6F35 (Fwd) Transmission With External Pcm Or TCM

Transmission Inputs 

Transmission Range Sensor - 6F35 uses a Non-contacting Pulse Width Modulated Transmission Range Sensor (TRS) that provides a duty cycle signal for each position. This signal is transmitted at a frequency of 125 Hz. The PCM decodes the duty cycle to determine the driver-selected gear position (Park, Rev, Neutral, OD, 3, 2, 1). This input device is checked for out of range frequency, low duty cycle and high duty cycle input signals. (P0706, P0707, P0708)

Select Shift Transmission (SST) Up/Down 

6F35 is picking up SST for 10 MY. This system has two new PCM inputs, an upshift switch and a downshift switch. The switches are built into the shifter (defined as an H-gate in this implementation):

Courtesy of FORD MOTOR CO.

Both PCM inputs are open when the shifter is on the left hand side. From Drive as the customer moves the shifter to the right both inputs transition from open to closed (the TRS continues to indicate Drive). The control system enters "Grade Assist Mode" (provides more engine braking but still follows an automatic shift schedule) at this point. If the customer never requests a shift the control system will remain in Grade Assist Mode.

The customer requests a shift by pushing the shifter up or down, which opens the appropriate switch. Once the customer requests a shift the control system transitions from Grade Assist Mode to SST. In SST the control system follows the customer's commands except for special conditions (downshifts to the lowest available gear at high pedal, downshifts at low speeds).

Diagnostics monitors for either switch closed in Park, Reverse or Neutral, and a failure will result in non-MIL P0815 (upshift switch error) or P0816 (downshift switch error) fault codes.

If either switch fails open the customer will not be able to enter Grade Mode or SST since both switches must transition from open to closed while in the Drive position to enter SST.

If either switch is detected failed Grade Assist Mode and SST are disabled and the control system defaults to Drive (normal automatic shift schedules).

Speed Sensors 

The Turbine Shaft Speed (TSS) sensor and Output Shaft Speed (OSS) sensor are Hall Effect inputs that are checked for rationality. The vehicle speed signal is provided from the ABS system (if present) to the PCM, or is derived from OSS. If the engine rpm is above the torque converter stall speed and engine load is high, it can be inferred that the vehicle must be moving. If there is insufficient output from the VSS sensor (if present), a malfunction is indicated (P0500). If there is insufficient output from the TSS sensor, a malfunction is indicated (P0715). If there is insufficient output from the OSS sensor, a malfunction is indicated (P0720).

Transmission Fluid Temperature 

6F35 has a feature called "Cold mode" (1st implemented in 5R110W in 2003 MY). If TFT is below -20 deg F, the transmission will limit operation to 1st, 2nd, 3rd, and 4th gears (5th and 6th gears are disabled). Cold mode remains in effect until TFT rises above -20 deg F or vehicle operation (based on shift times or heat generated by driving) indicates that TFT should not be in the cold mode range, at which point normal operation is enabled.

if TFT is failed at start up the transmission will be placed in cold mode and remain there until TFT is no longer failed and above -20 deg F or the vehicle operating conditions listed above trigger an exit from cold mode.

Once out of cold mode a TFT failure will not trigger cold mode (can only go into cold mode once/power-up); this mode is the same as implemented on 5R110W in 2003.5 MY.

TFT is monitored for circuit faults (P0712, P0713) and in-range failures (P0711)

For this reason all TFT diagnostics illuminate the MIL on 6F35.

Transmission Outputs 

Shift Solenoids 

6F has 5 shift solenoids:

1. SSA - a Variable Force Solenoid (VFS) that controls CB1234 (a brake clutch, grounds an element to the case, that is on in 1st, 2nd, 3rd and 4th gear)
2. SSB - a VFS that controls C35R (a rotating clutch on in 3rd, 5th and Reverse)
3. SSC - a VFS that controls CB26 (a brake clutch on in 2nd and 6th gear)
4. SSD - a VFS that controls either CBLR (a brake clutch on in 1st gear with engine braking and Reverse) or C456 (a rotating clutch on in 4th, 5th and 6th gear)
5. SSE - an On/Off solenoid that controls the multiplexing of SSD between CBLR and C456.

Output circuits are checked for opens, short to ground and short to power faults (codes listed in that order) by the PCM by monitoring the status of a feedback circuit from the output driver (SSA P0750, P0973, P0974; SSB P0755, P0976, P0977; SSC P0760, P0979, P0980; SSD P0765, P0982, P0983; SSE P0770).

The shift solenoids are also functional tested for stuck on and stuck off failures. This is determined by vehicle inputs such as gear command, and achieved gear (based on turbine and output speed). In general the shift solenoid malfunction codes actually cover the entire clutch system (solenoid, valves, and the clutch itself since using ratio there is no way to isolate the solenoid from the rest of the clutch system), BUT due to the hydraulic controls arrangement on 6F it is possible to isolate two specific solenoid failures from clutch system faults:

1. SSB stuck on from C35R stuck on - due to hydraulic interlock between CBLR and C35R we can isolate SSB stuck on from C35R by turning SSE on in 1st gear without engine braking (get 1st if SSB stuck on, get 3rd if C35R is stuck on)
2. SSD stuck off. Since SSD is multiplexed (controls both CBLR and C456) we can isolate CBLR stuck off and C456 stuck off from SSD stuck off since the latter impacts both clutch systems.

For SSA thru SSD Diagnostics will isolate the fault into clutch functionally (non-electrical) failed off (SSA P0751, SSB P0756, SSC P0761, SSD P0766) and clutch functionally failed on (SSA: P0752, SSB: P0757, SSC: P0762, SSD: P0767). The On/Off solenoid (SSE) controls the multiplexing of SSD between CBLR and C456 clutches. Using ratio we can determine if the multiplex valve is in the wrong position, but cannot be sure if the failure is due to the solenoid or a stuck valve. The multiplex valve is tested for stuck in default position (P0771, includes SSE stuck off) and stuck in spring compressed position (P0772, includes SSE stuck on) failures.

Gear ratio errors: 

If ratio errors are detected that do not match an expected pattern for a failed solenoid then gear ratio error fault codes (1st gear - P0731, 2nd gear - P0732, 3rd gear - P0733, 4th gear - P0734, 5th gear - P0735 or 6th gear - P0729) will be stored.

Torque Converter Clutch 

The Torque Converter Clutch (TCC) solenoid is a Variable Force Solenoid. TCC solenoid circuit is checked electrically for open, short to ground and short to power circuit faults internally in the PCM by monitoring the status of a feedback circuit from the output driver (P0740, P0742, P0744).

The TCC solenoid is checked functionally by evaluating torque converter slip under steady state conditions when the torque converter is fully applied. If the slip exceeds the malfunction thresholds when the TCC is commanded on, a TCC malfunction is indicated (P0741).

For 6F35 the TCC is controlled by a 2 valve system - TCC reg apply and TCC control valve. Normally the TCC VFS controls the positions of these valves - turning on the TCC VFS moves both valves from the release to the apply position. If the TCC control valve sticks in the apply position then there will be no flow thru the TCC (both apply and release sides exhausted) when commanded open, which will cause the converter to overheat.

A method to detect this failure was designed into the hardware - SSE pressure is routed to the TCC reg apply valve (SSE has no effect on TCC control valve). In 3rd gear or higher if TCC is open SSE can be turned on, moving the TCC reg apply valve to the apply position. If the TCC control valve is in the wrong (apply) position this will cause the TCC to apply. If the TCC applies when SSE is turned on in 3rd, 4th, 5th or 6th gear while TCC is commanded open (TCC VFS pressure low) the failure will be detected, a P2783 DTC fault code stored. Even though this test only detects failures of the control valve, the FMEM actions alter the shift and TCC lock schedules to keep the TCC applied as much as possible, so this failure has been made MIL.

Electronic Pressure Control 

The EPC solenoid is a variable force solenoid that controls line pressure in the transmission. The EPC solenoid has a feedback circuit in the PCM that monitors EPC current. If the current indicates a short to ground (low pressure), a high side switch will be opened. This switch removes power from all 6 VFSs and the on/off shift solenoid, providing Park, Reverse, Neutral, and 5M (in all forward ranges) with maximum line pressure based on manual lever position. This solenoid is tested for open (P0960), short to ground (P0962), and short to power (P0963) malfunctions.

High Side Switch 

6F35 has a high side switch that can be used to remove power from all 7 solenoids simultaneously. If the high side switch is opened, all 7 solenoids will be electrically off, providing Park, Reverse, Neutral, and 5M (in all forward ranges) with maximum line pressure based on manual lever position. The switch is tested for open faults (switch failed closed will provide normal control). If the switch fails, a P0657 fault code will be stored.

ADLER (chip that controls all 7 solenoids) diagnostics:

The solenoids are controlled by an ADLER chip. The main micro sends commanded solenoid states to the ADLER, and receives back solenoid circuit fault information.

If communication with the ADLER is lost a P1636 fault code will be stored. If this failure is detected the states of the solenoids are unknown, so the control system will open the high side switch (removes power from all the solenoids), providing P, R, N and 5M with open TCC and max line pressure.

TRID Block 

The TRID block is a portion of flash memory that contains solenoid characterization data tailored to the specific transmission to improve pressure accuracy.

The TRID block is monitored for two failures:

• TRID block checksum error / incorrect version of the TRID (P163E)
• TRID block not programmed (P163F)

If the TRID block is unavailable FMEM action limits operation to 1st and 3rd gear until the issue is correct.

Transmission Control Module (TCM only present on) 

The TCM has the same module diagnostics as a PCM - see miscellaneous CPU tests.

CAN Communications Error

The TCM receives information from the ECM via the high speed CAN network. If the CAN link or network fails, the TCM no longer has torque or engine speed information available. The TCM will store a U0073 fault code and will illuminate the MIL immediately (missing engine speed) if the CAN Bus is off. The TCM will store a U0100 fault code and will illuminate the MIL immediately (missing engine speed) if it stops receiving CAN messages from the ECM. A U0401 fault codes will be stored if the ECM sends invalid/faulted information for the following CAN message items: engine torque, pedal position.

TCM voltage 

If the system voltage at the TCM is outside of the specified 9 to 16 volt range, a fault will be stored (P0882, P0883).

Auxiliary Transmission Fluid Pump (Stop Start Applications) 

For Stop Start applications, an Electronic Auxiliary Transmission Oil Pump (ePump) has been added to the transmission to allow clutches to stay engaged when the engine stops. The auxiliary pump is an electric external pump bolted to the transmission case. This allows quicker response on restarts since the transmission is ready before the main pump begins outputting pressure.

Item	Part Number	Description
1	7005	Transmission case
2	7A136	Transmission fluid auxiliary pump-to-transmission case gasket
3	7B086	Transmission fluid auxiliary pump
4	W715302	Transmission fluid auxiliary pump-to-transmission case bolt (3 required)

The Electronic Auxiliary Transmission Oil Pump is a "smart" device - the PCM or TCM communicates with the pump via 2 Pulse Width Modulated (PWM) hardwires:

• PCM or TCM outputs a commanded pump speed to the pump using a PWM signal:

  Duty Cycle	RPM of Motor
  0 - 9.9%	Reserved for diagnostics
  10 - 19.9%	Off state
  20 - 22.9%	100 rpm (pre-shipment supplier test)
  23 - 90%	937.14 rpm to 4, 000 rpm (linear range of operation)
  90.1 - 100%	Reserved for diagnostics

• The pump outputs the fault status of the pump to the PCM or TCM using a PWM signal. The fault status is used to stores the appropriate DTC in the PCM or TCM.

  Duty Cycle	Indicated Operating Condition	DTC	Definition
  0-10%	Out of Range low	P0C2D	Electric Transmission Fluid Pump Control Module Feedback Signal Low
  10-15%	Under Current, Correct Speed	P0C27	Electric/Auxiliary Transmission Fluid Pump "A" Motor Current Low
  20-25%	Over Current, Correct Speed	P0C28	Electric/Auxiliary Transmission Fluid Pump "A" Motor Current High
  30-34%	Over Temperature	P175A	Transmission Fluid Over Temperature Condition - Electric Transmission Fluid Pump Disabled
  35-40%	Stalled	P0C2A	Electric/Auxiliary Transmission Fluid Pump "A" Motor Stalled
  45-50%	Correct Current and Speed	n/a
  55-60%	Over Speed, Correct Current	P0B0D	Electric/Auxiliary Transmission Fluid Pump Motor Control Module
  65-70%	Under Speed, Correct Current	P0B0D	Electric/Auxiliary Transmission Fluid Pump Motor Control Module
  75-80%	Current and Speed out of Range	P0C29	Electric/Auxiliary Transmission Fluid Pump "A" Driver Circuit Performance
  85-90%	No Command Signal Received from PCM	P2796	Electric Transmission Fluid Pump Control Circuit
  90-100%	Out of range high	P0C2E	Electric Transmission Fluid Pump Control Module Feedback Signal High
  Frequency out of range or duty cycle between valid ranges	Signal should be 120 Hz +/- 20 Hz. Should not see in-range but unused duty cycle values	P0C2C	Electric Transmission Fluid Pump Control Module Feedback Signal Range/Performance

Failures of the pump take the Stop Start system out of operation - if stopped the engine will restart, then will no longer stop for the remainder of the current drive cycle.