05-007-14-2918

Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
© 2014 Mazda Motor of America, Inc.
Subject:
Bulletin No:
05-007/14
Last Issued:
04/30/2014
SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH
2002 - 2003 MPV - SHIFT SHOCK - TRANSMISSION CONTROL MODULE (TCM) REFLASH
BULLETIN NOTE
• This bulletin supersedes the previous bulletin 05-001/04 issued 5/20/04 and 05-008/07 issued on 09/05/07.
The REPAIR PROCEDURE has been revised.
• Changes are noted below beside the change bar in Red.
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”.
PORT REWORK
STICKER
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CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
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.
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Bulletin No: 05-007/14
Last Issued: 04/30/2014
© 2014 Mazda Motor of America, Inc.
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 Type
A
Symptom Code
26
Damage Code
9J
Part Number Main Cause
Quantity
Operation Number / Labor Hours
AJ51-18-9E1N
0
XX531XRX / 0.7 Hrs.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
PROCEDURE 1: INSTALLING FLASHING SOFTWARE:
1. Turn the PC “ON”.
2. From “Web Security Logon (WSL)”, enter your “Username” and “Password”.
3. Select “Service”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
4. Select “Mazda Service Support System (MS3)” .
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”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
9. Select “Close”.
10. IMPORTANT: If you have a phone dialer program or any other programs open, make sure to close
them now.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
11. Click the “right” mouse button on an open area of the desktop.
12. Select “Properties” from the drop down menu.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
13. Select the “Screen Saver” tab.
14. Locate the file “reflash.zip” on your desktop and open it.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
15. On Windows 95, 98, ME, 2000 and NT, select “Actions” and “Select All”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
16. On Windows 95, 98, ME, 2000 and NT, select “Extract”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
17. On Windows 95, 98, ME, 2000 and NT, select “Desktop” and then select “Extract”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
18. On Windows 95, 98, ME, 2000 and NT, select “X” to close the window.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
19. The reflash software is now installed.
20. Proceed to “PROCEDURE 2: FIRST TIME TCM RE-FLASH”.
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Bulletin No: 05-007/14
Last Issued: 04/30/2014
© 2014 Mazda Motor of America, Inc.
PROCEDURE 2: FIRST TIME TCM RE-FLASH:
The figure below identifies the TCM Flash Kit components:
TCM Flash Kit Part Number: MT02-K2-001
NOTE: One kit was previously sent to each dealer. Replacement kits can be purchased on MSTORE.
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”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
3. Connect RS-232C cable to the Serial port (often identified with lOlOl) 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)
Dell (connect to Serial Port-1)
4. Connect the Reflash Cube 110 volt power supply cable.
5. Ensure the Reflash Cube is “OFF”, then turn the PC “ON”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
6. Find the folder on the desktop called “reflash” and open it.
7. Open the program called “Flash32r.exe”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
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.
8. Select the “Write program” button.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
9. Select the program file “FLASH04.BIN”, then select “Open”.
10. Select the “ROM file” button.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
11. Select the program file “FHEAF46.xho”, then select “Open”.
12. Change “End” to “7FFFF”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
13. Select the correct Com port for your type of PC from the drop down menu:
- For Compaq PCs select “Com4”
- For Dell PCs select “Com1”
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
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.
14. IMPORTANT: Verify the following settings.
15. Connect the two (2) Reflash Cube connectors to the Transmission Control Module (TCM).
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
NOTE: THE SUCCESS OF THE REFLASH PROCEDURE WILL DEPEND ON FOLLOWING STEPS 1622 EXACTLY.
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.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
19. After selecting “Connect”:
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”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
21. After selecting “Verify”.
22. Turn Reflash Cube “OFF”.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
23. Select “End”.
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.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
27. Select “Properties” from the drop down menu.
28. Select “Screen Saver” tab.
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.
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Bulletin No: 05-007/14
© 2014 Mazda Motor of America, Inc.
Last Issued: 04/30/2014
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:
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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