Automatic Transmission - Electronically Controlled Continuously Variable Transmission (Ecvt): Other Mercury Mariner II

Material

Material

Transaxle Components

The Electronically Controlled Continuously Variable Transmission (eCVT) has the following internal components

1. 65 kW traction motor
2. 28 kW generator
3. One-Way Clutch (OWC) clutch
4. Planetary gearset

Scheme 5

Park

With the range selector in PARK

1. the parking pawl locks the output shaft to the case.
2. the engine may be started.
3. the ignition key can be removed.
4. the ignition switch can be cycled from OFF to START or RUN.

Reverse

With the range selector in REVERSE

1. the vehicle may be operated in a rearward direction.
2. reversing lamps are illuminated.
3. if the vehicle is not started, there is no reverse gear engagement.

Neutral

With the range selector in NEUTRAL

1. no power flows through the transmission.
2. the output shaft is disengaged from the drive wheels.

Drive

The range selector DRIVE position provides

1. low speed driving.
2. acceleration.
3. cruise conditions.
4. deceleration.
5. maximum fuel economy during normal operation.

If the vehicle is not started, there is no forward gear engagement.

Low

The range selector LOW position provides

1. engine braking.
2. improved traction on slippery roads.

If the vehicle is not started, there is no forward gear engagement.

Brake Shift Interlock System

The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the floor selector lever assembly. If the ignition switch is in the RUN position, the BSIA is continually on unless the brake pedal is depressed.

External Controls

The external control of the eCVT is mechanically controlled by a selector lever cable connected to the floor selector lever. The floor shifter position determines PARK, REVERSE, NEUTRAL, DRIVE and low modes.

Motor Electronics Cooling System (MECS)

The vehicle uses a pump driven cooling system (referred to as the Motor Electronics Cooling System (MECS)) to transfer heat generated by the eCVT and the Hybrid Electric Vehicle (HEV) battery pack to the atmosphere. The system uses a coolant-to-air radiator design.

The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional cooling systems, there is no thermostat in the MECS, so coolant flow should be continuous and considerably less than traditional powertrain cooling systems.

The flow direction is from the degas bottle and DC/DC converter to the MECS pump through the eCVT, then through the MECS radiator from the LH to RH side of the vehicle back to the degas bottle.

The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt. Flow can be verified by visually inspecting for coolant flow into the degas bottle. Only a portion of the coolant flow is diverted to the degas bottle via the "T" in the coolant outlet hose.

Scheme 6

Differential Seals - LH

Special Tools Illustration Tool Name Tool Number Installer, LH Halfshaft Fluid Seal 205-115 Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A)

Scheme 7

Scheme 8

Material

Differential Seals - RH

Special Tools Illustration Tool Name Tool Number Installer, RH Halfshaft Fluid Seal 308-382 Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A)

Material

Transmission Insulator and Retainer - Upper

Special Tools Illustration Tool Name Tool Number Adapters for 303-290A 303-290A-01 Adapter for 303-290A (Lifting Hook) 303-290A-12 Adapter for 313-290A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A

Scheme 9

Scheme 10

Transaxle

Special Tools Illustration Tool Name Tool Number Front Drive Halfshaft Remover 205-241 (T86P-3514-A) Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift (014-00765) Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Tie-Rod End Remover 211-105 (T85M-3395-A) Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-292146) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
4. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
5. Disable the vehicle high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(ref-292193) article.
6. Drain the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.
7. Drain the motor electronics cooling system. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(ref-292220) article.
8. Remove the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.
9. Remove the engine air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(ref-292221) article.
10. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-292199) article.
11. Disconnect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
12. Remove the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
13. Remove the bolts and the lateral support crossmember.
14. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
15. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
16. Disconnect the LH suspension. Remove the nut and disconnect the stabilizer bar link. Remove the tie-rod end retaining nut. Remove the lower control arm knuckle bolt.
17. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
18. Disconnect the RH suspension. Remove the nut and disconnect the stabilizer bar link. Remove the tie-rod end retaining nut. Remove the lower control arm knuckle bolt.
19. Using the special tool, disconnect the LH and RH tie-rod end from the steering knuckle.
20. Separate the LH and RH lower control arms from the lower ball joints and position the steering knuckles aside.
21. Drain the transmission fluid. For additional information, refer to «Transmission Fluid Drain and Refill»(ref-292153-S07231551552008073100000) .
22. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
23. Using the special tools, remove the RH halfshaft from the intermediate shaft and secure the halfshaft aside.
24. Remove the 2 intermediate shaft retaining nuts.
25. Remove the intermediate shaft.
26. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(ref-292222) article.
27. Remove the 3 power transfer unit (PTU) heat shield bolts and the PTU heat shield.
28. Remove the bolts and the PTU-to-engine bracket.
29. Disconnect the PTU vent hose and position it aside.
30. Remove the 4 PTU-to-transaxle bolts and remove the PTU.
31. Disconnect the heater hoses from the heater core.
32. Disconnect the upper radiator and coolant vent hoses.
33. Disconnect the PCM electrical connector. Remove the wiring harness retainer nut.
34. Disconnect the engine control harness electrical connector.
35. Disconnect the upper evaporative emissions (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
36. Remove the selector lever cable fasteners from the stud bolts on the transaxle.
37. Remove the stud bolt and disconnect the transaxle harness electrical connector.
38. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
39. Disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown).
40. Remove the 3 nuts and position aside the DC-to-DC converter.
41. If equipped, disconnect the block heater electrical connector. Detach the harness retainer clips and position harness aside.
42. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
43. Remove the bolts and the transaxle control snow shield.
44. Disconnect the selector lever cable. Release the selector lever cable from the control lever. Remove the nuts from the selector lever cable bracket.
45. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
46. Disconnect the transaxle coolant hoses.
47. Remove the 2 harness fasteners, the nut and the ground cable.
48. Remove the 2 bolts and position the motor electronics coolant pump and ground strap aside.
49. Disconnect the lower radiator hose from the radiator.
50. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
51. Remove the front roll restrictor bolt.
52. Remove the rear roll restrictor bolt.
53. Remove the nut, bolts and the engine support crossmember. Discard the nut.
54. Remove the 2 transaxle-to-engine bolts.
55. Remove the 2 transaxle-to-engine bolts.
56. Remove the rear transaxle mount nut.
57. Remove the 3 bolts and the bracket.
58. Remove the lower support insulator through bolt.
59. Remove the 2 lower support insulator nuts and 1 lower support insulator bolt.
60. Remove the 2 lower support insulator studs.
61. Remove the lower support insulator.
62. Remove and discard the steering column coupling-to-steering gear pinch bolt and separate coupling from the steering gear.
63. Remove the 2 bolts and the roll restrictor bracket.
64. Using a suitable lift table, support the subframe.
65. Loosen the 2 subframe bolts.
66. Remove the 2 subframe nuts and lower the subframe. Remove the subframe from the lift table.
67. Using the special tools, secure the engine to the lift table.
68. Remove the engine mount bracket bolt.
69. Remove the nuts and the engine mount bracket.
70. Remove the bolt, nut and the rear transaxle mount brace.
71. Remove the nuts, bolt and rear transaxle mount.
72. Lower the engine and transaxle from the vehicle.
73. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
74. Disconnect the high voltage wiring harness electrical connector.
75. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
76. Remove the bolts and the transaxle damper.

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift (014-00765) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

Material

All vehicles

1. Install the transaxle damper. Tighten to 29 Nm (21 lb-ft).
2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Connect the high voltage wiring harness electrical connector.
4. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
5. Using the special tools, secure the engine to the lift table.
6. Raise the engine and transaxle into the vehicle.
7. Install the rear transaxle mount. Tighten the nuts to 90 Nm (66 lb-ft). Tighten the bolt to 103 Nm (76 lb-ft).
8. Install the rear transaxle mount brace. Tighten to 25 Nm (18 lb-ft).
9. Install the engine mount bracket. Tighten to 115 Nm (85 lb-ft).
10. Install the engine mount bracket bolt. Tighten to 115 Nm (85 lb-ft).
11. Using the lift table, raise the subframe into position and install the 2 nuts. Tighten to 150 Nm (111 lb-ft).
12. Tighten the 2 subframe bolts. Tighten to 175 Nm (129 lb-ft).
13. Install the roll restrictor bracket and bolts. Tighten to 115 Nm (85 lb-ft).
14. Connect the steering column coupling-to-steering gear and install the new pinch bolt. Tighten to 40 Nm (30 lb-ft).
15. Install the rear transaxle mount bracket and 3 bolts. Tighten to 90 Nm (66 lb-ft).
16. Install the rear transaxle mount nut. Tighten to 90 Nm (66 lb-ft).
17. Install the lower support insulator.
18. Install the 2 lower support insulator studs. Tighten to 12 Nm (9 lb-ft).
19. Install the 2 lower support insulator nuts and 1 lower support insulator bolt. Tighten nuts and bolt to 80 Nm (59 lb-ft).
20. Install lower support insulator through bolt. Tighten to 115 Nm (85 lb-ft).
21. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
22. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
23. Install the engine support crossmember. Tighten the bolts to 90 Nm (66 lb-ft). Tighten the new nut to 175 Nm (129 lb-ft).
24. Install the rear roll restrictor bolt. Tighten to 90 Nm (66 lb-ft).
25. Install the front roll restrictor bolt. Tighten to 115 Nm (85 lb-ft).
26. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten to 25 Nm (18 lb-ft).
27. Connect the lower radiator hose to the radiator.
28. Position the motor electronics coolant pump and the ground strap. Install the 2 bolts. Tighten to 20 Nm (15 lb-ft).
29. Install the wiring harness fasteners, the ground cable and nut. Tighten to 20 Nm (15 lb-ft).
30. Connect the transaxle coolant hoses.
31. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
32. Connect the selector lever cable. Install the selector lever cable bracket and the 2 nuts finger tight. Attach the selector lever cable to the control lever.
33. Position the control lever between the 2 casting ribs on the transaxle case.
34. Place the gear selector lever in the D position.
35. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
36. To verify the correct selector lever cable adjustment, observe the selector lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
37. Install the transaxle control snow shield. Tighten to 22 Nm (16 lb-ft).
38. Install the auxiliary coolant pump and connect the electrical connector. Tighten to 10 Nm (89 lb-in).
39. If equipped, connect the block heater electrical connector. Attach the harness retainer clips.
40. Position the DC-to-DC converter in place and install the 3 nuts. Tighten to 12 Nm (9 lb-ft).
41. Connect the DC-to-DC converter electrical connector and 2 wire harness retainer (1 shown).
42. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
43. Connect the transaxle harness electrical connector and install the stud bolt. Tighten to 10 Nm (89 lb-in).
44. Install the selector lever cable fasteners on the transaxle stud bolts.
45. Connect the upper evaporative emissions (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
46. Connect the engine control harness electrical connector.
47. Connect the PCM electrical connector. Position the harness and install the nut. Tighten to 6 Nm (53 lb-in).
48. Connect the upper radiator and coolant vent hoses.
49. Connect the heater hoses to the heater core.
50. Position the power transfer unit (PTU) in place and install the 4 bolts. Tighten to 45 Nm (33 lb-ft).
51. Connect the PTU vent hose.
52. Position the PTU-to-engine support bracket and install the bolts. Tighten to 40 Nm (30 lb-ft).
53. Install the PTU heat shield and the bolts. Tighten to 14 Nm (10 lb-ft).
54. Install the driveshaft. For additional information, refer to «DRIVESHAFT»(ref-292222) article.
55. Install the intermediate shaft.
56. Install the intermediate shaft retaining nuts. Tighten to 27 Nm (20 lb-ft).
57. Install the LH and the RH halfshafts. Install the ball joints into the knuckles.
58. Connect the RH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link and install the nut. Tighten to 63 Nm (46 lb-ft).
59. Install the RH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (11 lb-ft).
60. Connect the LH suspension. Install the lower ball joint-to-knuckle bolt. Tighten to 63 Nm (46 lb-ft). Position the tie-rod end and install the retaining nut. Tighten to 55 Nm (41 lb-ft). Connect the stabilizer bar link and install the nut. Tighten to 63 Nm (46 lb-ft).
61. Install the LH brake hose retainer and the ABS sensor bolt. Tighten to 15 Nm (11 lb-ft).
62. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-292156) article.
63. Install the lateral support crossmember and the bolts. Tighten to 115 Nm (85 lb-ft).
64. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-292150) article.
65. Connect the fuel supply tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-292213) article.
66. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-292199) article.
67. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.
68. Install the engine air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(ref-292221) article.
69. Enable the vehicle high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(ref-292193) article.
70. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-292182) article.
71. Fill and bleed the motor electronics cooling system. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING - HYBRID»(ref-292220) article.
72. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-292201) article.
73. Fill the transaxle. For additional information, refer to «Transmission Fluid Drain and Refill»(ref-292153-S07231551552008073100000) .