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Automatic Transmission Cooling System: Other Ford Explorer V

Automatic Trans 27 illustrations ~1584 words

Material(s)

Note. The use of any transmission fluid other than what is recommended for this transaxle will cause transaxle damage. The transmission fluid should be changed every 241, 350 km (150, 000 mi).

NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV10.32 L (10.9 qt) 6F50 and 6F55
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV8.5 L (9 qt) 6F35

MATERIAL(S)

NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV10.32 L (10.9 qt)
NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV8.5 L (9 qt) 6F35

General Procedure

  1. NOTE: Use Motorcraft® MERCON® LV Automatic Transmission Fluid for this transmission. Do not use any supplemental automatic transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail, which will affect the operation of the transmission. NOTE: Transmission fluid cooler backflushing will be carried out using the 222-00007 . Follow the manufacturer's instructions included with the machine. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. NOTE: If the 222-00007 or equivalent is not available, install a new transmission fluid cooler. Check and top off fluid level of the cooler line flusher with Motorcraft® MERCON® LV Automatic Transmission Fluid.
  2. Allow the fluid in the 222-00007 15-30 minutes to heat up to 60°C (140°F) before using.
  3. Disconnect the transmission fluid cooler tubes from the transmission fluid cooler.
  4. Install the line adapters on the transmission fluid cooler tubes.
  5. NOTE: The FRONT transmission fluid cooler tube on the thermal bypass valve is the transmission fluid cooler pressure tube. Attach the 222-00007 red line to the transmission fluid cooler pressure tube quick disconnect fitting.
  6. Attach the 222-00007 blue line to the transmission fluid cooler return tube quick disconnect fitting.
  7. Follow the equipment instructions to purge the transmission fluid cooler tubes and transmission fluid cooler prior to starting the flushing procedure.
  8. Allow the transmission fluid cooling system to backflush for 10-15 minutes, then flush the transmission fluid cooler in a normal flow direction for an additional 10-15 minutes.
  9. NOTE: Do not use water-based cleaners to clean or flush the transmission fluid cooler tubes or transaxle damage will occur. Mineral spirits can be used to clean the transmission fluid cooler tubes, providing the transmission fluid cooler tubes are flushed afterwards with clean Motorcraft® MERCON® LV Automatic Transmission Fluid and blown dry with shop air. Use only clean Motorcraft® MERCON® LV Automatic Transmission Fluid designated for this transaxle and torque converter being serviced. Clean the transaxle mounted fluid cooler tubes and replace the thermal bypass valve. REFER to «Thermal Bypass Valve - 2.0L GTDI»(ref-517575-S35062014072012121200000) , or REFER to «Thermal Bypass Valve - 3.5L Ti-VCT»(ref-517575-S00968217212012121200000) .

Selector Lever

WARNINGBefore beginning any service procedure in this service information, REFER to SAFETY WARNINGS . Failure to follow this instruction may result in serious personal injury.
NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV10.32 L (10.9 qt)

Scheme 7

Scheme 7: Transmission Fluid Cooler Tubes - 2.0L GTDI
Scheme 7: Transmission Fluid Cooler Tubes - 2.0L GTDI
ItemService Part NumberDescriptionTorqueMaterial NameNotes
17W063Transmission fluid cooler inlet hose
27W064Transmission fluid cooler outlet hose
37J081Transmission fluid cooler hose secondary latch (2 required)
4W712146Transmission mounted transmission fluid cooler tube bolt (2 required)10 Nm (89 lb-in)Install new bolts
57H420Transmission mounted transmission fluid cooler tube assembly nuts30 Nm (22 lb-ft)
67J324Backing ring
77D285Seal
8W520101Transmission fluid thermal bypass valve nuts9 Nm (80 lb-in)
97H322Transmission fluid thermal bypass valve

Scheme 8

Scheme 8: Removal
Scheme 8: Removal

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Scheme 18
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  3. Remove and discard the transmission mounted transmission fluid cooler inlet tube bolt.
  4. Loosen the transmission mounted transmission fluid cooler inlet tube nut and remove the transmission mounted transmission fluid cooler inlet tube.
  5. Inspect the transmission case to be sure that the transmission mounted transmission fluid cooler inlet tube seal and backing ring were removed with the transmission mounted transmission fluid cooler inlet tube and is not stuck in the transmission case. If the transmission mounted transmission fluid cooler inlet tube seal or backing ring is stuck in the transmission case, remove the seal and backing ring.
  6. Loosen the transmission mounted transmission fluid cooler outlet tube nut.
  7. Remove and discard the transmission mounted transmission fluid cooler outlet tube bolt and the transmission mounted transmission fluid cooler outlet tube.
  8. Inspect the transmission case to be sure that the transmission mounted transmission fluid cooler outlet tube seal and backing ring were removed with the transmission mounted transmission fluid cooler outlet tube and is not stuck in the transmission case. If the transmission mounted transmission fluid cooler outlet tube seal or backing ring is stuck in the transmission case, remove the seal and backing ring.
  9. Detach the 2 pin-type retainers and position wiring harness aside.
  10. Remove the transmission fluid cooler hose secondary latches.
  11. Remove the 2 transmission fluid thermal bypass nuts and lower the transmission fluid thermal bypass valve and transmission fluid cooler inlet and outlet hoses.
  12. Using 307-569 , disconnect the transmission fluid cooler inlet and outlet hoses from the transmission fluid thermal bypass valve.
  13. Remove the transmission fluid cooler inlet and outlet hoses from the transmission fluid cooler.

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Install the transmission fluid cooler inlet and outlet hoses to the transmission fluid cooler.
  2. Connect the transmission fluid thermal bypass valve to the transmission fluid cooler inlet and outlet hoses.
  3. Position the transmission fluid thermal bypass valve and install the 2 transmission fluid thermal bypass valve nuts. Torque: 9 Nm (80 lb-in).
  4. Install the transmission fluid cooler hose secondary latches.
  5. Position back the wiring harness and attach the 2 pin-type retainers.
  6. Inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean Motorcraft® MERCON® LV Automatic Transmission Fluid and install the backing rings and seals on the transmission mounted transmission fluid cooler tubes. Item Description 1 Backing ring 2 Seal
  7. Install the transmission mounted transmission fluid cooler outlet tube and a new transmission mounted transmission fluid cooler outlet tube bolt. Torque: 10 Nm (89 lb-in).
  8. Tighten the transmission mounted transmission fluid cooler outlet tube nut. Torque: 30 Nm (22 lb-ft).
  9. Install the transmission mounted transmission fluid cooler inlet tube and tighten the transmission mounted transmission fluid cooler inlet tube nut. Torque: 30 Nm (22 lb-ft).
  10. Install a new transmission mounted transmission fluid cooler inlet tube bolt. Torque: 10 Nm (89 lb-in)
  11. Install the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  12. Fill the transmission with Motorcraft® MERCON® LV Automatic Transmission Fluid and verify correct operation. REFER to «TRANSMISSION FLUID LEVEL CHECK»(ref-538870-S42044487752013033000000) .
NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV10.32 L (10.9 qt)

Scheme 21

Scheme 21: Transmission Fluid Cooler Tubes - 3.5L Ti-VCT
Scheme 21: Transmission Fluid Cooler Tubes - 3.5L Ti-VCT
ItemService Part NumberDescriptionTorqueMaterial NameNotes
1W712146Transmission fluid cooler tube bolt (2 required)10 Nm (89 lb-in)Install new bolts
27R081Transmission mounted transmission fluid cooler tube assembly30 Nm (22 lb-ft)
3W520101Transmission fluid thermal bypass valve nut (2 required)9 Nm (80 lb-in)
4Part of 7R081Clamps
57H322Transmission fluid thermal bypass valve
67J081Transmission fluid cooler hose secondary latch (2 required)
77R081Transmission fluid cooler hose assembly

Scheme 22

Scheme 22: Removal
Scheme 22: Removal

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Scheme 29
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  3. Remove and discard the transmission mounted transmission fluid cooler inlet tube bolt.
  4. Remove and discard the transmission mounted transmission fluid cooler outlet tube bolt.
  5. Loosen the 2 transmission mounted transmission fluid cooler tube nuts and remove the 2 transmission mounted transmission fluid cooler tubes from the transmission fluid thermal bypass valve and the transmission.
  6. Inspect the transmission case to be sure that the transmission mounted transmission fluid cooler tube seals and backing rings were removed with the transmission mounted transmission fluid cooler tubes and are not stuck in the transmission case. If the transmission mounted transmission fluid cooler tube seals or backing rings are stuck in the transmission case, remove the seals and backing rings.
  7. Disconnect the transmission fluid cooler hoses at the OTA transmission fluid multi cooler.
  8. Remove the 2 nuts, the transmission fluid thermal bypass valve and the transmission fluid cooler tubes from the vehicle.
  9. Remove the transmission fluid cooler hose secondary latches.
  10. Using 307-569 , disconnect the transmission return and inlet cooler hoses from the transmission fluid thermal bypass valve.

Scheme 30

Scheme 30: Installation
Scheme 30: Installation
  1. Install the transmission return and inlet cooler tubes into the transmission fluid thermal bypass valve.
  2. Install the transmission fluid cooler hose secondary latches.
  3. Install the transmission fluid thermal bypass valve, the transmission fluid cooler tubes and the 2 nuts. Torque: 9 Nm (80 lb-in).
  4. Connect the transmission fluid cooler hoses to the OTA transmission fluid multi cooler.
  5. Inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean Motorcraft® MERCON® LV Automatic Transmission Fluid and install the backing rings and seals on the transmission mounted transmission fluid cooler tubes. Seal 7D258 Backing ring 7J324
  6. Position the 2 transmission mounted transmission fluid cooler tubes on the transmission and tighten the 2 transmission fluid cooler tube nuts. Torque: 30 Nm (22 lb-ft).
  7. Install a new transmission mounted transmission fluid cooler outlet tube bolt. Torque: 10 Nm (89 lb-in).
  8. Install a new transmission mounted transmission fluid cooler inlet tube bolt. Torque: 10 Nm (89 lb-in).
  9. Install the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  10. Check the Motorcraft® MERCON® LV Automatic Transmission Fluid level and add Motorcraft® MERCON® LV Automatic Transmission Fluid as necessary.

Thermal Bypass Valve - 2.0L GTDI

WARNINGBefore beginning any service procedure in this service information, REFER to SAFETY WARNINGS . Failure to follow this instruction may result in serious personal injury.

Scheme 31

Scheme 31: Removal
Scheme 31: Removal
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000).
  3. For component location and reference see scheme 4
  4. Special Tool(s): Disconnect Tool TOC Line (1/2") 307-569

Thermal Bypass Valve - 3.5L Ti-VCT

WARNINGBefore beginning any service procedure in this service information, REFER to SAFETY WARNINGS . Failure to follow this instruction may result in serious personal injury.
NamePart NumberFord SpecificationFill Capacity/Quantity
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVCMERCON® LV10.32 L (10.9 qt)

Scheme 32

Scheme 32: Thermal Bypass Valve
Scheme 32: Thermal Bypass Valve
ItemService Part NumberDescriptionTorqueMaterial NameNotes
1Part of 7H420Transmission mounted transmission fluid cooler tube assembly nuts30 Nm (22 lb-ft)
2W520101Thermal bypass valve nuts (2 required)9 Nm (80 lb-in)
37J081Transmission fluid cooler hose secondary latches (2 required)
47R081Transmission fluid cooler hose assembly
57H322Thermal bypass valve

Scheme 33

Scheme 33: Removal
Scheme 33: Removal
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the ACL assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  3. Loosen the 2 transmission mounted transmission fluid cooler tube nuts from the transmission fluid thermal bypass valve. Torque: 30 Nm (22 lb-ft).
  4. Disconnect the transmission fluid cooler hoses at the OTA transmission fluid multi cooler.
  5. Remove the 2 nuts, the transmission fluid thermal bypass valve and the transmission fluid cooler tubes from the vehicle. Torque: 9 Nm (80 lb-in).
  6. Remove the transmission fluid cooler hose secondary latches.
  7. Using 307-569 , disconnect the transmission return and inlet cooler hoses from the transmission fluid thermal bypass valve.

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