Technical Service Operations Worksheets

Table Of Contents
Automatic Transmission Diagnostic Worksheet ...2 ZF 8 Speed Automatic Transmission Worksheet ..3 Manual Transmission / Transfer Case Diagnostic Worksheet ..4 CVT Transmission Diagnostic Worksheet 5

HEV Transmission Diagnostic Worksheet ..6

Check Engine Light Diagnostic Worksheet 7 70% Transmission Cost Analysis Worksheet 8 70% Engine Cost Analysis Worksheet ...10 6.7L Cummins Turbo Diesel Diagnostic Worksheet ..12 5.9L Cummins Diesel Fuel Diagnostic Worksheet .15

Automatic Transmission Diagnostic Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Check all that apply Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage:

No

Category
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

Does Not Occur

Slips

Late or Delayed

Early

Harsh

Shudder Search Busy

Stalls

SERVICE ADVISOR SECTION

Warning Lights: READY Engine Fuel When does this Performance Related Concern occur? Check all that apply. Always Part Throttle Intermittent Wide Open Throttle Trans Hot Braking Trans Cold Unable To Duplicate At Idle Cornering At _____ MPH With A/C On Other: Drive Conditions. Check all that apply. Road Condition Surface Condition Smooth Bumpy Flat Leaks: When Noise Concern: Buzz Whine Twisty Pot Holes Wet Dry

Anti-Lock

Traction Control

High Altitude Extremely Hot (Above 90 F) Extremely Cold (Below 10 F) While Towing On Severe Incline / Grade Gear Selector Position

Road Type Dirt Cement Gravel Black Top

Traffic Conditions Stop & Go Light Traffic Heavy Traffic

Clunk Rattle

Leaks: Where Noise Concern Occurs When: Moving In Gear Still Out of Gear Condition Duplication? Yes

Braking No

TECHNICIAN SECTION

Please Provide Environmental Data. Other Concerns: Trans Fluid Level: Correct Low Fluid Condition: Normal Burnt Clutch Volumes: L/R 2C/2-4 Shift Lever Status Check: Passed DTCs Before Repair / Replace: PCM TCM Part #: Cooler Pressure Tests Results:

High Mixed with ATF/Coolant? Yes No Metal Contamination OD 4C UD LC DC R Failed Line Pressure Gauge
Park Reverse Drive

Scan Tool

Desired

TCM Reflashed? Yes

No New Part #: 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:

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: Codes Registered:

Yes

No

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

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes No Complaint: Check all that apply Performance Related Concern - Transmission Clash High Category Grind Effort 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 Warning Lights: Always Intermittent Trans Hot Trans Cold At Idle At _____ MPH READY Engine Part Throttle Wide Open Throttle Braking Unable To Duplicate Cornering With A/C On Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage:

Pops Out

SERVICE ADVISOR SECTION

Performance Related Concern Transfer Case Clash High Category Grind Effort Low to High High to Low High Range Low Range For popping out of gear, have shift boot(s) been checked for binding? Yes No

Pops Out

Fuel

Anti-Lock

Traction Control

When does this Performance Related Concern occur? Check all that apply. 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. Road Condition Surface Condition Smooth Bumpy Flat Leaks: When Noise Concern: Buzz Whine Twisty Pot Holes Wet Dry

Road Type Dirt Cement Gravel Black Top

Traffic Conditions Stop & Go Light Traffic Heavy Traffic

Leaks: Where Noise Concern Occurs When: Clunk Rattle Moving Still In Gear Out of Gear No Braking

In what gear or range? Does loading the gearshift/range shift lever have an impact on the noise? Yes

TECHNICIAN SECTION

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 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 TECHNICIAN DIAGNOSIS: TECHNICIAN ID #: No TECHNICIAN SIGNATURE:

CVT Transmission Diagnostic Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Check all that apply Category 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 Warning Lights: Does Not Occur Slips Late or Delayed Early Harsh Shudder Search Busy Stalls Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage:

No

SERVICE ADVISOR SECTION

READY

Engine

Fuel

Anti-Lock

Traction Control

When does this Performance Related Concern occur? Check all that apply. 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 Extremely Hot (Above 85 F) Extremely Cold (Below 10 F) While Towing On Severe Incline / Grade Gear Selector Position

Other:
Drive Conditions. Check all that apply. Road Condition Surface Condition Smooth Bumpy Flat Leaks: When Noise Concern: Buzz Whine Clunk Rattle Twisty Pot Holes Wet Dry

Road Type Dirt Cement Leaks: Where Gravel Black Top

Traffic Conditions Stop & Go Light Traffic Heavy Traffic

Noise Concern Occurs When: Moving Still In Gear Out of Gear Braking

TECHNICIAN SECTION

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 All Pressures Checked While Idling DTCs Before Repair / Replace: Software PART #: Line Press Secondary Press PCM ABS Forward Clutch Reverse Brake TCM Other Primary Press Converter Reverse Press

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 TECHNICIAN DIAGNOSIS: TECHNICIAN ID #: TECHNICIAN SIGNATURE: No

HEV Transmission Diagnostic Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Check all that apply Category Engagement Into Drive Engagement Into Reverse Light Acceleration Heavy Acceleration Constant Speed (Indicate) Coasting Heavy Braking Light Braking Kickdown / WOT Accel. Warning Lights: Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage:

No

Does Not Occur

Slips

Late or Delayed

Early

Harsh

Shudder Search Busy

Stalls

SERVICE ADVISOR SECTION

READY

Engine

Fuel

Anti-Lock

Traction Control

ETC

HEV Service

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 Gear Selector Position ____ Extremely Hot (Above 90 F) Extremely Cold (Below 10 F) On Severe Incline / Grade Fuel Level______ Fuel Saver On (MDS Active) Road Type Dirt Cement Leaks: Where Noise Concern Occurs When: Clunk Rattle Moving Still In Gear Out of Gear Braking Coast Down (Regen.) Gravel Black Top During Engine Auto Stop During Engine Auto Start During Launch From Stop At ______ MPH High Altitude Other Traffic Conditions Stop & Go Light Traffic Heavy Traffic

Drive Conditions. Check all that apply. Road Condition Surface Condition Smooth Bumpy Flat Leaks: When Noise Concern: Buzz Whine Twisty Pot Holes Wet Dry

TECHNICIAN SECTION

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 DTCs Before Repair / Replace: Software PART #: Line Pressure Commanded Estimated Gauge HCP HCP (When Required by Service Manual Park (Main) PCM PCM Drive (Main) TCM TCM Park (Aux) DTCM DTCM Drive (Aux) ABS ABS 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

TECHNICIAN DIAGNOSIS: TECHNICIAN ID #:

No
TECHNICIAN SIGNATURE:

Check Engine Light Diagnostic Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage: No

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 If No, when does it come on? Is the light on steady? Yes No Does the light flash? Yes No No

DISPATCH TO A LEVEL 3 OR 4 TRAINED TECHNICIAN TECHNICIAN NAME & ID: DTCs Before Repair / Replacement: PCM Active: TCM Active: Other Module Active: 1. 2. 3. 4. 5. 6. 7. Verify the customer complaint: Any related symptoms: Any updated SBs related to concern: Symptom analysis: Problem isolation: Repair isolation problem: Verification of repair*:

PCM Stored: TCM Stored: Other Module Stored:

*Quality Control Must Match DTC Set Condition: PCM Part #: TCM Part #:

Flash Available?: Yes Flash Available?: Yes

No 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 SBs concerning transmission/transaxle repair and/or replacement.

70% Transmission Cost Analysis Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: OEM: TPK # (On Case) Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage: No

Reman: (On Reman Tag) Serial #

Build Date

Repair of Assembly Information

Part Name Part # Dealer Cost LOP Description LOP # Labor Hours

Cost Of Parts 40% Mark-up (.40) Total Parts $

Labor Hours X Hourly Rate Total Labor $

Repair = Total $

Replacement of Assembly Information

Part Name
Transmission Assembly Automatic Trans Fluid

Part #

Dealer Cost

LOP Description Trans. Replace Reverse Flush 70 % Teardown LOP * 4X4 * Skid Plate * Dual Exhaust * Two Piece Prop * AWD

LOP #

Labor Hours

Cost Of Parts 40% Mark-up (.40) Total Parts $

Labor Hours X Hourly Rate Total Labor $

Replace = Total $ (X.70) 70% Repair Allowance

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:

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
Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Contact Name: Phone # & Fax #: Last 8 Digits of VIN: Mileage: No

Repair of Assembly Information

Part Name Part # Dealer Cost LOP Description LOP # Labor Hours

Cost Of Parts 40% Mark-up (.40) Total Parts $

Labor Hours X Hourly Rate Total Labor $

Repair = Total $

Replacement of Assembly Information (If Applicable)

Part Name Part # Dealer Cost LOP Description LOP # Labor Hours

Cost Of Parts 40% Mark-up (.40) Total Parts $

Labor Hours X Hourly Rate Total Labor $

Replace = Total $ (X.70) 70% Repair Allowance

If the Repair Total exceeds the 70 % Repair Allowance, the Assembly should be replaced.

TECHNICIAN SIGNATURE:

PRINT NAME:

5.9L Cummins Diesel Fuel Diagnostic Worksheet

Dealer Name: Dealer Code: Date: RO #: Repeat Complaint: Yes Complaint: Contact Name: Phone #: Last 8 Digits of VIN: Mileage: No