(440-2497) 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: | 440-2497 |
| Date: ........... | Oktober 2004 |
| Market: | all |
| General fault diagnosis for automatic transmission |
| Cars affected |
Saab 9-5 M02-04 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
|
Hard shifting 2-3 during limited acceleration.
|
M02-03
|
|
2
|
Delay and hard shifting P-D and N-D
|
M02-03
|
|
3
|
Delay and hesitation during down shifting 3-2 at 50 - 70 km/h
|
M02-03
|
|
4
|
Sudden down shifting without reason with cold gearbox and at low speed
|
M02-03
|
|
5
|
Gear slips in Lock-up mode
|
M02-03
|
|
6
|
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.
|
M02-03
|
|
7
|
Close shifting at low speed
|
M02-04
|
|
8
|
Hard down shifting when braking to stop
|
M02-03
|
|
9
|
Very hard engagement of positions D and R
|
|
|
10
|
Noise
|
|
|
11
|
Diagnostic trouble codes for electrical components
|
|
|
12
|
Hard down shifting 3-2
|
M03
|
|
13
|
Oil leakage
|
|
Procedure table
The figures refer to the above symptom table.|
No.
|
Cause
|
Procedure
|
WIS
|
|
1
|
Incorrect servo cover for brake B4
|
a) Check the servo cover, replace if the washer in the cover is loose.
b) Clear the adaptation values c) Perform adaptation d) If possible, compare the repaired car with a car of the same type and model. |
|
|
2
|
Inertia in valve housing valves (SLS, SLT).
|
Replace valve housing with a modified one (part no. 5449780)
|
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Valve housing
|
|
3
|
Error in TCM software.
|
Update software in TCM. (Download from IRIS)
|
|
|
4
|
Problem with speed sensor, normally for output speed.
|
Replace speed sensor
|
|
|
5
|
A bushing may have moved and blocked the oilways.
|
a) Check the transmission fluid level and quality as well as that the oil cooler hoses have unhindered flow.
b) Check if a diagnostic trouble code has been detected. Clear the diagnostic trouble code and test drive the car. c) If the diagnostic trouble code returns, replace the gearbox. d) If the fault does not reappear, return the car to the customer. |
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Complete automatic transmission or - Automatic Transmission, fluid level
|
|
6
|
Error in TCM software.
|
a) Check the transmission fluid level and quality.
b) Update software in TCM. (Download from IRIS) M04 has modified valve housing and new software. Perform adaptation of the gearbox. c) If the problem remains on an M02-M03 despite the above procedure, replace the valve housing, part no. 5449780. Perform adaptation of the gearbox. |
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Automatic Transmission, fluid level
|
|
7
|
This is a concept selection for 5-speed automatic transmission.
|
None
|
|
|
8
|
Invalid adaptation.
|
a) Compare the gearbox serial number and the software ID number and make sure that they correspond.
b) Clear the adaptation values and perform adaptation, resetting. If the procedures do not help and the customer complaints continue, replace the gearbox. |
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Adaptation, resetting
|
|
9
|
Electrical fault
|
a) Read the value for the temperature sensor when the car is cold. Check that the value corresponds with the ambient temperature.
b) If the value differs too much, check that the temperature signal is working. Make sure that the wiring harnesses and connectors are working without open circuit |
9-5 (9600) - Transmission - Automatic Transmission - Technical data - Transmission fluid temperature sensor
|
|
10
|
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. c) Describe the character of the noise, whining sound, rattling, clicking etc. d) Checklist, completed with gearbox replacement. |
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Complete automatic transmission
|
|
11
|
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. |
9-5 (9600) - Transmission - Automatic Transmission - Component location
|
|
12
|
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. |
|
|
13
|
Oil leakage
|
a) Clean at the leakage and test drive the car.
b) If leakage returns, photograph the area and mark the area with a pen. c) Rectify the leak or replace the gearbox if necessary. Enclose the completed checklist and the photograph when the gearbox is returned. |
9-5 (9600) - Transmission - Automatic Transmission - Adjustment/Replacement - Complete automatic transmission
|
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 |
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