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Test E: Electronic Pressure Control Solenoid

WARNING: This page is about a different variant/trim than selected.

  1. Electronic Diagnostics

    Ensure transaxle harness connector is in acceptable condition. Repair as necessary. Ensure transaxle harness connector is fully seated. Connect NGS tester or equivalent to DLC. Perform KEY ON ENGINE OFF (KOEO) SELF-TEST  until continuous memory code(s) have been displayed. See QUICK TEST  under DIAGNOSIS & TESTING. Enter output test mode. See ADDITIONAL SYSTEM FUNCTIONS  under DIAGNOSIS & TESTING. Select ALL ON mode. Push START to turn outputs on. Push STOP to turn outputs off. If vehicle enters output test mode, remain in output test mode and go to next step. If vehicle will not enter output test mode, see SCAN TOOL UNABLE TO COMMUNICATE  under DIAGNOSIS & TESTING.

  2. Check Electrical Signal Operation

    Turn ignition switch to OFF position. Disconnect transaxle harness connector. Inspect condition of connector and repair as needed. Turn ignition switch to ON position. Using DVOM, connect positive lead to transaxle harness connector terminal No. 7 and negative lead to terminal No. 10. See Figure . While monitoring DVOM, press START and STOP to cycle EPC solenoid output on and off. If voltage changes at least .5 volt, go to step  5 . If voltage is unaffected, go to next step.

  3. Check Continuity Of EPC Solenoid Signal & VPWR Harness Circuits

    Ensure ignition switch is turned to OFF position. Disconnect PCM 104-pin connector, and inspect it for damaged terminals, corrosion and loose wires. Repair as necessary. Install breakout box, leaving PCM disconnected. Measure and record resistance between breakout box test pin No. 71 and transaxle harness connector terminal No. 7. Measure and record resistance between breakout box test pin No. 81 and transaxle harness connector terminal No. 10. If each resistance is less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open circuit. Connect all components. Disconnect breakout box and repeat QUICK TEST  under DIAGNOSIS & TESTING.

  4. Check EPC Solenoid Harness For Shorts To Power & Ground

    Measure and record resistance between breakout box test pins No. 71 and 81. Measure and record resistance between breakout box test pin No. 81 and test pins No. 24, 25, 51, 76, 77, 91 and 103. If each resistance is more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, repair short circuit. Connect all components. Disconnect breakout box and repeat QUICK TEST  under DIAGNOSIS & TESTING.

  5. EPC Solenoid Functional Test

    Connect PCM 104-pin connector. Disconnect transaxle harness connector. Connect transmission tester. Connect line pressure gauge. See HYDRAULIC PRESSURE TESTS under PERFORMANCE TESTS in FORD AX4S OVERHAUL article. Set Bench/Drive switch to DRIVE position. Set gear select switch to "1" position. Perform EPC solenoid function test. See tester instructions. Observe line pressure on gauge while depressing EPC switch with KOER. EPC solenoid should activate (Green LED) and line pressure should drop when EPC solenoid switch is depressed. If EPC solenoid operates correctly (Green LED), replace PCM. Inspect PCM power relay. Repair as necessary. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under DIAGNOSIS & TESTING. Repeat QUICK TEST  under DIAGNOSIS & TESTING. If LED turns Red (shorted to VPWR) or if EPC solenoid does not activate LED (shorted to ground or open circuit), go to next step. If solenoid is not operating, go to next step.

  6. Check Resistance Of EPC Solenoid

    Ensure transmission tester power is off. Connect ohmmeter to EPC solenoid jacks. If resistance is 3.23-5.50 ohms, go to next step. If resistance is not 3.23-5.50 ohms, go to step  8 .

  7. Check EPC Solenoid For Short To Ground

    Check continuity between BAT (-) jack and EPC solenoid jacks of transmission tester. If continuity exists, go to next step. If continuity does not exist, see SYMPTOM DIAGNOSIS under TROUBLE SHOOTING in FORD AX4S OVERHAUL article.

  8. Internal Electronic Diagnostics

    Drain transaxle fluid. Remove transaxle side cover. Inspect all internal harness connectors. Ensure all connectors are fully connected and not damaged. Repair as needed. If all connectors are okay, go to next step. Install all components in reverse order of disassembly. Fill transaxle with fluid. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under DIAGNOSIS & TESTING. Repeat QUICK TEST  under DIAGNOSIS & TESTING.

  9. Check Internal Harness Continuity

    Disconnect internal harness from EPC solenoid. Measure and record resistance between EPC jack on transmission tester and EPC solenoid connector Blue wire. Measure and record resistance between VPWR jack on transmission tester and EPC solenoid connector Green wire. If resistance readings are less than .5 ohm, go to next step. If any resistance reading is .5 ohm or more, replace internal harness. Go to step  12 .

  10. Check Internal Harness For Shorts To Ground

    Using transmission tester, check continuity between each EPC solenoid connector terminal and BAT (-) terminal of transmission tester. If continuity does not exist in either circuit, go to next step. If continuity exists in any circuit, replace internal harness. Go to next step.

  11. Check EPC Solenoid Resistance

    Using ohmmeter, measure resistance between EPC solenoid terminals. If resistance is 3.23-5.50 ohms, go to next step. If resistance is not 3.23-5.50 ohms, replace EPC solenoid. Install all components in reverse order of disassembly. Fill transaxle with fluid. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under DIAGNOSIS & TESTING. Repeat QUICK TEST  under DIAGNOSIS & TESTING.

  12. Check EPC Solenoid For Short To Ground

    Using ohmmeter, check continuity between each EPC solenoid terminal and ground. If continuity exists, replace EPC solenoid. Install all components in reverse order of disassembly. Fill transaxle with fluid. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under DIAGNOSIS & TESTING. Repeat QUICK TEST  under DIAGNOSIS & TESTING. If continuity does not exist, install all components in reverse order of disassembly. Fill transaxle with fluid. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  . Repeat QUICK TEST  . See SYMPTOM DIAGNOSIS under TROUBLE SHOOTING in FORD AX4S OVERHAUL article.
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