Automatic Transaxle - 6 Speed Ford Five Hundred I

GENERAL SPECIFICATIONS CHART

GENERAL SPECIFICATIONS CHART

GEAR AND SOLENOID OPERATION CHART

GEAR AND SOLENOID OPERATION CHART

GEAR RATIO REFERENCE CHART

GEAR RATIO REFERENCE CHART

SHIFT SPEED MANUAL D POSITION (MINIMUM THROTTLE)

SHIFT SPEED MANUAL D POSITION (MINIMUM THROTTLE)

SHIFT SPEED MANUAL L POSITION

SHIFT SPEED MANUAL L POSITION

ENGINE RPM SPECIFICATION

ENGINE RPM SPECIFICATION

SOLENOID RESISTANCE READING

SOLENOID RESISTANCE READING

CLUTCH AND BRAKE PRESSURE CHART

CLUTCH AND BRAKE PRESSURE CHART

TORQUE SPECIFICATIONS CHART

TORQUE SPECIFICATIONS CHART

Transaxle Description

This transaxle is a compact, lightweight, next generation electronically controlled, 6-speed automatic transaxle that employs a Ravigeneaux-type planetary gear.

This transaxle contains a high precision clutch hydraulic control system for a smooth, highly responsive gear shift feel.

All hydraulic functions are directed by electronic solenoids to control

Scheme 1

1. engagement feel.
2. shift feel.
3. shift scheduling.
4. modulated torque converter clutch (TCC) applications.
5. engine braking utilizing the coast clutch.

Identification Tags

When servicing the automatic transaxle, use the bar code identification label located on side of the transaxle case.

Scheme 2

Range Selection

The transmission has 5 range positions: P, R, N, D and L.

Scheme 3

Park

In the PARK position

1. there is no powerflow through the transaxle.
2. the parking pawl locks the final drive.
3. the engine may be started.
4. the ignition key may be removed.

Reverse

In the REVERSE position

1. the vehicle may be operated in a rearward direction, at a reduced gear ratio.
2. engine braking will occur.
3. the reverse lamps will be activated.

Neutral

In the NEUTRAL position

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

Drive

DRIVE is the normal position for the best fuel economy.

DRIVE provides

1. automatic shifts gears 1st through 6th.
2. apply and release of the torque converter clutch.
3. maximum fuel economy during normal operation.

Manual L Position

In this position the transaxle will upshift and downshift 1st through 4th gear with extended shift scheduling. Engine braking will occur in 1st through 4th gears.

This position provides

1. 1st through 4th gear operation only.
2. extended shift scheduling.
3. increased engine braking.

Shift Patterns

Based on signals from the sensors, the system controls gear shift lockup.

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. If applied, the transmission will disengage the torque converter clutch (TCC) to provide added acceleration.

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.

Automatic Gearshift Control

In automatic gearshift control, based on each gearshift pattern, SSA and SSB turn ON or OFF and SSC, SSD, SSE and SSF are operated linearly according to information that includes vehicle speed, the degree to which the accelerator is open and brake signal.

Driver Adaptive Shift Control

This automatic transaxle does not have a driving mode selection switch that allows drivers to select a mode themselves. The vehicle is ordinarily in adaptive mode. However, when specific conditions are met, the transmission control unit (TCU) selects a shifting pattern appropriate to driving conditions from all of the shifting patterns and switches automatically.

1. GREEN - Mode 1 - Switched from mode 2 to warm up the transmission fluid. This mode acts to protect the transaxle before the adaptive mode.
2. GREEN - Mode 2 - After engine start-up, warm-up speed is increased for a certain period when transmission fluid temperature is low and the vehicle speed is 0.
3. HIGH TEMP - When fluid temperature becomes too high, this mode activates lock-up at an earlier timing to stop the temperature rise and lower the temperature.
4. DOWN SLOPE - When driving down a slope, the transmission control module (TCM) detects a down slope based on the engine control unit signal and output rpm. TCM switches to down slope mode to alleviate the load to the brake by down shifting.

Gear Shift Control

When the shift lever is moved from N to D or from N to R, after the engine is started, a shift control solenoid assembly (SSC, SSD, SSE) is used for the fluid pressure required by C1 clutch or C3 clutch and appropriately regulated fluid pressure is supplied to the clutch, engaging smoothly without shock.

Reverse Converter Control

If the shift lever is moved from N to R while the vehicle is moving forward and the transaxle shifts into REVERSE, the wheels will be locked, which is extremely dangerous. In order to avoid this, the TCM inhibits the transaxle from shifting into REVERSE while moving forward.

Torque Converter Control

Based on output rpm signals, signals from the engine control unit (engine rpm and throttle opening) and vehicle speed, a smooth engagement is carried out through linear control of the torque converter clutch (TCC) solenoid. Also, the slip rate is detected by adding input rpm signals and slip control is carried out.

1. Engagement Control - control is carried out using a TCC solenoid. The TCC solenoid is linearly turned ON and OFF. The clutch inside the torque converter is operated and the pump impeller and turbine runner are connected. Through this the engine and the transaxle are coupled and engine output is connected directly to the transaxle, eliminating transaxle loss and enhancing fuel economy
2. Slip Control - control is carried out using a TCC solenoid. The TCC solenoid is linearly turned ON and OFF and the clutch within the torque converter is operated outside of the engagement range. The clutch slides without being in a completely coupled condition, increasing transaxle efficiency and enhancing fuel economy.

Torque Converter

The torque converter transmits and multiplies torque by means of automatic transmission fluid inside the torque converter. The torque converter is composed of the following

1. Converter case
2. Pump impeller assembly
3. Turbine assembly
4. Stator assembly/one-way clutch
5. Lock-up clutch

In addition, the use of the lock-up clutch is intended to improve fuel economy as a direct coupling between the engine and the transmission.

The standard torque converter components operate as follows

Scheme 4

1. Rotation of the converter housing and impeller sets 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, providing for torque multiplication.
4. The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency.
5. Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft.

Geartrain

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

Gear Ratio

GEAR RATIO CHART

Differential

The differential allows the halfshafts and wheels to rotate at different speeds during cornering.

The differential assembly consists of the following components

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

When driving in a straight line, both front wheels rotate at relatively the same speed. This means both side gears are rotating at the same speed, as well, while both pinion gears revolve (but do not rotate) with the side gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque.

C-1 Clutch

The C1 clutch connects the front planetary carrier to the rear sun gear of the rear planetary set. The C1 clutch is applied in 1st (typical operation during engine braking), 2nd, 3rd and 4th gears.

C-2 Clutch

The C2 clutch connects the intermediate shaft to the rear planetary carrier. The C2 clutch is applied in 4th, 5th and 6th gears.

C-3 Clutch

The C3 clutch connects the front planetary carrier to the middle sun gear of the rear planetary set. The C3 clutch is applied in 3rd and 5th gears, and also in reverse when the vehicle speed is 7 km/h (4 mph) or less.

B-1 Brake

The B1 brake locks the middle sun gear of the rear planetary gear set. The B1 brake is applied in 2nd and 6th gears.

B-2 Brake

The B2 brake locks the rear planetary carrier in reverse gear when the vehicle speed is 7 km/h (4 mph) or less.

F-1 One-Way Clutch

The Fl one way clutch locks the counterclockwise rotation of the rear planetary carrier during 1st gear operation (during both normal operation and engine braking).

Valve Body

The valve body supplies fluid by switching the fluid circuit for the hydraulic pressure that is generated by the fluid pump. Based on the hydraulic pressure generated by the fluid pump the TCM sends control signals to the solenoid valves in accordance with vehicle conditions. Upon activation of the solenoid valve, the control hydraulic pressure to the clutch and brakes is determined (according to the equilibrium with the obtained hydraulic pressure) and gear shift and lockup are accomplished. In addition, an appropriate amount of fluid is supplied to the torque converter, planetary gears and lubricating parts.

Electronic System Description

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

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

The transaxle control is separate from the engine control strategy in the powertrain control module (PCM), although some of the input signals are shared between the TCM and PCM. When determining the best operating strategy for transaxle operation, the TCM uses input information from certain engine-related and driver-demand related sensors and switches supplied by the PCM.

In addition, the TCM receives input signals from certain transaxle-related sensors and switches. The TCM also uses these signals when determining transaxle 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 best line pressure needed to optimize shift feel. To accomplish this the TCM uses output solenoids to control transaxle operation.

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

Transmission Control Module (TCM) Control Function

In automatic gear shift control, based on each gear shift pattern, SAA and SBB turn ON or OFF and SSC, SSD, SSE and SSF are operated linearly according to information that includes vehicle speed, the degree to which the accelerator is open and brake signals. For the gear and solenoid operation chart, refer to the GENERAL SPECIFICATION tables.

The transmission range (TR) sensor is built in the transmission control module (TCM), it detects the automatic transmission range information via the Hall-effect sensor and outputs the information to the TCM. The TCM reads the voltage and adjusts the automatic transmission range.

Brake Pedal Position (BPP) Switch

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

Scheme 5

The transmission fluid temperature sensor, which is integrated within the transmission wiring, is installed on the front of the valve body. It directs the fluid temperature within the hydraulic pressure control circuit and transmits a signal based on that temperature to the TCM. Through this it controls gear shift, lockup and slip in response to changes in fluid temperature for smooth shifting across wide fluid temperature zones.

Scheme 6

The transaxle 3-way solenoid assembly (SSA) is installed on the middle valve body. The transmission 3-way solenoid assembly (SSB) is installed on the front valve body. The solenoids turn ON and OFF in response to signals output from the TCM. According to the ON or OFF status of SSA or SSB, the 1st gear engine brake operates or the gear shifts into REVERSE. As a fail-safe function, if any transmission 3-way solenoid assembly abnormality occurs, the TCM will disable the current to the solenoids.

Scheme 7

The shift control solenoid assembly (SSC, SSD, SSE, SSF) is installed on the front valve body. The solenoids linearly control hydraulic pressure in response to signals, output from the TCM. Through this, it controls hydraulic pressure to the clutch (C1, C2, C3) and brakes (B1) for smooth shifting. According to the combination of ON or OFF status of the shift control solenoid assembly, the transmission shifts from 1st gear into 6th gear and vice versa. As a fail-safe function, if any shift control solenoid assembly abnormality occurs, the TCM will disable the current to the shift control solenoids.

Scheme 8

The pressure control solenoid (PCA) is installed on the front valve body. Based on a signal indicating the degree to which the throttle is opened, engine torque, and according to a duty ratio predetermined in the TCM, the solenoids control line hydraulic pressure by linearly changing the comparable throttle hydraulic pressure. Through this, it controls operating hydraulic pressure to the clutch and brakes for smooth shifting. As a fail-safe function, if any shift control solenoid assembly abnormality occurs, the TCM will disable the current to the shift control solenoids. The line pressure is maximized, if the shift control solenoid assembly current is disabled when any abnormality other than locking occurs.

Speed Sensor

The 2 speed sensors are installed in the transaxle case. One speed sensor detects revolutions of the intermediate shaft's C2 drum as input shaft revolutions. The other speed sensor detects the counterdrive gear as output shaft revolutions. These signals are transmitted to the TCM. Based on these signals, the TCM controls engine torque, shift timing and lockup.

Adaptive Shift Control

The TCM has an adaptive learning strategy to electronically control the transaxle which will automatically adjust the shift feel. The first few hundred miles of operation of the transaxle may have abrupt shifting. This is a normal operation. If the battery has been disconnected for any reason it will need to be kept disconnected for approximately 20 minutes to reset the adaptive shift pressure strategy or use the diagnostic tool to carry out the keep alive memory (KAM) reset.

Scheme 9

The torque converter clutch (TCC) solenoid is used in the transaxle control system to control the application, modulation and release of the torque converter clutch.

The TCC control solenoid is installed on the front valve body. Based on engine rpm, throttle opening degree signals and speed sensor signals, it linearly controls clutch hydraulic pressure. Through this, engagement and slip are controlled. As a fail-safe function, if any control solenoid assembly abnormality occurs, the TCM will disable the current to the TCC solenoid.

Diagnostic Strategy

Troubleshooting an electronically-controlled automatic transaxle 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. Powertrain Control/Emissions Diagnosis (PC/ED) manual
2. Technical Service Bulletins (TSBs)
3. Wiring Diagrams

These publications provide the information required when diagnosing transaxle 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 fluid levels and condition.
4. Check for non-factory-installed items and verify correct installation.
5. Check shift linkages for correct adjustment.
6. Check TSB messages regarding the concern.
7. Carry out quick tests, both KOER and KOEO.
8. Record all codes.

Diagnostics

1. Carry out on-board diagnostic procedures key on/engine off (KOEO) and key on/engine running (KOER).
2. Record all diagnostic trouble codes (DTCs).
3. Repair all non-transaxle codes first.
4. Repair all transaxle codes second.
5. Erase all continuous codes and attempt to repeat them.
6. Repair all continuous codes.
7. If only pass codes are obtained, proceed to the «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) for further information and diagnosis.

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

Diagnostic Flow Chart

DIAGNOSTIC FLOW CHART

Special Tool(s)

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 10

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 complaint or condition. Customer contact may be required in order to begin to verify the concern. Understand the conditions as to when the concern occurs. For example

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

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

Verification of Condition

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

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

Determine Customer Concern

Note. Some transaxle conditions may 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 temperatures
3. Type of terrain
4. Vehicle loaded/unloaded
5. City/highway driving
6. Upshift
7. Downshift
8. Coasting
9. Engagement (harsh or soft)
10. Noise/vibration - check for dependencies, either RPM dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent

Check Fluid Level and Condition

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

The fluid level reading on the fluid level indicator will differ depending on operating and ambient temperatures. The correct reading should be within the normal operating temperature range.

Fluid Level Check

Note. The transaxle fluid should be checked at normal operating temperature 70°C-80°C (158°F-176°F) on a level surface. Normal operating temperature can be reached after approximately 32 km (20 miles) of driving.

Under normal circumstances the fluid level should be checked during normal maintenance. If the transaxle starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked.

Scheme 11

1. With the transaxle in (P) PARK, the engine at idle, foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever in the PARK position.
2. Wipe the fluid level indicator cap and remove the fluid level indicator.
3. Wipe the fluid level indicator with a clean cloth.
4. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating range.

High Fluid Level

A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transaxle malfunction and/or damage. If an overfill reading is indicated, refer to TRANSMISSION FLUID DRAIN AND REFILL .

Low Fluid Level

A low fluid level could result in poor transaxle engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transaxle seals or gaskets.

Adding Fluid

If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill the fluid. For fluid type, refer to the SPECIFICATION CHART .

Fluid Condition Check

1. Check the fluid level.
2. Observe the color and the odor. The color under normal circumstances should be a dark red color, not brown or black or have a burnt odor.
3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain.
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 transaxle. The engine cooling system should also be inspected at this time.
6. If fluid contamination or transaxle failure is confirmed by the sediment in the bottom of the fluid pan, install a new transaxle. If installing a new transaxle, the cooler bypass valve, if equipped, coolers and cooler lines should be cleaned.
7. Carry out diagnostic checks and adjustments. Refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .

Road Testing Vehicle

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

The Shift Point Road Test and Torque Converter Operation Tests provide diagnostic information on shift controls and torque converter operation.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. Shift speed ranges are approximate for all applications.

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

1. Bring engine and transaxle up to normal operating temperature.
2. Operate vehicle with selector lever in D range.
3. Using the shift speeds chart, apply minimum throttle and observe the speeds at which the transaxle upshifts. The transaxle will upshift 1st through 6th gears.
4. Press accelerator pedal to the floor, wide-open throttle (WOT). The transaxle should downshift to the next lower gear depending on the vehicle speed. The torque converter clutch should release. SHIFT SPEED MANUAL D POSITION (MINIMUM THROTTLE) Manual D km/h mph 1-2 upshift 8-13 5-8 2-3 upshift 16-23 10-14 3-4 upshift 29-37 18-23 4-5 upshift 42-48 26-30 5-6 upshift 48-61 30-38 3-1 downshift 6-13 4-8 4-3 downshift 29-35 18-22 5-4 downshift 39-45 24-28 6-5 downshift 51-60 32-37 SHIFT SPEED MANUAL L POSITION Manual L km/h mph 1-2 upshift 29-39 18-24 2-3 upshift 74-89 46-55 3-4 upshift 113-130 70-81 4-5 upshift N/A N/A 5-6 upshift N/A N/A 2-1 downshift 21-27 13-17 3-2 downshift 61-69 38-43 4-3 downshift 100-114 62-71 5-4 downshift N/A N/A 6-5 downshift N/A N/A
5. If transaxle fails to upshift/downshift or TCC does not apply and release, refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) for possible causes.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

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

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection
2. Know and Understand the Customer's Concern
3. Verify the Concern - carry out the torque converter operation test
4. Carry out Diagnostic Procedures: Run On-Board Diagnostics. Refer to «DIAGNOSTICS»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed__diagnostics) . Repair all non-transmission related DTCs first. Repair all transmission DTCs. Rerun On-Board Diagnostic to verify repair. Carry out Line Pressure Test. Refer to «SPECIAL TESTING PROCEDURES»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . Carry out Stall Speed Test. Refer to «SPECIAL TESTING PROCEDURES»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . Carry out diagnostic routines. Refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . Use the index 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 repairing the torque converter.

Visual Inspection

This 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: Air conditioning Generator (alternator) Engine turbo Cellular telephone Cruise control CB radio Linear amplifiers Backup alarm signal Computer
2. Vehicle modification: These items, if not installed correctly, will affect the powertrain control module (PCM) 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. Leaks. Refer to «LEAKAGE INSPECTION»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed__leakage-inspection) . Correct linkage adjustments. Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-external-controls) .

Shift Linkage Check

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 for shift linkage adjustment.

Check TSBs

Refer to all technical service bulletins which pertain to the concern and follow the procedure.

Carry Out On-Board Diagnostics (KOEO, KOER)

After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using the diagnostic tool. Refer to the INTRODUCTION - GASOLINE article for diagnosis and testing of the powertrain control system.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

Scheme 12

Self Diagnosis Function

The transmission control module (TCM) monitors the communication status of each sensor, electronic component and the powertrain control module (PCM). If any malfunction should occur, the TCM function warns the driver and stores the malfunction as a diagnosis code.

Fail-Safe

With the fail-safe function, if any malfunction should occur in the automatic transmission system, the TCM will output a control signal, and control will be carried out to make traveling a minimum distance possible. If all shift solenoids malfunction, the TCM will cancel the output of control signals to the solenoids. If this happens, the automatic transmission gear shifting will be controlled by fluid pressure circuits only and the gears will shift as shown in the following table.

RANGE SELECTOR LEVER POSITION AND GEAR POSITION

On-Board Diagnostic With Diagnostic Tool

Note. For detailed instruction and other diagnostic methods using the diagnostic tool or equivalent, refer to the diagnostic tool tester manual and the INTRODUCTION - GASOLINE article .

These Quick Tests should be used to diagnose the powertrain control module (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 Codes
5. Quick Test 5.0 - Key On, Engine Running (KOER)
6. Special Test Modes Wiggle Test Mode Output Test Mode
7. PCM Reset Mode
8. Clearing DTCs P1000
9. OBD II Drive Cycle
10. Other diagnostic tool features

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

PID NAME, DESCRIPTION AND UNITS CHART

Transaxle Drive Cycle Test

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

After carrying out the Quick Test, use the following Transaxle Drive Cycle Test for checking continuous codes

Note. The Transaxle Drive Cycle Test must be followed exactly. Malfunctions must occur multiple times consecutively for shift error or torque converter clutch (TCC) code to set.

Note. When carrying out the Transaxle Drive Cycle Test, see the SOLENOID OPERATION CHART for correct solenoid operation. Refer to PINPOINT TESTS - NON OSC EQUIPPED VEHICLE .

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 transaxle in DRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the transaxle to shift into 6th gear. Hold speed and throttle steady for minimum of 15 seconds. Brake to a stop and remain stopped for minimum of 20 seconds.
5. Repeat Step 4 at least 5 times.
6. Carry out Quick Test and record continuous codes. If DTCs are present, refer to «DIAGNOSTIC TROUBLE CODE (DTC) CHARTS»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . Service all non-transaxle DTCs first as they can directly affect the operation of the transaxle. Repeat the Quick Test and Road Test to verify the correction. Erase DTCs, carry out the drive cycle test, and repeat the Quick Test after completing service on the DTCs. If the continuous test passes (system pass) and a concern is still present, refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) and check TSBs for diagnostic concern.

After On-Board Diagnostics

Note. The vehicle wiring harness, powertrain control module and non-transaxle sensors may affect transaxle operations. Service these concerns first.

After the On-Board Diagnostic procedures are completed, service all DTCs.

Begin with non-transaxle related DTCs, then service any transaxle related DTCs. Refer to the DIAGNOSTIC TROUBLE CODE (DTC) CHARTS for information on Condition and Symptoms. This chart will be helpful in referring to the correct manual(s) and to aid in diagnosing internal transaxle concerns and external non-transaxle inputs. The pinpoint tests are used in diagnosing electrical concerns of the transaxle. Make sure that the vehicle wiring harness and the powertrain control module (PCM) are diagnosed as well. Refer to the INTRODUCTION - GASOLINE article for diagnosing non-transaxle electronic components. The diagnostic routine hydraulic/mechanical charts will help in diagnosing internal transaxle concerns and external non-transaxle inputs.

Before Pinpoint Tests

Note. Prior to entering pinpoint tests, check the powertrain control module (PCM) wiring harness for correct connections, bent or broken pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and actuators for damage. Refer to the INTRODUCTION - GASOLINE article .

Note. If a concern still exists after electrical diagnosis has been carried out, refer to DIAGNOSIS BY SYMPTOM .

If DTCs appear while carrying out the on-board diagnostics, refer to the DIAGNOSTIC TROUBLE CODE (DTC) CHARTS for the appropriate repair procedure. Prior to entering pinpoint tests, refer to any TSBs for transaxle concerns.

Diagnostic Trouble Code Chart

DIAGNOSTIC TROUBLE CODE CHART

Scheme 13

Scheme 14

Scheme 15

Note. For testing, place the positive lead on the terminal with the + sign and place the negative lead on the terminal with the - sign.

PIN NUMBER DESCRIPTION CHART

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector as required.

Prior to carrying out the pinpoint tests, check the following

1. Transmission fluid level.
2. Transmission fluid condition (burned, metal particles or discolored).
3. Engine cooling system.
4. Other non-related transmission DTCs.

PINPOINT TEST A: SHIFT SOLENOIDS

Note. Refer to the Transaxle Vehicle Harness Connector illustration preceding these pinpoint tests.

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1. A1 ELECTRONIC DIAGNOSTICS Check to make sure the transmission harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Key in OFF position. Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: Retrieve DTC Codes. Are their any transmission DTCs fault present? Yes : For shift solenoids SSA and SSB, GO to A2. For shift solenoids PCA, SSC, SSD, SSE, SSF and TCC, GO to A4 . No : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. If concern is still present or reappears go to the appropriate pinpoint test steps: For shift solenoids SSA and SSB, GO to. For shift solenoids PCA, SSC, SSD, SSE, SSF and TCC, GO to A4.
2. A2 CHECK RESISTANCE OF THE ON/OFF SOLENOID CIRCUIT Key in OFF position. Remove the transmission control module (TCM). Measure the resistance at the transaxle bulkhead electrical connector between pin 2 and ground for SSB. Measure the resistance at the transaxle bulkhead electrical connector between pin 5 and ground for SSA. Is the resistance between 11-15 ohms? Yes : Install a new transmission control module (TCM) and re-flash to the latest level calibration. CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to A3. No : GO to A3.
3. A3 CHECK RESISTANCE OF THE ON/OFF SOLENOIDS Remove the transaxle side cover. Remove the wiring connector from the effected solenoid (SSA or SSB). Measure the resistance between solenoid pin 1 and ground of the affected solenoid. Is each solenoid resistance between 11-15 ohms? Yes : INSTALL a new internal wire harness or repair effected circuit. No : INSTALL a new main control.
4. A4 CHECK LINEAR SOLENOID SHORT TO GROUND Key in OFF position. Remove the transmission control module (TCM). Measure the resistance at transaxle bulkhead electrical connector between pins 1, 3, 4, 9, 10, 11, 14, 16, 17, 18, 21, 22 and ground. Is each resistance greater than 10,000 ohms? Yes : GO to A5. No : GO to A6 .
5. A5 CHECK RESISTANCE OF THE LINEAR SOLENOID(S) Inspect both sides of the transmission control module for damaged or pushed out pins, corrosion or damaged seals. For the TCC solenoid, measure the resistance between pin 4 and pin 9 at the transaxle. For the PCA solenoid, measure the resistance between pin 3 and pin 1 at the transaxle. For the SSF solenoid, measure the resistance between pin 21 and pin 16 at the transaxle. For the SSC solenoid, measure the resistance between pin 11 and pin 10 at the transaxle. For the SSD solenoid, measure the resistance between pin 17 and pin 18 at the transaxle. For the SSE solenoid, measure the resistance between pin 14 and pin 22 at the transaxle. Is the resistance between 5.0 - 5.6 ohms? Yes : Install a new transmission control module (TCM) and re-flash to the latest level calibration. CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to A6. No : GO to A6.
6. A6 CHECK CONTINUITY OF THE INTERNAL HARNESS Remove the transaxle side cover. Remove the wiring connector from the effected solenoid(s) (PCA, SSC, SSD, SSE, SSF and TCC). Measure the resistance between the bulkhead connector and the affected solenoid electrical connector. Is each solenoid resistance less than 5 ohms? Yes : INSTALL a new main control. No : INSTALL a new internal wire harness or repair effected circuit.

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1. B1 ELECTRONIC DIAGNOSTICS Connect the scan tool. Check to make sure the transmission harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Key in ON position. Select Diagnostic Data Link. Select TCM. Select PID/Transmission Fluid Temp (TFT). Enter the following diagnostic mode on the scan tool: PIDs; TFT. Does the vehicle enter PID/Transmission Fluid Temp (TFT)? Yes : GO to B2. No : REPEAT procedure to enter PID. If vehicle did not enter PID, REFER to the «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article .
2. B2 TEMPERATURE SIGNAL CHECK Key in ON position. Select Diagnostic Data Link. Select TCM. Select PID/Transmission Fluid Temp. Enter the following diagnostic mode on the scan tool: PIDs; TFT. Monitor the TFT PID. The temperature value should be within -55°C to 175°C (-65°F to 347°F). Is the TFT temperature within specified range? Yes : GO to B3. No : GO to B4
3. B3 WARM-UP/COOL-DOWN CYCLE While monitoring the TFT PIDs, carry out the following test: If transmission is cold, run transmission to warm it up. If transmission is warm, allow transmission to cool down. Do the TFT PIDs increase as the transmission is warmed up, decrease as the transmission is cooled and does the TFT stay within the specified range? Yes : Install a new transmission control module (TCM) and re-flash to the latest level calibration. CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to B4. No : GO to B4.
4. B4 SIGNAL RESISTANCE Remove the transmission control module (TCM). Inspect both sides of the transmission control module for damaged or pushed out pins, corrosion or damaged seals. Measure the resistance between pins 7 and 8 at the transmission bulkhead electrical connector. Refer to the following table «TRANSMISSION FLUID TEMPERATURE SENSOR RESISTANCE»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . TRANSMISSION FLUID TEMPERATURE SENSOR RESISTANCE °c °F Resistance (Ohms) 10 50 6.445 25 77 3.5 110 230 0.247 Record the resistance. Is the resistance within range? Yes : GO to B5. No : INSTALL a new internal harness and TFT assembly.
5. B5 SHORT TO GROUND Measure the resistance between pin 7 and ground at the transmission bulkhead electrical connector. Measure the resistance between pin 8 and ground at the transmission bulkhead electrical connector. Record the resistances. Are the resistances greater than 10,000 ohms? Yes : INSTALL a new transmission control module (TCM) and re-flash to the latest level calibration. No : INSTALL a new internal harness and TFT assembly.

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1. C1 ELECTRONIC DIAGNOSTICS Check to make sure the transmission control module connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Monitor the PID for the output shaft speed (OSS) sensor. Monitor and record speed. Does the OSS match the vehicle speed? Yes : CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to C2. No : GO to C2.
2. C2 CHECK OSS SENSOR RESISTANCE Remove the transmission control module (TCM). Measure the resistance at the transaxle bulkhead electrical connector between pin 19 and 20. Is the resistance less than 5 ohms? Yes : CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to C3. No : GO to C4 .
3. C3 CHECK OSS SENSOR FOR SHORT TO GROUND Remove the transmission control module (TCM). Measure the resistance at the transaxle bulkhead electrical connector between pin 19 and ground. Measure the resistance at the transaxle bulkhead electrical connector between pin 20 and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new transmission control module (TCM) and re-flash to the latest level calibration. CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to C4. No : GO to C4.
4. C4 CHECK OSS SENSOR RESISTANCE Remove the transmission side cover. Measure the resistance at the speed sensor electrical connector between pin 1 and 2. Is the resistance less than 5 ohms? Yes : INSTALL a new internal harness. No : INSTALL a new transaxle assembly.

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1. D1 ELECTRONIC DIAGNOSTICS Check to make sure the transmission control module connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Monitor the PID for the turbine shaft speed (TSS) sensor. Monitor and record speed. Does the TSS match the engine rpm? Yes : CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to D2. No : GO to D2.
2. D2 CHECK TSS SENSOR RESISTANCE Remove the transmission control module (TCM). Measure the resistance at the transaxle bulkhead electrical connector between pin 12 and 13. Is the resistance less than 5 ohms? Yes : CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to D3. No : GO to D4 .
3. D3 CHECK TSS SENSOR CIRCUIT FOR SHORT TO GROUND Remove the transmission control module. Measure the resistance at the transaxle bulkhead electrical connector between pin 12 and ground. Measure the resistance at the transaxle bulkhead electrical connector between pin 13 and ground. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new transmission control module (TCM) and re-flash to the latest level calibration. CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, GO to D4. No : GO to D4.
4. D4 ELECTRONIC DIAGNOSTICS Remove the transmission side cover. Measure the resistance at the TSS speed sensor electrical connector between pin 1 and 2. Is the resistance less than 5 ohms? Yes : CLEAR all DTCs. ROAD TEST to verify concern is not present. Concern could be intermittent. If concern is still present or reappears, INSTALL a new internal harness. No : The sensor is defective, INSTALL a new TSS sensor.

SPECIAL TOOL(S) CHART Transmission Fluid Pressure Gauge 307-004 (T57L-77820-A) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

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

Engine Idle Speed Check

Refer to the INTRODUCTION - GASOLINE article for diagnosis and testing of the engine idle speed.

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Note. In order to connect the pressure gauge to the transaxle, you will need to use an O-ring to pipe adapter (5/16-24 to 1/8 inch pipe thread adapter).

This test verifies that the pressure is within specification.

1. Connect a pressure gauge to the appropriate pressure tap.
2. Start the engine and check the pressures, see the Pressure Charts to determine if the pressures are within specification. CLUTCH AND BRAKE PRESSURE CHART Clutch Range Pressure C1 Drive (1st-4th) 196-1,372 kPa (28-199 psi) C2 Drive (4th-6th) 196-1,372 kPa (28-199 psi) C3 Drive (3rd, 5th) 196-1,372 kPa (28-199 psi) C3 Reverse 392-1,863 kPa (57-270 psi) B2 Low manual (1st) 588-1,372 kPa (85-199 psi) B2 Reverse 392-1863 kPa (57-270 psi) PRESSURE DIAGNOSTIC CHART Test Results Possible Source Values of both D and R ranges are lower than the standards Pressure control solenoid A (PCA) Primary regulator valve failure Oil pump failure Leak from hydraulic circuit of D or R range Only the value of D range is lower than the standards D range hydraulic circuit failure C1 clutch failure Only the value of R range is lower than the standards R range hydraulic circuit failure C3 clutch failure B2 brake failure
3. If the pressure is not within specification, install a new main control valve body.
4. If the pressures are OK, clear all DTC. Test drive vehicle, code could be intermittent. If DTC code returns, install a new valve body.

Stall Speed Test

The Stall Speed Test checks

1. torque converter clutch operation and installation.
2. holding ability of the forward clutch.
3. reverse clutch (the low-reverse bands).
4. planetary one-way clutch.
5. engine driveability concerns.

Conduct this test with the engine coolant and transmission fluid at correct levels and at normal operating temperature.

Apply the parking brake firmly for each Stall Speed Test.

1. Find the specified stall rpm for the vehicle, see the «STALL SPEED CHART»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . Use a grease pencil to mark the rpm on the dial of a tachometer. STALL SPEED CHART Engine Stall Speed 3.0L (4V) 2,390
2. Connect a tachometer to the engine.
3. In each of the following ranges R, D and L, press the accelerator pedal to the floor and hold it just long enough to let the engine get to wide open throttle. While making this test, do not hold the throttle open for more than 5 seconds at a time.
4. Note the results in each range.
5. After each range, move the selector lever to NEUTRAL and run the engine at 1,000 rpm for about 15 seconds to cool the torque converter before making the next test.
6. Use the stall speed diagnosis chart for corrective actions.
7. If stall speeds were too high, see the «STALL SPEED CHART»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . If stall speeds were too low, first check engine idle speed and tune up. If engine is OK, remove torque converter and check torque converter clutch for slippage.

Pressure Diagnostic Chart

PRESSURE DIAGNOSTIC CHART

Leakage Inspection

Use the following chart to inspect and correct any external transmission fluid leaks.

External Fluid Leaks

EXTERNAL FLUID LEAKS

External Sealing

The transaxle has the following parts to prevent external fluid leakage

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

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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 5 numbers in the illustration correspond with the 5 flow path steps.

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Leak Check Test

Fluid soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to 0.235L (1/2 pint) of transmission fluid have proven helpful in locating the source of fluid leakage. Such dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the fluid in the fluid cooler leaks into the engine cooling system. An ultraviolet light must be used to detect the fluorescent dye solution.

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Loosen the fluid drain plug and allow the fluid to drip. Note the color of the fluid.
3. Tighten the drain plug to 47 Nm (35 lb-ft).
4. Using a suitable nonflammable solvent, clean off any fluid from the top and bottom of the torque converter housing, flexplate, case and rear face of the engine and oil pan. Blow dry with compressed air.
5. Lower the vehicle.
6. Start and run the engine until the transaxle reaches its normal operating temperature.
7. Observe the back of the cylinder block and the top of the torque converter housing for evidence of fluid leakage. Run the engine at fast idle, then at engine idle, occasionally shifting to the DRIVE and REVERSE ranges.
8. Observe the front of the flexplate, back of the cylinder block, inside the torque converter housing and front of the case for evidence of fluid leakage.
9. Continue to run the engine until fluid leakage is evident and the probable source of leakage can be determined.
10. Lower the vehicle.
11. Turn the vehicle OFF.
12. If any leaks are evident, repair as necessary.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

The Diagnosis by Symptom charts give the technician diagnostic information, direction and suggest possible components, using a symptom as a starting point.

The Diagnosis by Symptom charts are divided into 2 categories: Electrical Routines, indicated by 200 series numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

Diagnosis by Symptom Chart Directions

1. Using the Symptom Index, select the concern/symptom that best describes the condition.
2. See the routine indicated in the diagnosis by Symptom Index.
3. Always begin diagnosis of a symptom with: Preliminary inspections. Verifications of condition. Checking the fluid levels. Carry out other test procedures as directed.
4. Begin with the routine indicated. Follow the reference or action required statements. Always carry out the on-board diagnostic tests as required. Never skip steps. Repair as required. These components are listed in the removal sequence and by the most probable cause. All components listed must be inspected to make sure of correct repair.

Diagnosis by Symptom Index

DIAGNOSIS BY SYMPTOM INDEX

Other Concerns: Transmission Fluid Level

POSSIBLE COMPONENT AND REFERENCE/ACTION

Other Concerns: Transmission Fluid Condition

POSSIBLE COMPONENT AND REFERENCE/ACTION

Other Concerns: Transmission Control Module Software

POSSIBLE COMPONENT AND REFERENCE/ACTION

Engagement Concerns: No Forward and/or No Reverse

POSSIBLE COMPONENT AND REFERENCE/ACTION

Engagement Concerns: Harsh

POSSIBLE COMPONENT AND REFERENCE/ACTION

Engagement Concerns: Soft

POSSIBLE COMPONENT AND REFERENCE/ACTION

Torque Converter Clutch Operations Concerns: Does Not Apply

POSSIBLE COMPONENT AND REFERENCE/ACTION

Torque Converter Clutch Operations Concerns: Cycling/Shutter/Chatters

POSSIBLE COMPONENT AND REFERENCE/ACTION

Material

MATERIAL SPECIFICATION CHART

1. Disconnect the transmission fluid cooler tubes from the transmission fluid cooler.
2. Disconnect the transmission fluid cooler tubes from the transaxle.
3. Carry out backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated.
4. To aid in attaching the cleaner to the transmission steel cooler tube, connect 3 additional rubber hoses to the transaxle ends of the steel transaxle cooler tube as follows: Connect the cleaner tank pressure tube to the steel transaxle cooler return tube. Connect a tank return hose to the steel transmission cooler pressure tube. Place the outlet end of this hose in the fluid tank reservoir. Connect a rubber hose to both ends of the transmission fluid cooler tubes (where the transmission fluid cooler tubes connect to the transmission fluid cooler).
5. Turn on the fluid pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system).
6. Switch off the fluid pump and disconnect the fluid pressure hose from the transaxle cooler return tube.
7. Use compressed air to blow out the cooler(s) and tubes (blow air into the transaxle cooler return tube) until all fluid is removed.
8. Remove the rubber return hose from the remaining steel cooler tube.
9. Once the cooler tubes have been flushed out, install a new transmission fluid cooler. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .

1. A new or remanufactured torque converter must be installed if one or more of the following statements are true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter stud(s), impeller hub or bushing are damaged. Discoloration of the torque converter (due to overheating). The torque converter is found to be out of specification when carrying out one of the following torque converter checks: One-Way Clutch Check End Play Check Stator to Turbine Interference Check Stator to Impeller Interference Check Torque Converter Leak Check 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

MATERIAL SPECIFICATION CHART

1. If a new or remanufactured torque converter is not being installed, the following procedures must be carried out: The torque converter must be thoroughly cleaned. Torque converters with drain plugs can be cleaned by using a suitable torque converter/fluid cooler cleaner. Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for transmission and reinstall.

MATERIAL SPECIFICATION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the transmission fluid drain plug and allow the fluid to drain.
3. Install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft).
4. Remove the transmission fluid fill plug.
5. Fill the transaxle with approximately 3.7L (4 quarts) of clean automatic transmission fluid.
6. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).
7. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
8. Wipe the fluid level indicator cap and remove the fluid level indicator.
9. Wipe the fluid level indicator with a clean cloth.
10. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. When installing a new transmission control module, the initialized learned values will need to be carried out.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Install the diagnostic tool.
3. Turn the ignition ON.
4. The diagnostic tool should indicate NEUTRAL. If the diagnostic tool does not indicate NEUTRAL, carry out transmission control module (TCM) adjustment. For additional information, refer to «TRANSMISSION CONTROL MODULE (TCM)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .
5. If NEUTRAL is indicated on the diagnostic tool, move the shift lever to PARK and turn the ignition OFF.
6. Turn the ignition ON and move the shift lever from PARK to DRIVE. The diagnostic tool should indicate each PRNDL position.
7. If the diagnostic display indicates each PRNDL position, check for any DTC codes.
8. If the diagnostic display does not indicate each PRNDL position, carry out «Transmission Control Module (TCM) Initial Learning»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. Clear all DTCs first.

Note. When installing a new transmission, transmission control module or reflashing the TCM, the initialized learned values will need to be carried out.

Note. This procedure cannot be carried out if the transmission fluid is not within the correct temperature specification.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Install the diagnostic tool.
3. Monitor and note the engagement and shift harshness on the diagnostic tool.
4. With the engine idling, monitor the transmission fluid temperature. The fluid temperature should be between 66°C-110°C (151°F-230°F).
5. With your foot on the brake, move the shift lever to NEUTRAL and hold for 3 seconds. Then move the shift lever to DRIVE and hold for 3 seconds. Carry this out 5 times. Then move the shift lever to PARK.
6. With your foot on the brake, move the shift lever to NEUTRAL and hold for 3 seconds. Then move the shift lever to REVERSE and hold for 3 seconds. Carry this out 5 times. Then move the shift lever to PARK.
7. Drive the vehicle and monitor the diagnostic tool.
8. Drive the vehicle with the throttle opening between 25-30%. Drive until the vehicle reaches 6th gear, not to exceed 80 km/h (50 mph). Then release the accelerator and coast to a stop within 60 seconds. Carry this out 10 times.
9. The engagement and shift harshness have decreased.

MATERIAL SPECIFICATION CHART

Removal

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the transmission fluid drain plug and allow the fluid to drain.
3. Disconnect the transmission fluid cooler tubes at the transaxle.
4. Disconnect the transmission fluid cooler tube bracket and position the tubes aside.
5. Remove the transmission fluid pan bolts and remove the pan.
6. Remove the sealer off the fluid pan.
7. Disconnect the wire harness from the solenoids. Remove the wire harness from the clamps. Disconnect the 8 solenoid connectors and the 2 speed sensor connectors.
8. Remove the 2 speed sensor wires from the solenoid clamp.
9. Remove the bolt and the lock plate and pull out the transmission fluid temperature (TFT) sensor.
10. Remove the 2 bolts, suction cover and gasket.
11. Remove the 6 main control valve body bolts in the sequence shown.
12. Remove the main control valve body.

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1. Connect the manual valve link and position the main control valve body in place.
2. Loosely install the 6 main control valve body bolts.
3. Install the suction cover gasket, cover and loosely install the 2 bolts.
4. Tighten the 8 bolts to 10 Nm (89 lb-in) in the sequence shown.
5. Lubricate the O-ring and install the transmission fluid temperature sensor. Tighten to 10 Nm (89 lb-in).
6. Connect the 2 speed sensor wires.
7. Connect the wire harness to the solenoids. Install the wire harness into the clamps. Connect the 8 solenoid connectors and the 2 speed sensor connectors.
8. Install a bead of sealer to the fluid pan.
9. Install the fluid pan. Tighten to 13 Nm (10 lb-ft).
10. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
11. Connect the transmission fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
12. Install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft).
13. Remove the transmission fluid fill plug.
14. Fill the transaxle with approximately 4.7L (5 quarts) of clean automatic transmission fluid.
15. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).
16. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
17. Wipe the fluid level indicator cap and remove the fluid level indicator.
18. Wipe the fluid level indicator with a clean cloth.
19. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

SPECIAL TOOL(S) CHART Installer, Output Shaft Seal 307-551

Scheme 54

MATERIAL SPECIFICATION CHART

1. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
2. Using a suitable awl, poke a small hole in the seal.
3. Using a suitable dent puller and slide hammer, remove the LH differential fluid seal.

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1. Position the new differential fluid seal in place.
2. Using the special tool, install the outer differential fluid seal.
3. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
5. Wipe the fluid level indicator cap and remove the fluid level indicator.
6. Wipe the fluid level indicator with a clean cloth.
7. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.
8. Remove the transmission fluid fill plug.
9. Fill the transaxle with clean automatic transmission fluid.
10. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).

SPECIAL TOOL(S) CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-047 (T77F-1102-A) Installer, Output Shaft Seal 307-550

Scheme 57

Scheme 58

MATERIAL SPECIFICATION CHART

1. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
2. Using the special tools, remove the differential fluid seal.

Scheme 59

1. Position the new differential fluid seal in place.
2. Using the special tool, install the outer differential fluid seal.
3. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
5. Wipe the fluid level indicator cap and remove the fluid level indicator.
6. Wipe the fluid level indicator with a clean cloth.
7. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.
8. Remove the transmission fluid fill plug.
9. Fill the transaxle with clean automatic transmission fluid.
10. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).

Scheme 60

Scheme 61

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Scheme 63

Scheme 64

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
4. Disconnect the shift cable end.
5. Disconnect the transmission control module (TCM) electrical connector.
6. Remove the manual control lever nut.
7. Remove the manual control lever.
8. Remove the bolts and remove the TCM.

Scheme 65

Scheme 66

1. Verify that the manual lever position markings are aligned. Markings should indicate that the manual lever is in the OVERDRIVE position.
2. Install the TCM. Tighten to 24 Nm (18 lb-ft).
3. Install the manual control lever.
4. Install the manual control lever nut. Tighten to 12 Nm (9 lb-ft).
5. Connect the TCM electrical connector.
6. Connect the shift cable end.
7. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
9. Reflash the TCM module to the latest level calibration available.
10. Check for correct vehicle operation.

MATERIAL SPECIFICATION CHART

Scheme 67

Scheme 68

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the 2 bolts for the rear transaxle mount.
3. Install a suitable transmission jack to support the transaxle.
4. Remove the upper transaxle mount bolts and remove the mount.

Installation

1. Clean the rear transaxle mount bolts using a wire brush and apply new threadlock and sealer to the threads.
2. Position the transaxle mount in place and install the bolts. Tighten to 55 Nm (41 lb-ft).
3. Install the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).

SPECIAL TOOL(S) CHART Installer, Shift Shaft fluid Seal 307-549

Scheme 69

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
4. Disconnect the shift cable end.
5. Disconnect the transmission control module (TCM) electrical connector.
6. Remove the manual control lever nut.
7. Remove the manual control lever.
8. Remove the bolts and remove the TCM.
9. Using a suitable pick, remove the manual control lever seal.

Scheme 70

Scheme 71

1. Using the special tool, install the manual control lever seal.
2. Verify that the manual lever position markings are aligned. Markings should indicate that the manual lever is in the OVERDRIVE position.
3. Install the TCM. Tighten to 24 Nm (18 lb-ft).
4. Install the manual control lever.
5. Install the manual control lever nut. Tighten to 12 Nm (9 lb-ft).
6. Connect the TCM electrical connector.
7. Connect the shift cable end.
8. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
9. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
10. Check for correct vehicle operation.

SPECIAL TOOL(S) CHART Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Support Bar, Engine 303-290A Adapters for 303-290 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

Scheme 72

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Scheme 130

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the air cleaner and the outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
4. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
5. Remove the upper roll restrictor bolt.
6. Remove the 4 roll restrictor brace bolts and the brace.
7. Disconnect the shift cable end.
8. Remove the electrical connector from the shift cable bracket.
9. Remove the 3 bolts for the shift cable bracket and position the cable and bracket aside.
10. Disconnect the wire harness from the transmission control module (TCM).
11. Disconnect the wire harness from the transaxle.
12. Disconnect the lower wire harness from the transaxle.
13. Remove the 4 bolts and the roll restrictor bracket.
14. Disconnect the wire harness from the roll restrictor.
15. Remove the positive crankcase ventilation (PCV) hose.
16. Disconnect the vacuum hoses from the throttle body.
17. Remove the bolt for the power steering line bracket and position aside.
18. Remove the plastic electrical cover for the starter motor electrical connectors.
19. Disconnect the 2 starter motor electrical connectors.
20. Remove the 2 bolts for the starter and the starter.
21. Remove the 2 retaining bolts and remove the roll restrictor and position aside.
22. Disconnect the ground wire.
23. Remove the 4 upper transaxle bolts.
24. If a transaxle exchange or overhaul is required, the transmission fluid must be drained. Remove the drain plug and allow the fluid to drain.
25. Remove the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
26. If removed, install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft).
27. Remove and discard the 2 nuts for the front exhaust pipe.
28. Remove and discard the 2 nuts for the rear exhaust pipe.
29. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
30. If equipped, disconnect the engine block heater electrical connector.
31. Position the heat shield for the knock sensor (KS) aside.
32. Remove the bolt and the KS.
33. Disconnect the KS wire harness from the transaxle.
34. Remove the transaxle-to-engine bolt.
35. Remove the bolt for the power steering hose.
36. Install the lower half of the lifting hook.
37. Install the upper half of the lifting hook.
38. Disconnect the vapor tube from the canister purge valve.
39. Remove the bolt for the power steering hose.
40. Install the special tool to the RH cylinder head.
41. Remove and discard the 2 bolts for the catalytic converter.
42. Install the special tool to the LH cylinder head.
43. Install the special tools to support the engine assembly.
44. Install the special tools to the LH (front) cylinder head.
45. Install the special tools to the RH (rear) cylinder head.
46. Install the special tools into the lifting hook near the EGR valve.
47. Disconnect the lower radiator hose from the retainers and position the hose aside.
48. Remove the 4 bolts retaining the power steering line to the subframe.
49. Disconnect the wire harness from the LH front of the subframe.
50. Remove the bolts and nuts for the power steering rack. Using mechanic's wire, hold the power steering rack up and out of the way.
51. Disconnect the HO2S electrical connector from the subframe.
52. Disconnect the 3 pushpins and position the splash shield aside.
53. Remove the nut for the front motor mount.
54. Remove the 2 bolts for the lower stabilizer mount.
55. Remove the nut for the rear motor mount.
56. Remove and discard the bolts for the rear transaxle mount.
57. Remove the 2 bolts for the LH rear subframe mount.
58. Remove the 2 bolts for the RH rear subframe mount.
59. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
60. Using a suitable powertrain lift, remove the 4 subframe bolts and the subframe.
61. Disconnect the HO2S electrical connector.
62. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
63. Remove the 2 pushpins and the rubber access plug.
64. Remove and discard the 4 torque converter nuts.
65. Disconnect the transmission fluid cooler tube bracket from the transaxle.
66. Disconnect the transmission fluid cooler tubes from the transaxle.
67. Position a suitable high-lift transmission jack under the transmission.
68. Remove the 3 transaxle-to-engine bolts.
69. Remove the transaxle from under the vehicle.
70. If installing a new transaxle, the fluid cooler tubes will need to be backflushed and cleaned. Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer to «TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .
71. If the transaxle is to be overhauled or if installing a new transaxle, a new transmission fluid cooler will need to be installed. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .
72. If installing a new transaxle, remove the rear transaxle mount.

SPECIAL TOOL(S) CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Converter Seal Installer 307-548

Scheme 131

MATERIAL SPECIFICATION CHART

Scheme 132

Scheme 133

1. Remove the transaxle. For additional information, refer to «TRANSAXLE»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .
2. Remove the torque converter.
3. Using the special tools, remove the torque converter hub seal.

Scheme 134

Scheme 135

Scheme 136

1. Position the torque converter hub seal in place.
2. Using the special tools, install the torque converter hub seal.
3. Install the torque converter.
4. Install the transaxle. For additional information, refer to «TRANSAXLE»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .

MATERIAL SPECIFICATION CHART

Disassembly

1. Remove the transaxle. For additional information, refer to «TRANSAXLE»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .
2. Remove the torque converter.

Assembly

1. Install the torque converter.
2. Install the transaxle. For additional information, refer to «TRANSAXLE»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .

SPECIAL TOOL(S) CHART Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent Engine Lifting Bracket Set 307-1140 Support Bar, Engine 303-290A Adapters for 303-290A 303-290A-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

MATERIAL SPECIFICATION CHART

Note. If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the fluid cooler tubes at this time. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .

If the transaxle was overhauled, or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new fluid cooler at this time. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

1. If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlocker to the threads.
2. If installing a new transaxle, install the rear transaxle mount. Tighten to 55 Nm (41 lb-ft).
3. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
4. Position the transaxle to the back of the engine.
5. Install the 3 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
6. Using new O-ring seals, connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
7. Connect the transmission fluid cooler tube bracket. Tighten to 10 Nm (89 lb-in).
8. Install 4 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
9. Install the lower rubber access plug and install the retaining pin.
10. Position the catalytic converter in place and loosely install the bolt for the bracket.
11. Connect the heated oxygen sensor (HO2S) electrical connector.
12. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
13. Install the 2 bolts for the LH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
14. Install the 2 bolts for the RH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
15. Install 2 new bolts for the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).
16. Install the nut for the rear motor mount. Tighten to 70 Nm (52 lb-ft).
17. Install the 2 bolts for the lower stabilizer mount. Tighten to 70 Nm (52 lb-ft).
18. Install the nut for the front motor mount. Tighten to 70 Nm (52 lb-ft).
19. Position the splash shield in place and install the 3 pushpins.
20. Connect the HO2S electrical connector to the subframe.
21. Position the power steering rack in place. Install the bolts and nuts. Tighten to 133 Nm (98 lb-ft).
22. Position the power steering line in place and install the 4 bolts. Tighten to 7 Nm (62 lb-in).
23. Connect the wire harness to the LH front of the subframe.
24. Position the lower radiator hose in place and connect the retainers.
25. Install the LH and RH stabilizer bar link into the struts and install new nuts. Tighten to 55 Nm (41 lb-ft).
26. Remove the special tool from the lifting hook near the EGR valve.
27. Remove the special tools from the RH (rear) cylinder head.
28. Remove the special tools from the LH (front) cylinder head.
29. Remove the special tools.
30. Install new bolts for the catalytic converter. Tighten to 40 Nm (30 lb-ft).
31. Remove the upper half of the lifting hook.
32. Remove the lower half of the lifting hook.
33. Install the transaxle-to-engine bolt. Tighten to 40 Nm (30 lb-ft).
34. Connect the KS wire harness to the transaxle.
35. Install the KS. Tighten to 10 Nm (89 lb-in).
36. Install the heat shield over the KS.
37. If equipped, connect the engine block heater.
38. Position the power steering hose in place and install the bolt. Tighten to 7 Nm (62 lb-in).
39. Tighten the catalytic converter bolt to the bracket. Tighten to 40 Nm (30 lb-ft).
40. Install the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
41. Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger. Tighten to 40 Nm (30 lb-ft).
42. Install 2 new nuts for the rear exhaust pipe. Tighten to 40 Nm (30 lb-ft).
43. Install 2 new nuts for the front exhaust pipe. Tighten to 40 Nm (30 lb-ft).
44. Install the 4 upper transaxle bolts. Tighten to 40 Nm (30 lb-ft).
45. Install the bolt for the power steering line. Tighten to 7 Nm (62 lb-in).
46. Connect the vapor tube to the canister purge valve.
47. Install the PCV hose.
48. Connect the vacuum hose to the throttle body.
49. Position the bracket for the power steering hose and install the bolt. Tighten to 7 Nm (62 lb-in).
50. Connect the ground wire. Tighten to 12 Nm (9 lb-ft).
51. Clean the roll restrictor bolts using a wire brush and apply new threadlock and sealer to the threads.
52. Position the roll restrictor in place and install the bolts. Tighten to 55 Nm (41 lb-ft).
53. Install the starter motor. Tighten to 26 Nm (19 lb-ft).
54. Connect the 2 starter motor electrical connectors. Tighten the larger nut to 12 Nm (9 lb-ft). Tighten the smaller nut to 5 Nm (44 lb-in).
55. Install the electrical cover for the starter motor electrical connectors.
56. Connect the wire harness to the roll restrictor.
57. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock and sealer to the threads.
58. Install the roll restrictor bracket and install 4 new bolts. Tighten to 40 Nm (30 lb-ft).
59. Connect the lower wire harness to the transaxle.
60. Connect the wire harness to the transaxle.
61. Connect the transmission control module (TCM) electrical connector.
62. Install the shift cable bracket and bolts. Tighten to 25 Nm (18 lb-ft).
63. Connect the electrical connector to the shift cable bracket.
64. Connect the shift cable end.
65. Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock and sealer to the threads.
66. Position the roll restrictor brace in place and install the bolts. Tighten to 55 Nm (41 lb-ft).
67. Clean the upper roll restrictor bolt using a wire brush and apply new threadlock and sealer to the threads.
68. Install the upper roll restrictor. Tighten to 48 Nm (35 lb-ft).
69. Install the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/ford/five-hundred/i-2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
70. Remove the transmission fluid fill plug.
71. Fill the transaxle with clean automatic transmission fluid.
72. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).
73. Install the air cleaner and outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
74. Install the battery tray and the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
75. Remove the fluid level indicator and make sure that the transaxle has fluid in it.
76. Reflash the TCM to the latest level calibration available.
77. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
78. Wipe the fluid level indicator cap and remove the fluid level indicator.
79. Wipe the fluid level indicator with a clean cloth.
80. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

See also:
• INTRODUCTION - GASOLINE
• AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS
• STARTING SYSTEM
• TRANSAXLE/TRANSMISSION COOLING
• JACKING & LIFTING
• FRONT DRIVE HALFSHAFTS
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• FRONT END BODY PANELS
• GENERAL SPECIFICATION
• DIAGNOSIS BY SYMPTOM
• DIAGNOSTICS
• LEAKAGE INSPECTION
• SOLENOID OPERATION CHART
• PINPOINT TEST A
• TORQUE CONVERTER