checking oil MERCEDES-BENZ SPRINTER 2006 User Guide

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT
RECOMMENDATIONS...................1
AUTOMATIC TRANSMISSION FLUID - NAG1 . 1
AXLE FLUID..........................2
BRAKE FLUID.........................2
HOAT COOLANT.......................2
ENGINE OIL - DIESEL ENGINES...........3
FUEL REQUIREMENTS - DIESEL ENGINE . . . 4
POWER STEERING FLUID...............5
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......5FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................5
HOISTING
STANDARD PROCEDURE - HOISTING........5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 6
TOWING
STANDARD PROCEDURE - TOWING.........7
MAINTENANCE SCHEDULES
DESCRIPTION..........................8
INTERNATIONAL SYMBOLS
DESCRIPTION..........................9
FLUID TYPES
DESCRIPTION
PARTS AND LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 1) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only MOPARtbrand parts,
lubricants and chemicals be used. MOPARtprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
AUTOMATIC TRANSMISSION FLUID - NAG1
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Use ATF approved to MB 236.10, MB 236.12, such
as Shell ATF 3403/M-115, MOPARtpart number
05127382AA, Fuchs/Shell ATF 3353, or equivalent.
Automatic Transmission Fluid (ATF) is red in color
when new. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine
oil or antifreeze. The red color is not permanent and
is not an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 1 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
VALUBRICATION & MAINTENANCE 0 - 1

FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, ALB
Controller, caliper seals, Antilock Brakes hydraulic
unit and all hydraulic fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Always clean the master cylinder reservoir and
caps before checking fluid level. If not cleaned, dirt
could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 13).
The correct fluid level is to the MAX indicator on
the side of the reservoir. If necessary, add fluid to the
proper level. (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - DESCRIPTION).
SPECIFICATIONS
BRAKE FLUID
The brake fluid to be used in this vehicle must be
approved to MB 331.0, such as MOPARtpart num-
ber 0459625AC. If the approved product is not avail-
able, use a DOT 4 brake fluid: minimum dry boiling
point (ERBP) 500ÉF, minimum wet boiling point
(WERBP) 356ÉF, maximum viscosity 1500 mm
2/s,conforming to FMVSS 116 and ISO 4925. No other
type of brake fluid is recommended or approved for
usage in the vehicle brake system. Use only approved
brake fluid or an equivalent from a tightly sealed
container.
Use brake fluid
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible (Fig. 14).
(2) Disconnect the electrical connector for the
brake fluid level indicator (Fig. 14).
(3) Remove the fluid reservoir (Fig. 14).Seal off
the ends and bore holes with plugs.
INSTALLATION
(1) Install the fluid reservoir and fill with fluid
(Fig. 14).
(2) Bleed the brake system.
Fig. 13 FLUID LEVEL TYPICAL
1 - FLUID RESERVOIR
2 - MAX LEVEL MARK
Fig. 14 FLUID RESERVOIR
1 - SUCTION GUN
2 - BRAKE FLUID CAP
3 - BRAKE FLUID LEVEL INDICATOR
4 - MASTER CYLINDER
5 - FLUID RESERVOIR
VABRAKES - BASE 5 - 15

(6) Working from the underside of the switch, gen-
tly rock the switch back and forth out of its mounting
location in the switch bezel.
INSTALLATION
(1) Install the heated seat switch in its mounting
location in the switch bezel.
(2) Connect electrical connections.
(3) Position the switch bezel and install the retain-
ing screw. Refer to the Body section for the proce-
dure.
(4) Install the storage bin. Refer to the Body sec-
tion for the procedure.
(5) Install the gear selector bezel trim. Refer to the
Body section for the procedure.
(6) Connect the negative battery cable.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system includes two seat heating
elements in each front seat, one for the seat cushion
(Fig. 1) and the other for the seat back. All models
use two resistor wire heating elements for each seat
that are connected in series with the Heated Seat
Relay. The temperature sensor is a Negative Temper-
ature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is located in the
seat cushion heating element for all models.The seat heating elements are glued onto the seat
and seat back cushions. The heated seat elements
and the temperature sensor cannot be adjusted or
repaired and, if faulty or damaged a new seat assem-
bly must be installed.
OPERATION
The heated seat elements resist the flow of electri-
cal current. When battery current is passed through
the elements, the energy lost by the resistance of the
elements is released in the form of heat. The heated
seat temperature sensor is a NTC thermistor. When
the temperature of the seat cushion cover rises, the
resistance of the sensor decreases. The heated seat
relay uses this temperature sensor input to monitor
the temperature of the seat, and regulates the cur-
rent flow to the seat heating elements accordingly.
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENT
For complete circuit diagrams, refer toWiring.
NOTE: When checking heated seat elements for
continuity, be certain to move the heating element
being checked. Moving the element, such as sitting
in the seat will eliminate the possibility of an inter-
mittent open in the element which would only be
evident if the element was in a certain position.
Failure to check the element in various positions
could result in an incomplete test.
(1) Disconnect and isolate the battery negative
cable. Disconnect the heated seat element wire har-
ness connector from under the seat cushion. Check
for continuity between the seat heater driver circuit
and ground. There should be continuity, less than 7
ohms. If OK, go to Step 2. If not OK, replace the seat
assembly.
(2) Check for continuity between the seat heater
B+ driver circuit cavity and the seat back frame.
There should benocontinuity. If OK, heating ele-
ment is OK at this time. If not OK, replace the seat
assembly.
HEATED SEAT RELAY
DESCRIPTION
The heated seat relay is an electromechanical
device that switches 12v battery current to the
heated seat elements when the relay control coil is
energized. The heated seat relay is located in the
Fuse Block, under the drivers seat. The heated seat
relay is a International Standards Organization
(ISO) relay. Relays conforming to the ISO specifica-
tions have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
Fig. 1 Heated Seat Element - Typical
1 - Seat Back Wire Harness
2 - Heated Seat Wire Harness Connector
3 - Heated Seat Cushion Element
8G - 12 HEATED SEATSVA

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DESCRIPTION..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSION
TESTING ENGINE......................3
STANDARD PROCEDURE - CYLINDER
LEAK DOWN TEST.....................3
STANDARD PROCEDURE - DETERMINING
CYLINDER PRESSURE LOSS.............4
REMOVAL
REMOVAL - ENGINE COVER.............4
REMOVAL............................5
INSTALLATION
INSTALLATION - ENGINE COVER..........9
INSTALLATION........................9
SPECIFICATIONS - TORQUE
SPECIFICATIONS.....................11
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
AIR CLEANER HOUSING
REMOVAL.............................21
INSTALLATION.........................22
CYLINDER HEAD
DESCRIPTION.........................22
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
HEAD BOLT INSPECTION...............22
STANDARD PROCEDURE - MEASURE
CYLINDER HEAD SURFACE.............22
REMOVAL
REMOVAL - CYLINDER HEAD............23
REMOVAL - CYLINDER HEAD FRONT
COVER.............................25
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 26
INSTALLATION
INSTALLATION - CYLINDER HEAD........26
INSTALLATION - CYLINDER HEAD FRONT
COVER.............................28
INSTALLATION - CYLINDER HEAD GUIDE
RAIL...............................28
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION.................28
STANDARD PROCEDURE - INSPECTING
TAPPET CLEARANCE..................30
REMOVAL.............................30
INSTALLATION.........................32CYLINDER HEAD COVER(S)
REMOVAL.............................33
INSTALLATION.........................34
VALVE STEM SEALS
DESCRIPTION.........................34
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS............35
REMOVAL - VALVES...................36
INSTALLATION
INSTALLATION - VALVE SPRINGS........36
INSTALLATION - VALVES...............37
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - REPLACING
ENGINE CORE AND OIL GALLERY PLUGS . . 37
STANDARD PROCEDURE - MEASURING
CYLINDER BORES....................38
CRANKSHAFT
DESCRIPTION.........................39
STANDARD PROCEDURE - MEASURE
CRANKSHAFT AND BLOCK JOURNALS....39
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
FLYWHEEL
REMOVAL.............................43
INSTALLATION
INSTALLATION.......................44
INSTALLATION - CRANKSHAFT LOCK.....44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING AND
REPAIRING CONNECTING RODS.........46
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................47
REMOVAL.............................47
INSTALLATION.........................49
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................53
INSTALLATION.........................54
VAENGINE 9 - 1

INSTALLATION - CYLINDER HEAD FRONT
COVER
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
NOTE: Dowel pins are used as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
(1) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 18).
NOTE: Install front cover of cylinder head within 10
minutes after applying sealant. Do not spread seal-
ing bead.
(2) Raise locking pawl of top guide rail and guide
front cover onto guide pins.
(3) Install bolts attaching front cover (Fig. 16)
Tighten bolts to 14N´m (124 lbs. in.).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
REMOVE SOURCES OF IGNITION FROM THE AREA.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELS
ONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS.
(4) Install vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).NOTE: Timing chain tensioner must be installed
with a new gasket.
(5) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(7) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)
INSTALLATION - CYLINDER HEAD GUIDE RAIL
(1) Carefully position the top guide rail onto the
guide pins.
(2) Counter hold the camshaft with an open end
wrench and install driver of inlet camshaft sprocket.
Tight bolt to 50N´m (37 lbs. ft.).
(3) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail
and install front cover at cylinder head (Fig. 16).
(5) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(6) Install engine cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(7) Reconnect negative battery cable.
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(8) Start engine and inspect for leaks.
CAMSHAFT(S)
STANDARD PROCEDURE
STANDARD PROCEDURE - CHECKING CAM-
SHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
Fig. 18 CYLINDER HEAD COVER SEALING
SURFACE
1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD
9 - 28 ENGINEVA

(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
(1) Remove the belt from the power steering pump.
(2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose
at the pump (Fig. 1).
(4) Remove the return hose from the pump (Fig.
1).
(5) Remove the bolts securing the power steering
pump to the engine (Fig. 1).
INSTALLATION
(1) Install the power steering pump to the engine
and tighten the bolts (Fig. 1). Tighten to 21 N´m (15
ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten
the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N´m (28 ft. lbs.).
(5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
Fig. 1 POWER STEERING PUMP
1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
8 - PULLEY
9 - PULLEY BOLT
19 - 12 PUMPVA

DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION
CAUTION: Before attempting any repair on a NAG1
automatic transmission, check for Diagnostic Trou-
ble Codes with the appropriate scan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance.
²Improper adjustments.
²Hydraulic malfunctions.
²Mechanical malfunctions.
²Electronic malfunctions.
²Transfer case performance (if equipped).
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary.
PRELIMINARY
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce-
dure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using the
appropriate scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
VEHICLE IS DISABLED
(1) Check fluid level and condition.(2) Check for broken or disconnected gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged driveplate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis-
sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
ble codes have been resolved.
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analy-
sis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, overrunning clutch, or line pressure problems.
A slipping clutch can often be determined by com-
paring which internal units are applied in the vari-
ous gear ranges. The Clutch Application chart
CLUTCH APPLICATION provides a basis for analyz-
ing road test results.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N N/A X X
R 3.16 X* X X X
R - Limp In 1.93 X X X
* = The shift components required during coast.
VAAUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 39

installed. Retaining rings are available in thick-
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and
2.2 mm (0.087 in.).
(31) Rotate the transmission so that the bellhous-
ing is pointed upward and ensuring that the output
shaft is allowed to move freely.
(32) Measure input shaft end-play (Fig. 58).
NOTE: If end-play is incorrect, transmission is
incorrectly assembled, or the geartrain end-play
shim is incorrect. The geartrain end-play shim is
selective.
(a) Attach Adapter 8266-18 (2) to Handle 8266-8
(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. End play should be 0.3-0.5 mm (0.012-0.020
in.). Adjust as necessary.(33) Install the output shaft washer onto the out-
put shaft.
(34) Install a new transmission rear seal into the
transmission case with Seal Installer 8902A (1) (Fig.
59).
(35) Place the transmission in PARK to prepare for
the installation of the output shaft nut.
(36) Install the propeller shaft flange onto the out-
put shaft and install an new flange nut. Tighten the
flange nut to 200 N´m (147.5 ft.lbs.).
(37) Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(38) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 60).
Fig. 58 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339
Fig. 59 Install Output Shaft Seal
1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE
Fig. 60 Align Staking Tool 9078
1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH
21 - 58 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
1. Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
2. A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged oil cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
3. Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever
a failure generates sludge and debris. This is neces-
sary because normal converter flushing procedures
will not remove all contaminants.
STANDARD PROCEDURE
CHECK OIL LEVEL
(1) Verify that the vehicle is parked on a level sur-
face.
(2) Remove locking pin (1) (Fig. 149). Remove the
plate of the locking pin with a suitable tool and press
out the pin remaining in the cap downwards.
(3) Remove cap (2).
WARNING: Risk of accident from vehicle starting off
by itself when engine running. Risk of injury from
contusions and burns if you insert your hands into
the engine when it is started or when it is running.
Secure vehicle to prevent it from moving off by
itself. Wear properly fastened and close-fitting work
clothes. Do not touch hot or rotating parts.
(4) Actuate the service brake. Start engine and let
it run at idle speed in selector lever position ªPº.
(5) Shift through the transmission modes several
times with the vehicle stationary and the engine
idling
(6) Warm up the transmission, wait at least 2 min-
utes and check the oil level with the engine running.
Push the Oil Dipstick 8863A in up to the stop on the
electrohydraulic unit and pull out again, read off oil
level, repeat if necessary.
NOTE: The dipstick will protrude from the fill tube
approximately 75mm (3 inches) when installed.
Fig. 149 Remove Dipstick Tube Cap Lock
1 - LOCKING PIN
2 - TUBE CAP
3 - DIPSTICK TUBE
21 - 132 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATIONVA

TEST ACTION APPLICABILITY
2 With the DRBIIIt, read DTCs.
Are any Speed Sensor or Sensor Supply DTCs present?All
Ye s!Repair any Speed Sensor and/or Sensor Supply DTCs before
proceeding with test.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 3
3 Ignition on, engine not running.
With the DRBIIIt, erase Transmission DTCs.
Start the engine.
Drive the vehicle to speeds to allow multiple 2-3 and 3-4 upshifts.
Does the DTC9INPUT SENSOR MISMATCH9reset and displayed as9ACTIVE9?All
Ye s!Go To 4
No!Go To 6
4 Remove the Transmission Oil Pan and inspect for debris or a plugged Transmission
Oil Filter.
Is there any debris, plugged Transmission Oil Filter, or signs of an Internal
Transmission problem?All
Ye s!Repair Internal Transmission as necessary. Pay particular atten-
tion to the Electrohydraulic Control unit. Refer to the Service
Information for proper repair procedures.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 5
5 If there are no possible causes remaining, view repair. All
Repair
Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
6 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wires while checking for shorts and open circuits.
NOTE: Check for any Technical Service Bulletins that may apply.
Were there any problems found?All
Ye s!Repair as necessary
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Test Complete.
79
TRANSMISSION - NAG1
INPUT SENSOR MISMATCH ÐContinued