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Automatic Transmission - Continuously Variable Transmission (CVT): Assembly: Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0000024
 Dial Indicator With Bracketry 100-002 (TOOL-4201-C)
GF0000942
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0000940
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0017616
 Drawbar (Heavy Duty Threaded) 204-029 (T77F-1176-A)
GF0017676
 Shim Selection Set (Bolts) 308-161 (T88C-77000-C)
GF0017677
 Shim Selection Set (Legs) 308-164 (T88C-77000-JF)
GF0017425
 Installer, Output Shaft Seal 307-527
GF0017430
 Installer, Output Shaft Seal 307-528
GF0017617
 Installer, Differential Bearing Cup 307-530 (includes 307-530-1 and 307-530-2)
GF0017495
 Variator Socket 307-545
GF0017494
 Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9)
GF0017678
 Differential Preload Set-Up Tool 307-533
GF0017679
 Stack Up Gauge 307-534
GF0017680
 Installer, C-Clip 307-565
Material

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
Fig 1: Exploded View Of Transaxle Components (1 Of 3)
GF0017681Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transaxle Components (2 Of 3)
GF0017682Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle Components (3 Of 3)
GF0017683Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W711326-S437 Nut - flex plate to converter (4 required)
2 W301636 Torx screw (attaches case to converter housing) (26 required)
3 7902 Torque converter
4 W301634 Torx screw (attaches pump cover to converter housing) (3 required)
5 7B325 Seal - pump cover
6 7F401 Seal - converter front pump
7 7A103 Piston pump
8 7H497 O-ring - fluid pump feed tube
9 7D203 Socket - pump piston
10 7A136 Gasket - pump to converter housing
11 7005 Converter housing assembly
12 7A108 Stator pump
13 W301950 Torx screw (7 required)
14 7L282 Breather tube assembly
15 W301637 Screw plug (2 required)
16 7B353 Gasket - case to converter housing
17 7H497 Sealing washer - aluminum side shaft lube tube bearing
18 7A206 Side shaft bearing lube tube
19 W301635 Screw
20 7H497 O-ring - Side shaft bearing lube tube
21 W301952 Antifatigue bolt (8 required)
22 7D404 O-ring
23 7D403 O-ring
24 7D402 Piston - reverse clutch
25 7B070 Piston - return spring - reverse clutch
26 7D256 Piston - return spring retainer - reverse clutch
27 7E085 Wave spring - reverse clutch
28 7B164 Reverse clutch friction plates (internally splined) (3 required)
29 7B442 Reverse clutch steel plates (externally splined) (3 required)
30 7B066 Plate - reverse clutch pressure
31 7B421 Snap ring - select fit - reverse clutch plate (6 required)
32 7J309 Dust cover - side shaft assembly
33 7059 Retaining ring
34 W301800 Torx screw (4 required)
35 7222 Bearing cover assembly - side shaft
36 7L280 O-ring
37 7H348 Side shaft gear assembly
38 7H338 Bearing - roller
39 7A153 Ring gear assembly
40 7029 Thrust washer
41 7H497 O-ring - input shaft to converter
42 7N519 Piston ring - input shaft to stator
43 7015 Input shaft (part of assembly 7015)
44 7D090 Needle bearing cage
45 7D014 Select fit washer (15 required)
46 7N168 Bearing - input shaft
47 7D090 Washer
48 7C122 K-ring
49 7D063 Sun gear
50 7H365 Snap ring - forward clutch - select fit (6 required)
51 7B066 Forward clutch pressure plate
52 7B066 Forward clutch friction plates (internally splined) (3 required)
53 7B164 Forward clutch steel plates (externally splined) (3 required)
54 7E085 Forward clutch wave spring
55 7C122 Snap ring - forward clutch
56 7H360 Oil dam - forward clutch
57 7B070 Forward clutch piston return spring
58 7A548 O-ring
59 7C099 O-ring
60 7A262 Forward clutch piston
61 7D404 SO-ring
62 7A360 Disk carrier - forward clutch drum
63 7L280 O-ring - primary shaft
64 7J362 Primary shaft assembly
65 W301947 Countersunk screw (4 required)
66 7085 Flex plate - primary bearing
67 7H338 Primary variator bearing
68 W301951 Primary variator nut
69 7F273 Piston ring
70 7H338 Roller sleeve
71 7059 Select fit retaining ring
72 7F342 Gear - spur (model dependent)
73 7J363 Secondary variator assembly
74 7J365 Sliding rail
75 7J365 Sliding rail
76 W301634 Torx screw
77 7C122 Snap ring - guide pin retaining ring
78 7K229 Ring washer - guide pin retaining ring
79 7C493 Guide pin
80 7G249 Chain
81 W301947 Countersunk screw (6 required)
82 7085 Flex plate - secondary bearing
83 7H338 Bearing - secondary variator
84 W301948 Secondary bearing nut
85 1177 Seal - differential converter side (model dependent)
86 4067 Shim - select fit
87 4222 Outer ring
88 7F465 Differential assembly (model dependent)
89 4221 Differential bearing race (converter housing side)
90 - Differential assembly
91 7F343 Gear - output (part of 7F465)
92 1177 Seal - inner differential
93 4221 Differential bearing race (case side)
94 4222 Outer ring
95 1177 Seal - differential case side
96 W301634 Torx screw (3 required)
97 7978 Oil baffle plate
98 7A434 Cover - top shell
99 W301799 Clip (4 required)
100 7L280 O-ring (4 required)
101 7A209 Selector lever feed tube and forward clutch feed tube
102 7L280 Forward clutch feed tube O-ring
103 7A209 Secondary variator pressure feed tube
104 7H497 O-ring (6 required)
105 7C122 Snap ring
106 7A209 Primary variator pressure feed tube
107 W301634 Torx screw (2 required)
108 7A192 Fixing plate - secondary variator pressure feed tube
109 7G084 Variator chain lubrication tube
110 7A256 Selector lever assembly
111 7277 Manual lever seal
112 7F105 Manual lever roll pin
113 7A232 Park rod
114 7E332 Manual lever detent spring
115 W301949 Detent spring retaining bolt (2 required)
116 W301627 Manual valve assembly bolts (2 required)
117 7D376 Manual valve
118 7G135 Sleeve
119 W301632 Torx screw (2 required)
120 7F293 TR range position sensor
121 W301801 Plug screw
122 7N243 Transmission fluid level indicator grommet
123 7A228 Fluid level indicator tube
124 - Bolt - fluid level indicator tube
125 7A020 Fluid level indicator
126 7223 Gasket
127 7222 Secondary variator cover assembly
128 W301619 Torx screws (8 required)
129 7D070 Park pawl return spring
130 7D071 Park pawl pin
131 7A441 Park pawl
132 W301950 Park pawl guide plate retaining screws (2 required)
133 7D419 Park pawl guide plate
134 7223 Primary variator cover gasket
135 7222 Primary variator cover assembly
136 7C062 Primary variator piston ring
137 7C122 Snap ring
138 7E050 O-ring - primary cover feed tube
139 W301619 Primary variator cover retaining screws (8 required)
140 7D023 Socket
141 7D203 Socket with bonded seals (vehicles built after 12/5/2005)
142 7B155 Pressure filter
143 7J126 Pressure filter O-ring
144 7C103 Thermal by-pass valve cover
145 W301798 Thermal by-pass valve retaining screws
146 7D203 Thermal by-pass valve feed tube
147 7D203 Thermal by-pass valve feed tube (vehicles built after 12/5/2005)
148 7005 Transmission case housing
149 7A209 Primary feed tube
150 7A209 Secondary feed tube
151 7E050 O-ring (6 required)
152 7A209 Pump pressure feed tube
153 7E050 Converter clutch feed tube
154 7D203 Manual valve feed tube
155 7H497 O-ring
156 W301627 Torx screws (8 required)
157 7G276 Guide sleeve
158 W301631 Torx screws
159 7A100 Mechatronic assembly (model dependent)
160 7H103 Output shaft speed (OSS) sensor
161 W301802 OSS sensor spacer
162 W301630 OSS sensor retaining screw
163 7A098 Transmission fluid filter assembly
164 7A191 Transmission fluid pan gasket
165 7E290 Transmission fluid pan magnet
166 7A194 Transmission fluid pan
167 W301628 Transmission fluid pan drain plug
168 W302192 Transmission fluid pan retaining screws (22 required)
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.
CAUTION: 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.
    2. Fig 4: Locating O-Ring Seals In Case
    GF0017684Courtesy of FORD MOTOR CO.
    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.
  2. Loosely install the range selector valve assembly.
    3. Fig 5: Locating Range Selector Valve Assembly
    GF0017685Courtesy of FORD MOTOR CO.
  3. Install the bolts.
    • Tighten to 5 Nm (44 lb-in).
    4. Fig 6: Installing Bolts
    GF0017686Courtesy 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.
    5. Fig 7: Locating Range Selector Valve Assembly Wiring Harness
    GF0017687Courtesy of FORD MOTOR CO.
    NOTE: Be careful not to pinch the wire harness when installing the detent spring.
  5. Install the manual lever detent spring.
    • Tighten to 10 Nm (89 lb-in).
    6. Fig 8: Locating Manual Lever Detent Spring Bolts
    GF0017507Courtesy of FORD MOTOR CO.
  6. Position the transaxle case onto the variators.
    7. Fig 9: Positioning Transaxle Case Onto Variators
    GF0017688Courtesy of FORD MOTOR CO.
  7. Install the spacer washer to the special tool.
    8. Fig 10: Installing Spacer Washer To Special Tool
    GF0017689Courtesy of FORD MOTOR CO.
  8. Assemble the remaining components of the special tool.
    9. Fig 11: Assembling Remaining Components Of Special Tool
    GF0017690Courtesy of FORD MOTOR CO.
    CAUTION: The special tools must be installed as shown or damage to the case will occur.
    CAUTION: 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.
  9. Install the special tools on the top of the case in the position shown.
    10. Fig 12: Installing Special Tools On Top Of Case
    GF0017691Courtesy of FORD MOTOR CO.
  10. Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.
    11. Fig 13: Identifying Special Tool
    GF0017692Courtesy of FORD MOTOR CO.
    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.
  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. Fig 14: Identifying Forcing Screws
    GF0017693Courtesy of FORD MOTOR CO.
  12. Install a new primary nut.
    13. Fig 15: Locating Primary Nut
    GF0017694Courtesy of FORD MOTOR CO.
  13. Install a new secondary nut.
    14. Fig 16: Locating Secondary Nut
    GF0017695Courtesy of FORD MOTOR CO.
    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 Nm (37 lb-ft).
    • Stage 2: Tighten to 500 Nm (369 lb-ft).
    16. Fig 17: Tightening Primary Variator Nut
    GF0017527Courtesy of FORD MOTOR CO.
  16. Using the special tools, tighten the secondary variator nut in 2 stages.
    • Stage 1: Tighten to 30 Nm (22 lb-ft).
    • Stage 2: Tighten to 150 Nm (111 lb-ft).
    17. Fig 18: Tightening Secondary Variator Nut
    GF0017528Courtesy 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.
    18. Fig 19: Locating Primary Feed Tube
    GF0017696Courtesy 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.
    19. Fig 20: Locating Square Cut Seal & O-Ring Seal
    GF0017521Courtesy of FORD MOTOR CO.
  19. Install a new primary cover gasket.
    20. Fig 21: Locating Primary Cover Gasket
    GF0017520Courtesy 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 Nm (35 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
    21. Fig 22: Tightening Primary Cover Bolts In Sequence
    GF0017697Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.
  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. Fig 23: Locating Feed Tube & Secondary Cover Gasket
    G03990830Courtesy of FORD MOTOR CO.
  22. If not previously done, install a new square cut seal in the secondary cover.
    23. Fig 24: Locating Square Cut Seal
    G03990829Courtesy 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 Nm (35 lb-in).
    • Stage 2: Tighten an additional 90 degrees.
    24. Fig 25: Tightening Secondary Cover Bolts In Sequence
    GF0017698Courtesy of FORD MOTOR CO.
  24. Install a new pressure filter.
    25. Fig 26: Locating Pressure Filter
    GF0017526Courtesy 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.
    26. Fig 27: Locating High Pressure Filter Feed Tube
    GF0017525Courtesy of FORD MOTOR CO.
  26. Install the pressure filter case cover.
    • Tighten to 10 Nm (89 lb-in).
    27. Fig 28: View Of Pressure Filter Case Cover & Bolts
    G03990844Courtesy of FORD MOTOR CO.
  27. Install the safety strap on the transaxle.
    28. Fig 29: Locating Safety Strap On Transaxle
    GF0017518Courtesy of FORD MOTOR CO.
  28. Install the special tool onto the transaxle case.
    • Tighten to 55 Nm (41 lb-ft).
    29. Fig 30: Installing Special Tool Onto Transaxle Case
    GF0017475Courtesy of FORD MOTOR CO.
    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.
  29. Using a magnet, carefully install the guide pin retaining ring plate.
    30. Fig 31: Locating Guide Pin Retaining Ring Plate
    GF0017699Courtesy of FORD MOTOR CO.
  30. Install the C-clip onto the special tool.
    31. Fig 32: Locating C-Clip Onto Special Tool (307-565)
    GF0017700Courtesy of FORD MOTOR CO.
  31. Using the special tool, install the guide pin retaining ring.
    32. Fig 33: Installing Guide Pin Retaining Ring
    GF0017701Courtesy 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.
    33. Fig 34: Locating Feed Tube O-Ring Seal
    GF0017506Courtesy of FORD MOTOR CO.
  33. Install the chain lube tube into the case.
    34. Fig 35: Locating Chain Lube Feed Tube
    GF0017505Courtesy of FORD MOTOR CO.
  34. Install the fluid feed transfer tube retainer bracket.
    • Tighten to 10 Nm (89 lb-in).
    35. Fig 36: Locating Chain Lube Feed Tube Retainer Screws & Retainer
    GF0017504Courtesy of FORD MOTOR CO.
  35. Install the transmission fluid baffle.
    • Tighten to 5 Nm (44 lb-in).
    36. Fig 37: Locating Fluid Baffle Screws & Baffle
    GF0017503Courtesy of FORD MOTOR CO.
  36. Install the new forward clutch primary shaft seals.
    37. Fig 38: Locating Forward Clutch Primary Shaft Seals
    GF0017702Courtesy of FORD MOTOR CO.
  37. Install the forward clutch drum without the clutch plates installed.
    38. Fig 39: Installing Forward Clutch Drum Without Clutch Plates
    GF0017703Courtesy of FORD MOTOR CO.
    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.
  38. Install the sun gear.
    39. Fig 40: Locating Sun Gear
    GF0017704Courtesy of FORD MOTOR CO.
  39. Install the sun gear spacer.
    40. Fig 41: Locating Sun Gear Spacer
    GF0017705Courtesy of FORD MOTOR CO.
  40. Install a new sun gear snap ring.
    41. Fig 42: Locating Sun Gear Snap Ring
    GF0017706Courtesy of FORD MOTOR CO.
    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.
    43. Fig 43: Locating Forward Clutch Pack Snap Ring
    GF0017707Courtesy of FORD MOTOR CO.
  43. Install the special tool and zero it out.
    44. Fig 44: Installing Special Tool
    GF0017708Courtesy 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.
    45. Fig 45: Lifting Up On Clutch Plates
    GF0017709Courtesy of FORD MOTOR CO.
    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.
    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

      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.
    47. Fig 46: Locating Forward Clutch Pack Snap Ring
    GF0017707Courtesy of FORD MOTOR CO.
  47. Remove the forward clutch plates, steel and friction.
    48. Fig 47: Locating Forward Clutch Plates, Steel & Friction
    GF0017710Courtesy of FORD MOTOR CO.
  48. Install the forward clutch wave spring.
    49. Fig 48: Locating Forward Clutch Wave Spring
    GF0017711Courtesy of FORD MOTOR CO.
  49. Install the forward clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
    50. Fig 49: Locating Forward Clutch Plates, Steel & Friction
    GF0017710Courtesy of FORD MOTOR CO.
  50. Install the forward clutch pressure plate.
    51. Fig 50: Locating Forward Clutch Pressure Plate
    GF0017712Courtesy of FORD MOTOR CO.
  51. Install the forward clutch pack snap ring.
    52. Fig 51: Locating Forward Clutch Pack Snap Ring
    GF0017707Courtesy of FORD MOTOR CO.
  52. Install the forward clutch roller cage bearing.
    53. Fig 52: Locating Input Shaft Roller Bearing
    GF0017502Courtesy of FORD MOTOR CO.
    NOTE: This is a selective fit washer for the input shaft set up.
  53. Install the forward clutch upper bearing washer.
    54. Fig 53: Locating Upper Input Shaft Roller Bearing Washer
    GF0017501Courtesy of FORD MOTOR CO.
  54. Install the forward clutch upper roller bearing.
    55. Fig 54: Locating Upper Input Shaft Roller Bearing
    GF0017500Courtesy 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.
    56. Fig 55: Locating O-Ring Seals & Split Ring Seal
    GF0017499Courtesy of FORD MOTOR CO.
  56. Install the input shaft and a new planet carrier thrust washer.
    57. Fig 56: Locating Input Shaft & Planet Carrier Thrust Washer
    GF0017498Courtesy of FORD MOTOR CO.
  57. Install the differential assembly in the case.
    58. Fig 57: Locating Differential Assembly
    GF0017497Courtesy of FORD MOTOR CO.
  58. Install the bearing race onto the differential assembly.
    59. Fig 58: Installing Bearing Race Onto Differential Assembly
    GF0017713Courtesy of FORD MOTOR CO.
  59. Compress the special tool and hand-tighten the bolt.
    60. Fig 59: Compressing Special Tool
    GF0017714Courtesy of FORD MOTOR CO.
  60. Install the special tools onto the case.
    61. Fig 60: Installing Special Tools Onto Case
    GF0017715Courtesy of FORD MOTOR CO.
  61. Position the case onto the special tools and install the bolts.
    • Tighten to 8 Nm (71 lb-in).
    62. Fig 61: Positioning Case Onto Special Tools
    GF0017716Courtesy of FORD MOTOR CO.
  62. Loosen the top bolt of the special tool. Using a feeler gauge, measure the opening.
    63. Fig 62: Loosening Top Bolt Of Special Tool & Checking Opening
    GF0017717Courtesy 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

    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.
    65. Fig 63: Locating Selective Bearing Race Shim Into Housing
    GF0017718Courtesy of FORD MOTOR CO.
  65. Position the new bearing race in place.
    66. Fig 64: Locating Bearing Race
    GF0017719Courtesy of FORD MOTOR CO.
  66. Install the special tools on this side of the case.
    67. Fig 65: Installing Special Tools
    GF0017720Courtesy 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.
    68. Fig 66: Installing Remaining Special Tools
    GF0017721Courtesy of FORD MOTOR CO.
  68. Install a new converter housing gasket.
    69. Fig 67: Locating Converter Housing Gasket
    GF0017482Courtesy of FORD MOTOR CO.
    NOTE: This is not a final torque. For this step only you can reuse the old bolts that were removed.
  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 Nm (71 lb-in).
    70. Fig 68: Locating Transaxle Converter Housing Bolts
    GF0017479Courtesy of FORD MOTOR CO.
  70. Install the special tool to measure the input shaft end play.
    • Tighten the wing nut.
    71. Fig 69: Installing Special Tool Onto Input Shaft
    GF0017722Courtesy 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 .
    72. Fig 70: Installing Remaining Special Tool
    GF0017723Courtesy of FORD MOTOR CO.
    NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.
  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 Nm (18 lb-in).
    • Stage 2: Tighten bolts to 8 Nm (71 lb-in).
    • Stage 3: Tighten an additional 90 degrees.
    73. Fig 71: Positioning Converter Housing In Place
    GF0017724Courtesy of FORD MOTOR CO.
  73. Install the side shaft gear assembly.
    • Tighten to 35 Nm (26 lb-ft).
    74. Fig 72: Locating Side Shaft Gear Assembly Bolts
    GF0017477Courtesy of FORD MOTOR CO.
  74. Position the output shaft seal in place.
    75. Fig 73: Positioning Output Shaft Seal
    GF0017725Courtesy of FORD MOTOR CO.
  75. Using the special tool, install the output shaft seal.
    76. Fig 74: Installing Output Shaft Seal
    GF0017726Courtesy of FORD MOTOR CO.
  76. Position the output shaft seal in place.
    77. Fig 75: Positioning Output Shaft Seal
    GF0017727Courtesy of FORD MOTOR CO.
  77. Using the special tool, install the output shaft seal.
    78. Fig 76: Installing Output Shaft Seal
    GF0017728Courtesy of FORD MOTOR CO.
    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.

    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.

  78. 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. Fig 77: Locating O-Ring Seals On Feed Tubes
    GF0017464Courtesy of FORD MOTOR CO.
  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
    80. Fig 78: Feed Tubes
    GF0017465Courtesy 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
    81. Fig 79: Feed Tubes
    GF0017466Courtesy of FORD MOTOR CO.
    NOTE: Note the location of the 5 feed tubes.
  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. Fig 80: Identifying Feed Tubes Inside Case
    G03990874Courtesy of FORD MOTOR CO.
    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.
  82. Position the mechatronic unit onto the case.
    83. Fig 81: View Of Mechatronic Unit
    G03990870Courtesy of FORD MOTOR CO.
  83. Tighten the mechatronic bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 40 degrees (1/8 turn).
    84. Fig 82: Tightening Mechatronic Unit Bolts In Sequence
    GF0017467Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  84. Lubricate the O-ring seal with clean transmission fluid and install the electrical connector into the case.
    85. Fig 83: Locating Electrical Connector
    GF0017461Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  85. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 Nm (53 lb-in).
    86. Fig 84: Locating Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
    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.
  86. Install the OSS sensor spacer, sensor and bolt.
    • Tighten to 8 Nm (71 lb-in).
    87. Fig 85: Locating OSS Sensor Bolt, Sensor & Spacer
    G03990892Courtesy of FORD MOTOR CO.
  87. Connect the electrical connectors.
    88. CAUTION: 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.
    CAUTION: 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.
  88. Lubricate the O-ring seal that is on the new filter with clean transmission fluid and install the fluid filter.
    89. Fig 86: Identifying Fluid Filter
    G03990695Courtesy of FORD MOTOR CO.
  89. Make sure that the filter is seated over one of the mechatronic bolts.
    90. Fig 87: Locating Mechatronic Bolts
    G03990711Courtesy of FORD MOTOR CO.
  90. Install a new transaxle fluid pan gasket.
    91. Fig 88: Locating Transaxle Fluid Pan Gasket
    G03990694Courtesy 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.
    92. Fig 89: Locating Magnet In Pan
    GF0017729Courtesy of FORD MOTOR CO.
  92. Install the transmission fluid pan. Tighten the bolts in the sequence indicated.
    • Tighten to 12 Nm (9 lb-ft).
    93. Fig 90: Tightening Transmission Fluid Pan Bolts In Sequence
    GF0017423Courtesy of FORD MOTOR CO.
    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.
  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. Fig 91: Identifying Location Of Index Slot In Pump
    GF0017730Courtesy of FORD MOTOR CO.
  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.
    95. Fig 92: Removing/Installing Torque Converter Using Special Tool
    G03991060Courtesy of FORD MOTOR CO.
  95. Using 4 new retainers, install the transaxle insulator.
    96. Fig 93: Locating Transaxle Insulator Retainers
    G03990976Courtesy of FORD MOTOR CO.
  96. Install a new transmission fluid tube indicator grommet.
    97. Fig 94: Locating Fluid Level Indicator Tube Grommet
    GF0017496Courtesy of FORD MOTOR CO.
  97. Install the transmission fluid level indicator and tube.
    • Tighten to 10 Nm (89 lb-in).
    98. Fig 95: Locating Fluid Level Indicator & Tube Bolt
    G03990977Courtesy 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 Nm (41 lb-ft).
    100. Fig 96: Identifying Upper Transaxle Mount Retaining Bolts
    G03991478Courtesy of FORD MOTOR CO.
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