MERCEDES-BENZ SPRINTER 2006 Service Manual

TEST ACTION APPLICABILITY
2 Turn the ignition off to the lock position.
Disconnect the Transmission Solenoid Assembly harness connector.
Start the engine.
With the brakes firmly applied, shift the gear selector into Drive.
Did the engine stall or stumble?All
Ye s!Repair the internal transmission. Pay particular attention to the
components related to the TCC. Refer to the Service Information
for the proper repair procedure.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 3
3 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance between ground and the TCC Solenoid Control circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the TCC Solenoid Control circuit for a short to ground.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid harness connector.
Measure the resistance of the TCC Solenoid Control circuit to all other circuits in the
Transmission Solenoid harness connector.
Is the resistance below 5.0 ohms on any circuit?All
Ye s!Repair the TCC Solenoid Control circuit for a short to other
circuits.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
11 6
TRANSMISSION - NAG1
TCC STUCK ON ÐContinued

Symptom:
TRANS TEMP SENSOR - P/N SWITCH CIRCUIT
When Monitored and Set Condition:
TRANS TEMP SENSOR - P/N SWITCH CIRCUIT
When Monitored: Always monitored with system active at each ignition cycle.
Set Condition: Temp sensor is open while in forward gears (1-5), temp sensor, open Trans
temp circuit, P/N Switch.
POSSIBLE CAUSES
SHIFTER ADJUSTMENT
SENSOR GROUND CIRCUIT OPEN
TEMP SENSOR - P/N SWITCH CIRCUIT OPEN
TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO GROUND
SENSOR GROUND CIRCUIT SHORT TO OTHER CIRCUITS
TEMP SENSOR- P/N SWITCH CIRCUIT SHORT TO OTHER CIRCUITS
TEMP SENSOR - P/N SWITCH
TCM - TEMP SENSOR - P/N SWITCH
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the service information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTCs. Check and repair all engine DTCs prior to
performing transmission symptom diagnostics.
With the DRBIIIt, read and record all Transmission DTCs.
NOTE: Check connectors - Clean/repair as necessary. Poor pin to terminal
connections can set DTCs.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Most DTCs set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
NOTE: Check for any Technical Service Bulletins that may apply.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
11 7
TRANSMISSION - NAG1

TEST ACTION APPLICABILITY
2 Check the Shifter Assembly adjustment per the Service Information.
Was the Shifter Assembly adjusted correctly?All
Ye s!Go To 3
No!Adjust the Shifter Assembly per the Service Information.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
3 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance of the Sensor Ground circuit between the TCM C2 harness
connector and the Transmission Solenoid Assembly harness connector.
Is the resistance above 5.0 ohms?All
Ye s!Repair the Sensor Ground circuit for an open or high resistance.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 4
4 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance of the Transmission Temp Sensor - P/N Switch circuit
between the TCM C2 harness connector and the Transmission Solenoid Assembly
harness connector.
Is the resistance above 5.0 ohms.All
Ye s!Repair the Transmission Temp Sensor - P/N Switch circuit for an
open.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 5
5 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance between ground and the Transmission Temp Sensor - P/N
Switch circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the Transmission Temp Sensor - P/N Switch circuit for a
short to ground.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 6
6 Turn the ignition off to the lock position.
Disconnect the TCM C1 and C2 harness connectors.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance between the Sensor Ground circuit and all other circuits in
the TCM C1 and C2 harness connectors.
Is the resistance below 5.0 ohms on any of the circuits?All
Ye s!Repair the Sensor Ground circuit for a short to other circuits.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 7
11 8
TRANSMISSION - NAG1
TRANS TEMP SENSOR - P/N SWITCH CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off to the lock position.
Disconnect the TCM C1 and C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance between the Temp Sensor - P/N Switch circuit and all other
circuits in the TCM C1 and C2 harness connector.
Is the resistance below 5.0 ohms on any circuit?All
Ye s!Repair the Transmission Temp Sensor - P/N Switch circuit for a
short to other circuits.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 8
8 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
NOTE: Make sure the Transmission Solenoid Assembly harness connector is
connected or the results of the test will be invalid.
With the brakes firmly applied, place the gear selector in Drive.
Measure the resistance between the Temp Sensor - P/N Switch circuit and the Sensor
Ground circuit in the TCM C2 harness connector.
Is the resistance between 500 and 2500 ohms?All
Ye s!Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Replace the Temp Sensor - P/N Switch Assembly per the Service
Information.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
11 9
TRANSMISSION - NAG1
TRANS TEMP SENSOR - P/N SWITCH CIRCUIT ÐContinued

Symptom:
TRANS TEMP SENSOR ERRATIC
When Monitored and Set Condition:
TRANS TEMP SENSOR ERRATIC
When Monitored: When transmission temperature is below 170É C (338É F)
Set Condition: When there is a 10É C (18É F) variation between each transmission
temperature sensor read. If the DTC is reset (after an ignition cycle), the DTC will be set
to Stored (Intermittent) status.
POSSIBLE CAUSES
TRANSMISSION TEMP SENSOR WIRING
TCM - TRANS TEMP SENSOR ERRATIC
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the service information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTCs. Check and repair all engine DTCs prior to
performing transmission symptom diagnostics.
With the DRBIIIt, read and record all Transmission DTCs.
NOTE: Check connectors - Clean/repair as necessary. Poor pin to terminal
connections can set DTCs.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Most DTCs set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
NOTE: Check for any Technical Service Bulletins that may apply.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 Ignition on, engine not running.
With the DRBIIIt, monitor the Transmission Temperature.
With the brakes firmly applied, place the gear selector in Drive.
While monitoring the DRBIIIt, wiggle the wires and connectors from the TCM to the
Transmission Solenoid Assembly.
Did the Transmission Temperature fluctuate while wiggling the wires?All
Ye s!Repair the wiring and/or connectors as necessary.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 3
120
TRANSMISSION - NAG1

TEST ACTION APPLICABILITY
3 Replace the Transmission Temp Sensor - P/N Switch Assembly per the Service
Information.
Perform W5J400 TRANSMISSION VERIFICATION TEST - VER 1.
Did the DTC, TRANS TEMP SENSOR ERRATIC, reset?All
Ye s!Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Test Complete.
121
TRANSMISSION - NAG1
TRANS TEMP SENSOR ERRATIC ÐContinued

Symptom:
TRANS TEMP SENSOR SHORTED
When Monitored and Set Condition:
TRANS TEMP SENSOR SHORTED
When Monitored: Always monitored with system active
Set Condition: Temperature sensor input below a threshold, failed temperature sensor,
short to ground, TCM
POSSIBLE CAUSES
TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO GROUND
TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO OTHER CIRCUITS
TCM - P/N SWITCH CIRCUIT
TRANSMISSION TEMPERATURE SENSOR
TCM - TRANS TEMP SENSOR SHORTED
TRANSMISSION TEMP SENSOR - P/N SWITCH
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the service information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTCs. Check and repair all engine DTCs prior to
performing transmission symptom diagnostics.
With the DRBIIIt, read and record all Transmission DTCs.
NOTE: Check connectors - Clean/repair as necessary. Poor pin to terminal
connections can set DTCs.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Most DTCs set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
NOTE: Check for any Technical Service Bulletins that may apply.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 Attempt to start the vehicle in Park and Neutral.
Does the engine start in either position, Park or Neutral?All
Ye s!Go To 3
No!Go To 5
122
TRANSMISSION - NAG1

TEST ACTION APPLICABILITY
3 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Place the gear selector to Drive (D).
Measure the resistance of the Transmission Temperature Sensor between the Temp
Sensor - P/N Switch circuit and the Sensor Ground circuit in the TCM C2 harness
connector.
Is the resistance between 500 ohms and 2500 ohms.All
Ye s!Go To 4
No!Check for a poor terminal to pin connections at the Solenoid
Assembly harness connector and repair as necessary. If no prob-
lems are found in the connector, replace the Transmission Tem-
perature Sensor - P/N Switch Assembly per the Service Informa-
tion.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
4 If there are no possible causes remaining, view repair. All
Repair
Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
5 Turn the ignition off to the lock position.
Disconnect the Transmission Solenoid harness connector.
NOTE: This procedure may set several DTCs in both the ECM and TCM.
Disregard and erase DTCs after this procedure.
With the gear selector in park, attempt to start the vehicle.
Does the vehicle start?All
Ye s!Replace the Transmission Temperature Sensor - P/N Switch
Assembly per the Service Information.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 6
6 Turn the ignition off to the lock position.
Disconnect the TCM C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance between ground and the Temp Sensor - P/N Switch circuit.
Is the resistance below 5.0 ohms?All
Ye s!Repair the Temp Sensor - P/N Switch circuit for a short to ground.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 7
7 Turn the ignition off to the lock position.
Disconnect the Transmission Solenoid Assembly harness connector.
Note: Check connectors - Clean/repair as necessary.
Disconnect the TCM C1 and C2 harness connectors.
Measure the resistance of the Temp Sensor - P/N Switch circuit to all other circuits
in the TCM C1 and C2 harness connectors.
Is the resistance below 5.0 ohms between any other circuit?All
Ye s!Repair the Temp Sensor - P/N Switch circuit for a short to other
circuits.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 8
123
TRANSMISSION - NAG1
TRANS TEMP SENSOR SHORTED ÐContinued

TEST ACTION APPLICABILITY
8 If there are no possible causes remaining, view repair. All
Repair
Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
124
TRANSMISSION - NAG1
TRANS TEMP SENSOR SHORTED ÐContinued

Symptom:
TRANSMISSION SLIPPING
When Monitored and Set Condition:
TRANSMISSION SLIPPING
When Monitored: Engine rpm greater than 450 rpm, output speed greater than 180 rpm,
no N2 - N3 input speed sensor errors present, no gear selector lever errors present, no ABS
system errors, no transfer case errors present, and all wheel speeds between 70 - 380 rpm
with no wheel slip detected. Set Condition: Calculated ratio not within allowable range for
the engaged gear. No shifting operation.
Set Condition: The TCM constantly calculates the transmission ratio based on the N2 -
N3 input speed signals and the calculated output shaft speed (CAN message from the
ABS). The TCM will detect if the transmission is slipping or an invalid gear ratio is present
POSSIBLE CAUSES
OTHER DTCS PRESENT
AXLE - MECHANICAL - GEAR RATIO
INTERNAL TRANSMISSION
TCM - TRANSMISSION SLIPPING
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the service information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTCs. Check and repair all engine DTCs prior to
performing transmission symptom diagnostics.
With the DRBIIIt, read and record all Transmission DTCs.
NOTE: Check connectors - Clean/repair as necessary. Poor pin to terminal
connections can set DTCs.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Most DTCs set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
NOTE: Check for any Technical Service Bulletins that may apply.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
125
TRANSMISSION - NAG1