transmission MERCEDES-BENZ SPRINTER 2006 Service Manual

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

TEST ACTION APPLICABILITY
2 With the DRBIIIt, read Transmission DTCs.
Are there any Improper Gear and/or Improper Ratio DTCs present?All
Ye s!Refer to the Transmission category and perform the appropriate
symptom.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 3
3 Verify the correct axle gear ratio and make sure there are no mechanical problems.
Refer to the Service Information for the proper procedures.
Were there any problems found?All
Ye s!Refer to the Service Information for proper repair procedures.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Go To 4
4 Determine if the Transmission is mechanically slipping.
Is the transmission slipping?All
Ye s!Repair internal transmission as necessary. Refer to the Service
Information for the proper repair procedure.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
No!Replace the Transmission Control Module.
Perform NAG1 TRANSMISSION VERIFICATION TEST - VER 1.
126
TRANSMISSION - NAG1
TRANSMISSION SLIPPING ÐContinued

Verification Tests
NAG1 TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY
1. Reconnect any disconnected components.
2. Connect the DRBIIItto the Data Link Connector.
3. With the DRBIIIt, erase ABS DTCs.
4. With the DRBIIIt, erase ECM DTCs.
5. With the DRBIIIt, erase Transmission DTCs.
6. With the DRBIIIt, display Transmission Temperature. Start and run the engine until the
Transmission Temperature is HOT, above 43É C (110É F).
7. Check the Transmission fluid and adjust if necessary. Refer to the Service Information for the
proper Fluid Fill procedure.
8. NOTE: If internal repairs were performed and the shift quality is still poor, it may
be necessary to check the internal repair. Also check for any TSBs and/or Controller
Flash updates that may apply.
9. ROAD TEST PROCEDURE
10. Road test the vehicle. Make fifteen to twenty 1-2, 2-3, 3-4 and 4-5 upshifts.
11. Perform these shifts from a standing start to 72 km/h (45 MPH) with a constant throttle
opening of 20 to 25 degrees.
12. With speeds below 40 km/h (25 MPH), make five to eight wide open throttle kickdowns to
1st gear. Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown.
13. With the DRBIIIt, read Transmission DTCs.
Were there any Diagnostic Trouble Codes set?All
Ye s!Repair is not complete, refer to appropriate symptom.
No!Repair is complete.
127
VERIFICATION TESTS

8.0 COMPONENT LOCATIONS
8.1 ENGINE CONTROL MODULE
8.2 TRANSMISSION CONTROL MODULE
8.3 TRANSMISSION SOLENOID ASSEMBLY
C
O
M
P
O
N
E
N
T
L
O
C
A
T
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O
N
S
129
COMPONENT LOCATIONS

9.0 CONNECTOR PINOUTS
ELECTROHYDRAULIC CONTROL UNIT - BLACKCAV CIRCUIT FUNCTION
1 20BL/DG N3 INPUT SPEED SENSOR
2 16BR/GY MODULATION PRESSURE SOLENOID CONTROL
3 20BL/GY N2 INPUT SPEED SENSOR
4 20GY/BL TEMPERATURE SENSOR-P/N SWITCH
5- -
6 16BK SOLENOID SUPPLY VOLTAGE
7 20BK/BL SENSOR SUPPLY VOLTAGE
8 16WT/BL 2-3 SOLENOID CONTROL
9 16YL 3-4 SOLENOID CONTROL
10 16BK/RD SHIFT PRESSURE SOLENOID CONTROL
11 16YL/BL TCC SOLENOID CONTROL
12 20PK SENSOR GROUND
13 16WT 1-2/4-5 SOLENOID CONTROL
SHIFTER ASSEMBLY - BLACKCAV CIRCUIT FUNCTION
1- -
2 20GY/DG/RD LAMP DRIVER
3 20BL/DG K-ABS/SHIFTER ASSEMBLY
4 18BR GROUND
5 20BK/BL/RD BRAKE LAMP SWITCH
6 20DG/WT CAN C BUS (+)
7 20DG CAN C BUS (-)
8 18BK/DG TRANSMISSION RELAY OUTPUT
9 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 16WT/RD BACK-UP LAMP
TRANSMISSION CONTROL MODULE C1 - BLACKCAV CIRCUIT FUNCTION
1 20BL K-TCM/RADIO
2- -
3- -
4- -
5- -
6- -
7- -
8- -
9- -
10 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 16BK/DG TRANSMISSION RELAY OUTPUT
30 18BR GROUND
C
O
N
N
E
C
T
O
R
P
I
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131
CONNECTOR PINOUTS

TRANSMISSION CONTROL MODULE C2 - BLACKCAV CIRCUIT FUNCTION
12 20BL/GY N2 INPUT SPEED SENSOR
13 20BK/BL SENSOR SUPPLY VOLTAGE
14 16WT 1-2/4-5 SOLENOID CONTROL
15 16YL 3-4 SOLENOID CONTROL
16 16WT/BL 2-3 SOLENOID CONTROL
17 16YL/BL TCC SOLENOID CONTROL
33 20PK SENSOR GROUND
34 20GY/BL TEMPERATURE SENSOR-P/N SWITCH
35 20BL/DG N3 INPUT SPEED SENSOR
36 16BR/GY MODULATION PRESSURE SOLENOID CONTROL
37 16BK/RD SHIFT PRESSURE SOLENOID CONTROL
38 16BK SOLENOID SUPPLY VOLTAGE
H 20DG/WT CAN C BUS (+)
L 20DG CAN C BUS (-)
C
O
N
N
E
C
T
O
R
P
I
N
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132
CONNECTOR PINOUTS

TRANSMISSION RELAY (RELAY BLOCK)CAV CIRCUIT FUNCTION
30 16BK/DG TRANSMISSION RELAY OUTPUT
85 16BR GROUND
86 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
87 16RD FUSED B(+)
87A - -
C
O
N
N
E
C
T
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P
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133
CONNECTOR PINOUTS

11.2 TRANSMISSION TEMP SENSORC
H
A
R
T
S
A
N
D
G
R
A
P
H
S
138
CHARTS AND GRAPHS