Automatic Transmission - Cvt Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

FORWARD CLUTCH PACK

FORWARD CLUTCH PACK

REVERSE CLUTCH PACK

REVERSE CLUTCH PACK

INPUT SHAFT END PLAY SPECIFICATION

INPUT SHAFT END PLAY SPECIFICATION

DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION

DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Transaxle Description

This transaxle represents the start of a new generation of automatic transmissions. This is a continuously variable transaxle (CVT) that permits the engine to operate at its most efficient running speeds. There are no discrete gear shifts and no interruptions in the power flow during acceleration. Instead, optimum use is always made of the engine's potential to transmit its full torque to the wheels. Since this is a continuously variable transaxle, there is an infinite number of gear ratios, so that the optimum engine operating point can always be found. Like the engine, it is located transversely in the vehicle. The mechanical section of the automatic transaxle contains 2 pressure controlled variator assemblies, a high performance chain and a single planetary gear set. The variator assemblies function as pulleys. One is connected to the engine output through the converter. The other is connected to the driveline through the transaxle differential. The chain passes around the pulleys connecting the transaxle input and output. The axial distance on each pulley where the chain travels can be varied. As the axial distance on one pulley decreases (becomes narrow) the other pulley increases (becomes wider) creating the speed (gear) ratio between them. This ratio varies continuously. The chain length remains constant. The single planetary gear set is used to change the rotation of the pulley assemblies for forward or reverse driving ranges. A combined hydraulic and electronic control system (mechatronic) is used to control the transaxle function. The mechatronic is located inside the transaxle. The CVT uses a torque converter with a lock-up clutch.

Scheme 198

Internal Fluid Filter

The high pressure transmission fluid filter is located inside of the transaxle housing, just behind the transmission pressure filter case cover. The transmission filter is accessible by removing the transmission pressure filter case cover. The filter should be changed ever time the fluid is changed or whenever the transaxle is overhauled.

Range Selection

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

Scheme 199

Park

In the PARK position

1. there is no power flow through the transaxle.
2. the parking pawl locks the output shaft to the case.
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. backup lamps are illuminated.

Neutral

In the NEUTRAL position

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

Drive

This DRIVE position provides

1. power to the wheels for forward motion.

Low

This LOW position provides

1. engine braking in low gear.

Torque Converter

The converter consists of the impeller, the turbine wheel, the reactive element (stator) and the fluid used to transmit the torque. The impeller is driven by the engine and imparts a circular flow to the fluid in the converter. The angle of the fluid flow is deflected when it strikes the turbine wheel. The fluid leaves the turbine wheel close to the hub, and passes through the stator, where it is again deflected and enters the impeller at an angle. The change in the direction of fluid flow at the stator generates a reaction torque that increases the torque at the turbine. The ratio between turbine torque and impeller torque is the torque conversion ratio. The greater the speed difference between the impeller and the turbine, the greater the increase in torque; this increase reaches a maximum when the turbine is stationary. As turbine speed rises, the increase in torque lessens. When the turbine is running at about 85 percent of the impeller speed, the increase in torque drops to one, that is to say turbine and impeller torques are identical. The stator, which bears against the gearbox housing via a one-way clutch and the stator shaft, can then revolve freely in the fluid flow, and the freewheel is overrun. From this moment, the converter operates purely as a fluid coupling. During the torque conversion phase, the stator is stationary and bears against the housing through the freewheel.

Torque Converter Clutch

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

Fluid Pump

The fluid pump is a high-pressure radial-piston pump, the pump flow is controlled by the main pressure regulator in the valve body portion of the mechatronic unit. There are 8 pistons located radially around the circumference of the pump.

The pump is driven directly from the engine via the outer housing of the converter and supplies the transaxle with fluid. The converter is not supported on the pump bearings but on a plain bearing between the stator shaft and the converter hub. The pump draws in fluid from the fluid pan filter and discharges fluid at high pressure to the main regulator valve in the valve body.

Variator Assemblies

The continuously variable transaxle (CVT) has 2 pressure-controlled variators that function as pulleys

1. Primary variator (input)
2. Secondary variator (output)

The primary variator transmits input torque to the chain which drives the secondary variator. The secondary variator supplies torque to the differential.

The variators function as variable speed pulleys. The chain wraps around both variators like a V-belt. The variators, controlled by fluid pressure, change the path of the chain moving over the pulleys to vary the pulley speed gear ratio. The variators provide input to output ratio of the transaxle like a conventional automatic transaxle uses fixed planetary ratios.

Transaxle Electronic Control System

The following is a list components that are incorporated within the mechatronic assembly

1. Transmission control module (TCM)
2. Transmission fluid temperature (TFT) sensor
3. Speed sensors
4. Turbine shaft speed (TSS) sensor and primary variator speed sensor
5. Main control valve body
6. Pressure control solenoids
7. Pressure sensors

The output shaft speed (OSS) is part of the transaxle electronic control system but it is not part of the mechatronic assembly. The OSS sensor is bolted to the case and reads the differential gear.

Mechatronic Assembly

The mechatronic assembly is a large assembly located in the transaxle fluid pan. The assembly consists of the following

1. Hydraulic main control valve body
2. Five pressure control (VFS) solenoids
3. Two pressure sensors
4. Transmission control module (TCM)
5. Transmission fluid temperature sensor
6. Two speed sensors

Main Control Valve Body

The valve body controls the system hydraulic pressure, clutch apply pressure and variator pressure using hydraulic valves actuated by pressure control solenoids controlled by the TCM.

Pressure Control Solenoids

The 5 pressure control solenoids are of a variable force solenoid (VFS) type

1. Main pressure control (PCA) solenoid A
2. Main system pressure
3. TCC torque converter clutch apply
4. Pressure control (PCB) solenoid B primary variator pulley pressure
5. Pressure control (PCC) solenoid C secondary variator pulley pressure
6. Pressure control (PCD) solenoid supplies pressure for forward and reverse clutches

Pressure Sensors

There are 2 pressure sensors

1. Main system pressure sensor
2. Secondary variator (output pulley) pressure

Transmission Control Module (TCM)

The transmission control module controls transaxle function. It is the transaxle-to-vehicle-system interface. Also supplies the signal to the powertrain control module (PCM) for starter interlock. Diagnostic trouble codes that are transaxle-related are supplied to the PCM, ABS and AWD modules from the TCM. The transmission fluid temperature sensor is built into the TCM.

TCM monitored inputs from other electronic modules

1. Electronic control module (ECM) throttle position sensor engine torque engine speed
2. ABS module vehicle speed wheel speed active states
3. Traction control module (AWD) vehicle speed wheel speed active states
4. Anti-lock brake system

Transmission Fluid Temperature (TFT) Sensor

The TCM utilizes one transmission fluid temperature sensor which is integrated within the TCM. The TCM uses the sensor input to activate various operational strategies.

Speed Sensors

The CVT transaxle uses 3 speed sensors

1. Primary variator speed sensor
2. Turbine shaft speed (TSS) sensor
3. Output shaft speed (OSS) sensor

Turbine Shaft Speed (TSS) Sensor and Primary Variator Speed Sensor

The primary variator speed sensor and the turbine shaft speed (TSS) sensor are housed in the transmission control module (TCM). The TCM is attached to the mechatronic unit. Both speed sensors are Hall-effect.

The primary variator speed sensor reads the primary pulley shaft speed.

The speed sensor for the primary pulley is part of the transmission control module. It is an non-contact Hall sensor which measures the rotational speed of the primary pulley.

Output Shaft (OSS) Sensor

The OSS sensor functions as 2 sensors in one. The OSS sensor indicates output shaft speed by reading the differential spurr gear. The OSS sensor also provides rotational direction for forward and reverse motion. The OSS sensor connects to the mechatronic assembly electronically.

Transmission Range Sensor

The transaxle range sensor is located within the transaxle. This sensor is a Hall-effect type sensor. It detects the driver selected transaxle range through a mechanical linkage from the range selector lever.

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 shortcuts 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 Diagram

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 customers concern.
2. Verify the concern by operating the vehicle.
3. Check the fluid levels and condition.
4. Check for non-factory add-on items.
5. Check shift linkages for correct adjustment.
6. Check TSB messages regarding the concern.

Diagnostics

1. Carry out on-board diagnostic procedures Key On/Engine Off (KOEO) and Key On/Engine Running (KOER).
2. Record all diagnostic trouble codes (DTCs).
3. Repair all non-transaxle DTC codes first.
4. Repair all transaxle DTC codes second.
5. Erase all continuous codes and attempt to repeat them.
6. Repair all continuous codes.
7. If only pass codes are obtained, go to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) for additional 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 CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 200

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 involved when the concern occurs. For example

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

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

Determine Customer Concern

Note. Some transaxle conditions may cause engine concerns. An electronic pressure control short circuit can cause engine misfiring. If the torque converter clutch does not disengage, the engine will stall.

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. Coasting
7. Engagement
8. Noise/vibration - check for dependencies, either rpm dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent or temperature dependent
9. Check the CVT transmission fluid level. Refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

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 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 and re-check fluid level.

Low Fluid Level

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

Adding Fluid

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

Note. The continuously variable transaxle (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 was 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.
6. If the transaxle is to be overhauled or if installing a new transaxle, install a new transmission fluid cooler and clean and flush the fluid cooler tubes. Refer to «TRANSAXLE/TRANSMISSION COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .
7. Carry out diagnostic checks and adjustments. Refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL 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-transmission-cvt__diagnostics) . Repair all non-transaxle-related DTCs first. Repair all transaxle DTCs. Rerun On-Board Diagnostic to verify repair. Carry out diagnostic routines. Refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) . 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.

Torque Converter Operation Test

Note. The torque converter clutch will not engage if the transmission fluid temperature is below 0°C (32°F).

1. Using the special tool, make sure that the transmission fluid temperature is within specification 43°C-47°C (109°F-117°F).
2. Accelerate the vehicle to 35-60 km/h (22-37 mph) and maintain a consistent speed.
3. Release the accelerator pedal to close the throttle and press the accelerator to partially open the throttle while monitoring the special tool engine speed and TCC PID 194D. The TCC PID on the special will read 0 when the TCC clutch is released, and 1 when the TCC is applied. The engine speed will increase when the TCC is released and decrease when the TCC is applied.
4. If these actions do not occur, refer to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) in this section.

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. NON OEM electronic add-on items: Remote starter equipment Air conditioning Generator (alternators) 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 transaxle function. Pay particular attention to add-on wiring splices in the PCM harness or transaxle wiring harness, abnormal tire size, or axle ratio changes. Damaged, bent, broken or loose fluid cooler tubes. Leaks. Refer to «LEAKAGE INSPECTION»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) . Correct linkage adjustments.

Shift Linkage Check

Hydraulic leakage at the manual control valve can cause delay in engagements and/or variator slipping while operating, if the linkage is not correctly adjusted.

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

On-Board Diagnostic (OBD) 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. On-Board Diagnostic (OBD) II Drive Cycle
10. Other Diagnostic Tool Features

For other diagnostic testing features using the diagnostic tool, refer to the INTRODUCTION - GASOLINE article . Other diagnostic methods include the following

1. Parameter Identification (PID) Access Mode
2. Freeze Frame Data Access Mode
3. Oxygen Sensor Monitor Mode

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

Diagnostic PID Chart

DIAGNOSTIC PID CHART

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

Diagnostic Trouble Code Chart

DIAGNOSTIC TROUBLE CODE CHART

Worldwide Diagnostic System (WDS)

When following powertrain diagnostics for OBD II vehicles, the system may be checked by an off-board tester referred to as a diagnostic tool. This section contains information for carrying out diagnostics with a diagnostic tool. A diagnostic tool has certain generic capabilities that are standard across the automotive industry in the United States. All functions are selected from a menu. Refer to the instruction manual provided by the tool manufacturer.

Scheme 201

SPECIAL TOOL 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 202

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 transaxle DTC

PINPOINT TEST A: TRANSMISSION FLUID PRESSURE SENSORS

Note. An internal fluid leak, incorrectly installed transmission fluid pan filter, cut/damaged mechatronic assembly feed tube O-rings or a transmission fluid pump leaking or not operating correctly can cause a difference in the pressure readings. Always check the fluid pan filter for correct installation, the mechatronic assembly bolt torque for correct torque setting, O-rings and feed tubes for damage and leaks, and the fluid pump for correct operation prior to installing a new or the original mechatronic assembly. If the feed tubes, O-rings or fluid pan filter are damaged or if the fluid pump is not operating correctly, install new components as required. Recheck the pressures using the pinpoint test. If the pressure readings are still incorrect, install a new mechatronic assembly.

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. A1 PRESSURE SENSOR DIAGNOSTICS Key in OFF position. Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: PIDs: Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure Sensor (PCC_MES). Are the pressure sensor readings between 0-80 kPa (0-12 psi)? Yes : Pressure sensors are OK. GO to A2. No : Pressure sensors are faulty. INSTALL a new mechatronic assembly.
2. A2 CHECK PRESSURE AT IDLE Key in START position. Engine speed at idle. Enter the following diagnostic mode on the scan tool: PIDs: Engine Speed (RPMTCM), Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). Monitor and record the PIDs. Are the presssure sensor readings less than 300 kPa (44 psi)? Yes : CHECK pan filter for restriction or for correct installation. If pan filter is installed correctly and not restricted, INSTALL a new fluid pump. REFER to the notes preceding this pinpoint test. No : GO to A3.
3. A3 CHECK PRESSURE AT IDLE Enter the following diagnostic mode on the scan tool: PIDs: Engine Speed (RPMTCM), Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). Monitor and record the PIDs. Is the main pressure sensor less than the pulley 2 (secondary) sensor pressure? Yes : GO to A4. No : GO to A5 .
4. A4 CHECK PRESSURE AT IDLE Enter the following diagnostic mode on the scan tool: PIDs: Engine Speed (RPMTCM), Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). NOTE: If the main pressure is less than the pulley 2 pressure the difference cannot be greater than 400 kPa (58 psi). Monitor and record the PIDs. Is the difference between the main pressure sensor and the pulley 2 (secondary pressure sensor) less than 400 kPa (58 psi)? Yes : GO to A5. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)
5. A5 CHECK PRESSURE OFF IDLE Engine speed above 2,000 rpm. Enter the following diagnostic mode on the scan tool: PIDs: Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). Monitor and record the PIDs. Is the main and pulley 2 pressures greater than 300 kPa (44 psi)? Yes : GO to A6. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)
6. A6 CHECK PRESSURE OFF IDLE Engine speed above 2,000 rpm. Enter the following diagnostic mode on the scan tool: PIDs: Engine Speed (RPMTCM), Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). Monitor and record the PIDs. Is the main pressure less than the pulley 2 pressure? Yes : GO to A7. No : GO to A8 .
7. A7 CHECK PRESSURE OFF IDLE Engine speed above 2,000 rpm. Enter the following diagnostic mode on the scan tool: PIDs: Engine Speed (RPMTCM), Main Pressure Sensor (PCA_MES) and Pulley 2 Pressure (secondary) Sensor (PCC_MES). NOTE: If the main pressure is less than the pulley 2 pressure the difference cannot be greater than 400 kPa (58 psi). Monitor and record the PIDs. Is the difference between the main pressure and the pulley 2 pressure less than 400 kPa (58 psi)? Yes : GO to A8. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)
8. A8 CHECK MAIN PRESSURE DURING TEST DRIVE Drive the vehicle and monitor the diagnostic tool. Engine RPM should be above 2,100. Compare the difference between PIDs: (PCA MES) and (PCC MES). Is the difference between PIDs: (PCA MES) and (PCC MES) less than 300 kPa (44 psi)? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. No : INSPECT the transaxle internally for damaged O-rings or seals. INSPECT the varaitors for damage. REPAIR as required. REFER to «TRANSAXLE DISASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. B1 ELECTRONIC DIAGNOSTICS Connect the scan tool. Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Key in ON position. Enter the following diagnostic mode on the scan tool: PIDs: Diagnostic Data Link, TFT. Does the vehicle enter TFT PID? 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. Enter the following diagnostic mode on the scan tool: TFT. Monitor the TFT PID. The temperature value should be within -55°C to 175°C (-65°F to 347°F). Is the TFT voltage within specified range? Yes : GO to B3. No : INSTALL a new mechatronic assembly.
3. B3 WARM-UP/COOL-DOWN CYCLE While monitoring PID: TFT, carry out the following test: If transaxle is cold, run transaxle to warm it up. If transaxle is warm, allow transaxle to cool down. Does the TFT PIDs increase as the transaxle is warmed up or decrease as the transaxle is cooled. Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. If concern is still present or reappears, INSTALL a new mechatronic assembly. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)

PINPOINT TEST C: TRANSMISSION RANGE (TR) SENSOR

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. C1 VERIFY RANGE SELECTOR LEVER Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: PID: TR. Move the range selector throughout all the gear ranges. Does the PID TR match all the selected gears? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. No : ADJUST the shift cable, REFER to «AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-external-controls) . CLEAR the DTCs code. If the DTC code reappears it is internal to the transaxle. REFER to «TRANSMISSION RANGE (TR) SENSOR»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

PINPOINT TEST D: TORQUE CONVERTER CLUTCH

1. D1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. Drive the vehicle with a steady speed up to and above 24 km/h (15 mph). Monitor PID: (PCE/TCC). The TCC commanded pressure should be greater than 400 kPa (44 psi) and the turbine shaft speed should be equal to engine speed. Is the lockup commanded pressure greater than 400 kPa (44 psi) and the turbine speed equal to engine speed? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. No : INSTALL a new torque converter.

PINPOINT TEST E: EXCESSIVE CLUTCH SLIPPAGE

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. E1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. With the vehicle in DRIVE and REVERSE at idle, monitor PIDs. (CLTAMP_MES) actual current for forward/reverse clutch solenoid and (CLTAMP_CMD) for commanded current forward/reverse clutch solenoid. Is the current value between both PIDS no greater than 10 milliampere? Yes : GO to E2. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)
2. E2 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. With the vehicle in DRIVE and REVERSE at idle, monitor PIDs. (TR) (TSS_SRC), Pulley A (SPD_PULA) Speed. The turbine shaft speed should be equal to Pulley A (primary) Speed. Is the turbine speed equal to pulley A (primary) speed? Yes : GO to E3. No : REFER to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
3. E3 ELECTRONIC DIAGNOSTICS Connect the scan tool. With the vehicle in NEUTRAL and PARK at idle, monitor PIDs. (TR), (TSS_SRC), Pulley A (SPD_PULA) Speed. The turbine shaft speed should be equal to engine speed, and pulley A (primary) speed should be at zero. Is the turbine speed equal to engine speed, and pulley A (primary) speed at zero? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. No : REFER to «DIAGNOSIS BY SYMPTOM»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

PINPOINT TEST F: OUTPUT SHAFT SPEED (OSS) SENSORS

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. F1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in START position. Enter the following diagnostic mode on the scan tool: OSS_SRC (OSSA), OSSB. Monitor and record speed. Do OSS A and OSS B equal each other? Yes : GO to F2. No : INSTALL a new OSS sensor.
2. F2 ELECTRONIC DIAGNOSTICS Enter the following diagnostic mode on the scan tool: OSS_SRC (OSSA), OSSB. Drive the vehicle and monitor and record speed. Both the OSS A and OSS B should read the same. Do OSS A and OSS B follow the vehicle speed and read the same? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. If concern is still present or reappears, INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.) No : INSTALL a new OSS sensor.

PINPOINT TEST G: TURBINE SHAFT SPEED (TSS) SENSOR

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. G1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Key in START position. With the vehicle in NEUTRAL and PARK at idle, monitor PIDs. (TR), (TSS_SRC), Pulley A (SPD_PULA) Speed and (RPMTCM). The turbine shaft speed should be equal to engine speed, and pulley A (primary) speed should be at zero. Is the turbine speed equal to engine speed, and pulley A (primary) speed at zero? Yes : System functionally correctly. Intermittent fault. No : GO to G2.
2. G2 ELECTRONIC DIAGNOSTICS With the vehicle in DRIVE and REVERSE at idle, monitor PIDs. (TR), (TSS_SRC), Pulley A (SPD_PULA) Speed and (RPMTCM). The turbine shaft speed should be equal to Pulley A (primary) speed. Is the turbine speed equal to pulley A (primary) speed? Yes : System functionally correctly. No : INSTALL a new mechatronic assembly. (Refer to the note preceding this pinpoint test.)

PINPOINT TEST H: TRANSMISSION CONTROL MODULE SIGNAL

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. H1 TRANSMISSION CONTROL MODULE SIGNAL OUT OF RANGE Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in connector and in good condition before proceeding. Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: PID: Ignition Voltage (D10B). Is the ignition voltage between 11 and 15 volts. Yes : GO to H2. No : REPAIR the open or short circuit harness side.
2. H2 TRANSMISSION CONTROL MODULE SIGNAL OUT OF RANGE Connect the scan tool. Key in ON position. Enter the following diagnostic mode on the scan tool: PID: VPWRTCM. Is the operating voltage between 11 and 15 volts. Yes : System operating correctly. No : Fix other DTCs first. Charge the vehicle battery.

PINPOINT TEST I: PRIMARY PULLEY SPEED SENSOR

Note. The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

1. I1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. With the vehicle in NEUTRAL and PARK at idle, monitor PIDs. (TR), (TSS_SRC), Pulley A (SPD_PULA) speed and (RPMTCM) engine speed. The pulley A (primary) speed should be at zero. Is the pulley A (primary) speed at zero? Yes : GO to I2. No : INSTALL a new mechatronic unit. (Refer to the note preceding this pinpoint test.)
2. I2 ELECTRONIC DIAGNOSTICS With the vehicle in DRIVE and REVERSE at idle, monitor PIDs. (TR), (TSS_SRC), Pulley A (SPD_PULA) speed and (RPMTCM) engine speed. The turbine shaft speed should be equal to Pulley A (primary) speed. Is the turbine speed equal to pulley A (primary) speed? Yes : System functionally correctly. No : INSTALL a new mechatronic unit. (Refer to the note preceding this pinpoint test.)

SPECIAL TOOL CHART 100W/12 volt DC UV Lamp 164-R0751

Scheme 203

Material

MATERIAL SPECIFICATION

Leakage at the transaxle pan-to-case gasket often can be stopped by tightening the attaching bolts to 11 Nm (8 lb-ft). If necessary, install a new pan case gasket.

Check the fluid tubes and fittings between the transaxle and the auxiliary cooler. If leakage cannot be stopped by tightening the clamps or the cooler tube retainer, install new parts. When fluid is found leaking between the transaxle case and the cooler tube fittings, check for a missing or damaged O-ring seal, then tighten the fitting to maximum specification.

If the leak continues, install new fluid cooler tubes.

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

If leakage is found at the transaxle internal harness connector, install a new O-rings.

Fluid Leakage in Torque Converter Area

In diagnosing and correcting fluid leaks in the torque converter area, use the following procedures to locate the exact cause of the leakage. Leakage at the front of the transaxle, as evidenced by fluid around the torque converter housing, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of the leak before removing the transaxle 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 steps following correspond with the numbers in the illustration.

Scheme 204

1. Fluid leaking by the converter hub seal lip will tend to move along the drive hub and onto the back of the torque converter. Except in the case of a total seal failure, fluid leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near the outside diameter of the housing.
2. Fluid leakage by the outside diameter of the converter hub seal and the case will follow the same path that leaks by the inside diameter of the converter hub seal follow.
3. Fluid leakage from the converter cover weld or the converter-to-flexplate stud weld will appear at the outside diameter of the torque converter on the back face of the flexplate and in the converter housing only near the flexplate. If a converter-to-flexplate stud or converter cover weld leak is suspected, install a new torque converter.
4. Fluid leaking from the pump cover, pump cover bolts or the torque converter hub seal inside the converter housing will flow down the back of the torque converter housing. Leakage may be from loose or missing pump cover bolts, defective pump cover seal or defective torque converter hub seal.
5. Engine oil leaks are sometimes incorrectly diagnosed as transaxle converter hub seal leaks. The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the concern. Leakage at the valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block, causing oil to be present in or at the bottom of the torque converter housing. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing. Leakage at the crankshaft rear oil seal will work back to the flexplate and then into the torque converter housing. Leakage at the oil pressure sensor. Cracks in the block. Leakage from the engine oil pan.

Leak Check Test

1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is bluish green when new and will darken to dark green or brown as it ages. Unless a considerable amount of makeup fluid has been added or the fluid has been changed, the blue color should assist in pinpointing the leak.
2. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the torque converter area by washing with a suitable nonflammable solvent and blow dry with compressed air.
3. Wash out the torque converter housing and the front of the flexplate. The torque converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transaxle reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, then at engine idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and inside the torque converter housing and front of the case. Run the engine until fluid leakage is evident and the probable source of leakage can be determined.

Leak Check Test With A Black Light

UV Fluorescent Tracer Dye (164-R3706 or equivalent specifically formulated for ATF) is used to detect a transmission fluid leak.

1. Add UV Fluorescent Tracer Dye to the transmission fluid. Use one 30.0 mL (1oz) of dye solution for every 3.8 L (4 quarts) of transmission fluid.
2. Start and run the engine until the transaxle reaches its normal operating temperature 90°C (194°F). Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle, then at engine idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and inside the torque converter housing and front of the case. Continue running the engine until fluid leakage is evident and the probable source of leakage can be determined.

MATERIAL SPECIFICATION

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

Because this transaxle has a thermal bypass valve in it, the only way to carry out the backflushing and cleaning is to disconnect the cooler tubes from the transaxle and the fluid cooler, and flush the cooler tubes only.

If new fluid cooler tubes need to be installed due to being damaged or are plugged, refer to TRANSAXLE/TRANSMISSION COOLING .

If the transaxle is to be overhauled or if installing a new transaxle, install a new oil-to-air (OTA) transmission fluid cooler. Refer to TRANSAXLE/TRANSMISSION COOLING .

SPECIAL TOOL 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 Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

Diagnosis by Symptom Chart Directions

Note. When the diagnostic system detects a fault specific to this transmission, a transmission related Diagnostic Trouble Code (DTC) will be set. The wrench light on the dash may illuminate. Care must be taken when diagnosing DTCs when other non-transmission related DTCs set. As with any transmission diagnostics, all non-related transmission DTCs must be addressed prior to diagnosing transmission DTCs. The wrench light will also illuminate for faults detected in the Anti-lock Brake System (ABS) or Electronic Throttle Control (ETC) system.

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 most probable cause. All components listed must be inspected to make sure of correct repair.

Diagnosis by Symptom Index

DIAGNOSIS BY SYMPTOM CHART

Engagement Concern: No Forward

DIAGNOSIS PROCEDURE

Engagement Concern: No Reverse

DIAGNOSIS PROCEDURE

Engagement Concern: Harsh Reverse

DIAGNOSIS PROCEDURE

Engagement Concern: Harsh Forward

DIAGNOSIS PROCEDURE

Engagement Concern: Delayed/Soft Reverse

DIAGNOSIS PROCEDURE

Engagement Concern: Delayed/Soft Forward

DIAGNOSIS PROCEDURE

Engagement Concern: No Forward and No Reverse

DIAGNOSIS PROCEDURE

Torque Converter Operation Concerns: No Apply

DIAGNOSIS PROCEDURE

Torque Converter Operation Concern: Cycling/Shudder/Chatter

DIAGNOSIS PROCEDURE

Other Concerns: Shift Lever Efforts High

DIAGNOSIS PROCEDURE

Other Concerns: External Leaks

DIAGNOSIS PROCEDURE

Other Concerns: Noise/Vibration - Forward or Reverse

DIAGNOSIS PROCEDURE

Other Concerns: No Park Range

DIAGNOSIS PROCEDURE

Other Concerns: Transaxle Overheating

DIAGNOSIS PROCEDURE

1. A new torque converter must be installed if one or more of the following statements is true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter stud or studs, impeller hub or bushing are damaged. Discoloration or distortion of cover (due to overheating). Evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes: Major metallic failure. Multiple clutches or clutch plate failures. Sufficient component wear which results in metallic contamination. Internal torque converter contamination present. For additional information refer to «TORQUE CONVERTER CONTAMINATION INSPECTION»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

MATERIAL SPECIFICATION

1. If a new torque converter is not being installed, the following steps must be completed.
2. With the torque converter on a bench, pour a small amount of CVT transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the CVT transmission fluid.
3. Observe the color and odor of the fluid. The CVT transmission fluid should be green or dark green, not brown or black. Odor may indicate an overheating condition such as clutch disc failure.
4. Examine the stain on the tissue for evidence of particles (spec of any kind). If particles are present in the fluid a new torque converter must be installed.
5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter.

MATERIAL SPECIFICATION

Note. This transaxle has a thermal bypass valve located in the high pressure filter case cover. The transmission fluid cooler tubes need to be disconnected from the transmission fluid cooler and the high pressure filter case cover in order to carry out the backflushing and cleaning of the cooler tubes.

1. Disconnect the transmission fluid cooler tubes from the transmission fluid cooler.
2. Disconnect the transmission fluid cooler tubes from the high pressure filter case cover.
3. Clean and flush cooler tubes using clean CVT transmission fluid. If there is a lot of dirt and contaminates, it is acceptable to use mineral spirts to clean the fluid cooler tubes providing they are blown dry with shop air and any residue cleaned out by final flushing with clean CVT transmission fluid.
4. Once the cooler tubes have been cleaned and flushed out, install a new OTA transmission fluid cooler. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cooling-system) .

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

MATERIAL SPECIFICATION

Drain

Note. Install a new high-pressure case filter when changing the transmission fluid. For additional information, refer to HIGH PRESSURE FILTER AND CASE COVER .

Scheme 205

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 fluid pan drain plug and allow the fluid to drain.
3. Install the fluid pan drain plug. Tighten to 25 Nm (18 lb-ft).
4. Fill the transaxle with approximately 4.7 L (5 quarts) of clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

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

MATERIAL SPECIFICATION

Scheme 206

Note. This procedure is designed for checking the fluid level on a vehicle that has just come in off the road with the transmission fluid in the normal operating range 88°C-92°C (190°F-198°F).

Scheme 207

Note. This procedure is for setting correct fluid level and can also be used to check correct fluid level.

Scheme 208

Scheme 209

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.

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

MATERIAL SPECIFICATION

Removal

Note. When carrying out a fluid change interval, the removal of the fluid pan and filter is not required. When carrying out a fluid change interval, the installation of a new high-pressure case filter and seals is required.

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

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 fluid pan drain plug and allow the fluid to drain.
3. Remove the fluid pan bolts and the fluid pan.
4. Remove and discard the fluid pan gasket.
5. Remove and discard the fluid filter. Use a suitable seal pick to remove the seal if it is stuck in the case.
6. Disconnect the transmission fluid cooler tubes from the pressure filter cover.
7. Remove and discard the 4 transmission fluid cooler tube seals.
8. Remove the pressure filter cover.
9. Remove and discard the O-ring seal from the pressure filter cover.
10. Remove the pressure filter feed tube.
11. Remove and discard the O-ring seals from the feed tube.
12. Remove and discard the pressure filter.

Scheme 218

Scheme 219

Scheme 220

1. Install a new pressure filter.
2. Lubricate the new O-ring seals in clean continuously variable transmission (CVT) automatic transmission fluid and install them on the feed tube.
3. Install the pressure filter feed tube.
4. Lubricate the new O-ring seal in clean CVT automatic transmission fluid and install it on the pressure filter cover.
5. Install the pressure filter cover. Tighten to 10 Nm (89 lb-in).
6. Lubricate the 4 new O-ring seals in clean CVT automatic transmission fluid and install them on the fluid cooler tube.
7. Connect the transmission fluid cooler tubes to the pressure filter cover. Tighten to 10 Nm (89 lb-in).
8. Install a new fluid filter and seal assembly.
9. Make sure that the filter is seated over one of the mechatronic bolts.
10. Install a new fluid pan gasket.
11. Install the fluid pan and the bolts. Tighten in the sequence shown. Tighten to 12 Nm (9 lb-ft).
12. Install the fluid pan drain plug. Tighten to 25 Nm (18 lb-ft).
13. Fill the transaxle with approximately 4.7 L (5 quarts) of clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Installer, Output Shaft Seal 307-527 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

Scheme 221

Scheme 222

Scheme 223

MATERIAL SPECIFICATION

Scheme 224

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 the special tools, remove the differential fluid seal.

Scheme 225

Scheme 226

1. Lubricate the new differential fluid seal in clean continuously variable transmission (CVT) automatic transmission fluid and position the differential fluid seal in place.
2. Using the special tool, install the differential fluid seal.
3. Install the LH half shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Handle, Driver 205-153 (T80T-4000-W) Installer, Output Shaft Inner Seal 307-537 Installer, Output Shaft Seal 307-528 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

Scheme 227

Scheme 228

MATERIAL SPECIFICATION

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

1. Remove the 2 driveshaft brace outer bolts.
2. Remove and discard the 6 bolts from the front driveshaft flange.
3. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. Remove and discard the 2 retaining nuts for the front exhaust pipe.
5. Remove and discard the 2 retaining nuts for the rear exhaust pipe.
6. Remove and discard the 2 retaining nuts and disconnect the rubber hanger from the catalytic converter pipe.
7. Remove the upper PTU bracket bolts and the bracket.
8. Remove the 4 PTU bolts and the PTU.
9. Using mechanic's wire, position the rear driveshaft aside.
10. Using the special tools, remove the outer differential fluid seal.
11. Using the special tools, remove the inner differential fluid seal.

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

1. Lubricate the new inner seal in clean continuously variable transmission (CVT) automatic transmission fluid and position the inner seal in place.
2. Using the special tools, install the new inner differential fluid seal.
3. Lubricate the new outer seal in clean CVT automatic transmission fluid and position the outer differential fluid seal in place.
4. Using the special tool, install the outer differential fluid seal.
5. Wipe off any residual grease or contaminants from the PTU splines. Apply a thin, uniform coating of grease to all the PTU spline surfaces before assembly.
6. Position the PTU and the rear driveshaft in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
7. Install the upper PTU bracket and bolts. Tighten to 55 Nm (41 lb-ft).
8. Install 2 new bolts and connect the rubber hanger for the catalytic converter. Tighten to 40 Nm (30 lb-ft).
9. Install 2 new nuts for the rear exhaust pipe. Tighten to 40 Nm (30 lb-ft).
10. Install 2 new nuts for the front exhaust pipe. Tighten to 40 Nm (30 lb-ft).
11. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
12. Install the driveshaft cross brace. Tighten to 30 Nm (22 lb-ft).
13. Using new bolts, install the driveshaft flange. Tighten to 25 Nm (18 lb-ft).
14. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

MATERIAL SPECIFICATION

Scheme 242

Scheme 243

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 Threadlocker to the threads.
2. Position the transaxle mount in place and install the upper bolts. Tighten to 55 Nm (41 lb-ft).
3. Install the rear transaxle mount. Install the bolts. Tighten to 90 Nm (66 lb-ft).

SPECIAL TOOL CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Installer Output Shaft Seal 307-529 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 244

MATERIAL SPECIFICATION

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 245

1. Lubricate the new differential seal in clean continuously variable transmission (CVT) automatic transmission fluid and position the differential fluid seal in place.
2. Using the special tool, install the outer differential fluid seal.
3. Install the half shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Installer, Transfer Gear Dust Cover 307-526 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 246

MATERIAL SPECIFICATION

Scheme 247

Scheme 248

Scheme 249

Scheme 250

1. Remove the 2 outer bolts for the driveshaft brace.
2. Remove and discard the 6 bolts from the front driveshaft flange.
3. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
4. Remove and discard the 2 retaining nuts for the front exhaust pipe.
5. Remove and discard the 2 retaining nuts for the rear exhaust pipe.
6. Remove and discard the 2 retaining nuts and disconnect the rubber hanger from the catalytic converter pipe.
7. Remove the upper PTU bracket bolts and the bracket.
8. Remove the 4 PTU bolts and the PTU.
9. Using mechanic's wire, position the rear driveshaft aside.
10. Remove the exhaust gas recirculation (EGR) tube.
11. Remove the side shaft gear assembly dust cover.
12. Remove the 4 bolts and remove the side shaft gear assembly.
13. Remove and discard the side shaft gear assembly O-ring seal.
14. Inspect the side shaft gear assembly for damage. If damage is indicated, install new components. For additional information, refer to «SIDE SHAFT GEAR ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

Scheme 251

1. Lubricate the new side shaft gear assembly O-ring with clean CVT automatic transmission fluid and install the O-ring onto the side shaft gear assembly.
2. Install the side shaft gear assembly bolts. Tighten to 23 Nm (17 lb-ft).
3. Using the special tool, install the side shaft gear assembly dust cover.
4. Install the EGR tube. Tighten to 40 Nm (30 lb-ft).
5. Wipe off any residual grease or contaminants from the PTU splines. Apply a thin, uniform coating of grease to all of the PTU spline surfaces before assembly.
6. Position the PTU and the rear driveshaft in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
7. Install the upper PTU bracket and bolts. Tighten to 55 Nm (41 lb-ft).
8. Install 2 new bolts and connect the rubber hanger for the catalytic converter. Tighten to 40 Nm (30 lb-ft).
9. Install 2 new nuts for the rear exhaust pipe. Tighten to 40 Nm (30 lb-ft).
10. Install 2 new nuts for the front exhaust pipe. Tighten to 40 Nm (30 lb-ft).
11. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
12. Install the driveshaft cross brace. Tighten to 30 Nm (22 lb-ft).
13. Using new bolts, install the driveshaft flange. Tighten to 30 Nm (22 lb-ft).
14. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Installer, Transfer Gear Dust Cover 307-526 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

MATERIAL 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. Remove the exhaust gas recirculation (EGR) tube.
3. Remove the side shaft gear assembly dust cover.
4. Remove the 4 bolts and remove the side shaft gear assembly.
5. Remove and discard the side shaft gear assembly O-ring seal.
6. Inspect the side shaft gear assembly for damage. If damage is indicated, install new components. For additional information, refer to «SIDE SHAFT GEAR ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

1. Lubricate the new side shaft gear assembly O-ring with clean continuously variable transmission (CVT) automatic transmission fluid and install the O-ring onto the side shaft gear assembly.
2. Install the side shaft gear assembly bolts. Tighten to 23 Nm (17 lb-ft).
3. Using the special tool, install the side shaft gear assembly dust cover.
4. Install the EGR tube. Tighten to 40 Nm (30 lb-ft).
5. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Installer, Shift Shaft Fluid Seal 307-538

MATERIAL SPECIFICATION

Scheme 252

Scheme 253

Scheme 254

1. 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) .
2. Disconnect the shift cable end.
3. Remove the roll pin and the manual lever.
4. Using a suitable pick, remove the selector shaft seal.

Scheme 255

Scheme 256

1. Position the new seal in place.
2. Using the special tool, install a new selector shaft seal.
3. Position the manual lever in place and install the roll pin.
4. Connect the shift cable end.
5. Install the battery tray and battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
6. If required, top off the transaxle with clean continuously variable transaxle (CVT) transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Installer, Forward Clutch Feed Tube Seal 307-539 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent scan tool

MATERIAL SPECIFICATION

Scheme 257

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Scheme 261

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 the mount.
5. Remove and discard the bolts for the primary cover and remove the cover.
6. Remove and discard the primary cover gasket.
7. Remove and discard the O-ring seal from the small feed tube and remove the larger feed tube.
8. Remove and discard the O-ring seals from the feed tube.
9. Remove the retaining clip and the primary cover feed tube.
10. Remove and discard the 2 square cut seals, the O-ring seal and the retaining clip from the primary cover feed tube.

Scheme 262

Scheme 263

1. Lubricate the O-ring seal in clean CVT automatic transmission fluid and install a new seal and a new retaining clip on the feed tube.
2. Install the special tool onto the feed tube.
3. Using the special tool, install 2 new square cut seals.
4. Lubricate the O-ring seal in clean continuously variable transmission (CVT) automatic transmission fluid and install the feed tube into the primary cover and install the clip.
5. Lubricate the O-ring seals in clean CVT automatic transmission fluid and install new O-ring seals on the feed tube.
6. Lubricate the O-ring seals in clean CVT automatic transmission fluid. Install the large feed tube into the case and install a new O-ring seal on the small feed tube.
7. Install a new primary cover gasket.
8. Using new bolts, install the primary cover. Tighten the bolts in the sequence shown in 2 stages: Stage 1: Tighten to 4 Nm (35 lb-in). Stage 2: Tighten an additional 90 degrees.
9. Clean the rear transaxle mount bolts using a wire brush and apply new threadlock to the threads.
10. Position the mount onto the subframe and install the rear transaxle support insulator. Tighten to 55 Nm (41 lb-ft).
11. Install the 2 bolts for the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).
12. If more fluid is needed, remove the fluid fill plug.
13. Fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
14. Install the fluid fill plug. Tighten to 35 Nm (26 lb-ft).

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

MATERIAL SPECIFICATION

Scheme 264

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Scheme 267

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 fluid cooler tube bracket from the transaxle.
3. Disconnect the transmission fluid cooler tubes from the transaxle.
4. Remove and discard the 4 transmission fluid cooler tube seals.
5. Remove only the 3 retainers and carefully position the insulator aside to gain access to the secondary variator cover.
6. Remove and discard the bolts for the secondary cover and remove the cover.
7. Remove and discard the square cut seal from the secondary cover.
8. Remove and discard the seal on the feed tube and the gasket from the secondary cover.

Scheme 268

1. Lubericate the O-ring with clean continuously variable transmission (CVT) automatic transmission fluid and install the O-ring seal on the feed tube and install a new secondary cover gasket.
2. Install a new square cut seal in the secondary cover.
3. Using new bolts, install the secondary cover. Tighten the bolts in sequence in 2 stages: Stage 1: Tighten to 4 Nm (35 lb-in). Stage 2: Tighten an additional 90 degrees.
4. Carefully position the insulator over the retaining pins and install the 3 retainers.
5. Lubricate the 4 new seals in clean CVT automatic transmission fluid and install transmission fluid cooler tube seals.
6. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
7. Install the fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
8. If more fluid is needed, remove the fluid fill plug.
9. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) in this section.
10. Install the fluid fill plug. Tighten to 35 Nm (26 lb-ft).

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

MATERIAL 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. Remove the fluid cooler tube bracket from the transaxle.
3. Disconnect the transmission fluid cooler tubes from the transaxle.
4. Remove and discard the 4 transmission fluid cooler tube seals.
5. Remove the pressure filter cover.
6. Remove and discard the O-ring seal from the pressure filter cover.
7. Remove the pressure filter feed tube.
8. Remove and discard the O-ring seals from the feed tube.
9. Remove and discard the high-pressure case filter.

1. Install a new high-pressure case filter.
2. Lubricate the new O-ring seals with clean continuously variable transmission (CVT) automatic transmission fluid and install them on the feed tube.
3. Install the pressure filter feed tube.
4. Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install it on the pressure filter cover.
5. Install the pressure filter cover. Tighten to 10 Nm (89 lb-in).
6. Lubricate the 4 new transmission fluid cooler tube seals in clean CVT automatic transmission fluid and install them onto the fluid cooler tubes.
7. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
8. Install the fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
9. If more fluid is needed, remove the fluid fill plug.
10. If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
11. Install the fluid fill plug. Tighten to 35 Nm (26 lb-ft).

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

MATERIAL SPECIFICATION

Scheme 269

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Scheme 274

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. Disconnect the transaxle bulk head electrical connector. Rotate the electrical connector counterclockwise to disconnect.
4. Remove the fluid pan drain plug and allow the fluid to drain.
5. Remove the fluid pan bolts and the fluid pan.
6. Remove and discard the fluid pan gasket.
7. Remove and discard the fluid filter. Use a suitable seal pick to remove the seal if it is stuck in the case.
8. Remove the main electrical outer shell bolt.
9. Rotate the outer shell connector in order to release it from the mechatronic electrical connector. Rotate the connector counterclockwise to remove.
10. Remove the electrical connector by lifting it out of the case.
11. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
12. Remove the 8 bolts from the mechatronic unit.
13. Remove the mechatronic unit from the transaxle.
14. Remove all of the 5 feed tubes. Remove the clutch (manual valve) supply feed tube. Remove the primary pressure feed tube. Remove the secondary pressure feed tube. Remove the main (pump) pressure feed tube (smaller tube). Remove and discard the torque converter clutch pressure feed tube.
15. Remove and discard all of the seals on the feed tubes. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube. Remove and discard the O-ring seals from the primary pressure feed tube. Remove and discard the O-ring seals from the secondary pressure feed tube. Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube). Discard the torque converter clutch pressure feed tube.

Scheme 275

Scheme 276

Scheme 277

Scheme 278

1. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the feed tubes. Align the inner tube and install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube. Install new O-ring seals on the primary pressure feed tube. Install new O-ring seals on the secondary pressure feed tube. Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).
2. Lubricate the O-ring seals with clean CVT automatic transmission fluid and install all of the feed tubes into the case. Align the inner tube and install the clutch (manual valve) supply feed tube. Install the primary pressure feed tube. Install the secondary pressure feed tube. Install the main (pump) pressure feed tube (smaller tube). Install a new torque converter clutch pressure feed tube.
3. Position the mechatronic unit onto the case.
4. Tighten the mechatronic bolts in sequence in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten an additional 40 degrees (1/8 turn).
5. Install the electrical connector into the case.
6. Rotate the outer shell connector in place and install the bolt. Tighten to 6 Nm (53 lb-in).
7. Connect the electrical connectors.
8. Install a new fluid filter and seal assembly.
9. Make sure that the filter is seated over one of the mechatronic bolts.
10. Install a new fluid pan gasket.
11. Install the fluid pan and the bolts. Tighten in the sequence shown. Tighten to 12 Nm (9 lb-ft).
12. Install the fluid pan drain plug. Tighten to 25 Nm (18 lb-ft).
13. Connect the transaxle bulk head electrical connector.
14. Fill the transaxle with approximately 4.7 L (5 quarts) of clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) in this section.
15. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

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

MATERIAL 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. 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 fluid pan drain plug and allow the fluid to drain.
4. Remove the fluid pan bolts and the fluid pan.
5. Remove and discard the fluid pan gasket.
6. Remove and discard the fluid filter. Use a suitable seal pick to remove the seal if it is stuck in the case.
7. Depress the tab on the electrical connector and pull up on the output shaft speed (OSS) connector to disconnect.
8. Remove the OSS sensor bolt, sensor and spacer.

Scheme 279

Scheme 280

1. Install the OSS sensor spacer, sensor and bolt. Tighten to 8 Nm (71 lb-in).
2. Connect the electrical connectors.
3. Install a new fluid filter.
4. Make sure that the filter is seated over one of the mechatronic bolts.
5. Install a new fluid pan gasket.
6. Install the fluid pan and the bolts. Tighten in the sequence shown. Tighten to 12 Nm (9 lb-ft).
7. Install the fluid pan drain plug. Tighten to 25 Nm (18 lb-ft).
8. Fill the transaxle with approximately 4.7 L (5 quarts) of clean continuously variable transmission (CVT) automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL 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 303-290A 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

Scheme 281

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Scheme 338

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Scheme 340

Scheme 341

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 remove the roll restrictor brace.
7. Disconnect the shift cable end.
8. Remove the electrical connector from the shift cable bracket.
9. Remove the 2 bolts for the shift cable bracket and position the cable and bracket aside.
10. Disconnect the wire harness from the transaxle.
11. If equipped, remove the auxiliary coolant flow pump assembly. Disconnect the electrical connector. Remove the bolts and position the pump assembly aside.
12. Disconnect the lower wire harness from the transaxle.
13. Remove the 4 bolts for the roll restrictor bracket and remove the bracket.
14. Disconnect the wire harness from the roll restrictor, remove the 2 bolts and remove 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 it 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 remove the starter.
21. Remove the fluid cooler tube bracket from the transaxle.
22. Disconnect the ground wire.
23. Disconnect the transaxle bulk head electrical connector. Rotate the electrical connector counterclockwise to disconnect.
24. Disconnect the wire harness from the transaxle.
25. Remove the 4 upper transaxle bolts.
26. If a transaxle exchange or overhaul is required, the transmission fluid must be drained. Remove the drain plug and allow the fluid to drain.
27. 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)
28. If removed, install the drain plug. Tighten to 25 Nm (18 lb-ft).
29. Remove and discard the 2 nuts for the front exhaust pipe.
30. Remove and discard the 2 nuts for the rear exhaust pipe.
31. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
32. Remove the 2 outer bolts for the driveshaft brace.
33. Remove and discard the 6 bolts from the front driveshaft flange.
34. Remove the upper PTU bracket bolts and the bracket.
35. Remove the 4 bolts for the PTU and remove the PTU.
36. Using mechanic's wire, position the rear driveshaft aside.
37. If equipped, disconnect the engine block heater electrical connector.
38. Position the heat shield for the knock sensor aside.
39. Remove the bolt and remove the knock sensor.
40. Disconnect the knock sensor wire harness from the transaxle.
41. Remove the transaxle-to-engine bolt.
42. Remove the bolt for the power steering hose.
43. Install the lower half of the lifting hook.
44. Install the upper half of the lifting hook.
45. Disconnect the vapor tube from the canister purge valve.
46. Remove the bolt for the power steering hose.
47. Install the special tool to the RH cylinder head.
48. Remove and discard the 2 bolts for the catalytic converter.
49. Install the special tool to the LH cylinder head.
50. Install the special tools to support the engine assembly.
51. Install the special tools to the LH (front) cylinder head.
52. Install the special tools to the RH (rear) cylinder head.
53. Install the special tools into the lifting hook near the EGR valve.
54. Disconnect the lower radiator hose from the retainers and position the hose aside.
55. Remove the 4 bolts that hold the power steering line to the subframe.
56. Disconnect the wire harness from the LH front of the subframe.
57. Remove the bolts and nuts for the power steering rack. Use mechanic's wire to hold the power steering rack and up to the side.
58. Disconnect the HO2S electrical connector from the subframe.
59. Disconnect the 3 push pins and position the splash shield aside.
60. Remove the nut for the front motor mount.
61. Remove the 2 bolts for the lower stabilizer mount.
62. Remove the nut for the rear motor mount.
63. Remove the bolts for the rear transaxle mount.
64. Remove the 2 bolts for the LH rear subframe mount.
65. Remove the 2 bolts for the RH rear subframe mount.
66. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
67. Using a suitable powertrain lift, remove the 4 subframe bolts and remove the subframe.
68. Disconnect the HO2S electrical connector.
69. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
70. Remove the pin and remove the rubber access plug.
71. Remove and discard the 4 torque converter nuts.
72. Disconnect the transmission fluid cooler tubes from the transaxle.
73. Remove and discard the 4 transmission fluid cooler tube seals.
74. Remove the transmission fluid cooler tube bracket bolts.
75. Position a suitable high-lift transmission jack under the transmission.
76. Remove the 3 transaxle-to-engine bolts.
77. Remove the transaxle from under the car.
78. If the transaxle is to be overhauled or if installing a new transaxle, 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) .
79. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission 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-transmission-cvt) .
80. If removing the transaxle for something other than a transaxle related repair, inspect the differential seals for damage or leaking. If leaking or damage is indicated install new differential seals. For additional information, refer to «DIFFERENTIAL SEALS - LH»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) , «DIFFERENTIAL SEALS - RH, ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «DIFFERENTIAL SEALS - RH, FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
81. If installing a new transaxle, remove the bolts and remove the rear transaxle support insulator.
82. If installing a new transaxle, remove and discard the 4 retainers and remove the transaxle insulator.
83. If installing a new transaxle, remove the bolt and remove the fluid level indicator and tube.

SPECIAL TOOL 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 303-290A 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

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 roll restrictor brace.
7. Disconnect the shift cable end.
8. Remove the electrical connector from the shift cable bracket.
9. Remove the 2 bolts for the shift cable bracket and position the cable and bracket aside.
10. Disconnect the wire harness from the transaxle.
11. If equipped, remove the auxiliary coolant flow pump assembly. Disconnect the electrical connector. Remove the bolts and position the pump assembly aside.
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, remove the 2 bolts and remove 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 remove the starter.
21. Remove the fluid cooler tube bracket from the transaxle.
22. Disconnect the ground wire.
23. Disconnect the transaxle bulk head electrical connector. Rotate the electrical connector counterclockwise to disconnect.
24. Disconnect the wire harness from the transaxle.
25. Remove the 4 upper transaxle bolts.
26. If a transaxle exchange or overhaul is required, the transmission fluid must be drained. Remove the drain plug and allow the fluid to drain.
27. 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) .
28. If removed, install the drain plug. Tighten to 25 Nm (18 lb-ft).
29. Remove and discard the 2 nuts for the front exhaust pipe.
30. Remove and discard the 2 nuts for the rear exhaust pipe.
31. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
32. If equipped, disconnect the engine block heater electrical connector.
33. Position the heat shield for the knock sensor aside.
34. Remove the bolt and remove the knock sensor.
35. Disconnect the knock sensor wire harness from the transaxle.
36. Remove the transaxle-to-engine bolt.
37. Remove the bolt for the power steering hose.
38. Install the lower half of the lifting hook.
39. Install the upper half of the lifting hook.
40. Disconnect the vapor tube from the canister purge valve.
41. Remove the bolt for the power steering hose.
42. Install the special tool to the RH cylinder head.
43. Remove and discard the 2 bolts for the catalytic converter.
44. Install the special tool to the LH cylinder head.
45. Install the special tools to support the engine assembly.
46. Install the special tools to the LH (front) cylinder head.
47. Install the special tools to the RH (rear) cylinder head.
48. Install the special tools into the lifting hook near the EGR valve.
49. Disconnect the lower radiator hose from the retainers and position the hose aside.
50. Remove the 4 bolts that hold the power steering line to the subframe.
51. Disconnect the wire harness from the LH front of the subframe.
52. Remove the bolts and nuts for the power steering rack. Use mechanic's wire to hold the power steering rack up to the side.
53. Disconnect the HO2S electrical connector from the subframe.
54. Disconnect the 3 push pins and position the splash shield aside.
55. Remove the nut for the front motor mount.
56. Remove the 2 bolts for the lower stabilizer mount.
57. Remove the nut for the rear motor mount.
58. Remove the bolts for the rear transaxle mount.
59. Remove the 2 bolts for the LH rear subframe mount.
60. Remove the 2 bolts for the RH rear subframe mount.
61. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
62. Using a suitable powertrain lift, remove the 4 subframe bolts and remove the subframe.
63. Disconnect the HO2S electrical connector.
64. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
65. Remove the 2 push pins and remove the rubber access plug.
66. Remove and discard the 4 torque converter nuts.
67. Disconnect the transmission fluid cooler tubes from the transaxle.
68. Remove and discard the 4 transmission fluid cooler tube seals.
69. Remove the transmission fluid cooler tube bracket bolts.
70. Position a suitable high-lift transmission jack under the transaxle.
71. Remove the 3 transaxle-to-engine bolts.
72. Remove the transaxle from under the vehicle.
73. If the transaxle is to be overhauled or if installing a new transaxle, 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) .
74. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission 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-transmission-cvt) .
75. If removing the transaxle for something other than a transaxle related repair, inspect the differential seals for damage or leaking. If leaking or damage is indicated install new differential seals. For additional information, refer to «DIFFERENTIAL SEALS - LH»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) , «DIFFERENTIAL SEALS - RH, ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «DIFFERENTIAL SEALS - RH, FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
76. If installing a new transaxle, remove the bolts and remove the rear transaxle support insulator.
77. If installing a new transaxle, remove and discard the 4 retainers and remove the transaxle insulator.
78. If installing a new transaxle, remove the bolt and remove the fluid level indicator and tube.

SPECIAL TOOL CHART Handle, Torque Converter 307-091 (T81P-7902-C) Holding Fixture, Transmission 307-003 (T57L-500-B) Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9) Variator Socket 307-545

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1. Remove and discard the 4 retainers and remove the transaxle insulator.
2. Remove the bolts and remove the rear transaxle mount.
3. Remove the bolt and remove the fluid level indicator and tube.
4. Remove the fluid level indicator tube grommet.
5. Using the special tool, remove the torque converter.
6. Make an identifying mark on the torque converter where the pump pilot is located for correct installation.
7. Install the special tool onto the transaxle case. Tighten to 55 Nm (41 lb-ft).
8. Position the transaxle into the bench fixture.
9. Remove the side shaft gear assembly bolts.
10. Remove the side shaft gear assembly from the case.
11. Remove the transaxle fluid pan.
12. Remove and discard the transaxle fluid pan gasket.
13. Remove and discard the fluid filter. Use a suitable seal pick to remove the seal if it is stuck in the case.
14. Remove the main electrical outer shell bolt.
15. Rotate the outer shell connector in order to release it from the mechatronic electrical connector. Rotate the connector counterclockwise to remove.
16. Remove the electrical connector by lifting it out of the case.
17. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
18. Remove the OSS sensor bolt, sensor and spacer.
19. Remove the 8 bolts from the mechatronic unit.
20. Remove the mechatronic unit from the transaxle.
21. Remove all of the 5 feed tubes. Remove the clutch (manual valve) supply feed tube. Remove the primary pressure feed tube. Remove the secondary pressure feed tube. Remove the main (pump) pressure feed tube (smaller tube). Remove and discard the torque converter clutch pressure feed tube.
22. Remove and discard all of the seals on the feed tubes. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube. Remove and discard the O-ring seals from the primary pressure feed tube. Remove and discard the O-ring seals from the secondary pressure feed tube. Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube). Discard the torque converter clutch pressure feed tube.
23. Remove and discard the 26 retaining bolts for the transaxle converter housing.
24. Remove the converter housing. It will be necessary to pry the case halves apart.
25. Remove and discard the converter housing gasket.
26. Remove the differential assembly.
27. Remove the input shaft. Remove and discard the planet carrier thrust washer.
28. Remove and discard the O-ring seals and the split ring seal.
29. Remove the upper input shaft roller bearing.
30. Remove the upper input shaft roller bearing washer.
31. Remove the input shaft roller bearing.
32. Remove the fluid baffle screws and the baffle.
33. Remove the chain lube feed tube retainer screws and the retainer.
34. Remove the chain lube feed tube.
35. Remove and discard the feed tube O-ring seal.
36. Remove the 2 bolts and the manual lever detent spring.
37. Remove the 2 bolts for the range selector valve assembly and remove the valve assembly.
38. Remove and discard the sun gear retaining ring.
39. Remove the sun gear and bearing spacer.
40. Inspect the sun gear and spacer for damage. If damage is indicated, install a new sun gear and spacer.
41. Remove the forward clutch assembly.
42. Using a magnet and a small screwdriver, remove and discard the guide pin retaining ring.
43. Using a magnet, remove the guide pin retaining ring washer.
44. Install the special tool onto the variators.
45. Secure the special tool with a strap.
46. Remove the special tool.
47. Remove the end portion of the transmission holding fixture tool that fits into the bench fixture. Install the end portion onto the variator holding fixture so it can be mounted into the bench fixture.
48. Install the transaxle case half and the variator assembly into the bench fixture. Remove the strap.
49. Remove and discard the bolts for the primary cover and remove the cover.
50. Remove and discard the primary cover gasket.
51. Remove and discard the O-ring seal from the feed tube and the square cut seal.
52. Remove the feed tube from the case.
53. Remove and discard the bolts for the secondary cover and remove the cover.
54. Remove and discard the seal on the secondary feed tube and the gasket from the case.
55. Remove and discard the secondary feed tube snap ring.
56. Remove the pressure filter cover.
57. Remove the pressure filter feed tube.
58. Remove and discard the O-ring seals from the feed tube.
59. Remove and discard the pressure filter.
60. Using the special tool, remove and discard the primary variator nut.
61. Using the special tool, remove and discard the secondary variator nut.
62. Install the special tools.
63. Using the special tools, lift the transaxle case up off the variator assembly.
64. For the cleaning and inspection of the variators, refer to «VARIATOR/CHAIN AND SPUR GEAR ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Puller, Bearing 205-D064 (D84L-1123-A) or equivalent Installer, Transfer Gear Dust Cover 307-526

Scheme 375

MATERIAL SPECIFICATION

Disassembly

Note. Note the side gear assembly is model-dependent, depending on gear ratio.

If there is excessive contamination present, this entire procedure will need to be carried out.

Inspect the side shaft gear assembly for damage. If no damage is indicated the installation of a new O-ring seal and dust cover only will be required.

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1. Inspect the side shaft gear assembly for damage (chipped teeth, worn bearing or contamination). If no damage or contamination is indicated the installation of a new O-ring seal and dust cover will only be required.
2. Remove and discard the side gear assembly O-ring seal.
3. Remove and discard the rubber dust cover.
4. If required, remove and discard the snap ring.
5. If required, using the special tool, press the gear from the bearing.
6. The cover, bearing and retaining snap ring are only serviced as an assembly.

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1. If removed, press the gear assembly into the cover.
2. If removed, install a new snap ring.
3. Using the special tool, install a new rubber dust cover.
4. Install a new side gear assembly O-ring seal.

SPECIAL TOOL CHART Slide Hammer 307-005 (T59L-100-B) Remover, Input Shaft Oil Seal 308-375 Handle, Driver 205-153 (T80T-4000-W) Installer, Output Shaft Inner Seal 307-537

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1. Clean and inspect the differential bearings, if damage or wear is indicated or the bearings show signs of contamination, install a new differential assembly. If installing a new differential assembly, new bearing races will need to be installed in the transaxle case. Inspect the bearings on the differential assembly, if damage is indicated install a new differential assembly.
2. Inspect the ring gear for damage. If the ring gear is damaged remove the bolts and the ring gear.
3. For all wheel drive (AWD) vehicles, use the special tools to remove the inner seal.

Scheme 384

1. For AWD vehicles, use the special tools to install the new seal.
2. If the ring gear was removed, install a new ring gear, tighten in 2 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten an additional 45 degrees.

SPECIAL TOOL CHART Piston Spring Compressor 307-525

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MATERIAL SPECIFICATION

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1. Remove the forward clutch pack snap ring.
2. Remove the forward clutch plates: pressure plate, steel plates, friction plates and wave spring.
3. Using the special tool, remove and discard the forward clutch piston retaining ring.
4. Remove the piston cover.
5. Remove the return spring.
6. Remove the piston.
7. Remove and discard the inner and outer piston seals.
8. Remove and discard the clutch housing seal.

Assembly

Note. Soak all of the new clutch plates in clean continuously variable transaxle (CVT) transmission fluid.

Note. To correctly select the selective snap ring, the forward clutch assembly will need to be assembled incorrectly.

Note. The forward clutch is not completely assembled in this procedure. The remaining assembly of the forward clutch is carried out in the assembly of the transaxle.

1. Install a new housing seal.
2. Install a new inner and outer piston seal.
3. Lubricate the new seals in clean CVT transmission fluid and install the piston.
4. Install the return spring.
5. Install the piston cover.
6. Position the piston retaining ring in place prior to installing the special tool. Using the special tool, install a new piston retaining ring.

MATERIAL SPECIFICATION

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1. Remove the bolts for the transaxle range sensor and remove it from the valve.
2. Remove and inspect the manual control valve.

Scheme 397

1. Install the manual control valve into the housing and connect the transaxle range sensor. Make sure that the tab on the manual valve is correctly seated into the transaxle range sensor. Tighten to 5 Nm (44 lb-in).

SPECIAL TOOL CHART Installer, Forward Clutch Feed Tube Seal 307-539

MATERIAL SPECIFICATION

Scheme 398

1. Install a new O-ring seal and a new retaining clip on the forward clutch feed tube.
2. Install the special tool onto the forward clutch feed tube.
3. Using the special tool, install 2 new square cut seals.
4. Lubricate the O-ring seals in clean continuously variable transaxle (CVT) transmission fluid, install the forward clutch feed tube into the primary cover and install the retaining clip.
5. Install a new primary variator cover feed tube with bonded seals.
6. Install a new square cut seal on the secondary cover.

Disassembly and Assembly

1. Remove and discard the O-ring seal from the pressure filter case cover.
2. Remove the pressure relief valve retaining clip.
3. Slightly press down on the relief cover so the cover will come up and can be removed.
4. Remove the pressure relief valve cover, relief valve and spring.
5. Clean and flush all parts. Blow dry all components.
6. To assemble, reverse the disassembly procedure.

SPECIAL TOOL CHART Slide Hammer 100-001 (T50T-100-A) Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) Remover, Output Shaft Seal/Housing 307-460 Remover and Installer, Stator Needle Bearing 307-540 (includes 307-540/1 and 307-540/2) Piston Spring Compressor 307-525 Remover, Differential Bearing Race 307-532

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1. Remove the lube tube bolt and remove the secondary shaft and stator needle bearing lube tube from the case.
2. Remove the bolt from the lube tube and discard both the sealing washers.
3. Remove and discard the O-ring seals from the lube tube.
4. If required, remove the secondary variator shaft roller bearing cage from the outer race.
5. If required, use the special tool and remove the roller bearing race.
6. If required, remove the side shaft gear roller bearing cage from the outer race.
7. Using the special tools, remove the bearing race.
8. Using a center punch, knock out the differential seal.
9. Install the special tool.
10. The selective shim and bearing race will be installed in the case during assembly of the transaxle after differential set up is completed. From the other side of the case, use a brass punch and knock out the bearing race.
11. Remove the reverse clutch plate snap ring.
12. Remove the reverse clutch ring gear and the friction plates, steel plates, separator plate and wave spring.
13. Using the special tool, remove the return spring retainers.
14. Remove the return spring.
15. Remove the reverse clutch piston. Apply a small amount of air pressure. Remove the reverse clutch piston.
16. Remove and discard the reverse clutch piston inner and outer O-ring seals.
17. Clean and inspect all the reverse clutch parts and install new as required.
18. Remove and discard the roller bearing cage assembly from the outer race.
19. Using the special tools, remove and discard the roller bearing race.
20. Remove the 7 bolts from the stator.
21. From the opposite side of the case, use a dead blow hammer and tap the stator assembly out of the case.
22. Inspect the stator assembly for damage, if damage is indicated install new components.
23. Remove the 3 pump dust cover bolts and remove and discard the cover.
24. Remove the 8 bolts and the pump assembly.
25. Remove the pump gasket and the feed tube.
26. Remove and discard the O-ring seals from the ends of the feed tube.
27. Using a suitable tool, remove the pump/torque converter seal.

SPECIAL TOOL CHART Remover, Differential Bearing Race 307-532 Step Plate 205-D017 (D80L-630-6) or equivalent Step Plate 205-D018 (D80L-630-7) or equivalent

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1. Remove and discard the O-ring seal from the feed tube.
2. Remove the secondary variator feed tube from the case.
3. Remove and discard the O-ring seal from the secondary feed tube.
4. Remove the manual valve assembly feed tube.
5. Remove and discard the O-ring seals from the manual valve feed tube.
6. If necessary, remove the park rod assembly. Hold the park pawl back. Lift the park rod away from the park pawl. Slide the park rod and manual lever out of the case.
7. If necessary, use a magnet to remove the guide pin for the park pawl.
8. If necessary, remove the park pawl and the park pawl spring.
9. If the park system has been removed, remove the primary variator bearing cover plate.
10. If the park system has been removed, remove the primary variator feed tube from the case.
11. If the park system has been removed, remove and discard the O-ring seal for the primary variator feed tube.
12. If the park system has not been removed and the installation of a new bearing is required, remove the primary variator bearing cover plate.
13. Remove the secondary variator bearing cover plate.
14. Using the special tool and a press, remove the primary variator bearing.
15. Using the special tool and a press, remove the secondary variator bearing.
16. Using a punch, remove the differential seal.
17. Install the special tool just under the bearing race.
18. Using a brass punch and the special tool, remove the bearing race.
19. Remove the roll pin and remove the manual control lever.
20. Remove the manual control lever shaft seal.
21. Clean and inspect the case assembly for damage, if any damage is indicated install new parts as necessary.

SPECIAL TOOL CHART Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547/1 and 307-547/5) Compressor, Secondary Variator 307-564 Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C) Puller, Bearing 205-D064 (D84L-1123-A) or equivalent Plate, Bearing/Oil Seal 205-090 (T75L-1165-B) Installer, Second Gear Bushing 308-580

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1. Using the special tool, open the secondary variator in order to remove the chain guides, primary variator and chain. Tighten to 7 Nm (62 lb-in).
2. Remove both chain guides.
3. Lift the primary variator up and move it over (toward the secondary variator on the special tool) in order to remove the chain and the primary variator.
4. With the chain resting on the special tool, carefully remove the primary variator.
5. Carefully remove the chain.
6. Do not hold the chain in a manner that will allow it to rub against itself.
7. For horizontal handling, always handle the chain with 2 hands, never allow either end to sag to one side.
8. It is acceptable to hold the chain in one hand and allow the chain to hang vertically from that hand.
9. Slowly release the special tool and remove it.
10. Remove the secondary variator assembly from the special tool.
11. Inspect the primary and secondary variator chain mating surfaces for nicks and gouges. Inspect the variator chain for damage. If any damage is indicated, the installation of all 3 variator components will be required.
12. Remove and discard the snap ring.
13. Using the special tools, remove the spur gear.

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1. Using the special tool, install the spur gear onto the variator assembly.
2. If removed, press the gear onto the variator assembly and install the snap ring.
3. Install the secondary variator assembly into the special tool.
4. Install the special tool and open up the secondary variator assembly. Tighten to 7 Nm (62 lb-in).
5. Position the variator chain in place.
6. Position the primary variator on the special tool.
7. Carefully position the chain around the primary variator.
8. Once the chain is around the primary variator, lift up slightly and slide the variator over until it drops into the holding fixture.
9. Install both chain guides.
10. Remove the special tool.

SPECIAL TOOL CHART Drawbar (Heavy Duty Threaded) 204-029 (T77F-1176-A) Installer, Differential Bearing Race 307-530 Installer, Differential Bearing Race 307-531 Pilot, Transfer Gear Roller Bearing 307-541 Installer, Primary Variator Bearing 307-563 Installer, Secondary Variator Bearing 307-536 Installer, Shift Shaft Fluid Seal 307-538

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MATERIAL SPECIFICATION

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1. Position the differential bearing race in place.
2. Install the special tools.
3. Install the remaining tools from the other side of the case. Using the special tool, install the bearing race.
4. Position the secondary variator bearing in place (sealed bearing).
5. Install the special tool.
6. From the other side of the case assemble the remaining tools.
7. Using the special tools, install the secondary bearing.
8. Position the primary variator bearing in place (roller type bearing).
9. Install the special tool.
10. From the other side of the case, assemble the remaining special tools.
11. Using the special tools, install the primary bearing.
12. Install the secondary bearing cover plate and the bolts. Tighten the bolts in a crisscross pattern. Tighten to 10 Nm (89 lb-in).
13. If the park system components have not been removed then install the primary bearing cover plate at this time. Tighten the bolts in a crisscross pattern. Tighten to 10 Nm (89 lb-in).
14. If removed, install the primary variator feed tube into the case.
15. If the primary variator feed tube was removed, install the primary bearing cover plate and the bolts. Tighten the bolts in a crisscross pattern. Tighten to 10 Nm (89 lb-in).
16. If removed, install the park pawl.
17. If removed, install the park pawl spring and guide pin.
18. If removed, install the manual lever and park rod in the case. Install the manual lever and park rod into the case. Hold the park pawl back. Position the park rod into the case.
19. Lubricate the new O-ring seal with clean continuously variable transmission (CVT) automatic transmission fluid and install the O-ring seal on the primary variator feed tube.
20. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals onto the manual valve feed tube.
21. Install the manual valve feed tube in the case.
22. Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install the O-ring seal on the secondary feed tube.
23. Install the secondary feed tube.
24. From the opposite side of the case, install a new C-clip on the secondary feed tube.
25. Position the new manual control lever seal in place.
26. Using the special tool, install the manual control lever seal.
27. Install the manual control lever and the roll pin.

SPECIAL TOOL CHART Dial Indicator With Bracketry 100-002 (TOOL-4201-C) Handle, Driver 205-153 (T80T-4000-W) Aligner, Transaxle Pump 307-544 (includes 307-544/1, 307-544/2, 307-544/3 and 307-544/4A) Installer, Front Pump Seal 307-524 Installer, Transfer Gear Roller Bearing 307-535 Installer, Pump Cover 307-542 Piston Spring Compressor 307-525 Remover and Installer, Stator Needle Bearing 307-540 (includes 307-540/1 and 307-540/2) Alignment Pins, Transmission Main Control Body 307-127 (T94P-77000-P) Installer, Secondary Variator Bearing 307-536

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MATERIAL SPECIFICATION

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1. Inspect the pump for contamination, if contamination is present a new pump must be installed. The new pump assembly comes with a new seal. The seal will need to be removed and discarded in order to align and install the pump into the case. Install the special tool into a soft-jawed vice.
2. Set the pump assembly onto the special tool to correctly align the pump.
3. Install the special tool into the center of the special tool to keep the pump centered.
4. Install the special tool onto the top of the pump.
5. Install the pump gasket. Note the location of the bleed slots in the gasket.
6. Install the special tools. Note the location of the bleed slot in the gasket.
7. Lubricate the new O-ring seals with clean continuously variable transaxle (CVT) transmission fluid and install the O-ring seals onto the feed tube.
8. Install the feed tube into the pump cover.
9. Using the special tool, install the stator support.
10. Install the remaining bolts. Tighten the bolts in a crisscross pattern. Tighten to 14 Nm (10 lb-ft).
11. Using the special tool, install the stator support bearing.
12. From the opposite side of the case, install the pump assembly into the transaxle case.
13. Loosely install the pump bolts.
14. Remove the special tools and loosely install the remaining bolts.
15. Tighten in the sequence shown. Tighten to 16 Nm (12 lb-ft).
16. Remove the special tool.
17. Remove the special tool.
18. Using the special tool, install a new pump seal.
19. Position the pump dust cover in place.
20. Install the special tools.
21. Using the special tools, install the pump dust cover.
22. Install the bolts. Tighten to 10 Nm (89 lb-in).
23. Install new inner and outer O-ring seals.
24. Install the reverse clutch piston.
25. Install the return spring.
26. Using the special tool, install the return spring retainers.
27. Install a steel plate, a friction plate, a second steel plate, a second friction plate, a third steel plate, a third friction plate and the pressure plate.
28. Install the reverse clutch plate snap ring.
29. Install the special tool. Zero out the special tool.
30. Using compressed air, apply air to the case so the clutch plates contact the reverse clutch snap ring and record the measurement. Enter this measurement in the following table on the line labeled A. Repeat this step 3 times and take the average of the 3 readings.
31. Select the selective snap ring. SNAP RING SPECIFICATION Description Reading A B + 0.54 mm (0.02 in) C - 1.50 mm (0.059 in) (D) Clearance Add line A to B, then subtract line C and enter this total on line D. Line D is the actual clearance of the snap ring used during this measurement. If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.
32. Remove the reverse clutch pack snap ring. REVERSE CLUTCH SELECTIVE SNAP RING SPECIFICATION Part Number Snap Ring Thickness 7H365 2.00 mm (0.07 in) 7H365 1.80 mm (0.07 in) 7H365 1.60 mm (0.06 in) 7H365 1.40 mm (0.05 in) 7H365 1.20 mm (0.04 in) 7H365 1.00 mm (0.03 in)
33. Remove the reverse clutch plates, steel and friction.
34. Install the reverse clutch wave spring.
35. Install the ring gear assembly.
36. Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
37. Install the reverse clutch pressure plate.
38. Install the reverse clutch pack snap ring.
39. Inspect the bearing race and shim for damage. If damage is indicated install a new race. If new differential bearing is installed, a new bearing race should also be installed.
40. Using the special tools, install the roller bearing and race as an assembly.
41. Using the special tools, install the roller bearing and race as an assembly.
42. Lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals onto the secondary shaft and stator needle bearing lube tube.
43. Using new sealing washers, install the bolt onto the lube tube.
44. Lubricate the O-ring seals with clean CVT transmission fluid and install the secondary shaft and stator needle bearing lube tube into the case. Tighten to 10 Nm (89 lb-in).

SPECIAL TOOL CHART Handle, Torque Converter 307-091 (T81P-7902-C) Installer, Front Pump Seal 307-524

Scheme 504

1. Remove the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
2. Using the special tool, remove the torque converter.
3. Make an identifying mark on the torque converter, where the pump pilot is located, for correct installation.
4. Using a suitable tool, remove the torque converter seal.
5. Using the special tool, install a new pump seal.
6. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
7. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
8. Install the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Handle, Torque Converter 307-091 (T81P-7902-C) Installer, Pump Cover 307-542 Alignment Pins, Transmission Main Control Body 307-127 (T94P-77000-P)

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Scheme 506

1. Remove the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
2. Using the special tool, remove the torque converter.
3. Make an identifying mark on the torque converter, where the pump pilot is located, for correct installation.
4. Remove the 3 bolts.
5. Using a suitable tool, remove the pump cover seal.
6. Position the new pump cover seal in place and install the special tools.
7. Using the special tools, seat the pump cover in place.
8. Install the 3 bolts. Tighten to 10 Nm (89 lb-in).
9. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
10. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
11. Install the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Handle, Torque Converter 307-091 (T81P-7902-C)

1. Remove the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
2. Using the special tool, remove the torque converter.
3. Make an identifying mark on the new torque converter, where the pump pilot is located, for correct installation.
4. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
5. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
6. Install the transaxle. For additional information, refer to «TRANSAXLE - ALL WHEEL DRIVE (AWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «TRANSAXLE - FRONT WHEEL DRIVE (FWD)»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

SPECIAL TOOL CHART Dial Indicator With Bracketry 100-002 (TOOL-4201-C) Handle, Torque Converter 307-091 (T81P-7902-C) Holding Fixture, Transmission 307-003 (T57L-500-B) Drawbar (Heavy Duty Threaded) 204-029 (T77F-1176-A) Shim Selection Set (Bolts) 308-161 (T88C-77000-C) Shim Selection Set (Legs) 308-164 (T88C-77000-JF) Installer, Output Shaft Seal 307-527 Installer, Output Shaft Seal 307-528 Installer, Differential Bearing Cup 307-530 (includes 307-530-1 and 307-530-2) Variator Socket 307-545 Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9) Differential Preload Set-Up Tool 307-533 Stack Up Gauge 307-534 Installer, C-Clip 307-565

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MATERIAL SPECIFICATION

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1. Position the transaxle case onto the variators.
2. Install the spacer washer to the special tool.
3. Assembly the remaining components of the special tool.
4. Install the special tools on the top of the case in the position shown.
5. Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.
6. Press the transaxle case down onto the variator assembly. Hold the transaxle case level. Turn the secondary forcing screw 2 complete turns. Turn both forcing screws at the same time evenly until the case just contacts the variators.
7. Install a new primary nut.
8. Install a new secondary nut.
9. Make sure that the manual control lever is in the PARK position.
10. Using the special tools, tighten the primary variator nut in 2 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 500 Nm (369 lb-ft).
11. Using the special tools, tighten the secondary variator nut in 2 stages. Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten to 150 Nm (111 lb-ft).
12. Lubricate the new O-ring seals with clean continuously variable transmission (CVT) automatic transmission fluid and install the O-ring seals on the primary cover feed tube.
13. Install the primary cover feed tube into the case.
14. Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install a new square cut seal and the O-ring seal.
15. Install a new primary cover gasket.
16. Using new bolts, install the primary cover and tighten in the sequence shown in 2 stages: Stage 1: Tighten to 4 Nm (35 lb-in). Stage 2: Tighten an additional 90 degrees.
17. Lubricate the new O-ring with clean automatic transmission fluid and install the O-ring seal on the feed tube. Install a new secondary cover gasket.
18. If not previously done, install a new square cut seal in the secondary cover.
19. Using new bolts, install the secondary cover and tighten in the sequence shown in 2 stages: Stage 1: Tighten to 4 Nm (35 lb-in). Stage 2: Tighten an additional 90 degrees.
20. Install a new pressure filter.
21. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the pressure filter feed tube.
22. Install the pressure filter feed tube.
23. Install the pressure filter case cover. Tighten to 10 Nm (89 lb-in).
24. Install the safety strap on the transaxle.
25. Install the special tool onto the transaxle case. Tighten to 55 Nm (41 lb-ft).
26. Using a magnet, carefully install the guide pin retaining ring plate.
27. Install the C-clip onto the special tool.
28. Using the special tool, install the guide pin retaining ring.
29. If not previously done, lubricate the new seals with clean CVT automatic transmission fluid and install the O-ring seals in the case.
30. Loosely install the range selector valve assembly.
31. Install the bolts. Tighten to 5 Nm (44 lb-in).
32. Make sure that when routing the range selector valve assembly wiring harness it is between the bolt holes and is pressed into the case retainers.
33. Install the manual lever detent spring. Tighten to 8 Nm (71 lb-in).
34. Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install the O-ring seal on the chain lube tube.
35. Install the chain lube tube into the case.
36. Install the fluid feed transfer tube retainer bracket. Tighten to 10 Nm (89 lb-in).
37. Install the transmission fluid baffle. Tighten to 5 Nm (44 lb-in).
38. Install new forward clutch primary shaft seals.
39. Install the forward clutch drum without the clutch plates installed.
40. Install the sun gear.
41. Install the sun gear spacer.
42. Install a new sun gear snap ring.
43. Install all plates and pressure plate but not the wave spring.
44. Install the forward clutch snap ring.
45. Install the special tool. Zero out the special tool.
46. Lift up on the clutch plates by inserting a screwdriver in the clutch pack and record the measurement. Enter this measurement in the following table on the line labeled A.
47. Select the selective snap ring. SNAP RING SPECIFICATION Description Reading A B + 0.51 mm (0.02 in) C - 1.40 mm (0.055 in) (D) Clearance Add line A to B, then subtract line C and enter this total on line D. Line D is the actual clearance of the snap ring used during this measurement. If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.
48. Remove the forward clutch pack snap ring. FORWARD CLUTCH SELECTIVE SNAP RING SPECIFICATION Part Number Snap Ring Thickness 7B421 2.00 mm (0.078 in) 7B421 1.80 mm (0.070 in) 7B421 1.60 mm (0.062 in) 7B421 1.40 mm (0.055 in) 7B421 1.20 mm (0.047 in) 7B421 1.00 mm (0.039 in)
49. Remove the forward clutch plates, steel and friction.
50. Install the forward clutch wave spring.
51. Install the forward clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
52. Install the forward clutch pressure plate.
53. Install the forward clutch pack snap ring.
54. Install the forward clutch roller cage bearing.
55. Install the forward clutch upper bearing washer.
56. Install the forward clutch upper roller bearing.
57. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals and split ring seal.
58. Install the input shaft and a new planet carrier thrust washer.
59. Install the differential assembly in the case.
60. Install the bearing race onto the differential assembly.
61. Compress the special tool and hand-tighten the bolt.
62. Install the special tools onto the case.
63. Position the case onto the special tools and install the bolts. Tighten to 8 Nm (71 lb-in).
64. Loosen the top bolt of the special tool. Using a feeler gauge measure the opening.
65. Measure the thickness of the bearing shim that came out when the race was removed. The thickness of the bearing shim should match the measured opening of the special tool. If the measurements do not match use a new selective bearing race shim.
66. Install the selective bearing race shim into the housing. DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION Part Number Selective Shim Thickness 7F119 1.00 mm (0.039 inch) 7F119 1.05 mm (0.041 inch) 7F119 1.10 mm (0.043 inch) 7F119 1.15 mm (0.045 inch) 7F119 1.20 mm (0.047 inch) 7F119 1.25 mm (0.049 inch) 7F119 1.30 mm (0.051 inch) 7F119 1.35 mm (0.053 inch) 7F119 1.40 mm (0.055 inch) 7F119 1.45 mm (0.047 inch) 7F119 1.50 mm (0.059 inch) 7F119 1.55 mm (0.061 inch) 7F119 1.60 mm (0.063 inch) 7F119 1.65 mm (0.065 inch) 7F119 1.70 mm (0.067 inch) 7F119 1.75 mm (0.068 inch) 7F119 1.80 mm (0.070 inch) 7F119 1.85 mm (0.072 inch) 7F119 1.90 mm (0.074 inch) 7F119 1.95 mm (0.076 inch) 7F119 2.00 mm (0.078 inch) 7F119 2.05 mm (0.080 inch) 7F119 2.10 mm (0.081 inch)
67. Position the new bearing race in place.
68. Install the special tools on this side of the case.
69. Install the remaining special tools from the other side of the case. Using the special tools, install the bearing race.
70. Install a new converter housing gasket.
71. Position the converter housing in place. Install only 8 bolts evenly around the case to do the input shaft end play. It may be necessary to remove the install the correct shim. Tighten the bolts in a crisscross sequence. Tighten bolts to 8 Nm (71 lb-in).
72. Install the special tool to measure the input shaft end play. Tighten the wing nut.
73. Install the remaining special tool. Push down on the special tool and zero out the dial indicator. Lift up on the special tool and record the measurement 0.22-0.53 mm (0.008-0.021 inch) If the measurement is not within specification install a new input shaft bearing spacer. For additional information, refer to «FORWARD CLUTCH»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
74. Position the converter housing in place. Install new converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts. Starting at No. 1, tighten the bolts in a counterclockwise rotation. Stage 1: Tighten bolts to 2 Nm (18 lb-in). Stage 2: Tighten bolts to 8 Nm (71 lb-in). Stage 3: Tighten an additional 90 degrees.
75. Install the side shaft gear assembly. Tighten to 23 Nm (17 lb-ft).
76. Position the output shaft seal in place.
77. Using the special tool, install the output shaft seal.
78. Position the output shaft seal in place.
79. Using the special tool, install the output shaft seal.
80. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the feed tubes. Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube. Install new O-ring seals on the primary pressure feed tube. Install new O-ring seals on the secondary pressure feed tube. Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).
81. Lubricate the seals with clean transmission fluid and install all of the feed tubes into the case. Align the inner tube and install the clutch (manual valve) supply feed tube. Install the primary pressure feed tube. Install the secondary pressure feed tube. Install the main (pump) pressure feed tube (smaller tube). Install a new torque converter clutch pressure feed tube.
82. Position the mechatronic unit onto the case.
83. Tighten the mechatronic bolts in 2 stages. Stage 1: Tighten the bolts in the sequence shown to 5 Nm (44 lb-in). Stage 2: Tighten the bolts in the sequence shown 40 degrees (1/8 turn).
84. Lubricate the O-ring seal with clean CVT automatic transmission fluid and install the electrical connector into the case.
85. Rotate the outer shell connector in place and install the bolt. Tighten to 6 Nm (53 lb-in).
86. Install the OSS sensor spacer, sensor and bolt. Tighten to 8 Nm (71 lb-in).
87. Connect the electrical connectors.
88. Lubricate the O-ring seal that is on the new filter with clean CVT automatic transmission fluid and install the fluid filter.
89. Make sure that the filter is seated over one of the mechatronic bolts.
90. Install a new transaxle fluid pan gasket.
91. Make sure that the magnets in the pan are in the correct location prior to installing the transmission fluid pan.
92. Install the transaxle fluid pan. Tighten the bolts in the sequence indicated. Tighten to 12 Nm (9 lb-ft).
93. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
94. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
95. Using 4 new retainers, install the transaxle insulator.
96. Install a new fluid tube indicator grommet.
97. Install the fluid level indicator and tube. Tighten to 10 Nm (89 lb-in).
98. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
99. Position the transaxle mount in place and install the upper retaining bolts. Tighten to 55 Nm (41 lb-ft).

SPECIAL TOOL 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 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

MATERIAL SPECIFICATION

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 .

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1. If installing a new transaxle, install the fluid level indicator and tube and the bolt. Tighten to 10 Nm (89 lb-in).
2. If installing a new transaxle, install the transaxle insulator using new retainers.
3. If removed, clean the rear transaxle mount bolts using a wire brush and apply new Threadlocker to the threads.
4. If installing a new transaxle, install the rear transaxle support insulator. Tighten to 55 Nm (41 lb-ft).
5. Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.
6. Position the transaxle to the back of the engine.
7. Install the 3 transaxle-to-engine retaining bolts. Tighten to 40 Nm (30 lb-ft).
8. Install 4 new transmission fluid cooler tube seals.
9. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
10. Position the transmission fluid cooler tubes in place and install the bolts. Tighten to 10 Nm (89 lb-in)
11. Install 4 new torque converter retaining nuts. Tighten to 36 Nm (27 lb-ft).
12. Install the lower rubber access plug and install the retaining pin.
13. Position the catalytic converter is place and loosely install the bolt for the bracket.
14. Connect the HO2S electrical connector.
15. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
16. Install the 2 bolts for the LH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
17. Install the 2 bolts for the RH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
18. Install the 2 bolts for the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).
19. Install the nut for the rear motor mount. Tighten to 70 Nm (52 lb-ft).
20. Install the 2 bolts for the lower stabilizer mount. Tighten to 70 Nm (52 lb-ft).
21. Install the nut for the front motor mount. Tighten to 70 Nm (52 lb-ft).
22. Position the splash shield in place and install the 3 push pins.
23. Connect the HO2S electrical connector to the subframe.
24. Position the power steering rack in place. Install the bolts and nuts. Tighten to 133 Nm (98 lb-ft).
25. Position the power steering line in place and install the 4 bolts. Tighten to 7 Nm (62 lb-in).
26. Connect the wire harness to the LH front subframe.
27. Position the lower radiator hose in place and connect the retainers.
28. Install the LH and RH stabilizer bar link into the struts and install new nuts. Tighten to 55 Nm (41 lb-ft).
29. Remove the special tool from the lifting hook near the EGR valve.
30. Remove the special tools from the RH (rear) cylinder head.
31. Remove the special tools from the LH (front) cylinder head.
32. Remove the special tools.
33. Install new bolts for the catalytic converter. Tighten to 40 Nm (30 lb-ft).
34. Remove the upper half of the lifting hook.
35. Remove the lower half of the lifting hook.
36. Install the transaxle-to-engine bolt. Tighten to 40 Nm (30 lb-ft).
37. Connect the knock sensor wire harness to the transaxle.
38. Install the knock sensor. Tighten to 10 Nm (89 lb-in).
39. Install the heat shield over the knock sensor.
40. If equipped, connect the engine block heater.
41. Position the power steering hose in place and install the bolt. Tighten to 7 Nm (62 lb-in).
42. Tighten the catalytic converter bolt to the bracket. Tighten to 40 Nm (30 lb-ft).
43. Wipe off any residual grease or contaminants from the PTU splines. Apply a thin, uniform coating of constant velocity joint grease to all of the PTU spline surfaces before assembly.
44. Position the power transfer unit (PTU) and the rear driveshaft in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
45. Install the upper PTU bracket and the bolts. Tighten to 55 Nm (41 lb-ft).
46. Install the LH and RH half shafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
47. Install the driveshaft cross brace. Tighten to 30 Nm (22 lb-ft).
48. Using new bolts, install the driveshaft flange. Tighten to 25 Nm (18 lb-ft).
49. 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).
50. Install 2 new nuts for the rear exhaust pipe. Tighten to 40 Nm (30 lb-ft).
51. Install 2 new nuts for the front exhaust pipe. Tighten to 40 Nm (30 lb-ft).
52. Install the 4 upper transaxle bolts. Tighten to 40 Nm (30 lb-ft).
53. Install the bolt for the power steering line. Tighten to 7 Nm (62 lb-in).
54. Connect the vapor tube to the canister purge valve.
55. Install the PCV hose.
56. Connect the vacuum hose to the throttle body.
57. Position the bracket for the power steering hose and install the bolt. Tighten to 7 Nm (62 lb-in).
58. Install the fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
59. Connect the ground wire. Tighten to 12 Nm (9 lb-ft).
60. Connect the wire harness to the transaxle.
61. Connect the transaxle bulk head electrical connector.
62. Install the starter motor. Tighten to 26 Nm (19 lb-ft).
63. 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).
64. Install the electrical cover for the starter motor electrical connectors.
65. Clean the roll restrictor bolts using a wire brush and apply new Threadlocker to the threads.
66. Position the roll restrictor in place and install the bolts and connect the wire harness to the roll restrictor. Tighten to 40 Nm (30 lb-ft).
67. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new Threadlocker to the threads.
68. Install the roll restrictor bracket and the bolts. Tighten to 40 Nm (30 lb-ft).
69. Connect the lower wire harness to the transaxle.
70. If equipped, install the auxiliary coolant flow pump assembly. Tighten to 7 Nm (62 lb-in). Connect the electrical connector.
71. Connect the wire harness to the transaxle.
72. Install the shift cable bracket and bolts. Tighten to 25 Nm (18 lb-ft).
73. Connect the electrical connector to the shift cable bracket.
74. Connect the shift cable end.
75. Clean the 4 roll restrictor brace bolts using a wire brush and apply new Threadlocker to the threads.
76. Position the roll restrictor brace in place and install the 4 bolts. Tighten to 40 Nm (30 lb-ft).
77. Clean the upper roll restrictor bolt using a wire brush and apply new Threadlocker to the threads.
78. Install the upper roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
79. 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) .
80. 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) .
81. 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) .
82. If required, fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
83. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

SPECIAL TOOL 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 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12 Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

MATERIAL SPECIFICATION

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 .

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1. If installing a new transaxle, install the fluid level indicator and tube and the bolt. Tighten to 10 Nm (89 lb-in).
2. If installing a new transaxle, install the transaxle insulator using new retainers.
3. If removed, clean the rear transaxle mount bolts using a wire brush and apply new Threadlocker to the threads.
4. If installing a new transaxle, install the rear transaxle support insulator. Tighten to 55 Nm (41 lb-ft).
5. Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.
6. Position the transaxle to the back of the engine.
7. Install the 3 transaxle-to-engine retaining bolts. Tighten to 40 Nm (30 lb-ft).
8. Install 4 new transmission fluid cooler tube seals.
9. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
10. Position the transmission fluid cooler tubes in place and install the bolts. Tighten to 10 Nm (89 lb-in)
11. Install 4 new torque converter retaining nuts. Tighten to 36 Nm (27 lb-ft).
12. Install the lower rubber access plug and install the retaining pin.
13. Position the catalytic converter in place and loosely install the bolt for the bracket.
14. Connect the HO2S electrical connector.
15. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts. Tighten to 90 Nm (66 lb-ft).
16. Install the 2 bolts for the LH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
17. Install the 2 bolts for the RH rear subframe mount. Tighten to 48 Nm (35 lb-ft).
18. Install the 2 bolts for the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).
19. Install the nut for the rear motor mount. Tighten to 70 Nm (52 lb-ft).
20. Install the 2 bolts for the lower stabilizer mount. Tighten to 70 Nm (52 lb-ft).
21. Install the nut for the front motor mount. Tighten to 70 Nm (52 lb-ft).
22. Position the splash shield in place and install the 3 push pins.
23. Connect the HO2S electrical connector to the subframe.
24. Position the power steering rack in place. Install the bolts and nuts. Tighten to 133 Nm (98 lb-ft).
25. Position the power steering line in place and install the 4 bolts. Tighten to 7 Nm (62 lb-in).
26. Connect the wire harness to the LH front subframe.
27. Position the lower radiator hose in place and connect the retainers.
28. Install the LH and RH stabilizer bar link into the struts and install new nuts. Tighten to 55 Nm (41 lb-ft).
29. Remove the special tool from the lifting hook near the EGR valve.
30. Remove the special tools from the RH (rear) cylinder head.
31. Remove the special tools from the LH (front) cylinder head.
32. Remove the special tools.
33. Install new bolts for the catalytic converter. Tighten to 40 Nm (30 lb-ft).
34. Remove the upper half of the lifting hook.
35. Remove the lower half of the lifting hook.
36. Install the transaxle-to-engine bolt. Tighten to 40 Nm (30 lb-ft).
37. Connect the knock sensor wire harness to the transaxle.
38. Install the knock sensor. Tighten to 10 Nm (89 lb-in).
39. Install the heat shield over the knock sensor.
40. If equipped, connect the engine block heater.
41. Position the power steering hose in place and install the bolt. Tighten to 7 Nm (62 lb-in).
42. Tighten the catalytic converter bolt to the bracket. Tighten to 40 Nm (30 lb-ft).
43. 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) .
44. 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).
45. Install 2 new nuts for the rear exhaust pipe. Tighten to 40 Nm (30 lb-ft).
46. Install 2 new nuts for the front exhaust pipe. Tighten to 40 Nm (30 lb-ft).
47. Install the 4 upper transaxle bolts. Tighten to 40 Nm (30 lb-ft).
48. Install the bolt for the power steering line. Tighten to 7 Nm (62 lb-in).
49. Connect the vapor tube to the canister purge valve.
50. Install the PCV hose.
51. Connect the vacuum hose to the throttle body.
52. Position the bracket for the power steering hose and install the bolt. Tighten to 7 Nm (62 lb-in).
53. Install the fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
54. Connect the ground wire. Tighten to 12 Nm (9 lb-ft).
55. Connect the wire harness to the transaxle.
56. Connect the transaxle bulk head electrical connector.
57. Install the starter motor. Tighten to 26 Nm (19 lb-ft).
58. 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).
59. Install the electrical cover for the starter motor electrical connectors.
60. Clean the roll restrictor bolts using a wire brush and apply new Threadlocker to the threads.
61. Position the roll restrictor in place and install the bolts and connect the wire harness to the roll restrictor. Tighten to 40 Nm (30 lb-ft).
62. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new Threadlocker to the threads.
63. Install the roll restrictor bracket and 4 bolts. Tighten to 40 Nm (30 lb-ft).
64. Connect the lower wire harness to the transaxle.
65. If equipped, install the auxiliary coolant flow pump assembly. Tighten to 7 Nm (62 lb-in). Install the electrical connector.
66. Connect the wire harness to the transaxle.
67. Install the shift cable bracket and bolts. Tighten to 25 Nm (18 lb-ft).
68. Connect the electrical connector to the shift cable bracket.
69. Connect the shift cable end.
70. Clean the 4 roll restrictor brace bolts using a wire brush and apply new Threadlocker to the threads.
71. Position the roll restrictor brace in place and install 4 bolts. Tighten to 40 Nm (30 lb-ft).
72. Clean the upper roll restrictor bolt using a wire brush and apply new Threadlocker to the threads.
73. Install the upper roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
74. 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) .
75. 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) .
76. 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) .
77. If required, fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK AND SETTING»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .
78. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the notis vehicle TCM reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

See also:
• INTRODUCTION - GASOLINE
• TRANSAXLE/TRANSMISSION COOLING
• AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS
• JACKING & LIFTING
• FRONT DRIVE HALFSHAFTS
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• FRONT END BODY PANELS
• PROCEDURE
• DIAGNOSTICS
• PINPOINT TEST B
• PINPOINT TEST H
• PINPOINT TEST A
• PINPOINT TEST D
• PINPOINT TEST E
• PINPOINT TEST C
• PINPOINT TEST G
• PINPOINT TEST I
• PINPOINT TEST F