service Manual
Powertrain
Body
Chassis
Transmission

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1 SYSTEMCOVERAGE ...............................................1
1.2 SIX -STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATIONOFSYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 GENERALDESCRIPTION............................................1
3.2 FUNCTIONALOPERATION...........................................1
3.2.1 AUTOSTICK FEATURE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.2 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUSOILTEMPERATURES. ..............................2
3.3 DIAGNOSTICTROUBLECODES ......................................2
3.3.1 HARDCODE...............................................3
3.3.2 ONETRIPFAILURES........................................3
3.3.3 INTERMITTENTCODE.......................................3
3.3.4 STARTSSINCESETCOUNTER...............................3
3.3.5 TROUBLECODEERASURE..................................3
3.3.6 QUICKLEARN .............................................3
3.3.7 CLUTCHVOLUMES.........................................4
3.3.8 EATXDTCEVENTDATA.....................................4
3.3.9 ELECTRONIC PINION FACTOR (IF APPLICABLE) . . . . . . . . . . . . . . . .4
3.4 USING THE DRBIII!.................................................5
3.5 DRBIII!ERRORMESSAGES .........................................5
3.5.1 DRBIII!DOES NOT POWER UP (BLANK SCREEN). . . . . . . . . . . . . . .5
3.5.2 DISPLAYISNOTVISIBLE....................................5
3.5.3 SOME DISPLAY ITEMS READ "---".............................5
3.6 TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND FWD ADAPTER
(MILLERTOOL#8333-1A) ............................................5
4.0 DISCLAIMERS, SAFETY, AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.1 DISCLAIMERS......................................................6
4.2 SAFETY...........................................................6
4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2.2 VEHICLE PREPARATION FOR TESTING . . . . . . . . . . . . . . . . . . . . . . .6
4.2.3 SERVICINGSUB-ASSEMBLIES ...............................6
4.2.4 DRBIII!SAFETYINFORMATION ..............................6
4.3 WARNINGS........................................................7
4.3.1 VEHICLEDAMAGEWARNINGS...............................7
4.3.2 ROAD TESTING A COMPLAINT VEHICLE. . . . . . . . . . . . . . . . . . . . . . .7
4.3.3 ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) . . . . .8
4.4.4 BULLETINSANDRECALLS...................................8
5.0 REQUIREDTOOLSANDEQUIPMENT ......................................8
6.0 GLOSSARYOFTERMS...................................................8
6.1 ACRONYMS .......................................................8
6.2 DEFINITIONS ......................................................9
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .11
i

TABLE OF CONTENTS - Continued
TRANSMISSION - NGC
P0122-THROTTLE POSITION SENSOR/APPS LOW . . . . . . . . . . . . . . . . . . . . . . . . . .12
P0123-THROTTLE POSITION SENSOR/APPS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .14
P0124-THROTTLE POSITION SENSOR/APPS INTERMITTENT . . . . . . . . . . . . . . . . .16
P0218-HIGH TEMPERATURE OPERATION ACTIVATED . . . . . . . . . . . . . . . . . . . . . . .18
P0562-LOWBATTERYVOLTAGE..........................................20
P0602-CONTROL MODULE PROGRAMMING ERROR. . . . . . . . . . . . . . . . . . . . . . . . .25
P0604-INTERNALTCM ..................................................26
P0605-INTERNALTCM ..................................................26
P0613-INTERNALTCM ..................................................26
P0706-CHECKSHIFTERSIGNAL..........................................27
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE . . . . . . . . . . . . .35
P0712-TRANSMISSION TEMPERATURE SENSOR LOW. . . . . . . . . . . . . . . . . . . . . . .38
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . .41
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT . . . . . . . . . . . . .45
P0715-INPUTSPEEDSENSORERROR....................................47
P0720-OUTPUTSPEEDSENSORERROR..................................51
P0725-ENGINE SPEED SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
P0731-GEARRATIOERRORIN1ST.......................................57
P0732-GEARRATIOERRORIN2ND.......................................59
P0733-GEARRATIOERRORIN3RD.......................................62
P0734-GEARRATIOERRORIN4TH.......................................65
P0736-GEARRATIOERRORINREVERSE..................................68
P0740-TCCOUTOFRANGE..............................................70
P0750-LRSOLENOIDCIRCUIT............................................72
P0755-2/4SOLENOIDCIRCUIT ...........................................76
P0760-ODSOLENOIDCIRCUIT...........................................80
P0765-UDSOLENOIDCIRCUIT ...........................................84
P0841-LR PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . .92
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
P0870-OD HYDRAULIC PRESSURE TEST FAILURE .........................101
P0871-OD PRESSURE SWITCH SENSE CIRCUIT ...........................106
P0884-POWERUPATSPEED............................................110
P0888-RELAYOUTPUTALWAYSOFF .....................................111
P0890-SWITCHEDBATTERY ............................................116
P0891-TRANSMISSION RLY ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
P0897-WORN OUT/BURNT TRANSAXLE FLUID.............................122
P0944-LOSS OF PRIME.................................................124
P0952-AUTOSTICK INPUT CIRCUIT LOW..................................127
P0992-2-4/OD HYDRAULIC PRESSURE TEST FAILURE ......................130
P1652-SERIAL COMMUNICATION LINK MALFUNCTION......................132
P1684-BATTERY WAS DISCONNECTED ...................................134
P1687-NO COMMUNICATION WITH THE MIC ..............................137
P1694-BUS COMMUNICATION WITH ENGINE MODULE......................139
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION ..............140
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION................144
P1790-FAULT IMMEDIATELY AFTER SHIFT ................................148
P1793-TRD LINK COMMUNICATION ERROR ...............................149
P1794-SPEED SENSOR GROUND ERROR ................................150
P1797-MANUAL SHIFT OVERHEAT .......................................152
*BACKUP LAMPS COME ON WHILE SHIFTER IS NOT IN REVERSE POSITION. .154
*BACKUP LAMPS INOPERATIVE .........................................155
ii

TABLE OF CONTENTS - Continued
*NO MANUAL AUTOSTICK OPERATION ...................................157
*PRNDL FAULT CLEARING PROCEDURE..................................159
*TRANSMISSION NOISY WITH NO DTC’S PRESENT ........................160
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S ..........................161
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP ..................162
VERIFICATION TESTS
VERIFICATION TESTS ..................................................163
8.0 COMPONENT LOCATIONS ..............................................165
8.1 AUTOSTICK (IF EQUIPPED) ........................................165
8.2 CONTROL MODULE LOCATIONS....................................165
8.3 PRESSURE PORT LOCATIONS .....................................165
8.4 TRANSMISSION COMPONENT LOCATIONS ..........................166
9.0 CONNECTOR PINOUTS ................................................167
AUTOSTICK SWITCH - NATURAL 4 WAY ..................................167
DATA LINK CONNECTOR - BLACK 16 WAY ................................167
INPUT SPEED SENSOR - GRAY 2 WAY ...................................167
LEFT BACK-UP LAMP - BLACK 2 WAY ....................................167
FUSES (PDC) .........................................................169
POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 38 WAY ..............170
POWERTRAIN CONTROL MODULE C2 - BLACK/ORANGE 38 WAY ............171
POWERTRAIN CONTROL MODULE C3 - BLACK/NATURAL 38 WAY............172
10.0 SCHEMATIC DIAGRAMS................................................173
10.1 EATX 40/41TE ....................................................173
10.2 NGC 40/41TE ....................................................174
11.0 CHARTS AND GRAPHS ................................................175
11.1 TRANSMISSION RANGE SENSOR STATES ...........................175
11.2 PRESSURE SWITCH STATES.......................................175
11.3 SOLENOID APPLICATION CHART ...................................176
11.4 SHIFT LEVER ERROR CODES......................................176
11.5 TRANSMISSION TEMPERATURE SENSOR ...........................176
iii

NOTES
iv

1.0 INTRODUCTION
NGC CONTROLLER
For 2005 model year, J R veh icles will int egrat e
the Transmission Contr ol Module a n d P ower t r ain
Con t r ol Module in t o a single con t r ol m odu le. Th is
new m odu le is the Next Gen eration Con t roller for
Da im lerCh r ysler an d will be referred t o a s t h e
Powertrain Con t r ol Module (P CM).
Some of the ch a n ges you will see are several new
Dia gn ost ics Tr ou ble Codes a n d su ppor t in g dia gn os-
tic pr ocedures which reflect t h e n ew combin ed m od-
ule tech n ology. The PCM will ha ve fou r color coded
connect or s, C1 through C4, (C1-BLK, C2-GRAY, C3-
WHITE , C4-GRE E N), ea ch P CM con n ector will h ave
38 pin s. Two new t ools a r e u sed for probin g and
repa ir in g the new P CM connect or s. Miller tool
#3638, a n d Miller t ool #8815. Miller tool #3638 is
design ed t o release the pins fr om the PCM h a r n ess
connect or s. You m u st u se t h e Miller t ool #3638 to
release the harn ess con n ector ter m in a ls or h a rness
connect or or t erminal damage will occu r. Miller tool
#8815 wa s designed for pr obing t h e P CM harness
connect or s. You m u st u se Miller tool #8815 for prob-
ing th e P CM ter m in a ls or da m a ge t o the ter m in a l
will occur resu lt in g in a poor ter m in a l to pin con n ec-
tion. Ther e a r e a lso new Verification test s an d mod-
ule repla cemen t pr ocedures for t h e n ew PCM.
Th e procedu r es contained in t his m a nual inclu de
all of th e specifications, instructions, and gr a ph ics
needed to diagnose,
*40/41TE (EATX) Electronic Automatic Transmis-
sion problems
*40/41TE (NGC) E lectronic Au t om a t ic Tr a n sm is-
sion problems
Th e diagnostics in t h is m a n u a l ar e ba sed on t h e
failure condition or symptom being pr esen t a t t h e
time of dia gn osis.
When repa ir s a re r equ ir ed, refer to the appropr i-
ate volume of t h e service ma n u a l for the proper
rem ova l a n d r epair pr ocedure.
Dia gn ost ic pr ocedures ch a n ge every year. New
diagnostic syst ems may be added a n d/or carryover
system s m ay be en h a n ced. READ TH IS MANUAL
BE F ORE TRYING TO DIAGNOSE A VEHICLE
TROUBLE CODE . It is recommen ded t h a t you
review the en t ir e m a n u al t o becom e fa m ilia r with
all new and cha n ged diagnostic procedu r es.
Th is book r eflect s m a n y su ggested ch a nges from
rea ders of pa st issues. After using this book, if you
have any comm ents or recom m endations, please fill
out the form at the ba ck of t h e book a nd ma il it ba ck
to us.
1.1 SYSTEM COVERAGE
Th e diagnostic pr ocedure m a n u a l covers a ll 2005
J R veh icles equipped with a 40/41TE transaxle.
1.2 SIX -STEP TROUBLESHOOTING
PROCEDURE
Dia gn osis of t h e 40/41TE Elect r on ic t r a n sa xle is
done in six basic steps:
ver ifica t ion of com pla in t
ver ifica t ion of a n y r elated sym pt om s
symptom analysis
problem isolation
repa ir of isola t ed pr oblem
ver ifica t ion of pr oper oper a t ion
2.0 IDENTIFICATION OF
SYSTEM
Th e 40/41TE Transmission family ca n be iden t i-
fied th r ou gh a visu a l inspect ion . Con fir m t h e pr e-
sen se of a Solenoid/Pressu r e Switch Assem bly,
Transmission Ra n ge Sen sor, Inpu t Speed Sensor
and Ou t pu t Speed Sensor all loca t ed on the sa m e
side of the t r a n sm ission ca se. Refer to the Ser vice
Information for tra n sm ission ID tag descriptions.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
Th e 40/41TE elect r onic tra n sa xle is a con ven-
tional t r a n sa xle in that it uses hydr a u lica lly ap-
plied clu t ch es to sh ift a pla n etary gear t r a in . How-
ever, the elect r on ic cont rol syst em r eplaces many of
the mechanical and hydraulic com pon ents used in
conven t ion a l t r a nsm ission va lve bodies.
3.2 FUNCTIONAL OPERATION
Th e 40/41TE electronic tra n sa xle h a s a fully
adaptive control syst em. The system per for m s it s
functions ba sed on continuous rea l-t im e sen sor
feedba ck in for m a t ion . The con t r ol syst em au t om a t -
ically ada pt s to changes in engine per for ma nce and
friction elemen t va r ia t ion s to provide con sist ent
shift qu a lit y. The control system ensures th a t clut ch
oper a t ion du r in g u psh ift in g a nd down sh ift in g is
more respon sive without increa sed h a rsh ness.
1
GENERAL INFORMATION

Th e con t r ol module continuou sly checks for elec-
trical pr oblem s, m echanical pr oblem s, a n d som e
hydraulic problems. When a pr oblem is sensed, t h e
control modu le st or es a dia gn ost ic trouble code.
Some of t hese codes ca u se t h e t r a n sa xle t o go into
Lim p-in or default mode. While in th is m ode, elec-
trical power is removed fr om t h e transaxle, de-
en ergizing the t r a n sm ission con t r ol r elay, and sole-
noid pa ck. When t h is ha ppens, the on ly t r a n sa xle
mech a n ica l fu n ction s a r e:
Park and Neutral
Reverse
Secon d Gea r
No upshifts or down sh ift s a r e possible. Th e posi-
tion of t h e m a n u a l valve alone allows t h e t h r ee
ranges t h at are a va ila ble. Although vehicle per for-
mance is seriously degr a ded wh ile in this mode, it
allows the owner t o dr ive t h e vehicle in for ser vice.
On ce t h e DRBIII#is in the Transmission portion
of the dia gn ost ic pr ogr a m , it consta n t ly monitors
the control modu le t o see if t h e syst em is in Lim p-in
mode. If the t r a n sa xle is in Limp-in m ode, the
DRBIII#will flash t h e r ed LED.
3.2.1 AUTOSTICK FEATURE (IF
EQUIPPED)
Th is fea t u r e a llows t h e dr iver t o manually sh ift
the transa xle wh en the shift lever is moved t o th e
AutoStick posit ion . Wh en in Au toSt ick mode, t h e
instrumen t clu st er displays t h e cu r r ent gea r.
3.2.2 TRANSMISSION OPERATION AND
SHIFT SCHEDULING AT VARIOUS
OIL TEMPERATURES.
Th e transmission covered in this manual h a s
uniqu e sh ift schedu les depen din g on t h e t emper a -
ture of t h e t ra nsmission oil. The shift sch edule is
modified to ext end t h e life of the tra n sm ission while
oper a t in g u n der ext r eme con dit ion s.
Th e oil tem perature is m ea su r ed with a Temper-
ature Sen sor on t h e 40/41TE transmission. Th e
Temper a t u r e Sensor is an integr a l componen t of t he
Transmission Range Sen sor (TRS). If the Tem pera-
ture Sen sor is fa u lt y, the transmission will defa u lt
to a calcula t ed oil t emper a t u r e. Oil t emper a t u r e
will t h en be ca lcu la t ed th r ou gh a com plex hea t
transfer equ a tion u sin g engine coola n t t emper a -
ture, batter y/a mbien t t emper a t u r e, and engine off
time. Th ese inputs a r e r eceived fr om t h e P CI bus
per iodica lly a n d u sed to in it ia lize t h e oil tem pera-
ture at st art u p. Once the en gin e is start ed, t h e
control module u pda tes t h e tra n sm ission oil tem -
per a t u r e based on t or que conver t er slip speed, ve-
hicle speed, gea r, and engine coolant tem perature to
det ermine an est im a t ed oil tem perature during
veh icle oper a t ion . Veh icles using calculated oil t em-
per a t u r e, ar e rea son a bly a ccu r a t e, during n or m a l
oper a t ion . H owever, if a tra n sm ission is overfilled, a
transmission oil cooler becom es restricted, or if a
customer dr ives a ggr essively in low gear, t h e ca lcu -
lated oil t emper a t u r e will be in a ccu r a te. Con se-
qu ently th e sh ift sch edule selected may be inappro-
priate for the curren t con dit ion s.
3.3 DIAGNOSTIC TROUBLE CODES
Dia gn ost ic t r ou ble codes (DTC’s) a r e codes st or ed
by th e P CM (NGC) or TCM (E ATX) depen din g on
application a n d h elp diagnose Tra n sm ission pr ob-
lems. They are viewed using the DRBIII#scan tool.
Alwa ys begin by per for m in g a visual inspect ion of
the wiring, connect or s, cooler lin es and t he trans-
mission. Any obviou s wiring problems or leaks
should be r epa ir ed pr ior t o performing any diagnos-
tic t est pr ocedur es. Some en gin e dr iveabilit y pr ob-
lem s ca n be misin t erpret ed as a transm ission prob-
lem . Ensure that the en gin e is ru n n in g proper ly
and n o en gin e DTC’s a r e pr esen t th a t cou ld cause a
transmission complaint.
If t h ere is a bu s comm un ica tion pr oblem , trouble
codes will not be accessible until th e bus pr oblem is
fixed. The DRBIII#will display an appropriate
message.
Each dia gn ost ic t r ou ble code is dia gn osed by
followin g a specific t esting sequen ce. Th e dia gn ost ic
test pr ocedures con t a in st ep-by-st ep instr u ct ion s
for deter m in in g the cause of a t ra nsmission diag-
nostic trouble code. P ossible sources of t h e code a r e
checked a n d eliminated on e by on e. It is n ot n eces-
sary to per for m a ll of t h e test s in t h is book to
diagnose an individual code. These t ests a r e based
on the pr oblem being pr esen t a t t he time t h a t t h e
test is run.
All testing should be done w ith a fully charged
ba tt e ry.
If the control modu le r ecords a DTC th a t will
adver sely affect veh icle emissions, it will r equ est
(via the communication bu s) t h a t t h e P CM illum i-
nate the Ma lfu n ction Indicat or La m p (MIL). Al-
though t h ese DTC’s will be st or ed immedia tely a s a
1 trip fa ilu r e, it m a y take u p t o five minutes of
accumulated t r ou ble confirmation set the DTC and
illuminate the MIL. Three con secutive successfu l
OBDII (E URO STAGE III OBD) t r ips or clearing
the DTC’s with a dia gn ost ic t ool (DRBIII#or equ iv-
alent) is required to extinguish the MIL. When the
Transmission Con t r ol system r equ ests that the
PCM illuminate the MIL, the PCM sets a DTC
P0700 ($89) to a lert the tech n icia n t h a t t h ere are
DTC’s in t h e Tra n sm ission Control System . You
must also erase the DTC P0700 in the PCM, in
order t o extinguish the MIL.
2
GENERAL INFORMATION

3.3.1 HARD CODE
Any Diagnostic Trouble Code (DTC) that is set
wh enever the syst em or componen t is mon it or ed is
a HARD code. Th is m eans th a t th e problem is t h ere
every time t h e Tr a n sm ission Con t r ol Syst em ch ecks
that system or com pon ent. Some codes will set
immedia t ely at star t u p a n d ot h ers will requ ir e a
road test u n der specific conditions. It m u st be
det ermined if a code is repeat a ble (H a r d) or in t er-
mitten t befor e a t t empting diagnosis.
3.3.2 ONE TRIP FAILURES
A One Trip F a ilu r e, when r ead fr om t h e Tr a n s-
mission Control System , is a h a r d OBDII (EURO
STAGE III OBD) code that has not matured for th e
full 5 min u t es to a h a r d fa ult . This applies t o codes
that will only set a ft er 5 minutes of su bstituted gear
oper a t ion .
3.3.3 INTERMITTENT CODE
A diagnostic t r ou ble code tha t is not t here every
time the Transmission Con t r ol System ch ecks t h e
circuit or function is a n a in t erm it t ent code. Som e
inter m it t ent codes a r e ca u sed by wir in g or con n ec-
tor problems. H owever inter m it t ent gea r r atio
codes a r e usua lly ca u sed by inter m it t ent h ydr a u lic
sea l leaka ge in the clu t ch a n d/or a ccu m u la t or cir-
cuits. Problems t h a t com e a n d go like t h is a r e t h e
most difficult to diagnose, t h ey must be looked for
under t h e specific conditions t h a t ca u se t h em.
3.3.4 STARTS SINCE SET COUNTER
For t h e m ost r ecen t code, the Starts Sin ce Set
counter counts t he n um ber of times t h e vehicle has
started sin ce it wa s la st set. Th e counter will count
up t o 255 st a r t s. Not e t h a t t h is code on ly applies t o
the la st or m ost r ecen t code set.
When t h ere are n o dia gn ost ic t r ou ble codes st or ed
in mem or y, t he DRBIII#will display NO DTC’S
PRE SE NT and t h e reset coun t er will show
"STARTS SINCE CLE AR = XXX
Th e nu m ber of starts helps deter m in e if the
diagnostic trouble code is ha r d or in t ermitten t.
– If t h e cou n t is less t h a n 3, th e code is u su a lly a
hard code.
– If t h e cou n t is gr eater t h a n 3, it is con sidered
an inter m it t ent code. This m eans that the
en gin e h a s been started m ost of t h e t im e
wit h ou t t h e code r ecurring.
3.3.5 TROUBLE CODE ERASURE
A Dia gn ost ic t r ou ble code will be clea red fr om
control m odu le mem or y if it has n ot r eset for 40
wa r m -u p cycles.
A warm-up cycle is defined a s su fficient vehicle
oper a t ion su ch t h a t th e coolant tem pera t u r e has
risen by a t least 22°C (40° F ) fr om engine st a r t in g
and rea ch es a minimum t emper a t ur e of 71°C
(160° F ).
Th e Malfun ct ion In dica t or Lamp (MIL) will tu r n
off after 3 good trips or wh en the DTC’s a r e cleared
from t he con t r ol m odu le.
3.3.6 QUICK LEARN
Th e Quick Lea r n fu n ct ion cu st om izes a da pt ive
paramet ers of t h e con t r ol module to th e t r a n sm is-
sion character ist ics of a veh icle. Th is gives the
customer improved "a s r eceived"shift quality com-
pared t o th e initial para m eter s st or ed in the cont r ol
module.
Not es a bout Qu ick Learn Fea t u res
Th e n a t u r e of t h e Quick Lea r n fu n ct ion requ ir es
that cer t a in fea t u r es must be t a ken in t o consider-
ation.
> Quick Lea r n should gen erally not be used as a
repa ir pr ocedur e unless dir ected by a r epair or
diagnostic procedu r e. If the transmission sys-
tem is exhibit in g a pr oblem t h a t you t h in k is
caused by a n in va lid CVI, you sh ou ld t r y to
relearn the value by per for m in g t h e a ppr opr i-
ate driving ma n euver s. In m ost cases, if Quick
Learn makes a vehicle shift better, th e vehicle
will ret u r n with t h e sa me problem.
> Befor e performing Qu ick Lea r n , it is impera-
tive that t h e vehicle be sh ift ed in t o OD wit h
the engine r u n n in g and t h e oil level set to the
correct level. This st ep will pu r ge air from the
clutch circuits to pr even t erroneou s clu t ch
volume values, wh ich cou ld ca u se poor initia l
shift qu a lit y.
> If a new contr ol module is inst a lled on a
veh icle with a H OT en gin e, Qu ick Lea r n will
cause the control module to report a cold
calculated oil temper a t ur e. Th is r equ ir es
monitoring the ca lcu la ted oil t emper a t u r e us-
ing the DRBIII#. If t h e t emper a t ur e is below
15 C (60° F) , th e t r a n sm ission must be run at
idle or driven in gear until t h e tem perature
goes above 15 C (60° F ). If th e temperature is
above 93C (200° F), th e t r a n sm ission must
cool to below 93 C (200° F).
> F ir st gear is en ga ged in overdrive a ft er Qu ick
Learn is com pleted. Place the veh icle in par k
after performing Qu ick Learn.
Th e Quick Lea r n fu n ct ion sh ou ld be per for m ed:
– Upon in st a lla t ion of a new service control
module
– After repla cemen t or r ebu ild of in t ernal t ra ns-
mission com pon ent s or t h e t or que conver ter
– If on e or more of t h e clu t ch volumes in dexes
(CVI’s) con t a in skewed rea din gs beca u se of
abn or m a l con dit ion s.
3
GENERAL INFORMATION

To per for m the Qu ick Lea r n pr ocedure, the fol-
lowin g con dit ion s must be m et.
– It is im perative that the veh icle be shifted in t o
OD with the en gin e r u n n in g and t h e oil level
set to t h e cor r ect level. Th is step will pu rge t h e
air in the clutch circuits to pr even t erroneou s
clutch volume values, which could ca u se poor
initial shift qua lit y.
– Pla ce the selector lever in neu t r a l.
–Thebrakesmustbeapplied.
–Theenginemustbeidling.
– Th e th rot tle a ngle (TP sensor) m u st be less
than 3 degrees.
– Th e sh ift lever posit ion m u st st a y in n eutral
until prompted t o sh ift in t o OD.
– Th e sh ift lever m u st st ay in OD aft er th e "Shift
to Overdrive"pr om pt until the DRBIII#indi-
cates t h e pr ocedure is com plete.
– Th e oil tem pera t u r e m u st be bet ween 15 C
(60°) and 93 C (200° F).
NOTE: The above conditions must be
maintained during the procedure to keep the
procedure from being aborted.
Th e Quick Learn pr ocedure is perform ed with t h e
DRBIII#by selecting "Transmission"system then
"Miscellaneou s"fu n ct ion s, t h en "Qu ick Lea rn". Fol-
low the procedu r e in st r u ct ion s displayed on the
DRBIII#.
3.3.7 CLUTCH VOLUMES
Theory of Operation: The volumes of the trans-
mission flu id n eeded to apply t h e friction elem ents
are cont in u ou sly mon it or ed an d learned for a da p-
tive controls. As t h e clu t ch friction m a t erial wea r s,
the volume of fluid n eeded t o a pply the clutch
increa ses. Th e followin g a r e t ypica l clu t ch volu m es,
the clutches m a y be damaged if the volumes a r e
grea t er or less th a n t h e specified below:
Th e LR clutch volume is u pda t ed when doin g a 2-1
or 3-1 coa st down shift. Th e tran sm ission t emper a -
ture must be between 21-49 C (70-120° F ). Th e
clutch volu m e sh ould be between 35 and 83.
Th e 2/4 clutch volume is u pda t ed when doin g a 1-2
shift. The transmission t emper a ture must be above
43 C (110° F). Th e clu t ch volu m e sh ou ld be between
20 and 77.
Th e OD clutch volum e is updated when doin g a 2-3
shift. The transmission t emper a ture must be above
43 C (110° F). Th e clu t ch volu m e sh ou ld be between
40 and 150.
Th e UD clutch volume is u pda ted when doin g a 4-3
or 4-2 shift. The transmission t emper a t u r e m u st be
above 43 C (110° F ). Th e clu t ch volume should be
between 24 and 70.
Tra n s m i s s i o n E ffe c t s : These CVIs t h a t a r e ou t of
range are u su a lly set with other DTC’s, wh ich
indicates an in t ernal t r a n sm ission pr oblem .
Possible Causes:
> Clutch pa ck clea r a n ce ou t of spec
> Sn ap ring out of position or br oken
> Broken r eturn spring
> H ydr aulic leak in t o clutch circuit wit h n ear-zer o
volume
3.3.8 EATX DTC EVENT DATA
EATX DTC E VE NT DATA can be used as a
diagnostic aid wh en exper iencing Elect r on ic Tra n s-
missions wit h in t ermitten t pr oblem s. Wh en a Dia g-
nostic Tr ou ble Code (DTC) is set , th e vehicles trans-
mission inputs a r e st or ed in t h e con t r oller mem or y
and are retrievable with the DRBIII#. This in for-
mation can be helpfu l when a DTC can n ot be
duplicated.
Th e E ATX DTC EVENT DATA is loca t ed in the
DRBIII#, u n der the Tra n sm ission syst em men u , in
the su b-screen Miscellaneou s. It is a good practice
to docu m ent th e E ATX DTC E VE NT DATA before
beginning any diagnostic or ser vice pr ocedure.
A thorough under st a n din g of h ow t he t ra nsmis-
sion wor ks is ben eficial in order t o inter pr et the
data cor r ectly. These skills a r e n ecessa ry in or der to
avoid a n in cor r ect diagnosis.
A MASTERTECH video and r efer ence book wa s
produced in J anuary 2002 t h a t explains m a n y of
the fea t u r es of the EATX DTC E VE NT DATA wit h
several examples on how to in t erpret t h e in for m a -
tion a n d su ggested t r a in in g ma t erial t o help u n der-
stand a ll t h e specifics.
EATX DTC EVENT DATA ca n only be er a sed by:
1. Discon n ecting the batter y.
2. Per for m in g a DRBIII#QUICK LE ARN proce-
dure.
3. Reprogramming the NGC/E ATX con tr oller.
Erasing Transmission DTCs does n ot clear the
EATX DTC EVENT DATA.
3.3.9 ELECTRONIC PINION FACTOR (IF
APPLICABLE)
Th e t r ansmission output speed sign a l supplies
distance pulses t o t h e con t r ol module, wh ich are
used t o calculate speed a n d m ileage. A pin ion factor
is st or ed in the contr ol m odu le in or der to pr ovide
the appropriate dista n ce pu lses for other vehicle
system s. The pin ion fa ct or is pr ogr a m m ed into t h e
control module a t t h e a ssembly pla n t .
Usin g the following st eps, th e pinion factor can be
checked an d/or r eset u sin g the DRBIII#:
4
GENERAL INFORMATION

1. Select Transmission system , then Miscellan eous
functions, then P in ion F a ct or. The DRBIII#will
display th e cu r r ent tire size.
2. If the tire size is in cor r ect, pr ess t h e E n t er key
and t h en select the cor r ect size.
3. Press t h e P a ge Back key to exit t h e r eset pr oce-
dure.
Not es About Elect r on ic P in ion F a ct or Fea t u r es
Th e n a t u r e of the electronic pin ion fa ct or r equ ir es
that cer t a in fea t u r es must be t a ken in t o consider-
ation.
> If n o pin ion fa ct or is st or ed in a n in st a lled con t r ol
module, the veh icle speedom eter will not operate,
engine speed will be limited to 2300 RPM, and
catalyst damage m a y occur.
> Select in g a wrong tir e size will cause the speed-
omet er to be in a ccu r a t e a n d will also ca u se a n y
speed rela t ed fea t u r es to oper a te im pr operly.
Note: After replacing the PCM (NGC) or TCM
(EATX), you must reprogram pinion factor
3.4 USING THE DRBIII!
Refer t o t h e DRBIII#user s guide for instruct ion s
and a ssist a n ce with r eading tr ou ble codes, er a sin g
trouble codes, and ot h er DRBIII#functions.
3.5 DRBIII!ERROR M ESSAGES
Un der n or m a l opera t ion , t h e DRBIII#will dis-
play one of on ly two error messa ges:
– User-Requ ested WARM Boot
– User-Requ ested COLD Boot
If the DRBIII#should displa y a n y ot h er error
messa ge, recor d the entire displa y a n d ca ll t h e
S.T.A.R. Center.
3.5.1 DRBIII!DOES NOT POWER UP
(BLANK SCREEN)
If the LED’s do n ot ligh t or n o sou n d is emitted a t
start up, ch eck for loose ca ble connect ion s or a bad
cable. Ch eck the veh icle bat t ery voltage. A m in i-
mum of 11 volts is required t o a dequ a t ely power t h e
DRBIII#.
If all connect ion s a re pr oper between t h e
DRBIII#a n d t h e vehicle or other devices, and t h e
veh icle ba t t ery is fully ch a r ged, an in opera t ive
DRBIII#m a y be t h e r esult of fa u lt y cable or vehicle
wir in g. F or a blank scr een , r efer to th e appropriate
Body Diagnostic manua l.
3.5.2 DISPLAY IS NOT VISIBLE
Low t emper a t u r es will affect t h e visibilit y of th e
display. Adjust the con t r a st t o com pensate for this
condition.
3.5.3 SOME DISPLAY ITEMS READ $---$
Th is is ca u sed by th e scrolling t h e DRBIII#dis-
play a sin gle lin e u p or down. The line wh ich was
scrolled ont o the scr een m igh t r ead "---".Usethe
page down or page up fun ct ion t o display t h e
information.
3.6 TRANSMISSION SIMULATOR (MILLER
TOOL # 8 3 3 3 ) AND FWD ADAPTER
(MILLER TOOL #8333-1A)
Note: Remove the starter Relay when using
the transmission simulator
*Failure to remove the Starter Relay can
cause a PCM - No Response condition.
*The removal of the Starter Relay will also
prevent the engine from starting in gear.
*The Transmission Simulator will not
accurately diagnose intermittent faults.
Th e t ra nsmission sim u la t or, sim ply pu t , is a n
electronic device t h a t simulates the electronic func-
tions of any E ATX or NGC controlled t r a n sm ission
(40TE , 41TE, 42LE , 42RLE , 45RFE, and 545RFE).
Th e basic function of t h e sim u la t or is t o a id t h e
tech n icia n in deter m in in g if an internal t r a n sm is-
sion problem exist s or if the problem resides in t h e
veh icle wir in g or con t r ol m odu le. It is only usefu l for
electrical pr oblem s. It will n ot a id in t h e dia gn osis
of a fa iled m echanical componen t , but it can tell you
if t h e control module a n d wiring a r e workin g pr op-
er ly a n d t h a t the pr oblem is in t erna l t o the t r ans-
mission.
Th e ign it ion switch sh ou ld be in t h e lock position
before a t t empting t o in st a ll th e simula t or. Follow
all instructions included with the sim u la t or. If the
5
GENERAL INFORMATION

feedba ck from the simulator is in dou bt, you can
ver ify t h e simulators oper a t ion by installing it on a
kn own good veh icle. A "kn own good vehicle"would
be defin ed as a veh icle that does n ot set a ny DTC’s
and drives a n d sh ift s a s expect ed.
On e important point to r emem ber is th a t t h e
Simulator receives power fr om t h e Tra ns Rela y
Ou t pu t cir cu it . If t h e transmission system is in
Lim p-in (Rela y open), t h e sim u la t or will not oper-
ate. This is n ot r eally an indication of a problem,
bu t a n a ddit ion a l sym pt om . If the sim u la t or does
not power up ("P"led lit ), th is is a n indication t h a t
the problem is still present wit h t h e sim u la t or
hooked up. Th is in dica t es that the pr oblem is in t h e
wir in g or con t r ol m odu le a n d n ot t h e t r a n sm ission .
Miller Tool # 8333-1A consists of the adapter
cables a nd overlay necessary to a da pt t h e sim u la t or
to TE /AE /RLE /LE transmissions.
4.0 DI SCLAIMERS, SAFET Y,
AND WARNINGS
4.1 DISCLAIMERS
All infor m a t ion , illu st r a t ion s, a n d specifica t ion s
contained in t h is m a n u a l ar e ba sed on t h e latest
information a va ila ble at the time of pu blication.
Th e right is r eser ved to ma ke ch a n ges at a ny time
wit h ou t n ot ice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set t h e pa r king brake a nd block t h e wheels befor e
test in g or repairing the vehicle. If is especially
important to block the wheels on fr on t-wheel drive
veh icles: t h e pa rking bra ke does n ot h old t h e dr ive
wheels.
Some oper a t ion s in t h is ma nu al r equ ir e t h a t
hydraulic tubes, hoses, a n d fittings, disconnect ed
for inspect ion or t esting pu r poses. These system s,
wh en fully charged, contain fluid a t h igh pr essure.
Before discon n ecting any hydra u lic tubes, hoses,
and fit t in gs, be su r e t h a t t h e syst em is fu lly depr es-
surized. Wh en servicing a vehicle, a lways wea r eye
protect ion , a n d rem ove any met a l jewelr y su ch a s
wa t ch bands or bracelets that might ma ke an ina d-
ver t ent electrical contact.
When dia gn osin g a Tr a n sm ission syst em prob-
lem , it is importa n t t o follow approved pr ocedur es
wh ere applicable. These pr ocedures ca n be found in
the ser vice in for m a t ion . Followin g these pr ocedures
is ver y importa n t t o t h e safet y of individuals per-
forming diagnostic test s.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Ma ke sure the veh icle bein g test ed h a s a fu lly
charged ba t t ery. If it does n ot , fa lse dia gn ost ic
DTC’s or er ror m essages m a y occur. It is ext r emely
important tha t a ccu r a t e sh ift lever posit ion da t a is
available t o the con t r ol module. The accuracy of any
DTC foun d in mem or y is dou btful unless t h e Shift
Lever Test, performed on th e DRBIII#Sca n Tool,
passes without failure.
4.2.3 SERVICING SUB-ASSEMBLIES
Some componen t s of the Transmission syst em ar e
to be serviced a s a n a ssembly on ly. Attem pt in g to
rem ove or r epa ir certain system su b-componen t s
may resu lt in personal inju r y a n d/or im pr oper sys-
tem operation. Only t h ose com pon ents with ap-
proved r epair and installat ion pr ocedures in t h e
ser vice in for m a t ion sh ou ld be serviced.
4.2.4 DRBIII!SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIII!MULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND THE SPECIFICATION LIMITS.
•Follow the veh icle m a n u fa ct u rer’s service speci-
fications a t a ll t im es.
•Do n ot u se t h e DRBIII#if it has been damaged.
•Do not use the test lea ds if the insulation is
damaged or if m etal is exposed.
•To a void elect r ica l sh ock, do not t ou ch t h e test
lea ds, t ips or th e circu it being t ested.
•Ch oose t h e pr oper r a n ge a n d function for the
mea su r emen t . Do n ot t r y voltage or cu r r ent mea-
surem ents tha t ma y exceed the ra t ed capacity.
6
GENERAL INFORMATION

•Do n ot exceed t h e limits sh own in the table.
FUNCTION INPUT LIMIT
Volts 0-500 volt s pea k AC
0-500 volt s DC
Oh m s (resist ance)* 0-1.12 m egohms
Frequen cy m easur ed
Frequen cy gener a t ed
0-10 kh z
Temper a t u r e -58-1100°F
-50-600°C
*Oh m s ca n n ot be measur ed if volt age is pr esen t .
Oh m s ca n be measured on ly in a n on -power ed
circuit.
•Volta ge between any ter m in a l and ground m u st
not exceed 500v DC or 500v pea k AC.
•Use ca u t ion when m easured volt a ge a bove 25v
DC or 25v AC.
•Th e circuit bein g t ested m u st be pr ot ected by a
10A fuse or cir cu it brea ker.
•Use t h e low cu r r ent sh u n t t o mea su r e cir cu it s up
to 10A. Use the h igh cu r r ent clamp to mea su r e
circuits exceeding 10A.
•When t esting for t he pr esen ce of voltage or cu r-
ren t , make su r e t h e m eter is fu n ct ion in g cor-
rect ly. Take a rea din g of a kn own volt a ge or
curren t befor e a ccepting a zer o r eading.
•When m easuring curren t , con n ect the m eter in
ser ies with t h e loa d.
•Discon n ect t h e live test lea d befor e discon n ecting
the com m on t est lea d.
•When u sin g t h e met er function, keep the
DRBIII#a way from spark plu g or coil wires t o
avoid m easuring er r or fr om ou t side in t erfer ence.
4.3 WARNINGS
4.3.1 VEHICLE DAMAGE WARNINGS
Before discon n ecting any contr ol m odu le, ma ke
sure the ignition is "lock"position. Failure t o do so
could da m a ge t h e m odu le.
When t esting voltage or con t in u it y a t a n y con t r ol
module, use the ter m in a l side (not t h e wire en d) of
the connect or. Do n ot probe a wir e t h r ou gh the
insulation: t h is will da m a ge t h e wire a n d even t u -
ally cau se t h e wire to fail beca u se of cor r osion .
Be ca r eful wh en performing electrical test s so as
to prevent acciden ta l sh or t in g of ter m in a ls. Such
mistakes can da m age fuses or componen t s. Also, a
secon d DTC could be set , m a king dia gn osis of t h e
original problem m ore difficu lt .
When r eplacing a blown fu se, it is im por t ant to
use only a fuse having th e cor r ect a m pera ge r a t in g.
Th e u se of a fuse wit h a r a t in g other than in dica t ed
may r esult in a danger ou s elect r ica l system over-
load. If a proper ly rated fu se con t in u es t o blow, it
indicates a pr oblem in t h e circuit that must be
correct ed.
4.3.2 ROAD TESTING A COMPLAINT
VEHICLE
Some complaints will requ ir e a t est dr ive a s pa r t
of t h e r epair verification pr ocedur e. Th e pu r pose of
the test drive is t o t r y to duplicat e t h e dia gn ost ic
DTC or sym pt om con dit ion .
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read
DRBIII!screen while in motion. Do not hang
the DRBIII!from the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIII!.
Roa d t esting is an essential step in t h e diagnostic
process th a t m u st n ot be overlooked. Along wit h t h e
diagnostic inform a t ion obtained from t h e DRBIII#
Scan Tool and the or igin a l cu st omer concer n , t h e
road test h elps ver ify th e problem was curren t a n d
any repairs performed, fixed t h e vehicle correct ly.
Alwa ys operate and obser ve t h e vehicle under a c-
tual driving conditions.
J u st a s im por ta nt as the roa d t est is, t h ere ar e
prelim in a r y in spections tha t sh ou ld be performed
prior t o t h e road test . Always check t h e fluid level
and con dit ion befor e t a king th e vehicle on a r oa d
test . Deter m in e if a n in cor r ect flu id type is bein g
used, improper flu id will r esult in er r a t ic t r a n sm is-
sion oper a t ion .
Some of t h e con dit ion s of in cor r ect flu id level a r e
as follows:
•Delayed engagement
•Poor shifting or er r a tic sh ift in g
•Excessive n oise
•Overheating
Th e n ext step is t o ver ify that t h e sh ift lin kage is
correct ly a djusted. If th e sh ift er is incorrect ly a d-
ju st ed, a number of complaints ca n r esult.
Th e con t r ol module monitors t he Sh ift Lever
Position (SLP ) Sensor continuously. If t h e shifter is
incorrect ly a djusted, t h e con t r ol m odu le will sense a
shift lever position that is n ot cor r ect for the gear
chosen by the dr iver. Th is may ca u se a DTC t o be
set.
Th e following compla in t s m a y also be t h e r esult
of an incorrect ly a djusted sh ift er:
•Delayed clu t ch engagem ent
•Erratic shifts
•Vehicle will drive in n eutr a l
7
GENERAL INFORMATION

•Engine will not cran k in park or neutral
•Shifter will be able t o be moved without the key
in t h e ign it ion
•Not a ble to rem ove t h e ign it ion key in pa r k
•Parkin g pa wl will n ot engage pr operly
Th e sh ift er sh ou ld a lso be adju st ed when r eplac-
ing th e Tr a n sm ission , repa ir in g the valve body, or
wh en repa ir in g any com pon ent between t h e sh ift
lever a n d t h e Tr a n sm ission .
Some quest ion s t o a sk you r self wh en per for m in g
the road t est are a s follows:
•Is t he complaint or concer n what you think th e
problem is, based on t h e customer s description?
•Is t he Tra n sm ission operat in g normally, or is
ther e a r eal problem?
•When does t h e pr oblem occu r ?
•Is t h e pr oblem on ly in on e gea r ra nge?
•What tem perature does t h e pr oblem occu r ?
•Does t he veh icle have t o sit over n igh t for t h e
problem t o occu r?
•Does t h e t r a n sm ission go in t o Limp-in m ode?
4.3.3 ELECTRONIC PINION FACTOR
WARNINGS (IF APPLICABLE)
Th e pinion factor must be set wh en repla cin g t h e
control m odu le. Note: The pinion factor is a
fixed number and cannot be changed or up-
dated in some vehicle applications. If the pin-
ion factor is n ot set or incorrect ly set , any speed
rela t ed functions will not operate cor r ectly i.e.
speedomet er, speed cont rol, r ollin g door locks, ot h er
control m odu les will be affected t h a t depend on
speed information.
4.4.4 BULLETINS AND RECALLS
Alwa ys perform a ll Sa fety Reca lls a n d Technical
Ser vice Bullet in s t ha t a r e a pplica ble to the prob-
lem.
5.0 REQUIRED TOOLS AND
EQUIPMENT
>DRBIII#(dia gn ost ic r ead-out box) - Mu st be a t
latest release level.
> Tr a n sm ission Sim u la t or (Miller # 8333)
> Ada pt er ha r n ess/ pa n el overlay kit for Transmis-
sion Simulator (Miller # 8333-1A) for F WD veh i-
cles.
>Jumperwires
> Test Ligh t (m in im u m of 25 ohms of r esistance)
> Diagnost ic pinout box (Miller # 8815)
> Term in a l r emover (Miller # 3638)
>Ohmmeter
> Voltm eter
> P ressur e ga u ge 0-2068 kPa (0-300 PSI)
6.0 GLOSSARY OF TERMS
6.1 ACRONYMS
BCM Body Con t r ol Module
CKT Circuit
CVI Clutch Volu m e In dex
DLC Da t a Link Con n ector
DRBIII#Diagnostic Readout Box
DTC Diagnost ic Trouble Code
EATX Electronic Automatic Transaxle
EMCC Elect r on ica lly Modulated Con verter
Clu t ch
FCM Front Con t r ol Module (pa r t of t h e
IPM system)
FEMCC F u ll E lectronically Modu la t ed Con-
ver t er Clu t ch
IOD Ignition off-draw
IPM In t egrated P ower Module
IRT Intelligent Recovery Timer
ISS In pu t Speed Sensor
LED Ligh t E m it t in g Diode
LR Low/reverse Clutch or Pressu r e
Swit ch
LU Lockup
MIC Mech a n ica l In st r u ment Clu st er
MIL Malfunction Indicator La m p
NGC Next Gen era t ion Controller
OBDII On Board Dia gn ost ics
OD Overdrive Clutch or Pressu r e
Swit ch
OSS Output Speed Sen sor
PCM Powertrain Control Modu le
PEMCC Pa r t ia l E lectr on ica lly Modulated
Con verter Clutch
PLU Pa rtial Lockup
8
GENERAL INFORMATION

REV Rever se Clutch
SLPK Solenoid Pack
SSV Solen oid Switch Va lve
SW Swit ch
TCC Tor que Con verter Clutch
PCM Combin ed PCM an d Transmission
Con t r ol Module
TP Th r ot t le P osit ion
TRD Tor que Reduction
TRS Transmission Range Sen sor
UD Un derdrive Clu t ch
2/4 2n d an d 4th gea r Clutch or Pres-
sure Swit ch
6.2 DEFINITIONS
OB D II (EURO S TAGE III OB D ) Trip - A veh icle
start and dr ive cycle su ch t h a t a ll on ce per t r ip
diagnostic monitors h a ve r u n .
Key Start - A veh icle start and run cycle of a t least
20 seconds.
Warm -u p Cy c le - A veh icle start a n d r u n cycle
such that the engine coola n t m u st r ise to a t lea st
71 C (160° F) a n d m u st r ise by at least 4.4 C (40° F )
from initial st a r t u p. To cou n t a s a warm-up cycle,
no DTC m a y occu r du r in g t h e cycle.
9
GENERAL INFORMATION

NOTES
10

7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
11

Symptom:
P 0122-THROTTLE P OSITION S EN S OR/AP P S LOW
Wh e n Mo n i t o re d a n d S e t Co n d it io n :
P 0122-THROTTLE P OSITION SENS OR/AP P S LOW
When Mon itor ed: Cont inu ou sly wit h t he ign ition on a n d en gine r un n ing.
Set Condit ion: This DTC will set if the monit ored TP S volta ge dr ops below .078 volts for
th e per iod of 0.48 secon ds.
POSSIBLE CAUSES
RELATED TPS ENGINE DTC’S PRESENT
POWE RTRAIN CONTROL MODULE
INTERMITTENT WIRING AND CONNECTORS
TEST ACTION APP LICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With t he DRBIII#, read En gine DTC’s. Ch eck a n d repair all En gine DTC’s pr ior t o
perform ing an y t ran smission sympt om diagn ost ics.
With t he DRBIII#, read Tr ansm ission DTC’s. Recor d all DTC’s an d 1 Trip Failu res.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Using t h e wirin g diagr am/sch em atic as a guide, in spect t h e wirin g and connector s.
Repa ir a s necessary.
Perform t h e Shift Lever P osition Test. If the test does n ot pass, r efer t o Sympt om test
for P0706 Ch eck Shift er Signal.
For Gea r Ra t io DTC’s, check a n d record a ll CVI’s.
Most DTC’s set on st art u p but som e m ust be set by dr ivin g t he vehicle su ch t ha t a ll
diagn ostic m onitor s have ru n .
NOTE: Verify flash level of Powertrain Control Module. Some problems are
corrected by software upgrades to the Transmission and Engine software.
NOTE: Check for applicable TSB’s related to the problem.
Perform t h is pr ocedu re prior to Sym ptom diagnosis.
All
Con tin u e
Go To 2
2 With the DRBIII#, ch eck E ngin e DTC’s, this in cludes all one trip fa ilur es.
Are th er e a ny E ngin e TP S DTCs pr esen t ?
All
Ye s →Refer t o t he P owert r ain ca t egor y a nd perform t he a ppropr iate
symptom.
Perform 40/41TE (NGC) TRANSMISSION VERIF ICATION
TE ST - VE R 1.
No →Go To 3
12
TRANSMISSION - NGC

TEST ACTION APP LICABILITY
3 With t he DRBIII#, recor d t h e EATX E VENT DATA to help iden tify the con dition s in
wh ich the DTC wa s set .
With the DRBIII#, erase Tra n smission DTCs.
N OTE: To e ra s e E ATX EVEN T D ATA in fo rm a ti on , a B ATTE RY D IS CON NE CT
must be performed. Performing a BATTERY DISCONNECT will reset all
learned Transmission values to controller defaults which may lead to
erratic shift schedules.
Dr ive th e veh icle an d try to duplicate t h e condit ions in wh ich th e DTC wa s r epor ted
by th e E ATX EVE NT DATA.
With the DRBIII#, read Tr ansm ission DTCs.
Did the DTC P0122 THROTTLE POSITION SENSOR LOW, reset?
All
Ye s →Go To 4
No →Go To 5
4NOTE: Due to the integration of the Powertrain and Transmission Control
Modu les, bus commun ication betw een th e modules is internal.
Using th e sch em a tics a s a gu ide, in spect the wir ing an d con nectors. Repa ir as
necessary. Pa y par t icula r a tt ent ion to all power and gr ound cir cu its.
If th ere a r e no possible ca uses r em ain in g, view repa ir.
All
Repair
Repla ce the P owert r ain Con t rol Modu le per the Service Inform a -
tion . WITH TH E DRBIII#P E RF ORM QUICK LEARN.
Perform 40/41TE (NGC) TRANSMISSION VE RIFICATION
TE ST - VE R 1.
5 Th e con dition s necessary t o set t h is DTC are not pr esent a t t his time.
Using th e sch em a tics a s a gu ide, in spect t he wiring an d conn ector s specific to this
circu it.
Wiggle t h e wir es wh ile checkin g for short ed a n d open circu it s.
Pay pa rticu lar a t tention t o t h e TPS signal an d sen sor gr ou nd cir cu its.
With the DRBIII#, ch eck the E ATX EVE NT DATA to h elp ident ify th e condit ions in
wh ich the DTC wa s set .
Were t h er e any problems fou nd?
All
Ye s →Repair a s n ecessa ry.
Perform 40/41TE (NGC) TRANSMISSION VERIF ICATION
TE ST - VE R 1.
No →Test Complet e.
13
TRANSMISSION - NGC
P 0122-THROTTLE P OSITION S EN S OR/AP P S LOW — Continued

Symptom:
P 0123-THROTTLE P OSITION S EN S OR/AP P S HIGH
Wh e n Mo n i t o re d a n d S e t Co n d it io n :
P 0123-THROTTLE P OSITION SENS OR/AP P S HIGH
When Mon itor ed: Cont inu ou sly wit h t he ign ition on a n d en gine r un n ing.
Set Condition: This DTC will set if t he monitor ed TPS volt age rises above 4.94 volts for
th e per iod of 0.48 secon ds.
POSSIBLE CAUSES
RELATED TPS ENGINE DTC’S PRESENT
POWE RTRAIN CONTROL MODULE
INTERMITTENT WIRING AND CONNECTORS
TEST ACTION APP LICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With t he DRBIII#, read En gine DTC’s. Ch eck a n d repair all En gine DTC’s pr ior t o
perform ing an y t ran smission sympt om diagn ost ics.
With t he DRBIII#, read Tr ansm ission DTC’s. Recor d all DTC’s an d 1 Trip Failu res.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Using t h e wirin g diagr am/sch em atic as a guide, in spect t h e wirin g and connector s.
Repa ir a s necessary.
Perform t h e Shift Lever P osition Test. If the test does n ot pass, r efer t o Sympt om test
for P0706 Ch eck Shift er Signal.
For Gea r Ra t io DTC’s, check a n d record a ll CVI’s.
Most DTC’s set on st art u p but som e m ust be set by dr ivin g t he vehicle su ch t ha t a ll
diagn ostic m onitor s have ru n .
NOTE: Verify flash level of Powertrain Control Module. Some problems are
corrected by software upgrades to the Transmission and Engine software.
NOTE: Check for applicable TSB’s related to the problem.
Perform t h is pr ocedu re prior to Sym ptom diagnosis.
All
Con tin u e
Go To 2
2 With the DRBIII#, ch eck E ngin e DTC’s, this in cludes all one trip fa ilur es.
Are th er e a ny E ngin e TP S DTCs pr esen t ?
All
Ye s →Refer t o t he P owert r ain ca t egor y a nd perform t he a ppropr iate
symptom.
Perform 40/41TE (NGC) TRANSMISSION VERIF ICATION
TE ST - VE R 1.
No →Go To 3
14
TRANSMISSION - NGC

TEST ACTION APP LICABILITY
3 With t he DRBIII#, recor d t h e EATX E VENT DATA to help iden tify the con dition s in
wh ich the DTC wa s set .
With the DRBIII#, erase Tra n smission DTCs.
N OTE: To e ra s e E ATX EVEN T D ATA in fo rm a ti on , a B ATTE RY D IS CON NE CT
must be performed. Performing a BATTERY DISCONNECT will reset all
learned Transmission values to controller defaults which may lead to
erratic shift schedules.
Dr ive th e veh icle an d try to duplicate t h e condit ions in wh ich th e DTC wa s r epor ted
by th e E ATX EVE NT DATA.
With the DRBIII#, read Tr ansm ission DTCs.
Did the DTC P0123 THROTTLE POSITION SENSOR HIGH, reset?
All
Ye s →Go To 4
No →Go To 5
4NOTE: Due to the integration of the Powertrain and Transmission Control
Modu les, comm unication be tw ee n th e modules is internal.
Using th e sch em a tics a s a gu ide, in spect the wir ing an d con nectors. Repa ir as
necessary. Pa y par t icula r a tt ent ion to all power and gr ound cir cu its.
If th ere a r e no possible ca uses r em ain in g, view repa ir.
All
Repair
Repla ce the P owert r ain Con t rol Modu le per the Service Inform a -
tion . WITH TH E DRBIII#P E RF ORM QUICK LEARN.
Perform 40/41TE (NGC) TRANSMISSION VE RIFICATION
TE ST - VE R 1.
5 Th e con dition s necessary t o set t h is DTC are not pr esent a t t his time.
Using th e sch em a tics a s a gu ide, in spect t he wiring an d conn ector s specific to this
circu it.
Wiggle t h e wir es wh ile checkin g for short ed a n d open circu it s.
Pay pa rticu lar a t tention t o t h e TPS signal an d sen sor gr ou nd cir cu its.
With the DRBIII#, ch eck the E ATX EVE NT DATA to h elp ident ify th e condit ions in
wh ich the DTC wa s set .
Were t h er e any problems fou nd?
All
Ye s →Repair a s n ecessa ry.
Perform 40/41TE (NGC) TRANSMISSION VERIF ICATION
TE ST - VE R 1.
No →Test Complet e.
15
TRANSMISSION - NGC
P 0123-THROTTLE P OSITION S EN S OR/AP P S HIGH — Continued