General notes — Part 2 Ford Fusion I facelift

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1. Measure the bushing of the front sun gear. Front sun gear bushing inner diameter Standard: 18.000-18.018 mm {0.70866-0.70936 in} Maximum: 18.038 mm {0.71016 in}
2. If not as specified, replace the front sun gear.
3. Measure the bushing of the end cover. End cover bushing inner diameter Standard: 23.600-23.621 mm {0.92913-0.92995 in} Maximum: 23.641 mm {0.93075 in}
4. If not as specified, replace the end cover.
5. Measure the bushing of the secondary sun gear. Secondary sun gear bushing inner diameter Standard: 26.000-26.021 mm {1.02362-1.02445 in} Maximum: 26.041 mm {1.02524 in}
6. If not as specified, replace the secondary sun gear.
7. Assemble the SST .
8. Lift the transaxle case and mount it on the SST . NOTE: If the transaxle case has been newly replaced perform step (9).
9. Install the oil pipe.
10. Install the bearing race, then tighten torx screws. Tightening torque 10.8-13.7 N.m {110-140 kgf.cm, 95.5-121 in.lbf}
11. Install the bearing race to the transaxle case.
12. Install the locknut. Set the primary gear. Set the distance piece and bearing. Loosely tighten the locknut. Set the SSTs in the order shown. Tighten the locknut from the end cover side to adjust the preload within the specification. Primary gear preload 0.50-0.90 N.m {5.10-9.17 kgf.cm, 4.42-7.96 in.lbf} Stake the locknut. Remove the SST
13. Install the front internal gear and one-way clutch.
14. Apply petroleum jelly to the bearing, and secure it to the front planetary gear component.
15. Install the front planetary gear component.
16. Apply petroleum jelly to the bearing, and secure it to the front sun gear.
17. Install the front sun gear.
18. Install the rear planetary gear. NOTE: Rotate the engine stand so that the oil pan faces downward. Pull the front internal gear and one-way clutch component a little until the groove for the snap ring appears, then install the snap ring.
19. Install the snap ring.
20. Rotate the engine stand so that the end cover faces upward, and verify that the snap ring is installed accurately.
21. Install the band servo component. Install the servo return spring and servo piston. Apply ATF to the O-ring, and install it to the transaxle case. Install the servo retainer. Tightening torque 11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}
22. Apply petroleum jelly to the bearing, and secure it to the clutch component.
23. Install the clutch component.
24. Install the 2-4 brake band.
25. Select the band strut. Find an appropriate bolt (under head length: 60-70 mm {2.36-2.75 in}) , and tighten the 2-4 brake band with the bolt. Tightening torque 4.9 N.m {50 kgf.cm, 43 in.lbf} Measure the dimension A shown in the figure. Remove the bolt. Measure the dimension B shown in the figure. Calculate according to the formula below. B - A = C (The middle of the under head length) C - 4 = D (The lower limit of under head length) C - 4.7 = E (The upper limit of under head length) Select a band strut whose length should be between D and E. Band strut length for 2-4 brake band servo stroke (mm {in}) BAND STRUT LENGTH SPECIFICATIONS 36.0 {1.417} 36.5 {1.437} 37.0 {1.457} 37.25 {1.467} 37.5 {1.476} 37.75 {1.486} 38.0 {1.496} 38.25 {1.506} 38.5 {1.516} 39.0 {1.535} - - Install the selected band strut. Tightening torque 37-52 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}
26. Use the following procedure to adjust the total end play. Install the thickest bearing race (2.6 mm {0.102 in}) to the end cover. Install the end cover to the clutch component. Measure the clearance A between transaxle case and end cover. Calculate according to the formulas below. Select an appropriate bearing race whose bearing thickness matches the calculated limits. A - 2.6 mm {0.102} (Bearing thickness) = B B - 0.25 = C (The lower limit of bearing thickness) B - 0.50 = D (The upper limit of bearing thickness) Select a bearing race whose thickness is between D mm {in} and C mm {in}. Bearing race sizes BEARING RACE SIZES mm {in} 1.8 {0.071} 2.0 {0.079} 2.2 {0.087} 2.4 {0.094} 2.6 {0.102} - CAUTION: The bearing race and end cover may be damaged if the end cover is not installed correctly to the transaxle case. Align the projection of the bearing race within the area of the arrows shown in the figure, and then install the end cover to the transaxle case. Remove the end cover, apply petroleum jelly to the selected bearing race, then install it to the end cover.
27. Apply ATF to new seal ring, and install it to the end cover. Seal ring inner diameter A: 47.1 mm {1.854 in} B: 55.8 mm {2.197 in}
28. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the end cover.
29. Apply ATF to the O-ring and install it to the transaxle case.
30. Install the end cover to the transaxle case. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
31. Install the reduction brake to the transaxle case. (See «REDUCTION BRAKE DISASSEMBLY/ASSEMBLY»(ref-277058-S30044060012008011500000) .) NOTE: If the transaxle case has been newly replaced perform Step (32).
32. Install the needle bearing using the SST as shown in the figure.
33. Install the spacer and one-way clutch No.2 to the transaxle case.
34. Apply ATF to new seal ring, and install it to the transaxle case.
35. Apply petroleum jelly to the needle bearing, and secure it to the transaxle case.
36. Install the direct clutch component to the transaxle case.
37. Install the secondary sun gear.
38. Install the output gear component.
39. Install the bearing race to the output gear component.
40. Apply petroleum jelly to the needle bearing, and secure it to the output gear component.
41. Use the following procedure to adjust the total end play. Measure clearance A between the installation surface and the hole depth of the converter housing. Install the bearing to the output gear component. Measure clearance B between the converter housing installation surface and the bearing. Calculate the total end play according to the following formula: step (1) value - step (3) value = total end play. select the snap ring. Adjust shim size for output gear component total end play ADJUST SHIM SIZE FOR OUTPUT GEAR COMPONENT TOTAL END PLAY total end play {in} Adjust shims sizes mm {in} 1.431-1.481 {0.057-0.058} 1.20 {0.047} 1.381-1.431 {0.055-0.056} 1.15 {0.045} 1.331-1.381 {0.053-0.054} 1.10 {0.043} 1.281-1.331 {0.051-0.052} 1.05 {0.041} 1.231-1.281 {0.049-0.050} 1.00 {0.039} 1.181-1.231 {0.047-0.048} 0.95 {0.037} 1.131-1.181 {0.045-0.046} 0.90 {0.035} 1.081-1.131 {0.043-0.044} 0.85 {0.033} 1.031-1.081 {0.041-0.042} 0.80 {0.031} 0.981-1.031 {0.039-0.040} 0.75 {0.029} 0.931-0.981 {0.037-0.038} 0.70 {0.028} 0.881-0.931 {0.035-0.036} 0.65 {0.026} 0.831-0.881 {0.033-0.034} 0.60 {0.024} 0.781-0.831 {0.031-0.032} 0.55 {0.022} 0.731-0.781 {0.029-0.030} 0.50 {0.020} Install the selected adjustment shim to the converter housing.
42. Install the bearing using the SST as shown in the figure. Press-in force 8.8 kN {897 kgf, 1978 lbf}
43. Install the pawl return spring to the transaxle case.
44. Install the packing pawl and parking pawl shaft to the transaxle case.
45. Install the pawl return spring to the parking pawl and parking pawl shaft.
46. Install the support plate to the transaxle case.
47. Install the actuator plate to the transaxle case. Tightening torque 11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}
48. Install the differential.
49. Install the forward clutch hub.
50. Install the forward clutch component.
51. Apply a light coat of silicone sealant to the contact surfaces of the converter housing and the transaxle case.
52. Install the converter housing. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft-lbf}
53. Install the SST into the differential side gears.
54. Apply ATF to the new O-ring and install it to the oil pump.
55. Install the oil pump. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
56. Install the parking rod lever component. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
57. Apply ATF to the new O-ring and install it to the manual shaft.
58. Install the manual shaft. Install the manual shaft to the manual plate and detent bracket component. Install the knock pin.
59. Install the accumulator component.
60. Install the coupler component. CAUTION: Make sure that the head of the manual valve and the parking rod are assembled properly. If they are not, the ranges cannot be changed.
61. Install the primary control valve body. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} No mark: 70 mm {2.756 in}
62. Apply ATF to the new O-ring and install it to the oil strainer.
63. Install the oil strainer.
64. Match the harness colors, then connect the solenoid connector and TFT sensor. SOLENOID VALVE DESCRIPTION Solenoid valve Color of connector (harness side) Pressure control solenoid A Black Shift solenoid A White Shift solenoid B Blue Shift solenoid C Green Shift solenoid D White Shift solenoid E Black
65. Install the ground. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
66. Apply a light coat of silicone sealant to the contact surfaces of oil pan and transaxle case.
67. Install the oil pan. Tightening torque 6-8 N.m {62-81 kgf.cm, 54-70 in.lbf}
68. Apply ATF to the new O-ring and install it to the transaxle case.
69. Install the tubular pins.
70. Install the coupler component.
71. Install the secondary control valve body and ground. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} C: 50 mm {1.969 in}
72. Match the harness colors, then connect the solenoid connector. SOLENOID VALVE DESCRIPTION Solenoid valve Color of connector (harness side) Pressure control solenoid B White Shift solenoid F Black WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
73. Apply a light coat of silicone sealant to the contact surfaces of oil cover and transaxle case.
74. Install the oil cover. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}
75. Install the oil pipe and connector bolt. Tightening torque 24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
76. Install the connector pipe. Tightening torque 24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
77. Apply ATF to the new O-ring and install it to the intermediate sensor.
78. Install the intermediate sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
79. Apply ATF to the new O-ring and install it to the vehicle speed sensor.
80. Install the vehicle speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
81. Apply ATF to the new O-ring and install it to the input/turbine speed sensor.
82. Install the oil pressure switch. Tightening torque 17.1-22.1 N.m {1.75-2.25 kgf.m, 12.7-16.2 ft.lbf}
83. Install the input/turbine speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
84. Install the transaxle range switch. Rotate the manual shaft to the N position. Turn the protrusion a resistance between the terminals B and C become 750 ohms. Install the TR switch while aligning the protrusion and groove as shown. hand-tighten the TR switch mounting bolts. Inspect the resistance between the terminals B and C. If not as specified, readjust the TR switch. Resistance 750 ohms Tighten the TR switch mounting bolts Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} CAUTION: Do not use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut, or the transaxle may be damaged. Install the manual shaft lever and the washer. Set the adjustable wrench as shown to hold the manual shaft lever, and tighten the manual shaft nut. Tightening torque 32-46 N.m {3.2-4.7 kgf.m, 24-33 ft.lbf}
85. Remove the transaxle from the SST.
86. Apply ATF to the new O-ring and install it to the oil filler tube.
87. Install the oil dipstick and oil filler tube to the transaxle. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}
88. Drain any ATF remaining in the torque converter.
89. Pour in solvent (approx. 0.5 L {0.53 US qt, 0.44 Imp qt}).
90. Shake the torque converter to clean the inside.
91. Pour out the solvent.
92. Pour the ATF.
93. Install the torque converter by aligning its gap to the oil pump inner rotor gap as shown in the figure.
94. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing. Between the end of the torque converter and the end of the converter housing Distance A: 21.4 mm {0.84 in}