Automatic Transaxle/transmission - FNR5: Removal & Installation Ford Fusion I рестайлинг

Transmission Fluid Cooler Tube Replacement

Refer to TRANSAXLE/TRANSMISSION COOLING article.

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the drain plug and allow the transmission fluid to drain.
3. Install the drain plug. Tighten to 29 Nm (21 lb-ft).
4. Remove the transmission fluid pan. Remove the bolts. Using a suitable tool, separate the bead of sealer.
5. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.

INSTALLATION

1. Apply a 1.5 mm (0.059 in) thick bead of sealer to the transaxle on the transmission fluid pan sealing surface.
2. Install the transmission fluid pan. Tighten to 7 Nm (62 lb-in).
3. Fill the transaxle with clean transmission fluid.

Main control

1. Remove the transmission fluid pan. For additional information, refer to «Transmission Fluid Pan»(ref-291885-S15707149952008073000000) .
2. Disconnect the Transmission Fluid Temperature (TFT) sensor electrical connector.
3. Remove the transmission fluid filter.
4. Remove the ground wire bolt. Disconnect the electrical connectors and remove the main control wiring harness. Shift Solenoid A (SEA), wire color (BU/GN). Shift Solenoid B (SSB), wire color (BK/GN). Shift Solenoid C (SSC), wire color (BU/BN). Pressure Control Solenoid A (PCA), wire color (BU/OG). Shift Solenoid D (SSD), wire color (WH). Shift Solenoid E (SSE), wire color (RD).
5. Remove the 14 main control valve body bolts and remove the main control valve body and solenoids as an assembly.
6. Remove the accumulator pistons and springs.
7. Remove the 4 shift solenoid bracket bolts and remove the bracket. Remove the affected solenoid. Item Part Number Description 1 7G484 Shift Solenoid A (SEA) 2 7G484 Shift Solenoid B (SSB) 3 7G484 Shift Solenoid C (SSC)
8. Remove the bolts and remove affected solenoid. Item Part Number Description 1 7G383 Pressure Control Solenoid A (PCA) 2 7H148 Shift Solenoid D (SSD) 3 7H148 Shift Solenoid E (SSE)
9. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
10. Remove the 11 solenoid body cover bolts and remove the solenoid body cover. Using a suitable tool, separate the bead of sealer.
11. Clean the silicone from the solenoid body side cover and transaxle case surfaces thoroughly with metal surface prep.
12. Disconnect the electrical connectors. Disconnect the electrical connector for the Pressure Control Solenoid B (PCB). Disconnect the electrical connector for the Shift Solenoid F (SSF).
13. Remove the bolt and the ground wire.
14. Remove the 2 bolts and the solenoid body assembly.
15. Remove the bolts, bracket and the PCB.
16. Remove the bolt and the SSF.
17. Inspect the O-ring seals for damage, install new O-rings as required.
18. Inspect the guide pins for damage, install new guide pins as required.

SSF and PCB

1. Prior to installing the solenoid body make sure that the guide pins are in place.
2. Prior to installing the solenoid body make sure that the O-ring seals are in place.
3. Install the SSF and install the bolt. Tighten to 9 Nm (80 lb-in).
4. Install the PCB, bracket and bolts. Tighten to 9 Nm (80 lb-in).
5. Install the solenoid body assembly and the 2 bolts. Tighten to 9 Nm (80 lb-in).
6. Install the ground wire and the bolt. Tighten to 9 Nm (80 lb-in).
7. Connect the electrical connectors. Connect the electrical connector for the PCB. Connect the electrical connector for the SSF.
8. Apply a 1.5 mm (0.059 in) thick bead of sealer to the transaxle on the side cover sealing surface.
9. Install the solenoid body cover and install the 11 bolts. Tighten to 7 Nm (62 lb-in).
10. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
11. Install the affected solenoid and the bolts. Tighten to 9 Nm (80 lb-in). Item Part Number Description 1 7G383 Pressure Control Solenoid A (PCA) 2 7H148 Shift Solenoid D (SSD) 3 7H148 Shift Solenoid E (SSE)
12. Install the affected solenoid, the bracket and the 4 shift solenoid bracket bolts. Tighten to 9 Nm (80 lb-in). Item Part Number Description 1 7G484 Shift Solenoid A (SEA) 2 7H448 Shift Solenoid B (SSB) 3 7H448 Shift Solenoid C (SSC)
13. Install the accumulator pistons and springs. Accumulator 1 and 2. Accumulator N and D.
14. Install the main control valve body and loosely install the bolts.
15. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown. Tighten to 9 Nm (80 lb-in).
16. Install the main control valve wiring harness, connect the electrical connectors and install the ground wire bolt. SEA, wire color (BU/GN). SSB, wire color (BK/GN). SSC, wire color (BU/BN). PCA, wire color (BU/OG). SSD, wire color (WH). SSE, wire color (RD). Tighten to 10 Nm (89 lb-in).
17. Install the transmission fluid filter.
18. Connect the TFT sensor electrical connector.
19. Install the transmission fluid pan. For additional information, refer to «Transmission Fluid Pan»(ref-291885-S15707149952008073000000) .

1. Disconnect the intermediate shaft speed sensor electrical connector.
2. Remove the bolt and the intermediate shaft speed sensor. To install, tighten to 10 Nm (89 lb-in). Check the sensor bore. Check the O-ring seal for nicks or cuts and install a new O-ring if necessary.

1. To install, reverse the removal procedure.

1. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
2. Remove the bolt and the TSS sensor. To install, tighten to 10 Nm (89 lb-in). Check the TSS sensor bore. Check the O-ring seal for nicks or cuts and install a new O-ring if necessary.

1. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Place a drain pan beneath the Output Shaft Speed (OSS) sensor.
3. Remove the OSS sensor. Disconnect the OSS electrical connector. Remove the OSS bolt. Inspect the OSS bore.
4. Inspect the OSS O-ring seal for nicks or cuts, install a new OSS O-ring if necessary.

1. Install the OSS sensor. Tighten the OSS sensor bolt to 10 Nm (89 lb-in). Connect the OSS electrical connector.
2. Check the transmission fluid level and add transmission fluid as necessary.
3. Start the engine and move the selector lever through all gear positions.

1. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
2. Using a suitable tool, remove the LH differential fluid seal.

1. Position the new differential fluid seal on the Output Shaft Seal Installer and Handle.
2. Using the Output Shaft Seal Installer and Handle, install the halfshaft seal.
3. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.

1. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
2. Using a suitable tool, remove the RH differential fluid seal.

1. Position the new differential fluid seal on the Output Shaft Seal Installer and Handle.
2. Using the Output Shaft Seal Installer and Handle, install the halfshaft seal.
3. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Disconnect the Transmission Range (TR) sensor electrical connector and the selector lever cable end.
3. Remove the TR sensor (the automatic transaxle is removed for clarity). Remove the nut and the manual control lever. Remove the bolts and the TR sensor.

1. Install the TR sensor and loosely install the bolts (the automatic transaxle is removed for clarity).
2. Using the Transmission Range Sensor Alignment Tool, align the TR sensor and tighten the bolts. Tighten to 10 Nm (89 lb-in).
3. Install the manual control lever. Tighten to 22 Nm (16 lb-ft).
4. Adjust the manual control lever to TR sensor D position. L (LOW) D (DRIVE) N (NEUTRAL) R (REVERSE) P (PARK) When in position D, the marks on the manual control lever line up with the marks on the TR sensor.
5. Connect the selector lever cable and the TR sensor electrical connector.

Scheme 469

1. Disconnect the 2 electrical connectors.
2. Remove the 3 nuts and remove the TCM. To install, tighten to 10 Nm (89 lb-in).

1. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
3. Using the Engine Support Bar, support the engine.
4. Remove the transaxle support insulator bracket bolts.
5. Remove the transaxle support insulator frame bolts.
6. Remove the 4 screws and position the LH fender splash shield aside.
7. Remove the 6 pin-type retainers and the LH front structure-to-subframe splash shield.
8. Remove the transaxle support insulator frame bolts and remove the insulator.

1. Clean the transaxle support insulator frame bolts using a wire brush and apply new threadlock to the threads.
2. Position the transaxle support insulator in place and install the transaxle support insulator frame bolts. Tighten to 62 Nm (46 lb-ft).
3. Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
4. Position the LH splash shield in place and install the 4 screws.
5. Install the 2 upper transaxle support insulator frame bolts. Tighten to 62 Nm (46 lb-ft).
6. Install the 2 transaxle support insulator bracket bolts. Tighten to 90 Nm (66 lb-ft).
7. Remove the Engine Support Bar.
8. Install the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.

Special Tools Illustration Tool Name Tool Number Retainer, Torque Converter 307-566 Support Bar, Engine 303-F072

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the Air Cleaner (ACL) assembly. Disconnect the Mass Air Flow (MAF) sensor electrical connector. Disconnect the engine breather. Disconnect the brake booster vacuum hose. Loosen the clamp and remove the ACL assembly.
3. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
4. Remove the battery tray. Disconnect the positive battery cable fastener from the battery tray. Disconnect the 3 wiring harness retainers. Remove the battery tray nut. Remove the battery tray bolt and remove the battery tray.
5. Disconnect the selector lever cable end from the manual control lever.
6. Remove the 2 bolts, disconnect the harness and position the selector lever cable and bracket aside.
7. Disconnect the Transmission Range (TR) sensor electrical connector, transmission main valve body electrical connector, and disconnect the harness retainer from the transaxle and position the harness aside.
8. Disconnect the Turbine Shaft Speed (TSS) sensor, intermediate shaft speed sensor and 5th gear valve body electrical connector and position the harness aside.
9. Remove the ground strap.
10. Remove the 3 top bellhousing bolts.
11. Remove the 2 roll restrictor bracket bolts.
12. Install the Engine Support Bar.
13. Remove the 2 transaxle support insulator bracket bolts and lower the transaxle.
14. Remove the 3 nuts and remove the transaxle support insulator bracket.
15. Disconnect the pressure switch electrical connector.
16. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
17. Remove the 4 screws and position the RH fender splash shield aside.
18. Remove the 6 pin-type retainers and the RH front structure-to-subframe splash shield.
19. Remove the 4 screws and position the LH fender splash shield aside.
20. Remove the 6 pin-type retainers and the LH front structure-to-subframe splash shield.
21. Remove the LH front power steering bracket bolt.
22. Remove the 2 LH power steering tube bracket bolts.
23. Remove the RH power steering tube bracket bolt.
24. Remove the transmission fluid pan drain plug and allow the transmission fluid to drain.
25. Install the transmission fluid drain plug. Tighten to 29 Nm (21 lb-ft).
26. Remove the 2 LH bolts and the RH bolt and position the steering gear aside using mechanic's wire.
27. Remove the nuts and disconnect the sway bar links from the front struts.
28. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
29. Insert a suitable tool into the RH side of the differential to hold the differential side gears in place.
30. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
31. Support the subframe with a suitable powertrain lift.
32. Remove the 2 rear subframe nuts.
33. Remove the 4 bolts and the subframe support brackets.
34. Remove front subframe nuts.
35. Lower the subframe and remove it from the vehicle.
36. Position the boot aside and remove the starter electrical connectors.
37. Remove the wiring harness retainer from the starter stud.
38. Remove the 2 stud bolts and the starter.
39. Disconnect the transmission fluid cooler hoses from the transaxle.
40. Remove and discard the 4 torque converter nuts.
41. Remove the nut and the bracket from the torque converter housing stud bolt.
42. Support the transaxle with a suitable transmission jack.
43. Remove the 3 rear torque converter housing bolts.
44. Remove the 3 front torque converter housing bolts.
45. Separate the transaxle from the engine and install the Torque Converter Retainer.
46. Remove the transaxle from the vehicle.
47. If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned. Carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to «Transmission Fluid Cooler - Backflushing and Cleaning»(ref-291885-S30487775142008073000000) .

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 .

1. Make sure that the torque converter is installed correctly.
2. Check the installation depth of the torque converter. Lay a steel straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
3. Using a transmission jack, secure the transaxle using a safety strap.
4. Remove the Torque Converter Retainer.
5. Move the transaxle into position.
6. Install the 3 front torque converter housing bolts. Tighten to 47 Nm (35 lb-ft).
7. Install the 3 rear torque converter housing bolts. Tighten to 47 Nm (35 lb-ft).
8. Remove the transmission jack.
9. Install the bracket and the nut on the torque converter housing stud bolt. Tighten to 25 Nm (18 lb-ft).
10. Install new torque converter nuts. Tighten to 37 Nm (27 lb-ft).
11. Connect the transmission fluid cooler hoses to the transaxle.
12. Position the starter in place and install the 2 bolts. Tighten to 35 Nm (26 lb-ft).
13. Install the wiring harness fastener on the starter stud.
14. Install the starter electrical connectors and install the boot back into position. Tighten to 12 Nm (106 lb-in). Tighten to 5 Nm (44 lb-in).
15. Position the subframe in place using a suitable powertrain lift.
16. Install the front subframe nuts. Tighten to 150 Nm (111 lb-ft).
17. Position the subframe support brackets in place and loosely install the bolts.
18. Install the rear subframe nuts. Tighten to 150 Nm (111 lb-ft).
19. Tighten the subframe support bracket bolts. Tighten to 103 Nm (76 lb-ft).
20. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
21. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
22. Install the sway bar links and nuts to the front struts. Tighten to 40 Nm (30 lb-ft).
23. Position the steering gear in place and install the 2 LH and RH bolts. Tighten to 107 Nm (79 lb-ft).
24. Install the RH power steering tube bracket bolt. Tighten to 9 Nm (80 lb-in).
25. Install the 2 LH power steering tube bracket bolts. Tighten to 9 Nm (80 lb-in).
26. Install the LH power steering tube bracket bolt. Tighten to 9 Nm (80 lb-in).
27. Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
28. Position the LH splash shield in place and install the 4 screws.
29. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
30. Position the RH splash shield in place and install the 4 screws.
31. Connect the Output Shaft Speed (OSS) sensor electrical connector.
32. Connect the pressure switch electrical connector.
33. Position the transaxle support insulator bracket in place and install the 3 nuts. Tighten to 80 Nm (59 lb-ft).
34. Raise the transaxle using the Engine Support Bar and install the 2 transaxle support insulator bracket bolts. Tighten to 62 Nm (46 lb-ft).
35. Install the 2 roll restrictor bracket bolts. Tighten to 90 Nm (66 lb-ft).
36. Remove the Engine Support Bar.
37. Install the 3 top torque converter housing bolts. Tighten to 47 Nm (35 lb-ft).
38. Install the ground strap. Tighten to 25 Nm (18 lb-ft).
39. Connect the Turbine Shaft Speed (TSS) sensor, intermediate shaft speed sensor and the 5th gear valve body electrical connectors.
40. Connect the main valve body and the Transmission Range (TR) sensor electrical connectors and connect the wiring harness to the transmission.
41. Position the selector lever cable and bracket in place, and connect the electrical harness fastener and install the 2 bolts. Tighten to 20 Nm (177 lb-in).
42. Connect the selector lever cable end to the manual control lever.
43. Install the battery tray. Position the battery tray in place and install the battery tray bolt. Tighten to 9 Nm (80 lb-in). Connect the 3 wiring harness retainers. Install the battery tray nut. Tighten to 9 Nm (80 lb-in). Connect the positive battery cable fastener to the battery tray.
44. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-291883) article.
45. Fill the transaxle with clean transmission fluid.