A/T - MIL ON/DTC P783 Set
TSB 06-7-304/17/06
WRENCH LIGHT ON - DTC P0783
FORD:
2006 Explorer
MERCURY:
2006 Mountaineer
ISSUE
Some 2006 Explorer 4dr and Mountaineer vehicles built prior to 1/31/2006 equipped with a 6R60 transmission may exhibit the powertrain malfunction indicator lamp (Wrench Light) on with diagnostic trouble code (DTC) P0783 (3-4 Shift Error). This may be the result of transmission fluid contamination, or a contaminated shift solenoid.
ACTION
Refer to the following Service Procedure to determine the appropriate repair procedure.
SERVICE PROCEDURE
1. Check transmission fluid for presence of water contamination by removing the transmission dipstick. If water contamination is present, replace the transmission assembly. If no water contamination is present, proceed to Step 2.
NOTE
TRANSMISSION FLUID CONTAMINATED BY WATER WILL HAVE A "PINK" MILKY APPEARANCE.
NOTE
IF TRANSMISSION REPLACEMENT IS REQUIRED, FOLLOW ALL NORMAL PROCEDURES AND GUIDELINES FOR PRIOR APPROVAL.
2. Test drive vehicle to obtain transmission shifts through all gear ranges.
a. If the transmission unsuccessfully attempts the 3-4 shift up to five (5) times, then turns on the Wrench Light and reverts to fail-safe mode, the shift solenoid is suspect. Proceed to Step 3.
b. If concern is present and can not be duplicated, do not continue with this TSB. Follow normal Workshop Manual diagnostics.
3. Remove the mechatronic assembly and replace the shift solenoid using the following steps:
a. Remove the mechatronic assembly following the procedure listed in the online Workshop Manual, Section 307-01B.
b. Once the mechatronic assembly is removed, remove the six (6) long bolts attaching the transmission control module (TCM) to the mechatronic assembly (Figure 1), and carefully separate the TCM from the mechatronic assembly.
NOTE
DO NOT USE TOOLS TO SEPARATE THE TCM FROM THE MECHATRONIC ASSEMBLY. DO NOT SEPARATE THE VALVE BODY HALVES DURING THIS PROCEDURE.
c. Remove the eight (8) solenoid bracket bolts and the solenoid bracket (Figure 2).
NOTE
DISASSEMBLY OF THE VALVE BODY IS NOT REQUIRED. THE SHIFT SOLENOID CAN BE IDENTIFIED AS THE ONLY WHITE SOLENOID ON THE MAIN CONTROL ASSEMBLY.
d. Remove and replace only the white shift solenoid (Figure 2).
e. Reinstall the solenoid bracket and the eight (8) bolts. Tighten to 71 lb-in (8 N.m).
f. Carefully reinstall the TCM onto the mechatronic assembly. Reinstall the six (6) bolts and tighten in the sequence shown in (Figure 3) to 53 lb-in (6 N.m).
g. Before reinstalling the mechatronic assembly into the transmission case, verify presence and proper orientation of the thermal bypass valve (Figure 4), center support seals (Figure 5) and pump adapter seal (Figure 6).
NOTE
THERMAL BYPASS VALVE - SPRING SIDE TOWARD TRANSMISSION CASE.
NOTE
REUSE CENTER SUPPORT SEALS. ENSURE PRESENCE AND PROPER LOCATION.
NOTE
REUSE PUMP ADAPTOR SEAL INSTALL AS SHOWN.
CAUTION
ONE (1) OR MORE OF THE CENTER SUPPORT SEALS MAY HAVE REMAINED IN THE MECHATRONIC ASSEMBLY DURING REMOVAL AND SHOULD BE INSTALLED INTO THE TRANSMISSION CASE AT THIS TIME.
h. Reinstall the mechatronic assembly following the procedure in the online Workshop Manual, Section 307-01B.
NOTE
VERIFY MANUAL VALVE AND CONTROL LEVER LINKAGE ALIGNMENT UPON INITIAL REINSTALLATION OF THE MECHATRONIC ASSEMBLY (FIGURE 7).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060703A 2006 Explorer, 3.3 Hrs.
Mountaineer 4.6L Engine
6R60 Transmission:
Replace Shift Solenoid,
Includes Time To Verify
Concern, Replace
Solenoid, Refill
Transmission, And
Reprogram The
Transmission Control Unit
(Do Not Use With
7000A13, 7191A, 7191A1,
7191A2, 7191A10,
7191AZG)
MT060703 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If
Available
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G484 49
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