Automatic Transmission - 6r60 Ford Explorer Sport Trac II

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

ASSEMBLY WEIGHT

ASSEMBLY WEIGHT

CLUTCH APPLICATION CHART

CLUTCH APPLICATION CHART

SOLENOID APPLICATION CHART

SOLENOID APPLICATION CHART

a TCM Controlled

Note. All friction and steel plates use a wave design plate.

END PLAY

END PLAY

CLUTCH PLATE QUANTITY

CLUTCH PLATE QUANTITY

Note. Shift speed ranges are approximate for all applications. For specific applications (engine, axle ratio, tire size and application), refer to the Automatic Transmission Specification booklet. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

SHIFT SPEEDS

SHIFT SPEEDS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

a Specific tightening sequence required. See the procedure in this article.

Transmission Description

Note. Use this section of the workshop manual for the 6R60 6-speed transmission only. Do not substitute with other procedures regardless of similarities.

This transmission has an internal thermal bypass valve contained within the case. The thermal bypass valve will not allow the use of any type of transmission fluid exchange machine to be used on this transmission.

This transmission uses planetary gears with hydraulic electronic controls. The transmission control module (TCM) and the main control valve body units form a composite element that is installed as a single unit inside the automatic transmission.

This transmission has

1. six forward speeds.
2. torque converter with an integral converter clutch.
3. electronic shift and pressure controls.
4. single planetary gear set.
5. double planetary gear set.
6. two fixed multi-disc clutches.
7. three multi-plate clutches.

All hydraulic functions are directed by electronic solenoids to control

1. engagement feel.
2. shift feel.
3. shift scheduling.
4. modulated torque converter clutch (TCC) applications.

This transmission has a mechatronic unit also referred to as a TCM which contains

1. turbine shaft speed (TSS) sensor.
2. output shaft speed (OSS) sensor.
3. an internal P, R, N, D selector shaft position sensor.
4. transmission fluid temperature (TFT) sensor.

Engine power reaches the transmission by a torque converter with an integral converter clutch. The 6 forward gears and one reverse gear are obtained from single planetary sets.

This automatic transmission is a 6-speed electronically controlled transmission comprising the basic elements of a TCM, main control valve body unit, torque converter, one solenoid valve and 6 pressure regulators. Gear selection is achieved by the control of automatic transmission fluid flow to operate various internal clutches. The TCM operates the electrical components and provides for the control of gear selection shift pressure, which increases refinement and torque converter slip.

In the event of a system fault, the TCM also provides for failure mode effect management (FMEM) to maintain maximum functional operation of the transmission with a minimum reduction in driver, passenger or vehicle safety. In the event of a total loss of control or electrical power, the basic transmission functions P, R, N and D are retained. Also 3rd or 5th gear is retained by the hydraulic system. The gear retained is dependent upon the gear selected at the time of the failure.

Scheme 1

Identification Tags

The identification tag is located on the left side of the case just rearward of the manual control lever.

Scheme 2

Range Selection

The transmission has 7 range positions: P, R, N, D, 3, 2 and 1.

Scheme 3

Park

In the PARK position

1. there is no power flow through the transmission.
2. the parking pawl locks the output shaft to the case.
3. the engine can be started.
4. the ignition key can be removed.

Reverse

In the REVERSE position

1. the vehicle can be operated in a rearward direction, at a reduced gear ratio.
2. backup lamps are illuminated.

Neutral

In the NEUTRAL position

1. there is no power flow through the transmission.
2. the output shaft is not held and is free to turn.
3. the engine can be started.

D Position

The D position is the normal position for most forward driving.

The D position provides

1. automatic shifts 1-6 and 6-1.
2. apply and release of the torque converter clutch.
3. maximum fuel economy during normal operation.
4. engine braking in all gears.

Position 3 - 3rd Gear

This position provides

1. manual 3rd gear.
2. engine braking in 3rd gear.

Position 2 - 2nd Gear

This position provides

1. manual 2nd gear.
2. engine braking in 2nd gear.

Position 1 - 1st Gear

This position provides

1. first gear operation only.
2. engine braking for descending steep grades.

Downshifts

Under certain conditions, the transmission will downshift automatically to a lower gear range (without moving the range selector lever). There are 3 categories of automatic downshifts

1. Coastdown
2. Torque demand
3. Forced or kickdown shifts

Coastdown

The coastdown downshift occurs when the vehicle is coasting down to a stop.

Torque Demand

The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio.

Kickdown

For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are subject to variations due to tire size, engine and transmission calibration requirements.

Torque Converter

The torque converter is a 3-element unit containing a 3-plate clutch. The clutch can be controlled and engaged in any gear 2 to 6. Calibration parameters may be set to allow lockup in a higher gear only. The clutch is applied by removing fluid pressure from one side of the plate. The torque converter transmits and multiplies torque. The torque converter includes the following 3 elements

1. Impeller assembly
2. Turbine assembly
3. Reactor assembly

The standard torque converter components operate as follows

1. Rotation of the converter housing and impeller set the fluid in motion.
2. The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft.
3. The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
4. Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft.

Torque Converter Clutch

The torque converter clutch is a device that reduces slip in the torque converter and, therefore, helps to keep fuel consumption to a minimum.

The torque converter clutch is engaged and released by the control system.

Pressure at the torque converter clutch piston is determined by an electronic pressure control valve.

Geartrain

Power is transmitted from the torque converter to the planetary gearsets through the input shaft. Clutches are used to hold and drive certain combinations of gearsets. This results in 6 forward ratios and one reverse ratio which are transmitted to the output shaft and differential. The ratios are as follows

Single Planetary Gearset

The single planetary gear overdrive carrier is driven by the input shaft. The single planetary gear set consists of the following components

1. One sun gear
2. Four planetary gears meshing with the sun gear
3. One planetary carrier
4. One ring gear

Ravigenaux Planetary Gearset

The ravigenaux planetary gearset is splined to the output shaft and consists of the following components

1. Two sun gears of different sizes
2. Three short planetary gear pinions meshing with the sun gears
3. Three long planetary gear pinions meshing with the sun gears
4. One planetary carrier
5. One ring gear

Output Shaft

The output shaft provides torque to the driveshaft and rear axle assembly. It is driven by the ring gear of the planetary gearset.

Shift Elements

Note. All friction and steel clutch plates use a wave designed plate.

In addition to the torque converter, the other shift elements are

1. three rotating multi-plate clutches: forward, direct and overdrive.
2. two fixed multi-disc brakes: intermediate and low/reverse.

All gear shifts from 1st to 6th or from 6th to 1st are power-on overlapping shifts. That is, during the shift, one of the clutches must continue to transmit the drive at lower main pressure until the other clutch is able to accept the input torque.

The shift elements, clutches or brakes are engaged hydraulically. The transmission fluid pressure builds up between the cylinder and the piston, pressing the clutches together.

The purpose of these shift elements is to carry out in-load shifts with no interruption to traction.

Multi-plate clutches forward, direct and overdrive supply power from the engine to the planetary geartrain. Multi-disc brakes, intermediate and low/reverse, press against the transmission housing in order to achieve a torque reaction effect.

Multi-Plate Clutch

Clutches overdrive, forward and direct are balanced in terms of dynamic pressure. That is, its piston is exposed to the transmission fluid flow on both sides, in order to prevent pressure buildup in the clutch as speed increases. This equalization process is achieved by a baffle plate and pressure-free transmission fluid supply by a lubricating passage, through which the space between piston and baffle plate is filled with transmission fluid.

The advantages of this dynamic pressure equalization are

1. reliable clutch engagement and release in all speed ranges.
2. improved shift refinement.

Shift Overlap Control

The electro-hydraulic shift action is obtained by means of various valves in the transmission control module (TCM) and main control valve body, actuated by pressure regulators. They engage or disengage the relevant clutches or brakes at the correct moments.

Fluid Pump

The torque converter is supported in the fluid pump by a needle roller bearing. The fluid pump is driven directly from the engine by the torque converter shell and supplies transmission fluid to the transmission and the hydraulic control unit.

The fluid pump draws in transmission fluid through a transmission fluid filter and delivers it at high pressure to the main pressure valve in the main control valve body unit. The valve adjusts the pressure and returns excess transmission fluid to the transmission fluid pan.

Transmission Fluid Filter

All transmission fluid that is picked up from the transmission fluid pan passes through the transmission fluid filter. The transmission fluid filter and its accompanying seal are part of the transmission fluid path from the transmission fluid pan to the transmission fluid pump.

Transmission Electronic System

The transmission control module (TCM) and its input/output network control the following operations

1. Shift timing
2. Clutch pressure (shift feel)
3. Line pressure (shift feel)
4. Torque converter clutch

In addition, the TCM receives input signals from certain transmission-related sensors. The TCM also uses these signals when determining transmission operating strategy.

Using all of these input signals, the TCM can determine when the time and conditions are right for a shift or when to apply or release the torque converter clutch. It will also determine the pressure needed to optimize shift feel. To accomplish this, the TCM uses 6 pressure control solenoids and one shift solenoid to control transmission operation.

The following provides a brief description of each of the sensors and actuators used to control transmission operation.

Transmission Control Module (TCM) and Main Control Valve Body

The TCM and main control valve body are a combination of hydraulic and electronic control units. Both of these modules are installed in the transmission inside the transmission fluid pan.

Transmission Control Module (TCM)

The TCM for the transmission is mounted on top of the main control valve body. The TCM for the transmission has been designed to operate correctly in the environment in which the TCM is located.

The TCM is activated and deactivated by the ignition supply and is connected to the transmission harness by a 16-pin connector.

The TCM controls the operation of the transmission. The TCM processes information in both analog and digital forms, such as

1. transmission input speed.
2. transmission output speed.
3. throttle position.
4. gear selection.
5. engine torque.
6. engine speed.
7. transmission fluid temperature (TFT).
8. brake pedal position (BPP).
9. engine oil temperature.
10. engine coolant temperature.
11. ABS wheel speed.

The information is then used by the TCM to decide which shift pattern to select and for shift energy management. Electro-hydraulic solenoid valves and pressure regulators control the transmission gear changes.

Five pressure regulators and one solenoid valve are used to control direct transmission fluid flow to select internal clutches and control the fluid pressure at the clutch. A separate pressure regulator is used exclusively for torque converter clutch control.

The TCM monitors all transmission inputs and outputs to confirm correct system operation. If a fault occurs, the TCM is able to carry out default action. It informs the driver of the problem through the instrument cluster diagnostic MIL light.

The TCM will shut down if the TCM hardware temperature rises above a predetermined temperature. Prior to shutting down, the TCM will log a fault code and enter a mechanical limp-home mode.

Solenoids

The hydraulic module contains one solenoid valve. The solenoid valve is activated by the TCM and is either open or closed. It is used to switch the position valve.

There are 6 electronic pressure control valves which convert an electronic current into a proportional hydraulic pressure. They are energized by the TCM and actuate the valves belonging to the relevant switching elements.

Solenoids VFS1, VFS3 and VFS6 are proportional in operation, meaning that hydraulic pressure increases with an increase in current. Solenoids VFS2, VFS4 and VFS5 are inversely proportional in operation, meaning that hydraulic pressure decreases with an increase in current. Solenoid SS1 is a shift solenoid having a ON/OFF operation.

Controller Area Network (CAN) Interface

For the TCM to carry out shift point and shift quality management, a number of external signals are required. For shift point management alone, the TCM requires output speed sensor, throttle pedal position, brake pedal status, gear selection position, transmission fluid temperature, four wheel drive (4WD) position, traction control, engine speed and engine torque. The controller area network (CAN) bus is used to share information between control modules.

Brake Pedal Position (BPP) Switch

The brake pedal position (BPP) switch tells the TCM when the brakes are applied. The torque converter clutch disengages when the brakes are applied. The BPP switch closes when the brakes are applied and opens when they are released.

Cylinder Head Temperature (CHT) Sensor

The cylinder head temperature (CHT) sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature.

Accelerator Pedal Position (APP) Sensor

The accelerator pedal position (APP) sensor is mounted on the accelerator pedal. The APP sensor detects the position of the accelerator pedal and inputs this information as a voltage to the PCM. The PCM broadcasts the APP on the CAN bus. The TCM reads APP off the CAN message. The PCM uses the APP sensor information to aid in determining shift scheduling and torque converter control.

Turbine Shaft Speed (TSS) Sensor

The turbine shaft speed (TSS) sensor is a Hall-effect type sensor.

The TSS sensor is mounted internally and is located on the transmission control module.

Output Shaft Speed (OSS) Sensor

The output shaft speed (OSS) sensor is a Hall-effect type sensor.

The OSS sensor is mounted internally and is located on the transmission control module.

Transmission Control Switch (TCS)

The transmission control switch (TCS) is a momentary contact switch that is located on the selector lever. Pushing the TCS will either disengage or engage the overdrive function of the automatic transmission. If OVERDRIVE is disengaged, the word O/D OFF will illuminate on the instrument cluster and forward gears 1 through 4 are available. The overdrive cancel feature resets after the ignition switch is cycled.

Transmission Fluid Temperature (TFT) Sensor

The transmission fluid temperature (TFT) sensor is located on the TCM. The TCM uses the sensor input to activate various shift strategies. The sensor is in the form of a temperature-dependent resistor.

The resistance value of the TFT sensor varies with temperature change. The TCM monitors the voltage across the TFT to determine the temperature of the transmission fluid.

The TCM uses this initial signal to determine whether a cold start shift schedule is necessary. The TCM also inhibits torque converter clutch operation at low transmission fluid temperatures.

Transmission Range (TR) Sensor

The TCM uses the position of the transmission range (TR) sensor, housed in the TCM, to determine the selected gear range from the range selector lever.

The TR sensor completes the start circuit in P and N, and the back-up lamp circuit in R. The sensor also opens/closes a set of switches that are monitored by the TCM to determine the position of the manual lever (P, R, N, D, 3, 2 and 1).

Adaptive Shift Strategy

Adaptive shift strategy is comprised of

1. Shift Energy Management - this function involves reducing or increasing engine output torque during shifting. Reduces excessive energy of the friction packs Increases transmission service life Improves shift quality Unique shift schedules are selected based on vehicle operation conditions and environmental conditions Trailer towing mode
2. Pressure Modulation - this function monitors the hydraulic pressure in a shift. This pressure must be matched accurately to the transmission input torque to better provide shift comfort.
3. Shift Quality Adapts - is used to provide a higher quality and consistent shift feel. Monitoring and adapting shift pressures and shift energy to overcome hardware variability over time achieve this.
4. The TCM has the ability to control the engine output torque during the shift, synchronized with the operation of the transmission clutches.
5. Trailer towing mode uses a different shift and converter map. This new map reduces the number of gearshifts when towing, climbing steep hills and while driving at higher altitudes.

Transmission Control Module (TCM) Monitoring Functions

The TCM monitors all transmission input and output to identify possible transmission failures. If a fault is detected, the TCM takes the appropriate action to make sure that the transmission enters a safe mode of operation.

1. Voltage Supply - this function monitors the vehicle battery voltage.
2. Watchdog Monitoring - the watchdog monitoring has 2 functions: Checks for faults in the driver circuits by activating each driver. Checks to see if the safety circuit is functioning correctly.
3. TCM Temperature - If the TCM temperature rises above a predetermined temperature, the TCM will shut down. Prior to shutting down, the TCM will log a fault code during shutdown. The transmission will enter a mechanical limp-home mode.
4. Pressure Regulator/Solenoid - Each pressure regulator and solenoid is monitored for open and short circuits. The TCM also checks that the current being delivered to each solenoid valve or pressure regulator is within limits.
5. Torque Converter Control - The TCM checks and verifies that the torque converter has been engaged correctly. If the torque converter has not engaged correctly, the TCM will carry out the fail-safe action of opening the converter clutch.

Diagnostic Strategy

Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.

Note. Do not take short cuts or assume that critical checks or adjustments have already been made.

Follow the procedures as written to avoid missing critical components or steps.

To correctly diagnose a concern, have the following publications available

1. «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article
2. TSBs
3. Wiring Diagram

These publications provide the information required when diagnosing transmission concerns.

Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.

Preliminary Inspection

1. Know and understand the customer's concern.
2. Verify the concern by operating the vehicle.
3. Check the transmission fluid levels and transmission fluid condition.
4. Check for non-factory add-on items.
5. Check shift linkages for correct adjustment.
6. Check TSBs regarding the concern.

Diagnostics

1. Carry out on-board diagnostic procedures Key On/Engine Off (KOEO) and Key On/Engine Running (KOER).
2. Record all DTCs.
3. Repair all non-transmission codes first.
4. Repair all transmission codes second.
5. Erase all continuous codes and attempt to repeat them.
6. Repair all continuous codes.
7. If only pass codes are obtained, go to «Diagnosis By Symptom»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__diagnosis-by-symptom) in this article for information and diagnosis.

Follow the diagnostic sequence to diagnose and repair the concern the first time.

Diagnostic Flow Chart

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 4

Prior to carrying out the flow test, the following items should be checked

1. Know and understand the customer concerns.
2. Check the transmission fluid level and transmission fluid condition.
3. Verify the concern by operating the vehicle.
4. Check for non-factory-installed items and verify correct installation.
5. Check the selector lever linkage adjustments.
6. Check TSBs for vehicle concerns.
7. Carry out quick test both key ON engine running (KOER) and key ON engine OFF (KOEO).
8. Record all codes.
9. Verify that the transmission control module (TCM) is at the latest calibration release level.

DIAGNOSTIC FLOW CHART

The following items must be checked prior to beginning the diagnostic procedures

Know and Understand the Concern

In order to correctly diagnose a concern, first understand the customer concern or condition. Customer contact may be required in order to begin to verify the concern. Understand the conditions, including 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/unloaded

After understanding when and how the concern occurs, proceed to Verification of Condition.

Verification of Condition

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

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

Determine Customer Concern

Note. Some transmission conditions can cause engine concerns. An electronic pressure control short circuit can cause engine misfiring. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the following items

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. Upshifting
7. Downshifting
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.

Transmission Fluid Level Check

Note. If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.

Note. If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked.

This transmission is equipped with an internal thermal bypass located in the case. This internal thermal bypass valve will shut off transmission fluid flowing to the transmission fluid cooler if the transmission fluid temperature falls below normal operating temperature. Refer to Transmission Fluid Level Check .

Scheme 5

High Transmission Fluid Level

If an overfill reading is indicated, remove any excessive transmission fluid. Refer to Transmission Fluid Level Check .

Low Transmission Fluid Level

A low transmission fluid level can result in poor transmission engagement, slipping or failure. This may also indicate a leak in one of the transmission seals or gaskets.

Adding Transmission Fluid

Note. If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.

Add transmission fluid using the refill procedure. Refer to Transmission Fluid Drain and Refill .

Transmission Fluid Condition Check

1. Check the transmission fluid level.
2. Remove the transmission fluid fill plug and transmission fluid level indicator and allow the transmission fluid to drip onto a facial tissue and examine the stain.
3. Observe the color and the odor. The color under normal circumstances should be dark reddish, not black or have a burnt odor.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time.
6. If transmission fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and transmission fluid cooler tubes. A new oil-to-air (OTA) cooler must be installed.

Water in Transmission Fluid

To correctly repair an automatic transmission or transaxle that has had water or coolant introduced into the system, completely disassemble, clean and replace the following parts

1. All internal and external seals
2. All friction material; clutches and bands
3. Torque converter
4. All parts with bonded seals
5. All solenoids
6. All transmission fluid filters

Prior to installing the transmission or transaxle, the transmission fluid cooler(s), transmission fluid cooler tubes and transmission fluid cooler hoses need to be flushed and cleaned.

Shift Point Road Test

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

This test verifies that the shift control system is operating correctly.

1. Bring engine and transmission up to normal operating temperature.
2. Operate vehicle with selector lever in D position.
3. Apply minimum throttle and observe speeds at which upshift occurs and the torque converter engages. Refer to «SHIFT SPEEDS»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) .
4. Move the selector lever into the manual 3 position. The transmission should downshift to 4th gear. Release the accelerator pedal; engine braking should occur.
5. Press the accelerator pedal to floor, wide open throttle (WOT). Transmission should shift from 4th to 3rd, depending on vehicle speed. The torque converter clutch (TCC) should disengage and then reapply.
6. With the selector lever in D position and speed above 80 km/h (50 mph) and less than half throttle, move the selector lever from D position to manual 2 position and remove pressure from the accelerator pedal. The transmission should downshift into 2nd gear. With the vehicle remaining in manual 2 position, move the selector lever into manual 1 position and release the accelerator pedal. The transmission should downshift into 1st gear at speeds below approximately 45-56 km/h (28-35 mph).
7. If the transmission fails to upshift/downshift or the TCC does not apply and release, refer to «Diagnosis By Symptom»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__diagnosis-by-symptom) . NOTE: Shift speed ranges are approximate for all applications. For specific applications (engine, axle ratio, tire size and application), refer to the Automatic Transmission Specification booklet. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws. SHIFT SPEEDS Throttle Position Shift mph km/h Light Throttle 1-2 9 14 Approximately 30% 2-3 16 26 Pedal Travel 3-4 24 39 4-5 32 51 5-6 40 64 Closed Throttle 6-5 29 47 5-4 24 39 4-3 20 32 3-2 7 11 2-1 4 6 Wide Open 1-2 30 48 Throttle (WOT) 2-3 56 90 3-4 80 138

Road Test - Adaptive Drive Cycle

Note. Using the scan tool, clear the adaptive table before conducting an adaptive drive cycle test.

Note. All adaptive drive cycle tests are carried out with the transmission fluid temperature at normal operating temperature 80°C-82°C (175°F-180°F).

Note. All adaptive drive cycle test are carried out with the range selector lever in the D position.

This test will begin the adaptive learning schedule to provide a better shift quality and shift feel.

1. Verify that the transmission fluid temperature (TFT) PID is above 80°C (175°F).
2. Clear transmission control module (TCM) keep alive memory (KAM) and adaptive table using the scan tool.
3. Accelerate from rest with light throttle. The 1-2, 2-3 and 3-4 shifts must occur at engine speeds between 1300-1800 RPM.
4. Continue to accelerate gently to 80 km/h (50 mph) so that the transmission shifts into 5th gear.
5. Brake gently to a complete stop and hold foot on brake for at least 15 seconds.
6. Repeat Steps 3-6 a total of 5 times.

Torque Converter Diagnosis

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary inspection.
2. Know and understand the customer's concern.
3. Verify the condition - carry out the torque converter operation test.
4. Carry out diagnostic procedures. Carry out on-board diagnostics. Refer to «Diagnostics»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) . Repair all non-transmission related DTCs first. Repair all transmission-related DTCs. Rerun on-board diagnostics to verify repair. Carry out Stall Speed Test. Refer to «Special Testing Procedures»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__special-testing-procedures) . Carry out Diagnostic Routines. Refer to «Diagnosis By Symptom»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__diagnosis-by-symptom) . Use the Diagnosis by Symptom to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter.

Torque Converter Operation Test

The Torque Converter Operation Test verifies that the torque converter clutch (TCC) control system and the torque converter are operating correctly.

1. Carry out Quick Test with scan tool. Refer to the «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. Check for DTCs.
2. Connect a scan tool to the vehicle.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in D position.
4. After normal operating temperature is reached, maintain a constant speed of about 56 km/h (35 mph) in 5th gear for 10 seconds.
5. Release the accelerator pedal and monitor the scan tool TP voltage to approximately 1.25 volts or 30% throttle.
6. Monitor the TCC and engine speed PID. The TCC should release and engine RPMs should increase before the 5-4 shift occurs. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as TCC shudder. For diagnosis of the following items, refer to the appropriate articles of the workshop manual and the «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. Spark plugs - check for cracks, high resistance or broken insulators Plug wires Fuel injector - filter may be plugged Fuel contamination - engine driveability concerns EGR valve - valve may let in too much exhaust gas and cause engine to run lean Vacuum leak - engine will not get correct air/fuel mixture Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture Fuel pressure - may be too low Engine mounts - loose/damaged mounts can cause vibration concerns Axle joints - check for vibration

Visual Inspection

A visual inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as

1. Electronic add-on items: A/C generator (alternator) engine turbo cellular telephone cruise control CB radio linear booster backup alarm signal computer
2. Vehicle modification

These items, if not installed correctly, will affect the PCM, transmission control module (TCM) or transmission function. Pay particular attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire size or axle ratio changes.

1. Leaks; refer to «Leakage Inspection»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__leakage-inspection) .
2. Correct selector lever linkage adjustments; refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-external-controls) article.

Selector Lever Linkage Check

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

Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating if the linkage is not correctly adjusted. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS article for selector lever linkage adjustment.

Check TSBs

Refer to all TSBs that pertain to the transmission concern and follow the procedure as described.

Carry Out On-Board Diagnostics (Key ON Engine OFF [KOEO], Key ON Engine Running [KOER])

After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using the scan tool. Refer to the Introduction - Gasoline Engines article.

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool 73 III Automotive Meter 105-R0057 or equivalent

Diagnosing an electronically controlled automatic transmission is simplified by using the following procedures. One of the most important things to remember is that there is a definite procedure to follow. Do not take shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics With Scan Tool

Note. For detailed instruction and other diagnostic methods using the scan tool, refer to the scan tool tester manual and the Introduction - Gasoline Engines article. These quick tests should be used to diagnose the PCM and should be carried out in order.

1. Quick Test 1.0 - Visual Inspection
2. Quick Test 2.0 - Set Up
3. Quick Test 3.0 - Key ON, Engine OFF (KOEO)
4. Quick Test 4.0 - Continuous Memory
5. Quick Test 5.0 - Key ON, Engine Running (KOER)
6. Special Test Mode Wiggle Test Output Test Mode
7. PCM Reset Mode
8. Clearing DTCs
9. OBD II Drive Cycle

Other Scan Tool Features

For additional information on other diagnostic testing features using the scan tool, refer to the Introduction - Gasoline Engines article.

Output State Control (OSC) Mode

Output state control (OSC) allows the technician to take control of certain parameters to function the transmission.

For example, OSC allows the technician to shift the transmission only when commanding a gear change. If the technician commands 1st gear in OSC, the transmission will remain in 1st gear until the technician commands the next gear.

Another example of the OSC features is that a technician can command the torque converter to turn ON or OFF to check operation.

This transmission OSC has one mode of operation; DRIVE. This mode has a unique set of operating requirements that the technician must meet before allowed to operate the torque converter or select gears.

Note. To operate OSC, the digital transmission range (TR) sensor and the output shaft speed (OSS) sensor must be operational. No DTCs related to the digital TR sensor or the OSS can be present.

1. The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to the vehicle requirements for each test.
2. If the vehicle requirements are NOT MET when SENDING the OSC value, the PCM will not carry out the command. OSC is aborted and must be restarted.
3. If, after the sent value is substituted, the vehicle requirements are no longer met, the PCM will cancel the OSC value and resume normal operations. No error message will be sent.
4. The OSC may be canceled at any time.

OSC Procedures

1. Pull DTCs.
2. Repair any existing DTCs.
3. Make sure that the OSS and digital TR sensors are functional.
4. Monitor the OSS_SRC and TR PIDs to verify functionality.
5. Access transmission PIDs.

OSC - Transmission in Drive Mode

The OSC provides the following Drive Mode functions

1. GEAR_OSC# - Allows upshifts and downshifts.
2. TCC_OSC# - Engages or disengages the torque converter clutch (TCC).

GEAR_OSC# in Drive Mode

The Drive Mode allows the technician to choose the following options

1. 1 - TCM selects 1st gear.
2. 2 - TCM selects 2nd gear.
3. 3 - TCM selects 3rd gear.
4. 4 - TCM selects 4th gear.
5. 5 - TCM selects 5th gear.
6. 6 - TCM selects 6th gear.

The Drive Mode for GEAR_OSC# operates ONLY when

1. The OSS and digital TR sensor are operational.
2. No OSS and digital TR sensor DTCs are set.
3. The key is ON, engine running.
4. The transmission shifter is in the D position.
5. Vehicle speed is above 3 km/h (2 mph).

OSC Command Values

1. 1 - TCM selects 1st gear.
2. 2 - TCM selects 2nd gear.
3. 3 - TCM selects 3rd gear.
4. 4 - TCM selects 4th gear.
5. 5 - TCM selects 5th gear.
6. 6 - TCM selects 6th gear.

Drive Mode Procedure for GEAR_OSC#

Follow operating instructions from scan tool menu screen.

1. Select GEAR_OSC# command.
2. Select PIDs to be monitored.
3. Command the transmission to the desired gear within the vehicle requirements.
4. Monitor all selected PIDs during test.
5. Cancel GEAR_OSC# command at any time.

TCC_OSC# in Drive Mode

The Drive Mode allows the technician to choose the following options

1. TCC_OSC# - Activates the torque convertor clutch (TCC) locked and unlocked.
2. Locked - Applies the TCC.
3. Unlocked - Releases the TCC.

Drive Mode for TCC_OSC# Unlocked operates only when

1. The OSS and digital TR sensor are set.
2. NO OSS and digital TR sensor DTCs are set.
3. The key is ON, engine running.
4. The transmission shifter is in the D position.
5. Vehicle speed is above 10 km/h (16 mph).

Drive Mode for TCC_OSC# Locked operates only when

1. The OSS and digital TR sensor are operational.
2. No OSS and digital TR sensor DTCs are set.
3. The key is ON, engine running.
4. The transmission shifter is in the D position.
5. Vehicle speed is above 10 km/h (16 mph).
6. TFT is above 38°C (100°F).
7. The brake is not applied below 32 km/h (20 mph).
8. Steady vehicle speed is maintained.

OSC Command Values

1. Locked - Applies the TCC.
2. Unlocked - Releases the TCC.

Drive Mode Procedures for TCC_OSC#

Follow operating instructions from the scan tool menu screen.

1. Select TCC_OSC# command.
2. Select PIDs to be monitored.
3. Command the transmission to lock and unlock the TCC within the vehicle requirements.
4. Monitor all selected PIDs during tests.
5. Cancel the TCC_OSC# command at any time.

Diagnostic Parameters Identification (PID) Chart

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

OSC PARAMETERS AND ADDITIONAL PIDS

Transmission Drive Cycle Test

Material

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Note. The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur 4 times consecutively for shift error DTC to be set, and 5 times consecutively for continuous torque converter clutch (TCC) code to set.

Note. When carrying out the Transmission Drive Cycle Test, refer to the Solenoid Application Chart for correct solenoid operation.

After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous codes.

1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With the selector lever in D, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into 6th gear. Hold speed and throttle open steady for a minimum of 15 seconds.
5. With transmission in 6th gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stop lamps. Then, hold speed and throttle steady for a minimum of 5 seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat Steps 4 through 6 at least 5 times.
8. Carry out the Quick Test and record continuous DTCs. If the DTCs are still present, refer to «Diagnostic Trouble Code (DTC) Charts»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__diagnostic-trouble-code-dtc-charts) . Repair all non-transmission DTCs first as they can directly affect the operation of the transmission. Repeat the Quick Test and the Road Test to verify the correction. Erase the DTCs, carry out the Drive Cycle Test and repeat the Quick Test after completing the repair on the DTC. If the continuous test passes and a concern is still present, refer to «Diagnosis By Symptom»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__diagnosis-by-symptom) in this article and TSBs for concerns.

After On-Board Diagnostic

Note. The vehicle wiring harness, PCM and non-transmission sensors may affect transmission operations. Repair these concerns first.

After the on-board diagnostic procedures are completed, repair all DTCs.

Begin with non-transmission related DTCs, then repair any transmission-related DTCs. Use the DTC Table for information on condition and symptoms. This chart will be helpful in referring to the correct manual(s) and aids in diagnosing internal transmission concerns and external non-transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns. Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The Introduction - Gasoline Engines article will aid in diagnosing non-transmission electronic components.

Diagnostic Trouble Code (DTC) Charts

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Using a scan tool to retrieve DTCs, begin with and correct all non-transmission related DTCs. Start with the U-DTCs (communication link codes) then repair any transmission-related DTCs.

Limp-home mode is a default condition to protect the engine and transmission when a fault occurs. Limp-home mode depends on the actual gear the vehicle was in when the fault has occurred.

1. For gears 1-3, the limp-home default will be 3rd gear.
2. For gears 4-6, the limp-home default will be 5th gear.

The limp-home gear will be held until the vehicle is placed in R, P or the vehicle has been restarted. After these action(s) the vehicle will default to the limp-home mode of 3rd gear.

DTC TABLE

Scheme 6

Pinpoint Tests

Refer to appropriate SYSTEM WIRING DIAGRAMS article, Transmission Controls - 6HP26 for schematic and connector information.

Note. Make sure the Selector Lever Cable is correctly adjusted. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS article.

Scheme 7

Scheme 8

Scheme 9

1. A1 VERIFY DTC Select PARK. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Retrieve DTCs Is DTC P1707 current? YES : Go to A2 . NO : INSPECT PCM connector C175B, transmission connector C1473 and the in-line harness connector C146 are fully connected, pins are fully seated and are in good condition. CLEAR DTCs and TEST the system for normal operation.
2. A2 CHECK CIRCUIT FOR OPEN Key in OFF position. Disconnect: PCM C175B Disconnect: Transmission C1473 Measure the resistance between C175B-38 and C1473-10. Is the resistance less than 5 ohms? YES : Go to A3 . NO : REPAIR circuit CET40 (GN-OG) for an open. CLEAR DTCs and TEST the system for normal operation.
3. A3 CHECK CIRCUIT FOR A SHORT TO GROUND Measure the resistance between C175B-38 and ground. Is the resistance greater than 10,000 ohms? YES : Go to A4 . NO : REPAIR circuit CET40 (GN-OG) for a short to ground.
4. A4 CHECK CIRCUIT FOR A SHORT TO VOLTAGE Measure the voltage between C175B-38 and ground. Is any voltage present? YES : REPAIR circuit CET40 (GN-OG) for a short to voltage. NO : REPLACE the mechatronics unit. CLEAR DTC and TEST the system.

Special Testing Procedures

The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the transmission.

Engine Idle Speed Check

Refer to the Introduction - Gasoline Engines article for diagnosis and testing of the engine idle speed.

Scheme 10

A no-drive condition can exist, even with correct transmission fluid pressure, because of inoperative clutches or bands. Refer to the Clutch Application Chart to determine the appropriate elements. A clutch concern can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the concern.

Example: When the selector lever is in a forward gear range (D, 3, 2, 1), a no-drive condition may be caused by an inoperative forward clutch.

1. Drain the transmission fluid. Remove the transmission fluid pan.
2. Remove the transmission fluid filter and seal assembly and the mechatronics unit.
3. The inoperative clutches can be located by applying air pressure into the appropriate clutch port.
4. Apply air pressure to the appropriate clutch port. A dull thud may be heard or movement felt when a clutch piston is applied. If the clutch seals or check ball are leaking, a hissing may be heard.
5. If the clutches fail to operate during the air check: the piston seals are not seated, damaged or not installed correctly. plugged feed holes for clutch apply in the case and/or clutch cylinder. damaged piston and/or clutch cylinder.
6. Service as required and recheck.

Leakage Inspection

Special Tools Illustration Tool Name Tool Number 100W/12 Volt DC UV Lamp 164-R0751 or equivalent

Material

The transmission has the following parts to prevent external transmission fluid leakage

1. Gaskets
2. Lip-type seals
3. O-ring seals
4. Seal rings
5. Seal grommets
6. Seal washers
7. Thread sealant

Leakage at the transmission fluid pan gasket often can be stopped by tightening the bolts to specification. Refer to SPECIFICATIONS .

When transmission fluid is found to be leaking between the transmission case and the transmission fluid cooler tube fitting, tighten the fitting to maximum specification.

If transmission fluid leakage is found at the manual control lever shaft, install a new seal.

Check for transmission fluid leaking from the end of the extension housing. Leakage can result from a damaged seal, missing garter spring or worn extension bushing. Install a new seal assembly, bushing or both, as necessary.

Fluid Leakage in Torque Converter Area

Leakage at the front of the transmission, as evidenced by fluid around the torque converter housing part of the case, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of the leak before removing the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the illustration. The 6 numbers in the illustration correspond with the 6 flow path steps.

Scheme 11

Transmission Leak Check Test Procedure

Add dye to the transmission fluid. Use 30.0 mL (1 oz) of dye for every 3.8L (4 qt) of transmission fluid. Add any additional transmission fluid to bring it to the correct level. Such dyes can be used to determine whether an engine fluid or transmission fluid leak is present, or if the fluid in the transmission fluid cooler hose leaks into the engine coolant system. An ultraviolet light must be used to detect the fluorescent dye solution.

1. Remove the transmission fluid level fill plug and note the color of the transmission fluid that drips out. Original factory fill transmission fluid is clear and red if the transmission fluid has been exchanged.
2. Clean off any transmission fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the torque converter area by washing with a suitable non-flammable solvent and blow-dry with compressed air.
3. Wash out the torque converter housing and the front of the flexplate. The torque converter housing may be washed out using clean solvent and a squirt-type oil can. Blow-dry all washed areas with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Shift the transmission through all the gear ranges to make sure that the dye has circulated through the transmission. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage. Observe the front of the flexplate, back of the cylinder block (in as far as possible) and inside the torque converter housing and front of the case. Run the engine until fluid leakage is evident and the probable source of leakage can be determined. Repair as required. EXTERNAL FLUID LEAKS Leak Path Possible Source Leaks at the fluid pan to case Transmission fluid pan bolts not tightened to specification Transmission fluid pan gasket damaged Transmission case pan rail damaged Fluid cooler tubes or O-rings leaking Transmission fluid cooler tube(s), cooler tube O-rings damaged Transmission fluid cooler tube hold down plate damaged Leaks at the fluid cooler Transmission fluid cooler damaged Transmission fluid cooler tube O-rings damaged Leaks at the manual control lever Manual control lever seal missing or damaged Mechatronic harness connector O-ring on connector missing or damaged

Leak Check Test With A Black Light

Dye-Lite® ATF/Power Steering Fluid Leak Detection Dye 164-R3701 or equivalent (specifically formulated for ATF) is used to detect a transmission fluid leak.

1. Add dye to the transmission fluid. Use one 30.0 mL (1 oz) of dye solution for every 3.8L (4 qt) of transmission fluid.
2. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of transmission fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, then at engine idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the transmission. Observe the front of the flexplate, back of the cylinder block (in as far as possible), inside the torque converter housing and the entire case until transmission fluid leakage is evident and the probable source of leakage can be determined.

Transmission Fluid Cooler Tube Replacement

For installation of new transmission fluid cooler tube, refer to TRANSAXLE/TRANSMISSION COOLING article.

Transmission Fluid Cooler

Note. Cleaning and backflushing the transmission fluid cooling system, along with following all the normal cleaning and inspection procedures during disassembly and reassembly, will keep contaminants from entering the transmission, causing a repeat repair.

When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into use.

Diagnosis By Symptom

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

The Diagnosis By Symptom gives the technician diagnostic information and direction, and suggests possible components using a symptom as a starting point. All routines start out with any potential electrical components that can cause or contribute to the symptom described. The routines then list all possible hydraulic or mechanical components that can cause or contribute the symptom described.

Diagnosis by Symptom Chart Directions

1. Using the Diagnosis by Symptom, select the condition that best describes the condition.
2. Refer to the routine indicated in the Diagnosis by Symptom Chart.
3. Always begin diagnosis of a symptom with: preliminary inspections. verifications of condition. checking the fluid levels. carrying out other test procedures as directed.
4. Begin with the ROUTINES, if indicated. Follow the reference or action required statements. Always carry out the on-board diagnostic tests as required. Never skip steps. Repair as required. If the concern is still present after electrical diagnosis, then proceed to the Hydraulic/Mechanical Routine listed.
5. The list contains only possible hydraulic or mechanical components that may cause or contribute to the concern. These components are listed in the removal sequence and by most probable cause. All components listed must be inspected to make sure that repairs are complete.

DIAGNOSIS BY SYMPTOM CHART

Diagnostic Routines

ENGAGEMENT CONCERNS: NO FORWARD IN D

ENGAGEMENT CONCERNS: NO REVERSE

ENGAGEMENT CONCERNS: HARSH REVERSE

ENGAGEMENT CONCERNS: HARSH FORWARD ONLY

ENGAGEMENT CONCERNS: DELAYED/SOFT REVERSE ONLY

ENGAGEMENT CONCERNS: DELAYED/SOFT FORWARD ONLY

ENGAGEMENT CONCERNS: NO FORWARD AND NO REVERSE

ENGAGEMENT CONCERNS: HARSH FORWARD AND HARSH REVERSE

ENGAGEMENT CONCERNS: DELAYED FORWARD AND DELAYED REVERSE

SHIFT CONCERNS: SOME/ALL SHIFTS MISSING

SHIFT CONCERNS: TIMING - EARLY/LATE

SHIFT CONCERNS: TIMING - ERRATIC/HUNTING (SOME/ALL)

SHIFT CONCERNS: FEEL - SOFT OR SLIPPING (SOME OR ALL)

SHIFT CONCERNS: FEEL - HARSH (SOME/ALL)

SHIFT CONCERNS: NO 1ST GEAR IN DRIVE, ENGAGES IN A HIGHER GEAR

SHIFT CONCERNS: NO 1ST GEAR MANUAL

SHIFT CONCERNS: NO 2ND GEAR MANUAL

SHIFT CONCERNS: NO 3RD GEAR MANUAL

SHIFT CONCERNS: NO 1-2 SHIFT

SHIFT CONCERNS: NO 2-3 SHIFT

SHIFT CONCERNS: NO 3-4 SHIFT

SHIFT CONCERNS: NO 4-5 SHIFT

SHIFT CONCERNS: NO 5-6 SHIFT

SHIFT CONCERNS: NO 6-5 SHIFT

SHIFT CONCERNS: NO 5-4 SHIFT

SHIFT CONCERNS: NO 4-3 SHIFT

SHIFT CONCERNS: NO 3-2 SHIFT

SHIFT CONCERNS: NO 2-1 SHIFT

TORQUE CONVERTER CLUTCH OPERATION CONCERNS: DOES NOT APPLY

TORQUE CONVERTER CLUTCH OPERATION CONCERNS: CYCLING/CHATTER

TORQUE CONVERTER CLUTCH OPERATION CONCERNS: ALWAYS APPLIED/STALLS VEHICLE

OTHER CONCERNS: EXTERNAL LEAKS

Note. Noise, vibration and harshness (NVH) symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION AND HARSHNESS article. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to NOISE, VIBRATION AND HARSHNESS article for the next likely system and continue diagnosis.

NOISE/VIBRATION - FORWARD OR REVERSE

ENGINE WILL NOT CRANK

NO PARK RANGE

TRANSMISSION OVERHEATING

FLUID VENTING/FOAMING

Transmission Fluid Cooler Backflushing and Cleaning

Material

1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major metallic failure is indicated.
2. Using a suitable torque converter/fluid cooler cleaner, flush the transmission fluid cooler and tubes.
3. Connect the cleaner pressure and return lines appropriately in the following sequence. Connect the pressure line to the transmission fluid cooler inlet tube. Connect the return line to the transmission fluid cooler outlet tube. Place the outlet end of the return line in the transmission fluid tank reservoir.
4. Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF.
6. Disconnect the cleaner pressure line at the transmission fluid cooler tube.
7. Using compressed air, blow through the transmission fluid cooler inlet tube until all transmission fluid is removed.
8. Remove the rubber hoses from the transmission fluid cooler tubes.

Transmission Fluid Drain and Refill

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Transmission Fluid Fill Tube 307-570 Transporter Fluid Evacuator/Injector 307-D465 or equivalent Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent Rubber Tip Air Nozzle 100-D009 (D93L-7000-A)

Scheme 12

Scheme 13

Material

Drain

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Install a new transmission fluid pan gasket, if required.
5. Install the transmission fluid pan. Tighten to 14 Nm (10 lb-ft).

Transmission Fluid Refill

Note. If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked.

Note. Here is an overview of the Transmission Fluid Drain and Refill procedure. Adding 3.3L (3.5 qt) of clean transmission fluid to the transmission is an initial fill enabling you to start the engine. The cold transmission fluid level range shown in the procedure allows the vehicle to be driven. The vehicle should be driven to allow the transmission fluid temperature to reach 85°C-88°C (185°F-190°F) in order to purge the air from the transmission fluid cooling system. Fill the transmission fluid to the full range on the transmission fluid level indicator at the normal operating range 80°C-85°C (175°F-185°F).

1. Using the special tool, add 3.3L (3.5 qt) of clean transmission fluid to the transmission through the transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure.
2. Check the transmission fluid level cold. The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90°F-110°F). With the engine running, use the scan tool to monitor transmission fluid temperature and engine speed. Place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 RPM).
3. Separate the transmission fluid level indicator from the transmission fluid fill plug.
4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established.
5. Add clean transmission fluid to the cold level location as shown in the illustration. Transmission fluid cold level.
6. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).
7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the transmission fluid cooling system, eliminating any trapped air in the cooling system. With the engine idling (600-750 RPM) in PARK, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F).
8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case.
9. Separate the transmission fluid level indicator from the transmission fluid fill plug.
10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established.
11. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark.
12. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).

Adding Additional Transmission Fluid

Note. To get an accurate transmission fluid level reading the engine should be idling (600-750 RPM) in PARK.

1. Install the special tool into the transmission fluid fill hole.
2. Fill the special tool with approximately 0.47L (1 pt) of clean transmission fluid.
3. Hang the special tool under the vehicle, upright and close to the transmission.
4. Connect the special tools. Connect the open end of the hose from the special tool onto the special tool from the transmission case.
5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Transmission fluid will immediately start flowing out of the special tool into the transmission.
6. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established.
7. Using the scan tool verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark.
8. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).

Removing Transmission Fluid

Note. To get an accurate transmission fluid level reading the engine should be idling (600-750 RPM) in PARK.

1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the special tools to extract any excessive transmission fluid.
2. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established.
3. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Material

Note. If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.

Note. If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked.

Note. Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark.

Note. If the installation of a new transmission fluid cooler, cooler tubes have been carried out the vehicle must be driven to get the transmission fluid to a temperature of 88°C (190°F) in order to purge the air from the transmission fluid cooling system.

1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK.
2. With the engine idling (600-750 RPM) in PARK, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion of the transmission case.
4. Separate the transmission fluid level indicator from the transmission fluid fill plug.
5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level.
6. Using the scan tool, verify that the transmission fluid temperature is between 80°C-85°C (175°F-185°F). Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark.
7. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft).

1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter rivets, impeller hub or bushing are damaged. Discoloration (due to overheating). Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major metallic failure. Multiple clutches or clutch plate failures. Sufficient component wear which results in metallic contamination. Internal torque converter contamination present. For additional information, refer to «Torque Converter Contamination Inspection»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__torque-converter-contamination-inspection) .

Torque Converter Contamination Inspection

Material

1. If a new or remanufactured torque converter is not being installed, the following steps must be completed.
2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the fluid.
3. Observe the color and odor of the fluid. The fluid should be red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure.
4. Examine the stain on the tissue for evidence of particles (specks of any kind). Examine the transmission fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the transmission fluid, a new torque converter must be installed.
5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter.
6. Add 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand.
7. Thoroughly drain the transmission fluid.

Fluid Pan, Gasket and Filter

Material

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Remove the transmission fluid pan gasket.
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.

INSTALLATION

Note. If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The transmission fluid filter may be reused if no excessive contamination is indicated.

1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter seal is in the case, carefully remove the transmission fluid filter seal without scratching the case.
2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the transmission fluid filter seal with clean transmission fluid.
3. Install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.
5. Install a new transmission fluid pan gasket if required.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-drain-and-refill) .

Note. If a new or the existing mechatronic assembly is installed, the transmission control module (TCM) will need to be reflashed to the latest level calibration available.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
3. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed.
4. Remove the transmission fluid pan and allow the transmission fluid to drain.
5. Remove the transmission fluid pan gasket.
6. Remove and discard the transmission fluid filter.
7. Pull the release tab and pull down on the bulkhead connector retainer.
8. With the release tab down, pull the outer shell of the bulkhead electrical connector out of the TCM.
9. Pull the bulkhead electrical connector out of the transmission.
10. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly.

Note. Before reinstalling the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time.

1. Verify the 4 rubber feed tubes for the center support are in place. Black feed tube. Green feed tube. Blue feed tube.
2. Verify the rubber adapter is in place.
3. Verify the thermal bypass valve is in the case.
4. Position the mechatronic assembly in place and loosely install the 11 bolts. Align the manual valve and control lever linkage.
5. Tighten the mechatronic bolts in the sequence shown. Tighten to 6 Nm (53 lb-in).
6. With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
7. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.
8. Install a new transmission fluid filter.
9. Install a new transmission fluid pan gasket if required.
10. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
11. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
12. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-drain-and-refill) .
13. If a new or the existing mechatronic assembly is installed, the TCM will need to be reflashed to the latest level calibration available.

Output Shaft Seal

Special Tools Illustration Tool Name Tool Number Installer, Transmission Extension Housing Fluid Seal 307-560 Installer, Fluid Pump Seal 307-556 Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A)

Scheme 14

Material

Note. Rear wheel drive (RWD) shown, four wheel drive (4WD) similar.

Scheme 15

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the rear driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/explorer-sport-trac/ii-2006-2010/remont/driveshaft-universal-joints/#driveshaft) article.
3. Remove and discard the output shaft flange nut.
4. Remove the output shaft flange.
5. Using the special tools, remove the output shaft seal.
6. Remove the transfer case. For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/ii-2006-2010/remont/transfer-case/#transfer-case) article.
7. Using the special tools, remove the output shaft seal.

RWD vehicles

1. Position a new output shaft seal.
2. Using the special tool, install the output shaft seal.
3. Install the output shaft flange.
4. Install a new output shaft flange nut. Tighten to 60 Nm (44 lb-ft). After installing the new nut, it must be staked at the slots to prevent it from coming loose.
5. Install the rear driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/explorer-sport-trac/ii-2006-2010/remont/driveshaft-universal-joints/#driveshaft) article.
6. Position the output shaft seal.
7. Using the special tool, install a new output shaft seal.
8. Install the transfer case. For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/ii-2006-2010/remont/transfer-case/#transfer-case) article.
9. Fill and check the transmission fluid. For additional information, refer to «Transmission Fluid Level Check»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) .

Manual Control Lever Shaft and Seal

Special Tools Illustration Tool Name Tool Number Installer, Shift Shaft Fluid Seal 307-559

Scheme 16

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the selector lever cable shield.
3. Disconnect the selector lever cable end.
4. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed.
5. Remove the transmission fluid pan and allow the transmission fluid to drain.
6. Remove and discard the transmission fluid filter.
7. Remove the transmission fluid pan gasket.
8. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
9. Pull the release tab and pull down on the bulkhead connector retainer.
10. With the release tab down, pull the outer shell of the bulkhead electrical connector out of the transmission control module (TCM).
11. Pull the bulkhead electrical connector out of the transmission.
12. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly.
13. Remove the park pawl abutment.
14. Remove the manual control lever. Remove the roll pin. Slide the manual control lever shaft out of the case. Hold the spacer to keep it from falling out of the case. Remove the manual valve inner detent lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.

1. Position a new manual control lever seal in place.
2. Using the special tool, install a new manual control lever shaft seal.
3. Install the manual control lever in the case. Slide the manual control lever in the case. Position the spacer in place while sliding the manual control lever into the spacer. Position the manual valve inner detent lever while sliding the manual control lever and lining up the roll pin hole. Install the roll pin.
4. Position the manual lever and park rod in place. Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park pawl abutment. Tighten to 10 Nm (89 lb-in).
6. Verify the 4 rubber feed tubes for the center support are in place. Black feed tube. Green feed tube. Blue feed tube.
7. Verify the rubber adapter is in place.
8. Verify the thermal bypass valve is in the case.
9. Position the mechatronic assembly in place and loosely install the 11 bolts. Align the manual valve and control lever linkage.
10. Tighten the mechatronic bolts in the sequence shown. Tighten to 6 Nm (53 lb-in).
11. With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
12. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
13. Install a new transmission fluid filter.
14. Install a new transmission fluid pan gasket if necessary.
15. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
17. Connect the selector lever cable onto the ball stud and move the locking tab down. Listen for the audible click. Pull back on the selector lever cable to make sure that it is correctly installed.
18. Install the selector lever cable shield.
19. Using the transmission fluid refill procedure, fill and check the transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-drain-and-refill) .

Transmission - Four Wheel Drive (4WD)

Special Tools Illustration Tool Name Tool Number Retainer, Torque Converter 307-346 (T97T-7902-A)

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
5. Remove the transfer case. For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/ii-2006-2010/remont/transfer-case/#transfer-case) article.
6. Position a suitable transmission jack to the transmission. Securely strap the transmission to the jack.
7. Remove the LH exhaust heat shield bolt.
8. If equipped, remove the RH exhaust heat shield.
9. Remove the 4 RH side crossmember bolts and the nut.
10. Remove the 4 LH side crossmember bolts and the nut.
11. Disconnect the RH and LH heated oxygen sensors (HO2S) and the catalyst monitor sensor electrical connectors.
12. Remove and discard the RH and LH exhaust flange nuts.
13. Remove the dual converter Y-pipe bolts, discard the nuts and remove the dual converter Y-pipe.
14. Remove the fuel line bracket bolt from the bracket. Position the bracket and lines aside.
15. Remove the selector lever cable shield.
16. Disconnect the selector lever cable end and remove the selector lever cable bracket bolts. Position the selector lever cable and bracket aside.
17. Remove the flexplate inspection cover bolts and the inspection cover.
18. Remove and discard the 4 flexplate-to-torque converter nuts.
19. Remove the plastic starter motor electrical connector cap.
20. Remove the starter motor electrical connectors.
21. Remove the ground wire from the stud.
22. Remove the 3 starter motor bolts and the starter motor.
23. Remove the transmission cooler tube bracket bolt.
24. Disconnect the engine oil low level sensor electrical connector.
25. Remove the transmission fluid cooler tube bracket nut and position the bracket and transmission fluid cooler tubes aside.
26. Remove the catalyst monitor sensor electrical connector from the LH side of the transmission.
27. Disconnect the wiring harness from the top of the transmission.
28. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
29. Remove the 7 transmission-to-engine bolts.
30. Slide the transmission back enough to install the special tool.
31. Remove the transmission from the vehicle.
32. If the transmission is to be overhauled or if installing a new transmission, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to «Transmission Fluid Cooler Backflushing and Cleaning»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-cooler-backflushing-and-cleaning) .

Transmission - Rear Wheel Drive (RWD)

Special Tools Illustration Tool Name Tool Number Retainer, Torque Converter 307-346 (T97T-7902-A)

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
3. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/explorer-sport-trac/ii-2006-2010/remont/driveshaft-universal-joints/#driveshaft) article.
4. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are removed.
5. Remove the transmission fluid pan and allow the fluid to drain.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (124 lb-in).
7. Remove the selector lever shield.
8. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.
9. Remove the flexplate inspection cover bolts and the inspection cover.
10. Remove the rubber torque converter nut access plug.
11. Remove and discard the 4 flexplate-to-torque converter nuts.
12. Remove the transmission fluid cooler tube bracket bolt.
13. Remove the transmission-to-engine bolt.
14. Remove the transmission fluid cooler tube bracket nut and position the transmission fluid cooler tube bracket and tubes aside.
15. Remove the plastic starter motor electrical connector cap.
16. Remove the starter motor electrical connectors.
17. Remove the ground wire from the stud.
18. Remove the starter motor bolts and the starter motor.
19. Remove the LH exhaust heat shield bolt.
20. Remove the RH exhaust heat shield bolts and heat shield.
21. Disconnect the RH and LH Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) connectors.
22. Remove the fuel line bracket bolt and position the fuel line bracket and fuel lines aside.
23. Position a suitable high-lift transmission jack under the transmission.
24. Remove the 2 crossmember nuts.
25. Remove the 8 crossmember bolts.
26. Remove the 3 transmission insulator bolts and remove the transmission insulator.
27. Remove and discard the RH and LH exhaust flange nuts.
28. Remove the 2 dual converter Y-pipe bolts, discard the nuts and remove the dual converter Y-pipe.
29. Disconnect the wire harness from the top of the transmission.
30. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
31. Remove the 6 remaining transmission case bolts.
32. Slide the transmission back far enough to install the Torque Converter Retainer.
33. Remove the transmission from the vehicle.
34. If the transmission is to be overhauled or if installing a new transmission, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to «Transmission Fluid Cooler Backflushing and Cleaning»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-cooler-backflushing-and-cleaning) .

Special Tools Illustration Tool Name Tool Number Slide Hammer 100-001 (T50T-100-A) Handle, Torque Converter 307-091 (T81P-7902-C) Remover, Input Shaft Oil Seal 308-375 Retaining Ring Pliers 307-343 (T95P-77001-AHR) Collet, 1-1/4 to 1-1/24 Inch 303-D022 (D80L-100T) or equivalent Actuator Pin 303-D012 (D80L-100-H) or equivalent Remover, Front Pump 307-553 Remover, Needle Bearing 307-562 (includes 307-562/1 and 307-562/2)

Scheme 17

Scheme 18

Scheme 19

Scheme 20

All vehicles

1. Using the special tools, remove the torque converter.
2. Remove the transmission fluid pan.
3. Remove the transmission fluid pan gasket.
4. Remove and discard the transmission fluid filter.
5. Press the release tab and lift up on the bulkhead connector retainer.
6. With the release tab up, pull the outer shell of the bulkhead electrical connector.
7. Pull the outer shell of the bulkhead electrical connector out of the transmission.
8. Remove the 11 bolts from the mechatronic assembly.
9. Remove the mechatronic assembly.
10. Remove the rubber adapter and the transmission fluid filter seal.
11. Remove and discard the 4 rubber feed tubes for the center support. Note the size and location while removing for correct installation. Black feed tube Green feed tube Blue feed tube
12. Remove the thermal bypass valve from the case.
13. Inspect the thermal bypass valve for damage, install a new valve if damage is indicated.
14. Using the special tools, remove and discard the front pump seal.
15. Remove and discard the front pump bolts.
16. Using the special tools, remove the front pump support. Make sure that the selective shim is on the back side of the pump.
17. Remove and discard the front pump O-ring seal from the plate assembly.
18. Remove the forward (clutch A)/overdrive (clutch E) clutch assembly.
19. Remove the caged roller bearing.
20. Remove the direct clutch assembly.
21. Using the special tool, remove the center support snap ring.
22. Remove the center support.
23. Remove the bearing from the back of the center support if it is there.
24. Remove the planet carrier and the low/reverse clutch pack as an assembly.
25. Remove the low/reverse bearing race.
26. Remove the low/reverse sun gear.
27. Remove the sun gear from the planet assembly.
28. Remove the top and the bottom roller bearings from the sun gear.
29. Remove the roller bearing race in the bottom of the carrier.
30. Remove the washer.
31. Remove the 4 bolts and the transmission support bracket.
32. Remove and discard the output shaft flange nut.
33. Remove the output shaft flange.
34. Remove the planet carrier hub and output shaft assembly.
35. Remove the output shaft seal.
36. Remove the anti-click washer.
37. Remove the snap ring from the case.
38. Using the special tools, remove the roller bearing.
39. Using a suitable tool, remove the inner bearing snap ring.
40. Using the special tool, remove the bearing assembly.
41. Remove the planet carrier hub and output shaft assembly.
42. Remove and discard the output shaft seal.
43. Remove the snap ring from the case.
44. Remove the bearing spacer.
45. Using a suitable tool, remove the inner bearing snap ring.
46. Using the special tool, remove the bearing assembly.
47. Remove the park pawl abutment.
48. Remove the manual control lever. Remove the roll pin. Slide the manual control lever shaft out of the case. Hold the spacer to keep from falling into the case. Remove the manual valve inner detent lever and the park rod as an assembly.
49. Remove and discard the manual control lever seal.
50. Remove the bolt from the back of the case to gain access to the park pawl pin.
51. From the inside of the case, push the park pawl pin out toward the back side of the case while holding the spring and the park pawl. Remove the park pawl pin then remove the park pawl and spring.

DISASSEMBLY

1. Remove the direct clutch outer shell retaining ring.
2. Remove the direct clutch hub.
3. Remove the forward clutch and sun shaft assembly.
4. Remove the intermediate shaft bearing.
5. Remove the intermediate shaft assembly.
6. Remove the overdrive clutch pack from the forward clutch pack.

Forward Clutch Assembly

Special Tools Illustration Tool Name Tool Number Clutch Pack End Play Gauge 307-555 Compressor, Clutch Spring 307-015 (T65L-77515-A) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Piston Spring Compressor 307-525

Scheme 21

Material

Scheme 22

1. Remove the sun gear from the forward clutch assembly. With a small screwdriver or a suitable pick inserted into the sun, gear push on the retaining ring in 3 places while lifting up on the sun gear to remove.
2. Remove the forward clutch pack snap ring.
3. Remove and inspect the forward clutch steel and friction plates.
4. Install the special tool under the forward clutch drum.
5. Using the special tools, slightly collapse the balance dam to gain access to the retaining ring. Remove the retaining ring.
6. Prior to removing the balance dam, make an identifying mark on the balance dam and the center part of the housing. This is for correct alignment during the assembly.
7. Remove the balance dam.
8. Remove and discard the O-ring seal from the balance dam.
9. Remove the forward clutch return spring.
10. Install the forward clutch into the front pump to remove the forward clutch piston. Apply a small amount of shop air to remove the piston.
11. Remove and discard the inner and outer piston O-ring seals.
12. Remove the sun gear from the planet assembly.
13. Remove the bearing from the sun gear.
14. Inspect the sun gear and bearing for damage. Install new components as necessary.

ASSEMBLY

1. Install the planetary assembly snap ring, if necessary.
2. Make sure the planetary snap ring is oriented as shown.
3. Install the bearing onto the sun gear.
4. Install the sun gear into the planet assembly with the bearing facing down and the recess part of the gear up.
5. Install new O-ring seals onto the forward clutch piston.
6. Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into the forward clutch drum.
7. Install the forward clutch return spring.
8. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean transmission fluid.
9. Align the marks made during disassembly and install the balance dam into the forward clutch drum.
10. Using the special tools, slightly collapse the balance dam to install the retaining ring. Install the retaining ring.
11. If required, install new forward clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending up with the pressure plate.
12. Install the forward clutch plate snap ring.
13. Install the forward clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
14. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
15. Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B. Description Reading Reading A Reading B Add reading A to reading B for a total end clearance Divide the total reading by 2 for an average end clearance
16. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
17. Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks in place.

Overdrive Clutch Assembly

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Compressor, Spring Washer 307-209 Clutch Pack End Play Gauge 307-555

Material

Scheme 23

1. Remove the thrust bearing (T3).
2. Remove the overdrive clutch pack snap ring.
3. Remove the overdrive clutch pack.
4. Using the special tool and a press, remove and discard the overdrive clutch balance piston retaining ring.
5. Remove the overdrive clutch balance piston.
6. Remove the overdrive clutch return spring.
7. Remove the overdrive clutch apply piston.
8. Remove and discard the outer O-ring seal on the overdrive clutch balance piston.
9. Remove and discard both the inner (one large and one small) O-ring seals on the overdrive clutch apply piston.
10. Remove and discard the 2 scarf cut seals and the roller bearing.

1. Install 2 new scarf cut seals and a new roller bearing.
2. Install a new outer O-ring seal on the overdrive clutch balance piston.
3. Install 2 new inner O-ring seals on the overdrive clutch apply piston.
4. Lubricate all the O-ring seals with clean automatic transmission fluid. Install the overdrive clutch apply piston into the drum with the O-ring seals and the 3 pads facing down toward the drum.
5. Install the overdrive clutch return spring.
6. Lubricate all the O-ring seals with clean automatic transmission fluid. Install the overdrive clutch balance piston.
7. Using the special tool, install a new overdrive clutch balance piston retaining ring.
8. If required, install new overdrive clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate on the top.
9. Install the overdrive clutch pack snap ring.
10. Install the overdrive clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
11. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
12. Rotate the overdrive clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B. Description Reading Reading A Reading B Add reading A to reading B for a total end clearance Divide the total reading by 2 for an average end clearance
13. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
14. Install a new thrust bearing (T3).

Forward/Overdrive Clutch Assembly - Assembly

Material

1. Install the overdrive clutch pack onto the forward clutch and planetary gear set.
2. Install the intermediate shaft assembly.
3. Install the intermediate shaft bearing (T4).
4. Install the forward clutch and sun shaft assembly.
5. Install the direct clutch hub.
6. Install the direct clutch outer shell retaining ring.

Direct Clutch Assembly

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Compressor, Clutch Spring 307-015 (T65L-77515-A) Clutch Pack End Play Gauge 307-555 Direct Clutch Pack Service Fixture 307-552

Material

Scheme 24

1. Remove and discard the 2 scarf cut seals and the roller bearing.
2. Remove the thrust bearing (T5).
3. Remove the direct clutch snap ring.
4. Remove the direct clutch steel and friction plates.
5. Install the special tools onto the direct clutch assembly.
6. Using the special tool, remove the direct clutch return spring retainer.
7. Remove the special tool.
8. Remove the direct clutch return spring washer.
9. Remove the direct clutch return spring.
10. Slightly press down on the balance piston and remove and discard the snap ring.
11. Remove the baffle plate from the direct clutch piston.
12. Remove the direct clutch piston.
13. Remove and discard the outer O-ring seal from the balance piston.
14. Remove and discard the outer and inner O-ring seals from the apply piston.
15. Inspect the direct clutch drum for damage. If damage is indicated, install a new direct clutch drum.

1. Install a new inner and outer O-ring seals on the apply piston.
2. Install a new outer O-ring seal on the balance piston.
3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
4. Lightly coat the O-ring seals in clean transmission fluid and install the apply piston into the direct clutch balance piston.
5. Slightly press down on the balance piston and install a new snap ring.
6. Install the direct clutch return spring.
7. Install the direct clutch return spring washer.
8. Install the special tool.
9. Using the special tool, install the direct clutch return spring retainer.
10. If required, install new direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.
11. Install the direct clutch snap ring.
12. Install a new thrust bearing (T5).
13. Install the direct clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
14. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
15. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B. Description Reading Reading A Reading B Add reading A to reading B for a total end clearance Divide the total reading by 2 for an average end clearance
16. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
17. Install 2 new scarf cut seals and the roller bearing.

Intermediate Clutch Assembly

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Piston Spring Compressor 307-525 Clutch Pack End Play Gauge 307-555

Material

Scheme 25

1. Remove the thrust bearing (T6).
2. Remove the intermediate clutch plate snap ring.
3. Remove the intermediate clutch plates.
4. Using the special tool, remove and discard the intermediate clutch return spring retainer.
5. Remove the intermediate clutch return spring top plate.
6. Remove the intermediate clutch return spring.
7. Applying a slight amount of air to the port, remove the intermediate clutch piston.
8. Remove and discard the inner and outer intermediate clutch piston O-ring seals.

1. Install new inner and outer intermediate clutch piston O-ring seals.
2. Lightly coat the O-ring seals in clean transmission fluid and install the intermediate clutch piston.
3. Install the intermediate clutch return spring.
4. Install the intermediate clutch return spring top plate.
5. Using the special tool, install a new intermediate clutch return spring retainer.
6. If required, install new intermediate clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate.
7. Install the intermediate clutch plate snap ring.
8. Install the intermediate clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
9. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
10. Rotate the intermediate clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B. Description Reading Reading A Reading B Add reading A to reading B for a total end clearance Divide the total reading by 2 for an average end clearance
11. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
12. Install the thrust bearing (T6).

Low/Reverse Clutch Assembly

Special Tools Illustration Tool Name Tool Number Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Compressor, Clutch Spring 307-525 Gauge, D-Clutch Measurement 307-554 Depth Micrometer 303-D075 (D92P-4201-A) or equivalent

Material

Scheme 26

Note. The low/reverse clutch plates are installed in the case during the assembly procedure.

1. Remove and discard thrust bearing on the center support.
2. Using the special tool, remove the retaining ring.
3. Remove the low/reverse clutch return spring.
4. Remove the low/reverse clutch piston from the low/reverse clutch drum.
5. Remove and discard the low/reverse clutch piston O-ring seals.
6. Remove and discard the low/reverse drum O-ring seals.

Low/reverse piston

1. Install new low/reverse clutch piston O-ring seals.
2. Install new low/reverse drum O-ring seals.
3. Lubricate the O-ring seal with clean transmission fluid and install the low/reverse piston.
4. Install the low/reverse clutch return spring.
5. Using the special tool, install the retaining ring.
6. Install a new roller bearing on the center support.
7. Install the special tool into the case.
8. Install the special tool into the case as shown.
9. Measure case stop depth. Description Reading Measure the distance from the top of the upper gauge bar to the top of the lower gauge bar. Record this reading as the case measurement. Record as reading A
10. Measure the clutch pack height. Description Reading A. Place the clutch pack with the pressure plate on to the special tool with the wave spring down. Slide the clutch off to the side so the probe of the dial indicator is touching the gauge plate of the special tool. Zero out the dial indicator. B. Carefully lift the probe up enough to slide the clutch pack under the probe to take a reading. Record this reading. Rotate the clutch pack 180 degrees and take a second reading. Add the first and second readings together and divide the total by 2. Record this reading as B.
11. Measure the piston to center support shoulder height. Description Reading Measure the piston to center support shoulder height. Record this measurement. Rotate the center support 180 degrees and record this measurement. Add the first and the second measurements, then divide by 2. Record this as reading C.
12. Calculate the end clearance Description Reading Total C measurement Subtract B and C from A to determine end clearance End clearance specification 0.8-1.4 mm (0.031-0.055 in) Compare the end clearance to the specification. If the end clearance is out of specification, select the next thinner or thicker plate as required and repeat Steps 10, 11 and 12.

Mechatronic Assembly

Material

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Note. Make an identifying mark on each solenoid and the corresponding bore for correct assembly.

Note. Solenoids may visually appear the same but their designs/functions are different. Caution must be taken not to assemble the mechatronics assembly incorrectly. Incorrect solenoid installation will result in poor transmission shift quality.

Note. Note where the 8 check balls, 6 solenoid dampers, 2 internal valves and springs and 2 internal filters are located for reassembly.

Mechatronic assembly upper half

1. Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
2. Remove the 6 long bolts from the transmission control unit (TCM) unit.
3. Carefully separate the TCM from the mechatronic assembly.
4. Remove 19 short bolts from the mechatronic assembly.
5. Separate the lower half of the mechatronic assembly from the upper half of the mechatronic assembly.
6. Remove and discard the separator plate.
7. Remove the clips, caps, valves and spring from each bore in the mechatronic assembly. Note the location and order for reassembly. Refer to the preceding exploded views.
8. Remove the transmission control valves, check balls and filter screens from the mechatronic assembly. Note the location and order for reassembly. Refer to the preceding exploded views.
9. Using clean mineral spirits, clean the upper half of the mechatronic assembly.
10. Remove the 8 solenoid bracket bolts and the solenoid bracket.
11. Remove the solenoids.
12. Remove the clips, caps, valves and spring from each bore in the mechatronic assembly. Note the location and order for reassembly. Refer to the preceding exploded views.
13. Using clean mineral spirits, clean the lower half of the mechatronic assembly.

Mechatronic assembly upper half

1. Install the clips, caps, valves and spring into each bore. Refer to the preceding exploded views.
2. Install the clips, caps, valves and spring into each bore.
3. Install the solenoids into their correct bores as indicated during disassembly.
4. Install the solenoid bracket and the 8 bolts. Tighten to 6 Nm (53 lb-in).
5. Install the transmission control valves, check balls and filter screens into the mechatronic assembly. Refer to the preceding exploded views.
6. Install a new separator plate.
7. Assemble the lower half and the upper half of the mechatronic assembly.
8. Loosely install the 19 short bolts into the mechatronic assembly.
9. Carefully install the TCM onto the mechatronic assembly.
10. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown. Tighten to 6 Nm (53 lb-in).
11. Tighten the 19 short bolts in the sequence shown. Tighten to 6 Nm (53 lb-in).

Pump Assembly

Special Tools Illustration Tool Name Tool Number Installer, Fluid Pump Seal 307-556

Material

1. Remove the front pump washer.
2. Remove and discard the front pump O-ring seal from the plate assembly.
3. Remove and discard the front pump seal rings from the stator support.
4. Remove the 11 bolts and separate the pump plate assembly from the pump body.
5. Remove and discard the pump body outer seal.
6. Remove and inspect the inner and the outer pump gears. Clean all pump components in solvent. Dry the parts with compressed air. Inspect the pump gears, faces, gear teeth, pump housing and mating surfaces for damage or scoring. Install a new pump as necessary.

1. Install the pump gears with the dot facing the pump plate assembly.
2. Install a new pump body outer seal.
3. Assemble the plate assembly and the pump body assembly. Tighten to 15 Nm (11 lb-ft).
4. Install the 2 front pump seal rings onto the stator support. Make sure the seals are fully seated in the stator support seal grooves and the seal ends are oriented 180 degrees apart.
5. Install a new pump outer diameter front pump O-ring seal.
6. Using the special tool, install the front pump seal.
7. Install the pump thrust washer.

Special Tools Illustration Tool Name Tool Number Aligner, Valve Body 307-334 (T95L-70010-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) End Play Gauge, Transmission 307-534 Handle, Driver 205-153 (T80T-4000-W) Handle, Torque Converter 307-091 (T81P-7902-C) Installer, Ball Bearing 307-557 Installer, Fluid Pump Seal 307-556 Installer, Needle Bearing 307-558 Installer, Shifter Fluid Seal 307-559 Installer, Transmission Extension Housing Fluid Seal 307-560 Remover, Transmission Fluid Pump 307-553 Retaining Ring Pliers 307-343 (T95P-77001-AHR)

Scheme 31

Material

Scheme 32

Scheme 33

Scheme 34

All vehicles

1. If removed, position the rear case roller bearing in the case.
2. Using the special tools, install the roller bearing.
3. Install the snap ring.
4. Using the special tools, install the rear case roller bearing in the case.
5. Install the roller bearing snap ring.
6. Using the special tools, install the rear bearing spacer.
7. Install the rear bearing spacer snap ring.
8. Place the transmission in the vertical position.
9. Install the planet carrier hub and output shaft assembly.
10. Install the silver shim (caged bearing) on the planet carrier hub and output shaft assembly.
11. Position the park pawl pin into the case.
12. Position the park pawl into the case and push the park pawl pin in to hold the park pawl and spring in position.
13. Install the park pawl pin bolt. Tighten to 35 Nm (26 lb-ft).
14. Position a new output shaft seal in place.
15. Using the special tool, install the output shaft seal.
16. Install the anti-click washer.
17. Position a new output shaft seal in place.
18. Using the special tool, install the output shaft seal.
19. Install the output shaft flange.
20. Install a new output shaft flange nut. Tighten to 60 Nm (44 lb-ft). After installing the new nut, it must be staked at the slots to prevent it from coming loose.
21. Install the rear transmission mount bracket. Tighten to 48 Nm (35 lb-ft).
22. Install the roller bearing race in the bottom of the carrier.
23. Snap the top and the bottom roller bearings onto the sun gear.
24. Install the sun gear into the planet assembly.
25. Install the low/reverse sun gear.
26. Install the planet carrier.
27. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates, and ending with the wave spring plate on the top.
28. Install the low/reverse thrust bearing (T7).
29. Install the select fit thrust gear shim on the T7 thrust bearing.
30. Install the center support into the case.
31. Using the special tool, install the center support snap ring. Tap the snap ring into the case to make sure that it is seated into the case.
32. Using the special tool, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.006-0.013 in). If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
33. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.
34. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in). If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
35. Install the roller bearing if not previously installed on the direct clutch drum.
36. Install the direct clutch drum.
37. Install the bearing on the direct clutch assembly.
38. Install the forward and overdrive clutch assembly.
39. Install the pump washer.
40. Install the special tool into the case.
41. If the pump assembly was not disassembled and assembled, install a new pump outer diameter front pump O-ring seal.
42. Using the special tool, install the front pump seal.
43. Using the special tools, install the front pump.
44. Make sure that the pump is correctly aligned with the case.
45. Loosely install the new front pump bolts with the new washers.
46. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern. Tighten to 10 Nm (89 lb-in).
47. Install the special tool onto the input shaft to measure end play. Tighten the wing nut.
48. Install the remaining special tool. Push down on the special tool and zero out the dial indicator. Lift up on the special tool and record the measurement 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification install a new pump washer. Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.
49. Install the park pawl abutment. Tighten to 10 Nm (89 lb-in).
50. Position a new manual control lever seal in place.
51. Using the special tool, install a new manual control lever shaft seal.
52. Position the manual lever and park rod in place. Push down on the park pawl and slide the park rod in place.
53. Install the manual control lever in the case. Slide the manual control lever in the case. Position the spacer in place while sliding the manual control lever into the spacer. Position the manual valve inner detent lever while sliding the manual control lever and lining up the roll pin hole. Install the roll pin.
54. Install the 4 rubber feed tubes for the center support. Black feed tube. Green feed tube. Blue feed tube.
55. Install the thermal bypass valve into the case.
56. Install the rubber adapter.
57. Loosely install the 11 mechatronic bolts. Align the manual valve and control lever linkage.
58. Tighten the bolts in the sequence shown. Tighten to 6 Nm (53 lb-in).
59. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
60. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.
61. Install a new transmission fluid filter.
62. Install a new transmission fluid pan gasket if required.
63. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
64. Install the torque converter.

Special Tools Illustration Tool Name Tool Number Retainer, Torque Converter 307-346 (T97T-7902-A)

Material

1. Install the special tool.
2. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
3. Remove the special tool.
4. With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.
5. Install the 7 transmission-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
6. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
7. Connect the wire harness to the top of the transmission.
8. Install the catalyst monitor sensor electrical connector to the LH side of the transmission.
9. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube bracket nut. Tighten to 12 Nm (9 lb-ft).
10. Connect the engine oil low level sensor electrical connector.
11. Install new O-rings on the transmission fluid cooler tubes.
12. Install the transmission fluid cooler tube bracket bolt. Tighten to 25 Nm (18 lb-ft).
13. Install the starter motor and the 3 starter motor bolts. Tighten to 26 Nm (19 lb-ft).
14. Install the ground wire on the stud and install the ground wire nut. Tighten to 23 Nm (17 lb-ft).
15. Install the starter motor electrical connectors. Tighten to 12 Nm (9 lb-ft). Tighten to 6 Nm (53 lb-in).
16. Install the plastic starter motor electrical connector cap.
17. Install 4 new torque converter nuts. Tighten to 35 Nm (26 lb-ft).
18. Install the flexplate inspection cover and the inspection cover bolts. Tighten to 35 Nm (26 lb-ft).
19. Position the selector lever cable in place, install the selector lever cable bracket bolts and connect the selector lever cable end. Tighten to 27 Nm (20 lb-ft). Listen for the audible click. Pull back on the selector lever cable to make sure that it is correctly installed.
20. Install selector lever cable shield.
21. Install the fuel line bracket bolt. Tighten to 25 Nm (18 lb-ft).
22. Position the dual converter Y-pipe in place and install the dual converter Y-pipe bolts and new nuts. Tighten to 40 Nm (30 lb-ft).
23. Install new LH and RH exhaust flange nuts. Tighten to 40 Nm (30 lb-ft).
24. Connect the RH and LH heated oxygen sensors (HO2S) connectors and the catalyst monitor sensor electrical connectors.
25. Install the 4 RH side crossmember bolts and the nut. Tighten the vertical bolts to 80 Nm (59 lb-ft). Tighten the horizontal nut to 90 Nm (66 lb-ft).
26. Install the 4 LH side crossmember bolts and the nut. Tighten the vertical bolts to 80 Nm (59 lb-ft). Tighten the horizontal nut to 90 Nm (66 lb-ft).
27. If equipped, install the RH exhaust heat shield. Tighten to 15 Nm (11 lb-ft).
28. Install the LH exhaust heat shield bolt. Tighten to 15 Nm (11 lb-ft).
29. Install the transfer case. For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/ii-2006-2010/remont/transfer-case/#transfer-case) article.
30. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
31. Verify that the selector lever cable is correctly adjusted. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-external-controls) article.
32. Reflash the transmission control module (TCM) to the latest level of software.
33. Using the transmission refill procedure, fill the transmission with clean transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-drain-and-refill) .

Special Tools Illustration Tool Name Tool Number Retainer, Torque Converter 307-346 (T97T-7902-A)

Material

1. Install the special tool.
2. Install the transmission insulator bracket and the transmission insulator bracket bolts. Tighten to 48 Nm (35 lb-ft).
3. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
4. Remove the special tool.
5. With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.
6. Install the 7 transmission-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
7. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
8. Connect the wire harness to the top of the transmission.
9. Install the catalyst monitor sensor electrical connector to the LH side of the transmission.
10. Position the dual converter Y-pipe in place and install the 2 dual converter Y-pipe bolts and new nuts. Tighten to 40 Nm (30 lb-ft).
11. Install new LH and RH exhaust flange nuts. Tighten to 40 Nm (30 lb-ft).
12. Connect the RH and LH heated oxygen sensors (HO2S) electrical connectors and the catalyst monitor sensor electrical connectors.
13. Position the transmission insulator in place and install the 2 transmission insulator bolts. Tighten to 80 Nm (59 lb-ft).
14. Position the rear crossmember in place and loosely install the transmission insulator nuts.
15. Install the 8 crossmember bolts. Tighten to 80 Nm (59 lb-ft). Tighten to 90 Nm (66 lb-ft).
16. Tighten the transmission insulator nuts. Tighten to 103 Nm (76 lb-ft).
17. Install the LH exhaust heat shield bolt. Tighten to 15 Nm (11 lb-ft).
18. If equipped, install the RH exhaust heat shield. Tighten to 15 Nm (11 lb-ft).
19. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube bracket nut. Tighten to 12 Nm (9 lb-ft).
20. Connect the engine oil low level sensor electrical connector.
21. Install new O-rings on the transmission fluid cooler tubes.
22. Install the transmission cooler tube bracket bolt. Tighten to 25 Nm (18 lb-ft).
23. Position the starter motor in place and install the 3 starter motor bolts. Tighten to 26 Nm (19 lb-ft).
24. Install the ground wire on the stud and install the ground wire nut. Tighten to 23 Nm (17 lb-ft).
25. Install the starter motor electrical connectors. Tighten to 12 Nm (9 lb-ft). Tighten to 6 Nm (53 lb-in).
26. Install the plastic starter motor electrical connector cap.
27. Install 4 new flexplate-to-torque converter nuts. Tighten to 35 Nm (26 lb-ft).
28. Install the rubber access plug.
29. Install the flexplate inspection cover and the flexplate inspection cover bolts. Tighten to 35 Nm (26 lb-ft).
30. Position the selector lever cable in place, install the selector lever cable bracket bolts and connect the selector lever cable end. Tighten to 27 Nm (20 lb-ft). Listen for the audible click. Pull back on the selector lever cable to make sure that it is correctly installed.
31. Install the selector lever cable shield.
32. Position the fuel line in place and install the bolt. Tighten to 25 Nm (18 lb-ft).
33. Install the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/explorer-sport-trac/ii-2006-2010/remont/driveshaft-universal-joints/#driveshaft) article.
34. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
35. Verify that the selector lever cable is correctly adjusted. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-external-controls) article.
36. Reflash the transmission control module (TCM) to the latest level of software.
37. Using the transmission fluid refill procedure, fill the transmission with clean automatic transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60__transmission-fluid-drain-and-refill) .

See also:
• Introduction - Gasoline Engines
• AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS
• BATTERY, MOUNTING AND CABLES
• TRANSAXLE/TRANSMISSION COOLING
• ENGINE SYSTEM - GENERAL INFORMATION
• NOISE, VIBRATION AND HARSHNESS
• STARTING SYSTEM
• JACKING AND LIFTING
• DRIVESHAFT
• TRANSFER CASE
• Diagnosis By Symptom
• Transmission Fluid Level Check
• Transmission Fluid Drain and Refill
• Special Testing Procedures
• Leakage Inspection
• Diagnostic Trouble Code (DTC) Charts
• Shift Point Road Test
• Diagnostic Parameters Identification (PID) Chart
• Mechatronic Assembly
• Forward Clutch Assembly
• Direct Clutch Assembly
• Low/Reverse Clutch Assembly
• Pump Assembly
• Intermediate Clutch Assembly
• Overdrive Clutch Assembly
• Transmission - Four Wheel Drive (4WD)
• Transmission - Rear Wheel Drive (RWD)
• Output Shaft Seal
• Manual Control Lever Shaft and Seal
• Fluid Pan, Gasket and Filter
• Torque Converter Contamination Inspection
• Transmission Fluid Cooler Backflushing and Cleaning