72
Automatic Transmission/Transaxle Theory, Operation and Diagnostics Session 2 Course #17041.23D2 Participant Guide Revised 03/07/07

Gm Tech Info 6t70 6l80

Embed Size (px)

Citation preview

Page 1: Gm Tech Info 6t70 6l80

Service Technical College

Automatic Transmission/Transaxle Theory, Operation and

Diagnostics Session 2

Course #17041.23D2

Participant Guide Revised 03/07/07

Page 2: Gm Tech Info 6t70 6l80

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Caution

In order to reduce the risk of personal injury or property damage, carefully observe the following information:

The service manuals of General Motors Corporation are intended for use by professional, qualified technicians. Attempting service procedures without the appropriate training, tools, and equipment could cause personal injury, vehicle damage, or improper vehicle operation. Proper vehicle service is important to the safety of the service technician and to the safe, reliable operation of all motor vehicles. If a replacement part is needed, use the same part number or an equivalent part. Do not use a replacement part of lesser quality.

The service manuals contain effective methods for performing service procedures. Some of the procedures require the use of tools that are designed for specific purposes. Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by General Motors, must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle. The service manuals contain Cautions and Notices that must be observed carefully in order to reduce the risk of personal injury. Improper service may cause vehicle damage or render the vehicle unsafe. The Cautions and Notices are not all-inclusive. General Motors can not possibly warn of all the potentially hazardous consequences that may result by not following the proper service procedures. The service manuals cover service procedures for vehicles that are equipped with Supplemental Inflatable Restraints (SIR). Failure to observe all SIR Cautions and Notices could cause air bag deployment, personal injury, or otherwise unneeded SIR repairs. Refer to the SIR component and wiring location views in Restraints before performing a service on or around SIR components or wiring. If multiple vehicle systems are in need of repair, including SIR, repair the SIR system first to reduce the risk of accidental air bag deployment and personal injury.

January 2002

Page 3: Gm Tech Info 6t70 6l80

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Table of Contents Welcome and System Instructions ..................................................................................................................................i

Introduction........................................................................................................................................................................i-1

Module 2: Saab 9-7x/4L60 Diagnostic Scenario 1...................................................................................................2-1

Module 3: Six Speed – 6T70/75 Diagnostic Scenario 2..........................................................................................3-1

Module 4: Six Speed – 6L50/80/90 Diagnostic Scenario 3.....................................................................................4-1

Evaluation....................................................................................................................................................................... E-1

© 2007

Instructor Name:

This manual contains information about service for Automatic Transmissions and Transaxles. Always refer to applicable vehicle service information and appropriate Dealer Technical Service Bulletins for additional information regarding system operation and diagnostic/repair procedures. When this manual refers to a brand name, a number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes at any time without notice. No part of this book may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without prior written permission of General Motors Corporation. This applies to all text, illustrations, tables and charts.

Page 4: Gm Tech Info 6t70 6l80

System Instruction ii

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Using the Distance Learning Equipment Before the broadcast begins, please read the following information which will help you to understand the genesis equipment and OneTouch keypad — your links to the instructor and the other course participants.

Logging in to the system

1. Press MENU on the remote control or on the front panel. 2. Select the program from the Electronic Program Guide (EPG) using the

arrow keys or .

3. Press OK or to make selection. 4. For live interactive programs, login to a host will occur automatically after 15

seconds. Keypads will initialize. 5. Once the keypad asks for your ID, enter your student identification number

(U.S. Social Security or Employee ID, Canadian EIN, Mexican IMSS or Person ID, effective January 2005) on your OneTouch keypad, and then press the Enter key. The message "Validating" appears on the keypad for a few seconds. Next, your name appears. This confirms that you have logged in correctly.

If you are experiencing any technical difficulties, please call: • Corporate sites - GM Distance Learning Help Desk: 1-877-996-9942 • Dealer/Retail sites - GM Training Help Desk: 1-888-748-2687 and press

Prompt 1

Speaking to the Instructor NOTE: The keypad microphone is located between the Speak and Wait lights, and should be re-seated onto its circuit board regularly to allow for clear communication. Participants must do this at the beginning of every broadcast by pressing down on the area around the microphone. For best results while speaking to the instructor, follow these tips:

1. Place the keypad near the front of your desk. Put your class materials between you and the keypad.

2. Speak directly into the microphone on the keypad. The microphone is located just below the row of five function keys. Speak in a normal tone from your standard seated position. You will be heard by all of the other course participants and the instructor.

Page 5: Gm Tech Info 6t70 6l80

i System Instructions

Participant Guide © 2007 General Motors Corporation Revised 03/07/07

All Rights Reserved

Ask a question, make acomment, enter adiscussion, or cancel a callto the instructor.

Signal the instructoranonymously that you donot understand.

Answer a multiple-choicequestion.

Answer a question with anumeric answer.

Erase a numeric answer.

See the next quizquestion’s answer set, andany response you mayhave entered for thatquestion.

See the previous quizquestion’s answer set, andany response you mayhave entered for thatquestion

Your WAIT light will be turned on and yourname will be added to the queue. YourSPEAK light will come on when it is yourturn to speak. If you press the CALL key asecond time, your WAIT light will go off, andyour call will be canceled.

The percentage of students signaling theinstructor is displayed on the instructor’smonitor. The instructor may adjust thelecture accordingly.

If you are taking a multiple question quiz, theanswer is stored until you answer the lastquestion. On single questions the answer istransmitted to the host site when you pressthe ANSWER key.

If you are taking a multiple questions quizthe answer is stored until you answer thelast question. On single questions,theanswer is transmitted to the host site whenyou press the ENTER key.

The next question’s ID and answer characterset will appear on the keypad display. If youhave already answered the question, youranswer will also display.

The previous question’s ID and answercharacter set will appear on the keypaddisplay. If you have already answered thequestion, your answer will also display.

The answer in the window will be erased. Onsingle questions, you must press CLEARbefore you press ENTER.

NOTE: To confirm that your response has beenreceived by the system, your letter or numberchoice will be found in brackets in the upperright-hand corner of the keypad display.

If you want to... press: and this will happen...

Call

+ Enter

A B C D E

Clear

NextQuest

Prev Ques

Flag

Using the Keypad

GM Distance Learning Help Desk: 1-877-996-9942 (Corporate Sites) GM Training Help Desk: 1-888-748-2687, Prompt 1 (Dealer/Retail Sites)

Page 6: Gm Tech Info 6t70 6l80
Page 7: Gm Tech Info 6t70 6l80

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Automatic Transmission/Transaxle Theory, Operation and Diagnostics

Introduction

Page 8: Gm Tech Info 6t70 6l80
Page 9: Gm Tech Info 6t70 6l80

Introduction i-1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Welcome Welcome to the Automatic Transmission/Transaxle Theory, Operation and Diagnostics IDL, Session 2.

One Touch Familiarization • Press the red call button to ask a

question • Wait for a green light before speaking • Anticipate a momentary delay when

speaking • Contact the Technical help desk at

1-888-748-2687, prompt 1, if necessary.

Course Goal Upon successful completion of this course, you will be able to diagnose and repair Automatic Transmission/Transaxle concerns.

Recommended Prerequisites WBT (18043.01W-R2) WBT (18043.02W-R2) WBT (18043.03W-R2) WBT (10041.00W) WBT (17041.20W-R2)

Strategy Based Diagnostics Step 1. Verify customer concern Step 2. Make quick checks Step 3. Follow diagnostic system checks Step 4. Check service bulletins Step 5. Diagnostics Step 6. Decision on cause isolation Step 7. Repair and verification

Special Instructions The diagnostic charts in this courseware are for reference only. Refer to Service Information when servicing any Automatic Transmission or Transaxle.

Session 2 Objectives Describe the Shift Speed Chart Use the Shift Speed Chart Road Test Review diagnostic procedures for

the 6T70/75 Identify electrical inputs Diagnose vehicle concern

Question 1 In which ooff the following regions is your dealership located? A. Atlanta B. Chicago C. Dallas D. Los Angeles E. New York

Page 10: Gm Tech Info 6t70 6l80

i-2 Introduction

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

* Sample course component combinations *Course Components • A 1-component course has no prerequisite or follow-up component • A 2-component course has a recommended prerequisite CBT or Video component which

you should complete before attending the IDL (or) it consists of an IDL or CBT followed by a Hands-On component which you will need to take in order to complete the course

• A 3-component course has a recommended prerequisite CBT or Video component which

should be completed before attending the IDL. You will need to take the follow-up Hands-On component in order to complete the entire course

The dealership STS Report is credited when all components of the course are completed. NOTICE: You’ll see your Training Record and Individual Training Plan change after each course component is successfully completed. Just visit www.gmtraining.com and check TMS.

To purchase authentic GM Service Training Materials, contact the GM Training Materials Headquarters at 800-393-4831.

STC Training Courses* Video CBT IDL Hand-On

1−Component Course X

2−Component Course X X

3−Component Course X X X

Page 11: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics

Session 2

Module 2

Saab 9-7x / 4L60 Diagnostic Scenario 1

Page 12: Gm Tech Info 6t70 6l80
Page 13: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Topics • Proper engine operation

• Road Test

• Transmission Fluid Checking

• Fuel System Pressure Check Diagnostic Scenario #1 Vehicle: 2007 Saab 9-7x with 17,000 miles Customer Concern: Transmission does not

shift properly

Notes:

Module 2 Objectives • Describe the Shift Speed Chart

• Use the Shift Speed Chart

• Diagnose Transmission/Engine Concern

How are we going to verify our customer’s concern?

What action should be taken at this time?

Page 14: Gm Tech Info 6t70 6l80

2-2 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Symptoms - Automatic Transmission Diagnostic Category Diagnostic Information

Fluid Diagnosis

This category contains the following topics:

• Fluid condition: appearance, contaminants, smell, overheating

• Line pressure: high or low • Fluid leaks

Refer to Transmission Fluid Checking Refer to Oil Pressure High or Low Refer to Fluid Leak Diagnosis Refer to Oil Out the Vent.

If symptom is not found Refer to Transmission Fluid Checking . Refer to Road Test . Refer to Line Pressure Check .

• Refer to Symptoms – Automatic Transmission to aid in diagnostics.

Notes:

What should be our next step after verifying the customer’s concern?

Page 15: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Video Outline: Transmission Road Test – Part 1

Fluid Check • The main things to remember

− check the level and condition of the transmission fluid.

− check the fluid level at least twice to get an accurate reading.

Road Test Important: The Road Test Procedure should be performed only as part of the Symptom Diagnosis. Refer to Symptoms - Automatic Transmission

• The Road Test can be an important diagnostic tool when diagnosing an automatic transmission concern

• The particular functions and checks will vary slightly between vehicles because of the different powertrain packages used.

• Today we’ll be demonstrating this procedure on the 2007 Saab 9-7X.

• There are a few preliminary checks that need to be completed before we take the vehicle out for the road test.

• First, begin by ensuring the engine is performing properly.

• Next, ensure that both the level and condition of the transmission fluid are satisfactory.

• Then check the pressure of the vehicle’s tires to rule out low tire pressure as a potential cause.

• Poor over-the-road performance due to improper tire inflation may be perceived as a transmission related concern.

Video Notes: _____________________________________

_____________________________________

_____________________________________

_____________________________________

Page 16: Gm Tech Info 6t70 6l80

2-4 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Video Outline: Transmission Road Test – Part 1 cont.

• Note -- To ensure accuracy, the road

test must be completed in the following sequence: − Electrical Function Check

− Up-shift Control and Torque Converter Clutch Apply

− Part Throttle Detent Downshifts

− Manual Downshifts

− Coasting Downshifts – and –

− Manual Gear Range Selection

• You’re now ready to begin the road test…but it begins in the service bay.

• Use the scan tool to perform the Electrical Function Check.

• This ensures that the electrical data parameters are being received by the PCM.

• After connecting the Scan Tool, ensure the vehicle is in PARK, and set the parking brake

• Then, start the engine.

• Check the values associated with the following parameters. − Engine Torque

− Calculated Throttle Position

− Engine Speed

− Transmission Input Speed

− Transmission Output Speed

− Commanded Gear

− Shift Solenoid 1

− Shift Solenoid 2

− 3-2 Downshift Solenoid

− Gear Ratio

− Transmission Range Switch A, B, C & P

− Switch A, B, C and P

− Transmission Range Transmission Fluid Pressure Switches A, B and C

− Transmission Fluid Pressure Switch

− Engine Coolant Temperature

− Transmission Fluid Temperature

− Transmission Hot Mode

Video Notes:

Page 17: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-5

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Video Outline: Transmission Road Test – Part 1 cont.

− Pressure Control Solenoid Actual

Current

− Pressure Control Solenoid Reference Current

− Pressure Control Solenoid Duty Cycle

− Brake Switch

− TCC Enable Solenoid

− TCC Duty Cycle

− Transmission Slip Counter

− TCC Slip Speed

− Last Shift Time

− 1-2 Shift Time

− 2-3 Shift Time

− 3-4 Shift Time

− Ignition Voltage

− Four Wheel Drive

− Four Wheel Drive – Low

− Transfer Case Ratio

• Next – monitor the TCC Brake Switch parameter while applying and releasing the brake pedal.

• The Scan Tool should display:

• APPLIED when the brake pedal is applied

• RELEASED when the brake pedal is released

• Now we’ll check garage shifts

• With the brake and parking brake both applied, move the gear selector through the following ranges, pausing two to three seconds in each position

− PARK to REVERSE

− REVERSE to NEUTRAL

− NEUTRAL to DRIVE

• Each shift should be immediate and not harsh.

• Next, using the scan tool’s data list, look at the transmission range. While pressing the brake pedal

• Next, we’ll take a look at transmission range using the scan tool’s engine data list.

• Verify that all positions match the display on the Scan Tool

Video Notes:

Page 18: Gm Tech Info 6t70 6l80

2-6 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Video Outline: Transmission Road Test – Part 1 cont.

• For our purposes, we have selected:

− Calculated Throttle Position

− Engine Speed

− Transmission output speed

− Commanded Gear

− and TCC Slip Speed

• Other parameters that can also be monitored include:

− PC Solenoid Duty Cycle

− Brake Switch

− TCC Enable Solenoid

− TCC Duty Cycle

• There are many preliminary checks and steps in the road test that need to be completed before we even get the vehicle out of the garage

• Verify that all positions match the display on the Scan Tool

• When completed, return the gear selector to PARK.

• Throttle angle input is checked next.

• Again, apply brake pedal and ensure the parking brake is set.

• Ensure the gear selector is in PARK.

• Use the Scan Tool to monitor the Throttle Angle Position which should increase and decrease with engine RPM.

• It’s important to record the results of any checks that do not perform properly, for reference after completion of the road test.

• The final step in preparation for the road test is to setup the Scan Tool to monitor the parameters we want to display during the actual test. You can select up to five data parameters.

• Select parameters that relate as closely as possible to the symptom and the conditions associated with the concern.

Video Notes:

Page 19: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-7

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Video Outline: Transmission Road Test – Part 2

Video Notes:

• At this point, now we’re ready to evaluate transmission performance on the road.

• Begin by checking engagement quality by performing the Up-shift Control and Torque Converter Clutch Apply test.

• Accelerate the vehicle using the chosen throttle position then hold the throttle steady.

• You can select either 12.5% or 25% throttle position. For our purposes we chose the 25% throttle position.

• As the transmission up-shifts, there should be a noticeable shift feel or a 100-300 rpm engine speed change within one to two seconds of the commanded gear change.

• However, the TCC feel may not be noticeable.

• Look for a 100 – 300 rpm engine speed change.

• Now, compare the actual shift speeds to the shift speed table.

• Shift speeds may vary slightly due to fluid temperature or other operating variables, including hydraulic delays in responding to electronic controls.

• Make note of any:

− Slipping

− Harsh, soft or delayed shifts

− Noise or vibration

Question 2 How long should you pause between shifts when moving the gear selector through all its ranges during garage shifts? A. 1-2 seconds B. 2-3 seconds C. 3-4 seconds D. No Pause

Page 20: Gm Tech Info 6t70 6l80

2-8 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Video Outline: Transmission Road Test – Part 2 cont.

• While driving, monitor the current of the

Torque Converter Clutch. • When the TCC applies, there should be

a noticeable drop in engine speed and slip speed to below 100 RPM

• On most applications, the Torque Converter Clutch can be released by applying and releasing the brake pedal.

• The Part Throttle Detent Downshift portion of the road test begins with placing the gear selector in DRIVE and accelerating the vehicle to 40-55 miles-per-hour in O/D with TCC apply.

• Next, quickly increase the throttle angle to greater than 50% and verify the TCC releases and the transmission downshifts immediately.

• The full throttle detent downshift occurs in similar fashion to the part throttle detent downshift except that you need to quickly increase throttle to 100%.

• The vehicle should downshift from 4th to 2nd and TCC releases.

• Manual Downshift testing is not required for vehicles with Driver Shift Control.

• Since the Saab 9-7, is not equipped with Driver Shift Control ─ we will be performing Manual Downshift testing.

• The first phase is the 4-to-3 downshift. − In OVERDIVE accelerate to between

40 and 55 miles-per-hour with TCC applied.

− While moving the gear selector to THIRD, release the throttle.

− Verify the TCC releases, the transmission downshifts immediately to THIRD and the engine slows the vehicle.

• Now repeat manual downshift testing, at the respective speeds, for the 4-to-2, and 4-to-1 manual downshifts.

• Observe and note the transmission is performing the same way.

• The next portion of our test, Coasting Downshifts, has us accelerate the vehicle to OVERDRIVE with the TCC applied, release the throttle and lightly apply the brakes.

• The TCC releases and the downshifts are occurring at the speeds shown in the Shift Speed table.

Page 21: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-9

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Video Outline: Transmission Road Test – Part 3

• The next test is -- Manual Gear Range Selection.

• This portion of the Road Test is not applicable on Vehicles equipped with Driver Shift Control.

• Reverse testing is first.

• Using a 10 to 15 percent throttle position, perform the following tests:

− Stop the vehicle and place it into REVERSE.

− Slowly accelerate.

− Verify there is no noticeable slip, noise or vibration.

• Next, test FIRST gear.

• Stop the vehicle and shift the gear selector into FIRST gear.

• Slowly accelerate to 20 miles-per-hour.

• Verify:

− No upshifts occur.

− The TCC does not engage.

− And there is no noticeable slip, noise or vibration.

• The manual SECOND gear phase begins with the vehicle stopped.

• Place the gear selector into SECOND and accelerate to 35 miles-per-hour.

• With this test, verify:

− vehicle starts in 2ND

− The 2-3 shift does NOT occur

− And there is no noticeable slip, noise or vibration

• The manual THIRD gear phase also begins with the vehicle stopped.

• Place the gear selector into THIRD gear and accelerate to 40 miles-per-hour.

• With this test, verify:

− The 1-2 shift occurs.

− The 2-3 shift occurs.

− And there is no noticeable slip, noise or vibration.

• That concludes the physical portion of the Road Test.

• The final step is to return to the garage and analyze the data we observed.

Video Notes:

Page 22: Gm Tech Info 6t70 6l80

2-10 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Shift Speed

Notes:

2007 Saab 9-7x 4.2L (LL8) M30

Min. Throttle

Upshift WOT (mph/rpm) WOT 3-1

D1 2-1

MIN TCC ON

Trans Cal

Trans Model

Axle Ratio 1-2 2-3 3-4 1-2 2-3 3-4 -- -- --

A SDD, TDD 3.42 13.5 26.6 34.8 49.5/6100 93.1/6100 N/A 39 41 44.5

B SDD, TDD 3.73 12.4 24.4 31.9 45.4/6100 85.3/6100 N/A 36 39 40.4 C SDD, TDD 4.10 11.3 22.2 29 41.3/6100 77.7/6100 N/A 32 34.2 36.8

Shift Speeds are Given in MPH, except where noted.

Question 3 What other piece of diagnostic information can help us in resolving our concern? A. Shift Speed Chart B. Pressure Test C. Service Fast Learn Adapts D. Clear Shift Adapts

Page 23: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-11

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Tech 2

TIS Animation: Easy Acceleration • The vehicle speed was ____________

• Throttle Position was ______________

• Commanded gear was _____________

• Engine Speed was _____________

Notes:

What operating parameters do you think we should plot or graph to aid us in diagnostics?

What, if anything does this information tell us?

Page 24: Gm Tech Info 6t70 6l80

2-12 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

TIS Animation: Hard Acceleration • The vehicle speed was ____________

• Throttle Position was ______________

• Commanded gear was _____________

• Engine Speed was _____________

Notes:

Just like before, what, if anything does this information tell us?

Page 25: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-13

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Range Reference Chart 4L60-E

Review • Diagnostic System Check – Vehicle

• Checked Tire Pressures

• Checked Transmission Fluid

• Completed Road Test

• Reviewed Shift Speed Chart

Notes:

Range Park Reverse Neutral OD D 2 1 Gear 1st 2nd 3rd 4th 1st 2nd 3rd 1st** 2nd 1st 2nd***

1-2 Shift Solenoid ON* ON* ON* ON OFF OFF ON ON OFF OFF ON OFF ON OFF 2-3 Shift Solenoid ON* ON* ON* ON ON OFF OFF ON ON OFF ON ON ON ON

2-4 Band -- -- -- -- A -- A -- A -- -- A -- A Reverse Input Clutch -- A -- -- -- -- -- -- -- -- -- -- -- --

Overrun Clutch -- -- -- -- -- -- -- -- -- A A A A A Forward Clutch -- -- -- A A A A A A A A A A A

Forward Sprag Clutch Assembly -- -- -- H H H -- H H H H H H H

3-4 Clutch -- -- -- -- -- A A -- -- A -- -- -- -- Lo/Roller Clutch -- -- -- H -- -- -- H -- -- H -- H -- Lo/Rev Clutch A A -- -- -- -- -- -- -- -- -- -- A --

Given the information from the scan tool, the Shift Speed Chart and the Range Reference Chart, do we now have enough information to determine what the cause of our concern could be?

Page 26: Gm Tech Info 6t70 6l80

2-14 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Inspections 1 • Inspect PCM

• Inspect vacuum hoses

• Inspect air intake ducts Inspections 2 • Inspect for air leaks

• Inspect wiring harness

• Inspect sensors/components

Notes:

Symptoms – Vehicle Engine Symptoms – Engine Controls for the 4.2L engine

Symptoms - Engine Controls Perform Diagnostic System Check - Vehicle and verify all of the following items.

Is there anything other than the transmission that could be causing the transmission to operate incorrectly, and if so, what?

Page 27: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-15

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Fuel System Diagnosis Fuel System

• Return-less, on-demand

• Fuel Pressure Regulator

• Correct fuel pressure • Electric, Turbine style fuel pump

• Supplies high pressure fuel

Step Action Values Yes No

1 Did you perform the Diagnostic System Check - Vehicle? -- Go to

Step 2

Go to Diagnostic System Check -

Vehicle

2

Important: Inspect the fuel system for damage or external leaks before proceeding with this diagnostic.

1. Turn ON the ignition, with the engine OFF.

2. Command the fuel pump relay ON with a scan tool.

Does the fuel pump operate?

--

Go to Step 3

Go to Fuel Pump Electrical Circuit

Diagnosis Notes:

Page 28: Gm Tech Info 6t70 6l80

2-16 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Fuel System Diagnosis Step 3: • Ignition OFF

• Accessories OFF

• Install Pressure Gage

Fuel Pressure Reading

Fuel Pressure Gage • Answering NO in step 3 directs us to step 8 in the Fuel System Diagnosis Document.

Fuel System Diagnosis Step 3 cont: • Ignition ON/Engine OFF

• Pump Relay ON

• Observe Gage

Notes:

Page 29: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 2-17

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Notes:

Steps 8 - 10

Step Action Values Yes No

8 Is the fuel pressure more than the specified value?

395 kPa (57 psi)

Go to Step12

Go to Step9

9

Inspect the fuel feed pipe for a restriction.

Did you find and correct the condition?

-- Go to

Step 13 Go to

Step 10

10

Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs .

Did you find and correct the condition?

--

Go to Step 13

Go to Step 12

Step 12

Step Action Values Yes No

12

Replace the fuel sender. Refer to Fuel Sender Assembly Replacement . Did you complete the replacement?

-- Go to Step 13 --

Page 30: Gm Tech Info 6t70 6l80

2-18 Saab 9-7x / 4L60 - Diagnostic Scenario 1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Fuel Sender Assembly Replacement

Correct Fuel Pressure Reading

Module 2 Summary Conducted Road Test Described the Shift Speed Chart Conducted Fuel System Pressure Check Diagnosed a Transmission Concern

Notes:

Document ID# 1647287

Fuel Sender Assembly Replacement

Tools Required J 45722

Fuel Tank Sending Unit Wrench

Removal Procedure

Remove the fuel tank. Refer to Fuel Tank Replacement

Document ID# 1647287

Fuel Sender Assembly Replacement

Tools Required J 45722

Fuel Tank Sending Unit Wrench

Removal Procedure

Remove the fuel tank. Refer to Fuel Tank Replacement

Page 31: Gm Tech Info 6t70 6l80

Automatic Transmission: Diagnosing the Transmission/Transaxle

Session 2

Module 3

Six Speed – 6T70/75 Diagnostic Scenario 3

Page 32: Gm Tech Info 6t70 6l80
Page 33: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

The concept behind the six-speed front and all-wheel drive transaxle family is to enable compact packaging not possible before with powerful transverse powertrain layouts

• The exercises and activities in this module will be conducted using a 2007 GMC Acadia with the 6T70 Automatic Transaxle.

Off Axis Transaxle

• This 4T45-E is a typical off-axis transaxle.

Topics • On/Off Axis Transaxle

• Primary Differences

• Gearset

• Torque Converter

• Diagnostic scenario

Notes:

Module 3 Objectives • Review the components of the

6T70/75

• Review diagnostic procedures for the 6T70/75

• Diagnose transmission concern associated with the 6T70/75

Page 34: Gm Tech Info 6t70 6l80

3-2 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

On Axis Transaxle

• This is a a typical on-axis transaxle.

Torque Converter

• This is what the torque converter looks like when disassembled.

6T70 vs. 6T75 • Torque

• Gear set

• Case

Torque Converter Removal

6T70/75 Gear Set

• If the torque converter has to be removed, use the J-46409 Lift Assist Tool to lift torque converter.

Page 35: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

MIL in IPC

Diagnostic Scenario 2 Vehicle: 2007 GMC Acadia w/ 88 miles Customer Concern: MIL is illuminated

• The MIL is in fact illuminated so our customer’s concern has been verified

Service Manual/Bulletins, Transmission/Transaxle, Automatic Transmission 6T70/6T75, Diagnostic Information and Procedures, and finally DTC P0717.

Notes:

Question 4 Why are the helical gears in the 6T70/75 ground and honed to exact dimensions and tolerances? A. Minimize gear failures B. Minimize vibration C. Extend gear life D. Minimize gear wear

Page 36: Gm Tech Info 6t70 6l80

3-4 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

DTC P0716 or P0717 Diagnostic Instructions • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic

procedure. • Review Strategy Based Diagnosis for an overview of the diagnostic approach. Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Diagnostic System Check - Vehicle 1. Before beginning vehicle diagnosis, the following preliminary inspections/tests must

be performed:

• Ensure that the battery is fully charged. Refer to Battery Inspection/Test. • Ensure that the battery cables are clean and tight. • Inspect for any open fuses. Refer to Power Distribution Schematics and

Electrical Center Identification Views. • Ensure that the grounds are clean, tight, and in the correct location. Refer to

Ground Distribution Schematics and Power and Grounding Component Views. • Inspect the easily accessible systems or the visible system components for

obvious damage or conditions that could cause the concern. This would include checking to ensure that all connections/connectors are fully seated and secured.

• Inspect for aftermarket devices that could affect the operation of the system. Refer to Checking Aftermarket Accessories.

• Search for applicable service bulletins. If the preceding inspections/tests resolve the concern, go to Diagnostic Repair Verification.

Notes:

Page 37: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-5

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Component Level DTCs • Sensor DTCs

• Solenoid DTCs

• Relay DTCs

Scan Tool

System Level DTCs

• Misfire DTCs

• Evap DTCs

• Fuel Trim DTCs

• Step 3 has us verify communication with all control modules.

• Step 4 has us access the Power Mode Parameter.

• Steps 5 & 6 have us verify the vehicle cranks, starts and idles.

• Step 7 has us advance to the All DTCs screen on the scan tool to obtain DTCs.

DTC P0717 Freeze Frame • We have the option of either looking at

a Freeze Frame of the data or the Failure Record for the DTC.

DTC P0717 Failure Record

Important: Do not clear any DTCs unless instructed to do so by a diagnostic procedure.

Important: If any DTCs are Powertrain related DTCs, select Capture Info to store the DTC information with the scan tool.

Page 38: Gm Tech Info 6t70 6l80

3-6 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Diagnostic Trouble Code (DTC) List - Vehicle The master DTC list includes all applicable DTCs in alphanumeric order with descriptors.

DTC DTC Descriptor Module That Sets the DTC Diagnostic Procedure

P0717 Input Speed

Sensor Circuit Low Voltage

TCM DTC P0716 or P0717

DTC P07161 or P0717

Diagnostic Instructions • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic

procedure. • Review Strategy Based Diagnosis for an overview of the diagnostic approach. • Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Notes:

Page 39: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-7

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Circuit/System Verification • Start the engine in Park and observe

the transmission ISS on the scan tool while varying the engine speed. The transmission ISS should vary with the engine speed and not drop out.

System Verification

Failure Record Data 1

Drive 6IMS

HI LOW LOW HIIMS A/B/C/P

0.00 : 1Gear Ratio

OnShift Solenoid 2

OffShift Solenoid 1

2Commanded Gear

22 mphVehicle Speed

Replicated OSS K Status

OKISS/OSS Supply Voltage

799 RPMTransmission OSS

0 RPMTransmission ISS

2482 RPMEngine Speed

11 %Calc. Throttle Position

98 ft-lbsEngine Torque

Drive 6IMS

HI LOW LOW HIIMS A/B/C/P

0.00 : 1Gear Ratio

OnShift Solenoid 2

OffShift Solenoid 1

2Commanded Gear

22 mphVehicle Speed

Replicated OSS K Status

OKISS/OSS Supply Voltage

799 RPMTransmission OSS

0 RPMTransmission ISS

2482 RPMEngine Speed

11 %Calc. Throttle Position

98 ft-lbsEngine Torque

Notes:

What, if anything in the Failure Record Data would give us an indication as to what may be going on? _______________________________

_______________________________

_______________________________

Page 40: Gm Tech Info 6t70 6l80

3-8 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Failure Record Data 2

Failure Record Data 3

Notes:

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

13.80 VoltsIgnition Voltage

2473 RPMTCC Slip Speed

ClosedTCC BrakeSwitch

114 ºFTCM Temperature

118 ºFTrans. Fluid Temp.

185 ºFECT

LowTFP Switch 5

LowTFP Switch 1

HighTFP Switch 4

LowTFP Switch 3

LowTFP Switch 2

Page 41: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-9

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Circuit/System Testing - 1 • Ignition ON

• Observe ISS/OSS Voltage

• Should display OK

Failure Record Data 4

• If the transmission ISS/OSS supply circuit voltage displays OK, the next thing we want to do is to visually inspect.

Visually Inspect • ISS

• Harness

• Connector

• Control Solenoid (W/body & TCM)

• Clutch Housings

Notes:

Page 42: Gm Tech Info 6t70 6l80

3-10 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

J-35616 Test Kit

• Using the J-35616 test kit will prevent any accidental or undue damage to electrical connections or connectors.

J38522-1 Variable Signal Generator

• Step 2 of Circuit/System Testing directs us to complete the Control Solenoid Valve and Transmission Control Module Assembly Input Shaft Speed/Output Shaft Speed Input Test.

• Set the Variable Signal Generator to:

• 8 volts

• Frequency 120 – and –

• Duty Cycle 50%

Notes:

Page 43: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-11

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

TCM Connector

Scan Tool & Signal Generator

• Remove the connector from the TCM. • Signal generator and scan tool connected.

Signal Generator Connected

Transmission ISS

• Connect the leads from the signal generator to the TCM Speed Sensor terminals.

• The scan tool should display transmission ISS somewhere between 100 and 400 RPM.

Notes:

Page 44: Gm Tech Info 6t70 6l80

3-12 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

ISS Replacement Prelim. • Disconnect negative battery cable

• Remove retainer nuts

• Remove oil cooler lines

• Drain the transmission fluid

• Remove cover

Once we have completed all the preliminary steps listed, then we can proceed with replacing the ISS.

Input Speed Sensor Replacement

• The procedure for replacement of the

ISS is fairly simple and straightforward. • Getting to the ISS takes more time than

replacing it.

Question 5 When using the J38552-1 Variable Signal Generator to test the ISS, the Duty Cycle should be set at ________. A. 20% B. 40% C. 50% D. 80%

Page 45: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 3-13

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Video Outline: On Vehicle ISS Replacement

• The following procedure details how to

replace the Input Speed Sensor Assembly, on-vehicle, without removing the transaxle.

• After raising the vehicle, drain the transmission fluid.

• Replace the drain plug and tighten to specification.

• Disconnect the Input Speed Sensor’s electrical connectors from the control solenoid (with body and TCM) valve assembly.

• A special tool, DT-47734 Input Speed Sensor Tether, is used with this procedure.

• Attach the Input Speed Sensor Tether to the Input Speed Sensor’s electrical connector locking tab.

• Remove the Input Speed Sensor bolt. • Depending on the application, you may

have to remove an engine/transaxle mount to gain access to the Input speed sensor.

• Gently pull on the Input Speed Sensor to remove it.

• Disconnect Special Tool DT-47734 and connect it to the new Input Speed Sensor.

• Gently pull on the tool to pull the Input Speed Sensor Wiring Harness through the transaxle.

• You may have to work the wire and the tool back-and-forth a couple of times to get the connector through the case opening.

• If the dry lubricant on the replacement Input Speed Sensor Seal is damaged or missing, lubricate the seal with transmission fluid.

• Install the Input Speed Sensor. • Due to the physical characteristics of

plastic, it is important to use thread-locker, GM P/N 12345382, on the Input Speed Sensor Bolt or it may eventually come loose.

• Tighten to specification.

• Install the new Valve Body Cover Assembly Gasket.

• Install the Valve Body Cover Assembly and tighten the bolts to the appropriate specification.

• Lower the vehicle and fill the transaxle fluid to the appropriate level.

• Remember, it is extremely important to have the fluid at the appropriate temperature.

• Refer to the Fluid Checking Procedure in S.I.

Video Notes:

Page 46: Gm Tech Info 6t70 6l80

3-14 Six Speed – 6T70/75 – Diagnostic Scenario 2

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Module 3 Summary Reviewed the components of the 6T70/75. Reviewed diagnostic procedures for the 6T70/75. Diagnosed transmission concern associated with the 6T70/75.

Notes:

Page 47: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics

Session 2

Module 4

Six Speed – 6L50/80/90 Diagnostic Scenario 3

Page 48: Gm Tech Info 6t70 6l80
Page 49: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-1

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Topics • Review Range Reference Chart

• Review and complete Diagnostic System Check – Vehicle

• Review inputs

• Review Circuit/System Testing

6L80 Range Reference Chart

• This is the Range Reference Chart for

the 6L50/6L80/6L90.

• This chart highlights the major apply components that function in the selected gear range as well as the specific gear operation within that gear range.

• Those items indicated with an asterisk ( * ) are those that are applied with no load.

• OFF = No Pressure

• ON = Pressurized

Notes:

Module 4 Objectives • Identify electrical inputs

• Identify potential DTCs

• Review diagnostic procedures

• Diagnose vehicle concern

Page 50: Gm Tech Info 6t70 6l80

4-2 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

There are several default transmission protection modes in case there is an electrical or mechanical failure of any shift solenoid or pressure control solenoid

Electrical Default Protection Modes • 1 – 2 – 3 = 3rd

• 4 – 5 – 6 = 5th

Range Reference Chart cont.

• In our example with NO 3rd gear you

can determine the 3-5-Rev is suspect because 1st and 2nd gears operate normally.

• This clutch is also used in reverse so we are able to verify 3-5-Rev operation by shifting the transmission into reverse.

Mechanical Default Protection Modes • Vehicle Speed

• Transmission range

• Component

Notes:

Page 51: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Control Solenoid Expanded View

Electrical Inputs The Hydra-matic 6 speed RWD transmission incorporates electronic controls that utilize the Transmission Control Module – TCM – to:

• Control shift points

• Control TCC application and release

• Control line pressure All shift solenoids, pressure control solenoids, transmission fluid temperature sensor and fluid pressure switches are contained in the control solenoid valve assembly

Control Solenoid Valve Assembly

• This picture gives us a better view of where all the individual component parts of the control solenoid are located

• 16 pin connector

• 4 Clutch Pressure Control Solenoids

• TCC Pressure Control Solenoid

• 1 Line Pressure Control Solenoid

• 4 Transmission Fluid Pressure Switches

• 2 Shift Solenoids

• Filter Plate Assembly

• Transmission Fluid Temperature Sensor

Notes:

Page 52: Gm Tech Info 6t70 6l80

4-4 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

16 Pin Connector

Control Solenoids • 4 Clutch Pressure Control Solenoids.

• 1 Line Pressure Control Solenoid.

• Shift Solenoids 1 and 2 – and –

• Torque Converter Clutch Pressure Control Solenoid.

16 Pin Connector Legend

Not Used----15-16CAN Hi 22500TN/BK14CAN Lo 22501TN13Run/Crank Voltage1339PK12CAN Lo2501TN11CAN Hi2500TN/BK10Accessory Voltage Power43YE9Not Used----8Tap Shift Controls5526PU7Brake Pedal Apply Signal17WH6Ground451BK/WH5Battery Positive Voltage2440RD/WH4Park/Neutral Signal1786OG/BK3Not Used----1-2

FunctionCircuit No.Wire ColorPin

Not Used----15-16CAN Hi 22500TN/BK14CAN Lo 22501TN13Run/Crank Voltage1339PK12CAN Lo2501TN11CAN Hi2500TN/BK10Accessory Voltage Power43YE9Not Used----8Tap Shift Controls5526PU7Brake Pedal Apply Signal17WH6Ground451BK/WH5Battery Positive Voltage2440RD/WH4Park/Neutral Signal1786OG/BK3Not Used----1-2

FunctionCircuit No.Wire ColorPin

Page 53: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-5

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

TFT Sensor

• The TFT sensor is part of the control solenoid valve assembly and is not serviced separately

SEAL

DIAPHRAM

PISTONUPPERCONTACT

DISC

LOWERCONTACT

SEAL

DIAPHRAM

PISTONUPPERCONTACT

DISC

LOWERCONTACT

SEAL

DIAPHRAM

PISTONUPPERCONTACT

DISC

LOWERCONTACT

TFP Switches • TFP or Transmission Fluid Pressure

switches are also located in the control solenoid valve assembly.

Fluid Pressure Switch Operation • TFP 1 = 3 – 5 and Reverse = Sol 2

• TFP 3 = 2 – 6 = Sol 4

• TFP 4 = 1-2-3-4 = Sol 5

• TFP 5 = CBR1 / 4-5-6 = Sol 3

Question 6 For any mechanical failure within a shift solenoid or pressure control solenoid, the transmission will default to the optimum gear to allow safe operation depending on three factors. Which answer does NOT go with the others? A. Transmission Range B. Vehicle Speed C. Transmission Fluid

Temperature D. Component Stuck

Page 54: Gm Tech Info 6t70 6l80

4-6 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Diagnostic Scenario #3 Vehicle: 2007 Chevrolet Corvette w/8,000 miles Customer Concern: MIL is illuminated

Knowns • Customer concern verified

• NO history

• 6L80 equipped

Document ID# 1413823

2007 Chevrolet Corvette Diagnostic Starting Point - Automatic Transmission Begin the system diagnosis with the Diagnostic System Check - Vehicle . The Diagnostic System Check - Vehicle will provide the following information:

• The identification of the control module or modules which command the system.

• The ability of the control module or modules to communicate through the serial data circuit.

• The identification of any stored diagnostic trouble codes (DTCs) and the status of

the codes. The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system and where the procedure is located.

Notes:

Page 55: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-7

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

The Diagnostic System Check also allows us to check all the modules in the vehicle at the same time.

Video Outline: 2007 Corvette Diagnostic System Check – Vehicle – Steps 1 - 3

• Inspect for aftermarket devices that could affect the operation of the system.

• If nothing is found during the preliminary inspection, the diagnostic system check directs us next to hook up the scan tool.

• Install a scan tool and CANdi module to ensure that the tool powers up.

• OK we see that the scan tool is able to power up. The next step is to enter Key On Engine Off mode, and check for a No Key Fob detected message in the DIC.

• The first step in diagnosing the customer concern is to perform the Diagnostic System Check. This step is critical and should be done every time, as it covers basics that may normally be overlooked.

• The first step in the Diagnostic System Check – Vehicle is to ensure that the battery is fully charged. The best way to perform this task is to use the Midtronics battery test tool to not only test the charge, but the overall condition of the battery and its ability to maintain its charge.

• Ensure that the battery cables are clean and tight. This step is frequently overlooked but, keep in mind, if the vehicle has ever been worked on, the odds that the battery has been disconnected for a service procedure are high, and it might not have been properly connected.

• Inspect for any open fuses. • Inspect the easily accessible systems or

the visible system components for obvious damage or conditions that could cause the symptom.

• Ensure that the grounds are clean, tight, and in the correct location.

Video Notes: _____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

Page 56: Gm Tech Info 6t70 6l80

4-8 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Scan Tool • Our scan tool is connected and it does

power up.

Ignition ON / Engine OFF Mode • Press and hold the bottom portion of the

ignition mode switch for 5 - 6 seconds to enter the Ignition ON/Engine OFF mode.

Diagnostic System Check – Vehicle – Step 7

Important #1

Important: Do not clear any DTCs unless instructed to do so by a diagnostic procedure.

Important #2

Important: If any DTCs are Powertrain related DTCs, select Capture Info in order to store the DTC information with the scan tool.

7. Advance to the List All DTCs selection on the scan tool. Verify there are no DTCs reported from any module.

If any DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and diagnose any current DTCs in the order they are displayed on the scan tool.

Page 57: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-9

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Document ID# 1773529 2007 Chevrolet Corvette

Diagnostic Trouble Code (DTC) List – Vehicle The master DTC list includes all applicable DTCs in alphanumeric order with descriptors.

DTC DTC Descriptor Module that Sets the

DTC Diagnostic Procedure

P0777 Clutch Pressure Control (PC)

Solenoid 2-Stuck On TCM DTC P0776 or P0777

Transmission Fluid Pan

• There is a tube in the bottom of the pan that is used to set fluid level.

Notes:

Notice: The transmission fluid level must be checked when the transmission fluid temperature (TFT) is between 30-50°C (86-122°F). If the TFT is not within this range, operate the vehicle or allow the fluid to cool as required. Setting the fluid level with a TFT outside this range will result in either an under or over-filled transmission. TFT>50°C=under-filled, TFT<30°C=over-filled. An under-filled transmission will cause premature component wear or damage. An over-filled transmission will cause fluid to discharge out the vent tube, fluid foaming, or pump cavitation.

Page 58: Gm Tech Info 6t70 6l80

4-10 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Trans Fluid Check • Monitor TFT

• Start/Idle

• Depress brake/shift gears

• PARK

• Idle 1 minute

• Raise vehicle

Transmission Fluid Temperature • If the TFT is not within the specified

values, reinstall the transmission oil level check plug and start the process over.

Notes:

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

THE ENGINE MUST BE RUNNING when the transmission oil level check plug is removed or excessive fluid loss will occur, resulting in an under-filled condition. An under-filled transmission will cause premature component wear or damage.

TECH TIP

Page 59: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-11

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Fluid Level Check Plug

J-21867 Pressure Gage

• To complete the Line Pressure Check, we will need the J-21867 pressure gage in addition to the scan tool.

• The next step is to remove the transmission oil level check plug from the transmission fluid pan.

• Allow any fluid to drain.

• Inspect the fluid color and the fluid should be red or dark brown as we discussed in our earlier modules.

• When we click the link for Line Pressure

• Check under Circuit/System Testing, we are redirected to the Line Pressure Check Document in SI.

Line Pressure Check • Connect scan tool

• Start engine

• Check fluid level

• Inspect for stored DTC’s

• Inspect Manual Linkage

• Turn OFF

Notes:

Circuit/System Testing 1. Perform the Line Pressure Check.

• If the pressure is out of specification, correct this concern first.

Page 60: Gm Tech Info 6t70 6l80

4-12 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Line Pressure Test Hole Plug

• Remove the Line Pressure Test Hole plug and install the J21867 Pressure Gage.

Line Pressure Check • Access scan tool controls

• Start the engine Line Pressure Check

• Increase and decrease the Line PC Solenoid in increments of approximately 100 KPa (15 psi).

• Allow pressure to stabilize between increments.

Notes:

Important Note #2 The scan tool is only able to control the line PC solenoid in PARK and NEUTRAL with engine speeds below 1500 RPM.

Important Note #1 In order to achieve accurate line pressure readings, the following procedure must be performed at least 3 times in order to gather uniform pressure readings.

Page 61: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-13

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Control Solenoid Valve and Transmission Control Module Assembly Cleaning Procedure

Line Pressure Check cont. • Pressure Variance

• Turn engine OFF

• Remove J-28867

• Re-install plug

• Make sure you check eSI for any current bulletins and torque specifications.

• Everything checked out within limits.

• Because P0777 is a performance DTC, it could just be a solenoid valve sticking or binding due to minor debris.

• For these types of situations, there is a cleaning procedure to help dislodge any debris.

Control Solenoid Valve Cleaning

• Procedure resides in TCM

• Activated by scan tool

Notes:

Page 62: Gm Tech Info 6t70 6l80

4-14 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Control Solenoid Valve and Transmission Control Module Assembly Cleaning procedure • Operate transmission to temp

• Select Service Cleaning

• Engine OFF for 30 seconds

• May take 10 minutes When the cleaning procedure is completed, the DTC enable criteria is run again, and retested to see if the DTC concern has been corrected. This did not resolve our concern because the DTC did reset.

C HFE GC HFE G

DT-47825 Control Solenoid Test Plate

• You will need the DT-47825 Control Solenoid Test Plate to complete this procedure.

• The recommended shop air pressure is 620.5 - 689.4 Kpa (90-100 psi).

Control Solenoid Valve

• Inspect for damage, bent pins, debris, contamination, broken retaining tab.

• Inspect the connectors near the terminal pins for metallic debris.

• Inspect the control solenoid valve assembly solenoid leads for contamination or metallic debris.

• Inspect the 4 retaining tabs for cracks.

Notes:

_____________________________________

_____________________________________

_____________________________________

_____________________________________

You DO NOT need to check each solenoid individually, only the suspect solenoid.

TECH TIP

Page 63: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-15

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Valve Solenoid Test • TCM cycles solenoids ON and OFF

− TCM will normally cycle some of the transmission solenoids On and Off.

• Normal function

• Pressure gage will jump

Control Solenoid Valve and Transmission Control Module Assembly Test Bock to Component Identification Chart

The TCM connector sleeve allows the test tool harness to be correctly oriented for electrical operation of the TCM. Do not connect the test harness to the TCM without using the connector sleeve. Failure to use the sleeve could allow the test harness to be incorrectly positioned, which will result in permanent TCM damage.

TECH TIP To avoid solenoid overheating and possible internal damage, do not continuously operate the solenoid for more than 2 minutes at a time.

TECH TIP

Page 64: Gm Tech Info 6t70 6l80

4-16 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

The test has been completed and we have a sticking valve.

The next step is to replace the Control Solenoid Valve and Transmission Control Module Assembly.

Run the Test #1

• Align & Install Electrical connector

• Clean part and tool as required

• Bolt test plate to control solenoid (w/body and TCM) valve assembly mounting surface

Run the Test #2

• Connect the test harness

• Connect shop air

• Command solenoid ON and OFF Run the Test #3

• Read test results

• Connect solenoid valve ON and OFF

• Release air between tests

Notes:

It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM, or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

TECH TIP

Page 65: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-17

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Service Fast Learn Adapts • 6 Speed Auto Trans procedure

• Clutch Data learned

• Scan Tool initiation

Special Functions Screen

• Select F1: Transmission Output Controls.

BEFORE performing the Service Fast Learn Adapts procedure ensure the following conditions have been met.

Prep for Fast Learn Adapts Procedure

• Block Drive Wheels

• Apply Parking Brake

• Apply Service Brake

• 0 % Throttle

• TFT 70-100º C or 158-212º F

Cycle gear selector Transmission Control Module Screen

Powertrain Screen

• Select F6: Fast Learn Adapt Process.

• Select F2: Special Functions.

Page 66: Gm Tech Info 6t70 6l80

4-18 Six Speed – 6L50/80/90 – Diagnostic Scenario 3

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All Rights Reserved

Once the Service Fast Learn Adapts procedure has completed all 3 stages, the transmission will remain in a NEUTRAL state.

Important note: • Engine OFF

− Once the procedure is complete, shut OFF the engine and power down the TCM.

• Scan Tool Communication Loss

− You will lose communication to the scan tool.

• Restart engine

• Procedure complete

− At this point, the Service Fast Learn Adapts procedure is complete

Fast Learn Stages • Automatically initiated

• Scan tool provides instructions

• Follow instructions as required 3 Fast Learn Stages • PARK test setup

• DRIVE mode

• REVERSE mode

Notes:

If at any time during the procedure the required conditions are NOT met, Service Fast Learn Adapts may abort and the process may need to be started over from the beginning.

TECH TIP

Page 67: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 4-19

Participant Guide © 2007 General Motors Corporation Revised 03/07/07 All rights reserved

Module 4 Summary Identified electrical inputs. Identified potential DTCs. Reviewed diagnostic procedures. Diagnosed vehicle concern. Reviewed Service Fast Learn Adapts

Evaluation Instructions ♦ Turn to the evaluation at the end of this session in your workbook; remove and

complete the course evaluation as instructed.

♦ Use the keypad to answer the multiple choice questions.

♦ Press the “Next Quest” key after answering each question.

♦ Press “Yes” when completed.

♦ Fill out the back of the evaluation form.

♦ Include today's date, time and time zone.

♦ Fax your written evaluation to the Detroit IDL Center at (586) 576-3319.

Page 68: Gm Tech Info 6t70 6l80
Page 69: Gm Tech Info 6t70 6l80

Automatic Transmission/Transaxle Theory, Operation & Diagnostics

Session 2

Evaluation

Page 70: Gm Tech Info 6t70 6l80
Page 71: Gm Tech Info 6t70 6l80

Service Technical Level 1 Evaluation E-1 Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2 Course #17041.23D2

Version 1.0 2007 General Motors Corporation All Rights Reserved

Customer Satisfaction Survey Interactive Distance Learning

We value your opinion regarding this course. Please take a few minutes to complete this evaluation, including your suggestions for course improvements. If a statement does not apply, leave it blank.

Relevance / Value S

trong

ly Di

sagr

ee

Disa

gree

Som

ewha

t Agr

ee

Agr

ee

Stro

ngly

Agre

e

1. This course provides knowledge/skills useful to me now and/or in the future. A B C D E

2. This course met the stated objectives. A B C D E

3. I will recommend this course to others. A B C D E Design

4. The amount of material presented in this course is just right. A B C D E

5. The content is realistic and practical. A B C D E

6. The content is sequenced so that it is easily understood. A B C D E

7. The participant materials support the instructor’s presentation. A B C D E Instructor

8. The instructor appeared well-prepared and organized. A B C D E

9. The instructor demonstrated a thorough understanding of the subject matter. A B C D E

10. The instructor presented course material at a comfortable pace. A B C D E

11. The instructor responded effectively to questions. A B C D E Delivery

12. There were no technical (equipment) problems during this course. A B C D E

13. Handouts, workbook, visuals and/or other aids are clear, effective, and understandable. A B C D E

14. The activities / exercises helped me better understand the information presented. A B C D E Customer Satisfaction Survey

Page 72: Gm Tech Info 6t70 6l80

E-2 Service Technical Level 1 Evaluation Course #17041.23D2 Automatic Transmission/Transaxle Theory, Operation & Diagnostics, Session 2

Version 1.0 2007 General Motors Corporation All Rights Reserved

Interactive Distance Learning We value your opinion regarding this course. Please take a few minutes to complete this evaluation, including your suggestions for course improvements

Course Date: _____/_____/_____ Time: _________________ Time Zone: AT ET CT MT PT Instructor's Name: __________________________________________________ Additional Comments Please share any additional comments you may have to improve the relevance of this training.

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________ Please share any additional comments you may have to improve the design of this training.

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________ Please share any additional comments you may have regarding the instructor conducting this training.

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________ Please share any additional comments you may have to improve the delivery of this training.

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________ Please share any additional comments, positive or negative, you may have regarding course improvements.

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

Thank you for taking the time to help us build an effective GM Distance Learning Program. Please fax to: Detroit IDL Center at 586-576-3319