FixVault
Home › Mercury › 2006 › Montego Base, AWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transmission - CVT › Installation › Fluid Pump

Fluid Pump

SPECIAL TOOL(S)

G04657173Courtesy of FORD MOTOR CO.
 Aligner, Transaxle Pump 307-544 (includes 307-544/1, 307-544/2, 307-544/3 and 307-544/4A)
G04657174Courtesy of FORD MOTOR CO.
 Alignment Pins, Transmission Main Control Body 307-127 (T94P-77000-P)
G04657175Courtesy of FORD MOTOR CO.
 Installer, Front Pump Seal
307-524
G04657176Courtesy of FORD MOTOR CO.
 Installer, Pump Cover
307-542
G04657177Courtesy of FORD MOTOR CO.
 Piston Spring Compressor
307-525
G04657178Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G04657179Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
MATERIALS

Item Specification
Motorcraft Continuously Variable Chain Type Transmission Fluid XT-7-QCFT WSS-M2C933-A
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Threadlock 262 TA-26 WSK-M2G351-A6
CAUTION: 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.
    NOTE: The fluid pump assembly cannot be disassembled. It is serviced as an assembly only.
    Fig 1: Identifying Special Tool (307-544-1)
    G04657180Courtesy of FORD MOTOR CO.
  1. Install the special tool into a soft-jawed vise.
  2. Set the fluid pump assembly onto the special tool to correctly align the pump.
    Fig 2: Setting Fluid Pump Assembly Onto Special Tool (307-544-1)
    G04657181Courtesy of FORD MOTOR CO.
  3. Install the special tool into the center of the special tool to keep the pump centered.
    Fig 3: Identifying Special Tool (307-544-2)
    G04657182Courtesy of FORD MOTOR CO.
  4. Install the special tool onto the top of the pump.
    Fig 4: Identifying Special Tools (307-544-2, 307-544-4A)
    G04657183Courtesy of FORD MOTOR CO.
  5. Remove the pump with the special tools installed from the soft-jawed vise. Carefully turn the pump over. Do not let the special tools move or drop. If the tools fall out or move, the alignment procedure must be carried out again.
  6. Install the pump gasket. Note the location of the bleed slots in the gasket.
    Fig 5: Locating Pump Gasket
    G04657184Courtesy of FORD MOTOR CO.
  7. Install the special tools. Note the location of the bleed slot in the gasket.
    Fig 6: Identifying Special Tools (307-544-3)
    G04657185Courtesy of FORD MOTOR CO.
  8. Lubricate the new O-ring seals with clean continuously variable transmission (CVT) automatic transmission fluid. Install the O-ring seals onto the feed tube.
    Fig 7: Locating O-Ring Seals
    G04657186Courtesy of FORD MOTOR CO.
  9. Lubricate the inner and outer seals in clean CVT automatic transmission fluid. Install the feed tube into the pump cover.
    Fig 8: Identifying Feed Tube Into Pump Cover
    G04657187Courtesy of FORD MOTOR CO.
  10. From the opposite side of the case, install the fluid pump assembly into the transaxle case.
    Fig 9: Locating Fluid Pump Assembly Using Special Tools (307-544-3)
    G04657188Courtesy of FORD MOTOR CO.
  11. Loosely install the 6 fluid pump bolts.
    Fig 10: Locating Fluid Pump Bolts Using Special Tools (307-544-3)
    G04657189Courtesy of FORD MOTOR CO.
  12. Remove the special tools and loosely install the remaining 2 fluid pump bolts.
    Fig 11: Locating Fluid Pump Bolts (2 Of 2)
    G04657190Courtesy of FORD MOTOR CO.
  13. Tighten in the sequence shown.
    • Tighten to 16 N.m (12 lb-ft).
    Fig 12: Tightening Bolts In Sequence
    G04657191Courtesy of FORD MOTOR CO.
  14. Remove the special tool.
    Fig 13: Identifying Special Tools (307-544-2, 307-544-4A)
    G04657192Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new fluid pump seal.
    Fig 14: Identifying Special Tool (307-524)
    G04657193Courtesy of FORD MOTOR CO.
  16. Lubricate the inner and outer seals in clean CVT automatic transmission fluid, then position the pump dust cover in place.
    Fig 15: Locating Inner & Outer Seals
    G04657194Courtesy of FORD MOTOR CO.
  17. Install the special tools.
    Fig 16: Identifying Special Tools (307-127)
    G04657195Courtesy of FORD MOTOR CO.
  18. Using the special tools, install a new pump dust cover.
    Fig 17: Identifying Special Tools (307-127, 307-542)
    G04657196Courtesy of FORD MOTOR CO.
  19. Install the pump dust cover bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 18: Locating Pump Dust Cover Bolts
    G04657197Courtesy of FORD MOTOR CO.
  20. Lubricate the seals in clean CVT automatic transmission fluid. Install new inner and outer O-ring seals.
    Fig 19: Locating Inner & Outer O-Ring Seals
    G04657198Courtesy of FORD MOTOR CO.
  21. Install the reverse clutch piston.
    Fig 20: Locating Reverse Clutch Piston
    G04657199Courtesy of FORD MOTOR CO.
  22. Install the return spring.
    Fig 21: Locating Return Spring
    G04657200Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the return spring retainers.
    Fig 22: Identifying Special Tool (307-525)
    G04657201Courtesy of FORD MOTOR CO.
  24. Install the reverse clutch wave spring.
    Fig 23: Locating Reverse Clutch Wave Spring
    G04657202Courtesy of FORD MOTOR CO.
  25. Install the ring gear assembly.
    Fig 24: Locating Ring Gear Assembly
    G04657203Courtesy of FORD MOTOR CO.
  26. Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
    Fig 25: Locating Reverse Clutch Plates, Steel & Friction
    G04657204Courtesy of FORD MOTOR CO.
  27. Install the reverse clutch pressure plate.
    Fig 26: Locating Reverse Clutch Pressure Plate
    G04657205Courtesy of FORD MOTOR CO.
  28. Install the reverse clutch pack snap ring.
    Fig 27: Locating Reverse Clutch Pack Snap Ring
    G04657206Courtesy of FORD MOTOR CO.
  29. Install the new O-ring seal on the clutch feed tube and lubricate with clean CVT automatic transmission fluid.
    Fig 28: Locating Clutch Feed Tube
    G04657207Courtesy of FORD MOTOR CO.
  30. Install a new clutch feed sealing sleeve into the range selector valve assembly.
    Fig 29: Locating Clutch Feed Sealing Sleeve
    G04657208Courtesy of FORD MOTOR CO.
  31. Make sure when routing the range selector valve assembly wiring harness that it is still pressed into the case retainers and out of the way.
    Fig 30: Locating Range Selector Valve Assembly Wiring Harness
    G04657209Courtesy of FORD MOTOR CO.
  32. Install a new O-ring seal on the input shaft and lubricate it with clean CVT automatic transmission fluid.
    Fig 31: Locating O-Ring Seal On Input Shaft
    G04657210Courtesy of FORD MOTOR CO.
  33. Install a new converter housing gasket.
    Fig 32: Locating Converter Housing Gasket
    G04657211Courtesy of FORD MOTOR CO.
    34. NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.
    Fig 33: Positioning Converter Housing In Place
    G04657212Courtesy of FORD MOTOR CO.
  34. Position the converter housing in place. Install new transaxle 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.
  35. Install the side shaft gear assembly.
    • Tighten to 35 N.m (26 lb-ft).
      Fig 34: Locating Side Shaft Gear Assembly Bolts
      G04657213Courtesy of FORD MOTOR CO.
  36. Position the output shaft seal in place.
    Fig 35: Locating Output Shaft Seal
    G04657214Courtesy of FORD MOTOR CO.
    37. CAUTION: Early 2006 transaxle builds have feed tubes that vary in size and diameter. Be sure to identify location of tubes when removed, relative to size and location in the case. For transaxles built later in the 2006 model year, feed tubes 2 and 3 have changed and are the same size as tube 4. The converter housing case half also has changed. On later builds, the case bore for feed tubes 2 and 3 are not as deep. Early build and later build case half and feed tubes are not interchangeable unless both are replaced. Failure to replace both parts, if either is needed, will result in internal leakage and possible internal transmission damage.
    Fig 36: Locating O-Ring Seals On Feed Tubes
    G04657215Courtesy of FORD MOTOR CO.
  37. Lubricate the new O-ring seals with clean CVT automatic transmission fluid. Install the O-ring seals on the feed tubes (early build vehicles).
    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.
    3. Install new O-ring seals on the secondary pressure feed tube.
    4. Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).
  38. Lubricate the new O-ring seals with clean CVT automatic transmission fluid. Install the O-ring seals on the feed tubes (late build vehicles).
    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.
    Fig 37: Locating O-Ring Seals On Feed Tubes
    G04657216Courtesy of FORD MOTOR CO.
    39. CAUTION: If not done previously, lubricate all of the O-ring seals with clean CVT automatic transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the mechatronic assembly or internal damage to the transaxle will occur.
    NOTE: Note the location of the 5 feed tubes.
    Fig 38: Identifying Feed Tubes
    G04657217Courtesy of FORD MOTOR CO.
  39. Lubricate the seals with clean transmission fluid and 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 (smaller tube).
    5. Install a new torque converter clutch pressure feed tube.
    40. 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 39: Locating Mechatronic Unit
    G04657218Courtesy of FORD MOTOR CO.
  40. Position the mechatronic unit onto the case.
  41. Tighten the mechatronic bolts in 2 stages.
    • Stage 1: Tighten the bolts in the sequence shown to 5 N.m (44 lb-in).
    • Stage 2: Tighten the bolts in the sequence shown 40 degrees (1/8 turn).
    Fig 40: Tightening Mechatronic Unit Bolts In Sequence
    G04657219Courtesy of FORD MOTOR CO.
    42. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 41: Locating Electrical Connector
    G04657220Courtesy of FORD MOTOR CO.
  42. Lubricate the O-ring seal with clean CVT automatic transmission fluid and install the electrical connector into the case.
    43. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 42: Locating Electrical Connector Bolt
    G04657221Courtesy of FORD MOTOR CO.
  43. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 N.m (53 lb-in).
  44. Connect the electrical connectors.
    Fig 43: Locating Electrical Connectors
    G04657222Courtesy of FORD MOTOR CO.
    45. 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 44: Locating Fluid Filter
    G04657223Courtesy of FORD MOTOR CO.
  45. Lubricate the seal that is on the new filter with clean CVT automatic transmission fluid and install the fluid filter.
  46. Make sure that the filter is seated over one of the mechatronic bolts.
    Fig 45: Locating Mechatronic Bolts
    G04657224Courtesy of FORD MOTOR CO.
  47. Install a new transaxle fluid pan gasket.
    Fig 46: Locating Transaxle Fluid Pan Gasket
    G04657225Courtesy of FORD MOTOR CO.
  48. Make sure that the magnet in the pan is in the correct location prior to installing the transmission fluid pan.
    Fig 47: Locating Magnet In Pan
    G04657226Courtesy of FORD MOTOR CO.
  49. Install the transaxle fluid pan. Tighten the bolts in the sequence indicated.
    • Tighten to 12 N.m (9 lb-ft).
    Fig 48: Tightening Transaxle Fluid Pan Bolts In Sequence
    G04657227Courtesy of FORD MOTOR CO.
    50. CAUTION: Do not set the torque converter in the fluid pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.
    Fig 49: Locating Index Slot In Pump
    G04657228Courtesy of FORD MOTOR CO.
  50. 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.
  51. 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 50: Identifying Special Tool (307-091)
    G04657229Courtesy of FORD MOTOR CO.
  52. Using 4 new retainers, install the transaxle insulator.
    Fig 51: Locating Transaxle Insulator Retainers
    G04657230Courtesy of FORD MOTOR CO.
  53. Install the fluid level indicator.
    Fig 52: Locating Fluid Level Indicator
    G04657231Courtesy of FORD MOTOR CO.
  54. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  55. Position the transaxle mount in place and install the upper bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 53: Locating Transaxle Mount Bolts
    G04657232Courtesy of FORD MOTOR CO.
  56. Install the transaxle. For additional information, refer to TRANSAXLE - ALL WHEEL DRIVE (AWD)  or TRANSAXLE - FRONT WHEEL DRIVE (FWD) .
About FixVault