Ford Galaxy / Ford S-MAX. Manual — part 484

Parking the vehicle,
performing tests or making adjustments,
leaving the vehicle standing with the engine running.

Know and understand customer concern

The problem must be fully understood before fault diagnosis is started, in order to clearly
establish the cause of a concern. Detailed information from the customer may be needed
for this.

Ask the customer under which conditions the concern appears. For example:

Cold or warm engine?
At what engine speed, vehicle speed, load?
In which gear or range?
At high or low outdoor temperature?
With the vehicle loaded or empty?
On what road surface?
In what driving situation:

while accelerating?
on overrun?
when shifting up or down?

Do noises occur?
What is the quality of the shift?
Does the gear engaged correspond to the display?
When the incorrect operation occurred, did a warning appear in the IC?

Verification of Condition

NOTE: If noise or vibration is a concern, check for dependency on: rpm, vehicle speed,
gear range or temperature.
NOTE: In some cases, faults in the automatic transmission may cause concerns over the
way the engine runs. For example, it can cause the engine to stall if the torque converter
lock-up clutch does not disengage.

If necessary and it is possible, ask the customer to demonstrate the concern to you. It may
also be an error in the way in which the vehicle is operated. Reproduce the fault by possibly
driving the vehicle yourself.

Visual Inspection

The visual inspection extends to obvious damage to mechanical or electrical
components, e. g.

Electrical connectors and cable connections
Ease of operation of the selector lever
Selector lever position and selector lever display
Fluid leakage
Transmission fluid level check
Transmission fluid quality check
Modifications/retrofitting/tuning
Damage

If any causes for a concern are found during the visual inspection, they must be corrected
before any further checks are made.

Electrical connectors and cable connections

Electrical connectors to and from the automatic transmission control electronics must only
be separated or connected when no voltage is present.

Ease of operation of the selector lever

A selector lever which is difficult to move may be the cause of a customer concern.

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Therefore move the selector lever through all positions and in doing so check it for ease of
movement. If there is difficulty in movement, detach the cable from the transmission and
move the lever again, to determine whether the stiffness is caused by the transmission or
the cable.

Selector lever position and selector lever display

This test is possible with the vehicle stationary and the engine running, and while driving.
When moving through the selector lever positions, compare the position selected with the
display in the instrument cluster.

For adjustment work
REFER to:

Selector Lever Cable Adjustment

(307-05 Automatic Transmission/Transaxle

External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21, General
Procedures).

Test for fluid leaks

CAUTIONS:

Only use the automatic transmission fluid approved by Ford.

Do not use a pressure washer or steam cleaner near any electrical connector.

NOTE: Refer to the service instructions for the frequency of changing the automatic
transmission fluid.
NOTE: Careful location of the source of leaks can avoid unnecessary or expensive repairs.

Thoroughly clean the transmission, engine and surrounding area. Depending on the severity
of the leak, a short or longer road test should be performed. It can also be useful to look
for leaks with the vehicle on the lifting platform and the engine idling. Check that the fluid
which has leaked out is really transmission fluid, and not engine oil.

Transmission fluid level check

It is not possible to check the level of the transmission fluid visually, because there is no
dipstick. If there is a concern, the transmission fluid level must be checked.

If it is necessary to check the transmission fluid level, the fluid must be drained and refilled,
REFER to: (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic
Transaxle - AWF21)

Transmission Fluid Level Check

(General Procedures),

Transmission Fluid Drain and Refill

(General Procedures).

Fluid quality check

NOTE: Dirty or overheated transmission fluid can cause impairment. The quality of the
transmission fluid should therefore be tested if there is a concern.

Check the automatic transmission fluid for contamination and smell. If there are signs of
contamination, a test amount must be drained off through a paper filter and checked. If the
automatic transmission fluid smells burnt, this indicates overheating.

Modifications/retrofitting/tuning

Additional aftermarket systems (e.g. air conditioning, car telephone, cruise control, etc.
etc.) which are not approved by Ford, or which have been unprofessionally installed, and
also chip and engine tuning, can have an effect on the engine and transmission
management and lead to faults.

Diagnostics

Electrical faults which appear, even only momentarily, when the ignition is switched on, will
be stored in the fault memory of the relevant control unit and may have effects on the
control system. Loose connections and fuses or connectors which have been removed or
disconnected for testing purposes all count as electrical faults.

In order for the diagnosis of the automatic transmission to be meaningful, all other systems

such as the PCM, IC and ABS must be operating correctly, because through the CAN
databus they may have an effect on the TCM and therefore on the transmission control.

Perform a WDS/IDS self-test on the vehicle

In the self-test, the WDS/IDS downloads all the stored DTCs from the fault memories
of the individual controllers and displays them on its screen.

Print out the DTCs (faults) displayed (this is important for later analysis and/or in the
case of a guarantee).
Read out the freeze frame data belonging to each DTC and print them out.
Check the conditions under which the fault occurred.
Clear all fault memory, because stored faults may have an effect on the control process.

Fault finding road test with WDS/IDS

After the road test repeat the WDS/IDS selft-test.

Perform diagnosis with WDS/IDS.

In the event of fault codes, follow the instructions given by the WDS/IDS.

Rectify the faults displayed in the WDS/IDS.

Clear all fault memories again.

Functional test

To verify the function after the repair has been carried out, road test the vehicle and then
run a WDS self test to check that no DTCs (faults) have been stored.

Automatic Transmission/Transaxle -
Vehicles With: 6-Speed Automatic
Transaxle - AWF21 - Transmission Fluid
Level Check

S-MAX/Galaxy 2006.5 (02/2006-)

Print

General Procedures

Materials

General Equipment

Vehicles with diesel engine

Name

Specification

Automatic Transmission Oil E-AW WSS-M2C924-A / 4U7J-M2C924-AA

Ford diagnostic equipment

1. Refer to:

Health and Safety Precautions

(100-00

General Information, Description and Operation).

2. Make sure that the transmission is not in

emergency operation mode.

General Equipment:

Ford diagnostic equipment

3. Make sure that the parking brake is fully applied.

4. Start the engine.

5. Move the transmission selector lever to all

positions. In doing so, wait until the transmission
engages the corresponding range.

6.

7. Ensure that the gear oil temperature is 55 ± 2 °

C.

General Equipment:

Ford diagnostic equipment

8.

9.

Transmission fluid must run out of the
check bore.
Allow excess transmission fluid to drain