Initial Inspection

Diagnosis Flow Chart AX4S:

Preliminary Inspection
The following items must be checked before proceeding:
1. Know and Understand the customer's concern.
2. Validate customer's concern (when does it exist?)
a. Upshift
b. Downshift
c. Coasting
d. Engagement
e. Noise/Vibration

Note:
If Noise/Vibration check for dependencies.
- RPM dependent.
- Vehicle speed dependent.
- Shift dependent.
- Gear dependent.
- Range dependent.
- Temperature dependent.

3. Vehicle at normal operating temperature.
4. Check Fluid Level and Condition.

Note: The AX4S transaxle cannot have fluid level established at room temperature.
- Fluid level can only be checked at room temperature 21°C-35°C (70°F-95 °F) (dipstick cool to the touch) to verify that the level is above the DO NOT DRIVE mark.
- If fluid level is below, then add only enough Synthetic MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON equivalent to bring the level above the DO NOT DRIVE mark. Operating temperature must be obtained as outlined to establish correct fluid level if any fluid is added during room temperature check.

5. Visually inspect the vehicle for the following items:
- Vehicle Modifications.
- Electronic Add-On items.
- Leaks.
- Proper linkage adjustments.
6. Check TSB'S for Concern Information.
7. Perform the COMPLETE On-Board Diagnostic procedures (KOEO, KOER).

Verification of Condition
This section provides information which must be used in both determining the actual cause of customer concerns and performing the appropriate service procedures.

The following procedures must be used when verifying customer concerns for transmission:
1. Required equipment:
- Transmission Tester 007-0085C or equivalent
- SUPER STAR II Tester 007-0041B or equivalent

Note: The SUPER STAR II Tester 007-0041B or equivalent must be used on fast mode to properly display the On-Board Diagnostic codes.

- Digital Volt Ohmmeter 007-00407 or equivalent
- Transmission Range (TR) Sensor Cable (MLPS Cable) (007-00086) used with (007-0085C)
- Manual Lever Position Sensor Alignment Tool T92P-70010-AH
- 60-Pin Breakout Box 007-00033 or equivalent
2. Determine customer concerns relative to vehicle usage:
- Hot or cold vehicle operating temperature
- Hot or cold ambient temperatures
- Type or terrain
- Vehicle loaded/unloaded
- City driving/Highway driving

Note: Some transmission conditions may cause engine concerns. An EPC short circuit may cause alternate firing. The torque converter clutch not disengaging will stall the engine.

3. Fluid level and condition.
4. Road test vehicle to verify customer concerns using the Shift Point and Torque Converter Clutch Application Tests.

Note:
Inspect vehicle for non-Ford approved add-on devices such as:
- Air conditioning
- Generators (alternators)
- Engine turbos
- Cellular telephones
- Cruise controls
- CB radios
- Linear boosters
- Backup alarm signals
- Computers
- These items, if not installed properly, will a ifect PCM or transmission function. Pay particular attention to add-on wiring splices in the PCM or transmission wiring harness, abnormal tire size or axle ratio changes.

After a road test, with the vehicle warm and before disturbing any connectors, perform the Quick Testing using SUPER STAR II Tester 007-0041B or equivalent.