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Ford EXPEDITION 2005 Technical Training Manual
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Ford EXPEDITION 2005 Technical Training Manual

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See also: Owner's Manual , User Manual
FCSD

Technical Training

INTERACTIVE STUDY GUIDE
2005
EXPEDITION/NAVIGATOR
NEW MODEL TECHNICIAN
TRAINING
FCS-14000-DL
2005 EXPEDITION/NAVIGATOR NEW MODEL TECHNICIAN TRAINING
02-SEP-04
COURSE CODE: 30N29F0

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Summary of Contents for Ford EXPEDITION 2005

  • Page 1: Technical Training

    FCSD Technical Training INTERACTIVE STUDY GUIDE 2005 EXPEDITION/NAVIGATOR NEW MODEL TECHNICIAN TRAINING FCS-14000-DL 2005 EXPEDITION/NAVIGATOR NEW MODEL TECHNICIAN TRAINING 02-SEP-04 COURSE CODE: 30N29F0...

  • Page 3: Important Safety Notice

    The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc.
  • Page 4 – Ford Multimedia Training (FMT) – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are ‘‘the Best in the Business’’...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ....................... Intro-1 Technical Training ......................Intro-1 Ground Rules for Successful Completion ..............Intro-1 Logging On ........................Intro-2 Keypad Operation......................Intro-3 In-Dealership Training Map ..................Intro-4 Purpose......................... Intro-5 Agenda.......................... Intro-5 LESSON 1: OVERVIEW......................1-1 Objectives .......................... 1-1 Mechanical and Chassis Features ..................
  • Page 6 TABLE OF CONTENTS NOTES 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 7: Introduction

    The distance learning course you are about to take is intended to give you new knowledge and information about diagnosing and servicing Ford and Lincoln/Mercury vehicles. We hope you will apply this knowledge and information to ‘‘Fix It Right The First Time’’ as part of the effort to satisfy our customer, the owners of Ford and Lincoln/Mercury products.

  • Page 8: Logging On

    INTRODUCTION LOGGING ON Your response keypad transmits data and voice between you and the host site via telephone lines and satellite. It is your ‘‘lifeline,’’ connecting you to the instructor as well as to other participants. Using the keypad, you can become fully involved in the seminar, asking questions and contributing relevant comments.

  • Page 9: Keypad Operation

    INTRODUCTION KEYPAD OPERATION CALL Key • Press the CALL key if you have a question or comment. This places you in the call queue. The system indicates your name and location to the instructor. • It takes approximately 60 seconds for the instructor to respond. If you change your mind about asking the question, simply press the CALL key again.

  • Page 10: In-Dealership Training Map

    INTRODUCTION IN-DEALERSHIP TRAINING MAP Intro-4 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 11: Purpose

    INTRODUCTION PURPOSE The purpose of this FORDSTAR course is to provide Ford and Lincoln/Mercury service technicians with the knowledge needed to understand new systems, new or updated components and unique diagnostic and service procedures for the 2005 Expedition/Navigator. AGENDA The information in this course is presented in the following lessons: •...
  • Page 12 INTRODUCTION NOTES Intro-6 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 13: Lesson 1: Overview

    LESSON 1: OVERVIEW OBJECTIVES • Identify the new powertrain applications for Expedition and Navigator. • Identify exterior features. • Identify interior features. • Identify lifting and jacking points. • Identify maintenance check points. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04...

  • Page 14: Mechanical And Chassis Features

    LESSON 1: OVERVIEW Mechanical and Chassis Features Mechanical and Chassis Features • 5.4L 3-Valve Triton Engine w/Variable Cam Timing. • 6HP26 Automatic Transmission (Navigator only). • 4R75E Automatic Transmission (Expedition only). 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 15 – Three valves per cylinder – Electronic Throttle Control (ETC) Rather than focusing on a single item to gain improvements in power, Ford used an approach that included advancements on multiple fronts. These improvements contribute to overall power with reduced NVH, at low engine speeds.
  • Page 16 LESSON 1: OVERVIEW • Variable Cam Timing (VCT) varies cam timing to match performance demands. • Charge Motion Control Valves (CMCV) manage the flow of air into the cylinders. • Vibration-resistant ribbing and reinforcement in the lower engine block help manage and tune sound and vibration.
  • Page 17 LESSON 1: OVERVIEW Automatic Transmission 6HP26 Transmission The 2005 Expedition will use the 4R75E automatic transmission like the 2004 and 2005 F-150, while the Navigator uses the all-new 6HP26 automatic. The 6HP26 6-speed transmission uses total electronic control for all functions. The Transmission Control Module (TCM) and the main control valve body units are combined and installed as a single unit inside the automatic transmission.

  • Page 18: Exterior Features

    LESSON 1: OVERVIEW Exterior Features 2005 Navigator Exterior • New body side cladding – Bold new body side cladding is added to the 2005 Lincoln Navigator. The cladding is painted body color and enhances as well as protects the exterior appearance. •...
  • Page 19 LESSON 1: OVERVIEW 2005 Expedition Exterior • New badging for Limited and FX4 (mid 4th quarter availability). – Expedition for 2005 comes with new badging when equipped with the Limited and FX4 packages. • New power fold side view mirrors. –...

  • Page 20: Interior Features

    LESSON 1: OVERVIEW Interior Features 2005 Navigator Interior • New 6HP26 automatic transmission gear selector. – Lincoln Navigators are equipped with a new 6HP26 transmission. The gear selector allows for manual or automatic selection of first through fourth gear (O/D disabled) and first through sixth (O/D enabled). O/D is enabled by moving the gear selector handle to the left while in the D6/D4 gate and is disabled by moving it to the right.
  • Page 21 LESSON 1: OVERVIEW 2005 Expedition Interior The 2005 Expedition receives minor trim and finish updates as: • Power fold side view miror switch (Limited only). – The power fold mirrors are operated from a switch that is integral with the power mirror switch. –...

  • Page 22: Lifting And Jacking

    LESSON 1: OVERVIEW Lifting and Jacking Lifting and Jacking Points The front and rear lifting and jacking locations are as indicated. 1-10 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 23: Maintenance Check Points

    LESSON 1: OVERVIEW Maintenance Check Points Maintenance Check Points (Navigator Shown) Item Description Item Description Cabin Air Filter Engine Coolant Engine Air Filter Engine Oil Fill Power Steering Fluid Windshield Washer Solvent Engine Oil Dipstick Battery Brake Fluid All maintenance point locations are carry-over from 2004 with the exception of the transmission fluid (on Lincoln Navigator) and air filter element (on both).
  • Page 24 LESSON 1: OVERVIEW NOTES 1-12 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 25: Lesson 2: Chassis

    LESSON 2: CHASSIS OBJECTIVES • Identify changes to the TPMS. • Identify new suspension system features. • Identify new drive axle/differential driveline features. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04...

  • Page 26: Wheels And Tires

    LESSON 2: CHASSIS Wheels and Tires Tire Pressure Monitor • TPMS functionality is integrated into Vehicle Security Module (VSM) located in the right kick panel. • Communicates with sensor at 315 MHz. • Blue colored sensor (315 MHz), unique for 2005 Expedition and Navigator. •...
  • Page 27 EXHIBIT A TIRE PRESSURE MONITORING SYSTEM (TPMS) WARNING, OR OTHER RELATED CONDITIONS, IF AFTERMARKET WHEELS ARE INSTALLED. FORD MOTOR COMPANY DOES NOT RECOMMEND USING AFTERMARKET WHEELS ON ANY VEHICLES, ESPECIALLY TPMS EQUIPPED VEHICLES. ORIGINAL EQUIPMENT (OE) WHEELS ARE SPECIFICALLY DESIGNED TO ACCOMMODATE TPMS SENSORS.
  • Page 28 LESSON 2: CHASSIS Functionality - 2005 Model Year Sensor Wheel Package Item Description Item Description Blue, 315 Mhz Tire Pressure Sensor • 4-sensor system (road tires only, does not include spare). • RF-based. – Sensors transmit pressure and unique ID to VSM (integrated system). –...
  • Page 29 LESSON 2: CHASSIS Sensor Description TPMS Sensor Item Description Item Description Transmitter Case Aluminum Valve Air Hole: Top Inside: Core Potted Surface: Bottom Grommet • 315 MHz (Blue), Manchester Encoded, AM. • Pressure Sampling / Transmission. – Stationary – 15 minute sample /1 hour transmission. –...
  • Page 30 LESSON 2: CHASSIS Module Description • TPM System integrated into Vehicle Security Module (VSM). • Module designed to: – Receive tire pressure and sensor information (315MHz transmissions from sensors). – Process input information, determine correct status, and associate sensors with module (learn). –...
  • Page 31 LESSON 2: CHASSIS Cluster Messages The following are messages that can be displayed on the message center (if equipped on Expedition models, standard on Navigator). • Customer (Normal Message) – LOW TIRE PRESSURE • Customer (System Check) – TIRE PRESSURE SYSTEM ACTIVE •...
  • Page 32 LESSON 2: CHASSIS DTCs Description B1342 ECU Defective B2477 Module Configuration Failure B2868 Left Front Sensor Fault B2869 Right Front Sensor Fault B2870 Right Rear Sensor Fault B2871 Left Rear Sensor Fault B2872 Tire Sensor Fault B1217 Horn Relay Circuit Failure C2780 ECU in Manufacturing Mode 02-SEP-04...
  • Page 33 LESSON 2: CHASSIS TPMS PIDs NGS Name WDS Name Description LF_ID LF_ID_VSM LEFT FRONT TIRE SENSOR RF_ID RF_ID_VSM RIGHT FRONT TIRE SENSOR RR_ID RR_ID_VSM RIGHT REAR TIRE SENSOR LR_ID LR_ID_VSM LEFT REAR TIRE SENSOR ID LF_PRES LF_PSI_VSM BP COMPENSATED PRESSURE CALCULATED BY MODULE (BARO COMP VALUE) RF_PRES...
  • Page 34 LESSON 2: CHASSIS Possible Failure Modes and Root Causes • TPMS indicator light stays ON continuously. Message center (if equipped) Displays: ‘‘Low Tire Pressure’’. – Causes: 1. Air pressure is low or not set to required placard pressure. 2. Spare tire currently in use. –...

  • Page 35: Driveshaft

    LESSON 2: CHASSIS Driveshaft Driveshaft • Navigator 4x2 models use a unique 2-piece driveshaft. • Staked U-Joint Service. – The original u-joints are staked in place. There is no retaining clip. – The factory u-joints require the use of a special cutting tool to remove the stakes prior to the removal of the u-joint cups.

  • Page 36: Front Drive Axle/Differential

    LESSON 2: CHASSIS Front Drive Axle/Differential Front Drive Axle/Differential • New companion flange – The design of the front axle companion flange is unique to the 2005 Expedition and Navigator. When servicing, be sure to obtain the proper parts for your specific application. 2-12 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 37: Lesson 3: Powertrain

    LESSON 3: POWERTRAIN OBJECTIVES • Identify new 5.4L 3-valve engine features. • Explain the operation of the VCT system. • Explain the revised procedure for camshaft or phaser assembly replacement. • Identify 6HP26 automatic transmission features. • Explain the basic functions of the 6HP26 transmission controls. •...

  • Page 38: Engine - 5.4L

    – Variable cam timing – Three valves per cylinder Rather than focusing on a single item to gain improvements in power, Ford used an approach that included advancements on multiple fronts. These improvements contribute to overall power with reduced NVH, at low engine speeds.
  • Page 39 LESSON 3: POWERTRAIN • Charge Motion Control Valves (CMCV) manage the flow of air into the cylinders. • Vibration-resistant ribbing and reinforcement in the lower engine block help manage and tune sound and vibration. – The engine block ribbing strengthens the block wall similar to cross reinforcements in a building wall. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04...
  • Page 40 LESSON 3: POWERTRAIN 5.4L Three-Valve Head The three-valve head has two smaller intake valves and one larger exhaust valve. • The three-valve head includes all of the advantages of the four-valve head with fewer parts and less noise. CAUTION: Remove the spark plugs before removing the heads. The spark plugs are long and can be damaged if left in the head.
  • Page 41 LESSON 3: POWERTRAIN Air Filter Intake Air Filter Module (IAFM) The intake air distribution and filtering design has been replaced with: • New split line welded Intake Air Filter Module (IAFM). The IAFM is a one piece, plastic component that houses the air filter element and Mass Air Flow (MAF) sensor. CAUTION: When removing the air inlet tube from the IAFM, be sure to disengage the retaining tab at the top of the tube.
  • Page 42 LESSON 3: POWERTRAIN Mass Air Flow (MAF) Sensor The compact Mass Air Flow (MAF) sensor is located on the IAFM. • This sensor combines the Intake Air Temperature (IAT) and the MAF sensor. 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 43 LESSON 3: POWERTRAIN Electronic Throttle Control (ETC) ETC Throttle Body • The 5.4L 3V engine used in both the Expedition and Navigator utilizes Electronic Throttle Control (ETC). This system functions and is serviced similarly to the systems used on the Thunderbird and LS. Warning indications are via an instrument cluster mounted message center or warning light.
  • Page 44 LESSON 3: POWERTRAIN Charge Motion Control Valves (CMCV) The Charge Motion Control Valves (CMCV) are electronically controlled metal flaps at the end of each intake runner, eight in total (four per bank on one rod, operated together). • CMCVs work to speed up the intake air charge and induce a ‘‘tumble’’ effect into the combustion chamber at low engine speeds and loads.
  • Page 45 LESSON 3: POWERTRAIN CMCV Motor The CMCVs use one electronically controlled motor to operate the CMCVs for both sides of the intake manifold. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04...
  • Page 46 LESSON 3: POWERTRAIN CMCV Block Diagram The CMCVs are controlled electronically by the PCM. • The inputs used by the PCM for the CMCV operation are: – Engine Speed – Throttle Position – Air Temperature – Cylinder Head Temperature • The CMCV system does not use a feedback loop.
  • Page 47 LESSON 3: POWERTRAIN VCT System 5.4L Variable Cam Timing Solenoid Electrical Connector Conventional camshafts are permanently synchronized with the engine crankshaft to operate the intake and exhaust valves at a specific point in each combustion cycle. Variable Cam Timing (VCT), however, allows the valves to operate at variable points in the combustion cycle.
  • Page 48 LESSON 3: POWERTRAIN VCT Operation The theory of operation for the 5.4L VCT is similar to the 3.9L VCT used on the Lincoln LS and 2004 Ford F-150 w/5.4L. • The major differences are: – The 5.4L VCT system controls both intake and exhaust valve timing because the 3-valve setup uses one camshaft for both intake and exhaust valves.
  • Page 49 LESSON 3: POWERTRAIN The basics of VCT operation are: • A hydraulic timing mechanism (VCT phaser) rotates the camshafts in relation to their drive sprockets. – Provides performance that is precisely tailored to the engine speed and load. – VCT is electronically controlled (PCM duty cycled) and hydraulically operated. •...
  • Page 50 LESSON 3: POWERTRAIN 5.4L 3-Valve Camshaft Position Sensor The VCT system requires a cam position sensor for each camshaft. • The PCM can then monitor the actual camshaft position relative to the requested position. 3-14 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 51 LESSON 3: POWERTRAIN Oil Temperature Sensor The VCT system uses a replaceable oil temperature sensor, located on the oil pan. • Engine oil temperature has a direct effect on VCT operation. – Cold engine oil has high viscosity and slower flow characteristics. –...
  • Page 52 LESSON 3: POWERTRAIN Phaser Components VCT Phaser The VCT components include: • Camshaft phaser sprockets. • Right and left camshaft phaser sprocket assembly bolt and washer. • VCT valve bodies (housing). • VCT solenoids. • Right and left camshafts. NOTE: The phaser, phaser sprocket, vanes and the return spring are serviced as an assembly. 3-16 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 53 LESSON 3: POWERTRAIN Phaser Oil Vanes The oil vanes create oil cavities for valve-directed oil to rotate the camshaft in relation to the crankshaft. • Oil pushes on one side of the vanes to rotate the cam in one direction to advance timing. •...
  • Page 54 LESSON 3: POWERTRAIN VCT Phaser Disassembled The VCT phaser varies camshaft timing in response to oil pressure exerted on either side of the vanes. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. CAUTION: Always install a new bolt and washer whenever the VCT phasers are loosened.
  • Page 55 LESSON 3: POWERTRAIN VCT Solenoid Removal The VCT solenoid is serviced separately from the VCT valve body. No special tools are needed to remove the solenoid. The retaining bolt is captured in the mounting tab. 1. Disconnect the solenoid electrical connection. 2.
  • Page 56 LESSON 3: POWERTRAIN VCT Valve Body Oil Passages Item Description Item Description Solenoid filter Oil passage back into head Oil passage to advance side of VCT Oil metering orifice Oil passage to retard side of VCT Oil passage from head Oil passage to chain tensioner The valve body and solenoid work together to route oil to the vanes in the camshaft phaser to operate the VCT system.
  • Page 57 LESSON 3: POWERTRAIN Locking Pin The locking pin locks the camshaft in a fully advanced position when the engine is off. • The pin locks the phaser to the camshaft during startup. • After startup, oil pressure at the VCT assembly will unlock this pin, allowing VCT operation to resume. –...
  • Page 58 LESSON 3: POWERTRAIN Phaser/Camshaft Removal Procedure Remove Valve Cover The phaser replacement procedure has been revised for the 5.4L 3V engine. This revision allows for the servicing of either the left or right phaser or camshaft without having to remove the engine front cover. Remove the left and/or right valve cover(s).
  • Page 59 LESSON 3: POWERTRAIN Set Crankshaft Damper Notch to 1 o’clock Position Set the crankshaft keyway to 12 o’clock. The machined notch on the back face of the damper pulley should appear at about the 1 o’clock position. NOTE: The number one piston should have just passed TDC when the crank was turned the normal rotational direction of engine operation.
  • Page 60 LESSON 3: POWERTRAIN Cam Lobe Positioning Item Description Item Description Intake Lobe Exhaust Lobe Pointing Inward The camshaft must be positioned with the #1 or #8 exhaust lobe facing inward to the 3 o’clock position. • If the lobes are not positioned this way, the crankshaft will require one full additional rotation to 12 o’clock. 3-24 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 61 LESSON 3: POWERTRAIN Mark Crankshaft Damper The damper spoke pointing upwards just to the left of the machined notch is the one with the keyway cut in it. Chalk mark that spoke for easy viewing. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 3-25...
  • Page 62 LESSON 3: POWERTRAIN Loosen One Turn Loosen the camshaft phaser bolt one turn. Do not remove the bolt. CAUTION: DO NOT use an impact wrench when loosening the phaser bolt. Impact tools can damage internal phaser components. 3-26 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 63 LESSON 3: POWERTRAIN Remove Only the Indicated Followers When removing the followers, remove the exhaust followers from the exhaust manifold side of the camshaft and the intake followers from the intake side. • On the right side: – #1 cylinder - exhaust only –...
  • Page 64 LESSON 3: POWERTRAIN Set Crankshaft Damper Spoke to 6 o’clock Position Rotate the marked damper spoke clockwise to the 6 o’clock position. CAUTION: It is imperative that the engine is only rotated to the 6 o’clock position in a clockwise rotation.
  • Page 65 LESSON 3: POWERTRAIN Inset Timing Chain Wedge Tool Assemble the ESST 303-636 Timing Chain Wedge to the ESST 303-637 Handle. Insert the timing chain wedge tool between the chain spans. Four to six clicks will hold it. Mark the chain to the phaser for reinstallation. The ‘‘R’’...
  • Page 66 LESSON 3: POWERTRAIN Loosen #1 Camshaft Bearing Cap Bolts Mark the cam caps for proper reinstallation. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Loosen the camshaft bearing caps. Start with the #1 cap because it contains a thrust surface groove. If the cam were to be moved in some fashion with this cap intact, the cap could be damaged or broken.
  • Page 67 LESSON 3: POWERTRAIN Remove the Phaser Bolt The remaining followers will be loose on the lifters. Be sure to keep them in place so that the camshaft can be reinstalled. Remove the CMP sensor. Fully withdraw the camshaft sprocket phaser bolt by hand. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 3-31...
  • Page 68 LESSON 3: POWERTRAIN Remove the Phaser Using extreme care, withdraw the phaser from the nose of the camshaft. It may be necessary to slightly tip up the cam from the rear to allow chain disengagement. CAUTION: Do not let the camshaft set in the cylinder head unattended. The cam may fall out. 3-32 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 69 LESSON 3: POWERTRAIN Cam and Phaser Reassembly Seating Cam Followers Care should be taken to ensure that the remaining followers are properly seated prior to camshaft installation. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 3-33...
  • Page 70 LESSON 3: POWERTRAIN Phaser Pin and Cam Notch Item Description Item Description Phaser Pin Cam Notch It is extremely important to align the phaser pin with the camshaft end notch. NOTE: If these are not aligned during installation, the phaser and camshaft will be damaged. 3-34 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 71 LESSON 3: POWERTRAIN Installing the Bearing Caps Install the camshaft bearing caps in the reverse order of removal. NOTE: The camshaft bearing caps must be installed in their original locations. The front thrust cap should be installed last to prevent the cap from breaking. Next, install the phaser bolt by hand.

  • Page 72: Electronic Engine Controls

    LESSON 3: POWERTRAIN Electronic Engine Controls Electronic Engine Controls • New integrated 4x4 strategy. – 4x4 operational strategy is now incorporated into the PCM. This eliminates the need for a separate module to control the transfer case. • The PCM utilizes a 190 pin connector. •...
  • Page 73 LESSON 3: POWERTRAIN • New premium fuel calibration (Navigator). – The aggressive spark and fuel programming requires 91 octane (or higher) fuel for maximum performance. Expedition requires 87 octane fuel for optimal performance. NOTE: Refer to the Workshop Manual for diagnostic and service procedures for these items. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 3-37...

  • Page 74: Fuel Tank And Lines

    LESSON 3: POWERTRAIN Fuel Tank and Lines Fuel Tank and Lines • New fuel filter – The fuel filter is located on the front side of the fuel tank. It can be accessed by removing the road debris shield. Quick connect fittings are used for connection to the fuel lines. •...

  • Page 75: Engine Special Service Tools

    LESSON 3: POWERTRAIN Engine Special Service Tools Engine Special Service Tools Item Description Item Description ESST 307-516/1 Installer, Teflon Seal ESST 310-123 Remover/Installer Tank (4R75E Tool) Sender Unit ESST 307-516/2 Installer, Teflon Seal ESST 205-086-1 Adaptor for 205-086 (4R75E Tool) ESST 307-516/3 Installer, Teflon Seal ESST 418-F395 Diagnostic Service (4R75E Tool)

  • Page 76: Automatic Transmission

    LESSON 3: POWERTRAIN Automatic Transmission Description 6HP26 Transmission The 6HP26 transmission uses planetary gears with multiple clutches and electronic controls. The Transmission Control Module (TCM) and the main control valve body units are combined and installed as a single unit inside the automatic transmission.
  • Page 77 LESSON 3: POWERTRAIN • shift feel. • shift scheduling. • modulated Torque Converter Clutch (TCC) applications. • engine braking. This transmission has a mechatronic unit (valve body) which contains: • Turbine Shaft Speed (TSS) sensor. • Output Shaft Speed (OSS) sensor. •...
  • Page 78 LESSON 3: POWERTRAIN Operation 6HP26 Cutaway Engine power reaches the transmission by a torque converter with an integral converter clutch. The six forward gears and one reverse gear are obtained from both single and double planetary sets. This automatic transmission is a six-speed electronically controlled transmission comprised of a TCM, main control valve body unit, torque converter, one solenoid valve and six pressure regulators.
  • Page 79 LESSON 3: POWERTRAIN Identification Tag Identification Tag The identification tag is located on the left side of the case just rearward of the manual control lever. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 3-43...
  • Page 80 LESSON 3: POWERTRAIN Range Selection Shifter Pattern The transmission has eight range positions: P, R, N, D6, D4, 3, 2 and 1. In the Park position: • There is no power flow through the transmission • The parking pawl locks the output shaft to the case •...
  • Page 81 LESSON 3: POWERTRAIN The D6 position is the normal position for most driving conditions. It provides: • Automatic shifts 1-6 and 6-1 • Apply and release of the torque converter clutch • Maximum fuel economy during normal operation • Engine braking in sixth gear The D4 position provides: •...
  • Page 82 LESSON 3: POWERTRAIN Shift Patterns • Under certain conditions the transmission automatically downshifts to a lower gear range (without moving the range selector lever). There are three categories of automatic downshifts: – coastdown – torque demand – forced or kickdown shifts •...
  • Page 83 LESSON 3: POWERTRAIN Shift Elements Shift Elements Item Description Item Description Double Planetary Gearset Overdrive Clutch Forward Clutch Low/Reverse Clutch Transmission Case (Fixed) Single Planetary Gearset Direct Clutch Stator Shaft Intermediate Clutch Turbine Shaft The shift elements are: – Three rotating multi-plate clutches: forward, direct and overdrive. –...
  • Page 84 LESSON 3: POWERTRAIN The shift elements are engaged hydraulically. The transmission fluid pressure builds up between the cylinder and the piston, pressing the clutches together. The purpose of these shift elements is to carry out in-load shifts with no interruption to traction. Multi-plate clutches forward, direct and overdrive supply power from the engine to the planetary gear train.
  • Page 85 LESSON 3: POWERTRAIN Multi Plate Clutch Multi Plate Clutch Item Description Item Description Clutch Pack Cluster Turbine Shaft Piston Lubricating Oil Passage Cylinder Cup Spring Ring Gear (Planetary Gearset 1) Baffle Plate Main Pressure Supply to Clutch Inner Plate Carrier Multi plate clutches are used exclusively throughout the 6HP26 transmission.
  • Page 86 LESSON 3: POWERTRAIN Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter The transmission fluid pan, gasket and filter is a one-piece assembly. All transmission fluid is drawn from the transmission fluid pan by the fluid pump and passes through the filter. To drain and fill the 6HP26 transmission, perform the following steps: Drain With the vehicle in NEUTRAL, position it on a hoist.
  • Page 87 LESSON 3: POWERTRAIN 5. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. With the engine idling (600-750 rpm) in PARK and the transmission temperature at 30 C-50 C (86 F-122 F), check and adjust the transmission fluid level. 7.
  • Page 88 LESSON 3: POWERTRAIN Transmission Control Module (TCM) and Main Control Valve Body Transmission Control Module (TCM) and Main Control Valve Body The Main Control assembly (7A100) referred to as the mechatronic unit is made up of the following components, the TCM processor, seven control solenoids, and a typical main control assembly. The main control component houses valves and springs within the two halves (upper and lower).
  • Page 89 LESSON 3: POWERTRAIN Transmission Electronic System The TCM receives input signals from certain transmission-related sensors and switches. The TCM uses these signals to control the following operations: • Shift timing • Line pressure (shift feel) • Torque converter clutch To accomplish this, the TCM uses six pressure control solenoids and one shift solenoid to control transmission operation.
  • Page 90 LESSON 3: POWERTRAIN Transmission Control Module (TCM) Transmission Control Module (TCM) The TCM is mounted on top of the main control valve body. The control module has been designed to operate correctly in the environment in which the TCM is located. The TCM is activated and deactivated by the ignition supply and is connected to the transmission link harness by a 16-pin connector.
  • Page 91 LESSON 3: POWERTRAIN Solenoids Solenoids Item Description Item Description SSA (EDS1) SSD (EDS4) SSB (EDS2) SSE (MV1) SSC (EDS3) TCC (EDS6) PCA (EDS5) The hydraulic module contains one solenoid valve. The solenoid valve is activated by the TCM and is either open or closed.
  • Page 92 LESSON 3: POWERTRAIN Controller Area Network (CAN) Interface Controller Area Network (CAN) Interface For the TCM to carry out shift point and shift quality management, a number of external signals are required. For shift point management, the TCM requires Output Shaft Speed (OSS) sensor, Accelerator Pedal Position (APP) sensor, Brake Pedal Position (BPP) switch and Transmission Range (TR) sensor.
  • Page 93 LESSON 3: POWERTRAIN Sensors Integrated With TCM Sensors Integrated With TCM Item Description Item Description Output Shaft Speed (OSS) Sensor Turbine Shaft Speed (TSS) Sensor Transmission Fluid Temperature (TFT) Sensor • Several sensors are located on the TCM and main control valve body unit. •...
  • Page 94 LESSON 3: POWERTRAIN Transmission Range Position Sensor Transmission Range Position Sensor The TCM uses the position of this switch, housed on the TCM and main control valve body, to determine the selected gear range from the range selector lever. The sensor completes the start circuit in PARK and NEUTRAL, and the back-up lamp circuit in REVERSE. The sensor also opens/closes a set of switches that are monitored by the TCM to determine the position of the manual lever (P, R, N, D6, D4, 3, 2, 1).
  • Page 95 LESSON 3: POWERTRAIN Transmission Operational Strategies Adaptive shift strategy is comprised of the following functions: • Shift Energy Management - Reduces or increases engine output torque during shifting. – Reduces excessive energy at the clutch pack. – Increases transmission service life. –...
  • Page 96 LESSON 3: POWERTRAIN TCM Monitoring Functions The TCM monitors all transmission inputs and outputs to identify possible transmission failures. If a fault is detected, the TCM takes the appropriate actions to ensure the transmission enters a safe mode of operations. The PCM then sets a DTC and illuminates the Malfunction Indicator Lamp (MIL).
  • Page 97 LESSON 3: POWERTRAIN Monitoring The Substrate Temperature Sensor Substrate Temperature Sensor The TCM controls a number of high power solenoids and is surrounded by automatic transmission fluid. As a result, the TCM can get very hot. If the temperature of the hardware rises above a predetermined temperature, the TCM shuts down.

  • Page 98: Transmission Cooling

    LESSON 3: POWERTRAIN Transmission Cooling Transmission Cooling • New quick connect transmission oil cooler lines. – Quick connect fittings are used at the transmission line-to-radiator cooler connections. Use ESST 307-441, Disconnect Tool, Transmission Cooler Line to disconnect lines for service. Refer to the Workshop Manual for diagnostic and service procedures.

  • Page 99: 6Hp26 Transmission Special Service Tools

    LESSON 3: POWERTRAIN 6HP26 Transmission Special Service Tools Item Description 307-552 Direct Clutch Service Fixture 307-553 Front Pump Removal Tool 307-554 D Clutch Stack Gauge 307-555 Clutch Pack End Play Gauge 307-556 Fluid Pump 4x2 Rear Seal Installer 307-557 Case Bearing Installer 307-558 Case Second Bearing Installer 307-559...
  • Page 100 LESSON 3: POWERTRAIN NOTES 3-64 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 101: Lesson 4: Electrical

    LESSON 4: ELECTRICAL OBJECTIVES • Identify ETC warning features. • Identify climate control features. • Identify charging system features. • Identify Vehicle Security Module (VSM) features. • Identify module communication features. 2005 Expedition/Navigator New Model Technician Training 02-SEP-04...

  • Page 102: Climate Controlled Seats

    LESSON 4: ELECTRICAL Climate Controlled Seats Climate Controlled Seats Control Head Item Description Item Description Driver’s Side Intensity Level LEDs Passenger’s Side Heating/Cooling Control Switches Passenger’s Side Intensity Level LEDs Driver’s Side Heating/Cooling Control Switches For 2005, the climate controlled seats utilize one control module (located under the passenger side front seat) to control both front seats.

  • Page 103: Warning Devices

    LESSON 4: ELECTRICAL Warning Devices ETC Warning • New Electronic Throttle Control (ETC) warning message. • When an ETC system fault occurs, a message is displayed on vehicles equipped with message centers (all Navigators and Expeditions with high-line instrument clusters). •...

  • Page 104: Instrument Cluster Lighting

    LESSON 4: ELECTRICAL Instrument Cluster Lighting • In 2004 the Navigator had a seperate dimming module that could be serviced seperately. For 2005, the dimming control is integrated into the instrument cluster. If there is an issue with the dimming system that is isolated to the instrument cluster, the entire instrument cluster will require replacement.

  • Page 105: Charging System

    LESSON 4: ELECTRICAL Charging System Smart Charge Generator • The 2005 Expedition and Navigator are both equipped with a PCM-controlled charging system known as Smart Charge. On this system, the PCM determines the optimal charging voltage setpoint. Once the PCM has determined the optimal charging voltage for a given situation, the PCM signals the voltage regulator to control generator output.

  • Page 106: Vehicle Security Module

    LESSON 4: ELECTRICAL Vehicle Security Module For the 2005 Expedition/Navigator, the Vehicle Security Module (VSM) strategy has been revised to allow Remote Keyless Entry (RKE) transmitter data (IDs and rolling codes) to be retrieved and programmed using diagnostic tools. It is no longer necessary to reprogram the remote transmitters when a VSM is replaced. When a VSM is replaced using the PMI procedure, remote transmitter data is now also transferred to the new module.

  • Page 107: Module Communication Network

    LESSON 4: ELECTRICAL Module Communication Network Module Communication Network The diagnostic tool connects to each network through the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one diagnostic tester to diagnose and control any module on the four networks from one connector.
  • Page 108 LESSON 4: ELECTRICAL Communication Protocols The 2005 Expedition and Navigator feature the following comunication protocols: • Medium Speed Controller Area Network (MS-CAN) The MS-CAN has an unshielded twisted pair cable. The MS-CAN is used for the Vehicle Dynamics Module (VDM), the Dual Climate Control Seat Module (CCSM), the Dual Automatic Temperature Control (DATC) module, the instrument cluster, the Parking Aid Module (PAM), Liftgate/Trunk Module (LTM), and the Vehicle Security Module (VSM) communications.

  • Page 109: Appendix: Essential Special Service Tools

    APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS ESSENTIAL SPECIAL SERVICE TOOLS 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-1...
  • Page 110 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS NOTES Appendix-2 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...
  • Page 111 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-3...
  • Page 112 APPENDIX: ESSENTIAL SPECIAL SERVICE TOOLS Appendix-4 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

  • Page 113: Glossary Of Terms

    APPENDIX: GLOSSARY OF TERMS GLOSSARY OF TERMS 2005 Expedition/Navigator New Model Technician Training 02-SEP-04 Appendix-5...
  • Page 114 APPENDIX: GLOSSARY OF TERMS NOTES Appendix-6 02-SEP-04 2005 Expedition/Navigator New Model Technician Training...

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2005 navigator