REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Removal
- Disconnect negative battery cable. Disconnect positive battery cable and remove battery from vehicle. Position power distribution box aside, and remove battery tray. Remove air cleaner assembly.
- Disconnect solenoid body harness connector. (Scheme 220)or (Scheme 221). Compress tabs (2) on solenoid body harness receptacle (1) and push into case. (Scheme 222) Raise and support vehicle.
- Remove drain plug and drain transmission fluid. See «DRAINING & REFILLING»(ref-141472-S38560890402002062400000) under LUBRICATION. Remove left front fender splash shield. On Cougar, remove receiver-drier bracket screws and position away from main control cover assembly (if equipped). (Scheme 223)
- Disconnect Transmission Range (TR) sensor connector and remove sensor. (Scheme 220)or (Scheme 221). Disconnect shift cable and remove shift cable bracket. (Scheme 224)or (Scheme 225). Remove vent hose. Disconnect the transaxle oil cooler inlet line. (Scheme 226)
- Remove main control cover assembly (side cover) bolts in appropriate sequence. (Scheme 227) Remove cover and gasket. Remove 12 valve body bolts in appropriate sequence. (Scheme 228) Slightly lift valve body and remove "Z" link. (Scheme 229)
- Remove valve body with wiring harness. Remove thermal valve bracket. Pull valve body straight out of transaxle case. Ensure the manual valve control lever does not fall out while removing from the vehicle.
Scheme 220
Scheme 221
Scheme 222
Scheme 223
Scheme 224
Scheme 225
Scheme 226
Scheme 227
Scheme 228
Scheme 229
Installation
- Push the solenoid valve body harness connector up through the transaxle case. Install NEW O-ring on valve body harness connector receptacle. Install receptacle in transaxle case. (Scheme 222)
- Insert "Z" link into end of manual valve. (Scheme 229) Place valve body in position on transaxle case and install 12 valve body bolts. Tighten bolts in sequence to specification. (Scheme 228) See «TORQUE SPECIFICATIONS»(ref-141472-S20626330732002062400000). Loosen nut on ball stud of manual valve detent lever actuating rod assembly. (Scheme 231)
- Remove manual detent lever bolt and lever assembly. Using Shifter Shaft Alignment Tool (T94P-77000-H), move manual control lever shaft to Drive position. (Scheme 230) Install pin to hold the shifter shaft alignment tool in position. Move manual valve detent lever assembly to Drive position.
- Snug nut on ball stud. Remove shifter pin. Rotate shifter shaft alignment tool until socket can be installed on nut. Tighten nut on ball stud to specification. See «TORQUE SPECIFICATIONS»(ref-141472-S20626330732002062400000). Rotate lever back to Drive position and recheck adjustment. Remove pin and alignment tool.
- Install manual detent lever assembly. Tighten bolt to specification. Install main control cover (side cover) with NEW gasket. Tighten bolts in sequence to specification. (Scheme 232) See «TORQUE SPECIFICATIONS»(ref-141472-S20626330732002062400000).
- To complete installation, reverse removal procedures. Tighten drain plug to specification. (Scheme 232) See «TORQUE SPECIFICATIONS»(ref-141472-S20626330732002062400000). If removed, install thermostat housing.
- Install splash shield. Lower the vehicle. Install battery tray, battery and connect the battery cables. Fill the transaxle with appropriate fluid to proper level and check for correct transaxle operation. See «LUBRICATION»(ref-141472-S26882518112002062400000).
Scheme 230
Scheme 231
Scheme 232
- Assemble the Servo Cover Remover/Installer (T94P-77000-L). (Scheme 233) Remove the splash shield. Remove the transaxle oil cooler line bracket and bolt, and position the bracket out of the way. (Scheme 234) Using the servo cover remover/installer (1), compress the servo (2) and remove the retaining ring (3). (Scheme 235)
- Remove the servo cover remover/installer (1). Remove the servo cover assembly. Remove the intermediate and overdrive servo piston and return spring. Wipe the servo piston and the servo cover cap with a lint-free cloth.
- Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston is attached to the servo rod. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston. Inspect the servo retainer spring for cracks, breaks or deformation.
Scheme 233
Scheme 234
Scheme 235
| WARNING | Servo return spring force is very high. Failure to follow these instructions may result in personal injury. |
| CAUTION | Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. |
Note. If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
- Install the servo cover remover/installer. (Scheme 235) Tighten the bolt on the servo cover remover/installer. Install the servo cover retaining ring. If the case is stamped "WG", install a wide-groove snap ring, or the servo will be damaged.
- Loosen the servo cover remover/installer bolt. When the spring tension is released, remove the servo cover remover/installer. Install the transmission fluid cooler line. (Scheme 234) Install the splash shield. Lower the vehicle.
- Start the vehicle. Place gearshift lever in each gear and allow to engage. Check for leaks. Fill the transaxle with appropriate fluid to proper level and check for correct transaxle operation. See «LUBRICATION»(ref-141472-S26882518112002062400000).
Raise the vehicle. Place a drain pan under vehicle. Remove the fluid cooler return tube from the transaxle. Unscrew the return tube union. (Scheme 236) Unclip the return tube from the bracket. Remove the fluid cooler feed tube from the transaxle. (Scheme 226) Disconnect the feed tube (1), from the radiator. (Scheme 237) Disconnect the return tube (2), from the radiator. Unclip the tubes from the bracket.
Scheme 236
Scheme 237
Install new O-ring seals. Install the fluid cooler tubes. When installing oil cooler tubes, do not loosen oil cooler inlet to transaxle. Position and install the lower transaxle oil cooling tube. Position and install the upper transaxle cooling tube.
- Remove the front bumper cover. Disconnect the front oil cooler tube. (Scheme 238) Disconnect and remove the front cooler tube. (Scheme 239)
- Disconnect the rear cooler tube. (Scheme 240) Remove the rear transaxle cooler tube bracket bolt and the cooler tube. (Scheme 234)
- Lower the vehicle. Disconnect and remove the integral-to-auxiliary cooler tube. (Scheme 241) To install, reverse the removal procedure.
Scheme 238
Scheme 239
Scheme 240
Scheme 241
- Remove the driveshaft. Using the Drive Pinion Flange Holding Fixture (205-126), remove the pinion nut. (Scheme 242) Mark the companion flange relative to the pinion spline. Using the Steering Wheel Remover (211-014), remove the companion flange. (Scheme 243)
- Install the companion flange to engage the spline as previously marked. Using the special tool, install the companion flange. Install the pinion nut and tighten to the rotational torque previously recorded when removing the pinion nut. Install the driveshaft.
Scheme 242
Scheme 243
Remove the companion flange. See TRANSFER CASE COMPANION FLANGE . Remove the transfer case rear output shaft (pinion) seal.
Using the Oil Seal Installer (308-430), install the transfer case rear output shaft (pinion) seal. (Scheme 244) Install the companion flange. Fill the transfer case with appropriate fluid to proper level and check for correct transaxle operation. See LUBRICATION.
Scheme 244
Raise and support vehicle. Remove left front fender splash shield. Disconnect Turbine Shaft Speed (TSS) sensor harness connector. TSS sensor is located on exterior of pump housing. (Scheme 245) Unbolt and remove TSS sensor. To install, reverse removal procedure. Replace O-ring as needed. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
Scheme 245
Disconnect negative battery cable. Raise and support vehicle. Disconnect Vehicle Speed Sensor (VSS) harness connector. Disconnect speedometer cable. Unbolt and remove VSS. (Scheme 246) To install, reverse removal procedure. Replace O-ring as needed. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
