Automatic Transaxle/transmission: Maintenance Lincoln Aviator I

Fluid Pump

For component location, refer to DISASSEMBLED VIEWS .

1. The fluid pump provides the fluid pressure necessary to charge the torque converter, main control assembly, transmission cooling system, lubrication system and apply devices.
2. The fluid pump is a positive displacement, gear type pump. The fluid pump is driven by the torque converter impeller hub.

Transmission Fluid Temperature (TFT) Sensor

1. The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature.
2. The TFT is located on the solenoid body.
3. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and pressure control requirements.

It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits torque converter clutch (TCC) operation at low transmission fluid temperatures and use to determine pressure control (PC) solenoid operations.

Check Fluid Level and Condition

Note. If the vehicle has been operated for an extended period of time at highway speeds, city traffic, hot weather, or pulling a trailer, the fluid needs to cool down 30 minutes to obtain an accurate reading.

This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the transmission operation and could result in transmission damage. To correctly check and add fluid to the transmission, refer to TRANSMISSION FLUID LEVEL CHECK .

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 erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission damage. Refer to TRANSMISSION FLUID LEVEL CHECK to correct a possible overfill condition.

Low Fluid Level

A low fluid level can result in poor transmission engagement, slipping or damage. This can also indicate a leak in one of the transmission seals or gaskets.

Adding Fluid

If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid level plug in the bottom of the pan. Do not overfill the fluid. For fluid filling, refer to TRANSMISSION FLUID LEVEL CHECK . For fluid type, refer to GENERAL SPECIFICATIONS .

Fluid Condition Check

1. Check the fluid level. For additional information refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-193005-S21045706142005092300000) .
2. Observe the color and the odor of the fluid. Under normal circumstances the color should be dark reddish, not brown or black.
3. Allow the fluid to drip onto a 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 transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned.
6. Carry out diagnostic checks and adjustments. Refer to «DIAGNOSIS BY SYMPTOM»(ref-193005-S08387544602005092300000) .

Draining

1. With the vehicle in PARK, position on a hoist.
2. Use a suitable flush and fill machine to change the fluid.
3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in the fluid coolers.

Refill

1. Use only clean automatic transmission fluid.
2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes.
3. Lower the vehicle.
4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24-liter (0.5-pint) until the correct level is achieved. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-193005-S21045706142005092300000) .

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Fluid Fill Reference

Note. Left side of case is shown.

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1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible.
2. Remove the drain plug (large plug) and allow the fluid to drain.

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1. Install the fluid drain plug.
2. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug using a 3/16-inch Allen key.
3. Install the special tool into the pan.
4. Fill the special tool with clean automatic transmission fluid.
5. Hang the special tool under the vehicle, upright and close to the transmission.
6. Connect the special tools. Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the, Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan.
7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan.
8. Add two or three quarts of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose.
9. Start and run the engine until the transmission fluid temperature is between 27°C - 49°C (80°F - 120°F).
10. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat steps 9 and 10.
11. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose of the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container.
12. Allow the fluid to drain. When the fluid comes out as a thin stream or drip, the fluid is at the correct level.
13. Reinstall the small (center) fluid level indicating plug using a 3/16-inch Allen key.

Transmission Fluid Cooler - Backflushing and Cleaning

1. Carry out backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described. Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.

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1. With the vehicle in the NEUTRAL, position on a hoist.
2. Move the rubber boot back to gain access to the connector.
3. Disconnect the digital TR sensor connector.
4. Remove the shift cable from the manual control lever.
5. Remove the outer manual control lever.
6. Loosen the screws.
7. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
8. Install the outer manual lever.
9. Install the shift cable to the manual control lever.
10. Reconnect the digital TR sensor connector.
11. Move the rubber boot back over the connector.
12. Verify that the shift cable is adjusted correctly. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-193005-S38765111282005092300000) .
13. Lower the vehicle.
14. Verify that the vehicle will start in PARK and NEUTRAL, and that the reverse lamps illuminate in REVERSE.

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1. Place the transmission range selector lever in the first position all the way toward the rear of the vehicle.
2. Move the transmission range selector lever forward three detents. This should be the (D) position.
3. Position the vehicle on a hoist.
4. Disconnect the shift cable from the manual lever.
5. Rotate the manual lever forward until the travel stops. Then rotate the manual lever back three detents to the (D) position.
6. Using a suitable tool, unlock tab on the shift cable. With the cable unlocked, make sure the cable slides forward and backward.
7. Carry out the following: Make sure that the shift cable slides forward and backward. Connect the shift cable to the manual control lever, making sure not to move the lever. Move the cable to match the position of the manual lever. Press the shift cable adjustment lock downward to the lock position.
8. Lower the vehicle.
9. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range TR sensor. For additional information on the TR sensor adjustment, refer to «Transmission Range (TR) Sensor Adjustment»(ref-193005-S38537561152005092300000) .

Scheme 366

Note. Make sure that the fluid filter seals are correctly seated on the filter.

Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Note. Install a new transmission fluid filter.

Scheme 367

1. With the vehicle in PARK, position on a hoist.
2. Remove the components in the order indicated in the illustration.
3. To install, reverse the removal procedure.
4. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-193005-S15199184222005092300000) .

Item 6: Transmission Fluid Pan Filter Installation Note

1. Lubricate the seals and install the transmission fluid filter.

Item 3: Transmission Fluid Pan Installation Note

Scheme 368

1. Install the transmission fluid pan and gasket and loosely install the screws.

Item 2: Transmission Fluid Pan Screws Installation Note

Scheme 369

1. Tighten the screws in a crisscross sequence.

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Note. Make sure that the fluid filter seals are correctly seated on the filter.

Note. When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and this is a temporary condition and will eventually return to normal operating condition.

Note. Clean the area around the connector to prevent contamination of the solenoid body connector.

Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. With the vehicle in PARK, position on a hoist.
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.
5. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-193005-S15199184222005092300000) .

Item 22: Main Control Valve Body Installation Note

Scheme 374

1. Install the special tools into the transmission case.

Item 19, 20 and 21: Main Control Valve Body Screws Installation Note

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1. Using the special tools, install the main control valve body and loosely install the screws. Install the short screw. Install the screw with the larger head. Install the remaining screws.
2. Remove the special tools, and loosely install the screw.
3. Tighten the screws in the sequence shown.

Item 15: Reverse Servo Screws Installation Note

Scheme 378

1. Install the reverse servo. Tighten the screws in the sequence shown.

Item 14: Solenoid Body O-rings Seals Installation Note

Scheme 379

1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Items 11, 12 and 13: Solenoid Body and Screws Installation Note

1. Install the solenoid body. Tighten the screws in sequence shown.

Item 10: Transmission Fluid Pan Filter Installation Note

1. Lubricate the seals and install the transmission fluid filter.

Item 7: Transmission Fluid Pan Installation Note

Scheme 380

1. Install the transmission fluid pan and gasket and loosely install the screws.

Item 6: Transmission Fluid Pan Screws Installation Note

Scheme 381

1. Tighten the screws in a crisscross sequence.

Item 5: Solenoid Body Harness Electrical Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

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1. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.

Item 1: Output Shaft Seal Removal Note

Scheme 384

1. Using the special tools, remove the extension housing seal.

Item 1: Output Shaft Seal Installation Note

Scheme 385

1. Using the special tool, install the extension housing seal.

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1. Remove the transfer case assembly. For additional information, refer to «FOUR WHEEL DRIVE SYSTEMS»(ref-193007) .
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.
4. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-193005-S21045706142005092300000) .

Item 1: Output Shaft Seal Removal Note

Scheme 388

1. Using the special tools, remove the extension housing seal.

Item 1: Output Shaft Seal Installation Note

1. Using the special tool, install the extension housing seal.

Scheme 389

1. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
2. Support the transmission with a suitable jack.
3. Remove the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4x2»(ref-193005-S34180973482005092300000) .
4. Remove the components in the order indicated in the following illustration.
5. To install, reverse the removal procedure.
6. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-193005-S21045706142005092300000) .

Item 2: Extension Housing Removal Note

1. Remove the extension housing.

Item 2: Extension Housing Installation Note

1. Install the extension housing.

Scheme 390

1. Remove the transfer case assembly. For additional information, refer to «FOUR WHEEL DRIVE SYSTEMS»(ref-193007) .
2. Remove the components in the order indicated in the illustration.
3. To install, reverse the removal procedure.
4. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-193005-S21045706142005092300000) .

Item 2: Extension Housing Removal Note

1. Remove the extension housing.

Item 2: Extension Housing Installation Note

1. Install the extension housing.

Scheme 391

Note. When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and this is a temporary condition and will eventually return to normal operating condition.

Scheme 392

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. With the vehicle in PARK, position on a hoist.
3. Remove the components in the order indicated in the following illustration.
4. To install, reverse the removal procedure.
5. Verify that the shift cable is adjusted correctly. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-193005-S38765111282005092300000) .

Item 13: Solenoid Body O-Ring Seals Installation Note

Scheme 393

1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Item 10 and 11: Solenoid Body Screws Installation Note

1. Install the solenoid body. Tighten the screws in the sequence shown.

Item 6: Transmission Fluid Pan Installation Note

Scheme 394

1. Install the transmission fluid pan and gasket and loosely install the screws.

Item 5: Transmission Fluid Pan Screws Installation Note

Scheme 395

1. Tighten the screws in a crisscross sequence.

Item 4: Solenoid Body Harness Electrical Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

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1. On 4x4 vehicles, remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
2. On 4x2 vehicles, with the vehicle in NEUTRAL, position on a hoist.
3. It is not necessary to remove the shift cable and bracket from the transmission.
4. Remove the components in the order indicated in the following illustration.
5. To install, reverse the removal procedure
6. Refill the transmission with the specified fluid.
7. Verify that the shift cable is adjusted correctly. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-193005-S38765111282005092300000) .

Item 1: TR Sensor Electrical Connector Removal Note

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1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.

Item 6: TR Sensor Installation Note

1. Install the digital TR sensor and loosely install the screws.

Item 5: TR Sensor Screws Installation Note

1. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Item 1: TR Sensor Electrical Connector Installation Note

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1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.

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Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Scheme 403

1. With the vehicle in PARK, position on a hoist.
2. Remove the components in the order indicated in the following illustration.
3. To install, reverse the removal procedure.
4. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-193005-S15199184222005092300000) .

Item 5: Reverse Servo Screws Installation Note

Scheme 404

1. Install the reverse servo. Tighten the screws in the sequence shown in two stages. Stage 1: Tighten screws to 5 Nm (44 lb-in) Stage 2: Tighten screws to 11 Nm (8 lb-ft)

Item 3: Transmission Fluid Pan Installation Note

Scheme 405

1. Install the transmission fluid pan and gasket, and loosely install the screws.

Item 2: Transmission Fluid Pan Screws Installation Note

Scheme 406

1. Tighten the screws in a crisscross sequence.

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