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Shift Shock - Transmission Control Module (TCM) REFLASH (05-008/07)

Publication date: 2014-04-30
Reference number: 05-008/07
Supersedes refnos: 05-001/04, 05-007/14

SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH

SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH

TECHNICAL SERVICE BULLETIN

Reference Number(s): 05-007/14, Date of Issue:  04/30/2014
MAZDA: All 2002 - 2003 MPV
SECTION: Transmission/Transaxle
Superceded Bulletin(s): 05-001/04, Date of Issue:  5/20/04, 05-008/07, Date of Issue:  09/05/07

BULLETIN NOTE

APPLICABLE MODEL(S)/VINS

All 2002 - 2003 MPV with VINs up to JM3LW28**30367821

DESCRIPTION

The vehicle's automatic transaxle (ATX) may exhibit shift shock while the engine warms from cold to normal operating temperature. The symptom is intermittent, it does not occur all the time. The shift shock usually occurs during 1-2 or 2-3 upshifts, or 3-2 part throttle downshifts.

In most cases, the cause of the shift shock is from the TRANSMISSION CONTROL MODULE (TCM) software calibration. An updated software calibration is available on the Mazda Service Support System (MS3)  to correct the shifting concerns.

Customers having this concern should have their vehicle repaired according to the following repair procedure.

VEHICLE PRE-INSPECTION

Inspect the vehicle for a "Port Campaign" rework sticker affixed to the underside of the hood.

NOTE:
  • If a "Port Campaign" rework sticker with the number "04/B0/02" is affixed to the hood, the TCM Reflash has already been performed at the port. DO NOT re-flash the TCM. Use M-MDS to check for DTCs and repair the ATX according to the workshop manual.
  • If there is no "Port Campaign" rework sticker affixed to the hood, perform the TCM Re-flash. Proceed to the "REPAIR PROCEDURE ".
    G09248568

REPAIR PROCEDURE

  1. Check transaxle fluid level and add fluid as needed.
  2. Road test the vehicle to confirm the concern.
  3. Use M-MDS to check for DTCs.
    • If DTC(s) are retrieved, follow the troubleshooting procedures in the Workshop Manual for specific DTCs. If the shift shock concern is still present after repairs are made, proceed to Step 4.
  4. Write down the customer's radio station pre-sets.
  5. Disconnect the negative battery cable. 
  6. Remove the TRANSMISSION CONTROL MODULE (TCM) from the vehicle according to the Workshop Manual (Section 05-17 TCM REMOVAL/INSTALLATION).
  7. Re-flash the TCM according to the following procedures:
    NOTE: M-MDS WILL NOT BE USED to perform TCM reflash. A desktop PC with internet access and one available serial port is required.
    • If PC does not already have flashing software installed, proceed to "PROCEDURE 1: INSTALLING FLASHING SOFTWARE ". Flashing software only needs to be installed one (1) time on the PC.
    • If using flash kit and flashing software for the first time (after software has been installed), proceed to "PROCEDURE 2: FIRST TIME TCM RE-FLASH ".
    • If PC has flashing software installed and "PROCEDURE 2: FIRST TIME TCM RE-FLASH" has been competed at least one (1) time, proceed to "PROCEDURE 3: QUICK RE-FLASH " for fast re-flashing.
    NOTE: Complete Steps 8-16 below, AFTER  the TCM has been reflashed.
  8. Reinstall the reprogrammed TCM according to the Workshop Manual (Section 05-17 TCM REMOVAL/INSTALLATION).
  9. Reconnect the negative battery cable.
  10. Road test the vehicle and allow the transaxle to shift through all gears up and down with light throttle, then 1/2 throttle, then full throttle.
  11. Bring the vehicle to a stop.
  12. Place the gear selector in the "3" position and confirm a 2nd gear start and upshift to 3rd gear; stop again.
  13. Place the gear selector in "2" position and confirm that 2nd gear is held and no upshift occurs.
  14. Verify the repair by repeating Step 10, five to six additional times.
  15. Reset the customer's radio station pre-sets.
  16. Return the vehicle to the customer.

PART(S) INFORMATION

PART(S) INFORMATION

Part Number Description Qty. Notes
MT02-K2-001 TCM Flash Kit 1 Additional TCM Flash kits can be purchased from MStore

WARRANTY INFORMATION

NOTE:
  • Repairs performed outside the 48 month/50,000 mile New Vehicle Limited Warranty will require DCSM or DSA authorization.
  • Additional diagnostic time cannot be claimed for this repair.
WARRANTY INFORMATION

Warranty Type A
Symptom Code 26
Damage Code 9J
Part Number Main Cause AJ51-18-9E1N
Quantity 0
Operation Number/Labor Hours XX531XRX/0.7 Hrs.

PROCEDURE 1: INSTALLING FLASHING SOFTWARE

  1. Turn the PC "ON"  .
  2. From "Web Security Logon (WSL)",  enter your "Username"  and "Password"  .
    G09248569
  3. Select "Service"  .
    G09248570
  4. Select "Mazda Service Support System (MS3)"  .
    G09248571
  5. Select IDS/Infotainment -> IDS/MMDS Updates.
  6. Right click "2002-2004 MPV TCM Reflash Program"  .
  7. Select "Save Target as...". 
  8. Save to "Desktop". 
    G09248572
    G09248573
  9. Select "Close"  .
    G09248574
  10. IMPORTANT: If you have a phone dialer program or any other programs open, make sure to close them now.
  11. Click the "right" mouse button on an open area of the desktop.
    G09248575
  12. Select "Properties"  from the drop down menu.
    G09248576
  13. Select the "Screen Saver"  tab.
    G09248577
  14. Locate the file "reflash.zip"  on your desktop and open it.
    G09248578
  15. On Windows 95, 98, ME, 2000 and NT, select "Actions"  and "Select All"  .
    G09248579
    G09248580
  16. On Windows 95, 98, ME, 2000 and NT, select "Extract"  .
    G09248581
    G09248582
  17. On Windows 95, 98, ME, 2000 and NT, select "Desktop"  and then select "Extract"  .
    G09248583
    G09248584
    G09248585
  18. On Windows 95, 98, ME, 2000 and NT, select "X"  to close the window.
    G09248586
    G09248587
  19. The reflash software is now installed.
  20. Proceed to "PROCEDURE 2: FIRST TIME TCM RE-FLASH ".

PROCEDURE 2: FIRST TIME TCM RE-FLASH

The figure below identifies the TCM Flash Kit components:

G09248588

TCM Flash Kit Part Number: MT02-K2-001 

NOTE: One kit was previously sent to each dealer. Replacement kits can be purchased on MSTORE.
TCM FLASH KIT COMPONENTS

1 PC equipped with Windows 95, 98, or XP and an RS-232C Serial port
2 Reflash Cube
3 Transmission Control Module (TCM) [not included in kit, remove from vehicle]
4 RS-232C cable
5 110 volt power supply cable
6 On/Off switch
7 TCM connectors
  1. Completely "Shut Down"  the PC.
  2. Turn the Reflash Cube "OFF"  .
  3. Connect RS-232C cable to the Serial port (often identified with IOIOI) on the back of the PC. Use the following figures for the type of PC you have (due to the many different PC configurations, your PC may not match these figures exactly):

    Compaq (connect to Serial Port-B) 

    G09248589

    Dell (connect to Serial Port-1) 

    G09248590
  4. Connect the Reflash Cube 110 volt power supply cable.
  5. Ensure the Reflash Cube is "OFF"  , then turn the PC "ON"  .
  6. Find the folder on the desktop called "reflash"  and open it.
    G09248591
  7. Open the program called "Flash32r.exe"  .
    G09248592
    NOTE: If you receive the following error or one similar to it, click "OK" and proceed to the next step. The program will continue to function. When the correct COM port is selected during the reflash procedure, this error will not come up again.
    G09248593
  8. Select the "Write program"  button.
    G09248594
  9. Select the program file "FLASH04.BIN"  , then select "Open"  .
    G09248595
  10. Select the "ROM file"  button.
    G09248596
  11. Select the program file "FHEAF46.xho"  , then select "Open"  .
    G09248597
  12. Change "End"  to "7FFFF"  .
    G09248598
  13. Select the correct Com port for your type of PC from the drop down menu:
    • For Compaq PCs select "Com4" 
      G09248599
    • For Dell PCs select "Com1" 
      G09248600
      NOTE: If you receive an error message for every com port (Com1, Com2, Com3, or Com4), shut off the reflash cube and shut down the PC. Make sure the reflash cube is plugged in securely (or if there are 2 serial ports, try plugging into the other one) and restart the PC and try again. If all the com ports still give an error message, there may be a hardware configuration problem with the PC. Have a computer specialist inspect and repair the PC. Try to perform the procedure using another PC.
      NOTE: If you receive the following error or one similar to it, click "OK" and proceed to the next step. The program will continue to function. When the correct COM port is selected during the reflash procedure, this error will not come up again.
      G09248601
  14. IMPORTANT: Verify the following settings.
    G09248602
  15. Connect the two (2) Reflash Cube connectors to the Transmission Control Module (TCM).
    NOTE: THE SUCCESS OF THE REFLASH PROCEDURE WILL DEPEND ON FOLLOWING STEPS 16-22 EXACTLY.
    G09248603
  16. Ensure the Reflash Cube is still in the "OFF"  position.
  17. Switch the Reflash Cube to the "ON"  position.
  18. Wait 1-second, then select the "Connect" button within 10-seconds. 
    NOTE: If you click the "Connect" button too fast or too slow, you may not establish communication.
    G09248604
  19. After selecting "Connect": 
    G09248605
    NOTE: If the message "Writing program forwarding failure" is displayed in RED text, turn the Reflash Cube "OFF" and repeat Step 16.
  20. After selecting "Write". 
    G09248606
  21. After selecting "Verify"  .
    G09248607
  22. Turn Reflash Cube "OFF"  .
    G09248608
  23. Select "End"  .
    G09248609
  24. Disconnect the TCM.
  25. Using a permanent marker, write the letter "N"  and the "Date of Reflash"  near the part number found on the TCM to identify the new software calibration level.
  26. Click the "right" mouse button on an open area of the desktop.
    G09248610
  27. Select "Properties"  from the drop down menu.
    G09248611
  28. Select "Screen Saver"  tab.
    G09248612
  29. The TCM Reflash is now complete.
  30. Return to the Service Bulletin "REPAIR PROCEDURE " section and complete Steps  8 -  15 before returning the vehicle to the customer.

PROCEDURE 3: QUICK RE-FLASH

  1. Turn the screen saver "OFF"  (See Steps  11- 13 under "Procedure 1: Installing Flashing Software").
  2. Open the folder on the desktop called "reflash". 
  3. Open the program "Flash32r.exe". 
  4. Verify the following screen settings:
    G09248613
  5. Connect the two (2) Reflash Cube connectors to the Transmission Control Module (TCM).
  6. Switch the Reflash Cube "ON"  , wait 1-second, then select "Connect"  within 10-seconds.
  7. Wait for the message "Writing program forwarding completion" 
  8. Select "Write"  , and wait for the message "Flash-ROM writing completion"  .
  9. Select "Verify"  , and wait for the message "Verify completion"  .
  10. Turn the Reflash Cube "OFF"  .
  11. Repeat Steps 6-10 for additional TCM's.
    NOTE: If the procedure is interrupted, turn the Reflash Cube "OFF" and start again from Step 6.
  12. Select "End"  .
  13. Disconnect the TCM.
  14. Using a permanent marker, write the letter "N"  and the "Date of Reflash"  near the part number found on the TCM to identify the new software calibration level.
  15. Turn the screen saver back "ON"  (See Steps  26 -  28 under "Procedure 2: First Time TCM Re-Flash").
  16. The TCM Reflash is now complete.
  17. Return to the Service Bulletin "REPAIR PROCEDURE " section and complete Steps  8 -  15 before returning the vehicle to the customer.
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