A/T - Chattering Sounds/Shift Concerns
NUMBER: 21-007-05GROUP: Transmission
DATE: March 9, 2005
SUBJECT:
Automatic Transmission Shifting Concerns
MODELS:
2001 - 2005 (VA) Sprinter
SYMPTOM/CONDITION:
If the vehicle operator describes shifting concerns or shudder follow the diagnostic procedure below.
^ Chatter like sounds or shudder may be related to oil level or oil quality (P2005).
^ Shifting concerns may be caused by a fault in the Transmission Control Module (TCM) (P2502).
DIAGNOSIS/REPAIR:
1. Attempt to reproduce the Symptom/Condition and verify that the Symptom/Condition is caused by the transmission.
2. Use the DRBIII(R) to determine if any Diagnostic Trouble Codes (DTC's) are stored, record them on the repair order and repair as necessary before proceeding further with this service bulletin.
3. If the DTC "P2502 - Transmission Slipping" is present, proceed to Step # 4. If not, proceed to Step # 7.
4. Check the TCM p/n. If the TCM p/n is 030 545 18 32, 030 545 28 32 or 030 545 38 32, proceed to Step # 5. If not, proceed to Step # 7.
5. Replace the TCM, as follows:
a. Disconnect and isolate the negative battery cable.
b. Remove the seat track mounting bolts
c. Disconnect the electrical connectors, if equipped.
d. Remove two screws for the access panel.
e. Reposition the seat and the access panel out of the way.
f. Remove the two (2) fasteners mounting the 1CM to the mounting bracket.
g. Unplug the TCM electrical connectors.
h. Remove the TCM.
i. Connect the TCM electrical connectors to the new TCM, p/n 05120820AA.
j. Position the TCM to the mounting brackets and loosely install both fasteners. Tighten both fasteners.
k. Place the access panel in position and install the two screws.
l. Position seat in the vehicle and connect the electrical connectors, if equipped.
m. Install the seat track mounting bolts and tighten to 25 N.m (18 ft.lbs.).
n. Connect the negative battery cable.
6. Attempt to reproduce the Symptom/Condition. If the Symptom/Condition is corrected, proceed to Step # 17. If the Symptom/Condition still exists, proceed to Step # 7.
7. Remove the transmission oil filler cap. Using Miller special tool 8863B, check the transmission fluid level while the transmission is at normal operating temperature, 80° C (176° F), and adjust as necessary using Mopar p/n 05127382AA Automatic Transmission Fluid. Refer to the service information available in TechCONNECT under: Service Info, 21 - Transmission/Transaxle/Automatic - Nag1/Filter - Standard Procedure - Check Oil Level.
8. Reset the adaptation data in the TCM. Using the DRBIII(R) select:
a. "Run Memory Card Program" and follow the directions on the DRBIII(R).
b. When the Main Menu appears select "System Select"
c. Select "Transmission"
d. Select "Transmission Control (TCM)"
e. Select "System Test"
f. Select "Resetting of Adaptation Data" and follow the directions on the DRBIII(R).
g. When the Adaptation Data reset is completed, proceed to the next step.
9. Attempt to reproduce the Symptom/Condition. If the Symptom/Condition is corrected, proceed to Step # 17. If the Symptom/Condition still exists, proceed to Step # 10.
10. Change the filter and fluid in the transmission and the fluid in the torque converter using Mopar p/n 05127382AA Automatic Transmission Fluid. Refer to the service information available in TechCONNECT under: Service Info, 21 - Transmission/Transaxle/Automatic - Nag 1/Filter - Standard Procedure - Fluid/Filter Service.
11. Reset the adaptation data in the TCM. Using the DRBIII(R) select:
a. "Run Memory Card Program" and follow the directions on the DRBIII(R).
b. When the Main Menu appears select "System Select"
c. Select "Transmission"
d. Select "Transmission Control (TCM)"
e. Select "System Test"
f. Select "Resetting of Adaptation Data" and follow the directions on the DRBIII(R).
g. When the Adaptation Data reset is completed, proceed to the next step.
12. Attempt to reproduce the Symptom/Condition. If the Symptom/Condition is corrected, proceed to Step # 17. If the Symptom/Condition still exists, proceed to Step # 13.
13. If the chatter like sounds or shudder symptom is still present, check the condition of the flexplate. If the flexplate is warped or cracked, proceed to Step # 14. If the flexplate is not warped or cracked, proceed to Step # 16.
14. Replace the flexplate. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, Engine, Engine Block, Flexplate. When the flexplate repair is complete, proceed to the next step.
15. Attempt to reproduce the Symptom/Condition. If the Symptom/Condition is corrected, proceed to Step # 17. If the Symptom/Condition still exists, proceed to Step # 16.
16. Replace the torque converter. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 21 - Transmission/Transaxle/Automatic - Nag1/Torque Converter. When the torque converter repair is complete, proceed to the next step.
17. Perform the NAG1 Transmission Verification Test - VER-1. Refer to the service information available in TechCONNECT under: Diagnostics, Transmission, Verification Tests.
18. If necessary, reset the clock to the correct time and enter the radio code.
19. When the repair is complete, if the transmission oil fill cap was removed; be sure the 0 ring, p/n 05101154AA, is in place on the transmission oil filler cap and place the cap in the transmission oil fill tube (Fig. 1).
20. Install a new locking pin, p/n 5093746AA, in the cap to lock it in place.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.