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MAZDA Special Program (MSP03) - Shift Shock - Transmission Control Module (TCM) REFLASH (MSP03)

Publication date: 2014-04-30
Reference number: MSP03
Supersedes refnos: 05-003/04, 05-006/14, 05-009/07

MAZDA SPECIAL PROGRAM (MSP03) - SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH

MAZDA SPECIAL PROGRAM (MSP03) - SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH

TECHNICAL SERVICE BULLETIN

Reference Number(s): 05-006/14, Date of Issue:  04/30/2014
MAZDA: 2003 - 2004 MPV
SECTION: Transmission/Transaxle
Superceded Bulletin(s): 05-003/04, Date of Issue:  5/20/04, 05-009/07, Date of Issue:  09/05/07

BULLETIN NOTE

APPLICABLE MODEL(S)/VINS

2003 - 2004 MPV vehicles built from April 1, 2003 through January 26, 2004

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 Mazda Service Support System (MS3)  to correct the shifting concerns.

NOTE:
  • UNDER THE MAZDA SPECIAL PROGRAM (MSP03), ALL CURRENT DEALER INVENTORY AND RETAILED VEHICLES FOUND TO BE WITHIN THE ABOVE VIN RANGES, AND PRODUCED BETWEEN APRIL 1, 2003 THROUGH JANUARY 26, 2004, MUST BE INSPECTED AND REPAIRED ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS SERVICE BULLETIN.
  • BEFORE PERFORMING ANY REPAIR, VALIDATE THAT THE VEHICLE IS APPLICABLE TO THIS PROGRAM BY PERFORMING AN "eMDCS WARRANTY VEHICLE INQUIRY" AND VERIFYING THE VEHICLE DISPLAYS CAMPAIGN "MSP03". SEE "VEHICLE INSPECTION PROCEDURE " BELOW.

DEALER INVENTORY

Inspect and repair all current dealer inventory according to the procedures contained in this service bulletin.

RETAIL VEHICLES

When a retail vehicle is brought into the dealer for any type of repair or scheduled maintenance, inspect and repair the vehicle according to the procedures contained in this service bulletin.

VEHICLE INSPECTION PROCEDURE

  1. Verify the vehicle is within one of the following VIN ranges, AND produced between April 1, 2003 through January 26, 2004:
    • 2003 MPV

      VIN Range: JM3LW28**30367822 - 378984

    • 2004 MPV

      VIN Range: JM3LW28**40500013 - 518096

    • If the vehicle is within one of the above VIN ranges, and produced between April 1, 2003 through January 26, 2004, proceed to Step 1.
    • If the vehicle is not within one of the above VIN ranges, return the vehicle to the customer or inventory.
  1. Perform a Vehicle Status Inquiry using your eMDCS System and inspect the vehicle for an Authorized Modification Label MSP03  attached to the vehicle's hood.
    NOTE: Verify the campaign number as the vehicle may have multiple labels.
    G09248521

eMDCS System - Vehicle Status Inquiry Results 

VEHICLE STATUS INQUIRY

If eMDCS displays: Campaign Label is: Action Required:
"Campaign: MSP03 Open" Present Contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626 to update vehicle history
Not present Proceed to "REPAIR PROCEDURE "
"Campaign: MSP03 Closed" Present Return vehicle to inventory or customer
Not present Complete a label and apply it to vehicle's hood
"Campaign: MSP03 Open" or "Closed" is not displayed Does not apply Campaign does not apply to this vehicle. Return the vehicle to inventory or customer

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 8-17 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 1, five to six additional times.
  15. Reset the customer's radio station pre-sets.
  16. Complete the blue "Authorized Modification" label (9999-95-065A-00) with the Campaign number "MSP03" written on the sticker and affix it to the vehicle's hood.
    G09248522
  17. 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 99
Damage Code 99
Process Number A4423H
Part Number Main Cause AJ51-18-9E1N
Quantity 0
Operation Number/Labor Hours XX658XRX/0.7 Hrs.

PROCEDURE 1: INSTALLING FLASHING SOFTWARE

  1. Turn the PC "ON".
  2. From "Web Security Logon (WSL)",  enter your "Username"  and "Password"  .
    G09248523
  3. Select "Service"  .
    G09248524
  4. Select "Mazda Service Support System (MS3)"  .
    G09248525
  5. Search for "MSP03" on MS3 or select View Content -> Campaigns -> MSP -> MSP03.
  6. Right click "MSP03 - TCM Reflash Program". 
  7. Select "Save Target as...". 
  8. Make sure to save to "Desktop" 
    G09248526
    G09248527
  9. Select "Close". 
    G09248528
  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.
    G09248529
  12. Select "Properties"  from the drop down menu.
    G09248530
  13. Select the "Screen Saver"  tab.
    G09248531
  14. Locate the file "reflash.zip"  on your desktop and open it.
    G09248532
  15. On Windows 95, 98, ME, 2000 and NT, select "Actions"  and "Select All"  .
    G09248533
    G09248534
  16. On Windows 95, 98, ME, 2000 and NT, select "Extract"  .
    G09248535
    G09248536
  17. On Windows 95, 98, ME, 2000 and NT, select "Desktop"  and then select "Extract"  .
    G09248537
    G09248538
    G09248539
  18. On Windows 95, 98, ME, 2000 and NT, select "X"  to close the window.
    G09248540
    G09248541
  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:

G09248542

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) 

    G09248543

    Dell (connect to Serial Port-1) 

    G09248544
  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.
    G09248545
  7. Open the program called "Flash32r.exe"  .
    G09248546
    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.
    G09248547
  8. Select the "Write program"  button.
    G09248548
  9. Select the program file "FLASH04.BIN"  , then select "Open"  .
    G09248549
  10. Select the "ROM file"  button.
    G09248550
  11. Select the program file "FHEAF46.xho"  , then select "Open"  .
    G09248551
  12. Change "End"  to "7FFFF"  .
    G09248552
  13. Select the correct Com port for your type of PC from the drop down menu:
    • For Compaq PCs select "Com4" 
      G09248553
    • For Dell PCs select "Com1" 
      G09248554
      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.
      G09248555
  14. IMPORTANT: Verify the following settings.
    G09248556
  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.
    G09248557
  16. Ensure the Reflash Cube is still in the "OFF"  position.
    NOTE: If you click the "Connect" button too fast or too slow, you may not establish communication.
    G09248558
  17. Switch the Reflash Cube to the "ON"  position.
  18. Wait 1-second, then select the "Connect" button within 10-seconds. 
  19. After selecting "Connect": 
    G09248559
    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"  .
    G09248560
  21. After selecting "Verify"  .
    G09248561
  22. Turn Reflash Cube "OFF"  .
    G09248562
  23. Select "End"  .
    G09248563
  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.
    G09248564
  27. Select "Properties"  from the drop down menu.
    G09248565
  28. Select "Screen Saver"  tab.
    G09248566
  29. The TCM Reflash is now complete.
  30. Return to the Service Bulletin "REPAIR PROCEDURE" section and complete Steps 8 - 16 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:
    G09248567
  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 - 16 before returning the vehicle to the customer.
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