Automatic Transmission - 6R60: Maintenance Ford Explorer IV

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 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 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 .

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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.

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.

Transmission Fluid Cooler Backflushing and Cleaning

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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)

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Drain

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the 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 fluid leaking, the 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 automatic transmission fluid to the transmission is an initial fill enabling you to start the engine. The cold 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 cooling system. Fill the transmission fluid to the fill range on the 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 automatic transmission fluid to the transmission through the 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). Using the scan tool and the engine running, 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 fluid level indicator from the fill plug.
4. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the 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.
6. Install the 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 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 fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case.
9. Separate the fluid level indicator from the fill plug.
10. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug hole to check the 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 fluid level must be at the upper level of the crosshatch mark.
12. Install the fluid fill plug. Tighten to 35 Nm (26 lb-ft).

Adding Additional Transmission Fluid

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

1. Install the special tool into the fluid fill hole.
2. Fill the special tool with approximately 0.47L (1 pt) of clean automatic 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 fluid 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. Fluid will immediately start flowing out of the special tool into the transmission.
6. Reinstall the fluid level indicator only back into the fill plug hole to check the 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 fluid level must be at the upper level of the crosshatch mark.
8. Install the fluid fill plug. Tighten to 35 Nm (26 lb-ft).

Removing Transmission Fluid

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

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

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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»(ref-270881) .
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).

Fluid Pan, Gasket and Filter

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