Electrical Schematic - visualbits.netvisualbits.net/Car Stuff/Ford Ranger 1993-1999/07 TRANSMISSION/07...DIAGNOSIS AND TESTING Electrical Schematic Shift Lock Actuator — Aerostar

DIAGNOSIS AND TESTING

Electrical Schematic

Shift Lock Actuator — Aerostar

Shift Lock Actuator — Ranger

Section 07-05: Transmission, Automatic, External Controls 1997 Aerostar, Ranger Workshop Manual

Page 1 of 31997 Aerostar/Ranger

2011-04-28file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK75004.HTM~gen~ref.HTM

Shift Lock Actuator Connector (Aerostar)

Shift Lock Actuator Connector (Ranger)






Inspection and Verification

Visually inspect the following components of shift interlock system. Determine if any of the following electrical or mechanical concerns apply:


VISUAL INSPECTION CHART

Mechanical Electrical

� Blown fuse(s) Kinked or bound shift-lock cable

� Poor connections Kinked or bound shift cable

� Damaged wiring harness Damaged selector linkage

Shift control selector lever out of adjustment




Symptom Chart — Shift Control Linkage

NOTE: Use Rotunda 73 Digital Multimeter 105-R0051 o r equivalent to perform electrical Pinpoint Tests.

Use the Symptom Chart as an aid in determining possible conditions, sources and necessary service actions for shift control linkage.


SHIFT CONTROL LINKAGE

Condition Possible Source Action

� Shift Interlock System Does Not Release or Lock Properly

� Circuitry open/shorted.

� Blown fuse. � Damaged brake on/off

(BOO) switch. � Damaged shift lock

actuator.

� GO to Pinpoint Test A .

� Shift Control Linkage Binding, Out of Proper Gear Relationship

� Damaged shift cable and bracket.

� Loose shift cable and bracket.

� Loose retainer bracket. � Shift linkage misadjusted.

� GO to Pinpoint Test B .

� Transmission Range Indicator Does Not Correspond to the Gear

� Transmission shift cable bracket is loose.

� TIGHTEN bolts holding transmission shift cable bracket.

� Transmission control indicator linkage misadjusted.

� ADJUST PRNDL at steering column housing.

� Transmission shift cable loose from the transmission retainer bracket.

� TIGHTEN transmission shift cable bolts.

� Shift linkage misadjusted. � VERIFY shift cable adjustment. REFER to Adjustments in this section. ADJUST shift cable, if necessary.

� Clip securing the transmission shift cable to the transmission range selector lever is loose.

� INSTALL clip properly.

� Transmission Range Indicator Lamp Does Not Illuminate

� Bulb burned out. � REPLACE bulb.



� Wiring harness damaged. � INSTALL new wiring harness.

� Rattle, Noise, Buzz, etc.

� Selector lever knob loose. � REPLACE selector lever knob.

� Transmission range selector lever loose.

� TIGHTEN housing bolts.

� Shift interlock spring not hooked.

� ATTACH shift interlock spring properly.

� Water Enters Inside the Vehicle

� Cable assembly grommet not secure to dash panel.

� SECURE grommet to dash panel.

� Cable assembly grommet torn.

� INSTALL new transmission shift cable.

� Excessive Shift Effort � Kinked/broken transmission shift cable.

� ADJUST cable. TIGHTEN cable bracket screws.

� Cable bracket loose/bent. � REPLACE transmission shift cable.

� Transmission Range Selector Lever Will Not Shift from Range

� Transmission shift cable detached from transmission bracket.

� REINSTALL transmission shift cable.

� Lock tab loose.

� Broken transmission shift cable.

� REPLACE transmission shift cable.

� Internal transmission components damaged.

� REFER to Section 07-01A .

� Transmission Control Switch (TCS) Inoperative, DTC P1780

� Blown fuse. � Damaged TCS or TCS not

cycled during self test. � Damaged powertrain

control module. � Circuitry open/shorted.

� GO to Pinpoint Test C .

� Transmission Control Indicator Lamp (TCIL) Does Not Illuminate

� Burned out bulb. � Circuitry open/shorted. � Damaged powertrain

control module.

� GO to Pinpoint Test D .

� Transmission Control Indicator Lamp (TCIL) Stays Illuminated

� Circuitry open/shorted. � Damaged powertrain

control module.

� GO to Pinpoint Test E .






Pinpoint Tests

PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RE LEASE OR LOCK PROPERLY

A1 CHECK FUSES

Check the following fuses: � In the instrument panel fuse box, Aerostar:

� In the instrument panel fuse box, Ranger:

Are fuses OK?

A2 CHECK SYSTEM

� Replace blown fuse(s). � Key ON.

Do(es) fuse(s) fail again?

A3 CHECK POWER SUPPLY TO BRAKE ON/OFF (BOO) SWITCH


Fuse Location Amperage

1 15

5 15

Fuse Number Amperage

10 7.5

13 15

Yes No

GO to A3 . GO to A2 .

Yes No

GO to A8 . GO to A3 .



� Locate and disconnect brake on/off (BOO) switch. � Measure voltage on the "LG/R" wire between the BOO switch connector and ground.

Is voltage greater than 10 volts?

A4 CHECK BRAKE ON/OFF (BOO) SWITCH

� BOO switch connected. � Press brake pedal. � Measure voltage at the "LG" wire terminal between the BOO switch connector and ground.


A5 CHECK POWER SUPPLY TO SHIFT LOCK ACTUATOR

� Locate and disconnect shift lock actuator. � Key ON. � Measure voltage on the "GY/Y" wire at the shift lock actuator connector.


A6 CHECK POWER SUPPLY TO SHIFT LOCK ACTUATOR

� Key OFF. � Press brake pedal. � Measure voltage on the "R/LG" (Aerostar) or "LG" (Ranger) wire at the shift lock actuator connector.


A7 CHECK SHIFT LOCK ACTUATOR GROUND

Yes No

GO to A4 . REPAIR "LG/R" wire for open. RETEST system.

Yes No

GO to A5 . REPLACE BOO switch. RETEST system.

Yes No

GO to A6 . REPAIR "GY/Y" wire for open. RETEST system.

Yes No

GO to A7 . REPAIR "R/LG" OR "LG" wire foe open. RETEST system.



� Disconnect shift lock actuator connector. � Measure resistance of the "BK" wire between the shift lock actuator connector and ground.

Is resistance less than 5 ohms?

A8 CHECK POWER CIRCUITS FOR SHORT TO GROUND

� Disconnect shift lock actuator connector. � Remove blown fuse. � Check for continuity between blown fuse output circuit and know good ground.

Is continuity present?

PINPOINT TEST B: SHIFT CONTROL LINKAGE BINDING, OUT OF PROPER GEAR RELATIONSHIP

B1 CHECK SHIFT CONTROL LINKAGE

� Gain access to shift control linkage. � Actuate shift linkage in all ranges. � Observe all linkages during operation.

Is linkage damaged?

B2 CHECK TRANSMISSION SHIFT CABLE

� Check transmission shift cable and bracket installation and tightness.

Is shift cable properly installed and adjusted?

Yes No

REPLACE shift lock actuator. REPAIR "BK" wire for open. RETEST system.

Yes No

REPAIR circuit for short to ground. REPLACE fuse. RETEST system.

CHECK all other circuits that are spliced into circuit having blown fuse. REPAIR as required. If all other circuits are OK, REPLACE shift lock actuator. RETEST system.

Yes No

REPLACE shift control linkage. RETEST system. GO to B2 .

Yes No



B3 CHECK LINKAGE/CABLE FOR PROPER GEAR RELATIONSHIP

� Actuate transmission range selector lever in all ranges.

Does indicator match gear selection?

PINPOINT TEST C: TRANSMISSION CONTROL SWITCH (TCS) INOPERATIVE, DTC P1780

C1 CHECK FUSE 26

� Turn the ignition switch to the OFF position. � Check the I/P fuse (10A).

Is the resistance less than 5 ohms?

C2 CHECK TRANSMISSION CONTROL SWITCH (TCS) CIRCUIT FOR VOLTAGE

� Disconnect the powertrain control module harness connector. � Inspect the powertrain control module harness connector for damaged or pushed out pins, corrosion

or loose wires. � Install 104 Pin breakout box (014-00950); leave the PCM disconnected. � Measure the voltage between test pin 29 and test pin 24 and 77 at the breakout box while cycling the

several times.

Does the voltage cycle?

VERIFY shift cable adjustment. REFER to Adjustments in this section. ADJUST shift cable, if necessary. GO to B3 .

REPAIR as necessary. RETEST system.

Yes No

REPAIR is complete. RETEST system. REPLACE damaged linkage/cable. RETEST system.

Yes No

REINSTALL fuse. Go to C2 . REPLACE failed fuse. RETEST system. If fuse fails again,check for short to ground in circuits 298 (P/O) and 224 (T/W). RETEST system.

Yes No

REPLACE PCM. REMOVE breakout box. RETEST system. GO to C3 .



C3 CHECK 224 (T/W) FOR SHORT TO GROUND

� Turn the ignition switch to the OFF position. � Disconnect the transmission control switch harness connector. � Inspect both ends of the TCS connector for damaged or pushed out pins, corrosion or, loose wires. � Measure resistance between test pins 29 and test pins 24 and 77 at the breakout box.

Is the resistance greater than 10,000 ohms?

C4 CHECK CIRCUIT 298 (P/O) AND CIRCUIT 224 (T/W) FOR OPEN

� Disconnect the I/P fuse 26 (10A). � Measure resistance between the I/P fuse 26 (10A) connector pin I and the power side of the TCS

vehicle harness connector circuit 298 (P/O). � Measure resistance between test pin 29 at the breakout box and the signal side of TCS vehicle

harness connector circuit 224 (T/W).

Are all resistance's less than 5 ohms?

C5 CHECK CIRCUIT 224 (T/W) FOR SHORT TO POWER

� Measure resistance between test pin 29 and test pins 71 and 97 at the breakout box.

Is the resistance greater than 10,000 ohms?

PINPOINT TEST D: TRANSMISSION CONTROL INDICATOR LAM P (TCIL) DOES NOT ILLUMINATE

D1 CHECK TRANSMISSION CONTROL INDICATOR LAMP (TCIL) CIRCUIT FOR VOLTAGE

Yes No

GO to C4 . REPAIR circuit 224 (T/W). RETEST system.

Yes No

GO to C5 . REPAIR circuit 298 (P/O) and /or circuit 224 (T/W). REMOVE breakout box. RECONNECT all components. RETEST system.

Yes No

REPLACE transmission control switch. REMOVE breakout box. RECONNECT all components. RETEST system.

REPAIR circuit 224 (T/W). REMOVE breakout box. RECONNECT all components. RETEST system.



� Turn the ignition switch to the OFF position. � Disconnect the powertrain control module harness connector. � Inspect the powertrain control module harness connector for damaged or pushed out pins, corrosion

or loose wires. � Install 104 Pin breakout box (014-00950); leave the PCM disconnected. � Turn the ignition switch to the ON position. � Measure the voltage between test pin 79 and test pins 24 and 76 at the breakout box.

Is the voltage reading greater than 2 volts?

PINPOINT TEST E: TRANSMISSION CONTROL INDICATOR LAM P (TCIL) STAYS ILLUMINATED

E1 CYCLE TRANSMISSION CONTROL SWITCH

� Turn the ignition switch to the ON position. � Cycle the transmission control switch (TCS).

Does the transmission control indicator lamp (TCIL) turn on and off?

E2 CHECK CIRCUIT 911 (W/LG) FOR SHORT TO GROUND

� Turn the ignition switch to the OFF position. � Disconnect the powertrain control module harness connector. � Inspect the powertrain control module harness connector for damaged or pushed out pins, corrosion

or loose wires. � Turn the ignition switch to the ON position.

Does the TCIL remain on ?

Yes No

REPLACE PCM. CYCLE TCS to check operation of TCIL.

CHECK indicator bulb and fuse. If OK, open is wiring between ignition switch and test pin 79 at the PCM harness connector. REPAIR as needed. RETEST system.

Yes No

OK at this time. Concern may be intermittent. GO to E2 .

Yes No

REPAIR circuit 911 (W/LG). REMOVE breakout box. RECONNECT all components. RETEST system.

REPLACE PCM. RETEST system.





REMOVAL AND INSTALLATION

Transmission Range Selector Lever

Removal

1. If required, remove tilt handle assembly by unscrewing from the column.

2. Disconnect battery ground cable.


Item Part Number Description

1 7G357 Gearshift Lever Pin

2 7210 Gearshift Lever

3 3513 Steering Column Opening Weather Seal

4 7C464 Clip

5 3514 Steering Column Tube



3. Turn key lock cylinder to RUN position. Using a 1/8-inch drift, depress steering column lock cylinder pin through access hole and remove key lock cylinder.

4. Remove lower instrument panel cover retaining screws and remove cover.

5. Remove four retaining screws from steering column shroud. Remove the upper and lower steering column shrouds.

6. Using a small screwdriver, pry rubber shift lever cover upper attachment from pedestal on lock cylinder housing. Slide cover toward shift lever handle to expose shift lever retaining pin.

7. Using a small drift, tap retaining pin from bottom for removal. Discard lever retaining pin. Remove shift lever from shifter housing assembly.

Installation

1. Insert shift lever housing into opening in shifter housing assembly.

2. Install a new pin into position and tap in place until the head seats against shifter housing assembly.

3. Position shift lever cover on the lock cylinder housing. Insert lower attachment into the slot on side of housing.

4. Position upper attachment on mounting pin. Install a Tinnerman nut (Part No. 372659-S2) to secure cover to pedestal on lock cylinder housing.

5. Install steering upper and lower steering column shrouds with four screws.

6. Install lower instrument panel cover and retaining screws.

7. Install lock cylinder into lock cylinder housing.

8. Install tilt handle assembly onto column.

9. Connect battery ground cable.






Shift Lock Actuator

Removal

1. Remove steering column as outlined in Section 11-04A or Section 11-04B .

2. Unclip wire terminal from solenoid.

3. Remove insert plate and solenoid by removing three retaining screws.

4. Pry off clip.

Installation

1. NOTE: The clip which retains the solenoid to the in sert plate should not be replaced for service. The clip's sole purpose is an assembly aid for the assembly plant.

Position insert plate/solenoid assembly to the steering column and tighten the retaining screws.

2. Install the steering column in the vehicle as described in Section 11-04A or Section 11-04B .





Transmission Shift Cable and Bracket, Ranger



1 7212 Transmission Column Shift Selector Tube



Removal

1. Remove shift cable plastic terminal from the shift control selector lever pivot ball by prying with a screwdriver between cable plastic terminal and shift control selector lever and housing.

2. Remove transmission shift cable from steering column bracket by carefully lifting on the locking tab while pulling up on the fitting.

3. From inside passenger compartment, press tabs together on cable underbody attachment clip and push through the dash.

2 7E395 Shift Cable and Bracket

3 7A256 Manual Control Lever

4 7B229 Transmission Shift Cable Bracket

5 N605918-S300 Bolt (2 Req'd)

A — Tighten to 34-46 Nm (25-34 Lb/Ft)



4. From engine compartment, pry cable grommet from dash panel.

5. Remove plastic slide adjuster from manual lever pivot ball, prying with a screwdriver between the slide adjuster and manual control lever.

6. Remove transmission shift cable from transmission shift cable bracket by carefully pressing on the locking tabs while pulling up on the fitting.

7. From engine compartment, pull cable through the instrument panel opening.

Installation

1. From instrument panel, feed plastic terminal end of cable through opening in dash panel to engine compartment.

2. Press rubber grommet on transmission shift cable into dash panel.



3. From engine compartment, install transmission shift cable into transmission shift cable bracket and make sure locking ears are properly located and seated into bracket.

4. Insert cable underbody attachment clip in proper position.

5. Place transmission shift cable on manual lever pivot ball and press into place.

6. From the passenger compartment, install transmission shift cable into shift cable bracket and make sure locking tab is fully seated and locked into place.

7. Snap cable plastic terminal onto shift control selector lever pivot ball on the steering column.

8. Adjust transmission shift cable. Refer to Adjustments, Transmission Shift Cable and Bracket , Ranger in this section.

9. Remove the cable lock tab and replace with a new lock tab.




Transmission Shift Cable and Bracket, Aerostar

Removal



1 — 1.4 kg (3 Lb.) Weight (To Be Improvised in Shop)

2 7A256 Manual Control Lever

3 7E395 Transmission Shift Cable

4 7210 Gearshift Lever

5 7B229 Transmission Shift Cable Bracket

6 — Lock Mechanism Shown Unlocked (Part of 7E395)

7 — Lock Mechanism Shown Locked (Part of 7E395)

8 N605918-S2 Bolt, M10-1.50 x 20 (2 Req'd)

A — Tighten to 34-46 Nm (25-34 Lb-Ft)



1. Raise vehicle on hoist and position suitable safety stands under the vehicle.

2. Unclip shift cable end fitting from transmission outer manual lever.

3. Remove shift cable from transmission shift cable bracket (7B229) by carefully squeezing shift cable ears together. Push shift cable out of transmission shift cable bracket.

4. Remove safety stands and lower vehicle.

5. Using a screwdriver, unclip the shift cable end fitting from the shift control selector lever.

6. Carefully remove shift cable from steering column bracket by prying back the lock tab with a small screwdriver and pushing the cable from the transmission shift cable bracket.

7. Peel back the carpet to expose shift cable grommet and clip.

8. Remove shift cable clip by gently squeezing shift cable ears together with suitable pliers.

9. Remove the shift cable from the vehicle by pulling or pushing shift cable through floorpan hole.

Installation

1. Route cable through floorpan hole.

2. Install the shift cable to the steering column bracket, making sure lock tabs are fully seated into bracket.

3. Seat shift cable grommet.

4. Place shift control selector lever in the (D) position and place a 1.4 kg (3 lb.) weight on the end of the shift control selector lever.

5. Raise vehicle on a hoist and position suitable safety stands under vehicle.

6. Route the shift cable away from exhaust and seat cable in transmission shift cable bracket.

7. Position the manual control lever (7A256) in the overdrive (D) position. This is three detents from the frontmost lever position with the first position counting as one.

8. Attach shift cable end fitting to the transmission outer manual lever.

9. Fully seat lock tab on transmission cable.

10. CAUTION: Shift cable must be properly clipped to underbody. Failure to do so may result in the cable resting on the exhaust pipe, causing it to burn and ultimately causing complete loss of shifting ability.

Attach shift cable clip to vehicle underbody.

11. Remove safety stands and lower vehicle. Remove the weight from the shift control selector lever. Check for proper transmission engagement of all gears.






Transmission Control Switch

Removal

1. Disconnect the battery ground cable (14301).

2. Remove the plastic trim ring at the end of the transmission range selector lever.

3. Carefully pull the transmission control switch out of the transmission range selector lever.

Installation

To install, reverse the removal procedure.




CLEANING AND INSPECTION

Brake/Shift Interlock System

1. Turn ignition switch (11572) to RUN.

2. Verify that the transmission range selector lever is in PARK (P).

3. Without the brake pedal (2455) applied, verify that the transmission range selector lever cannot be shifted from PARK (P).

4. Apply the brake pedal. Verify that the transmission range selector lever can be shifted from PARK (P).

5. Shift to REVERSE (R).

6. Verify that the ignition switch cannot be turned to the LOCK position.

7. Shift to PARK (P).

8. Verify that the ignition switch can be turned to the LOCK position.

9. If the shift interlock system is not operating as specified, refer to Diagnosis and Testing in this section.




CLEANING AND INSPECTION

Transmission Range (TR) Selector Lever

Inspect the transmission range selector lever for damage, binding conditions and proper operation. Replace the transmission range selector lever as necessary. Refer to the procedure in this section.




ADJUSTMENTS

Transmission Shift Cable and Bracket, Aerostar

1. Place shift control selector lever in the (D) (OVERDRIVE) position.

2. Hang a 1.4 kg (3 lb.) weight on the end of the shift control selector lever.

3. Raise the vehicle on a hoist and position suitable safety stands under the vehicle.

4. Use a screwdriver and pry the shift cable end from the manual control lever ball stud.

5. To unlock the adjuster body, release the lock tab on the top side of the cable by pushing down on two tangs.

6. Move the shift cable back and forth the full adjustment length four or five times to remove any dirt. Be sure the adjuster body moves freely.

7. Position the manual control lever (7A256) in the overdrive (D) position. This is three detents from the front-most lever position with the first position counting as one.

8. Holding the cable end fitting, push the cable rearward until the end fitting lines up with the outer manual control lever ball stud. Connect the cable end fitting to the ball stud.

9. Push up on the lock tab to lock the adjuster body in the correctly adjusted position. Be sure locator tab is properly seated in the bracket. Make sure shift cable is clipped to floorpan at white cable mark and cable is routed into tunnel.

10. Remove safety stands and lower vehicle.

11. Adjust shift indicator pointer while transmission (7003) is still in the (D) position.

12. Remove the 1.4 kg (3 lb.) weight from the shift control selector lever.

13. After adjustment, check for P (PARK) engagement. Check the shift control selector lever in all positions with the engine (6007) running to make sure that transmission/detent action is correct. Verify that the vehicle starts in Park/Neutral and back-up lamps illuminate in Reverse. If not, verify digital transmission range (DTR) adjustment in Neutral. Readjust if required. Refer to Section 07-01A or Section 07-01B .






ADJUSTMENTS

Shift Indicator Cable

1. Remove tilt wheel handle and shank (3F609).

2. Remove ignition switch lock cylinder (11582). Refer to Section 11-04A or Section 11-04B .

3. Remove upper and lower steering column shrouds (3530).

4. Place gearshift lever (7210) in (D) (OVERDRIVE) position. A weight of 1.4 kg (3 lbs.) should be hung on the gearshift lever to make sure the gearshift lever is located firmly against the (D) detent.

5. Adjust shift cable (with adjustment wheel on PRNDL cable) until shift indicator completely covers (D) and calibration dots show no red.

6. Cycle gearshift lever through all of the positions and check that the shift indicator completely covers the proper letter or number in each position.

7. Install upper and lower steering column shrouds.

8. Install ignition switch lock cylinder. Refer to Section 11-04A or Section 11-04B .

9. Install tilt wheel handle and shank.




SPECIFICATIONS

SPECIFICATIONS


TORQUE SPECIFICATIONS

Description Nm Lb-Ft

Transmission Shift Cable Bracket Bolt (Ranger/Aerostar) 34-46 25-34



Documents

Electrical Schematic - visualbits.netvisualbits.net/Car Stuff/Ford Ranger 1993-1999/07 TRANSMISSION/07...DIAGNOSIS AND TESTING Electrical Schematic Shift Lock Actuator — Aerostar