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

Fluid Pump

SPECIAL TOOL(S)

G04656579Courtesy of FORD MOTOR CO.
 Piston Spring Compressor 307-525
G04656580Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G04656581Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
Fig 1: Exploded View Of Fluid Pump Components
G04656582Courtesy of FORD MOTOR CO.
NOTE:
  1. The removal and installation procedures for the fluid pump are unique and different from the Torque Converter Housing, Reverse Clutch and Pump Assembly - Disassembly and Assembly procedures in DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES . These procedures are to be used when only fluid pump installation is required. For complete transaxle overhaul and other procedures normally requiring the fluid pump to be removed and installed, refer to TORQUE CONVERTER HOUSING, REVERSE CLUTCH AND PUMP ASSEMBLY - DISASSEMBLY  and TORQUE CONVERTER HOUSING, REVERSE CLUTCH AND PUMP ASSEMBLY - ASSEMBLY .
  2. Throughout this procedure, certain steps will instruct you to remove and discard components. Always install new components where indicated.
  1. Remove the transaxle. For additional information, refer to TRANSAXLE - ALL WHEEL DRIVE (AWD)  or TRANSAXLE - FRONT WHEEL DRIVE (FWD) .
  2. Remove and discard the 4 retainers and remove the transaxle insulator.
    Fig 2: Locating Transaxle Insulator Retainers
    G04656583Courtesy of FORD MOTOR CO.
  3. Remove the rear transaxle mount-to-transaxle bolts and the rear transaxle mount.
    Fig 3: Locating Rear Transaxle Mount-To-Transaxle Bolts
    G04656584Courtesy of FORD MOTOR CO.
  4. Remove the fluid level indicator.
    Fig 4: Locating Fluid Level Indicator
    G04656585Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the torque converter.
    Fig 5: Identifying Special Tool (307-091) On Torque Converter
    G04656586Courtesy of FORD MOTOR CO.
  6. Make an identifying mark on the torque converter where the fluid pump pilot is located for correct installation.
    Fig 6: Locating Mark On Torque Converter
    G04656587Courtesy of FORD MOTOR CO.
    7. CAUTION: Be careful not to cross-thread the bolts while installing the special tool.
    Fig 7: Identifying Special Tool (307-003)
    G04656588Courtesy of FORD MOTOR CO.
  7. Install the special tool onto the transaxle case.
    • Tighten to 55 N.m (41 lb-ft).
  8. Position the transaxle into the bench fixture.
    Fig 8: Positioning Transaxle Into Bench Fixture Using Special Tool (307-003)
    G04656589Courtesy of FORD MOTOR CO.
  9. Remove the side shaft gear assembly bolts.
    Fig 9: Locating Side Shaft Gear Assembly Bolts
    G04656590Courtesy of FORD MOTOR CO.
  10. Remove the side shaft gear assembly from the case.
    Fig 10: Locating Side Shaft Gear Assembly
    G04656591Courtesy of FORD MOTOR CO.
  11. Remove the transaxle fluid pan.
    Fig 11: Locating Transaxle Fluid Pan
    G04656592Courtesy of FORD MOTOR CO.
  12. Remove and discard the transaxle fluid pan gasket.
    Fig 12: Locating Transaxle Fluid Pan Gasket
    G04656593Courtesy of FORD MOTOR CO.
    13. NOTE: Check the transaxle case to see if the filter pickup tube seal is stuck in the case. If the pickup tube seal is in the case it will need to be removed.
    Fig 13: Locating Fluid Filter
    G04656594Courtesy of FORD MOTOR CO.
  13. Remove and discard the fluid filter.
    • Use a suitable seal pick to remove the seal if it is stuck in the case.
  14. Remove the main electrical outer shell bolt.
    Fig 14: Locating Main Electrical Outer Shell Bolt
    G04656595Courtesy of FORD MOTOR CO.
    15. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 15: Locating Electrical Connector (1 Of 2)
    G04656596Courtesy of FORD MOTOR CO.
  15. Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
    • Rotate the connector counterclockwise to remove.
  16. Remove the electrical connector by lifting it out of the case.
    Fig 16: Locating Electrical Connector (2 Of 2)
    G04656597Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
    Fig 17: Locating Electrical Connectors
    G04656598Courtesy of FORD MOTOR CO.
  17. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
    18. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    NOTE: The 8 bolts that hold the mechatronic unit to the case are a different size Torx® bolt.
    Fig 18: Locating Mechatronic Unit Bolts
    G04656599Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts from the mechatronic unit.
    19. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 19: Locating Mechatronic Unit
    G04656600Courtesy of FORD MOTOR CO.
  19. Remove the mechatronic unit from the transaxle.
    20. NOTE:
    1. The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
    2. Note the location and size of the 5 feed tubes for reassembly.
    Fig 20: Identifying Feed Tubes
    G04656601Courtesy of FORD MOTOR CO.
  20. Remove all of the 5 feed tubes.
    1. Remove the clutch (manual valve) supply feed tube.
    2. Remove the primary pressure feed tube.
    3. Remove the secondary pressure feed tube.
    4. Remove the main (pump) pressure feed tube (smaller tube).
    5. Remove and discard the torque converter clutch pressure feed tube.
    21. 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 21: Locating O-Ring Seals (1 Of 2)
    G04656602Courtesy of FORD MOTOR CO.
  21. Remove and discard all of the seals on the feed tubes (early build vehicles).
    1. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
    2. Remove and discard the O-ring seals from the primary pressure feed tube.
    3. Remove and discard the O-ring seals from the secondary pressure feed tube.
    4. Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube).
    5. Discard the torque converter clutch pressure feed tube.
  22. Remove and discard all of the seals on the feed tubes (late build vehicles).
    1. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
    2. Remove and discard the O-ring seals from the primary pressure feed tube, the secondary pressure feed tube and the main (pump) pressure feed tube.
    3. Discard the torque converter clutch pressure feed tube.
    Fig 22: Locating O-Ring Seals (2 Of 2)
    G04656603Courtesy of FORD MOTOR CO.
  23. Remove and discard the 26 transaxle converter housing bolts.
    Fig 23: Locating Transaxle Converter Housing Bolts
    G04656604Courtesy of FORD MOTOR CO.
  24. Remove the converter housing. Carefully pry the case halves apart.
    Fig 24: Prying Case Halves Apart
    G04656605Courtesy of FORD MOTOR CO.
    25. NOTE: It is not necessary to remove the range selector valve assembly when removing the clutch feed sealing sleeve.
    Fig 25: Locating Clutch Feed Sealing Sleeve
    G04656606Courtesy of FORD MOTOR CO.
  25. Remove and discard the clutch feed sealing sleeve.
    26. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE:
    1. Using a plastic scraper, make sure that all gasket material is removed from the case.
    2. No further disassembly of the differential side case is required. Set the differential side case aside for reassembly once a new pump has been installed.
    Fig 26: Locating Converter Housing Gasket
    G04656607Courtesy of FORD MOTOR CO.
  26. Remove and discard the converter housing (split flange) gasket.
  27. Only remove and discard the clutch feed tube O-ring seal.
    Fig 27: Locating Clutch Feed Tube O-Ring Seal
    G04656608Courtesy of FORD MOTOR CO.
    28. NOTE: Do not install new clutch plates during this procedure.
    Fig 28: Locating Reverse Clutch Plate Snap Ring
    G04656609Courtesy of FORD MOTOR CO.
  28. Remove the reverse clutch plate snap ring.
  29. Remove the reverse clutch ring gear and the friction plates, steel plates, separator plate and wave spring.
    Fig 29: Locating Reverse Clutch Ring Gear
    G04656610Courtesy of FORD MOTOR CO.
  30. Using the special tool, remove the return spring retainers.
    Fig 30: Removing Return Spring Retainers Using Special Tool (307-525)
    G04656611Courtesy of FORD MOTOR CO.
  31. Remove the return spring.
    Fig 31: Locating Return Spring
    G04656612Courtesy of FORD MOTOR CO.
    32. NOTE: A small amount of air pressure may be needed to remove the reverse clutch piston from the drum.
    Fig 32: Identifying Reverse Clutch Piston
    G04656613Courtesy of FORD MOTOR CO.
  32. Use only regulated air pressure 206.85 kPa (30 psi) max. Carefully remove the reverse clutch piston.
    1. Apply the recommended amount of air pressure.
    2. Remove the reverse clutch piston.
  33. Remove and discard the reverse clutch piston inner and outer O-ring seals.
    Fig 33: Locating Reverse Clutch Piston Inner & Outer O-Ring Seals
    G04656614Courtesy of FORD MOTOR CO.
  34. Tag and identify all parts for reassembly.
    35. NOTE: The pump dust cover can be removed using a small punch from the opposite side of the case.
    Fig 34: Locating Pump Dust Cover Bolts
    G04656615Courtesy of FORD MOTOR CO.
  35. Remove the 3 pump dust cover bolts. Remove and discard the cover.
  36. Remove the 8 fluid pump bolts and the pump assembly from the converter housing.
    Fig 35: Locating Fluid Pump Bolts
    G04656616Courtesy of FORD MOTOR CO.
  37. Remove the feed tube.
    Fig 36: Locating Feed Tube
    G04656617Courtesy of FORD MOTOR CO.
  38. Remove and discard the O-ring seals from the ends of the feed tube.
    Fig 37: Locating O-Ring Seals
    G04656618Courtesy of FORD MOTOR CO.
    39. NOTE: Be careful not to damage the sealing surfaces of the pump.
    Fig 38: Locating Fluid Pump Seal
    G04656619Courtesy of FORD MOTOR CO.
  39. Using a suitable tool, remove the fluid pump seal.
  40. For fluid pump alignment and installation, refer to FLUID PUMP .
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