FORD FIESTA 2007 Workshop Manual

Automatic Transmission/Transaxle .
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
SECTION 307-01 Automatic Transmission/Transaxle
. Vehicles With: 4-Speed Automatic Transmission
(AW81-40)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications
........................................................................\
.............................................. 307-0 1 -3
DESCRIPTION AND OPERATION
Automatic Transaxle
........................................................................\
...................................
Transmission cross-section ........................................................................\
........................
Torque converter with Torque Converter Clutch (TCC) ......................................................
Fluid pump and stator shaft ........................................................................\
........................
........................................................................\
......... Planetary gearset ......................... .:
Clutches and brakes ........................................................................\
...................................
Intermediate gear stage and differential assembly .............................................................
Main control body ........................................................................\
.......................................
Internal' gearshift mechanism ........................................................................\
.....................
Fluid circuit ........................................................................\
.................................................
........................................................................\
....................................... Identification Tags
Type plate
........................................................................\
...................................................
Transmission Ranges and Power Flow ........................................................................\
......
Transmission ratio and power flow route - 1st gear ............................................................
Transmission ratio and power flow route - 2nd gear ..........................................................
Transmission ratio and power flow route . 3rd gear ...........................................................
Transmission ratio and power flow route . 4th gear ...........................................................
Transmission ratio and power flow route . reverse gear ....................................................
Transaxle Electronic Control System ........................................................................\
..........
........................................................................\
..................................................... Overview
Transmission control unit
........................................................................\
............................
........................................................................\
.................................... Gearshift strategies
Selector lever positions
........................................................................\
..............................
Signal transmission on the CAN databus ........................................................................\
...
........................................................................\
...................................................... Sensors
........................................................................\
.................................................... Actuators
DIAGNOSIS AND TESTING
Automatic Transaxle
........................................................................\
................................... 307-01
Inspection and Verification ........................................................................\
.................... 307-01
Diagnostic Trouble Code Chart
........................................................................\
.................. 307-01
........................................................................\
...................................... Line Pressure Test 307-01
Stall Speed Test
........................................................................\
....................................... 307-01
Time Lag Test
........................................................................\
............................................. 307-01
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
GENERAL PROCEDURES /' -
.. Transmission Fluid Level Check.. ........................................................................\
............... 307-01 - k
........................................................................\
............ Transmission Fluid Drain and Refill 307-01 -53
IN-VEHICLE REPAIR
........................................................................\
.............. Transmission Range (TR) Sensor 307-01 -55
Halfshaft Seal LH.. ........................................................................\
...................................... 307-01 -58
Halfshaft Seal RH ........................................................................\
....................................... 307-01 -59
Turbine Shaft Speed (TSS) Sensor ........................................................................\
......... 307-01-60
Vehicle Speed Sensor (VSS).. ........................................................................\
................ 307-01 -61
REMOVAL AND INSTALLATION
Transaxle.. ........................................................................\
.................................................. 307-01 -62
procarmanuals.com

Automatic TransmissionlTransaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
A WARN1NG:Refer to the Material Safety
Data Sheets for the Automatic Transmis-
sion Fluid E-AW. Failure to follow this
instruction may result in personal injury.
Certain Transmission and Power Steering
fluids supplied to Ford contain additives
which may cause skin irritation or other
skin reactions after contact.
Automatic transmission fluid
Grease
Capacities
Specif icat
ions
WSS-M2C 924-A
WSD-MI C
230-A
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids. Automatic transmission fluid
(including cooler and tubes)
I Transaxle to engine flange retaining bolts I 47 I 35 I - I
Litres
5.75
Torque Specifications
I Engine ground cable to transaxle retaining nut I 25 I 18 I - I
I Torque converter retaining nuts I 27 I 20 I - I
lb-in Item
I Starter motor retaining bolts I 47 I 35 I - I
,I Engine and transaxle rear mount retaining bolt I 80 I 59 I - I
Nm
I Lower arm to the wheel knuckle I 48 I 35 I - I
I b-ft
I tie-rod end to the wheel knuckle I 48 I 35 I - I
I Exhaust flexible pipe to catalytic converter I 44 I 32 I - I
I Engine support insulator bolts I 48 I 35 I - I
IGnition switch to starter motor solenoid cable I 7 I - I 62 I
I Battery to starter motor solenoid cable I 12 I 9 I - I
-I indicator tube to transaxle retaining bolt I 25 I 18 I - I
I Selector lever cable bracket retaining bolts I 20 I 15 I - I - -
I Ground cable to transaxle retaining bolt
I Engine rear mount outer retaining nuts
I Engine rear mount center retaining nut I 90 I 66 I - I
I Battery tray retaining bolts I 25 I 18 I - I
I Strut and spring assembly top mount nuts I 25 I 18 I - I - -
Transaxle drain plug
Vehicle speed sensor (VSS) heat shield retaining
1 nut
Turbine
shaft speed (TSS) sensor retaining bolt
Vehicle speed sensor (VSS) retaining stud bolt
2006.0 Fiesta 1212006 G371496en
17
5
13 13 -
-
10
44
-
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
SPECIFICATIONS
Transmission range (TR) sensor to selector shaft 7 -
locking nut
I Transmission range (TR) sensor retaining bolts I 5 I - I 44 I
I Manual shift lever retaining nut I 13 I 10 I - I
2006.0 Fiesta 1212006 G371496en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
DESCRIPTION AND OPERATION
Automatic Transaxle
Transmission cross-section
2006.0 Fiesta 1212006 ~380521 en
procarmanuals.com

Automatic Tr;
Vehicles Wil
307-01 -6 Transn
~nsmission/Transaxle -
:h: 4-Speed Automatic
~ission (AW81-40) --
DESCRIPTION AND OPERATION
Item Description
I 1 I I st - 3rd gear clutch 1
1 2 14th gear brake I
1 3 1 Reverse gear clutch I
1 4 )2nd - 4th gear brake I
1 5 1 Reverse gear brake I
1 6 1 3rdl4th gear clutch I
1 7 ITorque converter 1
1 8 1 Transmission input shaft I
1 9 I Fluid pump I - --
[ 10 1 Differential assembly I
~l~put wheel, planetary gearset I
11
1 13 1 Planetary gearset I
Intermediate gear stage
vlIlstgear one-way clutch I
1 15 1 2nd gear one-way clutch I
Torque converter with Torque
Converter Clutch (TCC)
Item Description
I 1 I Torque converter housing and impeller I
1 2 1 Turbine wheel 1
1 4 1 Transmission input shaft I
FlGwith roller-type one-way clutch (
The torque converter hydraulically transmits the
output torque from the engine to the input shaft of
the transmission.
The stator increases the torque up to the clutch
point (approx. 90
% speed difference between the
impeller and the turbine wheel).
In order to increase the efficiency of the automatic
transmission, the torque converter is also equipped
with a hydraulically activated TCC
The TCC is applied with slip to ensure soft
engagement.
i
When the TCC is engaged, the torque is '..
transmitted directly from the crankshaft via the
torque converter housing to the transmission input
shaft.
2006.0 Fiesta 1212006 ~380521 en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
DESCRIPTION AND OPERATION
The TCC is engaged depending on the current
driving situation when the selector lever is in
I position "D" and 3rd or 4th gear is engaged. When
4th gear is disabled
(OID Off) the TCC is
engaged in 3rd gear depending on the current
driving situation.
Fluid pump and stator shaft
Item Description It sucks up transmission fluid from the oil pan,
1
2
3
2006.0 Fiesta 1212006 G380521 en
Fluid pump housing
4 builds
up the oil pressure and then supplies it under
high pressure to the main control body.
Inner rotor, fluid pump
Outer rotor, fluid pump The
fluid pump is driven by the crankshaft via the
torque converter housing.
transmission housing.
The fluid pump is a G-rotor oil pump.
The stator shaft is bolted to the fluid pump. It
engages via teeth in the stator of the torque
converter and acts as a support for the latter.
Stator
shaft The
fluid pump housing is bolted to the
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40) 307-01 -8
DESCRIPTION AND OPERATION
Planetary
gearset
Description The following connections exist between the
/ individual components:
small sun gear - short planet gears - long planet
Long planet gear gears- annulus,
3 Small sun gear large sun gear - long planet gears - annulus.
4
5
The output always flows through the annulus.
6
2006.0 Fiesta 1212006 ~380521 en
Short planet gear
Transmission input shaft The different transmission ratios
are selected by
actuating and releasing the individual clutches and
brakes.
shaft via the corresponding clutch either onto the
A Ravigneaux planetary gearset is a two-stage
small sun gear (1st - 3rd gear) or the planet gear gearset with a shared planet gear carrier and one carrier (3rd and 4th gear) or the large sun gear annulus. (reverse gear).
Large sun gear
The drive is transmitted from the transmission input
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
DESCRIPTION AND OPERATION
Clutches and brakes
/
Description The clutches are multi-plate clutches.
I 1 I I st - 3rd gear clutch I
1 2 14th gear brake I
1 3 1 Reverse gear clutch I
1 4 12nd - 4th gear brake I
1 6 1 3rdl4th gear clutch I
1 7 1 1st gear one-way clutch I
1 8 12nd gear one-way clutch I
The transmission is equipped with three clutches
and five brakes. The brakes
are three multi-plate brakes and two
one-way sprag clutches.
The clutches serve to transmit the torque from the
transmission input
shaft to certain components of
the planetary
gearset.
The brakes serve to hold certain components of
the planetary
gearset.
In order to achieve a given transmission ratio, it is
necessary for at least one component of the
planetary
gearset to be held while the torque is
transmitted to another component.
These combinations produce the different
transmission ratios for the individual gears.
2006.0 Fiesta 1212006 G380521 en
procarmanuals.com

Automatic Transmission/Transaxle -
Vehicles With: $-Speed Automatic
Transmission
(AW81-40)
DESCRIPTION AND OPERATION
Overview of operation
Item Descri~tion
I 1 I I st - 3rd gear clutch I
1 2 12nd gear one-way clutch I
1 3 12nd - 4th gear brake I
1 4 1 1st gear one-way clutch
1 5 1 Reverse gear brake I
1 6 13rd14th gear clutch
Item Description
1 8 1 Output wheel, planetary gearset
I
1 7 1 From the torque converter
1 9 ( Intermediate gear stage I
I
1 10 1 Differential assembly I
I A I Planetary gearset, rear I
11
12
I B I Planetary gearset, front I
4th gear brake
Reverse gear clutch
2006.0 Fiesta 1212006 ~380521 en
procarmanuals.com