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Automatic Transmission - CVT: Assembly: Transaxle

SPECIAL TOOL(S)

G04656915Courtesy of FORD MOTOR CO.
 Dial Indicator With Bracketry 100-002 (TOOL-4201-C)
G04656916Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
G04656917Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G04656918Courtesy of FORD MOTOR CO.
 Drawbar (Heavy Duty Threaded)
204-029 (T77F-1176-A)
G04656919Courtesy of FORD MOTOR CO.
 Shim Selection Set (Bolts) 308-161 (T88C-77000-C)
G04656920Courtesy of FORD MOTOR CO.
 Shim Selection Set (Legs) 308-164 (T88C-77000-JF)
G04656921Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Seal
307-527
G04656922Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Seal 307-528
G04656923Courtesy of FORD MOTOR CO.
 Installer, Differential Bearing Cup
307-530 (includes 307-530-1 and 307-530-2)
G04656924Courtesy of FORD MOTOR CO.
 Variator Socket 307-545
G04656925Courtesy of FORD MOTOR CO.
 Holding Fixture, Transaxle Variator Assembly
307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9)
G04656926Courtesy of FORD MOTOR CO.
 Differential Preload Set-Up Tool
307-533
G04656927Courtesy of FORD MOTOR CO.
 Stack Up Gauge 307-534
G04656928Courtesy of FORD MOTOR CO.
 Installer, C-Clip 307-565
MATERIALS

Item Specification
Motorcraft Continuously Variable Chain Type Transmission Fluid XT-7-QCFT (US); CXT-7-LCF12 (Canada) WSS-M2C933-A
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Threadlock 262 TA-26 WSK-M2G351-A6
CAUTION:
  1. MERCON®, MERCON® V and MERCON® SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.
  2. Prior to installing the transaxle case onto the variator assembly, make sure that the manual valve feed tube is correctly installed in the case. Damage to the manual valve feed and variator could occur if not correctly installed.
  1. If not previously done, lubricate the new seals with clean transmission fluid and install the O-ring seals in the case.
    Fig 1: Locating O-Ring Seals In Case
    G04656929Courtesy of FORD MOTOR CO.
    2. NOTE: When installing the range selector valve assembly, make sure that the pin from the manual valve lever is correctly installed into the range selector valve assembly.
    Fig 2: Locating Range Selector Valve Assembly
    G04656930Courtesy of FORD MOTOR CO.
  2. Loosely install the range selector valve assembly.
  3. Install the bolts.
    • Tighten to 5 N.m (44 lb-in).
    Fig 3: Locating Bolts
    G04656931Courtesy of FORD MOTOR CO.
  4. Make sure when routing the range selector valve assembly wiring harness that it is between the bolt holes and is pressed into the case retainers.
    Fig 4: Locating Range Selector Valve Assembly Wiring Harness
    G04656932Courtesy of FORD MOTOR CO.
    5. NOTE: Be careful not to pinch the wire harness when installing the detent spring.
    Fig 5: Locating Manual Lever Detent Spring
    G04656933Courtesy of FORD MOTOR CO.
  5. Install the manual lever detent spring.
    • Tighten to 10 N.m (89 lb-in).
  6. Position the transaxle case onto the variators.
    Fig 6: Locating Transaxle Case Onto Variators
    G04656934Courtesy of FORD MOTOR CO.
  7. Install the spacer washer to the special tool.
    Fig 7: Locating Spacer Washer On Special Tools (307-547-2, 307-547-9)
    G04656935Courtesy of FORD MOTOR CO.
  8. Assemble the remaining components of the special tool.
    Fig 8: Identifying Special Tools (307-547-1, 307-547-2, 307-547-9)
    G04656936Courtesy of FORD MOTOR CO.
    9. CAUTION:
    1. The special tools must be installed as shown or damage to the case will occur.
    2. Make sure that when installing the case onto the variators, the case is NOT in PARK. If the case is in PARK damage to the case will occur.
    NOTE: The windows in the special tools must be facing you so that when pressing the case down, you can see when to stop.
    Fig 9: Identifying Special Tools (307-547-2, 307-547-7, 307-547-9)
    G04656937Courtesy of FORD MOTOR CO.
  9. Install the special tools on the top of the case in the position shown.
  10. Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.
    Fig 10: Identifying Special Tools (307-547-2, 307-547-7, 307-547-8)
    G04656938Courtesy of FORD MOTOR CO.
    11. CAUTION: This step must be followed exactly. Do not use any air tools when installing the case. Do not turn one forcing screw more than the other unless indicated. Failure to follow this instruction will result in damage to the case.
    Fig 11: Identifying Transaxle Case Level
    G04656939Courtesy of FORD MOTOR CO.
  11. Press the transaxle case down onto the variator assembly.
    1. Hold the transaxle case level. Turn the secondary forcing screw 2 complete turns.
    2. Turn both forcing screws evenly, at the same time, until the case just contacts the variators.
  12. Install a new primary nut.
    Fig 12: Locating Primary Nut
    G04656940Courtesy of FORD MOTOR CO.
  13. Install a new secondary nut.
    Fig 13: Locating Secondary Nut
    G04656941Courtesy of FORD MOTOR CO.
    14. NOTE: In order to tighten the variator nuts, the manual control lever must be in PARK to prevent the variators from turning.
  14. Make sure that the manual control lever is in the PARK position.
  15. Using the special tools, tighten the primary variator nut in 2 stages.
    • Stage 1: Tighten to 50 N.m (37 lb-ft).
    • Stage 2: Tighten to 500 N.m (369 lb-ft).
    Fig 14: Identifying Special Tool (307-545)
    G04656942Courtesy of FORD MOTOR CO.
  16. Using the special tools, tighten the secondary variator nut in 2 stages.
    • Stage 1: Tighten to 30 N.m (22 lb-ft).
    • Stage 2: Tighten to 150 N.m (111 lb-ft).
    Fig 15: Identifying Special Tool (307-545)
    G04656943Courtesy of FORD MOTOR CO.
  17. Lubricate the primary feed tube with clean continuously variable chain type transmission fluid.
    • If equipped with a primary feed tube that has removable O-ring seals, install new O-rings on the primary feed tube. Lubricate the seals with clean transmission fluid and install the feed tube into the case.
    • If equipped with a primary feed tube that has bonded seals, lubricate a new feed tube with clean transmission fluid and install the feed tube into the case.
    Fig 16: Locating Primary Feed Tube
    G04656944Courtesy of FORD MOTOR CO.
  18. Lubricate the new O-ring seal with clean transmission fluid and install a new square cut seal and the O-ring seal.
    Fig 17: Locating Square Cut Seal & O-Ring Seal
    G04656945Courtesy of FORD MOTOR CO.
  19. Install a new primary cover gasket.
    Fig 18: Identifying Primary Cover Gasket
    G04656946Courtesy of FORD MOTOR CO.
  20. Using new bolts, install the primary cover and tighten in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 4 N.m (35 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 19: Tightening Primary Cover Bolts In Sequence
    G04656947Courtesy of FORD MOTOR CO.
    21. NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.
    Fig 20: Locating Feed Tube & Secondary Cover Gasket
    G04656948Courtesy of FORD MOTOR CO.
  21. Lubricate the new O-ring with clean transmission fluid and install the O-ring seal on the feed tube. Install a new secondary cover gasket.
  22. If not previously done, install a new square cut seal in the secondary cover.
    Fig 21: Locating Square Cut Seal
    G04656949Courtesy of FORD MOTOR CO.
  23. Using new bolts, install the secondary cover and tighten in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 4 N.m (35 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 22: Tightening Primary Cover Bolts In Sequence
    G04656950Courtesy of FORD MOTOR CO.
  24. Install a new pressure filter.
    Fig 23: Locating Pressure Filter
    G04656951Courtesy of FORD MOTOR CO.
  25. Lubricate the high pressure filter feed tube with clean continuously variable chain type transmission fluid.
    • If equipped with a high pressure filter feed tube that has removable O-ring seals, install new O-rings on the feed tube. Lubricate the O-ring seals with clean transmission fluid and install the feed tube into the case.
    • If equipped with a high pressure filter feed tube that has bonded seals, lubricate a new feed tube with clean transmission fluid and install the feed tube into the case.
    Fig 24: Locating High Pressure Filter Feed Tube
    G04656952Courtesy of FORD MOTOR CO.
  26. Install the pressure filter case cover.
    • Tighten to 10 N.m (89 lb-in).
    Fig 25: Locating Pressure Filter Case Cover Bolts
    G04656953Courtesy of FORD MOTOR CO.
  27. Install the safety strap on the transaxle.
    Fig 26: Locating Safety Strap On Transaxle
    G04656954Courtesy of FORD MOTOR CO.
  28. Install the special tool onto the transaxle case.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 27: Identifying Special Tool (307-003) Onto Transaxle Case
    G04656955Courtesy of FORD MOTOR CO.
    29. NOTE: Be careful when installing the guide plate that it does not fall into the case. If the guide plate falls into the case, the case will need to disassembled.
    Fig 28: Locating Guide Pin Retaining Ring Plate
    G04656956Courtesy of FORD MOTOR CO.
  29. Using a magnet, carefully install the guide pin retaining ring plate.
  30. Install the C-clip onto the special tool.
    Fig 29: Locating C-Clip Onto Special Tool (307-565)
    G04656957Courtesy of FORD MOTOR CO.
  31. Using the special tool, install the guide pin retaining ring.
    Fig 30: Identifying Special Tool (307-565)
    G04656958Courtesy of FORD MOTOR CO.
  32. Lubricate the new O-ring seal with clean transmission fluid and install the O-ring seal on the chain lube tube.
    Fig 31: Locating O-Ring Seal
    G04656959Courtesy of FORD MOTOR CO.
  33. Install the chain lube tube into the case.
    Fig 32: Locating Chain Lube Tube
    G04656960Courtesy of FORD MOTOR CO.
  34. Install the fluid feed transfer tube retainer bracket.
    • Tighten to 10 N.m (89 lb-in).
    Fig 33: Locating Fluid Feed Transfer Tube Retainer Bracket
    G04656961Courtesy of FORD MOTOR CO.
  35. Install the transmission fluid baffle.
    • Tighten to 5 N.m (44 lb-in).
    Fig 34: Locating Transmission Fluid Baffle
    G04656962Courtesy of FORD MOTOR CO.
  36. Install the new forward clutch primary shaft seals.
    Fig 35: Locating Forward Clutch Primary Shaft Seals
    G04656963Courtesy of FORD MOTOR CO.
  37. Install the forward clutch drum without the clutch plates installed.
    Fig 36: Locating Forward Clutch Drum
    G04656964Courtesy of FORD MOTOR CO.
    38. NOTE: Note the recess in the top of the sun gear and the slight groove on the face of the gear teeth are facing up.
    Fig 37: Locating Sun Gear
    G04656965Courtesy of FORD MOTOR CO.
  38. Install the sun gear.
  39. Install the sun gear spacer.
    Fig 38: Locating Sun Gear Spacer
    G04656966Courtesy of FORD MOTOR CO.
  40. Install a new sun gear snap ring.
    Fig 39: Locating Sun Gear Snap Ring
    G04656967Courtesy of FORD MOTOR CO.
    41. NOTE: The clutch pack stack is made without the wave plate only.
  41. Install all plates and the pressure plate, but not the wave spring.
  42. Install the forward clutch snap ring.
    Fig 40: Locating Forward Clutch Snap Ring
    G04656968Courtesy of FORD MOTOR CO.
  43. Install the special tool and zero it out.
    Fig 41: Identifying Special Tool (100-002)
    G04656969Courtesy of FORD MOTOR CO.
  44. Lift up on the clutch plates by inserting a screwdriver in the clutch pack and record the measurement. Enter this measurement in the following table on the line labeled A.
    Fig 42: Locating Clutch Pack
    G04656970Courtesy of FORD MOTOR CO.
    45. NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.39-1.68 mm (0.055-0.066 inch).
  45. Select the selective snap ring.
    SELECTIVE SNAP RING CHART

    Description Reading
    A -
    B +0.51 mm (0.02 in)
    C -1.40 mm (0.055 in)
    (D) Clearance -
    • Add line A to line B, then subtract line C and enter this total on line D.
    • Line D is the actual clearance of the snap ring used during this measurement.
    • If the final measurement (D) is not within specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.

    Forward Clutch Selective Snap Ring 

    FORWARD CLUTCH SELECTIVE SNAP RING CHART

    Part Number Snap Ring Thickness
    7B421 2.00 mm (0.078 in)
    7B421 1.80 mm (0.070 in)
    7B421 1.60 mm (0.062 in)
    7B421 1.40 mm (0.055 in)
    7B421 1.20 mm (0.047 in)
    7B421 1.00 mm (0.039 in)
  46. Remove the forward clutch pack snap ring.
    Fig 43: Locating Forward Clutch Pack Snap Ring
    G04656971Courtesy of FORD MOTOR CO.
  47. Remove the forward clutch plates, steel and friction.
    Fig 44: Locating Forward Clutch Plates, Steel & Friction
    G04656972Courtesy of FORD MOTOR CO.
  48. Install the forward clutch wave spring.
    Fig 45: Locating Forward Clutch Wave Spring
    G04656973Courtesy of FORD MOTOR CO.
  49. Install the forward clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
    Fig 46: Locating Forward Clutch Plates, Steel & Friction
    G04656974Courtesy of FORD MOTOR CO.
  50. Install the forward clutch pressure plate.
    Fig 47: Locating Forward Clutch Pressure Plate
    G04656975Courtesy of FORD MOTOR CO.
  51. Install the forward clutch pack snap ring.
    Fig 48: Locating Forward Clutch Pack Snap Ring
    G04656976Courtesy of FORD MOTOR CO.
  52. Install the forward clutch roller cage bearing.
    Fig 49: Locating Forward Clutch Roller Cage Bearing
    G04656977Courtesy of FORD MOTOR CO.
    53. NOTE: This is a selective fit washer for the input shaft set up.
    Fig 50: Locating Forward Clutch Upper Bearing Washer
    G04656978Courtesy of FORD MOTOR CO.
  53. Install the forward clutch upper bearing washer.
  54. Install the forward clutch upper roller bearing.
    Fig 51: Locating Forward Clutch Upper Roller Bearing
    G04656979Courtesy of FORD MOTOR CO.
  55. Lubricate the new O-ring seals with clean transmission fluid and install the O-ring seals and split ring seal.
    Fig 52: Locating O-Ring Seals & Split Ring Seal
    G04656980Courtesy of FORD MOTOR CO.
  56. Install the input shaft and a new planet carrier thrust washer.
    Fig 53: Locating Input Shaft & Planet Carrier Thrust Washer
    G04656981Courtesy of FORD MOTOR CO.
  57. Install the differential assembly in the case.
    Fig 54: Locating Differential Assembly
    G04656982Courtesy of FORD MOTOR CO.
  58. Install the bearing race onto the differential assembly.
    Fig 55: Locating Bearing Race Onto Differential Assembly
    G04656983Courtesy of FORD MOTOR CO.
  59. Compress the special tool and hand-tighten the bolt.
    Fig 56: Identifying Special Tool (307-533)
    G04656984Courtesy of FORD MOTOR CO.
  60. Install the special tools onto the case.
    Fig 57: Identifying Special Tools (307-533, 308-164)
    G04656985Courtesy of FORD MOTOR CO.
  61. Position the case onto the special tools and install the bolts.
    • Tighten to 8 N.m (71 lb-in).
    Fig 58: Identifying Special Tools (307-533, 308-161, 308-164)
    G04656986Courtesy of FORD MOTOR CO.
  62. Loosen the top bolt of the special tool. Using a feeler gauge, measure the opening.
    Fig 59: Identifying Special Tool (307-533)
    G04656987Courtesy of FORD MOTOR CO.
  63. Measure the thickness of the bearing shim that came out when the race was removed. The thickness of the bearing shim should match the measured opening of the special tool. If the measurements do not match, use a new selective bearing race shim.
    DIFFERENTIAL BEARING RACE SELECTIVE SHIM THICKNESS

    Part Number Selective Shim Thickness
    7F119 1.30 mm (0.051 in)
    7F119 1.35 mm (0.053 in)
    7F119 1.40 mm (0.055 in)
    7F119 1.45 mm (0.057 in)
    7F119 1.50 mm (0.059 in)
    7F119 1.55 mm (0.061 in)
    7F119 1.60 mm (0.063 in)
    7F119 1.65 mm (0.065 in)
    7F119 1.70 mm (0.067 in)
    7F119 1.75 mm (0.068 in)
  64. Install the selective bearing race shim into the housing.
    Fig 60: Locating Selective Bearing Race Shim Into Housing
    G04656988Courtesy of FORD MOTOR CO.
  65. Position the new bearing race in place.
    Fig 61: Locating Bearing Race
    G04656989Courtesy of FORD MOTOR CO.
  66. Install the special tools on this side of the case.
    Fig 62: Identifying Special Tools (204-029, 307-530/1))
    G04656990Courtesy of FORD MOTOR CO.
  67. Install the remaining special tools from the other side of the case. Using the special tools, install the bearing race.
    Fig 63: Identifying Special Tools (204-029, 307-530/2)
    G04656991Courtesy of FORD MOTOR CO.
  68. Install a new converter housing gasket.
    Fig 64: Locating Converter Housing Gasket
    G04656992Courtesy of FORD MOTOR CO.
    69. NOTE: This is not a final torque. For this step only you can reuse the old bolts that were removed.
    Fig 65: Locating Converter Housing Bolts
    G04656993Courtesy of FORD MOTOR CO.
  69. Position the converter housing in place. Install only 8 bolts, evenly around the case, to carry out the input shaft end play. It may be necessary to remove the converter housing to install the correct shim. Tighten the bolts in a crisscross sequence.
    • Tighten the bolts to 8 N.m (71 lb-in).
  70. Install the special tool to measure the input shaft end play.
    • Tighten the wing nut.
    Fig 66: Identifying Special Tool (307-534)
    G04656994Courtesy of FORD MOTOR CO.
  71. Install the remaining special tool.
    • Push down on the special tool and zero out the dial indicator.
    • Lift up on the special tool and record the measurement 0.22-0.53 mm (0.008-0.021 in). If the measurement is not within specification, install a new input shaft bearing spacer. For additional information, refer to FORWARD CLUTCH .
    Fig 67: Identifying Special Tools (100-002, 307-534)
    G04656995Courtesy of FORD MOTOR CO.
    72. NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.
    Fig 68: Positioning Converter Housing In Place
    G04656996Courtesy of FORD MOTOR CO.
  72. Position the converter housing in place. Install new converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts. Starting at No. 1, tighten the bolts in a counterclockwise rotation.
    • Stage 1: Tighten bolts to 2 N.m (18 lb-in).
    • Stage 2: Tighten bolts to 8 N.m (71 lb-in).
    • Stage 3: Tighten an additional 90 degrees.
  73. Install the side shaft gear assembly.
    • Tighten to 35 N.m (26 lb-ft).
    Fig 69: Locating Side Shaft Gear Assembly Bolts
    G04656997Courtesy of FORD MOTOR CO.
  74. Position the output shaft seal in place.
    Fig 70: Locating Output Shaft Seal (1 Of 2)
    G04656998Courtesy of FORD MOTOR CO.
  75. Using the special tool, install the output shaft seal.
    Fig 71: Identifying Special Tool (307-528)
    G04656999Courtesy of FORD MOTOR CO.
  76. Position the output shaft seal in place.
    Fig 72: Locating Output Shaft Seal (2 Of 2)
    G04657000Courtesy of FORD MOTOR CO.
  77. Using the special tool, install the output shaft seal.
    Fig 73: Identifying Special Tool (307-527)
    G04657001Courtesy of FORD MOTOR CO.
    78. CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.
    Fig 74: Locating O-Ring Seals
    G04657002Courtesy of FORD MOTOR CO.
  78. Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.

    Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.

    Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.

    For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean transmission fluid and install the O-ring seals on the feed tubes.

    1. Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
    2. Install new O-ring seals on the primary pressure feed tube, secondary pressure feed tube and main (pump) pressure feed tube.
  79. For transaxles built before December 6, 2005 lubricate all of the O-ring seals with clean transmission fluid.
    1. Clutch supply feed tube
    2. Primary feed tube (longer tube)
    3. Secondary feed tube (longer tube)
    4. Main pressure feed tube (shorter tube)
    5. Torque converter clutch feed tube
    Fig 75: Identifying Feed Tube (1 Of 2)
    G04657003Courtesy of FORD MOTOR CO.
  80. For transaxles built after December 6, 2005, lubricate all of the bonded seals on the feed tubes with clean transmission fluid.
    1. Clutch supply feed tube
    2. Primary feed tube (short tube)
    3. Secondary feed tube (short tube)
    4. Main pressure feed tube (short tube)
    5. Torque converter clutch feed tube
    Fig 76: Identifying Feed Tube (2 Of 2)
    G04657004Courtesy of FORD MOTOR CO.
    81. NOTE: Note the location of the 5 feed tubes.
    Fig 77: Identifying Feed Tubes Into Case
    G04657005Courtesy of FORD MOTOR CO.
  81. Install all of the feed tubes into the case.
    1. Align the inner tube and install the clutch (manual valve) supply feed tube.
    2. Install the primary pressure feed tube.
    3. Install the secondary pressure feed tube.
    4. Install the main (pump) pressure feed tube.
    5. Install a new torque converter clutch pressure feed tube.
    82. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.
    Fig 78: Locating Mechatronic Unit
    G04657006Courtesy of FORD MOTOR CO.
  82. Position the mechatronic unit onto the case.
  83. Tighten the mechatronic bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 40 degrees (1/8 turn).
    Fig 79: Tightening Mechatronic Bolts In Sequence
    G04657007Courtesy of FORD MOTOR CO.
    84. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 80: Locating O-Ring Seal
    G04657008Courtesy of FORD MOTOR CO.
  84. Lubricate the O-ring seal with clean transmission fluid and install the electrical connector into the case.
    85. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 81: Locating Outer Shell Connector Bolt
    G04657009Courtesy of FORD MOTOR CO.
  85. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 N.m (53 lb-in).
    86. CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping a specific distance from the differential gears.
    Fig 82: Locating OSS Sensor Spacer, Sensor & Bolt
    G04657010Courtesy of FORD MOTOR CO.
  86. Install the OSS sensor spacer, sensor and bolt.
    • Tighten to 8 N.m (71 lb-in).
  87. Connect the electrical connectors.
    Fig 83: Locating Electrical Connectors
    G04657011Courtesy of FORD MOTOR CO.
    88. CAUTION:
    1. Make sure that the fluid filter pickup tube seal was removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.
    2. Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.
    Fig 84: Locating Fluid Filter
    G04657012Courtesy of FORD MOTOR CO.
  88. Lubricate the O-ring seal that is on the new filter with clean transmission fluid and install the fluid filter.
  89. Make sure that the filter is seated over one of the mechatronic bolts.
    Fig 85: Locating Mechatronic Bolts
    G04657013Courtesy of FORD MOTOR CO.
  90. Install a new transaxle fluid pan gasket.
    Fig 86: Locating Transaxle Fluid Pan Gasket
    G04657014Courtesy of FORD MOTOR CO.
  91. Make sure that the magnet in the pan is in the correct location prior to installing the transmission fluid pan.
    Fig 87: Locating Magnet In Pan
    G04657015Courtesy of FORD MOTOR CO.
  92. Install the transmission fluid pan. Tighten the bolts in the sequence indicated.
    • Tighten to 12 N.m (9 lb-ft).
    Fig 88: Tightening Transmission Fluid Pan Bolts In Sequence
    G04657016Courtesy of FORD MOTOR CO.
    93. CAUTION: Do not set the torque converter in the pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.
    Fig 89: Locating Index Slot In Pump
    G04657017Courtesy of FORD MOTOR CO.
  93. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
  94. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
    Fig 90: Identifying Special Tool (307-091)
    G04657018Courtesy of FORD MOTOR CO.
  95. Using 4 new retainers, install the transaxle insulator.
    Fig 91: Locating Transaxle Insulator Retainers
    G04657019Courtesy of FORD MOTOR CO.
  96. Install a new transmission fluid tube indicator grommet.
    Fig 92: Locating Transmission Fluid Tube Indicator Grommet
    G04657020Courtesy of FORD MOTOR CO.
  97. Install the transmission fluid level indicator and tube.
    • Tighten to 10 N.m (89 lb-in).
    Fig 93: Locating Transmission Fluid Level Indicator & Tube
    G04657021Courtesy of FORD MOTOR CO.
  98. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  99. Position the transaxle mount in place and install the upper retaining bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 94: Locating Transaxle Mount Bolts
    G04657022Courtesy of FORD MOTOR CO.
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