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Automatic Transaxle/transmission - Aisin AW21: Overhaul Ford Fusion I рестайлинг

Automatic Trans ~3042 words

DISASSEMBLY

  1. Remove the transaxle. For additional information, refer to «Transaxle - 3.0L»(ref-291884-S31483408352008073000000) or «Transaxle - 3.5L»(ref-291884-S05260550642008073000000) .
  2. Remove the torque converter.
  3. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the torque converter hub seal.

ASSEMBLY

  1. Position the torque converter hub seal in place.
  2. Using the Converter Seal Installer, install the torque converter hub seal.
  3. Install the torque converter.
  4. Install the transaxle. For additional information, refer to «Transaxle - 3.0L»(ref-291884-S16391701292008073000000) or «Transaxle - 3.5L»(ref-291884-S04306764312008073000000) .
  1. Remove the transaxle. For additional information, refer to «Transaxle - 3.0L»(ref-291884-S31483408352008073000000) or «Transaxle - 3.5L»(ref-291884-S05260550642008073000000) .
  2. Remove the torque converter.
  1. Install the torque converter.
  2. Install the transaxle. For additional information, refer to «Transaxle - 3.0L»(ref-291884-S16391701292008073000000) or «Transaxle - 3.5L»(ref-291884-S04306764312008073000000) .

Transaxle - 3.0L

Special Tools Illustration Tool Name Tool Number Engine Lifting Bracket Set 303-1140 Handle 205-153 (T80T-4000-W) Heat Gun 107-R0300 Installer, Halfshaft 204-161 (T97P-1175-A) Installer, Halfshaft Oil Seal 308-431 Installer, PTU Drive Gear Outer Oil Seal 308-430 Lifting Bracket, Engine 303-050 (T70P-6000) Remover/Installer, Bearing Cup 204-038 (T77F-1217-A) Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A) Support Bar, Engine 303-F072 Universal Adapter Bracket 014-0001 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) with appropriate hardware, or equivalent scan tool

ItemSpecification
Motorcraft Premium Automatic Transmission Fluid XT-8-QAW (US); CXT-8-LAW12 (Canada)WSS-M2C924-A
Multi-Purpose Grease XG-4 and/or XL-5ESB-M1C93-B
Threadlock and Sealer TA-25WSK-M2G351-A5

Material

Note. MERCON®, MERCON® V, MERCON® SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any transmission fluid other than what is recommended for this transaxle will cause transaxle damage.

Note. If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning .

All vehicles

  1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
  2. Position the transaxle to the back of the engine.
  3. Install the 5 transaxle-to-engine bolts. Tighten to 40 Nm (30 lb-ft).
  4. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.
  5. Install 3 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
  6. Install the inspection cover.
  7. Connect the wiring harness fastener to the stud bolt and position the Heated Oxygen Sensor (HO2S) bracket in place and install the bolt. Tighten to 12 Nm (106 lb-in).
  8. Position the transaxle insulator bracket in place. Apply threadlock and sealer to the threads and install the 2 nuts and the bolt. Tighten to 80 Nm (59 lb-ft).
  9. Raise the transaxle. Apply threadlock and sealer to the threads and install the 2 transaxle insulator-to-frame bolts. Tighten to 62 Nm (46 lb-ft).
  10. Remove the Engine Support Bar.
  11. Remove the Engine Lifting Bracket and the Universal Adapter Bracket "L" hook from the from the LH side of the engine.
  12. Remove the upper half of the Engine Lifting Bracket Set.
  13. Remove the lower half of the Engine Lifting Bracket Set.
  14. Position the Power Transfer Unit (PTU) in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
  15. Using the Bearing Cup Remover/Installer and Handle, install a new intermediate shaft seal.
  16. Using the Heat Gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating. If necessary, use the PTU Drive Gear Outer Oil Seal Installer and Halfshaft Oil Seal Installer to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tab. For an alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install. Make sure the deflector is completely seated all the way around.
  17. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
  18. Position the RH catalytic converter in place and install the catalytic converter-to-exhaust manifold nuts. Tighten to 40 Nm (30 lb-ft).
  19. Install the catalytic converter band clamp LH half and the 2 bolts. Tighten to 40 Nm (30 lb-ft).
  20. Install the catalytic converter band clamp RH half and install the 3 nuts. Tighten to 20 Nm (177 lb-in).
  21. Install the RH exhaust manifold heat shield and the 6 bolts. Tighten to 11 Nm (97 lb-in).
  22. Using the Exhaust Gas Oxygen Sensor Socket, install the RH HO2S. Tighten to 48 Nm (35 lb-ft).
  23. Connect the RH HO2S electrical connector.
  24. Using the Exhaust Gas Oxygen Sensor Socket, install the RH catalyst monitor sensor. Tighten to 48 Nm (35 lb-ft).
  25. Connect the RH catalyst monitor sensor electrical connector and attach the wiring harness retainer.
  26. Position the driveshaft in place, align the index marks made during removal and install the 4 driveshaft bolts. Tighten to 70 Nm (52 lb-ft).
  27. Position the RH halfshaft in place and install the 2 RH halfshaft bearing support bracket bolts. Tighten to 23 Nm (17 lb-ft).
  28. Position the RH halfshaft in the transaxle and install the 2 RH halfshaft bearing support bracket bolts. Tighten to 55 Nm (41 lb-ft).
  29. Install the bolt retaining the brake caliper hose. Tighten to 22 Nm (16 lb-ft).
  30. Connect the HO2S to the RH halfshaft bearing support bracket.
  31. Install the catalytic converter-to-engine block bracket and install the 2 bolts. Tighten to 35 Nm (26 lb-ft).
  32. Install the catalytic converter band clamp and the 2 bolts. Tighten to 20 Nm (177 lb-in).
  33. Install the RH exhaust manifold heat shield and the 2 bolts. Tighten to 11 Nm (97 lb-in).
  34. Loosely install the EGR tube nut on the RH exhaust manifold.
  35. Position the subframe in place using a suitable powertrain lift.
  36. Install the front subframe nuts. Tighten to 150 Nm (111 lb-ft).
  37. Position the subframe support brackets in place and loosely install the bolts.
  38. Install the rear subframe nuts. Tighten to 150 Nm (111 lb-ft).
  39. Tighten the subframe support bracket bolts. Tighten to 103 Nm (76 lb-ft).
  40. Position the power steering gear in place and install the 3 bolts. Tighten to 107 Nm (79 lb-ft).
  41. Position the power steering line bracket in place and install the bolts. Tighten to 9 Nm (80 lb-in).
  42. Install the 2 transaxle roll restrictor bolts. Tighten to 90 Nm (66 lb-ft).
  43. If equipped, install the roll restrictor heat shield and the bolts.
  44. Position the Y-pipe assembly in place and install the 2 exhaust flexible pipe-to-catalytic converter nuts. Tighten to 40 Nm (30 lb-ft).
  45. Install the Y-pipe bolts and the Y-pipe nuts. Tighten to 40 Nm (30 lb-ft).
  46. Install the RH damper fork through bolt connecting the fork to the lower control arm. Tighten to 103 Nm (76 lb-ft).
  47. Position the lower control arms in the knuckle and install the nuts. Tighten to 200 Nm (148 lb-ft).
  48. Using the Halfshaft Installer, install the LH halfshaft in the wheel hub. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
  49. Install the RH front wheel hub nut. Tighten 225 Nm (185 lb-ft).
  50. Using the Halfshaft Installer, install the RH halfshaft in the wheel hub. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
  51. Position the sway bar links in the struts and install the nuts. Tighten to 40 Nm (30 lb-ft).
  52. Install the LH front structure to subframe splash shield and install the pin-type retainers.
  53. Position the LH fender splash shield in place and install the 4 screws.
  54. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
  55. Position the RH fender splash shield in place and install the 4 screws.
  56. Position the power steering line bracket on the right cylinder head and install the bolt. Tighten to 7 Nm (62 lb-in).
  57. Install a new gasket and the EGR valve and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
  58. Install the EGR tube on the valve. Tighten to 40 Nm (30 lb-ft).
  59. Connect the EGR valve electrical connector.
  60. Tighten the EGR tube at the RH exhaust manifold. Tighten to 40 Nm (30 lb-ft).
  61. Install the 3 upper transaxle-to-engine retaining bolts. Tighten to 40 Nm (30 lb-ft).
  62. Install the starter and the 2 bolts. Tighten to 26 Nm (19 lb-ft).
  63. Connect the 2 starter motor electrical connectors. Tighten the larger nut to 12 Nm (106 lb-in). Tighten the smaller nut to 5 Nm (44 lb-in).
  64. Install the electrical cover for the starter motor electrical connectors.
  65. Install the 2 ground wires and ground wire bolts. Tighten to 12 Nm (106 lb-in).
  66. Connect the Transmission Control Module (TCM) electrical connector.
  67. Position the selector lever cable and bracket in place and install the selector lever cable nut and 2 selector lever cable bolts. Tighten to 12 Nm (106 lb-in).
  68. Connect the selector lever cable end.
  69. Remove the transmission fluid fill plug.
  70. Fill the transaxle with clean transmission fluid.
  71. Install the transmission fluid fill plug. Tighten to 39 Nm (29 lb-ft).
  72. Install the air cleaner and outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article or «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(ref-291911) article.
  73. Install the battery tray and the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
  74. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.
  75. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
  76. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
  77. Wipe the transmission fluid level indicator with a clean cloth.
  78. If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the transmission fluid level indicator. The transmission fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle will occur.
  79. Fill the transaxle to the correct fluid level.
  80. If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has reached the normal operating temperature.

Transaxle - 3.5L

Special Tools Illustration Tool Name Tool Number Engine Lifting Bracket 303-1245 Handle 205-153 (T80T-4000-W) Heat Gun 107-R0300 Installer, Halfshaft 204-161 (T97P-1175-A) Installer, Halfshaft Oil Seal 308-431 Installer, PTU Drive Gear Outer Oil Seal 308-430 Lifting Bracket, Engine 303-050 (T70P-6000) Remover/Installer, Bearing Cup 204-038 (T77F-1217-A) Spreader Bar 303-1246 Support Bar, Engine 303-F072 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

ItemSpecification
Motorcraft Premium Automatic Transmission Fluid XT-8-QAW (US); CXT-8-LAW12 (Canada)WSS-M2C924-A
Multi-Purpose Grease XG-4 and/or XL-5ESB-M1C93-B
Threadlock and Sealer TA-25WSK-M2G351-A5

Material

Note. MERCON®, MERCON® V, MERCON® SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any transmission fluid other than what is recommended for this transaxle will cause transaxle damage.

Note. If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning .

All vehicles

  1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
  2. Position the transaxle to the back of the engine.
  3. Install the 7 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
  4. Connect the transmission fluid cooler hoses to the transmission cooler tubes.
  5. Install 4 new torque converter nuts. Tighten to 36 Nm (27 lb-ft).
  6. Position the inspection cover in place and install the 2 fasteners.
  7. Position the power transfer unit Power Transfer Unit (PTU) in place and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
  8. Using the Bearing Cup Remover/Installer and Handle, install a new intermediate shaft seal.
  9. Using the Heat Gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white-colored tabs. Install the seal deflector immediately after heating. If necessary, use the PTU Drive Gear Outer Oil Seal Installer and Halfshaft Oil Seal Installer to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white-colored tab. For an alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install. Make sure the deflector is completely seated all the way around.
  10. Position the PTU support bracket in place and install the 5 bolts. Tighten to 70 Nm (52 lb-ft).
  11. Position the RH catalytic converter in place and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
  12. Install the 2 catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
  13. Connect the RH catalyst monitor sensor electrical connector.
  14. Position the driveshaft in place, align the index marks made during removal and install the bolts. Tighten to 70 Nm (52 lb-ft).
  15. Position the RH halfshaft in the transaxle and in the wheel hub and install the 2 bolts. Tighten to 23 Nm (17 lb-ft).
  16. Install the RH halfshaft in the transaxle and install the 3 bolts. Tighten to 55 Nm (41 lb-ft).
  17. Install the catalytic converter support bracket and install the 2 nuts. Tighten to 23 Nm (17 lb-ft).
  18. Install the 2 catalytic converter bracket bolts. Tighten to 20 Nm (177 lb-in).
  19. Position the subframe in place and install the 2 front subframe nuts. Tighten to 150 Nm (111 lb-ft).
  20. Position the subframe support brackets in place and loosely install the bolts.
  21. Install the rear subframe nuts. Tighten to 150 Nm (111 lb-ft).
  22. Tighten the subframe support bracket bolts. Tighten to 103 Nm (76 lb-ft).
  23. Position the steering gear in place and install the 3 bolts. Tighten to 107 Nm (79 lb-ft).
  24. Position the power steering cooler line bracket in place and install the bolts. Tighten to 9 Nm (80 lb-in).
  25. Install the 2 roll restrictor bracket bolts. Tighten to 90 Nm (66 lb-ft).
  26. Install the RH damper fork through bolt connecting the fork to the lower control arm. Tighten to 103 Nm (76 lb-ft).
  27. Position the lower control arms in the knuckle and install the nuts. Tighten to 200 Nm (148 lb-ft).
  28. Using the Halfshaft Installer, install the halfshaft in the wheel hub.
  29. Install a new front wheel hub nut. Tighten to 255 Nm (185 lb-ft).
  30. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
  31. Position the sway bar links in the struts and install the nuts. Tighten to 40 Nm (30 lb-ft).
  32. Position the Y-pipe in place and install the 6 Y-pipe nuts. Tighten to 40 Nm (30 lb-ft).
  33. Install the LH front structure to subframe splash shield and install the pin-type retainers.
  34. Position the LH fender splash shield in place and install the 4 screws.
  35. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
  36. Position the RH fender splash shield in place and install the 4 screws.
  37. Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 2 nuts and the bolt. Tighten to 80 Nm (59 lb-ft).
  38. Using the Engine Support Bar, raise the transaxle. Apply threadlock and sealant to the threads and install the transaxle support insulator through bolt. Tighten to 130 Nm (96 lb-ft).
  39. Remove the Engine Support Bar and Spreader Bar.
  40. Remove the Engine Lifting Bracket from the LH cylinder head.
  41. Install the 4 upper transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
  42. Install the starter and the 2 bolts. Tighten to 26 Nm (19 lb-ft).
  43. Connect the 2 starter motor electrical connectors and position back the electrical terminal cover. Tighten the larger nut to 12 Nm (106 lb-in). Tighten the smaller nut to 5 Nm (44 lb-in).
  44. Position the 2 ground straps in place and install the 2 ground strap bolts. Tighten to 12 Nm (106 lb-in).
  45. Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor.
  46. Connect the Transmission Control Module (TCM) electrical connector.
  47. Position the selector lever cable in place and install the 2 bolts and the nut. Tighten to 12 Nm (106 lb-in).
  48. Connect the selector lever cable end.
  49. Remove the transmission fluid fill plug.
  50. Fill the transaxle with clean transmission fluid.
  51. Install the transmission fluid fill plug. Tighten to 39 Nm (29 lb-ft).
  52. Install the upper intake manifold. For additional information, refer to «ENGINE - 3.5L»(ref-291903) article.
  53. Install the air cleaner and outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L»(ref-291904) article or «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(ref-291911) article.
  54. Install the battery tray and the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
  55. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.
  56. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
  57. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
  58. Wipe the transmission fluid level indicator with a clean cloth.
  59. If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle will occur.
  60. Fill the transaxle to the correct transmission fluid level.
  61. If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has reached the normal operating temperature.

More articles — Automatic Transaxle/transmission - Aisin AW21