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Main Control Valve Body: Installation

    NOTE: If cleaning of the main control assembly or inspecting the valves, refer to MAIN CONTROL - OVERHAUL . If installing a new main control assembly continue with this procedure.
    NOTE: Make sure that the manual control lever pin (part of the TR sensor) is correctly installed in the manual control valve.
  1. Position the TSS, OSS and TR sensor wiring harnesses aside and install the main control valve body, the TR sensor detent spring and the 10 bolts. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 1: Main Control Valve Body And TR Sensor Detent Spring Bolts Tightening Sequence
      G07931065Courtesy of FORD MOTOR CO.
    2. NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body can occur.
    NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transaxle will occur if the solenoid body is not correctly aligned.
    NOTE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transaxle will occur if the filter passages are not clean.
    Fig 2: Locating Solenoid Body Filter Assembly
    G07931066Courtesy of FORD MOTOR CO.
  2. Install a new solenoid body filter assembly by pushing it straight down on to the alignment tabs.
    3. NOTE: Make sure not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses when installing the solenoid body.
    NOTE: Install the different length bolts in the locations noted during disassembly.
  3. Install the solenoid body and the 11 bolts.
    1. 42 mm (1.653 in) bolt
    2. 63 mm (2.48 in) bolts
    3. 80 mm (3.149 in) bolts
    4. 95 mm (3.74 in) bolts
      Fig 3: Identifying Solenoid Body And Bolts
      G07931067Courtesy of FORD MOTOR CO.
  4. Tighten the solenoid body bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 4: Solenoid Body Bolts Tightening Sequence
      G07931068Courtesy of FORD MOTOR CO.
  5. Route the OSS sensor wiring harness and connect the electrical connector.
    Fig 5: Locating OSS Sensor Wiring Harness And Electrical Connector
    G07931069Courtesy of FORD MOTOR CO.
  6. Connect the TR sensor electrical connector.
    1. Connect the electrical connector.
    2. Slide the locking tab over.
      Fig 6: Identifying TR Sensor Electrical Connector And Locking Tab Cover
      G07931070Courtesy of FORD MOTOR CO.
  7. Connect the TSS sensor electrical connector.
    Fig 7: Locating TSS Sensor Electrical Connector
    G07931071Courtesy of FORD MOTOR CO.
  8. Inspect the transaxle main control cover seal for damage and install new if necessary.
    Fig 8: Locating Main Control Cover Seal
    G07931072Courtesy of FORD MOTOR CO.
    9. NOTE: Inspect the 20-pin solenoid body connector seal to make sure that the seal is on the inside of the main control cover or a transmission fluid leak will occur.
    NOTE: Install the studbolts in the locations noted during disassembly.
  9. Install the main control cover and loosely install the 14 bolts.
    1. Bolt location
    2. Studbolt location
      Fig 9: Identifying Main Control Cover Bolts And Studbolts
      G07931073Courtesy of FORD MOTOR CO.
  10. Tighten the main control cover bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 10: Main Control Cover Bolts Tightening Sequence
      G07931074Courtesy of FORD MOTOR CO.
  11. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the 2 transmission fluid cooler tube bracket nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 11: Locating Transmission Fluid Cooler Thermal Bypass Valve, Transmission Fluid Cooler Tube Assembly And Bracket Nuts
      G07931075Courtesy of FORD MOTOR CO.
  12. Connect the transaxle electrical connector.
    Fig 12: Locating Transaxle Electrical Connector
    G07931076Courtesy of FORD MOTOR CO.
    13. NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
    NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
  13. Install the manual control lever and the nut.
    • Tighten to 18 Nm (159 lb-in).
      Fig 13: Locating Manual Control Lever And Nut
      G07931077Courtesy of FORD MOTOR CO.
  14. Inspect the transmission fluid cooler tube backing ring and seal for damage and install a new backing ring or seal if necessary. Lubricate the transmission fluid cooler tube seal with clean transmission fluid and install the backing ring and seal on the transmission fluid cooler tube.
    Fig 14: Identifying Transmission Fluid Cooler Tube Backing Rings And Seals
    G07931078Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
  15. Position the transmission fluid cooler tube in place and install a new bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 15: Locating Transmission Fluid Cooler Tube Bolt
      G07931079Courtesy of FORD MOTOR CO.
  16. Tighten the transmission fluid cooler tube fitting.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 16: Locating Transmission Fluid Cooler Tube Fitting
      G07931080Courtesy of FORD MOTOR CO.
  17. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
      Fig 17: Rotating Manual Control Lever
      G07931081Courtesy of FORD MOTOR CO.
  18. Unlock the selector lever cable adjuster by sliding the locking tab over.
    Fig 18: Sliding Locking Tab Over
    G07931082Courtesy of FORD MOTOR CO.
  19. Slide the cable end forward or backward to align it with the manual control lever.
    Fig 19: Sliding Cable End Forward Or Backward
    G07931083Courtesy of FORD MOTOR CO.
  20. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 20: Locating Manual Control Lever
    G07931084Courtesy of FORD MOTOR CO.
  21. Slide the release tab back to lock the adjuster.
    Fig 21: Sliding Adjuster Tab To Lock Position
    G07931085Courtesy of FORD MOTOR CO.
  22. Position the ACL assembly in place and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
      Fig 22: Locating ACL Assembly Bracket Bolt
      G07931086Courtesy of FORD MOTOR CO.
  23. Tighten the ACL outlet pipe clamp at the TB.
    • Tighten to 5 Nm (44 lb-in).
      Fig 23: Locating Air Cleaner Outlet Pipe And Pipe Clamp
      G07931087Courtesy of FORD MOTOR CO.
  24. Connect the engine breather to the ACL assembly.
    Fig 24: Locating Engine Breather Of ACL Assembly
    G07931088Courtesy of FORD MOTOR CO.
  25. Connect the brake booster vacuum hose to the ACL assembly.
    Fig 25: Locating Brake Booster Vacuum Hose
    G07931089Courtesy of FORD MOTOR CO.
  26. Connect the MAF sensor electrical connector and connect the electrical harness fastener.
    Fig 26: Locating Mass Air Flow Sensor Electrical Connector And ACL Assembly Fastener
    G07931090Courtesy of FORD MOTOR CO.
  27. Fill with clean transmission fluid to the correct level.
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