Dodge Sprinter. Manual — part 528
Emergency running function
If DTCs occur, safe-driving conditions must be re-
tained but full functionality of the transmission will
be limited to avoid damaging the automatic trans-
mission. In the event of certain DTCs the TCM
switches to emergency running. The TCM will store
the appropriate DTC codes and solenoids will be
de-energized (turned off)
The transmission effects will be:
•
The last gear shifted remains in that position
•
The modulating pressure and shift pressure in-
crease to maximum value
•
The
torque
converter
clutch
is
disengaged
(turned off)
Shifting manually after a DTC detection
NOTE: The vehicle can still be shifted
manually to 2nd or reverse gear.
To accomplish these shifts you must
Stop the vehicle
Turn the ignition off
Start the engine
Place the selector lever into D for 2nd gear
Place the selector lever into R for reverse gear
The emergency running function is retained until
the DTC is eliminated or the stored DTC code is
erased.
Stored (Intermittent) DTCs can be reset by cy-
cling the ignition switch
3.3.3
TROUBLE CODE ERASURE
Diagnostic Trouble Codes can be erased in two
ways. The first is to erase the DTC with the DRBIII
or scan tool. The second is if the DTC is no longer
present, the DTC is reset by the TCM (after an
ignition cycle), which will place the DTC in an
intermittent status (Stored DTC).
When there are no diagnostic trouble codes
stored in memory, the DRBIII
t will display
(NO DTC’s DETECTED(
3.4
USING THE DRBIII
T
Refer to the DRBIII
t user’s guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIII
t functions.
3.5
DRBIII
T ERROR MESSAGES
Under normal operation, the DRBIII
t will display
one of only two error messages:
– User-Requested WARM Boot
– User-Requested COLD Boot
If the DRBIII
t should display any other error
message, record the entire display and call the
S.T.A.R. Center.
3.5.1
DRBIII
T DOES NOT POWER UP
(BLANK SCREEN)
If the LED’s do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage. A mini-
mum of 11 volts is required to adequately power the
DRBIII
t.
If all connections are proper between the DRBI-
II
t and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIII
t
may be the result of faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate Body
Diagnostic manual.
3.5.2
DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0
DISCLAIMERS, SAFETY,
AND WARNINGS
4.1
DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
5
GENERAL INFORMATION
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2
SAFETY
4.2.1
TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. If is especially
important to block the wheels on front-wheel drive
vehicles: the parking brake does not hold the drive
wheels.
Some operations in this manual require that
hydraulic tubes, hoses, and fittings, disconnected
for inspection or testing purposes. These systems,
when fully charged, contain fluid at high pressure.
Before disconnecting any hydraulic tubes, hoses,
and fittings, be sure that the system is fully depres-
surized.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a Transmission system prob-
lem, it is important to follow approved procedures
where applicable. These procedures can be found in
the service information. Following these procedures
is very important to the safety of individuals per-
forming diagnostic tests.
4.2.2
VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic
DTC’s or error messages may occur. It is extremely
important that accurate shift lever position data is
available to the TCM. The accuracy of any DTC
found in memory is doubtful unless the Shift Lever
Test, performed on the DRBIII
t Scan Tool, passes
without failure.
4.2.3
SERVICING SUB-ASSEMBLIES
Some components of the Transmission system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service information should be serviced.
4.2.4
DRBIII
T SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIII
T
MULTIMETER IS DANGEROUS. IT
CAN
EXPOSE
YOU
TO
SERIOUS
OR
POSSIBLY
FATAL
INJURY.
CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND THE SPECIFICATION LIMITS.
•
Follow the vehicle manufacturer’s service speci-
fications at all times.
•
Do not use the DRBIII
t if it has been damaged.
•
Do not use the test leads if the insulation is
damaged or if metal is exposed.
•
To avoid electrical shock, do not touch the test
leads, tips or the circuit being tested.
•
Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
•
Do not exceed the limits shown in the table.
FUNCTION
INPUT LIMIT
Volts
0-500 volts peak AC
0-500 volts DC
Ohms (resistance)*
0-1.12 megohms
Frequency measured
Frequency generated
0-10 khz
Temperature
-58-1100°F
-50-600C
*Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
•
Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
•
Use caution when measured voltage above 25v
DC or 25v AC.
•
The circuit being tested must be protected by a
10A fuse or circuit breaker.
•
Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
•
When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
•
When measuring current, connect the meter in
series with the load.
6
GENERAL INFORMATION
•
Disconnect the live test lead before disconnecting
the common test lead.
•
When using the meter function, keep the
DRBIII
t away from spark plug or coil wires to
avoid measuring error from outside interference.
4.3
WARNINGS
4.3.1
VEHICLE DAMAGE WARNINGS
Before disconnecting any control module, make
sure the ignition is
9lock9 position. Failure to do so
could damage the module.
When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation: this will damage the wire and eventu-
ally cause the wire to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second DTC could be set, making diagnosis of the
original problem more difficult.
When replacing a blown fuse, it is important to
use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system over-
load. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.
4.3.2
ROAD TESTING A COMPLAINT
VEHICLE
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
DTC or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read
DRBIII
T
screen while in motion. Do not hang
the DRBIII
T
from the rear view mirror or
operate
it
yourself.
Have
an
assistant
available to operate the DRBIII
T
.
Road testing is an essential step in the diagnostic
process that must not be overlooked. Along with the
diagnostic information obtained from the DRBIII
t
Scan Tool and the original customer concern, the
road test helps verify the problem was current and
any repairs performed, fixed the vehicle correctly.
Always operate and observe the vehicle under ac-
tual driving conditions.
Just as important as the road test is, there are
preliminary inspections that should be performed
prior to the road test. Always check the fluid level
and condition before taking the vehicle on a road
test. Determine if the incorrect fluid is being used,
improper fluid will result in erratic transmission
operation.
Some of the conditions of incorrect fluid level are as
follows:
•
Delayed engagement
•
Poor shifting or erratic shifting
•
Excessive noise
•
Overheating
The next step is to verify that the shift linkage is
correctly adjusted. If the shift linkage is incorrectly
adjusted, a number of complaints can result.
The TCM monitors the Shift Lever Position (SLP)
continuously. If the linkage is incorrectly adjusted,
the TCM will sense a shift lever position that is not
correct for the gear chosen by the driver. This may
cause a DTC to be set.
The following complaints may also be the result of
an incorrectly adjusted or worn linkage:
•
Delayed clutch engagement
•
Erratic shifts
•
Vehicle will drive in neutral
•
Engine will not crank in park or neutral
•
Gear shift linkage will be able to be shifted
without the key in the ignition
•
Not able to remove the ignition key in park
•
Parking pawl will not engage properly
The shift linkage should also be adjusted when
replacing the Transmission, repairing the valve
body, or when repairing any component between the
shift lever and the Transmission.
Some questions to ask yourself when performing
the road test are as follows:
•
Is the complaint or concern what you think the
problem is, based on the drivers description of the
problem?
•
Is the Transmission operating normally, or is
there a real problem?
•
When does the problem occur?
•
Is the problem only in one gear range?
•
What temperature does the problem occur?
•
Does the vehicle have to sit over night for the
problem to occur?
•
Does the transmission go into Limp-in mode?
4.4.4
BULLETINS AND RECALLS
Always perform all Safety Recalls and Technical
Service Bulletins that are applicable to the prob-
lem.
7
GENERAL INFORMATION
5.0
REQUIRED TOOLS AND
EQUIPMENT
> DRBIII
t (diagnostic read-out box) - DRBIIIt
must use the latest release level.
> Jumper wires
> Test Light
> Ohmmeter
> Voltmeter
6.0
GLOSSARY OF TERMS
6.1
ACRONYMS
ABS
Antilock Braking system
A/C
Air conditioner
A/D
Analog to Digital conversion
APP
Accelerator Pedal Position
CAN
Controller Area Network (Vehicle
Bus System)
CKT
Circuit
DLC
Data Link Connector
DRBIII
t
Diagnostic Readout Box
DTC
Diagnostic Trouble Code
ECM
Diesel Engine Controller
EMCC
Electronically Modulated Converter
Clutch
IOD
Ignition off-draw
ISS
Input Speed Sensor (N2 and N3)
K
K line communication bus
LED
Light Emitting Diode
MIL
Malfunction Indicator Lamp
OSS
Output Speed Sensor (derived from
the ABS controller)
PEMCC
Partial Electronically Modulated
Converter Clutch
PWM
Pulse width modulated
SKREEM
Sentry Key Remote Entry Module
SLA
Shift Lever Assembly
SW
Switch
TCC
Torque Converter Clutch
TCM
Transmission Control Module
TP
Throttle Position
TRD
Torque Reduction
TTS
Transmission Temperature Sensor
1-2/4-5
solenoid
controls the shift into and out of
2nd gear or 5th gear.
V2-3 so-
lenoid
controls the shift into and out of 3rd
gear
V3-4 so-
lenoid
controls the shift into and out of 4th
gear
VTCC
solenoid
is pulse width modulated and con-
trols the TCC clutch
Shift
Pressure
Solenoid
is a pulse width modulated solenoid
and controls the hydraulic pressure
to the shift elements.
Modula-
tion
pressure
solenoid
is a pulse width modulated solenoid
and controls the hydraulic system
pressure
6.2
DEFINITIONS
Driving cycle counter) - The starts since first set
counter indicates the number of driving cycles since
the first occurrence of an error.
8
GENERAL INFORMATION
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