Component Tests

Torque Converter Diagnosis
Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new torque converter.
Begin with the normal diagnostic procedures as follows:
1. Preliminary Inspection.
2. Know and Understand the Customer Concern.
3. Verify the Concern-Carry out the Torque Converter Clutch Operation Test.
4. Carry out Diagnostic Procedures.
- Run on-board diagnostics; see On-Board Diagnostics With NGS, refer to Diagnostics.
- Repair all non-transmission related DTCs first.
- Repair all transmission DTCs.
- Rerun on-board diagnostic to verify repair.
- Carry out the Line Pressure Test.
- Carry out the Stall Speed Test.
- Carry out the Diagnosis by Symptom Routine for torque converter diagnosis. Refer to Diagnosis By Symptom.
- Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and service as necessary before servicing the torque converter.

Torque Converter Operation Test
This test verifies that the torque converter clutch control system and the torque converter are operating correctly.
1. Carry out the Quick Test; see On-Board Diagnostics With NGS, refer to Diagnostics. Check for DTCs. Refer to the Diagnostic Trouble Code Charts.
2. Connect a tachometer to the engine.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in D5 position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot.
5. The engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, see Torque Converter Operation Concerns, Diagnosis By Symptom.
6. If the vehicle stalls in D5 or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, see Torque Converter Operation Concerns, Diagnosis By Symptom. Repair as necessary. If the vehicle does not stall in D5, refer to Diagnosis By Symptom.

Visual Inspection
This inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
- electronic add-on items:
- air conditioning
- generator (alternator)
- engine turbo
- cellular telephone
- cruise control
- CB radio
- linear booster
- backup alarm signal
- computer
- Vehicle modification:
These items, if not installed correctly, will affect the powertrain control module, or transmission function. Pay particular attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire size, or axle ratio changes.
- leaks. Refer to Leakage Inspection.
- correct linkage adjustments.

Shift Linkage Check
Check for a misadjustment in shift linkage by matching the detents in the transmission range selector lever with those in the transmission. If they match, the misadjustment is in the indicator. Do not adjust the shift linkage.
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating if the linkage is not correctly adjusted.

Check TSBs
Refer to all Technical Service Bulletins, which pertain to the transmission concern and follow the procedure.

Carry Out On-Board Diagnostics (KOEO, KOER)
After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using New Generation Star (NGS) Tester.