Removal Ford Five Hundred I

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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the 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.

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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

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MATERIAL SPECIFICATION

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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.

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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

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MATERIAL SPECIFICATION

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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.

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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

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the 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.