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US BULLETIN No: 05-003/04 DATE: 05/2004
CAN BULLETIN No: N/A
APPLIES TO: 2003-2004 MPV AFFECTED VINs: JM3 LW28** 30 367822 - JM3 LW28** 40 518096
SUBJECT: Mazda Special Program (MSP03) - Shift Shock - Transmission Control Module (TCM) Reflash
DETAILS:

APPLICABLE MODEL(S)/VINS

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

  • 2003 VIN Range: JM3LW28**30367822 - 378984
  • 2004 VIN Range: JM3LW28**40500013 - 518096

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. A new software calibration is available on ESI 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 APR. 1, 2003 THROUGH JAN. 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 Apr. 1, 2003 through Jan. 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 Apr. 1, 2003 through Jan. 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.
  2. 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.


    eMDCS System - Vehicle Status Inquiry Results

    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 WDS, NGS (in generic mode) or ground the TAT terminal in DLC #)1 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 below:

    NOTE: The WDS WILL NOT BE USED to perform TCM reflash on MPV models. A desktop PC with internet access and one available serial port is required.

    NOTE:

    • Click on "PROCEDURE 1: INSTALLING FLASHING SOFTWARE" link below if computer does not already have flashing software installed. Flashing software only needs to be installed one time.
    • Click on "PROCEDURE 2: FIRST TIME TCM RE-FLASH" link below if using flash kit and flashing software for the first time (after software has been installed).
    • Click on "PROCEDURE 3: QUICK RE-FLASH" link below if computer has flashing software installed and "PROCEDURE 2: FIRST TIME TCM RE-FLASH" has been competed one time. Use "PROCEDURE 3: QUICK RE-FLASH" for fast re-flashing.

    PROCEDURE 1: INSTALLING FLASHING SOFTWARE

    PROCEDURE 2: FIRST TIME TCM RE-FLASH

    PROCEDURE 3: QUICK RE-FLASH

    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. 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.

  17. Return the vehicle to the customer.

PARTS INFORMATION

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

WARRANTY INFORMATION

Note: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.

Warranty Type A
Symptom Code 99 
Damage Code 99 
Part Number Main Cause AJ51-18-9E1N  
Quantity
Operation Number XX658XRX 
Labor Hours 0.7 Hrs. 

NOTE: Additional diagnostic time cannot be claimed for this repair.

PROCEDURE 1: INSTALLING FLASHING SOFTWARE:

  1. Turn the computer "ON".
  2. Open your Internet browser "Microsoft Internet Explorer".
  3. If you see this screen, enter your "Login Profile" and "Password", otherwise go to Step 4.
  4. Select "Electronic Service Information (ESI)".
  5. Enter your "User Name" and "Password".
  6. Retype this address into the browser exactly as it appears:
  7. Select "MPV - REFLASH".
  8. Select "Save this file to disc".
  9. Make sure to save to "Desktop"
  10. Select "Close".
  11. Select "X" to close ESI (Internet Explorer Window).
  12. IMPORTANT: If you have a phone dialer program or any other programs open, make sure to close them now.
  13. Click the "right" mouse button on an open area of the desktop.
  14. Select "Properties" from the drop down menu.
  15. Select the "Screen Saver" tab.
  16. Locate the file "reflash.zip" on your desktop and open it.
  17. On Windows 95, 98, ME, 2000 and NT, select "Actions" and "Select All".
  18. On Windows 95, 98, ME, 2000 and NT, select "Extract".
  19. On Windows 95, 98, ME, 2000 and NT, select "Desktop" and then select "Extract".
  20. On Windows 95, 98, ME, 2000 and NT, select "X" to close the window.
  21. The reflash software is now installed.
  22. 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:

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 Personal computer 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 computer.
  2. Turn the Reflash Cube "OFF".
  3. Connect RS-232C cable to the Serial port (often identified with lOlOl) on the back of the computer. Use the following figures for the type of computer you have (due to the many different computer configurations, your computer 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 computer "ON".
  6. Find the folder on the desktop called "reflash" and open it.
  7. Open the program called "Flash32r.exe".
    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.
  9. Select the program file "FLASH04.BIN", then select "Open".
  10. Select the "ROM file" button.
  11. Select the program file "FHEAF46.xho", then select "Open".
  12. Change "End" to "7FFFF".
  13. Select the correct Com port for your type of computer from the drop down menu:
    • For Compaq computers select "Com4"
    • For Dell computers select "Com1"
    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 computer. 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 computer and try again. If all the com ports still give an error message, there may be a hardware configuration problem with the computer. Have a computer specialist inspect and repair the computer. Try to perform the procedure using another computer.

    NOTE: If you receive the above 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).
    NOTE: THE SUCCESS OF THE REFLASH PROCEDURE WILL DEPEND ON FOLLOWING STEPS 16-22 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.
  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"
  21. After selecting "Verify"
  22. Turn Reflash Cube "OFF".
  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.
  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.

PROCEDURE 3: QUICK RE-FLASH:

  1. Turn the screen saver "OFF" (See Steps 13-15 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 - 16 before returning the vehicle to the customer.
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." Consumers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies, consumers should contact their nearest authorized Mazda dealership.
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