Automatic Transmission Cooling System Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATION CHART

TORQUE SPECIFICATION CHART

Transaxle Cooling

These vehicles are equipped with an external fluid cooler. The cooler is mounted between the engine radiator and the A/C condenser. In operation, transmission fluid travels from the transaxle to the fluid cooler then back to the transaxle. The fluid cooler transfers heat from the transmission fluid to the outside air.

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Special Tool(s)

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

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Material Specifications

MATERIAL SPECIFICATION CHART

Inspection and Verification

1. Verify the customers concern by operating the vehicle to duplicate the condition.
2. If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary.
3. Install new components if a fluid leak is found in any of the transaxle cooling components.
4. If the concern(s) remains after the inspection, determine the symptom(s). GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system__symptom-chart) .

Symptom Chart

SYMPTOM CHART

Check Fluid Level and Condition (All Vehicles)

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 (6-Speed)

Note. The transmission 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.

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1. With the transaxle in 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 indicator tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating range.

High Fluid Level (6-Speed)

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 AUTOMATIC TRANSAXLE - 6 SPEED .

Low Fluid Level (6-Speed)

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 (6-Speed)

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

Fluid Condition Check (6-Speed)

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 and cooler tubes should be cleaned.
7. If the transaxle is to be overhauled or if installing a new transaxle, install a new transmission fluid cooler. For additional information, refer to «TRANSMISSION FLUID COOLER»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .

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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. Place the vehicle on a level surface.
3. Using the special tool, verify that the transmission fluid temperature is in the normal operating of 88°C-92°C (190°F-198°F).
4. Once the transmission fluid temperature range is verified, with the engine idling set the park brake and move the transmission selector level through all gear positions placing it in PARK.
5. Remove the fluid level indicator and wipe it with a clean lint free rag.
6. Place the fluid level indicator back into the fluid level indicator tube until it is fully seated, then remove the fluid indicator. Vehicles equipped with a fluid level indicator without Crosshatch marks With the transmission fluid in the normal operating temperature range 88°C-92°C (190°F-198°F) the minimum acceptable level would be at the top of the upper fluid level setting hole. The maximum acceptable level would be no more than 12 mm (0.47 in) up the fluid level indicator from the top of the upper level setting hole. Vehicles equipped with a fluid level indicator with Crosshatch marks With the transmission fluid in the normal operating temperature range 88°C-92°C (190°F-198°F) the minimum acceptable level would be at the bottom of the Crosshatch mark on the fluid level indicator. The maximum acceptable level would be no higher than the top of the Crosshatch (12 mm (0.47 in) from the top of the upper level setting hole) area.
7. Verify the correct fluid level for normal operating temperature range.
8. If fluid needs to be added, turn off the engine and allow the CVT transmission fluid to cool to the correct level setting range 43°C-47°C (109°F-117°F) and follow the transmission fluid level setting procedure for setting correct CVT transmission fluid level.

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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. Place the vehicle on a level surface.
3. Using the special tool, verify that the transmission fluid temperature is in the fluid level setting range 43°C-47°C (109°F-117°F).
4. Set the parking brake, place the range selector lever in PARK and run the engine at idle for 5 minutes.
5. Once the transmission fluid temperature range is in the 43°C-47°C (109°F-117°F) range, place your foot on the brake and move the transmission selector level through all gear positions placing it in PARK.
6. Remove the fluid level indicator and wipe it with a clean lint free rag. Place the fluid level indicator back into the fluid level indicator tube.
7. Remove the fluid level indicator and check for correct fluid level. The fluid level should be at the bottom of the top level indicator hole with the CVT automatic transmission fluid temperature in the 43°C-47°C (109°F-117°F) range.
8. If fluid needs to be added, add clean CVT automatic transmission fluid in 0.25-L (1/2-pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not over fill the transaxle and make sure the fluid temperature is in the correct range 43°C-47°C (109°F-117°F) or internal damage to the transaxle will occur. To install, tighten to 35 Nm (26 lb-ft). The wrench light on the dash will illuminate if the fluid level is low during the fluid refill process and the vehicle may experience harsh engagements.

High Fluid Level (CVT)

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 foaming, loss of fluid from the vent tube, fluid level indicator tube and possible transaxle malfunction and/or damage. If an overfill reading is indicated, loosen the fluid drain plug and allow a small amount of fluid to drain.

Low Fluid Level (CVT)

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

Adding Fluid (CVT)

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. For fluid type, refer to the SPECIFICATION CHART .

Fluid Condition Check (CVT)

Note. CVT fluid is bluish green when it is new. The CVT fluid will darken from bluish green to darker green or brown as it ages. If there is an internal concern with a mechanical component, there will be metallic residue in the pan. With other transmission fluids, the odor is an indicator of heat damage or other concerns. With CVT fluid, the odor will not indicate heat damage or other concerns.

1. Check the fluid level.
2. Observe the color. The color under normal circumstances should be bluish green when new and will darken to dark green or brown as it ages, not black.
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 fluid contamination or transaxle failure is confirmed by the sediment in the bottom of the fluid pan, the transaxle must be disassembled and completely cleaned or installed new. This includes the cooler tubes.
6. If the transaxle is to be overhauled or if installing a new transaxle, install a new transmission fluid cooler. For additional information, refer to «TRANSMISSION FLUID COOLER»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .

Material

MATERIAL SPECIFICATION CHART

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Note. Refer to the following when adding transmission fluid.

1. The constant variable transmission (CVT) transaxle uses: Motorcraft Continuously Variable Chain Type Transmission Fluid (XT-7-QCFT)
2. The 6-speed transaxle uses: Motorcraft Premium Automatic Transmission Fluid (XT-8-QAW)

Do not mix the fluid together, damage to internal components will result.

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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 8 retainers for the upper grille opening cover and remove the cover.
3. Remove the 8 retainers for the upper grille opening cover and remove the cover.
4. Remove the LH air deflector push pins. Position the air deflector aside.
5. Remove the RH air deflector push pins. Position the air deflector aside.
6. Remove the bolt from the LH A/C condenser bracket. To install, tighten to 10 Nm (89 lb-in).
7. Remove the bolt from the RH A/C condenser bracket. To install, tighten to 10 Nm (89 lb-in).
8. Carefully lift the A/C condenser off the retaining clips and position the condenser aside.
9. Remove the screw for the cooler tube retainer. To install, tighten to 10 Nm (89 lb-in).
10. Disconnect the fluid cooler hoses from the fluid cooler.
11. Lift the fluid cooler off the retainers and remove the fluid cooler.
12. Remove the fluid fill plug. To install, tighten to 35 Nm (26 lb-ft).
13. Partially fill the transaxle with clean automatic transmission fluid to make up what was lost during the installation of a new transmission fluid cooler. Using the transmission fluid level setting (CVT) procedure, continue filling the transaxle. For additional information, refer to «TRANSAXLE COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system__transaxle-cooling) . 6-speed transaxle
14. Remove the fluid fill plug. To install, tighten to 39 Nm (29 lb-ft).
15. To install, reverse the removal procedure. Fill the transaxle with Motorcraft Premium Automatic Transmission Fluid XT-8-QAW meeting Ford specification WSS-M2C924-A to the specified level. Prior to adding any transmission fluid, make sure that the vehicle is on a level surface. Check the fluid level to determine how much fluid will need to be added. Using a diagnostic tool, monitor the fluid temperature. Make sure that the fluid temperature is within specification. The fluid level should be within the normal operating range on the fluid level indicator.
16. Check the transaxle for correct operation.

MATERIAL SPECIFICATION CHART

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Note. Refer to the following when adding transmission fluid.

1. The CVT transaxle uses: Motorcraft Continuously Variable Chain Type Transmission Fluid (XT-7-QCFT)
2. The 6-speed transaxle uses: Motorcraft Premium Automatic Transmission Fluid (XT-8-QAW)

Do not mix the fluid together, damage to internal components will result.

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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. Disconnect the cooler hoses from the fluid cooler.
3. Disconnect the transmission fluid cooler tubes from the transaxle. To install, tighten to 10 Nm (89 lb-in).
4. Disconnect the wiring harness from the cooler tube.
5. Remove the fluid cooler tube bracket from the transaxle. Remove the fluid cooler tubes. To install, tighten to 10 Nm (89 lb-in).
6. Remove the fluid fill plug. To install, tighten to 35 Nm (26 lb-ft).
7. Partially fill the transaxle with clean automatic transmission fluid to make up what was lost during the installation of a new transmission fluid cooler tube. Using the transmission fluid level setting CVT procedure continue filling the transaxle. For additional information, refer to «TRANSAXLE COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system__transaxle-cooling) .
8. 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) .
9. Disconnect the cooler hoses from the fluid cooler.
10. Disconnect the transmission fluid cooler tubes at the transaxle. To install, tighten to 10 Nm (89 lb-in).
11. Disconnect the transmission fluid cooler tube bracket. Remove the fluid cooler tubes. To install, tighten to 10 Nm (89 lb-in).
12. Remove the fluid fill plug. To install, tighten to 39 Nm (29 lb-ft).
13. To install, reverse the removal procedure. Fill the transaxle with Motorcraft Premium Automatic Transmission Fluid XT-8-QAW meeting Ford specification WSS-M2C924-A to the specified level. Prior to adding any transmission fluid, make sure that the vehicle is on a level surface. Check the fluid level to determine how much fluid will need to be added. Using a diagnostic tool, monitor the fluid temperature. Make sure that the fluid temperature is within specification. The fluid level should be within the normal operating range on the fluid level indicator.
14. Check the transaxle for correct operation.

See also:
• AUTOMATIC TRANSAXLE/TRANSMISSION - CVT
• AUTOMATIC TRANSAXLE - 6 SPEED
• JACKING & LIFTING
• SYMPTOM CHART
• SPECIFICATION CHART
• TRANSAXLE COOLING