Automatic Transmission - CD4E: Other Ford Escape I facelift

LINE PRESSURE CHART

LINE PRESSURE CHART

GEAR RATIOS CHART

GEAR RATIOS CHART

Range Selection

The transaxle range selector lever has 6 positions: P, R, N, (D), 2, 1. In addition, a transmission control switch (TCS) allows the driver to prevent a shift to 4th gear (Overdrive) and uses engine compression to help slow the vehicle (engine braking) in 2nd and 3rd gear.

Scheme 331

Park

No power flow is transferred through the transaxle in PARK. A shift lever connected to a set of cams presses the parking pawl into the park gear on the driven sprocket. This locks the final drive and prevents the vehicle from rolling. For safety reasons, always apply the parking brake whenever the vehicle is parked.

Reverse

REVERSE allows the vehicle to be operated in a rearward direction, at a reduced gear ratio. Engine braking is provided in REVERSE.

Neutral

As in PARK, there is no power transferred through the transaxle in NEUTRAL. However, the final drive is not locked by the parking pawl, so the wheels are free to rotate. The vehicle may be started in NEUTRAL.

Drive

The DRIVE position provides all automatic shifts (1st through 4th), apply and release of the torque converter clutch, and maximum fuel economy during normal operation. Engine braking is provided in the 4th gear. Fourth gear (Overdrive) may be canceled by depressing the transmission control switch (TCS) that is located on the transmission range selector. Engine braking is also provided in 2nd and 3rd gear with the TCS on.

Second Gear Position

SECOND provides a 2nd gear hold position after automatic or manual upshift or downshift. When SECOND is selected from a stop, the transaxle will start in 2nd gear for maximum traction on slippery surfaces. Engine braking is provided in 2nd gear when in the SECOND position.

Low Position

MANUAL LOW provides a 1st gear hold after automatic or manual downshift. The transaxle is prevented from downshifting into 1st gear above a specific speed approximately 48 km/h (30 mph) to protect the powertrain from over speeding. Engine braking is provided in MANUAL LOW position making it especially useful for descending steep grades.

Upshifts

The powertrain control module (PCM) has an adaptive learn strategy to electronically control the transaxle. The adaptive learn strategy will automatically adjust the shift feel to the driver demands. The first few hundred miles of operation the transaxle may have abrupt shifts, this is a normal operation and will correct itself. If the battery has been disconnected for longer than 20 minutes the shift tables will reset and need to be relearned. Upshifting is controlled by the PCM. The PCM receives inputs from various engine and vehicle sensors along with driver demands to control shift scheduling, shift feel and torque converter clutch operation.

Downshifts

Under certain conditions the transaxle will downshift automatically to a lower gear range (without moving the transaxle range selector lever). There are 3 categories of automatic downshifts: coastdown, torque demand and forced or kickdown shifts.

Coastdown

The coastdown downshift occurs as the name indicates, when the vehicle is coasting down to a stop.

Kickdown

For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A forced downshift into 2nd gear is possible below 88 km/h (55 mph). Below approximately 40 km/h (25 mph) a forced kickdown to 1st gear will occur. For all shift speeds, specifications are subject to variation due to tire size and engine calibration requirements.

Scheme 332

Impeller and Cover

The impeller and cover assembly drives the impeller blades and pump assembly. The impeller is primarily responsible for driving the turbine with hydraulic fluid by means of centrifugal force. The cover provides a mating surface for the torque converter clutch piston plate and dampener assembly.

Turbine

The turbine is driven by centrifugal fluid force from the impeller. The turbine transmits input torque to the drive chain and driven sprocket through the turbine shaft.

Reactor

The reactor redirects fluid flow from the turbine back to the impeller so that fluid rotates in the same direction as the impeller. This action also assists in torque multiplication.

Turbine Shaft

The turbine shaft connects the torque converter stator with the forward/coast/direct clutch cylinder. When applied, the forward/coast/direct clutch cylinder transmits input torque to the reverse/overdrive ring gear assembly, which also acts as the drive sprocket. This allows input torque to be transmitted from the torque converter to the drive chain and driven sprocket.

Scheme 333

Geartrain

The geartrain includes the planetary gearsets, apply components and final drive gearset and differential.

Planetary Gearsets

The automatic transaxle has 2 planetary gearsets to provide operation in reverse and 4 forward speeds. The gearsets are comprised of the following components

Scheme 334

1. Low/intermediate sun gear assembly
2. Low/intermediate carrier assembly
3. Low/intermediate ring gear assembly
4. Reverse/overdrive sun gear and shell assembly
5. Reverse/overdrive carrier assembly
6. Reverse/overdrive ring gear assembly

Scheme 335

Drive Chain and Sprockets

A chain drive transfers torque from the torque converter turbine to the planetary gearsets. The chain drive is composed of the following components

1. Reverse/overdrive ring gear assembly which acts as a drive sprocket
2. Driven sprocket
3. Drive chain

The drive chain connects the reverse/overdrive sun gear with the driven sprocket. The final drive sun gear located on top of the driven sprocket meshes with the final drive gearset.

The final drive consists of a planetary gearset that transfers and multiplies torque from the planetary gearsets to the differential. The final drive consists of the following components

1. Final drive sun gear: is chain driven by the reverse/overdrive ring gear assembly and transfers torque to the final drive carrier.
2. Final drive carrier: the final drive carrier acts as the driven member and is part of the differential case.
3. Final drive ring gear: is held by the converter housing and is always the held member of the final drive planetary gearset.

Scheme 336

The differential assembly drives the differential pinion gears and the differential side gears, which in turn, drive the front wheel driveshaft and joints and provides differential action if driving wheels are turning at different speeds. The differential assembly consists of the following components

1. Differential case (part of the final drive carrier)
2. Two pinion gears supported by a pinion shaft
3. Two side gears supported by the differential case and halfshafts

Intermediate and Overdrive Band

The intermediate and overdrive band assembly holds the reverse clutch drum assembly to the transaxle case in 2nd and 4th gear. This action causes the reverse/overdrive sun gear and shell assembly to be held stationary in 2nd and 4th gears.

Intermediate and Overdrive Servo

The intermediate and overdrive servo is the hydraulic actuator which applies the intermediate and overdrive band assembly. Line pressure is applied through the servo apply circuit where it works on one side of the servo piston. This forces the piston to move up the servo bore in the transaxle case, which moves the servo apply rod against one end of the intermediate and overdrive band assembly. Because the other end of the intermediate and overdrive band assembly is anchored to the transaxle case, the ends of the intermediate and overdrive band assembly are squeezed around the reverse clutch drum assembly, holding the reverse clutch drum assembly stationary.

Forward Clutch

The forward clutch connects the turbine shaft to the outer race of the forward one-way clutch, which in turn drives the low/intermediate sun gear in all forward gear ranges. However, in 4th gear, the forward clutch transmits no power because the forward one-way clutch is overrunning. The forward clutch is a multi-disc clutch and is contained in the forward/coast/direct clutch cylinder assembly.

Direct Clutch

The direct clutch connects the turbine shaft to the low/intermediate ring gear assembly when the vehicle is in 3rd and 4th gears. It is a multi-disc clutch and is contained in the forward/coast/direct clutch cylinder assembly.

Reverse Clutch Coast Clutch

The reverse clutch connects the turbine shaft to the reverse/overdrive sun gear and shell assembly when it is in reverse gear. It is a multi-disc clutch and is contained in the reverse clutch drum assembly.

The coast clutch is a multi-disc clutch located beneath the forward clutch in the forward/coast/direct clutch cylinder assembly. It connects the low/intermediate sun gear assembly to the turbine shaft assembly when the transmission control switch is ON in the DRIVE position or when any manual gear is selected.

Low/Reverse Clutch

The low/reverse clutch holds the reverse/overdrive carrier assembly to the transaxle case when the transaxle is shifted into the R or 1 position. The low/reverse clutch is splined to the transaxle case and is a multi-disc clutch.

Forward One-Way Clutch (OWC)

The forward one-way clutch (OWC) is either a sprag or mechanical diode type, one-way clutch. The forward OWC combines with the forward clutch to connect the turbine shaft assembly to the low/intermediate sun gear assembly in 1st, 2nd and 3rd gears. The forward OWC overruns during all coasting operations and is always overrunning in 4th gear.

Low One-Way Clutch

The low OWC is a roller type OWC which allows the transaxle case to hold the reverse/overdrive carrier stationary when the transaxle is in 1st gear. The low OWC will only hold the reverse/overdrive carrier assembly during acceleration. When coasting, the low OWC will overrun, disconnecting the final drive from the compound planetary gearset.

Hydraulic System

The hydraulic system uses transmission fluid to cool, lubricate and provide hydraulic pressure to the hydraulic circuits within the transaxle.

Scheme 337

Main Control

The main control houses the hydraulic valves and solenoid valves. These valves direct fluid flow, restrict fluid flow and change fluid pressure. The main control receives signals from the solenoid valve body and changes those signals into hydraulic actions. These actions control the operation of the hydraulic clutches and intermediate and overdrive band assembly, and supply lubrication to the transaxle.

Low/Reverse Accumulator

The low/reverse accumulator cushions the application of the low/reverse clutch when the transaxle is shifted to reverse gear.

2-4 Accumulator

The 2 - 4 accumulator cushions the shift feel during intermediate and overdrive band applications.

Forward Accumulator

The forward accumulator cushions the application of the forward clutch when the transaxle is shifted into (D), 2 or 1.

Transaxle Electronic Control System

Shift timing, shift feel (line pressure) and torque converter clutch (TCC) control in the automatic transaxle are controlled electronically by the powertrain control module (PCM) and its input/output network. The transaxle control is separate from the engine control strategy in the PCM, although some of the input signals are shared. Some input signals come from the engine-related sensors, mass air flow (MAF) sensor or engine coolant temperature (ECT) sensor to give the PCM an idea of the load and climate under which the engine is operating. Some other inputs are based on driver inputs, such as accelerator pedal position which is relayed to the PCM by the throttle position (TP) sensor. Still other inputs are provided by the transaxle itself, from sensors such as the transmission range (TR) sensor (controlled by the placement of the transaxle range selector) and the transmission fluid temperature (TFT) sensor. Using all of these input signals, the PCM can determine when the time and conditions are right for a shift or converter clutch application. The PCM can also determine the line pressure needed to optimize shift feel. To accomplish these functions, the PCM controls 5 electronic solenoids, 2 ON/OFF solenoids for shifting, one pulse width modulating (PWM) solenoid for torque converter clutch control, an electronic pressure control (EPC) solenoid for line pressure control and a 3-2 timing/coast clutch solenoid to control the release of the coast clutch and the coordinated release of the direct clutch and the apply of the low and intermediate band, during a 3-2 downshift.

Powertrain Control Module (PCM)

The operation of the transaxle is controlled by the PCM. Many input sensors provide information to the PCM. The PCM then controls the actuators which affect transaxle operation.

Air Conditioning (A/C) Clutch

The A/C cycling switch is located on the suction accumulator/drier of an original equipment manufacture (OEM) factory-installed air conditioning system. When the air conditioning clutch cycling switch contacts close, the PCM receives a signal voltage from the A/C clutch switch indicating that the A/C compressor clutch is engaged. The PCM uses the A/C clutch cycling switch signal to adjust line pressure to compensate for the additional engine load.

Brake Pedal Position (BPP) Switch

The BPP switch signals the PCM when the brakes are applied. The BPP switch is closed when the brakes are depressed and open when they are released. The BPP switch will also disengage TCC when brake is applied.

Engine Coolant Temperature (ECT) Sensor

The ECT detects the temperature of the engine coolant and supplies the information to the PCM. The PCM uses the ECT sensor to control torque converter clutch (TCC) operation.

Electronic Ignition (El) System

The electronic ignition system consists of the PCM, a crankshaft position (CKP) sensor and one multi-tower ignition coil. The CKP sensor sends a crankshaft position signal to the PCM. The PCM then sends the appropriate ignition signal to the ignition coil. The PCM uses this signal in the transaxle shift strategy, as well as TCC control and electronic pressure control. Wide open throttle (WOT) shift control is also affected by the El system input.

Mass Air Flow (MAF) Sensor

The MAF directly measures the mass of the air flowing into the engine. The MAF sensor output is a D.C. (analog) signal ranging from about 0.5 volt to 5.0 volts used by the PCM to calculate the injector pulse width for air/fuel ratio. For transaxle strategies, the MAF sensor is used for electronic pressure control (EPC), shift and TCC scheduling.

Transmission Control Switch (TCS)

The TCS is a momentary contact switch. When the TCS switch is pressed, a signal is sent to the PCM. The PCM then energizes the transmission control indicator lamp (TCIL) and engages or disengages 4th gear operation and provides coast braking in 2nd and 3rd.

Transmission Control Indicator Lamp (TCIL)

The TCIL is located in the instrument panel and is labeled O/D OFF. The transmission control switch (TCS) controls the ON/OFF operation of the TCIL. When the driver initially presses the button of the TCS, the TCIL turns ON to indicate that transaxle operation in 4th gear is disabled. When the driver presses the TCS again, the TCIL turns OFF.

Throttle Position (TP) Sensor

The TP sensor is a potentiometer mounted on the throttle body. The TP sensor detects the position of the throttle plate and sends this information to the PCM as a varying voltage signal. If a fault occurs in the TP sensor circuit, the PCM will recognize that the TP sensor signal is out of specification. The PCM will then operate the transaxle at a high EPC pressure to prevent transaxle damage. The PCM also uses this signal for shift scheduling, EPC and TCC control.

Transmission Range (TR) Sensor

The PCM sends a voltage signal to the TR sensor. The TR sensor incorporates a series of step down resistors which act as a voltage divider. The PCM monitors this voltage, which corresponds to the position of the transmission range selector lever (P, R, N, (D), 2, 1) to determine desired gear and EPC pressure. The TR sensor is located on the top of the transaxle, and also contains the neutral/start, and reverse lamp circuits.

Turbine Speed Shaft (TSS) Sensor

The TSS sensor is a magnetic pickup that sends a signal to the PCM that indicates turbine shaft input speed. The TSS sensor provides converter turbine shaft speed information for TCC control strategy. Also used in determining static EPC pressure setting during shifts.

Output Shaft Speed (OSS) Sensor

The OSS sensor is a magnetic pick-up which detects the park gear teeth rotation and sends a signal to the PCM as an indicator of the transaxle output shaft speed. The OSS signal is processed by the PCM for shift scheduling and inputs to other control modules such as: Electronic Speedometer, Trip Computer, Speed Control, Adaptive Damping, Auxiliary Warning and Radio CD.

The PCM controls the operation of the transaxle through wiring to the solenoid valve body assembly mounted on the main control assembly. An electrical connector from the solenoid valve body assembly fastens to the top of the transaxle case, where it connects to PCM wiring. The solenoid valve body assembly is serviced as one part when any new components are installed.

Electronic Pressure Control (EPC) Solenoid

The EPC solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. This solenoid provides electronic pressure control (EPC) which regulates line pressure (LP) and line modulator (LM) pressure. This is controlled by producing a resisting pressure to the main regulator and line modulator circuits. The LP and LM pressures control the clutch application pressures.

3-2 Timing/Coast Clutch Solenoid (3-2 T/CCS)

The 3-2 T/CCS is a VFS. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. It supplies pressure to the S3 circuit to control the release of the direct clutch and to apply the intermediate and overdrive band during a 3-2 downshift. This solenoid also regulates the pressure in the S3 circuit to control the application and release of the coast clutch.

Know and Understand the Concern

In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer contact may be required in order to begin to verify the concern. Understand the conditions as to when the concern occurs. For example

1. Hot or cold vehicle temperature
2. Hot or cold ambient temperature
3. Vehicle driving conditions
4. Vehicle loaded or unloaded

After understanding when and how the concern occurs, proceed to verifying the concern.

Verification of Condition

This section provides information which must be used in both determining the actual cause of customer concerns and carrying out the appropriate repair procedures.

The following procedures must be used when verifying customer concerns for the transaxle

Determine Customer Concerns

Note. If noise/vibration, check for dependencies: rpm, vehicle speed, shift, gear, range or temperature.

Note. Some transaxle conditions may cause engine concerns. The torque converter clutch not disengaging will stall the engine.

1. Hot or cold vehicle operating temperature
2. Hot or cold ambient temperature
3. Type of terrain
4. Vehicle loaded/unloaded
5. City/highway driving
6. Upshift
7. Downshift
8. Coasting
9. Engagement
10. Noise/vibration - check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent

Shift Linkage Check

Check for a misadjustment in the shift linkage by matching the detents in the transmission range selector lever with those in the transaxle. If they match, the misadjustment is in the indicator. Do not adjust the shift linkage.

Hydraulic leakage at the manual control valve can cause delay in engagement and/or slipping while operating if the linkage is not correctly adjusted. Correctly adjust the shift linkage. Refer to AUTOMATIC TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS - CD4E .

Check TSBs

Refer to all Technical Service Bulletins which pertain to the transaxle concern and follow the procedures as outlined.

Output State Control (OSC) Mode

Note. Retrieve continuous codes and carry out a KOEO & KOER On-Demand Self Test before using output state control (OSC). Any diagnostic trouble codes (DTCs) related to the transmission range (TR) sensor, output shaft speed (OSS) sensor or the vehicle speed sensor (VSS) must be fixed first or the powertrain control module (PCM) will not allow the OSC to operate.

OSC on the scan tool allows the technician to easily and quickly control the main functions and components of this transmission. OSC is used to help test the electrical, hydraulic or mechanical concerns related to the transmission. The scan tool also provides PID information, along with the OSC functions, to accurately diagnose the transmission. For example, OSC allows the technician to shift the transmission, engage the converter clutch, or command line pressure or turn a solenoid off and on. OSC has 2 menus for operation, the BENCH mode and the DRIVE mode.

OSC - Bench Mode

The BENCH mode is functional only when the gear selector is in PARK or NEUTRAL. The BENCH mode may be used when the engine is either ON (running) or OFF. The BENCH mode allows the technician to function the following components

1. SS1 - Directs PCM to command Shift Solenoid A OFF or ON
2. SS2 - Directs PCM to command Shift Solenoid B OFF or ON
3. SSB_AMP - Directs PCM to command the current to the 3-2 Timing/Coast Clutch Solenoid
4. TCC - Directs PCM to command the Torque Converter Solenoid OFF or ON (OFF = 0% duty cycle and ON = 100% duty cycle)
5. LINEDSD - Directs PCM to command line pressure to either 50, 75, 100, 125, 150, 175, 200 PSI. The PCM will command the appropriate PCA current to obtain the commanded line pressure.

SS1, SS2, SSB_AMP and TCC in Bench Mode

These OSC functions are used to command SS1, 552, SSB_AMP and TCC solenoids OFF and ON when carrying out an electrical circuit check.

The OSC functions for parameters SS1, SS2 and TCC allows the technician to choose the following options

1. OFF - Directs PCM to command the solenoid OFF.
2. ON - Directs PCM to command the solenoid ON.
3. XXX - Cancels OSC command (returns solenoid to normal operation).

The OSC options to control SSB_AMP for the 3-2 Timing/Coast Clutch Solenoid in BENCH mode are as follows

1. 0 - Commands TCM to control current to zero amps.
2. 0.25 - Commands TCM to control current to 1/4 amp or 250 milliampere.
3. 0.50 - Commands TCM to control current to 1/2 amp or 500 milliampere.
4. 0.75 - Commands TCM to control current to 3/4 amp or 750 milliampere.
5. 1 - Commands TCM to control current to 1 amp or 1000 milliampere.
6. XXX - Cancels OSC and allows the PCM/TCM normal control of the VFS solenoids.

Controlling the solenoids allows the technician to measure the circuit current using an inductive pickup or to measure the circuit voltage when carrying out electrical tests.

The vehicle requirements for SENDING an OSC value for SS1, SS2, SSB_AMP or TCC are as follows

1. Key on/engine off or key on/engine running at idle.
2. Gear selector in PARK or NEUTRAL.

The vehicle requirements must be met when sending the OSC value for SS1, SS2, SSB_AMP and TCC solenoids. If the vehicle requirements are not met when sending the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted. After sending the OSC value, if the vehicle requirements are no longer met the ERROR MESSAGE will not appear but the OSC value will be canceled by the PCM (monitoring corresponding PID). The OSC value XXX may be sent anytime to cancel OSC.

LINEDSD in Bench Mode

The LINEDSD in BENCH mode may be used when carrying out an electrical check on the EPC solenoid or used to test the functionality of the transmission's electronic control of the line pressure. When testing the EPC for controlling the line pressure the technician is required to run the engine greater then 1500 rpm. The hookup of a hydraulic pressure gauge is required to actually test whether the transmission line pressure is correct. This will test whether the hydraulic pump, the pressure regulator and the EPC solenoid and other associated mechanical and hydraulic components are working properly.

The line pressure may be commanded between 60 psi and 180 psi. When carrying out an electrical test on the EPC solenoid, set LINEDSD to 180 psi to command the EPC solenoid OFF and 75 psi to command the PCA solenoid ON. Commanding the 180 psi may not electrically turn the pressure solenoid completely off and commanding 75 psi may not electrically turn the pressure solenoid completely on.

The OSC functions for the parameter LINEDSD allows the technician to choose the following options

1. 75 - Directs PCM to command line pressure to 75 psi.
2. 100 - Directs PCM to command line pressure to 100 psi.
3. 125 - Directs PCM to command line pressure to 125 psi.
4. 150 - Directs PCM to command line pressure to 150 psi.
5. 175 - Directs PCM to command line pressure to 175 psi.
6. XXX - Cancels OSC command line pressure (returns to normal operation).

The vehicle requirements for sending an OSC value for LINEDSD in BENCH mode is as follows

1. Key on/engine off or key on/engine running (engine speed greater then 1500 rpm).
2. Gear selector in PARK or NEUTRAL.

The vehicle requirements must be met when sending the OSC value for PCA. If the vehicle requirements are not met when sending the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted. After the OSC value for PCA is sent, if the vehicle requirements are no longer met the ERROR MESSAGE will not appear but the OSC value will be canceled by the PCM (monitoring corresponding PID). The OSC value XXX may be sent anytime to cancel OSC.

OSC - Drive Mode

The DRIVE mode allows control of 2 transmission functions. Each OSC function has a unique set of vehicle operating requirements that the technician is required to meet before he/she is allowed to operate OSC. The recommended procedure, when using the DRIVE mode, is to command one parameter at a time. The DRIVE mode allows the technician to control the following OSC functions on the transmission

1. OSCGEAR - Directs the PCM to upshift or down shift.
2. OSCTCC - Directs the PCM to engage or disengage the torque converter clutch.

OSCGEAR in Drive Mode

This OSC function is used to test the transmission gear changes. The advantage of using OSC for changing gears is to allow the technician to easily test a specific gear and/or upshift or down shift that has been identified as the customer complaint. When using the OSC to command a shift change, the PCM should command the correct or normal pressure for that shift. The transmission will remain in the gear that OSC has commanded until OSC commands another gear or OSC is cancelled.

The OSC functions for the OSCGEAR parameter allow the technician to choose the following options

1. 1 - Directs PCM to command 1st gear.
2. 2 - Directs PCM to command 2nd gear.
3. 3 - Directs PCM to command 3rd gear.
4. 4 - Directs PCM to command 4th gear.
5. XXX - Cancels OSC command for GEAR (returns to normal operation).

The vehicle requirements must be met when sending the OSC value for GEAR. If the vehicle requirements are not met when sending the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted. After the OSC value for GEAR is sent, if the vehicle requirements are no longer met the ERROR MESSAGE will not appear but the OSC value will be canceled by the PCM (monitoring corresponding PID). The OSC value XXX may be sent anytime to cancel OSC.

It is recommended to use the OSCTCC parameter in OSC to first turn off the converter clutch when testing the transmission gear changes. This will allow the technician to evaluate just the gear changes. If the torque converter clutch is not turned off, then the PCM may command the torque converter clutch to engage during a shift. This could make it more difficult for the technician to determine whether a bad shift is the result of the torque converter engaging or the actual gear change.

The vehicle requirements for SENDING a OSCGEAR value is as follows

1. Engine is running
2. Gear selector is in (D)
3. Vehicle speed is greater than 3 km/h (2 mph)
4. Vehicle speed must be lower than 48 km/h (30 mph) to command a downshift to 1st gear
5. Vehicle speed must be lower than 96 km/h (60 mph) to command a downshift to 2nd gear
6. Vehicle speed must be lower than 145 km/h (90 mph) to command a downshift to 3rd gear
7. Vehicle speed must be greater than 48 km/h (30 mph) to command an upshift to 4th gear

OSCTCC in Drive Mode

This function is used to test whether the torque converter clutch is locking and unlocking correctly.

The OSC functions for the TCC parameter allows the technician to choose the following

1. ON - Commands TCC solenoid ON (100% duty cycle) to engage the converter clutch.
2. OFF - Commands TCC solenoid OFF (0% duty cycle) to disengage the converter clutch.
3. XXX - Cancels OSC for TCC (returns to normal operation)

The vehicle requirements must be met when sending the OSC value for TCC. If the vehicle requirements are not met when sending the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted. After the OSC value for TCC is sent, if the vehicle requirements are no longer met the ERROR MESSAGE will not appear but the OSC value will be canceled by the PCM (monitoring corresponding PID). The OSC value XXX may be sent anytime to cancel OSC.

The vehicle requirements for SENDING the OSCTCC value OFF is as follows

1. Engine is running
2. Gear selector is in Overdrive
3. Vehicle speed is greater than 3 km/h (2 mph)

The vehicle requirements for SENDING the OSCTCC value ON is as follows

1. Engine is running
2. Gear selector is in (D)
3. Vehicle speed is greater than 3 km/h (2 mph)
4. Transmission fluid temperature (TFT) is between 16°C (60°F) and 116°C (240°F)
5. Brake is off when vehicle speed is below 32 km/h (20 mph)
6. Not an excessive load on the engine
7. Not during an upshift or downshift
8. Engine speed is greater then 1,500 rpm

Using Output State Control (OSC) and Monitoring PIDs

To confirm that the OSC value was sent by the scan tool and the PCM has accepted the OSC command, a corresponding PID for each OSC parameter must be monitored. After sending the OSC value, the corresponding PID value should be the same as the OSC value. Additional PIDS should be monitored to help the technician accurately diagnose the transmission. The following is a list of PIDs to monitor while using OSC.

OSC PARAMETER REFERENCE

PID DESCRIPTION

Rotunda Transmission Tester

The Rotunda Transmission Tester is used to diagnose electronically controlled transaxle and is used in conjunction with the pinpoint tests. The tests should be carried out in order. Installing the Rotunda Transmission Tester allows separation of the vehicle electronics and the transaxle electronics. Refer to the Rotunda Transmission Tester manual for these tests.

1. Bench Testing - Engine Off
2. Resistance/Continuity Test
3. Solenoid Voltage Test
4. Dynamic Testing - Engine On
5. EPC Solenoid
6. Transaxle Engagement
7. Upshifts/Downshifts
8. Torque Converter Clutch (TCC) Engagement
9. Coast Clutch Engagement
10. Turbine Shaft Speed (TSS) Sensor
11. Output Shaft Speed (OSS) Sensor
12. Transmission Range (TR) Sensor
13. Switch Test - Park/Neutral, Backup Lamp and Optional Circuits

Transaxle Connector Layouts

Note. This vehicle is equipped with a new style powertrain control module. This is a 50-pin control module with 3 separate connectors. One connector for the chassis (C), one for the transaxle (T) and one for the body (B). The pin numbers listed throughout these pinpoint tests will have the letter C and T to designate the connector.

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Shift Solenoid Failure Mode Chart "Always OFF"

Failed OFF due to PCM and/or vehicle wiring concerns, and/or solenoid electrically stuck off, and/or hydraulically or mechanically stuck off.

SHIFT SOLENOID FAILURE MODE CHART - ALWAYS OFF

SHIFT SOLENOID FAILURE MODE CHART - ALWAYS OFF

Shift Solenoid Failure Mode Chart "Always ON"

Failed ON due to PCM and/or vehicle wiring concerns, and/or solenoid electrically stuck on, and/or hydraulically or mechanically stuck on.

SHIFT SOLENOID FAILURE MODE CHART - ALWAYS ON

SHIFT SOLENOID FAILURE MODE CHART - ALWAYS ON

Engine Idle Speed Check

Refer to INTRODUCTION - GASOLINE article for Escape (gasoline) and Mariner or INTRODUCTION- HYBRID ESCAPE article for Escape (Hybrid) for the engine idle speed adjustment procedure.

Line Pressure Chart (2.3L and 3.0L)

LINE PRESSURE CHART (2.3L AND 3.0L)

Stall Speed Chart

STALL SPEED CHART

After testing DRIVE (D) and REVERSE (R), move transaxle range selector lever to NEUTRAL (N) and run engine for about 15 seconds to allow torque converter to cool before testing next range.

If the stall speeds were too high, refer to the following STALL SPEED DIAGNOSIS CHART . If the stall speeds were too low, first check engine tune-up. If engine is OK, remove torque converter and check torque converter one-way clutch for slippage.

Air Pressure Tests

A no-drive condition can exist even with correct transmission fluid pressure because of inoperative clutches or bands. Refer to the BAND AND CLUTCH APPLICATION CHARTS A and BAND AND CLUTCH APPLICATION CHART B to determine the appropriate elements. A clutch concern can be located by substituting air pressure for oil pressure to determine the location of the malfunction.

For example, when the transaxle range selector lever is in a forward gear range ((D), 2, 1), a no-drive condition can be caused by an inoperative forward clutch.

External Sealing

This transaxle has the following parts to prevent external fluid leakages

1. Gaskets
2. Lip type seals
3. O-rings
4. Seal rings

Scheme 343

Material

MATERIAL SPECIFICATION CHART

When internal wear or damage has occurred in the transaxle, metal particles, clutch plate material or band material can be carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transaxle concerns and must be removed from the system before the transaxle is returned for repair.

ENGAGEMENT CONCERN: NO FORWARD

DIAGNOSTIC ROUTINES - ENGAGEMENT CONCERN NO FORWARD

ENGAGEMENT CONCERN: NO REVERSE ONLY

DIAGNOSTIC ROUTINES - ENGAGEMENT CONCERN NO REVERSE ONLY

ENGAGEMENT CONCERN: HARSH REVERSE OR FORWARD

DIAGNOSTIC ROUTINES - ENGAGEMENT CONCERN HARSH REVERSE OR FORWARD

ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE OR FORWARD

DIAGNOSTIC ROUTINES - ENGAGEMENT CONCERN DELAYED/SOFT REVERSE OR FORWARD

ENGAGEMENT CONCERN: NO FORWARD AND NO REVERSE

DIAGNOSTIC ROUTINES - ENGAGEMENT CONCERN NO FORWARD AND NO REVERSE

SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOME OR ALL SHIFTS MISSING

SHIFT CONCERNS: SHIFT TIMING - EARLY/LATE

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SHIFT TIMING - EARLY/LATE

SHIFT CONCERNS: TIMING - ERRATIC/HUNTING

DIAGNOSTIC ROUTINES - SHIFT CONCERNS TIMING - ERRATIC/HUNTING

SHIFT CONCERNS: FEEL - SOFT/SLIPPING

DIAGNOSTIC ROUTINES - SHIFT CONCERNS FEEL - SOFT/SLIPPING

SHIFT CONCERNS: FEEL - HARSH

DIAGNOSTIC ROUTINES - SHIFT CONCERNS FEEL - HARSH

SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR ("D" POSITION)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS NO 1ST GEAR, ENGAGES IN HIGHER GEAR (D POSITION)

SHIFT CONCERNS: NO MANUAL 1ST GEAR (1st in "D" is OK)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS NO MANUAL 1ST GEAR (1ST IN D IS OK)

SHIFT CONCERNS: NO 1-2 SHIFT (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS NO 1-2 SHIFT (AUTOMATIC)

SHIFT CONCERNS: NO 2-3 SHIFT (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS NO 2-3 SHIFT (AUTOMATIC)

SHIFT CONCERNS: NO 3-4 SHIFT (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS NO 3-4 SHIFT (AUTOMATIC)

SHIFT CONCERNS: SOFT/SLIP 1-2 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 1-2 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: SOFT/SLIP 2-3 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 2-3 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 2-3 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: SOFT/SLIP 4-3 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 4-3 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: SOFT/SLIP 3-2 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 3-2 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: SOFT/SLIP 2-1 SHIFT ONLY (AUTOMATIC OR KICKDOWN)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS SOFT/SLIP 2-1 SHIFT ONLY (AUTOMATIC OR KICKDOWN)

SHIFT CONCERNS: HARSH 1-2 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS HARSH 1-2 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: HARSH 2-3 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS HARSH 2-3 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: HARSH 3-4 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS HARSH 3-4 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: HARSH 4-3 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS HARSH 4-3 SHIFT ONLY (AUTOMATIC)

SHIFT CONCERNS: HARSH 3-2 SHIFT ONLY (AUTOMATIC)

DIAGNOSTIC ROUTINES - SHIFT CONCERNS HARSH 3-2 SHIFT ONLY (AUTOMATIC)

OTHER CONCERNS: SHIFT LEVER EFFORT IS HIGH

DIAGNOSTIC ROUTINES - OTHER CONCERNS SHIFT LEVER EFFORT IS HIGH

OTHER CONCERNS: EXTERNAL LEAKS

DIAGNOSTIC ROUTINES - OTHER CONCERNS EXTERNAL LEAKS

OTHER CONCERNS: VEHICLE DRIVEABILITY

DIAGNOSTIC ROUTINES - OTHER CONCERNS VEHICLE DRIVEABILITY

OTHER CONCERNS: ENGINE WILL NOT CRANK

DIAGNOSTIC ROUTINES - OTHER CONCERNS ENGINE WILL NOT CRANK

OTHER CONCERNS: NO PARK RANGE

DIAGNOSTIC ROUTINES - OTHER CONCERNS NO PARK RANGE

OTHER CONCERNS: TRANSAXLE OVERHEATING

DIAGNOSTIC ROUTINES - OTHER CONCERNS TRANSAXLE OVERHEATING

DIAGNOSTIC ROUTINES - OTHER CONCERNS TRANSAXLE OVERHEATING

OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1ST POSITION

DIAGNOSTIC ROUTINES - OTHER CONCERNS NO ENGINE BRAKING IN MANUAL 1ST POSITION

OTHER CONCERNS: NO ENGINE BRAKING IN DRIVE (TCS ON) OR MANUAL 2ND POSITION

DIAGNOSTIC ROUTINES - OTHER CONCERNS NO ENGINE BRAKING IN DRIVE (TCS ON) OR MANUAL 2ND POSITION

OTHER CONCERNS: VEHICLE MOVEMENT WITH GEAR SELECTOR IN THE "N" POSITION

DIAGNOSTIC ROUTINES - OTHER CONCERNS VEHICLE MOVEMENT WITH GEAR SELECTOR IN N POSITION

MATERIAL SPECIFICATION CHART

MATERIAL SPECIFICATION CHART

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-232207) .
3. Remove the battery tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254) .
4. Disconnect the wiring harness from the battery tray bracket.
5. Remove the battery tray bracket.
6. Disconnect the vent hose from the main control cover.
7. Remove the lower radiator hose and position aside.
8. Remove the transmission fluid cooler tube bracket bolt.
9. Remove the main control cover bolts, cooler bypass studs and the cover.
10. Remove the main control cover gasket.

Scheme 350

1. Install the main control cover gasket.
2. Install the main control cover. Tighten to 13 Nm (10 lb-ft), in sequence see scheme 94
3. Position the transmission fluid cooler tube in place and install the bolt. Tighten to 25 Nm (18 lb-ft).
4. Install the lower radiator hose.
5. Connect the vent hose to the main control cover.
6. Install the battery tray bracket. Tighten to 10 Nm (89 lb-in).
7. Connect the wiring harness to the battery tray bracket.
8. Install the battery tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254).
9. Fill the transaxle with clean automatic transmission fluid.
10. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-232207).
11. Start the engine, run through all of the gears and check the fluid level.

MATERIAL SPECIFICATION CHART

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-232207) .
3. Remove the battery and tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254) .
4. Disconnect the wiring harness from the battery tray bracket.
5. Remove the battery tray bracket.
6. Disconnect the transaxle wiring harness electrical connector and the transmission range (TR) sensor electrical connector.
7. Disconnect the shift cable.
8. Remove the shift cable and bracket and position it aside.
9. Remove the vent tube hose from the main control cover.
10. Remove the lower radiator hose and position aside.
11. Remove the transmission fluid cooler tube bracket bolt.
12. Remove the main control cover bolts, studs and the cover.
13. Remove the main control cover gasket.
14. Remove the main control valve body bolts.
15. Lift the main control valve body while disconnecting the manual valve link.
16. Depress the retaining tabs and push the solenoid valve body electrical connector down through the transaxle case.
17. Make sure the manual valve does not fall out of the main control valve body while removing from the vehicle.

Scheme 357

Scheme 358

1. Install the manual control lever in the main control valve body.
2. Depress the retaining tabs and push the solenoid valve body electrical connector up through the transaxle case.
3. Position the main control valve body in place while connecting the manual valve link.
4. Install the main control valve body assembly. Tighten the bolts in the sequence indicated. Tighten to 10 Nm (89 lb-in).
5. Install the main control cover gasket.
6. Install the main control cover. Tighten the bolts and studs in the indicated sequence. Tighten to 13 Nm (10 lb-ft).
7. Position the transmission fluid cooler tube in place and install the bolt. Tighten to 25 Nm (18 lb-ft).
8. Install the lower radiator hose.
9. Install the shift cable and bracket. Tighten to 23 Nm (17 lb-ft).
10. Connect the shift cable end.
11. Connect the vent hose to the main control cover.
12. Connect the transaxle wiring harness electrical connector and the transmission range (TR) sensor electrical connector.
13. Install the battery tray bracket. Tighten to 10 Nm (89 lb-in).
14. Connect the wiring harness to the battery tray bracket.
15. Install the battery tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254) .
16. Fill the transaxle with clean automatic transmission fluid.
17. Fill the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-232207) .
18. Start the engine and run through all the gears and check fluid level.

MATERIAL SPECIFICATION CHART

Scheme 359

Scheme 360

Scheme 361

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 7 retainers and the LH splash shield. To install, tighten to 10 Nm (89 lb-in).
3. Remove the turbine shaft speed (TSS) sensor Disconnect the TSS electrical connector. Remove the TSS sensor bolt. Remove the TSS sensor. To install, tighten to 12 Nm (9 lb-ft).
4. Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary.
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATION CHART

Scheme 362

Scheme 363

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the 7 retainers and the LH splash shield. To install, tighten to 10 Nm (89 lb-in).
3. Remove the output shaft speed (OSS) sensor Disconnect the OSS electrical connector. Remove the OSS sensor bolt. Remove the OSS sensor. To install, tighten to 12 Nm (9 lb-ft).
4. Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary.
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATION CHART

Scheme 364

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the transaxle drain plug and drain the fluid.
3. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
4. Using the special tools, remove and discard the LH differential seal.

Scheme 365

1. Using the special tool, install the LH differential seal.
2. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
3. Using a small amount of thread sealant on the threads, install the transaxle drain plug. Tighten to 25 Nm (18 lb-ft).
4. Fill the transaxle with clean automatic transmission fluid.
5. Start the engine and run through all the gears and check fluid level.

MATERIAL SPECIFICATION CHART

Scheme 366

Scheme 367

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
2. Remove the transaxle drain plug and drain the transmission fluid.
3. Remove the RH halfshaft and intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
4. If equipped, remove the power takeoff (PTO). For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-232190) .
5. If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal.
6. If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal.

Scheme 368

Scheme 369

1. If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal.
2. If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal.
3. If equipped, install the PTO. For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-232190) .
4. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
5. Using a small amount of thread sealant on the threads, install the transaxle drain plug. Tighten to 25 Nm (18 lb-ft).
6. Fill the transaxle with clean automatic transmission fluid.
7. Start the engine and run through all the gears and check fluid level.

Low Reverse One-Way Clutch - Mechanical Diode Type

Note. The mechanical diode type one-way clutch does not use a thrust plate.

Note. The mechanical diode type one-way clutch cannot be disassembled.

Scheme 370

1. Inspect the one-way clutch for cracks and damaged splines. Make sure 3 rubber insulators are present. Install new rubber insulators if any damage is found. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new mechanical diode type one-way clutch.

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

1. Remove the reverse clutch hub retaining ring.
2. Remove the reverse clutch hub.
3. Remove the reverse clutch drum assembly.
4. Remove the direct clutch hub and shell from the forward/coast/direct clutch cylinder.
5. Remove and discard the 2 reverse clutch cylinder seals from the forward/coast/direct clutch cylinder assembly.
6. Remove the No. 2 direct clutch thrust washer from the forward/coast/direct clutch cylinder.
7. Remove and discard the forward/coast/direct clutch cylinder hub seal ring.

MATERIAL SPECIFICATION CHART

Scheme 376

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Scheme 391

1. Remove the direct clutch pressure plate retaining ring.
2. Disassemble the direct clutch pack. Remove the direct clutch pressure plate. Remove the direct clutch steel plates. Remove the direct clutch friction plates.
3. Remove the direct clutch spring retaining ring. Using the special tool, compress the direct clutch return springs. Remove the direct clutch return spring retaining ring.
4. Remove the direct clutch return spring assembly.
5. Remove the direct clutch piston assembly.
6. Remove and discard the direct clutch piston outer lip seal.
7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.
8. Remove the forward clutch pressure plate retaining ring.
9. Remove the forward and coast clutch plates. Forward clutch pressure plate Forward clutch external spline clutch plates (steel) Coast clutch internal spline clutch plates (friction) Coast clutch external spline clutch plates (steel) Coast clutch pressure plate Forward clutch wave spring Forward clutch internal spline clutch plates (friction)
10. Remove the forward/coast clutch return spring retaining ring. Using the special tool, compress the return spring. Remove the retaining ring.
11. Remove the forward/coast clutch return spring assembly.
12. Remove the forward and coast clutch pistons.
13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.
14. Remove and discard the forward clutch piston outer lip seal.
15. Separate the coast clutch piston assembly from the forward clutch piston assembly.
16. Clean all parts thoroughly in a clean automatic transmission fluid and blow dry with moisture-free regulated compressed air. Clean the steel clutch plates with a lint-free cloth. Soak the new clutch plates in the specified transmission fluid before assembly.
17. Inspect the parts for damage, cracks or wear. Spline teeth Clutch plates Seals Bushing Check balls in pistons Piston bore Passages and lubrication holes in the forward/coast/direct clutch cylinder Center hub weld Large snap ring grooves

Scheme 392

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Scheme 399

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Scheme 401

Scheme 402

Scheme 403

Scheme 404

1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
5. Mark the center of 2 adjacent legs on the top of the cylinder.
6. Find the center between the marks (45 degrees from either leg) and mark the cylinder.
7. Install the coast clutch piston assembly onto the special tool.
8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
9. Install the forward/coast clutch return spring assembly.
10. Install the forward/coast clutch return spring retaining ring. Using the special tool, compress the return spring. Install the forward/coast clutch retaining ring. Orient the gap between the piston legs.
11. Install the forward and coast clutch plates in the sequence see scheme 433 Coast clutch external spline clutch plates (steel) Coast clutch internal spline clutch plates (friction) Coast clutch pressure plate Forward clutch wave spring Forward clutch internal spline clutch plates (friction) Forward clutch external spline clutch plates (steel) Forward clutch pressure plate
12. Install the forward clutch pressure plate retaining ring. Center the select fit retaining ring on the 45 degree mark between the 2 adjacent legs.
13. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring. Take a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within specification, select and install the correct thickness retaining ring to obtain the standard clearance. Retaining ring sizes: 1.43 - 1.53 mm (0.056 - 0.060 in). 1.59 - 1.69 mm (0.062 - 0.066 in). 1.75 - 1.85 mm (0.069 - 0.073 in). 1.92 - 2.02 mm (0.075 - 0.079 in).
14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
16. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
17. Install the direct clutch return spring assembly.
18. Install the direct clutch return spring retaining ring. Using the special tool, compress the direct clutch return springs. Install the direct clutch return spring retaining ring.
19. Install the direct clutch plates. Install the direct clutch external spline (steel) clutch plates. Install the direct clutch internal spline (friction) clutch plates. Install the direct clutch pressure plate.
20. Install the direct clutch pressure plate retaining ring.
21. Measure the direct clutch clearance as follows: Install the special tool. Zero the dial on the direct clutch pressure plate. Pull the direct clutch pressure plate upward, and record the reading.
22. Make a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance. Retaining ring sizes: 1.28 - 1.38 mm (0.050 - 0.054 in). 1.39 - 1.49 mm (0.054 - 0.058 in). 1.52 - 1.62 mm (0.059 - 0.063 in). 1.65 - 1.75 mm (0.064 - 0.069 in).

MATERIAL SPECIFICATION CHART

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

1. Remove and discard the 7 pump support seal rings from the pump support.
2. Remove the 6 pump support bolts.
3. Separate the pump support and body assembly. Remove the pump support. Remove the pump body separator plate gasket. Remove the pump body separator plate. Remove the pump body.
4. Remove and discard the pump seal.
5. Remove the pump drive gear assembly. Remove the pump drive gear insert. Remove the pump drive gear. Remove the pump driven gear.
6. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
7. Inspect the pump body and gears for damage and wear. Driven gear teeth Drive gear teeth Gear bore Crescent Lubrication passages and holes
8. Inspect the pump support apply circuit passages and lubrication passages. Rear lube (from cooler TC circuit) Reverse clutch (RC) Direct clutch (DC) Forward clutch (FC) Coast clutch (CC) Converter clutch bypass (CBY)

Scheme 412

Scheme 413

Scheme 414

Scheme 415

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Scheme 417

Scheme 418

Scheme 419

1. Install the pump driven gear.
2. Install the pump drive gear assembly. Install the pump drive gear. Install the pump drive gear insert.
3. Using the special tool, measure the clearance between each gear and the pump body face. If the clearance exceeds specification, install a new pump assembly.
4. Install the special tool.
5. Align the pump support assembly. Fill the pump gear cavity with clean automatic transmission fluid to the top of the gears. Align the pump guide screws. Install the pump body. Install the pump body separator plate. Install the pump body separator plate gasket onto the pump body. Install the pump support.
6. Install the 6 pump support bolts. Tighten to 13 Nm (10 lb-ft).
7. Install the pump seal on the pump body.
8. Install the 7 pump support seal rings.
9. Measure the pump rotational torque. Install the pump drive shaft. Measure the pump rotational torque. Tighten to 0.3 Nm (2.65 lb-in). Remove the pump drive shaft. If rotational torque exceeds the specification, disassemble and inspect the pump assembly for contamination or incorrect end clearance.
10. Install the No. 1 pump support thrust bearing. Lubricate the seal rings with clean automatic transmission fluid.
11. Install the forward/coast/direct clutch cylinder and reverse clutch drum on the pump support.
12. Check the following passages of the forward/coast/direct clutch cylinder and reverse clutch drum with moisture-free compressed air, regulated to 276 kPa (40 psi). Reverse clutch passage Forward clutch passage Direct clutch passage Coast clutch passage Converter bypass (located on the bottom)

MATERIAL SPECIFICATION CHART

Scheme 420

Scheme 421

Scheme 422

Scheme 423

Scheme 424

Scheme 425

1. Remove the reverse clutch pressure plate retainer snap ring.
2. Remove the reverse clutch plates. Remove the pressure plate. Remove the friction plate. Remove the steel plate. Remove the inspect for damage or wear.
3. Remove the retaining ring. Using the special tool, compress the reverse clutch return springs.
4. Remove the reverse clutch return spring assembly.
5. Remove the reverse clutch piston assembly.
6. Clean the friction steel plates with a lint-free cloth.
7. Inspect the parts for damage and wear: Clutch plates Piston and seals Bushings Check ball in drum Drum outer surface band contact area Piston bore

Scheme 426

Scheme 427

Scheme 428

1. Before assembly, soak the internal spline clutch plates in clean automatic transmission fluid for 30 minutes.
2. Using the special tool, install the reverse clutch piston assembly with integral seals.
3. Install the reverse clutch return spring assembly.
4. Install the reverse clutch retaining ring. Using the special tool, compress the reverse clutch return springs.
5. Install the reverse clutch plates. Install the steel plates. Install the friction plates. Install the reverse clutch pressure plate.
6. Install the reverse clutch pressure plate retainer snap ring (selective fit).
7. Measure the clearance between the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring with a feeler gauge. Take a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within the specifications, select and install the correct thickness retaining ring to obtain the specified clearance. Retaining ring sizes: 1.39 - 1.49 mm (0.054 - 0.058 in). 1.53 - 1.63 mm (0.060 - 0.064 in). 1.68 - 1.78 mm (0.066 - 0.070 in).

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

Scheme 437

Scheme 438

1. Inspect the low/intermediate sun gear assembly for damage. Gear teeth Thrust bearing surfaces Journal surface
2. Inspect the low/intermediate carrier assembly. Pinion gear teeth Spline teeth Pinion gear surfaces Bushing surfaces Pinion gear bearings
3. Inspect the low/intermediate carrier assembly end play. Use a feeler gauge to measure end play. If end play is out of specification, install a new assembly.
4. Inspect the low/intermediate ring gear. Gear teeth Spline teeth Thrust bearing surfaces Journal surface Lug teeth
5. Inspect the reverse/overdrive sun gear and shell assembly for damage or wear. Gear teeth Lug teeth Thrust bearing surfaces Bushing surface
6. Inspect the reverse/overdrive carrier assembly. Pinion gear teeth Clutch plate spline teeth Pinion gear bearings Thrust bearing surfaces Bushing surfaces No. 8 thrust bearing captured between the pinions and carrier
7. Inspect the reverse/overdrive carrier assembly end play. Use feeler gauge to measure end play. If end play is out of specification, install a new assembly.
8. Inspect the reverse/overdrive ring gear. Gear teeth Spline teeth Drive sprocket teeth Thrust bearing surfaces Journal surface Bearings
9. Inspect the driven sprocket assembly. Gear teeth Parking gear lug teeth Driven sprocket teeth Thrust bearing surfaces Bearing surfaces Rivets Bushing surfaces Lubrication holes
10. Inspect the drive chain. Check the drive chain for wear, stretching or tightness of the chain links. The chain must move freely.

MATERIAL SPECIFICATION CHART

Automatic Transaxle - Disassembled Views

Scheme 439

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Scheme 509

1. Prepare the transaxle for assembly by proceeding with the following steps: Clean all parts (except the friction plates, seals and intermediate/overdrive band) in solvent. Dry all parts with moisture-free regulated compressed air (do not use shop towels). Lubricate all internal parts (including friction plates) with clean automatic transmission fluid. Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly: Drive sprocket thrust washers Driven sprocket thrust bearing shims Differential case thrust bearing shims Low/reverse clutch pressure plates During assembly, use petroleum jelly to hold the parts in place (do not use grease). Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
2. Install intermediate and overdrive band assembly into the transaxle case.
3. Install pump assembly into the case.
4. Install the pump assembly bolts. Tighten to 11 Nm (8 lb-ft)
5. Using the special tools, install the low/reverse clutch piston. Lubricate seals and piston bore with clean automatic transmission fluid.
6. Install the low/reverse clutch return spring assembly.
7. Install the low/reverse clutch return spring retaining ring.
8. Install the low/reverse clutch wave spring.
9. Install the low/reverse clutch plates. Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the thin 8-wave low/reverse clutch cushion spring. Install the low/reverse clutch pressure plate.
10. Install the special tool.
11. Measure the clearance between the low/reverse clutch pressure plate and the transmission end play gauge. Take a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance. Pressure plate sizes: 2.57-2.46 mm (0.101-0.097 in). 2.36-2.26 mm (0.092-0.089 in). 2.16-2.06 mm (0.085-0.081 in). 0.30-1.10 mm (0.012-0.043 in)
12. Remove the special tool, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring and the low/reverse clutch internal spline clutch plates (friction). Low/reverse clutch pressure plate Low/reverse clutch external spline clutch plates (steel) Low/reverse clutch wave spring Low/reverse clutch internal spline clutch plates (friction)
13. Install the No. 1 pump support thrust bearing assembly.
14. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
15. Install the turbine shaft.
16. Install the No. 4 turbine shaft thrust bearing.
17. Install the forward one-way clutch and low/intermediate sun gear assembly.
18. Install the No. 5 low/intermediate sun gear thrust bearing.
19. Install the low/intermediate carrier assembly.
20. Install the No. 6 low/intermediate carrier thrust bearing.
21. Install the low/intermediate ring gear assembly.
22. Install the No. 7 reverse/overdrive sun gear thrust bearing.
23. Install the reverse/overdrive sun gear and shell assembly.
24. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
25. Install the thick, 10-wave low/reverse clutch wave spring.
26. Install the low/reverse clutch plates (model dependent). Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the low/reverse clutch pressure plate previously selected.
27. Install the thin, 8-wave low/reverse clutch wave spring.
28. If equipped, install the low one-way clutch sprag-type assembly with the identification ring on the inner ring facing upward.
29. Install the low one-way clutch thrust plate.
30. If equipped, install the mechanical diode one-way clutch with the rubber isolators in the positions indicated.
31. Install the low one-way clutch retaining ring.
32. Install the manual valve detent lever actuating rod assembly. Install the parking cam actuator lever.
33. Install the manual valve detent lever.
34. Install the special tools. Tighten to 13 Nm (10 lb-ft).
35. Install the special tool with short spacers.
36. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area. Record this as dimension A.
37. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft. Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement. The average of these 2 dimensions is dimension B. Remove the special tools.
38. Subtract dimension B from dimension A to get dimension C.
39. Use dimension C to select the correct No. 11 driven sprocket shim. Select a shim from the driven sprocket shim chart. DRIVEN SPROCKET ALIGNMENT SHIM NO.11 CHART Shim Size mm Inch Transaxle case to driven sprocket/final drive sun gear thrust bearing shim AB: 2.20-2.10 0.086-0.082 Transaxle case to driven sprocket/final drive sun gear thrust bearing shim BB: 2.02-1.92 0.079-0.075 Transaxle case to driven sprocket/final drive sun gear thrust bearing shim CB: 1.85-1.75 0.072-0.068 Transaxle case to driven sprocket/final drive sun gear thrust bearing shim DB: 1.67-1.57 0.065-0.061 Transaxle case to driven sprocket/final drive sun gear thrust bearing shim EB: 1.50-1.40 0.059-0.052 Transaxle case to driven sprocket/final drive sun gear thrust bearing shim FB: 1.32-1.22 0.051-0.048 Distance measured during gauging procedure and appropriate thrust bearing shim AB: 14.34-14.1 0.564-0.557 Distance measured during gauging procedure and appropriate thrust bearing shim BB: 14.16-14.00 0.557-0.551 Distance measured during gauging procedure and appropriate thrust bearing shim CB: 13.99-13.83 0.551-0.544 Distance measured during gauging procedure and appropriate thrust bearing shim DB: 13.82-13.66 0.544-0.537 Distance measured during gauging procedure and appropriate thrust bearing shim EB: 13.65-13.49 0.537-0.531 Distance measured during gauging procedure and appropriate thrust bearing shim FB: 13.48-13.32 0.531-0.524
40. Install and lubricate the following: Lubricate the needles and seals in the No. 18 driven sprocket bearing. Install the selected No. 11 driven sprocket shim. Install the No. 12 driven sprocket bearing.
41. Install the No. 9 reverse/overdrive ring gear thrust bearing.
42. Install the reverse/overdrive ring gear assembly.
43. Install the special tools. Tighten to 13 Nm (10 lb-ft).
44. Install the special tool with short spacers.
45. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area. Repeat this measurement 180 degrees from the first measurement. The average of these 2 dimensions is dimension A. Remove the special tools.
46. Subtract 25.4 mm (1.00 in) thickness of special tool and the thickness of short spacers. This is the dimension B.
47. Subtract dimension A from dimension B. This is dimension C.
48. Select No. 10 thrust washer from the drive sprocket thrust washer chart. Use dimension C to select the No. 10 drive sprocket thrust washer. DRIVE SPROCKET ALIGNMENT NO 10 THRUST WASHER SPECIFICATIONS No.10 Thrust Washer mm Inch Drive sprocket to converter housing thrust washer AA: 1.51-1.41 0.059-0.052 Drive sprocket to converter housing thrust washer BA: 1.77-1.67 0.069-0.065 Drive sprocket to converter housing thrust washer CA: 2.03-1.93 0.079-0.075 Drive sprocket to converter housing thrust washer DA: 2.29-2.19 0.090-0.086 Distance measured during gauging procedure and appropriate thrust washer AA: 1.12-0.86 0.044-0.033 Distance measured during gauging procedure and appropriate thrust washer BA: 0.85-0.60 0.033-0.023 Distance measured during gauging procedure and appropriate thrust washer CA: 0.59-0.34 0.023-0.013 Distance measured during gauging procedure and appropriate thrust washer DA: 0.33-0.08 0.012-0.003
49. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
50. Remove the reverse/overdrive ring gear assembly.
51. Install the filter and seal assembly.
52. Install the special tool in the filter eyelet and transaxle hole.
53. Using the special tool, install the filter recirculating regulator exhaust seal.
54. Install the chain pan in the transaxle case.
55. Assemble and install the drive chain assembly. Drive chain (copper colored link facing upward) Driven sprocket assembly Reverse/overdrive ring gear assembly Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
56. Install the chain pan cover by snapping it into place.
57. Install the No. 13 driven sprocket thrust bearing.
58. Install the final drive carrier and differential assembly.
59. Install the special tools. Install the special tool. Install the special tool and bolts. Tighten to 13 Nm (10 lb-ft).
60. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub. The special tools must be relocated to carry out the second measurement. Repeat this measurement 180 degrees from the first measurement. The average of these 2 dimensions is dimension B.
61. Use combined thickness of the special tool with long spacers 177.8 mm (7.0 in) as dimension A.
62. Subtract dimension B from dimension A. This is dimension C.
63. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart. DIFFERENTIAL END PLAY NO 14 SHIM SPECIFICATIONS If dimension C is: Use No. 14 Differential Shim: 130.76 to 130.46 mm (5.148 to 5.136 in.) 1.08 to 0.98 mm (0.042 to 0.038 in.) 130.45 to 130.16 mm (5.136 to 5.124 in.) 1.38 to 1.28 mm (0.054 to 0.050 in.) 130.15 to 129.87 mm (5.124 to 5.113 in.) 1.67 to 1.57 mm (0.065 to 0.061 in.) 129.86 to 129.57 mm (5.113 to 5.101 in.) 1.97 to 1.87 mm (0.077 to 0.073 in.) 129.56 to 129.27 mm (5.101 to 5.089 in.) 2.27 to 2.17 mm (0.089 to 0.085 in.)
64. Install the differential bearing assembly Install the No. 14 differential bearing shim (selective fit). Install the No. 15 differential bearing.
65. Install the torque converter housing onto the transaxle case. Position and install the split flange gasket.
66. Install the torque converter housing-to-transaxle case bolts. Tighten to 22 Nm (16 lb-ft).
67. Lubricate the assembly with clean transmission fluid. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly. Install the intermediate and overdrive servo apply rod and piston assembly. Install the overdrive servo apply rod spring.
68. Install the special tool.
69. Assemble the special tool. Install struts. Install bar. Install bolts. Install the center bolt. Tighten to 4 Nm (35 lb-in).
70. Using the special tool, measure the distance to the bar of special tool. Record this as dimension A.
71. Back off the center bolt of special tool until the piston movement stops.
72. Using the special tool, measure the dimension to the bar of special tool record as dimension B. Subtract dimension A from B to find the travel. If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly. INTERMEDIATE/OVERDRIVE SERVO APPLY ROD SPECIFICATIONS Part Number Number of Rings Rod Length F3RP-7H188-CB 0 108.1 mm (4.25 in) F3RP-7H188-BB 1 107.1 mm (4.21 in) F3RP-7H188-AB 2 105.7 mm (4.16 in)
73. Wipe the servo piston and the servo cover cap with a lint-free cloth.
74. 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 attaches to the servo rod.
75. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
76. Inspect the servo retainer spring for cracks, breaks or deformation.
77. Install the special tool.
78. Tighten the special tool bolt. Install the servo cover retaining ring, using retaining ring pliers.
79. Loosen the special tool bolt. When spring tension is released, remove the special tool.
80. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 276 kPa (40 psi) of moisture-free regulated compressed air. Reverse clutch test port Forward clutch test port Direct clutch test port Low/reverse clutch test port Servo release test port Servo apply test port Transmission air test plate If air leakage is detected, disassemble the transaxle and locate source of leakage.
81. Install the thermostatic fluid level control valve. Position the thermostatic fluid level control valve. Install the bracket. Install the thermostatic fluid level control valve bracket bolt. Tighten to 12 Nm (9 lb-ft).
82. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
83. Connect the manual valve. Lift the main control away from the case. Connect the Z-link to the manual valve.
84. Install the main control valve body mounting bolts. Tighten to 10 Nm (89 lb-in).
85. Install the manual control lever. Tighten to 27 Nm (20 lb-ft).
86. Rotate the manual valve detent lever assembly to the NEUTRAL position. Low 1 Low 2 Drive Neutral Reverse Park
87. Position the transmission range (TR) sensor.
88. Using the special tool, align the TR sensor and tighten the bolts. Tighten to 11 Nm (8 lb-ft).
89. Install the main control cover gasket.
90. Install the main control valve body cover and bolts. Tighten to 13 Nm (10 lb-ft).
91. Install the vent tube.
92. Install a new transmission filler tube grommet.
93. Install the transmission filler tube assembly. Install the tube. Install the transmission filler tube bolt. Tighten to 8 Nm (71 lb-in). Install the fluid level indicator.
94. Install a new O-ring seal on the turbine shaft speed (TSS) sensor and install the sensor. Using petroleum jelly on the O-ring seal, position the TSS sensor into the case. Install the TSS sensor bolt. Tighten to 12 Nm (9 lb-ft).
95. Using the special tool, install the LH differential seal.
96. If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal.
97. If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal.
98. Using the special tool, install the torque converter fluid seal. Coat the torque converter seal garter spring with petroleum jelly.
99. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. Tighten to 25 Nm (18 lb-ft).
100. Install the pump driveshaft.
101. Using the special tool, install the torque converter.
102. Check the installation depth of the torque converter. Lay a straightedge on the transaxle converter housing. Check the clearance between the straightedge and the pilot hub. Clearance is 17 mm (0.66 in).
103. Remove the transaxle from the special tool.

MATERIAL SPECIFICATION CHART

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

1. Lubricate the torque converter pilot hub with grease.
2. Rotate the torque converter to place the paint dot in the 6 o'clock position.
3. Install the special tool.
4. Position the transaxle in place.
5. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.
6. Move the transaxle assembly toward the engine assembly and install the 4 bolts. Tighten to 40 Nm (30 lb-ft).
7. Install the transaxle retaining bolts. Tighten to 40 Nm (30 lb-ft).
8. Install 4 new torque converter nuts. Tighten to 40 Nm (30 lb-ft).
9. Install the transmission fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
10. Install the output shaft speed (OSS) sensor. Tighten to 12 Nm (9 lb-ft).
11. Install the fluid cooler tube. Connect the OSS sensor. Connect the turbine shaft speed (TSS) sensor (white connector). Connect the wiring harness retainer to the transmission case. Install the fluid cooler tube. Tighten to 23 Nm (17 lb-ft). Install the fluid cooler bolt. Tighten to 13 Nm (10 lb-ft).
12. Install the starter motor isolator.
13. Install the starter motor. Tighten to 35 Nm (26 lb-ft).
14. Install the starter terminals. Install the battery cable nut. Tighten to 12 Nm (9 lb-ft). Install the starter solenoid terminal nut. Tighten to 5 Nm (44 lb-in).
15. Install the wire harness clip retainer and the ground wire to starter bolts. Tighten to 27 Nm (20 lb-ft).
16. Install the lower front mount bracket. Tighten to 55 Nm (41 lb-ft).
17. Using the special tools, raise the transaxle.
18. Install the LH upper transaxle mount through bolt. Tighten to 103 Nm (76 lb-ft).
19. Remove the special tools.
20. Remove the special tools.
21. Install the upper transaxle bolts. Tighten to 40 Nm (30 lb-ft).
22. Connect the transmission range (TR) sensor electrical connector.
23. Connect the shift cable to the manual lever and install the 2 bolts. Tighten to 23 Nm (17 lb-ft).
24. Install the wire harness bracket nut and plug in the bulkhead electrical connector. Tighten to 10 Nm (89 lb-in).
25. Install the rear transmission mount. Tighten to 90 Nm (66 lb-ft).
26. Install the rear transaxle mount through bolt. Tighten to 115 Nm (85 lb-ft).
27. Install the dampener. Tighten to 40 Nm (30 lb-ft).
28. Install the power take-off (PTO) assembly. Tighten to 45 Nm (33 lb-ft).
29. Position the driveshaft in place and install the nuts. Tighten to 48 Nm (35 lb-ft).
30. Install the driveshaft. Tighten to 20 Nm (15 lb-ft).
31. Install the bracket. Tighten to 40 Nm (30 lb-ft).
32. Install the front nuts on the exhaust-to-intermediate shaft bracket. Tighten to 30 Nm (22 lb-ft).
33. Install the bolts on the rear of the exhaust-to-intermediate shaft bracket. Tighten to 30 Nm (22 lb-ft).
34. Install the flexpipe on the exhaust manifold and install the nuts. Tighten to 25 Nm (18 lb-ft).
35. Install the intermediate shaft.
36. Install the intermediate shaft retaining nuts. Tighten to 27 Nm (20 lb-ft).
37. Install the LH and RH halfshafts and frame bolts. Tighten to 115 Nm (85 lb-ft).
38. Using the special tool, install the LH half shaft into the wheel knuckle.
39. Install the LH hub nut. Tighten to 290 Nm (214 lb-ft).
40. Install the cross brace and the rear nut. Tighten to 150 Nm (111 lb-ft).
41. Install the 2 bolts for the brace. Tighten to 90 Nm (66 lb-ft).
42. Install the bolt for the mount. Tighten to 115 Nm (85 lb-ft).
43. Install the cross brace and the 4 bolts. Tighten to 48 Nm (35 lb-ft).
44. Install the LH splash shield and the 7 retainers.
45. Install the RH splash shield and the 5 retainers.
46. Install the vent tube to the fluid level indicator.
47. Install the air cleaner assembly. Install the bolt. Tighten to 10 Nm (89 lb-in). Connect the mass air flow (MAF) sensor. Connect the brake booster vacuum hose. Connect the wiring harness retainer. Connect the breather tube. Tighten the air cleaner clamp.
48. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
49. Fill the transaxle with clean automatic transmission fluid.
50. Check the fluid level and correct as necessary.

MATERIAL SPECIFICATION CHART

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

Scheme 520

Scheme 521

1. Install the mount bracket. Tighten to 90 Nm (66 lb-ft).
2. Lubricate the torque converter pilot hub with grease.
3. Install the special tool.
4. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
5. Position the transaxle in place.
6. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.
7. Move the transaxle assembly toward the engine assembly and install the bolt. Tighten to 40 Nm (30 lb-ft).
8. Install the transaxle bolt. Tighten to 40 Nm (30 lb-ft).
9. Install the lower transaxle bolts. Tighten to 48 Nm (35 lb-ft).
10. Install 4 new torque converter nuts. Tighten to 40 Nm (30 lb-ft).
11. Install the access cover.
12. Install the transmission fluid cooler tube. Tighten to 23 Nm (17 lb-ft).
13. Install the output shaft speed (OSS) sensor. Tighten to 12 Nm (9 lb-ft).
14. Install the fluid cooler tube. Connect the OSS sensor. Connect the turbine shaft speed (TSS) sensor (white connector). Install the fluid cooler tube. Tighten to 23 Nm (17 lb-ft). Install the fluid cooler bolt. Tighten to 13 Nm (10 lb-ft).
15. Raise the transaxle enough to install the lower cross brace.
16. Install the rear transaxle mount bolt. Tighten to 115 Nm (85 lb-ft).
17. Vehicles not equipped with a power takeoff (PTO), install the dampener.
18. Install the rear transaxle mount and install 1 bolt. Tighten to 40 Nm (30 lb-ft).
19. Install the PTO bolts. Tighten to 45 Nm (33 lb-ft).
20. Connect the electrical connectors to the lower mount bracket.
21. Install the cross brace and the rear nut. Tighten to 150 Nm (111 lb-ft).
22. Install the 2 bolts for the brace. Tighten to 90 Nm (66 lb-ft).
23. Install the bolt for the mount. Tighten to 115 Nm (85 lb-ft).
24. Install the bracket. Tighten to 40 Nm (30 lb-ft).
25. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
26. For vehicles equipped with a PTO, connect the rear driveshaft to the PTO. Install the PTO bolts. Tighten to 37 Nm (27 lb-ft).
27. Install the exhaust pipe and connect the exhaust pipe flange. Tighten to 29 Nm (21 lb-ft).
28. Connect the front flange. Tighten to 29 Nm (21 lb-ft).
29. Install the exhaust pipe. Install the rubber hanger. Install the exhaust pipe and install the bolts. Tighten to 29 Nm (21 lb-ft).
30. Install the cross brace. Tighten to 48 Nm (35 lb-ft).
31. Install the intermediate shaft.
32. Install the intermediate shaft retaining nuts. Tighten to 27 Nm (20 lb-ft).
33. Reconnect the HO2S sensor wire to the oil pan bolt studs and connect the connector.
34. Install the generator shield and install the bolt. Tighten to 10 Nm (89 lb-in).
35. Install the retainer for the generator shield.
36. Install the LH and RH halfshafts in the transaxle.
37. Connect the LH suspension. Install the lower ball joint into the knuckle and install the bolt. Tighten to 70 Nm (52 lb-ft). Install the tie rod end retaining nut. Tighten to 55 Nm (52 lb-ft). Install a new tie rod end nut cotter pin. Connect the sway bar link. Tighten to 43 Nm (32 lb-ft).
38. Connect the RH suspension. Install the lower ball joint into the knuckle and install the bolt. Tighten to 70 Nm (52 lb-ft). Install the tie rod end retaining nut. Tighten to 55 Nm (52 lb-ft). Install a new tie rod end nut cotter pin. Connect the sway bar link. Tighten to 43 Nm (32 lb-ft).
39. Install the LH splash shield and the 7 retainers.
40. Install the RH splash shield and the 7 retainers.
41. Lower the engine onto the RH engine mount.
42. Install the bolt for the RH engine mount. Tighten to 120 Nm (89 lb-ft).
43. Tighten the LH upper transaxle mount assembly. Tighten the 4 nuts for the bracket. Tighten to 40 Nm (30 lb-ft). Install the through bolt. Tighten to 103 Nm (76 lb-ft).
44. Install the upper transaxle retaining bolts. Tighten to 40 Nm (30 lb-ft).
45. Remove the special tools.
46. Remove the special tools.
47. Remove the special tools.
48. Connect the electrical connectors together and then connect them to the upper intake manifold.
49. Install the starter motor and install the bolts. Tighten to 25 Nm (18 lb-ft).
50. Install the ground cable. Tighten to 27 Nm (20 lb-ft).
51. Install the starter motor harness connector. Install the large nut. Tighten to 10 Nm (89 lb-in). Install the small nut. Tighten to 7 Nm (62 lb-in).
52. Install the shift cable and the bracket. Tighten to 19 Nm (14 lb-ft).
53. Connect the shift cable to the manual lever.
54. Connect the wire harness to the battery hold-down bracket.
55. Connect the EVAP and PTO vent hose to the transmission filler tube bracket.
56. Install the main control cover vent tube.
57. Position the bracket in place and install the nut. Connect the transaxle harness connector. Tighten to 10 Nm (89 lb-in).
58. Connect the transmission range (TR) sensor.
59. Using the special tool, align the digital TR sensor. Tighten to 10 Nm (89 lb-in).
60. Install the air cleaner as an assembly. Install the air cleaner assembly. Connect the air intake tube. Install the retaining bolt. Tighten to 10 Nm (89 lb-in). Install the breather tube. Connect the mass air flow (MAF) sensor electrical connector.
61. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
62. Fill the transaxle with clean automatic transmission fluid.
63. Check the fluid level and correct as necessary.