Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–1

7E3 – 1

Section 7E3

Hydra-Matic 5L40-E – Automatic Transmission: –

Hydraulic/Mechanical Diagnosis

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................4

1.1 How to Use This Section....................................................................................................................................... 4

1.2 Transmission General Description....................................................................................................................... 5

1.3 Transmission Definitions and Abbreviations...................................................................................................... 6

Throttle Positions .................................................................................................................................................. 6

Shift Conditions Definitions .................................................................................................................................. 6

Noise Conditions ................................................................................................................................................... 7

Transmission Abbreviations................................................................................................................................. 7

2 Diagnosis ................................................................................................................................................8

2.1 Basic Knowledge Required................................................................................................................................... 8

2.2 Functional Test Procedure.................................................................................................................................... 9

Functional Test Procedure Chart ......................................................................................................................... 9

2.3 Transmission Fluid Level, Check and Correct.................................................................................................. 11

2.4 Line Pressure Check ........................................................................................................................................... 12

2.5 Road Test Procedure........................................................................................................................................... 14

Introduction.......................................................................................................................................................... 14

Electrical Function Check................................................................................................................................... 15

Upshift Control and Torque Converter Clutch (TCC) Apply............................................................................. 16

Preliminary Checks .......................................................................................................................................... 16

Part Throttle Detent Do wnshift ......................................................................................................................... 17

Full Throttle Detent Downshift.......................................................................................................................... 17

Manual Downshifts........................................................................................................................................... 18

Coasting Downshifts......................................................................................................................................... 18

Manual Gear Range Selection ......................................................................................................................... 19

2.6 Torque Converter Diagnosis Procedure............................................................................................................ 20

Torque Converter Stator ..................................................................................................................................... 20

Poor Acceleration at Low Speed...................................................................................................................... 20

Poor Acceleration at High Speed ..................................................................................................................... 20

Noise..................................................................................................................................................................... 20

Torque Converter Clutch Shudder..................................................................................................................... 21

If Shudder Occurs During TCC Apply or Release ............................................................................................ 21

If Shudder Occurs After TCC has Applied........................................................................................................ 21

2.7 Torque Converter / Flexplate Vibration Test...................................................................................................... 23

Isolating Vibration................................................................................................................................................ 23

Indexing Torque Converter................................................................................................................................. 23

2.8 Noise and Vibration Analysis.............................................................................................................................. 24

2.9 Clutch Plate Diagnosis........................................................................................................................................ 25

Composition Plate Surface ................................................................................................................................. 25

Steel Plate Surface............................................................................................................................................... 25

Causes of Burned Clutch Plates....................................................................................................................... 25

Techline

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–2

7E3 – 2

2.10 Engine Coolant in Transmission........................................................................................................................ 26

2.11 Fluid Leak Diagnosis and Repair........................................................................................................................ 27

Methods for Locating Leaks ............................................................................................................................... 27

General Method................................................................................................................................................ 27

Powder Method................................................................................................................................................ 27

Dye and Black Light Method ............................................................................................................................ 27

Find the Cause of the Leak ................................................................................................................................. 28

Gaskets............................................................................................................................................................ 28

Seals ................................................................................................................................................................ 28

Possible Points of Fluid Leaks........................................................................................................................... 29

Transmission Fluid Pan.................................................................................................................................... 29

Case Leak........................................................................................................................................................ 29

Leak at the Torque Converter End................................................................................................................... 29

Leak at the Vent............................................................................................................................................... 29

Case Porosity Repair........................................................................................................................................... 31

2.12 Shift Solenoid Leak Test ..................................................................................................................................... 32

2.13 Range Reference Chart ....................................................................................................................................... 33

3 Symptoms Diagnosis...........................................................................................................................34

3.1 Symptoms Diagnosis Table................................................................................................................................ 34

3.2 Diagnostic Tables................................................................................................................................................ 36

Automatic Transmission Overheating ............................................................................................................... 36

Buzz Noise or High Frequency Rattle Sound.................................................................................................... 36

Degraded 1–2 and 2–1 Shifts.............................................................................................................................. 36

Degraded 2–3 and 3–2 Shifts.............................................................................................................................. 37

Degraded 4–5 Shift .............................................................................................................................................. 37

Drives with Selector Lever in Position N........................................................................................................... 37

Fifth Gear Only..................................................................................................................................................... 37

First and Second Gears Only.............................................................................................................................. 38

First Gear Only..................................................................................................................................................... 38

First, Fourth and Fifth Gears Only...................................................................................................................... 38

Fluid Pressure High or Low ................................................................................................................................ 39

Harsh Shift 4–5, or 5–4 ........................................................................................................................................ 40

Harsh Shift D–R.................................................................................................................................................... 40

Harsh Shifts.......................................................................................................................................................... 41

Harsh Torque Converter Clutch (TCC) Apply.................................................................................................... 41

Inaccurate Shift Points........................................................................................................................................ 42

No Drive in All Ranges ........................................................................................................................................ 42

No Engagement of Torque Converter Clutch (TCC) ......................................................................................... 43

No Engine Braking............................................................................................................................................... 43

No Engine Braking in First Gear......................................................................................................................... 44

No Engine Braking in First, Second and Third Gear......................................................................................... 44

No Engine Braking in Second Gear.................................................................................................................... 44

No Engine Braking in Third Gear........................................................................................................................ 45

No Fifth Gear........................................................................................................................................................ 45

No First Gear........................................................................................................................................................ 45

No Fourth Gear or Slips in Fourth Gear............................................................................................................. 46

No Reverse or Slips in Reverse.......................................................................................................................... 46

No Second Gear................................................................................................................................................... 46

No Third Gear....................................................................................................................................................... 47

Noise in Random Ranges.................................................................................................................................... 47

Popping Noise...................................................................................................................................................... 47

Power Mode Switch / Indicator Always On or Inoperative ............................................................................... 47

Second and Third Gears Only............................................................................................................................. 47

Slips or Shudders in First Gear.......................................................................................................................... 48

Slips While Shifting ............................................................................................................................................. 48

Whine Noise Varying with RPM or Fluid Pressure............................................................................................ 48

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–3

7E3 – 3

4 5L40-E Shift Speed Charts ..................................................................................................................49

4.1 Introduction.......................................................................................................................................................... 49

4.2 Shift Patterns – All With 3.6L Alloytec190 Engine ............................................................................................ 50

5 Power / Fluid Flow and Circuit Descriptions.....................................................................................52

6 Special Tools ........................................................................................................................................53

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–4

7E3 – 4

1 General Information

1.1 How to Use This Section

This Section contains the procedures for diagnosing the hydraulic / mechanical aspects of the Hydra-matic 5L40–E

automatic transmission. However, before diagnosing any problem with the 5L40 –E transmission, ALWAYS begin with the

Functional Test Procedure detailed in this Section.

After the cause of the problem has been determined,

refer to Section 7E4 Automatic Transmission – 5L40-E – On-Vehicle Servicing for the necessary procedures.

Alternatively, if the condition is considered to be electrical / electronic in nature then

refer to Section 7E2 Automatic Transmission 5L40-E – Electrical Diagnosis.

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7E3 – 5

1.2 Transmission General Description

The Hydra-matic 5L40–E is a fully automatic, five speed, rear wheel drive, electronically controlled transmission. It

consists primarily of a four-ele ment torque converter, one planetar y gear set, friction and mechanical clutches and a

hydraulic pressurisation and control system.

Refer to Section 7E1 Automatic Transmission – 5L4 0-E – General Information for further detail.

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7E3 – 6

1.3 Transmission Definitions and

Abbreviations

The following Definitions and Abbreviations are provided to establish a common la nguage for describing transmission

related conditions. Taking the few minutes to read this information may easily overcome unnecess ary waste of time by

being familiar with the terminology used within this Diagnosis Section.

Throttle Positions

Engine Braking – A condition where the engine is used to slo w the vehicle by manually downshifting during a zero

throttle coastdown.

Full Throttle Detent Downshift – A quick apply of the accelerator pedal to its full travel, forcing a downshift.

Heavy Throttle – Approximately 3/4 of accelerator pedal travel – 75 % throttle position.

Light Throttle – Approximately 1/4 of accelerator pedal travel – 25 % throttle position.

Medium Throttle – Approximately 1/2 of accelerator pedal t ravel – 50 % throttle position.

Minimum Throttle – The least amount of throttle opening required for an upshift.

Wide Open Throttle (WOT) – Full travel of the accelerator pedal – 100 % throttle position.

Zero Throttle Coastdown – A full release of the accelerator pedal while the vehicle is in motion and in drive range.

Shift Conditions Definitions

Bump – A sudden and forceful apply of a clutch or a band.

Chuggle – A bucking or jerking. This condition may be most noticeable when the converter clutch is engaged. It is

similar to the feel of towing a trailer.

Delayed – A condition where a shift is expected but does not occur for a period of time. This could be described as a

clutch or band engagement that does not occur as quickly as expected during a part throttle or wide open throttle apply

of the accelerator, or during manual downshifting to a lower range. This term is also defined as ‘Late’ or ‘Extended’.

Double Bump – Double Feel – Two sudden and forceful applies of a clutch or a band.

Early – A condition where the shift occurs before the vehicle has reached proper speed. This condition tends to labour

the engine after the upshift.

End Bump – A firmer feel at the end of a shift than at the start of the shift. This is also defined as ‘End Feel’ or ‘Slip

Bump’.

Firm – A noticeably quick apply of a clutch or band that is considered normal with a medium to heavy throttle. This apply

should not be confused with ‘Harsh’ or ‘Rou gh’.

Flare – A quick increase in engine rpm along with a momentary loss of torque. This most generally occurs during a shift.

This condition is also defined as ‘Sli pping’.

Harsh – Rough – A more noticeable apply of a clutch or band than ‘Firm’. This condition is considered undesirable at

any throttle position.

Hunting – A repeating quick series of upshifts and downshifts that causes a noticeab le change in engine rpm, such as a

4–3–4 shift pattern. This condition is also defined as ‘Busyness’.

Initial Feel – A distinctly firmer feel at the start of a shift than at the finish of the shift.

Late – A shift that occurs when the engine rpm is higher than normal for a given amount of throttle.

Shudder – A repeating jerking condition similar to ‘Chuggle’ but more severe and rap id. This condition may be most

noticeable during certain ranges of vehicle speed.

Slipping – A noticeable increase in engine rpm without a vehicle speed increase. A slip usually occurs during or after

initial clutch or band apply.

Soft – A slow, almost unnoticeable clutch or band apply with very little shift feel.

Surge – A repeating engine related condition of acceleration and deceleration that is less intense than ‘Chuggle’.

Tie-Up – A condition where two opposing clutch and / or bands are attempting to apply at the same time, causing the

engine to labour with a noticeable loss of engine rpm.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–7

7E3 – 7

Noise Conditions

Drive Link Noise – A whine or growl that increases or fades with vehicle speed and is most noticeable under a lig ht

throttle acceleration. It may also be noticeable in Park or Ne utral operating ranges with the vehicle stationary.

Final Drive Noise – A hum related to vehicle speed which is most noticeable und er a light throttle acceleration.

Planetary Gear Noise – A whine related to v ehicle speed, which is most noticeable in First, Second, Fourth gears or

Reverse. The condition may become less noticeable, or go away, after an upshift.

Pump Noise – A high pitched whine that increases in intens ity with engine rpm. This condition may also be notic eable in

all operating ranges with the v ehicle stationary or moving.

Torque Converter Noise – A whine usually noticed when a vehicle is stopped, and the transmissi on is in Drive or

Reverse. The noise will increase with engine rpm.

Transmission Abbreviations

A/C – Air Conditioning

A/T – Automatic Transmission

DLC – Diagnostic Link Connector

DTC – Diagnostic Trouble Co de

ECCC – Electronically-Controlled Capacity Clutch

ECM – Engine Control Module

ECT – Engine Coolant Temperature

IGN – Ignition

IMS – Internal Mode Switch

ISS – Input Speed Sensor

MAP – Manifold Absolute Pressure

MIL – Malfunction Indicator Lamp

NC – Normally Closed

NO – Normally Open

OBD – On Board Diagnostic

OSS – Output Speed Sensor

PCS – Pressure Control Solenoid

PM – Permanent Magnet

PWM – Pulse Width Modulation

rpm – Revolutions Per Minute

SS – Shift Solenoid

SOL – Solenoid

TAP – Transmission Adaptive Pressure

TCC – Torque Converter Clutch

TCM – Transmission Control Module

TFT – Transmission Fluid Temperature

WOT – Wide Open Throttle

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–8

7E3 – 8

2 Diagnosis

2.1 Basic Knowledge Required

You must be familiar with basic electron ics, fundamentals of automatic transmissions and hydraulics to use this Sectio n

of the Service Information. These will help you follow the diagnostic procedures deta iled in this Section.

A lack of basic knowledge of this

transmission and its controls when

performing diagnostic procedures could

result in incorrect diagnostic performance or

damage to the transmission components. Do

not, under any circumstances, attempt to

diagnose a transmission problem without this

basic knowledge.

You should be able to use a Digital Multi Meter (DMM), a circuit tester, fused jumper wires or leads and a line pressure

gauge set. Having access to a T ECH 2 is mandatory as many aspects of the transmission diagnosis require the use of

this tool.

The following Functional T est Procedure is d esig ned to verify the correct operation of components in the transmission

and to identify whether a condition is electrical in nature, or not. This will eliminate the unnec essary removal of

transmission components and time loss in rectification.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–9

7E3 – 9

2.2 Functional Test Procedure

When diagnosing an y Hydra-matic 5L40–E relate d hydraulic or mechanical condition, b eg in with this Functional Test

Procedure. This procedure will indicate the proper path of diagnosing the transmission, by describing the basic checks

and then referencing the location of specific checks.

The Functional Test Procedure is the first step in diagnosing mechanical or hydraulic transmission conditions. The

Functional Test provides procedures and references to the Symptom Diagnosis tab le for specific d iag nostic information.

It is important to realise that engine performance can greatl y affect transmission performance. Ensure that the complaint

is not the result of poor engine performance.

Functional Test Procedure Chart

Step Action Yes No

1 Verify customer complaint.

Has the customer complaint been verified? Go to Step 2 –

2 1 Perform Diagnostic System Check – Vehicle. Refer to

Diagnostic System Check – Vehicle, in Section 0D Vehicle

Diagnostics. NOTE

If an engine DTC fault is detected, the engine ECM may

activate default actions that could be interpreted as being a

transmission concern.

Has the Diagnostic System Check – Vehicle bee n performed? Go to Step 3

Go to Diagnostic

System Check –

Vehicle, in 0D

Vehicle Diagnostics.

3 1 Perform a visual inspection. Look for the following conditions:

• Vehicle damage

• Transmission fluid pan d amage

2 Check for worn or damaged suspensio n components. Refer to

Section 3A Front Suspension / Section 3B Front Suspe nsion or

Section 4A1 Rear Suspension / Section 4A2 Rear Suspension.

3 Check for worn or damaged steeri ng parts. Refer to Section 9

Steering.

4 Transmission range selector linkage damaged or out of

adjustment. Refer to Section 7E4 Automatic Transmission –

5L40-E – On-Vehicle Servicing.

5 Inspect for loose, worn, damage or missing:

• Mounts

• Brackets

• Mounting hardware

6 Transmission cooler or cooler line restrictions. Refer to Section

7E4 Automatic Transmission – 5L40-E – On-Vehicle Servicing.

7 Check for fluid leaks. Refer to 2.11 Fluid Leak Diagnosis and

Repair in this Section.

Was and item identified that need service? Go to appropriate

Section. Go to Step 4

4 1 Check transmission fluid level. Refer to Section 7E4 Automatic

Transmission – 5L40-E – On-V ehicle Servicing.

Is the procedure complete and the fluid l eve l correct? Go to Step 5 –

5 1 Perform the transmission road test procedures. Refer to 2.5

Road Test Procedure in this Section.

Did the vehicle exhibit any obj ectionable condition? Go to Step 6 System OK.

6 Did the vehicle exhibit objectionable torque converter operation? Go to Step 15 Go to Step 7

7 Did the vehicle exhibit a nois e condition? Go to 2.8 Noise and

Vibration Analysis in

this Section. Go to Step 8

8 Did the vehicle exhibit a vibration condition? Go to Step 9 Go to Step 10

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–10

7E3 – 10

Step Action Yes No

9 Did the vibration occur only during TCC apply or release?

Go to Step 15

Go to 2.8 Noise and

Vibration Analysis in

this Section.

10 Did the vehicle exhibit a shift speed con ditio n such as low or high shift

speeds? Go to Inaccurate

Shift Points, in

3.2 Diagnostic

Tables in this

Section. Go to Step 11

11 Check for any of the following shift quality (feel) conditions:

• Harsh, soft, delayed or no engagement

• Harsh, soft or delayed shifts

• Shift shudder, flare or tie-up

Were any of these conditions ev ident? Go to Step 12 Go to Step 13

12 Perform the hydraulic line pressure check. Refer to 2.4 Line Pressure

Check in this Section.

Is the line pressure within specification?

Go to Step 13

Go to Fluid

Pressure High or

Low in 3.2

Diagnostic Tables,

in this Section

13 Road test to check for any of the following shift pattern conditions:

• No upshift or downshift

• Only one or two forward gears

• No First gear, no Second gear, no Third gear or no Fourth

gear

• Slipping

• Non–First gear start

Were any of these conditions evident?

Go to 3.1 Symptoms

Diagnosis Table in

this Section. Go to Step 14

14 Check for any of the following range performance conditions:

• No Park, Reverse or Drive

• No engine braking

• No gear selection

• Incorrect gear selection

Were any of these conditions evident?

Go to 3.1 Symptoms

Diagnosis Table in

this Section. System OK

15 Refer to 2.6 Torque Converter Diagnosis Procedure in this Section to

check whether the vehicle exhibits any of the following TCC

conditions:

• Stuck on or off

• Early or late engagement

• Incorrect apply or release

• Soft or harsh apply

• Cluck or shudder

• No torque multiplication

• Excessive slip

• Poor acceleration

• Engine stalls

Were any of the above TCC conditions evident?

Complete the

recommended

procedure

recommendation in

2.6 Torque

Converter Diagnosis

Procedure in this

Section. System OK

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–11

7E3 – 11

2.3 Transmission Fluid Level, Check and

Correct

Vehicles equipped with the 5L40–E automatic transmission are not fitted with a conventional fluid level tube and dipstick

assembly. Addition of fluid to the transmission is via a threaded level hole in the left-hand side of the transmission case,

except for AWD models, that have the filler plug on the right-hand side. For the necessary procedure,

refer to Section 7E4 Automatic Transmission – 5L40-E – On-Vehicle Servicing.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–12

7E3 – 12

2.4 Line Pressure Check

Before performing a line pressure check, verify that the pressure control (PC) solenoid valve is receiving the correct

electrical signal from the TCM. Refer to Section 7E2 Automatic Transmission – 5L40-E – Electrical Diagnosis.

1 Connect TECH 2 to the DLC. Refer Section 0C TECH 2.

Keep the brakes firmly applied at all times to

prevent unexpected vehicle motion. Personal

injury may result if the vehicle moves

unexpectedly.

2 Start the engine and firmly appl y the parking brake.

3 Using TECH 2, inspect for any stored Diagnostic Trouble Codes (DTC).

4 Repair the vehicle, if necessary.

5 Check the fluid level. Refer to the 2.1 Transmission Fluid Level, Check and Correct in Section 7E4 Automatic

Transmission – 5L40-E – On-V ehicle Servicing.

6 Check the shift linkage for proper adjustment.

Refer to Section 7E4 Automatic Transmission – 5L4 0-E – On-Vehicle Servicing.

Do not allow the pressure gauge hose to come into

contact with the exhaust system. Transmission fluid is

flammable; contact with the exhaust system may cause

bodily injury or vehicle damage.

7 Turn the engine off. Remove the transmission

pressure test plug (40) and O-ring (66) using a 5 mm

Allen key socket and suitabl e equipment.

Figure 7E3 – 1

8 Install pressure gauge adaptor Tool No. J 21867–L40

and pressure gaug e assembly Tool No J 21867 to

transmission pressure test port.

9 Put the gear selector in Park range and firmly a pply

the park brake.

10 Start the engine and allow the engine to warm up at

idle. Check pressure gauge and adaptor to check

there are no fluid leaks.

Figure 7E3 – 2

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–13

7E3 – 13

The total test running time should not be

longer than 2 minutes. Running the test

longer than 2 minutes may damage the

transmission.

11 Access the PC solenoid valve control test on T ECH 2.

12 Increase the PC solenoid actual current from 0 to 1 amps in 0.1 amp i ncrements. Allow the pressure to stabilise for

5 seconds after each pressure change. Read and record the corresponding line pressure on the installed pressure

gauge.

13 Compare the recorded vehicl e data to the following line pressure specification chart.

Transmission Line Pressu re Specifications

Pressure Control

Solenoid Current (Amp) Line Pressure (kPa)

0.1 1,194 – 1,355

0.3 1,118 – 1,296

0.5 1,002 – 1,166

0.7 804 – 966

0.8 654 – 819

0.9 453 – 611

1.1 288 – 440

Engine running at 1,300 rpm

14 If pressure readings differ greatly from the chart, refer to Fluid Pressure High or Low in 3.2 Diagnostic Tables.

15 Turn engine off and remove the pressure gauge and

adaptor.

16 Inspect the pressure test plug (40) and O-ring (66) for

damage.

NOTE

If the pressure test plug (40) and O-ring (66) are

not damaged, they should be reused.

17 Reinstall the transmission pressure test plug (40) and

tighten to the correct torque specification

Transmission pressure test plug

to case torque specification..................................11 N.m

Figure 7E3 – 3

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–14

7E3 – 14

2.5 Road Test Procedure

NOTE

The Road Test Procedure should be performed

only as part of the Symptom Diagnosis. Refer to

3 Symptoms Diagnosis in this Section.

Introduction

Complete the test in the sequence given.

Incomplete testing cannot guarantee an

accurate evaluation.

The following test provides a method of evaluatin g the condition of the automatic transmission. The test is structured so

that most driving conditions would be ac hieved. The test is divided into the follo wing parts:

• Electrical Function Check

• Upshift Control and Torque Converter Clutch (TCC) Apply

• Part Throttle Detent Downshifts

• Full Throttle Detent Downshifts

• Manual Downshifts

• Coasting Downshifts

• Manual Gear Range Selection

• Reverse

• Manual Second

• Manual Third

• Manual Fourth

Before the road test, ensure the following:

• The engine is performing properly.

• Transmission fluid level is correct.

Refer to the Section 7E4 Automatic Transmission – 5 L4 0-E – On-Vehicle Servicing.

• Tyre pressures are correct.

During the road test:

• Perform the test only when traffic conditions permit.

• Operate the vehicle in a controlled, safe manner.

• Observe all traffic regulations.

• View TECH 2 data while conducting this tes t. T ake along a qualified assistant to operate the vehicle safely.

• Observe any unusual sounds or smells.

After the road test, inspect for the following:

• Diagnostic Trouble Codes (D TC) that may have set during the testing. Refer to the applicable DTC diagnostic

chart in Section 7E2 Automatic Transmission – 5L40-E – Electrical Diagnosis.

• TECH 2 data for any abnormal readings or data.

• Fluid leaks.

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7E3 – 15

Electrical Function Check

Perform this check first, in order to ensure that the electronic transmission components are connected and functioning

properly. If these components are not checked, a simple electrical conditi on could be misdiagnosed.

1 Connect TECH 2 to the DLC. Refer Section 0C TECH 2.

2 Ensure the shift selector is in Park and firmly apply the parking brake.

3 Start the engine and allo w to idle.

4 Verify that the following TECH 2 data par ameters can be obtained and are functioning properly.

Refer to TECH 2 Automatic Transmission Da ta Lists, in Section 7E2 Automatic Transmission – 5L40-E – Electrical

Diagnosis for typical data values. Data that is questionable may indicate a concern:

• Engine speed • Engine coolant temperature

• Transmission output speed • Transmission fluid temperature

• Vehicle speed • Accelerator pedal position

• IMS range • Ignition voltage

• Transmission range (engine list) • 1–2 shift solenoid

• Commanded gear • 2–3 shift solenoid

• PC solenoid reference current • 4–5 shift solenoid

• PC solenoid actual current • TCC solenoid dut y cycle

• PC solenoid dut y cycle • TCC slip speed

• Brake switch

5 Monitor the brake switch signal while depressing and releasing the brake pedal. TECH 2 should displa y:

• Open when the brake pedal is released.

• Closed when the brake pedal is depressed.

6 Check the garage shifts.

a Apply the brake pedal and ensure that the parking brake is set.

b Move the gear selector through the following ranges:

i. Park to Reverse

ii. Reverse to Neutral

iii. Neutral to DRIVE

c Pause 2 to 3 seconds in each gear position.

d Verify the gear engagements are immediate and not harsh.

High engagement may be caused by any of the following conditions:

• High idle speed – Compare e ngine idle speed to desired idle spee d.

• Commanded low PC solenoid current – Com pare PC solenoid reference current to PC solenoid actual

current.

• A default condition caused by certain DTCs that result in maximum line pressure to prevent slippage

Soft or delayed engagement may be caused by any of the following conditions:

• Low idle speed – Compare engine idle speed to desired idle speed.

• Low fluid level.

• Commanded high PC solenoid current – Compare PC solenoid reference current to PC solenoid actual

current.

• Cold transmission fluid – Inspect for low transmission fluid t emperature.

• Selector linkage Inspect the adjustment.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–16

7E3 – 16

7 Monitor transmission range on TECH 2, engine list – Apply the brake pedal and ensure that the parking brake is

set.

a Move the gear selector through all ranges.

b Pause 2–3 seconds in each range.

c Return gear selector to Park.

d Verify that all selector positions match the scan tool d isp lay.

8 Check accelerator pedal input – Apply the brake pedal and ensure that the parking brake is set.

a Ensure that the gear selector is in Park.

b Monitor accelerator pedal while increasing and decreasing engine sp eed with the throttle pedal. TECH 2

Throttle Position display sh ould increase and decrease with engine speed.

If any of the above checks do not perform properl y, record the result for reference after completion of the road test.

Upshift Control and Torque Converter Clutch (TCC) Apply

The TCM calculates the upshif t points based primarily on t wo inputs; throttle angle a nd vehicle speed. When the TCM

determines that conditions are met for a shift to occur, it will command the shift by closing or opening the ground circuit

for the appropriate solenoid.

Preliminary Checks

1 Refer to 4 5L40-E Shift Speed Charts in this Section and choose a throttle position of 12 %, 25 % or 50 %. All

throttle angles shown should be tested to cover the normal driving range.

2 Monitor the following TECH 2 data parameters:

• Throttle angle

• Vehicle speed

• Engine speed

• Output shaft speed

• Commanded gear

• Slip speed

• Solenoid states

3 Place the gear selector in the Drive ‘D’ positi on.

4 Accelerate the vehicle using the chosen throttle angle. Hold the throttle steady.

5 As the transmission upshifts, note the vehicle speed when the shift occurs for each gear change. There shou ld be

a noticeable shift feel or engine speed change within 1 to 2 seconds of the commanded gear change.

6 Compare the shift speeds to the shift speed charts in this S ection, refer to 4 5L40-E Shift Speed Charts. Shift

speeds may vary slightly due to adaptive learn parameters, transmission fluid temperature or hydraulic delays in

responding to electronic contr ols.

• Note any harsh, soft or delayed shifts or slipping.

• Note any noise or vibration.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–17

7E3 – 17

7 Repeat steps 1–6 to complete all throttle angl es.

NOTE

• This transmission is equipped with an

Electronically Controlled Capacity Clutch

(ECCC). The pressure plate does not fully

lock to the torque converter cover. The

pressure plate maintains a small amount of

slippage, approximately 20 rpm, in 3rd, 4th

and 5th gears. ECCC was developed to

reduce the possibility of noise, vibration or

chuggle caused by TCC apply. Typical apply

speeds are 49–52 km/h in 3rd gear and 65–

73 km/h in 4th gear. Full lock up does occur at

highway speeds.

• The TCC will not engage until the engine is i n

closed loop operation and the vehicle speed

is as shown in the shift speed charts in this

Section; refer to 4 5L40-E Shift Speed Chart s.

The vehicle must be in a near-cruise

condition, not acceler ating or c oasting, a nd o n

a level road surface.

8 Check for TCC apply in 3rd, 4th and 5th gears.

• Note the TCC apply point. When the TCC applies, there should be a noticeable drop in engine speed and a

drop in slip speed to below 100 rpm. If the TCC apply can not be detected:

• Check for DTCs. Refer to 2.6 Torque Converter Diagnosis Procedure in this Section.

• Refer to the 4 5L40-E Shift Speed Charts in this Section for the correct apply speeds.

• Lightly tap and release the brak e pedal. The TCC should release.

Part Throttle Detent Downshift

1 Place the gear selector in the OVERDRIVE position.

2 Accelerate the vehicle to 64 – 88 km/h in FIFTH gear.

3 Quickly increase throttle angle to greater than 50 %.

4 Verify the following:

a The TCC releases.

b The transmission downshifts immediately to FOURTH gear.

5 Place the gear selector in the OVERDRIVE position.

Full Throttle Detent Downshift

1 Accelerate the vehicle to spee ds of 64 – 88 km/h in FIFTH gear.

2 Quickly increase throttle angle to 100 % (Wide Open Throttle).

3 Verify the following:

a The TCC releases.

b The transmission downshifts immediately to THIRD gear.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–18

7E3 – 18

Manual Downshifts

The shift solenoid valves control the initial downshift for the 5–4, 4–3, 3–2 manual downshifts. The solenoid states should

change during or shortly after a manual downshift is selected.

Manual 5–4 Downshift

1 Place the gear selector in the ‘D’ position.

2 Accelerate the vehicle to 64 – 88 km/h in 5th gear.

3 Release the throttle while moving the gear se lector to 4th.

4 Check that the following occurs:

a The TCC releases.

b The transmission downshifts immediately to 4th gear.

c The engine slows the vehicle.

Manual 5–3 Downshift

1 Place the gear selector in the ‘D’ position.

2 Accelerate the vehicle to 64 – 72 km/h.

3 Release the throttle while moving the gear se lector to 3rd.

4 Check that the following occurs:

a The TCC releases.

b The transmission downshifts immediately to 3rd gear.

c The engine slows the vehicle.

Manual 5–2 Downshift

1 Place the gear selector in the ‘D’ position.

2 Accelerate the vehicle to 48 km /h.

3 Release the throttle while moving the gear se lector to 2nd.

4 Check that the following occurs:

a The TCC releases.

b The transmission downshifts immediately to 2nd gear.

c The engine slows the vehicle.

Coasting Downshifts

1 Place the gear selector in the ‘D’ position.

2 Accelerate the vehicle to 5th gear with the TCC applied.

3 Release the throttle and lightly apply the brakes.

4 Verify the following:

a The TCC releases.

b Downshifts occur at speeds shown in the Shift Speed table. Refer to 4 5L40-E Shift Speed Charts in this

Section.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–19

7E3 – 19

Manual Gear Range Selection

The shift solenoids control the upshifts in the manual gear ranges.

Perform the following tests using 10–15 % throttle angle.

Reverse

1 With the vehicle stopped, move the gear selector to Reverse.

2 Slowly accelerate the vehicle.

3 Verify that there is no noticeable slip, noise, or vibration.

Manual Second

1 With the vehicle stopped, move the gear selector to ‘2’.

2 Accelerate the vehicle to 32 km /h.

3 Verify the following:

a No upshifts occur

b The TCC does not apply

c There is no noticeable slip, noise, or vibration

Manual Third

1 With the vehicle stopped, move the gear selector to 3rd.

2 Accelerate the vehicle to 57 km /h.

3 Verify the following:

a The 1–2 shift occurs

b The 2–3 shift does not occur

c There is no noticeable slip, noise or vibration

Manual Fourth

1 With the vehicle stopped, move the gear selector to 4th.

2 Accelerate the vehicle to 64 km /h.

3 Verify the following:

a The 1–2 shift occurs

b The 2–3 shift occurs

c There is no noticeable slip, noise or vibration

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–20

7E3 – 20

2.6 Torque Converter Diagnosis Procedure

The Torque Converter Clutch (TCC) is applied by fluid pressure, which is controlled by a PW M solenoid valve. This

solenoid valve is located inside of the automatic transmission assembly. The solenoid valve is controlled through a

combination of computer controlled switches and sensors.

Torque Converter Stator

The torque converter stator roller clutch can have two different malfunctions.

• The stator assembly freewheels in both dire ctions.

• The stator assembly remains locke d up at all times.

Poor Acceleration at Low Speed

If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds above

50 – 55 km/h, the vehicle may respond normally. For poor acceleration, you should first determine that the exhaust

system is not blocked, and the transmission is in First gear when starting out.

If the engine freely accelerates to high rpm in Neutral, you can assume that the engine and the exhaust system are

normal. Check for poor performance i n Drive and Reverse to help determine if the stator is freewheeling at all times.

Poor Acceleration at High Speed

If the stator is locked up at all times, vehicle performance is normal when acceleratin g from a standstil l. Engine rpm and

vehicle speed are limited or r estricted at hig h spee ds. Visual examination of the converter may reveal a blue colour from

overheating.

If the converter has been removed, you can check the stator roller clutch by inserting a finger into the splined inner race

of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the inner race

clockwise, but you should have difficulty in moving the inner race counter-clockwise or you may be unable to move the

race at all.

Noise

NOTE

Do not confuse this noise with pum p whine noise,

which is usually noticeable in Park, Neutral and

all other gear ranges. Pump whine will vary with

line pressure.

You may notice a torque con v erter whine when the vehicle is stopped and the transmission is in Drive or Reverse. This

noise will increase as you increase engine speed. The noise will stop when the vehicle is moving or when you apply the

torque converter clutch, because both halves of the converter are then turning at the same speed.

Perform a stall test to make sure the noise is actually coming from the converter. Proceed as follows:

1 Place your foot on the brake.

2 Put the gear selector in Drive.

You may damage the transmission if you

depress the accelerator for more than 6

seconds.

3 Depress the accelerator to approximately 1,200 rpm for no more than 6 seconds. A torque converter noise will

increase under this load.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–21

7E3 – 21

Torque Converter Clutch Shudder

The key to diagnosing T orqu e Converter Clutch (TCC) shudder is to note when it happens and under what conditions.

TCC shudder which is cause d by the transmission should only occur duri ng the apply or the release of the converter

clutch. Shudder should never occur after the TCC plate is fully applied.

If Shudder Occurs During TCC Apply or Release

If the shudder occurs while the TCC is applying, the problem can be within the transmission or the torque converter.

Something is causing one of the foll owing conditions to occur, such as:

• Something is not allowing the clutch to become fully engaged.

• Something is not allowing the clutch to release.

• The clutch is releasing and applying at the same time.

One of the following conditions may be causing the problem to occur:

• Leaking turbine shaft seals

• A restricted release orifice

• Defective friction material on the T CC plate

If Shudder Occurs After TCC has Applied

If shudder occurs after the TCC has applied, there is usuall y nothing wrong with the transmission.

The TCC is not likely to slip after the TCC has been applied. Engine probl ems may go unnoticed under light throttle and

load, but they become noticeable after the TCC apply when going up a hill or accelerating. This is due to the mecha nical

coupling bet ween the engine and the transmission.

Once TCC is applied, there is no torqu e converter fluid coupling assistance. Engine or driveline vibrations could be

unnoticeable before TCC engagement.

Inspect the following components in order to avoid misdiagnosis of TCC shudder. An inspectio n will also avoid the

unnecessary disassembl y of a transmission o r the unnecessary replacement of a torque converter.

• Spark plugs – Inspect for cracks, high resistance or a broken insulator.

• Cylinder coil – Look for a black discoloration on the bottom of each cylinder coil. This indicates arcing while the

engine is misfiring.

• Fuel injector – The filter may be plugged.

• Vacuum leak – The engine will not get a correct amount of fuel. The mixture may run rich or lean depend ing on

where the leak occurs.

• MAF sensor – Like a vacuum leak, the engine will not get the correct amount of fuel for proper engine operation.

• Carbon on the intake valves – Carbon restricts the proper flow of air / fuel mixture into the cylinders.

• Flat cam – Valves do not open enough to let the proper fuel / air mixture into the cylinders.

• Oxygen sensor – This sensor may command the engine too rich or too lean for too long.

• Fuel pressure – T his may be too low.

• Engine mounts – Vibration of the mou nts can be multiplied by TCC engagement.

• Propeller Shaft(s) and Driveshaft joints – Check for vibration.

• Cylinder balance – Worn piston rings or poorly sealing valves can cause low power in a cylinder.

• Fuel contamination – T his causes po or engine performance.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–22

7E3 – 22

Replace the torque converter, if any of the following conditions exist:

• External leaks appear in the hub weld area.

• The converter hub is scored or damaged.

• The converter pilot is broken, damaged or fits poorly into the crankshaft.

• You discover steel particles after flushing the cooler and the cooler lines.

• The pump is damaged, or you discover steel particles in the converter.

• The vehicle has TCC shudder and / or no TCC apply. Replace the torqu e converter o nly after all hydraulic and

electrical diagnoses have been made. The converter clutch material may be glazed.

• The converter has an imbalance which cannot be corrected.

Refer to 2.7 Torque Converter / Flexplate Vibration Test in this Section.

• The converter is contaminated with engine coolant which contains antifreeze.

• An internal failure occurs in the stator roller clutch.

• You notice excessive end pla y.

• Overheating produces heavy debris in the clutch.

• You discover steel particles or clutch lining material in the fluid filter or on the magnet, when no internal parts in the

unit are worn or damaged. This conditi on indicates that lining material came from the converter.

For torque converter replacement procedures,

refer to Section 7E4 Automatic Transmission – 5L40-E – On -Vehicle Servicing, in this Service Information.

Do not replace the torque converter if you discover any of the following symptoms:

• The transmission fluid has an odour or the flu id is discoloured, even though metal or clutch facing particle s are not

present.

• Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining

material in the unit and inside the fluid filter.

• The vehicle has been e x posed to high mileage only. An exceptio n may exist where the lining of the torque

converter clutch dampener plate has seen excess wear by vehicles operated in heavy an d / or constant traffic,

such as taxi, delivery, or police use.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–23

7E3 – 23

2.7 Torque Converter / Flexplate Vibration

Test

Isolating Vibration

NOTE

Some engine / transmission combinations cannot

be balanced in this manner due to limited

clearances between the torque converter bolts

and the engine. Ensure that the bolts do not

bottom out in the lug nuts or the torqu e converter

cover could be dented and cause internal

damage.

To isolate and correct a flexplate or torque converter vibration, separate the torque converter from the flexplate to

determine if vibration is in the engine or transmission.

1 With the engine at idle speed and the transmission in Park or Neutral, observe the vibratio n.

2 Turn the engine OFF.

3 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

4 Mark the relationship of the converter to the fl ywheel.

5 Remove the bolts attaching the converter to the flywheel. Refer to 3.25 5L40-E Automatic Transmission, Remove,

in Section 7E4 Automatic Transmission – 5L40-E – On-Vehicle Servicing.

6 Slide the torque converter away from the flywheel.

7 Rotate the flexplate and torque converter, checkin g for defects such as cracks, damage d mounting threads or

missing balance weights. Refer to Section 7E4 Automatic Transmission – 5L40-E – On-Vehicle Servicing.

8 Lower the vehicle.

9 With the engine at idle speed and the tra nsmission in Park or Neutral, observe the vibration.

Refer to 2.8 Noise and Vibration Analysis, in this Section.

10 Turn the engine OFF.

Indexing Torque Converter

To determine and correct a torque converter vibration, the following procedure may have to be performed several times

to achieve the best possible torque converter to flexplate balance.

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the torque converter to flexplate bolts. Refer

to Section 7E4 Automatic transmission – 5L40-E – On-

Vehicle Servicing.

3 Rotate the torque converter one bolt positi on .

4 Align the torque converter hub (2) in the engine

crankshaft (3) and install the torque converter to

flywheel bolts.

5 Lower the vehicle.

6 With the engine at idle speed and the tra nsmission in

Park or Neutral, observe the vibration. Refer to

2.8 Noise and Vibration Analysis in this Section.

Repeat this procedure until the best possible balance

is obtained.

Figure 7E3 – 4

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–24

7E3 – 24

2.8 Noise and Vibration Analysis

A noise or vibration that is noticeable when the vehicle is in motion may not be the result of the transmission.

If noise or vibration is noticeable in Park and Neutral with the engine at idle, but is less noticeable as engine rpm

increases, the cause may be from poor engine performance.

1 Inspect the tyres for the following:

• Uneven wear

• Imbalance

• Mixed sizes

• Mixed radial tyre tread patterns. Refer to Section 10 Wheels and Tyres.

2 Inspect the suspension components for the following:

• Alignment and wear

• Loose fasteners. Refer to Section 3A Front Suspensio n / Section 3B Front Suspension and / or

Section 4A1 Rear Suspens ion / Section 4A2 Rear Suspension

3 Inspect the engine and transmission mounts for damage and loose bolts.

Refer to Section 6A1 Engine Mechanical – V6 and / or

Section 7E4 Automatic Tr ansmission – 5L40-E – On-Vehicle Servicing.

4 Inspect the transmission case mounting holes for the following:

• Missing bolts, nuts and studs

• Stripped threads

• Cracks

5 Inspect the flexplate for the following:

• Missing or loose bolts

• Cracks

• Imbalance

6 Inspect the torque converter for the following:

• Missing or loose bolts or lugs

• Missing or loose balanc e weights

• Imbalance

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–25

7E3 – 25

2.9 Clutch Plate Diagnosis

NOTE

All clutch plates in this transmission are single

sided; i.e. one side is composition coated, while

the other is plain steel.

Composition Plate Surface

1 Dry the plates and inspect the plates for the following conditions:

• Pitting

• Flaking

• Wear

• Glazing

• Cracking

• Charring

• Chips or metal particles embedded in the lining.

2 Replace a composition pl ate which shows any of these conditions.

Steel Plate Surface

Wipe the plates dry and inspec t the plates for heat discoloration. If the surfaces are smooth, even if colour smear is

indicated, you can reuse the plate. If the plate is discoloured with heat spots or if the surface is scuffed, replace the plate.

Causes of Burned Clutch Plates

The following conditions can result in a burned clutch plate:

• Incorrect usage of clutch plates

• Engine coolant in the transmission flu id

• A cracked clutch piston

• Damaged or missing seals

• Damaged fluid passage sleeves

• Low line pressure

• Valve body conditions:

– The valve body face is not flat

– Porosity is between channels

– The valve bushing clips are improperly installed

– The checkballs are misplaced

• The Teflon® seal rings are worn or damaged

• Low transmission fluid level

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–26

7E3 – 26

2.10 Engine Coolant in Transmission

If the transmission oil cooler has developed a leak allowing engine coolant to enter the tra nsmissio n, perform the

following:

1 Disassemble the transmission.

2 Replace all of the rubber t ype seals. The coolant will attack the seal material which will cause leakage.

3 Replace the composition-faced clutch plate assemblies. The facing materi al may separate from the steel centre

portion.

4 Replace all of the washers.

5 Replace the torque converter.

6 Thoroughly cle an and rebuild the transmission, using new gaskets and filter.

7 Flush the cooler lines after the transmission cool er has been properly repaired or replaced.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–27

7E3 – 27

2.11 Fluid Leak Diagnosis and Repair

The cause of most external t r ansmission fluid leaks can usually be located and repaired with the transmission installed in

the vehicle.

NOTE

The transmission fluid must be checked before

the fluid leak diagnosis is performed to prevent

damage to the transmission.

Check transmission fluid level. Refer to

2.3 Transmission Fluid Level, Check and Correct

in this Section.

Methods for Locating Leaks

General Method

1 Verify that the leak is automatic transmission fluid.

2 Thoroughly cle an the suspected leak area.

3 Operate the vehicle for 24 km or until normal oper ating temperature is reached.

4 Park the vehicle over clean paper or cardboard.

5 Switch off the engine.

6 Inspect for fluid spots on the paper.

7 Make necessary repairs and then rec heck that the leak has been rectified.

Powder Method

1 Thoroughly cle an the suspected leak area with solvent.

2 Apply an aerosol type powder, (e.g. foot powder) to the suspected leak ar ea.

3 Operate the vehicle for about 24 km or until normal operating temper ature is reached.

4 Switch off the engine.

5 Inspect the suspected leak area.

6 Trace the leak path through the powder in order to find the source of the leak.

7 Make necessary repairs and then rec heck that the leak has been rectified.

Dye and Black Light Method

While the following can be used as a guide, always follow the equipment manufacturer’s recommendations for use of the

equipment.

1 Pour the manufacturer’s recommended amo unt of d ye (suc h as J 28431-B) into the transmission.

Refer to 2.3 Transmission Fluid Level, Check and Correct in this Section.

2 Road test the vehicle under normal operati ng conditions.

3 Direct the black light (such as Tool No. J 42220) to the suspect area. Any fluid leak will appear as a brightly

coloured path, leading to the source.

4 Make necessary repairs and then rec heck that the leak has been rectified.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–28

7E3 – 28

Find the Cause of the Leak

Once the leak has been located an d traced back to its source, the cause of the leak must be determined for the repair to

be satisfactory.

For example, if you replace a gasket, but the sealing flange is bent, the new gasket will not repair the leak. You must also

repair the bent flange.

Before attempting to repair a leak, check for the following conditions and make repairs as necessary:

Gaskets

• Fluid level / pressure is too high

• Plugged vent or drain- back holes

• Improperly tightened fasteners

• Dirty or damaged threads

• Warped flanges or sealing surfaces

• Scratches, burrs or other damage to sealing surfaces

• Damage or worn gasket

• Cracking or porosity of the component

• Improper sealant used

• Incorrect gasket

Seals

• Fluid level / pressure is too high

• Plugged vent or drain- back holes

• Damaged seal bore

• Damaged or worn seal

• Improper installation

• Cracks in component

• Manual or output shaft surface is scratched, nicked or damage d

• Loose or worn bearing causing excess seal wear

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–29

7E3 – 29

Possible Points of Fluid Leaks

Transmission Fluid Pan

• Incorrectly tightened fluid pan bolts

• Improperly installed or damaged fluid pan gasket

• Damaged fluid pan or mounting face

• Incorrect fluid pan gasket

• Fluid Drain Plug

Case Leak

• Fluid Fill Plug

• Extension Housing

• Wiring harness O-ring seal

• Damaged manual shaft seal

• Loose or damaged fluid cooler line seals fittings

• Worn or damaged propeller shaft flange seal

• Loose line pressure test plug

• Porous casting

Leak at the Torque Converter End

• Converter leak in the weld are a

• Converter seal lip cut. Check the converter hub for damage

• Converter seal bushing moved forward and damaged

• Converter seal garter spring m issing from the seal

• Porous casting of the transmission case or the oil pump

Leak at the Vent

• Overfilled system

• Water or coolant in the fluid. The fluid will appear milky

• Transmission case por ous

• Plugged vent

• Drain-back holes plugged

• Incorrectly positioned flui d pump to transmission case gasket

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–30

7E3 – 30

Figure 7E3 – 5

Legend

(1) Torque Converter Assembly (40) Transmission Pressure Test Plug

(2) Fluid Cooler Pipe Connectors (56) Automatic Transmission Wiring Harness O-ring Seal

(4) Torque Converter Housing Fluid Seal Assembly (60) Automatic Transmission Fluid Pan Gasket

(24) Automatic Transmission Case Assembly (63) Automatic Transmission Fluid Drain Plug

(25) Case Extension Gasket (229) Torque Converter Housing Seal

(29) Propeller Shaft Flange Seal (243) Transmission Vent Tube

(36) Transmission Level Hole Plug (614) Transmission Shift Shaft Seal

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–31

7E3 – 31

Case Porosity Repair

Some external leaks are caus ed by case porosity in non-pressurised areas. You can usually repair thes e leaks with the

transmission in the car. Use the following notes to assist in the repair.

• Thoroughly cle an the area to be repaired with a cleaning solvent recommended by the epoxy adhesive

manufacturer. Air dry the area.

Epoxy adhesive may cause skin irritations

and eye damage. Read and follow all

information on the container label as provided

by the manufacturer.

• Using instructions from the manufacturer, mix a sufficient amount of an epoxy adhesive (‘Araldit e‘™ or a n

equivalent product) to make the repair.

• While the transmission case is still hot, apply the epoxy. You can use a clean, dry soldering acid brush to clean the

area and also to apply the epoxy cement. Make certain that the area to be repaired is fully covered.

• Allow the epoxy adhesive to dry for the recommended time before starting the engine and checking the results of

the repair.

• Repeat the fluid leak diagnos is procedure previously detailed.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–32

7E3 – 32

2.12 Shift Solenoid Leak Test

For Solenoid Leak testing pro c edures, refer to 3.22 Solenoid Leak Testing, in Section 7E4 Automatic Transmission –

5L40-E – On-Vehicle Servicing.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–33

7E3 – 33

2.13 Range Reference Chart

Figure 7E1 - 6

Range D / 4 / 3 / 2 Neutral Reverse Park

Gear 1 1 2 2 3 3 4 5 N R P

Engine Braking NO YES NO YES NO YES YES YES – YES –

Ratio 3.24 3.24 2.21 2.21 1.60 1.60 1.00 0.75 – 3.03 –

1–2 Shift

Solenoid Valve OFF OFF ON ON ON ON OFF OFF

ON/OFF

 ON/OFF



2–3 Shift

Solenoid Valve ON ON ON ON OFF OFF OFF OFF

ON/OFF

 ON/OFF



4–5 Shift

Solenoid Valve OFF ON OFF ON OFF ON ON OFF

ON/OFF

 ON/OFF



TCC Solenoid

Valve OFF OFF

ON/OFF

 ON/OFF

 – OFF –

Direct Clutch – – – – – – APPLIED APPLIED – – –

Coast Clutch APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED – – – –

Reverse Clutch – – – – – – – – – APPLIED –

Forward Clutch APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED – – –

Forward Clutch

Sprag LD LD LD LD LD LD LD – – – –

Overdrive Clutch – – – – – APPLIED – APPLIED – – –

Intermediate

Clutch Sprag – – – – LD LD – – – – –

Intermediate

Clutch – – – – APPLIED APPLIED APPLIED APPLIED – – –

Low Clutch

Sprag LD LD – – – – – – – – –

Low and Reverse

Clutch – APPLIED – – – – – – – APPLIED –

Second Clutch – – APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED – – –

Second Clutch

Sprag – – LD LD – – – – – – –

Second Coast

Clutch – – – APPLIED – – – – – – –

LD = Locked in Drive ON = Solenoid Energised OFF = Solenoid De-Energise d

 The solenoids state follows a shift pattern that depends upon vehicle speed and throttle position. It does not depend

upon the selected gear.

 Engine braking is electron ically controlled by the T CM and is available as a calibrated function.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–34

7E3 – 34

3 Symptoms Diagnosis

The following table consists of nine diagnostic categories that are located in the left hand colum n. Using this column,

choose the appropriate categ ory based on the operating cond itions of the vehicle or transmission. After selectin g a

category, use the right hand column to locate the specific symptom diagnostics information. Unless otherwise stated, this

specific information refers to 3.2 Diagnostic Tables in this Section.

The tables that follow provide more specific information relating to each of the symptoms listed.

NOTE

The Functional Test Procedure should be

performed before beginning any diagnosis, refer

to 2.2 Functional Test Procedure in this Section.

3.1 Symptoms Diagnosis Table

Diagnostic Category Diagnostic Information

Fluid Diagnosis

This category contains the following topics:

• Fluid condition – appearance, contaminants, smell,

overheating

• Line pressure – high or low

• Fluid leaks

Refer to 2.3 Transmission Fluid Level Check and Correct

Refer to Fluid Pressure High or Low

Refer to 2.1 Fluid Leak Diagnosis an d Repair

Refer to Automatic Transmission Overheating

Noise and Vibration Diagn osis

This category contains the following topics:

• Ratcheting noise

• Noise – drive gear, final drive, whine, growl, rattle,

buzz, popping

• Vibration

Refer to 2.8 Noise and Vibration Analysis

Refer to Buzz Noise or High Frequency Rattle Sound

Refer to Popping Noise

Refer to Whine Noise Varying with RPM or Fluid Pressure

Refer to Noise in Random Ranges

Range Performance Diagnosis

This category contains the following topics:

• Drives in Neutral

• No Park

• No Drive

• Shift selector indicator does not match transmission

gear range Refer to No Drive in All Ranges

Refer to Drives with Selector Lever in Position N

Shift Quality Feel Diagnosis

This category contains the following topics:

• Harsh, soft or slipping shifts

• Harsh, soft or delayed engagement

• Shift shudder, Flare or tie-up

• No engine braking

Refer to Harsh Shifts

Refer to Harsh Shift 4–5, or 5–4

Refer to Harsh Shift D – R

Refer to Degraded 1–2 and 2 –1 Shifts

Refer to Degraded 2–3 and 3 –2 Shifts

Refer to Slips or Shudders in First Gear

Refer to Degraded 4–5 Shift

Refer to No Engine Braking in Second Gear

Refer to No Engine Braking in First, Second and Third

Gear

Refer to No Engine Braking in Third Gear

Refer to No Engine Braking

Refer to No Engine Braking in First Gear

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7E3 – 35

Diagnostic Category Diagnostic Information

Shift Pattern Refer to First and Second Gears Only

Shift Speed Diagnosis

This category consists of the following topic:

• Inaccurate or inconsistent shift points

Refer to Inaccurate Shift Points

Refer to Power Mode Switch / Indicator Always On or

Inoperative

Torque Converter Diagnosis

This category contains the following topics:

• Torque converter diagnosis

• TCC does not apply

• TCC does not release

• TCC apply / release quality

Refer to Torque Converter Diagnosis Procedure

Refer to No Engagement of Torque Converter Clutch

(TCC)

Refer to Harsh Torque Converter Clutch (TCC) Apply

Multi-Function Display (MFD) Message

This category contains the following topics:

• Transmission hot idle engine light ON

• Snow flake light ON

• Sport light ON Refer to Transmission Indicators and Messages

Refer to Power / Economy Mode Operation

If Symptom Not Found Refer to Transmission Fluid Checking Procedure

Refer to Road Test Procedure

Refer to Line Pressure Check Proced ure

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–36

7E3 – 36

3.2 Diagnostic Tables

Automatic Transmission Overheating

Check Causes

Fluid Pump Assembly • Pressure regulator valve stuck

• Pressure regulator valve spring

• Line boost valve spring

• Line boost valve or bushing stuck, damag ed or

incorrectly assembled

• Pressure relief ball not seated or damaged

• Pressure relief ball spring

• Fluid pump screen assembly plugged or damaged

• Fluid pump rotor guide omitted or misassembled

• Fluid pump rotor cracked or broken

• Porosity in fluid pump

• Fluid pump surfaces not flat

• Excessive fluid pump rotor clearanc e

Pressure Control Solenoid Assembly • Contaminated

• O-rings cut or damaged

• Electrical connection

Inspect for active transmission DTCs Transmission DTC default action active

Buzz Noise or High Frequency Rattle Sound

Check Causes

Definition: A buzz or high frequency rattle.

• Trace Cooler Pipes

• Check for binding or contact at the Radiator, other

than at the Cooler Pipe connectors

Verify a pressure buzz by watching for a nee dle vibration

of the pressure gauge. A road test may be necessar y.

Refer to Road Test Procedure

Degraded 1–2 and 2–1 Shifts

Check Causes

Definition: One of the two following conditions occurs during a first to Second gear stea dy throttle upshift, or a Second

to First gear coast, or a light to moderate throttle detent downshift:

• Harsh shift feel An unacceptable quick gear change occurs.

• Soft shift feel An unacceptable long gear change occurs.

Second Clutch Damaged piston, 1-2, 2-1 shift

Damaged or worn clutch plates, 1-2, 2-1 shift

Pressure Control Solenoid Damaged

Fluid Pump Damaged

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–37

7E3 – 37

Degraded 2–3 and 3–2 Shifts

Check Causes

Definition: One of the two following conditions occurs during a second to Third gear steady throttle upshift, or a third to

second coast, or a light to moderate throttle detent downshift:

• Harsh shift feel – An unacceptabl e quick gear change occurs.

• Soft shift feel – An unacceptable long gear c hange occurs.

Intermediate Clutch Damaged piston, 2–3, 3–2 shift

Damaged or worn clutch plates, 2–3, 3–2 shift

Pressure Control Solenoid Damaged

Fluid Pump Damaged

Degraded 4–5 Shift

Check Causes

Definition: One of the two following conditions occurs during a fourth to Fifth gear steady throttle upshift, or a fifth to

fourth coast, or a light to moderate throttle detent downshift:

• Harsh shift feel – An unacceptabl e quick gear change occurs.

• Soft shift feel – An unacceptable long gear c hange occurs.

Coast Clutch • Damaged or cut piston

• Damaged or worn clutch plates

• Damaged or stuck ball check valve

Intermediate Clutch • Damaged piston, 2–3, 3–2 shift

• Damaged or worn clutch plates, 2–3, 3–2 shift

Overdrive Clutch • Damaged or worn clutch plates

• Damaged or worn piston

Pressure Control Solenoid Damaged

Fluid Pump Damaged

Drives with Selector Lever in Position N

Check Causes

Definition: Vehicle moves forward while in N eutral.

Forward Clutch and Coast Clutch Assembl y • Damaged or worn clutch plates

• Damaged or cut piston

• Damaged or stuck ball check valve

Selector Lever Adjustment

Fifth Gear Only

Check Causes

Definition: The transmission only provid es Fifth gear in Drive range. T he vehicle accelerates from a stop in Fifth gear.

Control Valve Body Accumulator Assembly Feed limit valve or spring stuck in the e xhau st position

Wiring Harness Improper electrical connection to shift solenoids

Inspect for active transmission DTCs Transmission DTC default action active

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–38

7E3 – 38

First and Second Gears Only

Check Causes

Definition: The transmission only provides first and Second gear in Drive range.

Control Valve Body Accumulator Assembly • 2–3 SS valve stuck

• 2–3 shift valve stuck applied

• Spacer plate or gaskets are positioned incorrectly or

damaged

First Gear Only

Check Causes

Definition: The transmission only provid es First gear in Drive range. The vehicle accelerates from a stop in First gear

and does not upshift.

Control Valve Body Accumulator Assembly • 1–2 shift control valve stuck applied

• 1–2 shift valve stuck applied

• The spacer plate or gasket ar e positioned incorrectly

or damaged

Shift Solenoid Valve Faulty electrical connection

First, Fourth and Fifth Gears Only

Check Causes

Definition: The transmission provides first, fourth and Fifth gear in Drive r ange.

Control Valve Body Accumulator Assembly • 1–2 SS valve stuck off

• Spacer plate or gaskets are positioned incorrectly or

damaged

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–39

7E3 – 39

Fluid Pressure High or Low

Check Causes

Definition: Transmission main line pressure that is determined to be high or low. Refer to 2.4 Line Pressure Checking

Procedure in this Section.

Fluid Pump Assembly • Pressure regulator valve stuck

• Pressure regulator valve spring

• Line boost valve spring

• Line boost valve or bushing stuck, damag ed or

incorrectly assembled

• Pressure relief ball not seated or damaged

• Pressure relief ball spring

• Pump slide seal out of location

• Fluid pump screen assembly plugged or damaged

• Fluid pump rotor guide omitted or incorrectly

assembled

• Fluid pump rotor cracked or broken

• Porosity in fluid pump

• Fluid pump surfaces not flat

• Excessive fluid pump rotor clearanc e

Fluid Filter • Intake pipe restricted

• Cracks in fluid filter

• Fluid filter seal missing, cut or damaged

Control Valve Body Accumulator Assembly • Manual valve scored or damaged

• Spacer plate or gaskets assembled incorrectly or

damaged

• Control valve top channel pl ate not flat

• Control valve bottom channel plate not flat

• Feed limit valve or spring stuck in the exhaust

position

Pressure Control Solenoid Assembly • Contaminated

• O-rings cut or damaged

• Electrical connection

System Voltage 12 volts not supplied to transmission

Clutch Accumulator Leaking

Inspect for active transmission DTCs Transmission DTC default action active

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–40

7E3 – 40

Harsh Shift 4–5, or 5–4

Check Causes

Definition: One of the two following conditions occurs during a 4th to 5th and 5th to 4th gear steady throttle upshift, or a

4th to 5th gear coast, or a light to moderate throttle detent downshift:

Harsh shift feel – an unacceptable quick gear change occurs.

Overdrive Clutch and Coast Clutch • Damaged or cut piston

• Damaged or worn clutch plates

Fluid Pump Assembly • Pressure regulator valve stuck

• Pressure regulator valve spring

• Line boost valve spring

• Line boost valve or bushing stuck, damag ed or

incorrectly assembled

• Fluid pump screen assembly plugged or damaged

• Fluid pump rotor guide omitted or incorrectly

assembled

• Fluid pump rotor cracked or broken

• Porosity in fluid pump

• Fluid pump surfaces not flat

• Excessive fluid pump rotor clearanc e

• Pump slide seal out of location

• Pump vanes damaged

• Pump slide spring damaged

Pressure Control Solenoid Damaged

Harsh Shift D–R

Check Causes

Definition: Gear engagement that is harsh when the eng ine is idling in Park or Neutral, and the gear selector is moved

to Drive or Reverse range.

Forward Clutch • Damaged or worn piston (436)

• Damaged or worn clutch plates (449)

• Damaged or stuck ball check valve (434)

Reverse Clutch • Damaged or worn piston (404)

• Damaged or worn clutch plates (418 / 417)

• Damaged or stuck ball check valve (403)

Fluid Pump Assembly Refer to Harsh Shift 4 – 5, or 5 – 4.

PC Solenoid Damaged

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–41

7E3 – 41

Harsh Shifts

Check Causes

Definition: Harsh shift feel - an unacceptable quick gear change occurs.

Pressure Control Solenoid • Damaged O-rings

• Contamination

Output Speed Sensor Open or grounded circuit

Input Speed Sensor Open or grounded circuit

Throttle Position Open or grounded circuit

Forward Clutch Assembly • Damaged or worn clutch plates

• Damaged or cut piston

• Damaged or stuck ball check valve

Control Valve Body Accumulator Assembly • Accumulator piston stuck

• Stuck or missing ball check valves

Fluid Pump • Pressure regulator valve stuck

• Pressure regulator valve spring

• Line boost valve spring

• Line boost valve or bushing stuck, damag ed or

incorrectly assembled

• Fluid pump screen assembly plugged or damaged

• Fluid pump rotor guide omitted or incorrectly

assembled

• Fluid pump rotor cracked or broken

• Porosity in fluid pump

• Fluid pump surfaces not flat

• Excessive fluid pump rotor clearanc e

• Pump slide seal out of location

• Pump vanes damaged

• Pump slide spring damaged

Inspect for active transmission DTCs Transmission DTC default action active

Harsh Torque Converter Clutch (TCC) Apply

Check Causes

Definition: An unacceptable quick TCC apply or release occurs in Third, Fourth or Fifth gear, Overdrive, Drive or Manual

Third range, with the throttle held steady.

Control Valve Body and Accumulator Assembly Stuck TCC regulator apply valve

TCC Solenoid Valve Stuck ON

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–42

7E3 – 42

Inaccurate Shift Points

Check Causes

Definition: An upshift or a downshift, or TCC apply, that occurs at a speed outside of the calibrated range. Refer to

4. 5L40–E Shift Speed Charts in this Section.

Fluid Pump Assembly • Stuck pressure regulator valve

• Sticking pump slide

Control Valve Body Accumulator Assembly Spacer plate and gasket misaligned or damaged

Throttle Position Sensor Disconnected or damaged

Input Speed Sensor • Disconnected or damaged

• Sensor to transmission case bolt not tightened

correctly

Output Speed Sensor • Disconnected or damaged

• Sensor to transmission case bolt not tightened

correctly

Shift Solenoids Leaking

Power Mode Active Refer to Power Mode Switch / Indicator Al ways On or

inoperative

No Drive in All Ranges

Check Causes

Definition: A large engine rpm increase is noted, with no vehicle for ward speed incre ase, during the following conditions:

• The engine is running.

• The transmission is in Drive range.

• The vehicle is stopped or moving slowly.

• The vehicle brakes are not applied.

• The throttle is opened 25 percent or greater.

Forward Clutch Assembly • Damaged or worn clutch plates

• Damaged or cut piston

• Damaged or stuck ball check valve

Forward Clutch Sprag • Damaged sprag

• Worn or pitted inner race

Fluid Pump • Damaged vanes

• Missing slide spring

• Fluid pump screen assembly plugged or damaged

• Fluid pump rotor guide omitted or misassembled

• Fluid pump rotor cracked or broken

• Porosity in fluid pump

• Fluid pump surfaces not flat

• Excessive fluid pump rotor clearanc e

Low Clutch Sprag • Damaged sprag

• Worn or pitted inner race

Input and Reaction Carrier Damaged or worn gears

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–43

7E3 – 43

No Engagement of Torque Converter Clutch (TCC)

Check Causes

Definition: A large difference in rpm is noted bet ween the engine speed and the transmission inp ut turbine speed in

Third or Fourth gear, Drive or Manual Third range when the TCC is commanded ON by the PCM.

Control Valve Body and Accumulator Assem bly • TCC regulator apply valve stuck released

• TCC regulator apply valve spring broken

Torque Converter Housing Transmission fluid pump cover damaged or misali gned

TCC PWM Solenoid Assembly • Stuck Off

• Internal damage

• Damaged or cut O-ring

• Screen damaged

• Electrical connector damage

Fluid Pump • Stuck, binding TCC control valve

• TCC enable valve

• Stick or binding TCC enable valve spring

• Misaligned gasket

Turbine Shaft Damaged or cut O-ring

Inspect for active transmission DTCs Transmission DTC default action active

No Engine Braking

Check Causes

Definition: A large engine rpm increase and for ward vehicle speed decrease do not immediately occu r when the

transmission is shifted from Overdrive or Fourth gear in Drive or Manual Third range to either First, Second gear, or Third

gear, Manual Second.

Coast Clutch • Damaged or cut piston

• Damaged or worn clutch plates

• Damaged or stuck ball check valve

Overdrive Clutch • Damaged or cut piston

• Damaged or worn clutch plates

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–44

7E3 – 44

No Engine Braking in First Gear

Check Causes

Definition: A large engine rpm increase and for ward vehicle speed decrease do not immediately occu r when the

transmission is shifted from Overdrive or Fourth gear in Drive or Manual Third range to First.

Low and Reverse Clutch • Damaged or cut piston

• Damaged or worn clutch plates

Control Valve Body Accumulator Assembly • 3–4 shift control valve stuck

• 3–4 shift valve stuck – 1st, 2nd or 3rd gear

• Low pressure control valve – 1st, 2nd or 3rd gears

• 4–5 SS valve stuck off – 1st, 2nd or 3rd gears

• 4–5 shift valve stuck applied – 1st, 2nd or 3rd gears

• 3–4 shift valve and / or 3–4 control shift valve stuck

released

• Low pressure control valve stuck released

• 4–5 shift valve and / or 4–5 control shift valve stuck

released

• 1–2 shift valve stuck released

No Engine Braking in First, Second and Third Gear

Check Causes

Definition: A large engine rpm increase and for ward vehicle speed decrease do not immediately occu r when the

transmission is shifted from Overdrive or Fourth gear in Drive range to either First or Second gear, Manual Second.

Control Valve Body Accumulator Assembly • 3–4 shift valve stuck released

• Missing or stuck low pressure control valve

• 4–5 shift valve and / or 4–5 control shift valve stuck

released

• 1–2 shift valve stuck released

• 2–3 shift valve and / or 2–3 control shift stuck

released

No Engine Braking in Second Gear

Check Causes

Definition: A large engine rpm increase and for ward vehicle speed decrease do not immediately occu r when the

transmission is shifted from Third to Fourth gear in Driv e or Manual Third range to either Second gear, Manual Second.

Coast Clutch • Damaged or cut piston

• Damaged or worn clutch plates

• Damaged or stuck ball check valve

• 3–4 shift valve and / or 3–4 control shift valve stuck

released

• Low pressure control valve stuck released

• 4–5 shift valve and / or 4–5 control shift valve stuck

released

• 1–2 shift valve stuck applied

• 2–3 shift and / or 2–3 control shift stuck released

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–45

7E3 – 45

No Engine Braking in Third Gear

Check Causes

Definition: A large engine rpm increase and for ward vehicle speed decrease in Third gear do not immediately occur

when the transmission is shifted from overdriv e or F ourth ge ar in Drive or Manual Third range to Third gear ran ge.

Overdrive Clutch • Damaged or cut piston

• Damaged or worn clutch plates

Control Valve Body Accumulator Assembly • 3–4 shift valve and / or 3–4 control shift valve stuck

released

• Low pressure control valve stuck released

• 4–5 shift valve and / or 4–5 control shift valve stuck

released

• 1–2 shift valve stuck applied

• 2–3 shift and / or 2–3 control shift stuck applied

No Fifth Gear

Check Causes

Definition: A large engine rpm increase is noted in Fifth gear, Drive ran ge, with little or no vehicle forward speed

increase. First, Second, Third gear and Fourth operation are normal. Shifts into Fifth gear are soft or do not occur.

Control Valve Body Accumulator Assembly • 4–5 SS valve stuck On

• 4–5 shift valve stuck applied

• 4–5 shift control valve stuck applied

Overdrive Clutch • Damaged or cut piston

• Damaged or worn clutch plates

No First Gear

Check Causes

Definition: A large engine rpm increase is noted in First gear, Drive ran ge, with little or no vehicle forward speed

increase. Second, Third and Fourth ge ar operation are normal. Shifts into First gear are soft or do not occur.

Control Valve Body Accumulator Assembly • 1–2 shift control valve stuck released

• 1–2 shift valve stuck released

• 1–2 SS valve stuck ON

Forward and Low Clutch Sprag • Damaged sprag

• Worn or pitted inner race

Forward Clutch Assembly Damaged

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–46

7E3 – 46

No Fourth Gear or Slips in Fourth Gear

Check Causes

Definition: A large engine rpm is noted in Fourth gear or no vehicle forward speed increase. Shifts into Fourth gear are

soft or do not occur.

Control Valve Body Accumulator Assembly • 3–4 shift valve stuck applied

• 3–4 shift control valve stuck applied

Direct and Reverse Clutch • Damaged or worn piston (406)

• Damaged or worn clutch plates

• Damaged ball check valve (405)

No Reverse or Slips in Reverse

Check Causes

Definition: A large engine rpm increase is noted with little or no vehicle rearward speed increase during the following

conditions:

• The engine is running.

• The transmission is in Reverse range.

• The vehicle is stopped or moving slowly.

• The vehicle brakes are not a pplied.

• The throttle is opened 25 percent or great er.

Direct and Reverse Clutch Assembly • Damaged reverse clutch housing ball check valve

• Damaged or cut piston

• Damaged or worn clutch plates

Control Valve Body Accumulator Assembly • Reverse lockout valve stuck

• TCC PWM solenoid valve leaking

Selector Lever Adjustment

No Second Gear

Check Causes

Definition: A large engine rpm increase is noted in Second gear, Drive range, with little or no vehicle forward speed

increase. First, Third, and Fourth gear operation are n ormal. Shifts into Sec ond gear are soft or do not occur.

Second Clutch • Damaged piston

• Damaged or worn clutch plates

Second Coast Clutch • Damaged piston

• Damaged or worn clutch plates

Second Clutch Sprag • Damaged sprag

• Worn or pitted inner race

Second Clutch Fluid Passage Sleeve Leaking

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–47

7E3 – 47

No Third Gear

Check Causes

Definition: A large engine rpm increase is noted in Third g ear, Drive ra nge, with no vehicle forward speed increase.

First, Second, and Fourth gear operation are normal. Shifts into Third gear are soft or do not occur.

Intermediate Clutch Sprag • Damaged sprag

• Worn or pitted inner race

Intermediate Clutch • Damaged piston

• Damaged or worn clutch plates

Intermediate Fluid Passage Sleeve Leaking

Noise in Random Ranges

Check Causes

Definition: Noise only in certain gear ran ges

Refer to 2.13 Range Reference Chart in this Section to determine the power flow and the applicable co mponents that

may be causing this noise.

Popping Noise

Check Causes

Definition: A popping noise, similar to popcorn popping

Fluid Pump System • Check fluid level.

• Inspect for pump cavitation, indicated by bubbles in

fluid.

• Inspect the transmission fluid filter for a leaky seam.

• Inspect the transmission fluid filter seal for improper

positioning or for a cut seal.

Power Mode Switch / Indicator Always On or Inoperative

Check Causes

Definition: The ‘PWR’ icon in the Multi Function Display (MFD) in the Instrument is either always activated or is not

activated when the momentary contact ‘PWR’ switch in the centre console is pressed with the ignition in the ON position.

‘A/S’ switch and/or electrical circuit. • Switch failure.

• Electrical circuitry relating to the switch circuit.

Instrument • MFD malfunction.

Second and Third Gears Only

Check Causes

Definition: The transmission only provid es second and Third gear in Drive rang e. The shift pattern as the vehicle

accelerates from a stop is 2-–2–3–3.

Control Valve Body Accumulator Assembly • 1–2 SS valve stuck applied

• Spacer plate or gaskets are positioned incorrectly or

damaged

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–48

7E3 – 48

Slips or Shudders in First Gear

Check Causes

Definition: A large engine rpm increase is noted in First gear, Drive ran ge, with little or no vehicle forward speed

increase. Second, Third, and Fourth gear op eratio ns are normal. Shifts into First gear are soft or do not occur. First gear

ratio is 2.921:1

Forward Clutch • Clutch plates worn

• Porosity in the piston

• Piston seal damaged

• Forward clutch housing ball check valve not sealing

or damaged

• Input shaft fluid seals damaged or missing

Control Valve Body Accumulator Assembly • Face not flat

• Spacer plate or gaskets positioned incorrectly or

damaged

Input Sun Gear Shaft Broken shaft

Forward Sprag Clutch Assembly Sprags not holding

Low Clutch Sprag Assembly Sprags not holding

Torque Converter Assembly Stator roller clutch not holding

Line Pressure Refer to Fluid Pressure High or Low

Slips While Shifting

Check Causes

Definition: A large engine rpm increase is noted in Fifth, Fourth, T hird, Second or first in Drive range, with little or no

vehicle forward speed increas e. Shifts into Fifth, F ourth, Third, Second or First gear are soft or do not occur.

Control Valve Body Accumulator Assembly • Accumulator piston seals

• Porosity in the accumulator piston housings

• Stuck or missing ball check valves

Pressure Control Solenoid Damaged

Fluid Pump Damaged

Whine Noise Varying with RPM or Fluid Pressure

Check Causes

Definition: In all ranges, a whine which may be sensitive to rpm load or which ceases when the TCC engages or which

is sensitive to the oil pressure

Torque Converter (1) Verify that the noise is internal to the torque converter by

placing your left foot on the brake with the gear or selector

in Drive.

Oil Pump System Pump whine noise, which is usually notice ab le in Park,

Neutral and all other gear ran ges. Pump whine will vary

with line pressure.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–49

7E3 – 49

4 5L40-E Shift Speed Charts

4.1 Introduction

To assist in the interpretation of the following charts, the following logic has been applied:

1 All upshifts are shown with a solid lin e an d filled diamond plot points – 1-2 is dark blue, 2-3 is red, 3-4 is dark green

and 4-5 is dark purple.

2 All downshifts also have a solid line with filled circular plot points – 2-1 is pale blue, 3-2 is orange, 4-3 is light green

and 5-4 is light purple (or lilac).

3 Torque converter clutch (TCC) apply points (‘App 2’, etc.) have a solid line with filled triangul ar plot points – ‘App 2’

is dark blue, ‘App 3’ is red, ‘App 4’ is dark green and ’App 5’ dark purple.

4 Torque converter clutch (TCC) release points (‘Rel 2’, etc) have a dashed lin e with open triangular plot points –

‘Rel 2’ is dark blue, ‘Rel 3’ is red, ‘Rel 4’ is d ark gree n and ‘Rel 5’ is dark purple.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–50

7E3 – 50

4.2 Shift Patterns – All With 3.6L Alloytec190

Engine

3. 6L HFV6 - ECONOM Y SHIFT MODE

100

120

0 25 50 75 100 125 150 175 200 225 250

Vehicle Speed [km/h]

Throttle [%

]

1-2 2-1 2-3 3-2 3-4 4-3 4-5 5-4

App 2 Rel 2 A pp 3 Rel 3 App 4 Rel 4 App 5 Rel 5

Figure 7E3 – 7

3. 6 L HFV6 - POWER SHI FT M ODE

100

120

0 25 50 75 100 125 150 175 200 225 250

Veh icle S peed [km/ h]

Throttle [%

]

1-2 2-1 2-3 3-2 3-4 4-3 4-5 5-4

App 2 Re l 2 App 3 Re l 3 App 4 Rel 4 App 5 Re l 5

Figure 7E3 – 8

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–51

7E3 – 51

3.6L HFV 6 - CRUI SE CONTRO L MO DE

100

120

0 25 50 75 100 125 150 175 200 225 250

Veh icle S peed [km/ h]

Throttle [%

]

1-2 2-1 2-3 3-2 3-4 4-3 4-5 5-4

App 2 Rel 2 App 3 Rel 3 App 4 Rel 4 App 5 Rel 5

Figure 7E3 – 9

3. 6 L HFV6 - ACTI VE SELECT MODE

100

120

0 25 50 75 100 125 150 175 200 225 250

Veh ic le Speed [km/ h]

Throttle [%

]

1-2 2-1 2-3 3-2 3-4 4-3 4-5 5-4

App 2 Rel 2 App 3 Rel 3 App 4 Rel 4 App 5 Re l 5

Figure 7E3 – 10

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–52

7E3 – 52

5 Power / Fluid Flow and Circuit

Descriptions

For information on the following power flows through the following range selections, that includes mechanical power

flows and hydraulic descriptions, refer to Power Flo ws, in the Hydra-Matic 4/5L40-E Technician’s Guide, included on the

current PV-SIP CD ROM:

• Park (Engine Running)

• Reverse

• Neutral (Engine Running)

• Overdrive Range, First Gear (Before First 1–2 Shift)

• Overdrive Range, First Gear (After First 1–2 Shift)

• Overdrive Range, Second Gear

• Overdrive Range, Third Gear

• Overdrive Range, Fourth Gear

• Overdrive Range, Fifth Gear (Torque Converter Clutch Released)

• Overdrive Range, Fifth Gear (Torque Converter Clutch from Released to Applied)

• Manual Fourth Gear (From Overdrive Range – Fifth Gear)

• Manual Third Gear (From Manual Fourth – Fourth Gear)

• Manual Second Gear (From Manual Third – Third Gear)

• Manual Second – First Gear (From Manual Secon d – Seco nd Gear)

NOTE

The above range descriptions each contain a

simplified hydraulic circuit to sho w what hydraulic

action occurs for that specific range. For the

complete hydraulic circuit for each range, that

also includes active fluid passages, refer to

Complete Hydraulic Circuits, in the Hydra-Matic

4/5L40-E Technician’s Guide.

Automatic Transmission – 5L40-E – Hydraulic and Mechanical Diagnosis Page 7E3–53

7E3 – 53

6 Special Tools

Tool Number Illustration Description Tool Classification

7000086i

Tech 2 Scan Tool

Used for diagnosis of vehicle electrical

systems.

Previously released

Mandatory

J 21867

Pressure Gauge and Ho se

Assembly

Used for checking automatic

transmission line pressure.

Previously released

J 21867–L40

Pressure Gauge Hose Adaptor

Use of this adaptor enables the

existing, J 21867 pressure gauge to

be installed to the 5L40-E

transmission line pressure test port.

New release

Mandatory

J 28431–B

Fluorescent Oil Dye

Used in conjunction with black light,

leak detection lamp J 42220 to locate

various types of vehicle fluid leaks.

Supplied in 24, 1 oz bottles.

Previously released

Desirable

J 42220

12 Volt Black Light

Also available as tool no. 16296

Used in conjunction with Fluorescent

Oil Dye to locate various types of

vehicle fluid leaks.

Previously released

Desirable