Technical Service Operations Worksheets
Table Of Contents
• Automatic Transmission Diagnostic Worksheet
• ZF 8 Speed Automatic Transmission Worksheet
• Manual Transmission / Transfer Case Diagnostic Worksheet
• CVT Transmission Diagnostic Worksheet
• HEV Transmission Diagnostic Worksheet
• Check Engine Light Diagnostic Worksheet
• 70% Transmission Cost Analysis Worksheet
• 70% Engine Cost Analysis Worksheet
• 6.7L Cummins Turbo Diesel Diagnostic Worksheet
• 5.9L Cummins Diesel Fuel Diagnostic Worksheet
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Category Does Not
Occur Slips
Late or
Delayed Early Harsh Shudder Search Busy Stalls
Engagement into Drive
Engagement into Reverse
1-2 Upshift
2-3 Upshift
3-4 Upshift
4-5 Upshift
5-6 Upshift
6-5 Downshift
5-4 Downshift
4-3 Downshift
3-2 Downshift
2-1 Downshift
Kickdown w/o Accel (indicate gears)
Converter Lockup
Check all that apply
Automatic Transmission
Diagnostic Worksheet
SE
RV
ICE
AD
VIS
OR
SE
CT
ION
READY Warning Lights: Engine Fuel Anti-Lock Traction Control
Always
Intermittent
Trans Hot
Trans Cold
At Idle
At _____ MPH
When does this Performance Related Concern occur? Check all that apply.
Part Throttle
Wide Open Throttle
Braking
Unable To Duplicate
Cornering
With A/C On
High Altitude
Extremely Hot (Above 90
F)
Extremely Cold (Below 10
F)
While Towing
On Severe Incline / Grade
Gear Selector Position
Other:
Drive Conditions. Check all that apply.
Leaks: When Leaks: Where
Surface Condition Road Condition Road Type Traffic Conditions
Wet
Dry
Smooth
Bumpy
Flat
Dirt
Cement
Stop & Go
Light Traffic
Heavy Traffic
Twisty
Pot Holes
Gravel
Black Top
Noise Concern:
Buzz
Whine
Clunk
Rattle
Moving
Still
In Gear
Out of Gear
Braking
Noise Concern Occurs When:
Please Provide Environmental Data. Condition Duplication? Yes No
Other Concerns:
Trans Fluid Level: Correct Low High Mixed with ATF/Coolant? Yes No
Fluid Condition: Normal Burnt Metal Contamination
Clutch Volumes: L/R 2C/2-4 OD 4C UD LC DC R
Shift Lever Status Check: Passed Failed
DTC’s Before Repair / Replace:
PCM TCM
TCM Part #: Reflashed? Yes No New Part #:
Cooler Pressure Tests Results: Cooler Flow Rate:
Are there any non-factory installed devises or modifications to the vehicle (CB radio, axle ratio changes, tire size changes, heavy
electrical draw add-ons, etc.): Yes No If Yes, please describe
Is this a fleet, taxi, or delivery vehicle? Yes No
TECHNICIAN DIAGNOSIS:
TECHNICIAN ID #: TECHNICIAN SIGNATURE:
Line Pressure Gauge Scan Tool Desired
Park
Reverse
Drive
TE
CH
NIC
IAN
SE
CT
ION
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
ZF 8 Speed Automatic Transmission
Diagnostic Worksheet
Dealer Name:
Dealer Code:
Date of Complaint:
RO #:
Repeat Complaint: Yes No
Vehicle Model:
Vehicle Build Date:
Transmission Software Level:
Transmission Model No.: 1090 (e.g. 1090 010 020)
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
Vehicle Sale Date:
Engine Software Level:
Transmission Serial No.
Customers Complained of:
Shift Quality
Function
Noise
Limp Mode
Leak
Other
Defect Details:
Transmission / Vehicle Fault Codes Registered: Yes No
Codes Registered:
Transmission Identification Plate: Is engraved onto the Left Hand side of the transmission casing
ZF – APPROVAL CONFIRMATION:
Approval Number:
Approval Date:
Component to be Dispatched:
Component Dispatch Date:
Manual Transmission/Transfer Case
Diagnostic Worksheet
SE
RV
ICE
AD
VIS
OR
SE
CT
ION
Category Clash
Grind
High
Effort
Pops
Out
Engagement into 1st
Engagement into Reverse
1-2 Upshift
2-3 Upshift
3-4 Upshift
4-5 Upshift
5-6 Upshift
6-5 Downshift
5-4 Downshift
4-3 Downshift
3-2 Downshift
2-1 Downshift
Category Clash
Grind
High
Effort
Pops
Out
Low to High
High to Low
High Range
Low Range
Performance Related Concern - Transmission Performance Related Concern – Transfer Case
For popping out of gear, have shift boot(s) been
checked for binding? Yes No
Check all that apply
READY Warning Lights: Engine Fuel Anti-Lock Traction Control
Always
Intermittent
Trans Hot
Trans Cold
At Idle
At _____ MPH
When does this Performance Related Concern occur? Check all that apply.
Part Throttle
Wide Open Throttle
Braking
Unable To Duplicate
Cornering
With A/C On
High Altitude
Extremely Hot (Above 90
F)
Extremely Cold (Below 10
F)
While Towing
On Severe Incline / Grade
Other:
Drive Conditions. Check all that apply.
Leaks: When Leaks: Where
Surface Condition Road Condition Road Type Traffic Conditions
Wet
Dry
Smooth
Bumpy
Flat
Dirt
Cement
Stop & Go
Light Traffic
Heavy Traffic
Twisty
Pot Holes
Gravel
Black Top
Noise Concern:
Buzz
Whine
Clunk
Rattle
Moving
Still
In Gear
Out of Gear
Braking
Noise Concern Occurs When:
Please Provide Environmental Data. Condition Duplication? Yes No
Other Concerns:
Factory Fill Lubricant: Yes No If No, what has been installed?
Fluid Condition: Normal Burnt Metal Contamination
Transmission / Transfer Case Part Number & Serial Number from Tag:
Is the factory installed shifter mechanism / linkage still being used? Yes No
Has the shift linkage been checked for adjustment? Yes No
Has clutch travel & free play been verified? Yes No
TE
CH
NIC
IAN
SE
CT
ION
Are there any non-factory installed devises or modifications to the vehicle (CB radio, axle ratio changes, tire size changes, heavy
electrical draw add-ons, etc.): Yes No
If Yes, please describe:
Is this a fleet, taxi, or delivery vehicle? Yes No
TECHNICIAN DIAGNOSIS:
TECHNICIAN ID #: TECHNICIAN SIGNATURE:
In what gear or range?
Does loading the gearshift/range shift lever have an impact on the noise? Yes No
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
Always
Intermittent
Trans Hot
Trans Cold
At Idle
At _____ MPH
Category Does Not
Occur Slips
Late or
Delayed Early Harsh Shudder Search Busy Stalls
Engagement Into Drive
Engagement Into Reverse
Breakaway, Light Acceleration
Breakaway, Heavy Acceleration
Cruise, Light Acceleration
Cruise, Heavy Acceleration
Manual Mode
Kickdown / WOT Acceleration
Converter Lookup
When does this Performance Related Concern occur? Check all that apply.
Part Throttle
Wide Open Throttle
Braking
Unable To Duplicate
Cornering
With A/C On
High Altitude
Extremely Hot (Above 85
F)
Extremely Cold (Below 10
F)
While Towing
On Severe Incline / Grade
Gear Selector Position
Drive Conditions. Check all that apply.
Leaks: When Leaks: Where
Noise Concern:
Buzz
Whine
Clunk
Rattle
Moving
Still
In Gear
Out of Gear
Braking
Check all that apply
Surface Condition Road Condition Road Type Traffic Conditions
Wet
Dry
Smooth
Bumpy
Flat
Dirt
Cement
Stop & Go
Light Traffic
Heavy Traffic
Twisty
Pot Holes
Gravel
Black Top
READY Warning Lights: Engine Fuel Anti-Lock Traction Control
Noise Concern Occurs When:
CVT Transmission Diagnostic Worksheet
Other:
Please Provide Environmental Data. Condition Duplication? Yes No
Other Concerns:
Trans Fluid Level: Correct Low High Mixed with ATF/Coolant? Yes No
Fluid Condition: Normal Burnt Metal Contamination
DTC’s Before Repair / Replace: Software PART #:
PCM ABS
TCM Other
TCM Part #: Reflashed? Yes No New Part #:
Are there any non-factory installed devises or modifications to the vehicle (CB radio, axle ratio changes, tire size changes, heavy
electrical draw add-ons, etc.): Yes No
If Yes, please describe:
Is this a fleet, taxi, or delivery vehicle? Yes No
TECHNICIAN DIAGNOSIS:
TECHNICIAN ID #: TECHNICIAN SIGNATURE:
All Pressures Checked While Idling
Line Press Secondary Press
Forward Clutch Reverse Brake
Primary Press Converter Reverse Press
SE
RV
ICE
AD
VIS
OR
SE
CT
ION
T
EC
HN
ICIA
N S
EC
TIO
N
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
HEV Transmission Diagnostic Worksheet
Category Does Not
Occur Slips
Late or
Delayed Early Harsh Shudder Search Busy Stalls
Engagement Into Drive
Engagement Into Reverse
Light Acceleration
Heavy Acceleration
Constant Speed (Indicate)
Coasting
Heavy Braking
Light Braking
Kickdown / WOT Accel.
When does this Performance Related Concern occur? Check all that apply.
Always
Intermittent
Trans Hot
Trans Cold
Braking
Cornering
Electric
At Idle
Part Throttle
Wide Open Throttle
While Towing
Tow Haul Active
Please Provide Environmental Data. Condition Duplication? Yes No
Description Of Issue:
Physical Underbody / Wheel Damage:
Trans Fluid Level: Correct Low High Fluid Condition: Normal Burnt Metal Contamination
Shift Level Status Test: HCP: Passed Failed TCM: Passed Failed
Does the issue occur with the Regenerative Brake System turned off? Yes No
DTC’s Before Repair / Replace: Software PART #:
HCP HCP
PCM PCM
TCM TCM
DTCM DTCM
ABS ABS
Gear Selector Position ____
Extremely Hot (Above 90
F)
Extremely Cold (Below 10
F)
On Severe Incline / Grade
Fuel Level______
Fuel Saver On (MDS Active)
During Engine Auto Stop
During Engine Auto Start
During Launch From Stop
At ______ MPH
High Altitude
Other
Drive Conditions. Check all that apply.
Leaks: When Leaks: Where
Noise Concern:
Buzz
Whine
Clunk
Rattle
Moving
Still
In Gear
Out of Gear
Braking
Coast Down (Regen.)
Check all that apply
Surface Condition Road Condition Road Type Traffic Conditions
Wet
Dry
Smooth
Bumpy
Flat
Dirt
Cement
Stop & Go
Light Traffic
Heavy Traffic
Twisty
Pot Holes
Gravel
Black Top
Noise Concern Occurs When:
Are there any non-factory installed devises or modifications to the vehicle (CB radio, axle ratio changes, tire size changes, heavy
electrical draw add-ons, etc.): Yes No
If Yes, please describe:
Is this a fleet, taxi, or delivery vehicle? Yes No
TECHNICIAN DIAGNOSIS:
TECHNICIAN ID #: TECHNICIAN SIGNATURE:
READY Warning Lights: Engine Fuel Anti-Lock Traction Control ETC HEV Service
Line Pressure (When Required by Service Manual
Commanded Estimated Gauge
Park (Main)
Drive (Main)
Park (Aux)
Drive (Aux)
SE
RV
ICE
AD
VIS
OR
SE
CT
ION
T
EC
HN
ICIA
N S
EC
TIO
N
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
Check Engine Light Diagnostic Worksheet
DISPATCH TO A LEVEL 3 OR 4 TRAINED TECHNICIAN
TECHNICIAN NAME & ID:
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
Are there any non-factory installed devices or modifications to the vehicle (CB radio, axle ratio changes, tire
size changes, heavy electrical draw add-ons, etc.)? Yes No
If Yes, please describe:
Is this a fleet, taxi, or delivery vehicle? Yes No
Is the check engine light on now? Yes No
If No, when does it come on?
Is the light on steady? Yes No
Does the light flash? Yes No
DTC’s Before Repair / Replacement:
PCM Active: PCM Stored:
TCM Active: TCM Stored:
Other Module Active: Other Module Stored:
1. Verify the customer complaint:
2. Any related symptoms:
3. Any updated SB’s related to concern:
4. Symptom analysis:
5. Problem isolation:
6. Repair isolation problem:
7. Verification of repair*:
*Quality Control Must Match DTC Set Condition:
PCM Part #: Flash Available?: Yes No
TCM Part #: Flash Available?: Yes No
New PCM Part #: New TCM Part #:
Service Advisor Signature: Technician Signature:
70% Transmission Cost Analysis Worksheet
The 70% Cost Analysis Worksheet was developed to help the technician verify and
document the cost difference between transmission/transaxle repair and replacement.
Potential chargebacks can many times be avoided by using the 70% Cost Analysis
Worksheet and following: SB 21-021-08.
This sheet should be completed and returned with each transaxle/transmission
replacement along with the appropriate Diagnostic Worksheet.
All transmission/transaxle replacements are SUBJECT TO TEARDOWN ANALYSIS.
CHARGEBACK MAY OCCUR WHEN THE COST OF REPAIR WAS LESS THAN 70% OF
UNIT REPLACEMENT EXPENSE.
Transmission/transaxle replacements authorized by Business Center personnel or the
Powertrain Service Center are subject to this same analysis and chargeback.
All 70% Cost Analysis Worksheets should be legibly completed. Metal in the fluid alone
does not condemn a front pump or valve body. Only a visual inspection or diagnostic
testing revealing actual damage justifies the replacement of these and other parts.
Please review other related Bulletins and SB’s concerning transmission/transaxle repair
and/or replacement.
70% Transmission Cost Analysis Worksheet
Part Name Part # Dealer Cost LOP Description LOP # Labor Hours
Cost Of Parts Labor Hours
40% Mark-up (.40) X Hourly Rate Repair
Total Parts $ + Total Labor $ = Total $
If the Repair Total exceeds the 70 % Repair Allowance, the Assembly should be replaced.
If this vehicle is restricted to the Powertrain Service Center they must be contacted.
TECHNICIAN SIGNATURE: PRINT NAME:
Replacement of Assembly Information
Repair of Assembly Information
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
OEM: “TPK” # (On Case) Reman: (On Reman Tag) Serial # Build Date
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
Part Name Part # Dealer Cost LOP Description LOP # Labor Hours
Transmission Assembly Trans. Replace
Automatic Trans Fluid Reverse Flush
70 % Teardown LOP
* 4X4
* Skid Plate
* Dual Exhaust
* Two Piece Prop
* AWD
Cost Of Parts Labor Hours
40% Mark-up (.40) X Hourly Rate Replace
Total Parts $ + Total Labor $ = Total $
(X.70) 70%
Repair Allowance
70% Engine Cost Analysis Worksheet
The 70% Engine Cost Analysis Worksheet was developed to help the technician verify
and document the cost difference between engine repairs vs. replacement (for
Transmissions/Transaxles see ePubs form # 81-016-4029).
All component replacements are SUBJECT TO TEARDOWN AND ANALYSIS.
Potential chargebacks can often be avoided by using the 70% Engine Cost Analysis
Worksheet.
A CLAIM REJECTION OR CHARGEBACK MAY OCCUR WHEN THE COST OF
REPAIR WAS LESS THAN 70% OF THE ASSEMBLY REPLACEMENT EXPENSE.
Note that Engine component replacements authorized by Business Center personnel are
subject to this same analysis and chargeback.
Refer to page ARG25 in the GWA Warranty Administration Manual for more details.
70% Engine Cost Analysis Worksheet Not For PSCII Use
Part Name Part # Dealer Cost LOP Description LOP # Labor Hours
Cost Of Parts Labor Hours
40% Mark-up (.40) X Hourly Rate Repair
Total Parts $ + Total Labor $ = Total $
If the Repair Total exceeds the 70 % Repair Allowance, the Assembly should be replaced.
TECHNICIAN SIGNATURE: PRINT NAME:
Replacement of Assembly Information (If Applicable)
Repair of Assembly Information
Part Name Part # Dealer Cost LOP Description LOP # Labor Hours
Cost Of Parts Labor Hours
40% Mark-up (.40) X Hourly Rate Replace
Total Parts $ + Total Labor $ = Total $
(X.70) 70%
Repair Allowance
Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone # & Fax #:
Last 8 Digits of VIN:
Mileage:
5.9L Cummins Diesel
Fuel Diagnostic Worksheet Dealer Name:
Dealer Code:
Date:
RO #:
Repeat Complaint: Yes No
Complaint:
Contact Name:
Phone #:
Last 8 Digits of VIN:
Mileage: