2001 Mercury Villager Service & Repair Manual

AUTOMATIC TRANSAXLE SECTION AT CONTENTS TROUBLE DIAGNOSIS - INDEX ....................................4 Alphabetical & P No. Index for DTC ...........................4 PRECAUTIONS ...............................................................6 Precautions for Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ ......................................................6 Precautions for On Board Diagnostic (OBD) System of A/T and Engine...........................................6 Precautions ..................................................................6 Service Notice or Precautions .....................................8 Wiring Diagrams and Trouble Diagnosis .....................9 PREPARATION .............................................................10 Special Service Tools ................................................10 Commercial Service Tools .........................................12 OVERALL SYSTEM ......................................................14 A/T Electrical Parts Location .....................................14 Circuit Diagram ..........................................................15 Cross-sectional View .................................................16 Hydraulic Control Circuit ............................................17 Shift Mechanism ........................................................18 Control System ..........................................................27 Control Mechanism....................................................29 Control Valve .............................................................33 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................35 Introduction ................................................................35 OBD-II Function for A/T System................................35 One or Two Trip Detection Logic of OBD-II ..............35 OBD-II Diagnostic Trouble Code (DTC) ....................35 Malfunction Indicator Lamp (MIL) ..............................38 CONSULT-II ...............................................................39 Diagnostic Procedure Without CONSULT-II ..............48 TROUBLE DIAGNOSIS - INTRODUCTION..................55 Introduction ................................................................55 Work Flow ..................................................................59 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........61 A/T Fluid Check .........................................................61 Stall Test ....................................................................61 Line Pressure Test .....................................................65 Road Test ...................................................................66 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................83 Symptom Chart ..........................................................83 TCM Terminals and Reference Value........................95 TROUBLE DIAGNOSIS FOR POWER SUPPLY........100 Wiring Diagram - AT - MAIN....................................100 DTC P0705 PARK/NEUTRAL POSITION SWITCH ...103 Description ...............................................................103 Wiring Diagram - AT - PNP/SW...............................105 Diagnostic Procedure ..............................................106 Component Inspection .............................................109 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT ....................................................................... 110 Description ............................................................... 110 Wiring Diagram - AT - FTS ...................................... 112 Diagnostic Procedure .............................................. 113 Component Inspection ............................................. 116 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR) ........................................... 117 Description ............................................................... 117 Wiring Diagram - AT - VSSA/T ................................ 119 Diagnostic Procedure ..............................................120 Component Inspection .............................................122 DTC P0725 ENGINE SPEED SIGNAL .......................123 Description ...............................................................123 Wiring Diagram - AT - ENGSS ................................124 Diagnostic Procedure ..............................................125 DTC P0731 A/T 1ST GEAR FUNCTION ....................127 Description ...............................................................127 Wiring Diagram - AT - 1ST ......................................130 Diagnostic Procedure ..............................................131 Component Inspection .............................................132 DTC P0732 A/T 2ND GEAR FUNCTION ....................133 Description ...............................................................133 Wiring Diagram - AT - 2ND......................................136 Diagnostic Procedure ..............................................137 Component Inspection .............................................138 DTC P0733 A/T 3RD GEAR FUNCTION ....................139 GI MA EM LC EC FE AX SU BR ST RS BT HA SC EL IDX

Description ...............................................................139 Wiring Diagram - AT - 3RD......................................142 Diagnostic Procedure ..............................................143 Component Inspection .............................................144 DTC P0734 A/T 4TH GEAR FUNCTION ....................145 Description ...............................................................145 Wiring Diagram - AT - 4TH ......................................149 Diagnostic Procedure ..............................................150 Component Inspection .............................................153 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE......................................................154 Description ...............................................................154 Wiring Diagram - AT - TCV......................................156 Diagnostic Procedure ..............................................157 Component Inspection .............................................158 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) ....159 Description ...............................................................159 Wiring Diagram - AT - TCCSIG ...............................161 Diagnostic Procedure ..............................................162 Component Inspection .............................................166 DTC P0745 LINE PRESSURE SOLENOID VALVE ...167 Description ...............................................................167 Wiring Diagram - AT - LPSV....................................169 Diagnostic Procedure ..............................................170 Component Inspection .............................................172 DTC P0750 SHIFT SOLENOID VALVE A ..................173 Description ...............................................................173 Wiring Diagram - AT - SSV/A ..................................175 Diagnostic Procedure ..............................................176 Component Inspection .............................................178 DTC P0755 SHIFT SOLENOID VALVE B ..................179 Description ...............................................................179 Wiring Diagram - AT - SSV/B ..................................181 Diagnostic Procedure ..............................................182 Component Inspection .............................................184 DTC P1705 THROTTLE POSITION SENSOR ...........185 Description ...............................................................185 Wiring Diagram - AT - TPS ......................................187 Diagnostic Procedure ..............................................188 Component Inspection .............................................191 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE..........................................................................192 Description ...............................................................192 Wiring Diagram - AT - OVRCSV..............................194 Diagnostic Procedure ..............................................195 Component Inspection .............................................197 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ....198 Description ...............................................................198 Wiring Diagram - AT - BA/FTS ................................200 Diagnostic Procedure ..............................................201 Component Inspection .............................................204 DTC VEHICLE SPEED SENSOR.MTR .......................205 Description ...............................................................205 Wiring Diagram - AT - VSSMTR..............................207 Diagnostic Procedure ..............................................208 CONTROL UNIT (RAM), CONTROL UNIT (ROM) .....209 Description ...............................................................209 On Board Diagnosis Logic.......................................209 DTC Confirmation Procedure ..................................209 Diagnostic Procedure ..............................................210 CONTROL UNIT (EEP ROM) ...................................... 211 Description ............................................................... 211 On Board Diagnosis Logic....................................... 211 DTC Confirmation Procedure .................................. 211 Diagnostic Procedure ..............................................212 TROUBLE DIAGNOSES FOR SYMPTOMS ...............213 Wiring Diagram - AT - NONDTC .............................213 1. O/D OFF Indicator Lamp Does Not Come On....216 2. Engine Cannot Be Started In P and N Position..218 3. In P Position, Vehicle Moves Forward or Backward When Pushed .........................................219 4. In N Position, Vehicle Moves ..............................220 5. Large Shock. N -> R Position .............................222 6. Vehicle Does Not Creep Backward In R Position ....................................................................224 7. Vehicle Does Not Creep Forward in D, 2 or 1 Position ....................................................................228 8. Vehicle Cannot Be Started From D 1 ...................231 9. A/T Does Not Shift: D 1 -> D 2 or Does Not Kickdown: D 4 -> D 2 ..................................................234 10. A/T Does Not Shift: D 2 -> D 3 .............................237 11. A/T Does Not Shift: D 3 -> D 4 .............................240 12. A/T Does Not Perform Lock-up .........................243 13. A/T Does Not Hold Lock-up Condition ..............245 14. Lock-up Is Not Released ...................................247 15. Engine Speed Does Not Return To Idle (Light Braking D 4 -> D 3 ).....................................................248 16. Vehicle Does Not Start From D 1 .......................250 17. A/T Does Not Shift: D 4 -> D 3 , When Overdrive Control Switch ON -> OFF .....................251 18. A/T Does Not Shift: D 3 -> 2 2 , When Selector Lever D -> 2 Position ..............................................252 19. A/T Does Not Shift: 2 2 -> 1 1 , When Selector Lever 2 -> 1 Position ...............................................253 20. Vehicle Does Not Decelerate By Engine Brake........................................................................254 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks) ........................................................254 A/T SHIFT LOCK SYSTEM.........................................263 Description ...............................................................263 Wiring Diagram - SHIFT - ........................................264 Shift Lock System Electrical Parts Location............265 CONTENTS (Cont’d) AT-2

Removal ...................................................................265 Diagnostic Procedure ..............................................266 Installation and Adjustment......................................268 Component Check ...................................................269 ON-VEHICLE SERVICE ..............................................270 Control Valve Assembly and Accumulators .............270 Revolution Sensor Replacement .............................271 Park/Neutral Position (PNP) Switch Adjustment .....271 Control Cable Adjustment ........................................272 Differential Side Oil Seal Replacement ...................272 REMOVAL AND INSTALLATION ...............................273 Removal ...................................................................273 Installation ................................................................274 OVERHAUL .................................................................276 Components.............................................................276 Oil Channel ..............................................................279 Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings ............................280 DISASSEMBLY............................................................281 REPAIR FOR COMPONENT PARTS .........................295 Manual Shaft............................................................295 Oil Pump ..................................................................298 Control Valve Assembly ...........................................302 Control Valve Upper Body .......................................310 Control Valve Lower Body .......................................314 Reverse Clutch ........................................................316 High Clutch ..............................................................319 Forward and Overrun Clutches ...............................324 Low & Reverse Brake..............................................329 Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub .................................................332 Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer...............................................336 Band Servo Piston Assembly ..................................341 Final Drive................................................................346 ASSEMBLY..................................................................350 Assembly (1) ............................................................350 Adjustment (1) .........................................................350 Assembly (2) ............................................................355 Adjustment (2) .........................................................361 Assembly (3) ............................................................363 SERVICE DATA AND SPECIFICATIONS (SDS) .......370 General Specifications .............................................370 Shift Schedule..........................................................370 Stall Revolution ........................................................370 Line Pressure...........................................................370 Control Valves..........................................................371 Accumulator .............................................................371 Clutch and Brakes ...................................................372 Final Drive................................................................373 Planetary Carrier and Oil Pump ..............................374 Input Shaft ...............................................................375 Reduction Pinion Gear ............................................375 Band Servo ..............................................................376 Output Shaft.............................................................376 Bearing Retainer ......................................................377 Total End Play..........................................................377 Reverse Clutch End Play ........................................377 Removal and Installation .........................................378 Shift Solenoid Valves ...............................................378 Solenoid Valves .......................................................378 A/T Fluid Temperature Sensor.................................378 Revolution Sensor ...................................................378 Dropping Resistor ....................................................378 GI MA EM LC EC FE AX SU BR ST RS BT HA SC EL IDX CONTENTS (Cont’d) AT-3

Alphabetical & P No. Index for DTC NDAT0001 ALPHABETICAL INDEX FOR DTC NDAT0001S01 Items (CONSULT-II screen terms) DTC Reference page CONSULT-II GST*1 A/T 1ST GR FNCTN P0731 AT-127 A/T 2ND GR FNCTN P0732 AT-133 A/T 3RD GR FNCTN P0733 AT-139 A/T 4TH GR FNCTN P0734 AT-145 A/T TCC S/V FNCTN P0744 AT-159 ATF TEMP SEN/CIRC P0710 AT-110 ENGINE SPEED SIG P0725 AT-123 L/PRESS SOL/CIRC P0745 AT-167 O/R CLTCH SOL/CIRC P1760 AT-192 PNP SW/CIRC P0705 AT-103 SFT SOL A/CIRC*2 P0750 AT-173 SFT SOL B/CIRC*2 P0755 AT-179 TCC SOLENOID/CIRC P0740 AT-154 TP SEN/CIRC A/T*2 P1705 AT-185 VEH SPD SEN/CIR AT*3 P0720 AT-117 *1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC AT-4

P NO. INDEX FOR DTC =NDAT0001S02 DTC Items (CONSULT-II screen terms) Reference page CONSULT-II GST*1 P0705 PNP SW/CIRC AT-103 P0710 ATF TEMP SEN/CIRC AT-110 P0720 VEH SPD SEN/CIR AT*3 AT-117 P0725 ENGINE SPEED SIG AT-123 P0731 A/T 1ST GR FNCTN AT-127 P0732 A/T 2ND GR FNCTN AT-133 P0733 A/T 3RD GR FNCTN AT-139 P0734 A/T 4TH GR FNCTN AT-145 P0740 TCC SOLENOID/CIRC AT-154 P0744 A/T TCC S/V FNCTN AT-159 P0745 L/PRESS SOL/CIRC AT-167 P0750 SFT SOL A/CIRC*2 AT-173 P0755 SFT SOL B/CIRC*2 AT-179 P1705 TP SEN/CIRC A/T*2 AT-185 P1760 O/R CLTCH SOL/CIRC AT-192 *1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. GI MA EM LC EC FE AX SU BR ST RS BT HA SC EL IDX TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC (Cont’d) AT-5

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2001 Mercury Villager Service & Repair Manual

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