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(440-2498) General fault diagnosis for automatic transmission

Symptom: Hard, delayed and incorrect shifting, rising engine speed during shifting with various symptoms.

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 440-2498
Date: ........... OktoberĀ 2004
Market: all
General fault diagnosis for automatic transmission

Cars affected

Saab 9-3 M03-04 with 5-speed automatic transmission

Background

The 5-speed automatic transmission has displayed a number of fault symptoms which are compiled in the following list of symptoms. The procedure descriptions are included in the table below.

If the slightest doubt exists over whether the complaint is justified or whether the gearbox is performing normally, make a comparison with another car of the same type.

Symptom description

Hard, delayed and incorrect shifting, rising engine speed during shifting with various symptoms.



Procedure

Refer to the list of fault symptoms below and to the table for procedures. There is a checklist at the end of the document which must be completed and enclosed with replaced gearboxes.

No. Symptom Model year affected
1 Delay and hesitation during down shifting 3-2 at 50 - 70 km/h M03 - M04
2 Sudden down shifting without reason with cold gearbox and low speed M03
3 Engine speed increases during shifting 2-3 after long periods of driving in top gear and then lowering speed to below 20 km/h, accelerating again and shifting up to 3rd gear. M03
4 Delay and hesitation during city driving and clicking noise. M03
5 Close shifting at low speed M03 - 04
6 Hard down shifting when braking to stop M03
7 Selector lever jams in P position. Diagnostic trouble code P0826 06 is detected. M03 - 04
8 Very hard engagement of positions D and R
9 Noise
10 Diagnostic trouble codes for electrical components
11 Hard down shifting 3-2 M03
12 Oil leakage
13 Water in transmission fluid


Procedure table

The figures refer to the above symptom table.

No. Cause Procedure WIS
1 Error in TCM software. Update software in TCM. (Download from IRIS)
2 Problem with speed sensor, normally for output speed. Replace speed sensor 9-3 - Transmission - Automatic Transmission - Adjustment/Replacement - Output shaft speed sensor
3 Error in TCM software. a) Update software in TCM. (Download from IRIS) M04 has a modified valve housing and new software. b) If the fault remains the transmission fluid level must be checked. c) If the problem remains on an M03 despite the above procedure, replace the valve housing, part no. 55354950. Perform adaptation of the gearbox. 9-3 - Transmission - Automatic Transmission - Adjustment/Replacement - Checking fluid level
4 Fault in engine control module software. Update software in TCM. (Download from IRIS). If the fault remains, contact the importer/ETAC.
5 This is a concept selection for 5-speed automatic transmission. None
6 Invalid adaptation. Perform adaptation, resetting. If the procedure does not help and the customer complaints continue, replace the gearbox. 9-3 - Transmission - Automatic Transmission - Adjustment/Replacement - Adaptation, resetting
7 Diagnostic trouble code P0826 06 is detected. Clear the diagnostic trouble code as necessary, add SLM with Tech2. New fault diagnosis for the diagnostic trouble code is in WIS. The problem is solved from Vehicle Identification Number 41055520 -
8 Electrical fault Check that the temperature signal is working. Make sure that the wiring harnesses and connectors are working without open circuit.
9 Noise a) Determine under which conditions the noise occurs (gear position, speed, accelerator pedal position, fluid temperature) b) Contact the importer / ETAC for help. Check whether the noise is related to engine speed or vehicle speed by changing gear position. c) Describe the character of the noise, whining sound, rattling, clicking etc. d) Checklist, completed with gearbox replacement 9-3 - Transmission - Automatic Transmission - Adjustment/Replacement - Automatic gearbox assembly
10 Diagnostic trouble codes a) Read out the diagnostic trouble codes, clear them and test drive the car. b) Check the function of the components identified by the diagnostic trouble code by checking whether the diagnostic trouble code is repeated with a non-faulty component. c) Check that the cables and connectors are working satisfactorily. 9-3 - Transmission - Automatic Transmission - Component location
11 Invalid gearbox type a) Check whether the Vehicle Identification Number and the gearbox number correspond. (In certain M03 cars the M04 gearbox has been installed) b) If the above is in order, compare the car with another car of the same type.
12 Oil leakage a) Clean at the leakage and test drive the car. b) If the leakage returns, photograph the area and mark the area with a pen. Rectify the leakage or if necessary replace the gearbox. Enclose the completed checklist and the photograph when the gearbox is returned.
13 Water in transmission fluid a) Always check the condition of the transmission fluid in the gearbox and oil cooler. b) In some cases diagnostic trouble code P0780-60 is generated. If so, follow the fault diagnosis. c) From M04 Loctite is used in the threads for the radiator connections as well as an improved gasket material. The Vehicle Identification Number limit for this is, for 4D: 51002378 and for CV: 46008366. d) From M05 the oil cooler has been modified. The Vehicle Identification Number limits are, for 4D: 51002378, CV: 56001058, Z19: 51000001 e) If the gearbox must be replaced, replace the radiator as well, and clean the cooling system for engine and gearbox with citrus-based degreasing agent before the gearbox is fitted.


Checklist

The list is to be completed and enclosed with the replaced gearbox

Issuer, name and telephone: Importer no: Dealer no:
Date: Report no:
Car information:
Vehicle Identification Number Type: Gearbox number:
TCM no: TCM letter code:
Engine type: Mileage:
Customer description of the fault symptom:
Mechanic's report incl. diagnosis:
Repair attempt:
Conditions when fault occurred: Persistent: ........... Intermittent: ........ Cold gearbox: ........ Warm gearbox: .......
When shifting from _______to________ Comments:
Occurs in gear position: 1.......... 2........... 3.......... 4.......... 5.......... Reverse......... Comments:
Occurs during: Acceleration: ....... Kick down: ....... Without acceleration: ....... Gentle acceleration: .......
Occurs at engine speed __________ (RPM).
Check performed: gear selector mechanism/adjustment: ........
Mode: Normal:......... Sport: ........ Winter: .........
Transmission fluid Level checked: ........ Fluid changed: ...........
Other comments:
Diagnostic trouble codes including symptom supplement before repair and test drive (e.g. Pxxxx xx):
Diagnostic trouble codes including symptom supplement after repair and test drive (e.g. Pxxxx xx):
SID display text / warning lamp on in MIU: ...........................
Control module information (read out with diagnostic tool)
Tech2 version:
Software number after SPS programming:


Warranty/Time Information