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daimler-chrysler
TABLE OF CONTENTS
1.0
INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX -STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0
IDENTIFICATION OF SYSTEM .............................................1
3.0
3.1 GENERAL DESCRIPTION ............................................1
3.2 FUNCTIONAL OPERATION ...........................................2
VARIOUS OIL TEMPERATURES ...............................2
3.2.2 LINE PRESSURE CONTROL ..................................3
3.2.3 DRIVE LEARN PROCEDURE .................................4
3.3 DIAGNOSTIC TROUBLE CODES ......................................5
3.3.1 HARD CODE ...............................................6
3.3.2 ONE TRIP FAILURES ........................................6
3.3.3 INTERMITTENT CODE .......................................6
3.3.4 STARTS SINCE SET COUNTER ...............................6
3.3.5 TROUBLE CODE ERASURE ..................................6
descriptions follow list) .......................................7
3.3.7 DTC DESCRIPTIONS ........................................8
3.3.8 QUICK LEARN ............................................19
3.3.9 CLUTCH VOLUMES ........................................20
T
................................................20
ERROR MESSAGES ........................................20
3.5.1 DRBIII
T
T
............................20
4.0 DISCLAIMERS, SAFETY, AND WARNINGS .............................21
4.1 DISCLAIMERS .....................................................21
4.2 SAFETY ..........................................................21
4.2.1 TECHNICIAN SAFETY INFORMATION .........................21
4.2.2 VEHICLE PREPARATION FOR TESTING ......................21
4.2.3 SERVICING SUB-ASSEMBLIES ..............................21
4.2.4 DRBIII
9
---
9
SAFETY INFORMATION .............................22
4.3 WARNINGS .......................................................22
4.3.1 VEHICLE DAMAGE WARNINGS ..............................22
4.3.2 ROAD TESTING A COMPLAINT VEHICLE. .....................22
4.4.4 BULLETINS AND RECALLS ..................................23
T
5.0
REQUIRED TOOLS AND EQUIPMENT .....................................23
6.0
GLOSSARY OF TERMS ..................................................23
6.1 ACRONYMS ......................................................23
6.2 DEFINITIONS .....................................................24
i
3.5 DRBIII
TABLE OF CONTENTS - Continued
7.0
DIAGNOSTIC INFORMATION AND PROCEDURES ...........................25
P0604-INTERNAL TCM ..................................................34
P0605-INTERNAL TCM ..................................................35
P0613-INTERNAL TCM ..................................................36
P0706-CHECK SHIFTER SIGNAL ..........................................37
P0715-INPUT SPEED SENSOR ERROR ....................................45
P0720-OUTPUT SPEED SENSOR ERROR ..................................49
P0725-ENGINE SPEED SENSOR CIRCUIT ..................................53
P0731-GEAR RATIO ERROR IN 1ST .......................................56
P0732-GEAR RATIO ERROR IN 2ND .......................................58
P0733-GEAR RATIO ERROR IN 3RD .......................................61
P0734-GEAR RATIO ERROR IN 4TH .......................................64
P0735-GEAR RATIO ERROR 4TH PRIME ...................................66
P0736-GEAR RATIO ERROR IN REVERSE ..................................68
P0750-LR SOLENOID CIRCUIT ............................................72
P0755-2C SOLENOID CIRCUIT ............................................76
P0760-OD SOLENOID CIRCUIT ...........................................80
P0765-UD SOLENOID CIRCUIT ...........................................84
P0770-4C SOLENOID CIRCUIT ............................................88
P0841-LR PRESSURE SWITCH SENSE CIRCUIT ............................92
P0845-2C HYDRAULIC PRESSURE TEST FAILURE ..........................96
P0846-2C PRESSURE SWITCH SENSE CIRCUIT ...........................102
P0867-LINE PRESSURE FAULT ..........................................106
P0868-LINE PRESSURE LOW ...........................................109
P0869-LINE PRESSURE HIGH ...........................................114
P0870-OD HYDRAULIC PRESSURE TEST FAILURE .........................119
P0871-OD PRESSURE SWITCH SENSE CIRCUIT ...........................125
P0875-UD HYDRAULIC PRESSURE TEST FAILURE .........................129
P0876-UD PRESSURE SWITCH SENSE CIRCUIT ...........................135
P0884-POWER UP AT SPEED ...........................................139
P0888-RELAY OUTPUT ALWAYS OFF .....................................140
P0890-SWITCHED BATTERY ............................................144
P0891-TRANSMISSION RELAY ALWAYS ON ...............................148
P0932-LINE PRESSURE SENSOR FAULT ..................................151
P0944-LOSS OF PRIME .................................................155
P0987-4C HYDRAULIC PRESSURE TEST FAILURE .........................158
P0988-4C PRESSURE SWITCH SENSE CIRCUIT ...........................164
P1684-BATTERY WAS DISCONNECTED ...................................168
P1715-RESTRICTED PORT IN T3 RANGE .................................172
P1736-GEAR RATIO ERROR IN 2ND PRIME ...............................173
P1790-FAULT IMMEDIATELY AFTER SHIFT ................................183
P1793-TRD LINK COMMUNICATION ERROR ...............................184
ii
TABLE OF CONTENTS - Continued
P1794-SPEED SENSOR GROUND ERROR ................................187
P1799-CALCULATED OIL TEMP IN USE ...................................190
P2700-INADEQUATE ELEMENT VOLUME LR ...............................194
P2701-INADEQUATE ELEMENT VOLUME 2C ...............................196
P2702-INADEQUATE ELEMENT VOLUME OD ..............................198
P2703- INADEQUATE ELEMENT VOLUME UD ..............................200
P2704-INADEQUATE ELEMENT VOLUME 4C ...............................202
P2706-MS SOLENOID CIRCUIT ..........................................204
*BACKUP LAMPS INOPERATIVE .........................................209
*CHECKING PARK/NEUTRAL SWITCH OPERATION .........................213
*POOR SHIFT QUALITY ................................................215
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S ..........................218
*TRANSMISSION SIMULATOR WILL NOT POWER UP .......................220
VERIFICATION TESTS ..................................................222
8.0
COMPONENT LOCATIONS ..............................................225
8.1 CRANKSHAFT POSITION SENSOR ..................................225
8.2 ELECTRONIC MODULE LOCATIONS .................................225
8.3 TRANSMISSION COMPONENT LOCATIONS ..........................225
8.4 TRANSMISSION CONTROL MODULE ................................226
8.5 TRANSMISSION LINE PRESSURE SENSOR ..........................226
9.0
CONNECTOR PINOUTS ................................................227
BRAKE LAMP SWITCH - GRAY 6 WAY ....................................227
C113 (DIESEL) - LT. GRAY (TRANSMISSION SIDE) ..........................227
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY .........................228
DATA LINK CONNECTOR - BLACK 16 WAY ................................229
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY ...........................229
GOVERNOR PRESSURE SENSOR .......................................231
INPUT SPEED SENSOR (4.7L) - BLACK 2 WAY .............................232
FUSES (JB) ...........................................................234
JUNCTION BLOCK C2 (LHD) - BLACK 52 WAY .............................235
JUNCTION BLOCK C2 (RHD) - BLACK 52 WAY .............................236
JUNCTION BLOCK C3 - BLACK 52 WAY ...................................237
LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY .............................238
LINE PRESSURE SENSOR (4.7L) - BLACK 4 WAY ..........................238
OUTPUT SPEED SENSOR (4.0L) - GRAY 2 WAY ............................238
OUTPUT SPEED SENSOR (4.7L) - BLACK 2 WAY ...........................238
iii
TABLE OF CONTENTS - Continued
FUSES (DIESEL) ......................................................243
BACK-UP LAMP RELAY (DIESEL) ........................................243
FUSES (GAS) .........................................................245
TRANSMISSION CONTROL RELAY (GAS) .................................245
RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY ............................246
SHIFTER ASSEMBLY (GAS) - WHITE 6 WAY ...............................246
SHIFTER ASSEMBLY C2 (DIESEL)-6WAY ................................247
THROTTLE POSITION SENSOR (4.7L)-3WAY .............................247
TRANSMISSION SOLENOID (4.0L) - BLACK 8 WAY .........................249
10.0 SCHEMATIC DIAGRAMS ................................................251
10.1 TRANSMISSION SCHEMATIC DIAGRAM. .............................251
11.0 CHARTS AND GRAPHS ................................................253
11.1 PRESSURE SWITCH STATES. ......................................253
11.2 SHIFT LEVER ERROR CODES ......................................253
11.3 TRANSMISSION RANGE SENSOR STATES ...........................254
iv
GENERAL INFORMATION
1.0 INTRODUCTION
cally applied clutches to shift a planetary gear
train. However, the electronic control system re-
places many of the mechanical and hydraulic com-
ponents used in conventional transmission valve
bodies.
The 45RFE/545RFE electronic transmission is a
fully electronically controlled transmission. The
Transmission Control Module (TCM) is similar to
(but not the same as) the one used in the 41TE and
42LE transmissions, therefore many similarities
exist in function and diagnosis.
The 45RFE/545RFE has an overrunning clutch
(used in 1st gear), an electronically controlled
torque converter clutch, 3 planetary gearsets, and
six clutch packs. The clutches are called 2nd Clutch
(2C), 4th Clutch (4C), Low/Reverse Clutch (LR),
Reverse Clutch (RC), Underdrive Clutch (UD), and
Overdrive Clutch (OD).
Although the 45RFE is considered a 4 speed
transmission, it really has 5 forward gear ratios.,
the 545RFE is considered a 5 speed transmission, it
really has 6 forward gear ratios. 2nd gear (1.67:1)
and 2nd prime (1.50:1) gear are so close in ratio that
they are not considered to be different gear ratios,
although both are used as 2nd gear under certain
conditions. During most upshift and downshift ma-
neuvers, 2nd gear will be used. 2nd prime gear is
only used for a high speed 4-2 downshift. The
545RFE transmission is essentially a software
change to the TCM that allows an additional over-
drive ratio of (.667:1). The gear ratio of 4th Prime is
achieved by applying the 2C and OD clutches. The
4th Prime is used above 52 MPH. All gear ratios in
the 45RFE/545RFE are achieved by applying two
elements (clutches). During a shift, one element is
released and another is applied, resulting in a
different ratio. This is called a clutch to clutch shift.
In order to perform a 4-2 downshift, two elements
would have to be released and two different ele-
ments applied. The 2nd prime gear ratio allows a
clutch to clutch 4-2’ (2nd prime) downshift.
The oil pump in the 45RFE/545RFE is a dual
stage positive displacement gear type pump. At idle
and low engine speeds, both stages are working.
Once the engine speed reaches a point where one
side of the pump can supply the necessary system
requirements, the second stage is vented. This
pump configuration gives the pressure and flow of a
large displacement pump at low speeds, and the
economy of a small displacement pump at higher
engine speeds. The oil pump housing also contains
some of the valves that are found in the valve body
in a 41TE or 42LE transmission. The Converter
Clutch Switch Valve, Converter Clutch Regulator
Valve, Torque Converter Limit Valve, and the Pres-
sure Regulator Valve, are all found in the oil pump
housing.
The procedures contained in this manual include
all of the specifications, instructions, and graphics
needed to diagnose 45RFE/545RFE Electronic Au-
tomatic Transmission (EATX) problems. The diag-
nostics in this manual are based on the failure
condition or symptom being present at the time of
diagnosis.
When repairs are required, refer to the appropri-
ate volume of the service manual for the proper
removal and repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added and/or carryover
systems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
TROUBLE CODE. It is recommended that you
review the entire manual to become familiar with
all new and changed diagnostic procedures.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
2002 Model Year WJ/WG equipped with a 45RFE/
545RFE Automatic Transmission.
1.2 SIX -STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the 45RFE/545RFE electronic trans-
mission is done in six basic steps:
²
Verification of complaint
²
Verification of any related symptoms
²
Symptom analysis
²
Problem isolation
²
Repair of isolated problem
²
Verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
The 45RFE/545RFE Transmission family can be
identified by confirming the presence of a 23 pin
electrical connector on the left hand side of the
transmission oriented vertically near the manual
lever.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 45RFE/545RFE electronic transmission is a
conventional transmission in that it uses hydrauli-
1
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