ffd serive manual

FFD-Ricardo, Inc.

12886 Westmore, Livonia, Michigan USA 48150

F116 Automatic Transmission

Service Information

DESCRIPTION

SPECIFICATIONS

GENERAL Transaxle Identification

Preliminary Checking Procedure/Checklist

Transaxle Fluid Level Checking Procedure

Line Pressure Check

MAINTENANCE Transaxle Fluid Change

Final Drive Fluid Change

ADJUSTMENTS Shift Control Cable

Neutral Start Switch

SERVICE PROCEDURES Drive Function Check Procedure/Diagnosis

Fluid Leak Diagnosis and Repair

Electrical Checks

Utilization of Ferrari SD1 Test Tool

Transmission or TCU Removal

Packaging for Shipment to FFD

FFD-Ricardo, Inc.



Service Information

DESCRIPTION The F116 automatic transaxle and electronic controller (TCU) are designed and built by FFD-

Ricardo in Livonia, Michigan, USA. The transaxle configuration is longitudinal, rear drive with

power input via a solid driveshaft in a torque tube. The transmission is derived from a GM 4T80E.

The transmission is a nonsynchronous, 4 speed automatic, controlled electronically by the TCU.

The transmission layout is torque converter/final drive/transmission. The 265 mm converter, which

includes a converter clutch, is connected to the transmission thru the hollow final drive pinon. The

final drive is a hypoid ring and pinion running thru a ZF limited slip differential. The transmission is

comprised of two planetary gearsets, 5 clutches, 2 bands, 2 sprags, and one roller clutch. The two-

stage main pump is supplied by scavenge pumps that allow a dry sump system to be utilized.

The transmission control system is a combination of hydraulics and electronics. Line pressure is

controlled via a variable force solenoid. Shifts are commanded via two on/off solenoids. The TCC

is modulated via a PWM solenoid. Sensors include input/output speed, temperature, and four

pressures. Torque management is implemented thru CAN communication with the Bosch Motronic

system to allow high speed/high torque operation. The electronic controls include OBD II

compatibility. A separate transmission fault lamp is provided to assist in service diagnosis.

FFD-Ricardo, Inc.



Service Information

SPECIFICATIONS Drive Configuration Longitudinal Rear Wheel Drive Transaxle Weight 176 kg wet Transaxle Dimensions LWH 1150 x 500 x 380 mm Gear Ratios 1st 2.960 2nd 1.626 3rd 1.000 4th 0.681 Rev 2.130 Final Drive Type/Ratio Hypoid Ring & Pinion/3.538 Converter 265mm, 135K, 1.95 TR Max Shift Speeds 1-2 6800 rpm (all torque managed) 2-3 6800 rpm 3-4 6000 rpm Transaxle Fluid Type/Quantity Transmission - Texaco Dexron III ATF/12.0 L Final Drive - Pakelo 75W-140 EP synthetic/2.2 L Electronics 2 On/Off Shift Solenoids Line Pressure Variable Force Solenoid Torque Converter Clutch (TCC) PWM Solenoid Input/Output Speed Sensors Pressure Switch Manifold (4 pressure switches) Transmission Temperature Sensor Transmission Controller FFD - Ricardo Inc. 16 bit microprocessor Vehicle Networks CAN ISO 9141-5 and 9141-2

FFD-Ricardo, Inc.



Service Information

GENERAL Transaxle Identification

Preliminary Checking Procedure


Line Pressure Check

Transaxle Identification

The transaxle is identified by a nameplate secured to the transmission end cover at the upper right

hand corner (visible thru trunk cover). In addition the transaxle serial number (last four digits only)

is stamped onto the RH transaxle mounting pad. All primary castings are etched with their own

serial numbers which must not be confused with the transaxle assembly serial number.

A sample transaxle nameplate is shown below. The “PART NO” is the FFD-Ricardo part number

for the transaxle, followed by a slash and the Ferrari part number. The “SERIAL NO” is the

individual transaxle assembly’s unique number. The “DATE” is the date that the transaxle was

built.

PreliminaryChecking Procedure

Before performing any work on an F116 automatic transmission, proper checking procedures must

be followed. The best place to diagnose the transmission problem is with the transmission in the

vehicle. Since many technicians are unfamiliar with automatic transmissions, following is a chart

that must be completed prior to calling FFD-Ricardo for any repair authorization.

FFD-Ricardo, Inc.


Ferrari F116 Automatic Transmission

Preliminary Checking Procedure - Service Dept FAX# (313) 522-9923 Transmission Serial #

Model Year/VIN

Odometer

Owner Complaint

Has transmission ever been repaired?

Did fault suddenly occur?

Is fault constant or intermittent?

Is fault better/worse at times?

Technician Evaluation Stopped - engine running

Is “Transmission Fault Lamp” illuminated? ________

If “yes”, when did it first come on? ______________________________________

* Proceed to “DRIVE FUNCTION CHECK PROCEDURE” with Ferrari Electrical Test Tool SD-1.

Does shifter move smoothly?Aligned? Does Park engage properly?__________________________

Is transmission oil level OK? __________________________

Does transaxle have any oil leaks? ____________________________________________________

Check for Noise at test conditions below?

idle 2000 rpm (test for 2 sec max)

Park

Reverse

Neutral

Drive 4

Drive 3

Drive 2

Drive 1

Preliminary Road Test (w/o Test Tool) Can owner’s complaint be verified? ____________________________________________

__________________________________________________________________________

Check: Does engine run satisfactory? __________________________________________________

Shift Quality OK all throttles? __________________________________________________

Shifts On-Time (shifts push out with throttle)? _____________________________________

Noise? or Vibration?__________________________________________________________

Chuggle (w/TCC engaged) ____________________________________________________

FFD-Ricardo, Inc.



Remove access panel in vehicle trunk

Remove dipstick by twisting a quarter turn counterclockwise

Wipe the stick clean with a lint free towel

With vehicle in Park and parking brake set, on a level area, start the engine

After idling approximately one minute, check fluid level using the dipstick

Clean and reinsert to verify the reading

If not oil appears on the stick, immediately add Dexron III ATF in 0.5 liter increments

Correct level is dependent on temperature as marked on the dipstick:

(Note: treat the cold level as an indicator only, hot level is most important)

Nominal “cold” is defined by oil temperatures between 21 and 32 C

Nominal “hot” is defined by oil temperatures between 82 and 93 C

Before adding oil to a “cold” transmission, or following seasonal vehicle storage:

Perform a general drive evaluation as described in section ____. item 1.3

Check the level per the aforemention method using the “hot” dipstick reference level

FFD-Ricardo, Inc.


Line Pressure Check

Transmission line pressure is controlled by the TCU. Line pressure provides an indication of

electronic and hydraulic system function. Testing line pressure is the first step in properly

diagnosing a transmission driveability fault. Note that line pressure control is a complex function,

not directly linked to throttle position or engine vacuum as in the past.

Attach the Line Pressure Gage

The engine must be OFF

Prepare a 0 - 2000 kPa gage on a 2 meter flexible hose

The hose must terminate in a 1/4” NPT male fitting

Remove the line pressure plug from the bottom, center of the case cover

Note - this must be substituted quickly for the gage assembly (fluid will drain)

Start the Engine in Park

Set the parking brake

Check for leaks

Record the line pressure at idle in Park

With an assistant, hold the vehicle service brake and shift to reverse

Record the line pressure - line should increase as shown below in the graph

Briefly, 2 seconds maximum, increase engine speed to 2000 rpm

Record line pressure

Repeat in Drive range

Provide this information to the Service Advisor

Remove Line Pressure Gage

Reinstall pipe plug in the case cover with suitable sealant to 15 ft-lb

FFD-Ricardo, Inc.



Service Information

MAINTENANCE Transaxle Fluid Change


Transaxle Fluid Change

The transaxle fluid and pump scavenge screens must be renewed at 40000 km intervals. The

replacement fluid must conform to the Dexron III standard for automatic transmission use. The

preferred fluid is Texaco ATF (Automatic Transmission Fluid).

Before changing ATF, always check the fluid level and condition. These observations may provide

direction for other service actions that may be required.

Raise vehicle on a hoist

Remove rear underbody cover to access transaxle

Remove rear structural crossmember

Place drain pan beneath

Remove 1/8-27 NPT pipe plug in case cover to drain end cover (see Figure)

Remove 1/8-27 NPT pipe plug in transaxle bottom plate

Remove bottom plate (24) M6-1.0 x 25 hex head bolts

Remove two scavenge screens and two seals in case

Check scavenge screen integrity - note condition

Clean bottom plate - note quantity/type of debris

Clean the magnet at rear of transmission

Reinstall seals in case first, then the new scavenge screens

Reinstall bottom plate w/new gasket and lock washers

Initially install all bolts finger tight

Tighten the two corner bolts to 2 N-m (pan has one slotted, one small)

Tighten remaing bolts to 2 N-m

Torque bolts to 11 N-m

Reinstall both drain plugs with Loctite 565, tighten to 11 N-m

Initially refill transmission w/6 liters of ATF

With vehicle in Park and parking brake set, start the engine

After running one minute, check fluid level

Add more ATF as required for proper setting

Check drain plugs and bottom plate for leaks

Reinstall access cover in trunk and underbody cover

FFD-Ricardo, Inc.



Service Information

MAINTENANCE


The final drive fluid must be renewed at 20000 km intervals maximum. If the engine oil is serviced

more frequently, the final drive fluid should also be changed at that time. The replacement fluid

must conform to the 75W-140 synthetic EP SAE GP6 fluid specification. The preferred fluid is

Pakelo 75W-140 synthetic EP.

Raise vehicle on a hoist

Remove rear underbody cover to access transaxle

Place drain pan beneath

Remove final drive air deflector (4) M6-1.0 x 10 hex head bolts

Remove plug from bottom of differential case to drain

Remove pipe plug in differential case sidecover

Reinstall drain plug with Loctite 565, tighten to 11 N-m

Refill final drive thru side plug hole with 2.2 liters of fluid

Reinstall drain sidecover plug with Loctite 565, tighten to 11 N-m

Road test vehicle for 10 - 15 km

Check for leaks

Reinstall air deflector and underbody cover

FFD-Ricardo, Inc.



Service Information

ADJUSTMENTS Shift Control Cable


Shift Control Cable

Adjust shift control cable per Chassis Service Procedure.


The neutral start safety switch must be properly adjusted to allow the engine to start in Park or

Neutral range.

Place vehicle in Park, ignition on, engine off, parking brake set

Remove access panel in vehicle trunk

Unplug vehicle harness plug from neutral start switch on transmission manual shaft

Check electrical continuity between pins as shown

If OK, select Neutral and check again for continuity

If no continuity, switch must be rotated

Note whether the alignment notches coincide

Loosen the two 13mm head bolts

Initially align the notches (in Neutral)

Twist the switch to achieve continuity

Secure the bolts to 11 N-m

Check Park range, if OK plug the harness back into the switch

Insure that the engine starts in both Park and Neutral

Reinstall access panel

FFD-Ricardo, Inc.



Service Information

SERVICE PROCEDURES Static Function Check Procedure

Drive Function Check Procedure

Verify Vehicle Hardware Interface

Electrical Checks

Fluid Leak Diagnosis and Repair

Transmission or TCU Removal

Packaging for Shipment to FFD

STATIC FUNCTION CHECK PROCEDURE

The purpose procedure is to verify the operation of the automatic transaxle system and diagnose

specific functional deficiencies.

This procedure is designed to function each of the components in the electrohydraulic control system

(sensors, solenoids, TCU, and hydraulic circuits) to insure correct operation before releasing the

vehicle to the customer.

The communication protocol between the Transmission Control Unit (TCU) and the Ferrari SD 1test

tool system is per ISO 9141-5.

The SD 1 system has the ability to communicate with the TCU to a) read specific address locations

containing error codes, and learned throttle value, b) clear error codes and learned throttle value,

and c) monitor various transaxle related parameters. Reference “Utilization of Test Tool” section

for specific installation and operating instructions.

Reading and Clearing Fault Codes Turn on the ignition. The Transmission Fault Lamp (TFL) illuminates for approximately two

seconds to verify lamp function and inform the driver that the TCU is operational. The TFL will

remain illuminated when an active fault is detected. Using the Ferrari SD 1 test tool, read the

existing fault codes. The tool provides an option , through the use of a specified menu, to clear the

existing faults (and full throttle learn) in order to begin the diagnostic process from a known

condition. Omit this step to retain the stored fault codes.

If the TFL remains illuminated after the fault clearing procedure is performed, a problem at the

transmission or the TCU is most probable. Reference the transaxle system wiring diagnosis and

repair instructions in the “Electrical Checks” section.

FFD-Ricardo, Inc.



Service Information

STATIC FUNCTION CHECK PROCEDURE continued

Since THROTTLE is a critical parameter for transmission control, it is necessary for the TCU to

learn the total range in each vehicle in order to apply accurate scaling. The throttle signal is

communicated to the TCU by the Bosch Motronic via the CAN bus. Zero throttle is learned and

adjusted in the Motronic, however the full throttle value must be learned and stored by the TCU after

performing the fault clearing procedure described above. Reference Section 1.2 below for specific

instructions.

1.0 Using the Ferrari SD 1 System to Verify System Function - Static Tests Enter the monitor mode of the test tool and check the parameters listed below during the specified

maneuvers. Record any faults generated during any maneuver.

1.1 - Checking the Main Transmission Electrical Connection.

**With the Ignition ON, engine not running, and throttle closed:

SUPPLY VOLTAGE - The supply volts to the TCU. A range of 9-14 volts is normal.

ENGINE RPM - Engine speed should read zero.

INPUT RPM and OUTPUT RPM - Input and output speeds should read <100 rev/min.

GEARLEVER - With engine OFF the internal gearlever pressure switch should read 2 (2nd).

COMMANDED GEAR - Commanded gear should also read 2.

TRANSMISSION TEMP. - The typical cold start range for a vehicle parked in a factory or

garage should be 10-40 C. Normal running operating range is

70-110C.

THROTTLE - Zero is the expected value.

S3 DUTY - The line pressure solenoid current should be within the range of

950-1050 mA.

FFD-Ricardo, Inc.



Service Information


1.2 - Learning Full Throttle and Checking Solenoid #3.

**Slowly push the accelerator pedal to the full open position, hold for at least 5 seconds, and return.

THROTTLE - The throttle reading should ramp from zero to a maximum of 100%

and return to zero.

S3 DUTY - Solenoid current should ramp according to throttle from approximately 1000 mA to 600

mA and return to 1000 mA.

1.3 - Checking the Oil level, Internal Gearlever Pressure Switch, and System Wiring.

**With the gearlever in Park position, start the engine.

ENGINE RPM - Engine idle speed should correspond with the dash tachometer. A typical

range is 700-1100 rpm.

INPUT RPM - Input speed should become equal to engine speed in Park.

GEARLEVER - Gearlever status should update to 5 (P/N).

COMMANDED GEAR - Commanded gear status should update to 5 (P/N).

**Check the Automatic Transmission Fluid (ATF) level per procedure.

**Depress the brake and select Reverse.

INPUT RPM - Input speed should ramp down to < 100 rev/min.

GEARLEVER - Gearlever status should update to read 6 (R).

COMMANDED GEAR - Commanded gear status should update to 6 (R).

FFD-Ricardo, Inc.



Service Information


**With the brake depressed, select Neutral.

INPUT RPM - Input speed should ramp up to equal engine speed.

GEARLEVER - Gearlever status should update to read 5 (P/N).

COMMANDED GEAR - Commanded gear status should update to 5 (P/N).

**With the brake depressed, select Drive.

INPUT RPM - Input speed should ramp down to <100 rev/min.

GEARLEVER - Gearlever status should update to read 4 (D4).

COMMANDED GEAR - Commanded gear status should update to 1 (1st).

**With the brake depressed, select D3.






FFD-Ricardo, Inc.



Service Information

DRIVE FUNCTION CHECK PROCEDURE

2.0 - Using the Ferrari SD 1 System to Verify System Function - Dynamic Tests Use the monitor mode of the test tool to check the parameters listed below during the specified

maneuvers.

Note that automatic gear changes do not directly follow the gearlever input, but are also based upon

throttle versus vehicle speed maps programmed in the TCU.

2.1 - Checking the Speed Sensors, Shift Solenoids, Communication with the Motronic, and Internal

Hydraulics.

**Start the engine, depress the brake, and select Drive. Release the brake and accelerate at light

throttle (10-15 %).

THROTTLE = 10-15% constant

GEARLEVER = 4 (D4)

630 < OUTPUT RPM > 1120, COMMANDED GEAR updates 1>>2


1550 < OUTPUT RPM > 2300, S4 DUTY ramps 0>>1000


NOTE: 2875 RPM = 100 KPH

**Hold THROTTLE constant for at least 5 seconds following the 3>>4 gear change.

FFD-Ricardo, Inc.



Service Information

DRIVE FUNCTION CHECK PROCEDURE continued

2.2 - Clutch Capacity and Temperature Sensor Checks.

2.2.1 - 4th gear and converter clutch capacity checks.

**Adjust the throttle opening to maintain a constant road speed of 100-120 km/hr. Hold this

constant cruising speed for at least 30 seconds.

OUTPUT RPM = 2875-3450

THROTTLE = approximately 1-5%

COMMANDED GEAR = 4 (4th)

S4 DUTY = 1000 (converter clutch is locked)

TRANS. TEMP. = Transmission oil temperature should increase. Normal

running operating range is 70-110 C.

2.2.2 - 3rd gear and converter clutch capacity checks.

**Close the throttle and select D3. Adjust the throttle opening to maintain a constant road

speed of 100-120 KPH. Hold this constant cruising speed for at least 30 seconds.



GEARLEVER = 3 (D3)

COMMANDED GEAR = 3 (3rd)

S4 DUTY = 1000 (converter clutch is locked)



FFD-Ricardo, Inc.



Service Information


2.2.3 - 2nd gear clutch capacity check.

**Close the throttle and coast down to 70-80 KPH. Select D2. Adjust the throttle opening

to maintain a constant road speed of 70-80 KPH. Hold this constant cruising speed for

approximately 30 seconds.



GEARLEVER = 2 (D2)

COMMANDED GEAR = 2 (2nd)

S4 DUTY = 0 (converter clutch is unlocked)

TRANS. TEMP. = Transmission oil temperature should increase. Normal running

operating range is 70-110 C.

2.2.4 - 1st gear clutch capacity check.

**Close the throttle and coast down to 30-40 KPH. Select D1. Adjust the throttle opening

to maintain a constant road speed of 30-40 KPH. Hold this constant cruising speed for

approximately 30 seconds.



GEARLEVER = 1 (D1)

COMMANDED GEAR = 1 (1st)

S4 DUTY = 0 (converter clutch is unlocked)



FFD-Ricardo, Inc.



Service Information


2.2.5 - Reverse gear clutch capacity check.

**Come to a complete stop. With the brake depressed, select Reverse. Release the brake

and accelerate at light throttle for approximately 10 seconds.

THROTTLE = 0-15% modulated

GEARLEVER = 6 (R)

COMMANDED GEAR = 6 (R)

3.0 - Verify Vehicle Hardware Interfaces - Road Test In order to verify various hardware interface items such as gearlever adjustment, transmission

mounts, axle and torque tube bolt retention, and park engagement, the following tests should be

performed during a vehicle road evaluation.

3.1 - Check Forward Park Engagement

3.1.1 - **Select Drive and allow the vehicle to roll forward on a level area.

**Select Park when output speed exceeds approximately 430 RPM.

The Park mechanism should ratchet until the vehicle is abruptly stopped at a

speed range of 15 to 230 OUTPUT RPM (<8 km/hr).

Note audible interference caused during the abrupt stop or rocking motion.

FFD-Ricardo, Inc.



Service Information

VEHICLE HARDWARE INTERFACE CHECK PROCEDURE continued

3.2 - Checking Reverse Park Engagement

3.2.1 - **Select Reverse and allow the vehicle to roll backward on a level area.

**Select Park when output speed exceeds approximately 430 RPM.

The Park mechanism should ratchet until the vehicle is abruptly stopped at a

speed range of 15 to 230 OUTPUT RPM (<8 km/hr).

Note any audible interference caused during the abrupt stop or rocking motion.

At any point in the test procedure that a fault code is logged, or a specified parameter is found to be

out of range, the functional test is considered failed. The test must therefore be immediately aborted

and the appropriate diagnostic flowchart referenced for repair.

The following is a list of all diagnostic trouble codes and their actions. Reference the appropriate

service instructions as outlined in the “Preliminary Checking Procedure” section.

FFD-Ricardo, Inc.



Service Information

FLUID LEAK DIAGNOSIS AND REPAIR Following is a list of potential external leak sources that could be serviced with the transmission

remaining in the vehicle. Always check the fluid level before addressing the leak in order to

understand the magnitude of the leak. These are the only elements to be serviced.

TRANSMISSION

Bottom Pan Gasket or Drain Plug

Pressure Taps

Manual Shaft Seal

Dipstick

Cooler Fittings

4th Servo Cover

End Cover Seal

FINAL DRIVE

Drain or Fill Plug

Speed Sensor Hole

TCC Circuit Plugs

Axle Seals (complex task)

FFD-Ricardo, Inc.



Service Information

ELECTRICAL CHECKS

The electrical components that can be serviced with the transmission remaining in the vehicle are

limited due to the complexity of the system. Servicing an actuator requires removal of a valve body

which is beyond the scope of field repairs. The electrical components which can be removed and

replaced are listed below.

OUTPUT SPEED SENSOR

Check resistance between two terminals. Specification is 1278 - 1562 ohms.

Check for open circuit between each terminal and the case

If sensor is discrepant, order a new part. Sensor Asm - Vehicle Speed #24204319

MODE SWITCH

Check resistance between

If switch is discrepant, order a new part. Neutral Start/Mode Switch #1994359

FURTHER ELECTRICAL CHECKS

Further electrical checks may be required to properly diagnose a problem. Below is a schematic of

the 14 pin transmission pass-thru connector. Check resistances to this diagram and record. Also

following is a complete wiring diagram, and a description of each sensor and actuator.

FFD-Ricardo, Inc.



Service Information

UTILIZATION OF FERRARI SD1 TEST TOOL

COMPLETE CHECKLIST/CALL RICARDO SERVICE DEPT

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Service Information

TRANSMISSION OR TCU REMOVAL

To remove transmission or TCU from vehicle, please see pages _____ or ______.

PACKAGING FOR SHIPMENT TO FFD

After completing the checklist and contacting the Service Department, it may be necessary to send

the transmission to FFD-Ricardo. Never send a unit without written authorization.

Package Transmission

Drain ATF from transmission by removing plug

Drain fluid from final drive

Insert transmission assembly in a plastic bag

Place in a wooden crate, approx inside dimensions 50 x 22 x 15”

Insure that air deflector brackets are not crushed

Fax shipping information to FFD-Ricardo Service Department

ffd serive manual

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