diagnostic check sheets.pdf

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


Dealer Name:

Dealer Code:

Date of Complaint:

RO #:


Vehicle Model:

Vehicle Build Date:

Transmission Software Level:

Transmission Model No.: 1090 (e.g. 1090 010 020)

Contact Name:

Phone # & Fax #:


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


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



Always

Intermittent

Trans Hot

Trans Cold

At Idle

At _____ MPH


Part Throttle

Wide Open Throttle

Braking

Unable To Duplicate

Cornering

With A/C On

High Altitude


F)


F)

While Towing


Other:




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



Other Concerns:

Factory Fill Lubricant: Yes No If No, what has been installed?


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


electrical draw add-ons, etc.): Yes No

If Yes, please describe:




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 #:


Complaint:

Contact Name:

Phone # & Fax #:


Mileage:

Always

Intermittent

Trans Hot

Trans Cold

At Idle

At _____ MPH

Category Does Not

Occur Slips

Late or


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


Part Throttle

Wide Open Throttle

Braking

Unable To Duplicate

Cornering

With A/C On

High Altitude


F)


F)

While Towing


Gear Selector Position



Noise Concern:

Buzz

Whine

Clunk

Rattle

Moving

Still

In Gear

Out of Gear

Braking



Wet

Dry

Smooth

Bumpy

Flat

Dirt

Cement

Stop & Go

Light Traffic

Heavy Traffic

Twisty

Pot Holes

Gravel

Black Top



CVT Transmission Diagnostic Worksheet

Other:


Other Concerns:

Trans Fluid Level: Correct Low High Mixed with ATF/Coolant? Yes No


DTC’s Before Repair / Replace: Software PART #:

PCM ABS

TCM Other

TCM Part #: Reflashed? Yes No New Part #:







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 #:


Complaint:

Contact Name:

Phone # & Fax #:


Mileage:

HEV Transmission Diagnostic Worksheet

Category Does Not

Occur Slips

Late or


Engagement Into Drive

Engagement Into Reverse

Light Acceleration

Heavy Acceleration

Constant Speed (Indicate)

Coasting

Heavy Braking

Light Braking

Kickdown / WOT Accel.


Always

Intermittent

Trans Hot

Trans Cold

Braking

Cornering

Electric

At Idle

Part Throttle

Wide Open Throttle

While Towing

Tow Haul Active


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 ____


F)


F)


Fuel Level______

Fuel Saver On (MDS Active)

During Engine Auto Stop

During Engine Auto Start

During Launch From Stop

At ______ MPH

High Altitude

Other



Noise Concern:

Buzz

Whine

Clunk

Rattle

Moving

Still

In Gear

Out of Gear

Braking

Coast Down (Regen.)



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 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 #:


Complaint:

Contact Name:

Phone # & Fax #:


Mileage:

Check Engine Light Diagnostic Worksheet

DISPATCH TO A LEVEL 3 OR 4 TRAINED TECHNICIAN

TECHNICIAN NAME & ID:

Dealer Name:

Dealer Code:

Date:

RO #:


Complaint:

Contact Name:

Phone # & Fax #:


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



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 #:


Complaint:

OEM: “TPK” # (On Case) Reman: (On Reman Tag) Serial # Build Date

Contact Name:

Phone # & Fax #:


Mileage:


Transmission Assembly Trans. Replace

Automatic Trans Fluid Reverse Flush

70 % Teardown LOP

* 4X4

* Skid Plate

* Dual Exhaust

* Two Piece Prop

* AWD


40% Mark-up (.40) X Hourly Rate Replace


(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



40% Mark-up (.40) X Hourly Rate Repair


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



40% Mark-up (.40) X Hourly Rate Replace


(X.70) 70%

Repair Allowance

Dealer Name:

Dealer Code:

Date:

RO #:


Complaint:

Contact Name:

Phone # & Fax #:


Mileage:

5.9L Cummins Diesel

Fuel Diagnostic Worksheet Dealer Name:

Dealer Code:

Date:

RO #:


Complaint:

Contact Name:

Phone #:


Mileage:

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