A/T - DTC U0101/C1612/Stuck In PARK/Stays In 3rd Gear

GROUP
Trans

NUMBER
035 [Rev 1, 3/7/11]

MODEL
2009MY Borrego (HM)
w/4.6L engine

DATE
March 2011

SUBJECT:
ZF ATM MECHATRONIC REPLACEMENT





Notice
Changes are also noted by asterisks.

This bulletin provides information relating to some Borrego (HM) vehicles with 4.6L engine and ZF 6-speed transmission that might exhibit illumination of ESC-OFF warning light and with the following conditions listed below.

^ The shift lever gets stuck in the park position

^ 3rd gear hold occurs while driving

^ DTC U0101, and/or C1612 for ESC/ESP system are detected





If any of the DTCs listed above occur, a possible cause may be static electricity affecting the TCU (Transmission Control Unit). To correct this condition, replace the described updated parts by following the procedure outline in this bulletin.

Before Replacing Mechatronic Assembly:

The cause for the condition(s) listed on the previous page may also be due to a poor connection at the main TCU harness at the CTG-2F connector. If necessary, restore connection after applying Stabilant 22A to the connector and then test drive the vehicle. If this does not correct the condition, proceed to step 1.

Mechatronic Replacement Service Procedure:

1. Lift up vehicle.





Disconnect the TCU wiring connector (A) at the rear of the transmission (B) by turning it counterclockwise.





2. Disconnected TCU wiring connector.





3. Remove the ATF drain plug (C) and drain transmission fluid.





4. Remove transmission oil pan and set aside in a safe, clean location.





Transmission shown with the oil pan removed.





5. Pull the white clip (D) downward as indicated in the photos.





6. Remove the guide sleeve (E) out of the case by turning sleeve counterclockwise.





7. Remove the ten (10) mounting bolts (circles), and then remove mechatronic assembly (F).





8. Remove the old adapter (G).





9. Install the new adapter (H) to the transmission as shown in the photo.





10.





11. Carefully align the range switch (I) with the manual valve (J) when installing new Mechatronic assembly as indicated in the photo.





12. After installing new mechatronic assembly (K) and the ten (10) mounting bolts; tighten the mounting bolts to the torque specification listed below, and in the proper sequence as shown in the 2nd photo.

Tightening torque:

5.9 lb-ft (8 Nm)





13. Install the new guide sleeve (L) by inserting, then turning the sleeve clockwise.





14. Push the white clip (M) upward until it locks into place as indicated in the photos.





15. Reinstall the transmission oil pan, and then tighten the twenty four (24) mounting bolts in the sequence shown starting with number 1.

Tightening torque:
7.4 lb-ft (10 Nm)





16. Reconnect TCU wiring connector (0).





*17. Remove the ATF filler plug (P) on the side of the transmission; then fill to the proper level with ZF Lifeguardfluid6 (P/N: UHO80 CH032). Use clean equipment to avoid contamination.*





AFFECTED PRODUCTION RANGE:





REQUIRED PARTS:





SERVICE ACTION WARRANTY CLAIM INFORMATION: