Automatic Transaxle - 6 Speed: Component Locations Mercury Montego III

Special Tool(s)

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

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The following items must be checked prior to beginning the diagnostic procedures.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. Shift speed ranges are approximate for all applications.

This test verifies that the shift control system is operating correctly.

1. Bring engine and transaxle up to normal operating temperature.
2. Operate vehicle with selector lever in D range.
3. Using the shift speeds chart, apply minimum throttle and observe the speeds at which the transaxle upshifts. The transaxle will upshift 1st through 6th gears.
4. Press accelerator pedal to the floor, wide-open throttle (WOT). The transaxle should downshift to the next lower gear depending on the vehicle speed. The torque converter clutch should release. SHIFT SPEED MANUAL D POSITION (MINIMUM THROTTLE) Manual D km/h mph 1-2 upshift 8-13 5-8 2-3 upshift 16-23 10-14 3-4 upshift 29-37 18-23 4-5 upshift 42-48 26-30 5-6 upshift 48-61 30-38 3-1 downshift 6-13 4-8 4-3 downshift 29-35 18-22 5-4 downshift 39-45 24-28 6-5 downshift 51-60 32-37 SHIFT SPEED MANUAL L POSITION Manual L km/h mph 1-2 upshift 29-39 18-24 2-3 upshift 74-89 46-55 3-4 upshift 113-130 70-81 4-5 upshift N/A N/A 5-6 upshift N/A N/A 2-1 downshift 21-27 13-17 3-2 downshift 61-69 38-43 4-3 downshift 100-114 62-71 5-4 downshift N/A N/A 6-5 downshift N/A N/A
5. If transaxle fails to upshift/downshift or TCC does not apply and release, refer to «DIAGNOSIS BY SYMPTOM»(ref-233010-S40556545652006052400000) for possible causes.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection
2. Know and Understand the Customer's Concern
3. Verify the Concern - carry out the torque converter operation test
4. Carry out Diagnostic Procedures: Run On-Board Diagnostics. Refer to «DIAGNOSTICS»(ref-233010-S42863492782006052400000) . Repair all non-transmission related DTCs first. Repair all transmission DTCs. Rerun On-Board Diagnostic to verify repair. Carry out Line Pressure Test. Refer to «SPECIAL TESTING PROCEDURES»(ref-233010-S37970144612006052400000) . Carry out Stall Speed Test. Refer to «SPECIAL TESTING PROCEDURES»(ref-233010-S37970144612006052400000) . Carry out diagnostic routines. Refer to «DIAGNOSIS BY SYMPTOM»(ref-233010-S40556545652006052400000) . Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and repair as required, before repairing the torque converter.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

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SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

PID NAME, DESCRIPTION AND UNITS CHART

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector as required.

Prior to carrying out the pinpoint tests, check the following

1. Transmission fluid level.
2. Transmission fluid condition (burned, metal particles or discolored).
3. Engine cooling system.
4. Other non-related transmission DTCs.

SPECIAL TOOL(S) CHART Transmission Fluid Pressure Gauge 307-004 (T57L-77820-A) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

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The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the transaxle.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Automotive Meter 105-R0057 or equivalent

The Diagnosis by Symptom charts give the technician diagnostic information, direction and suggest possible components, using a symptom as a starting point.

The Diagnosis by Symptom charts are divided into 2 categories: Electrical Routines, indicated by 200 series numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. When installing a new transmission control module, the initialized learned values will need to be carried out.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Install the diagnostic tool.
3. Turn the ignition ON.
4. The diagnostic tool should indicate NEUTRAL. If the diagnostic tool does not indicate NEUTRAL, carry out transmission control module (TCM) adjustment. For additional information, refer to «TRANSMISSION CONTROL MODULE (TCM)»(ref-233010-S17471030462006052400000) .
5. If NEUTRAL is indicated on the diagnostic tool, move the shift lever to PARK and turn the ignition OFF.
6. Turn the ignition ON and move the shift lever from PARK to DRIVE. The diagnostic tool should indicate each PRNDL position.
7. If the diagnostic display indicates each PRNDL position, check for any DTC codes.
8. If the diagnostic display does not indicate each PRNDL position, carry out «Transmission Control Module (TCM) Initial Learning»(ref-233010-S10172227992006052400000) .

SPECIAL TOOL(S) CHART Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Note. Clear all DTCs first.

Note. When installing a new transmission, transmission control module or reflashing the TCM, the initialized learned values will need to be carried out.

Note. This procedure cannot be carried out if the transmission fluid is not within the correct temperature specification.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Install the diagnostic tool.
3. Monitor and note the engagement and shift harshness on the diagnostic tool.
4. With the engine idling, monitor the transmission fluid temperature. The fluid temperature should be between 66°C-110°C (151°F-230°F).
5. With your foot on the brake, move the shift lever to NEUTRAL and hold for 3 seconds. Then move the shift lever to DRIVE and hold for 3 seconds. Carry this out 5 times. Then move the shift lever to PARK.
6. With your foot on the brake, move the shift lever to NEUTRAL and hold for 3 seconds. Then move the shift lever to REVERSE and hold for 3 seconds. Carry this out 5 times. Then move the shift lever to PARK.
7. Drive the vehicle and monitor the diagnostic tool.
8. Drive the vehicle with the throttle opening between 25-30%. Drive until the vehicle reaches 6th gear, not to exceed 80 km/h (50 mph). Then release the accelerator and coast to a stop within 60 seconds. Carry this out 10 times.
9. The engagement and shift harshness have decreased.

SPECIAL TOOL(S) CHART Installer, Output Shaft Seal 307-551

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SPECIAL TOOL(S) CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-047 (T77F-1102-A) Installer, Output Shaft Seal 307-550

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SPECIAL TOOL(S) CHART Installer, Shift Shaft fluid Seal 307-549

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
4. Disconnect the shift cable end.
5. Disconnect the transmission control module (TCM) electrical connector.
6. Remove the manual control lever nut.
7. Remove the manual control lever.
8. Remove the bolts and remove the TCM.
9. Using a suitable pick, remove the manual control lever seal.

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1. Using the special tool, install the manual control lever seal.
2. Verify that the manual lever position markings are aligned. Markings should indicate that the manual lever is in the OVERDRIVE position.
3. Install the TCM. Tighten to 24 Nm (18 lb-ft).
4. Install the manual control lever.
5. Install the manual control lever nut. Tighten to 12 Nm (9 lb-ft).
6. Connect the TCM electrical connector.
7. Connect the shift cable end.
8. Install the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
9. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
10. Check for correct vehicle operation.

SPECIAL TOOL(S) CHART Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent Engine Lifting Bracket Set 303-1140 Support Bar, Engine 303-290A Adapters for 303-290 303-290-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Remove the air cleaner and the outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
4. Remove the cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(ref-233046) .
5. Remove the upper roll restrictor bolt.
6. Remove the 4 roll restrictor brace bolts and the brace.
7. Disconnect the shift cable end.
8. Remove the electrical connector from the shift cable bracket.
9. Remove the 3 bolts for the shift cable bracket and position the cable and bracket aside.
10. Disconnect the wire harness from the transmission control module (TCM).
11. Disconnect the wire harness from the transaxle.
12. Disconnect the lower wire harness from the transaxle.
13. Remove the 4 bolts and the roll restrictor bracket.
14. Disconnect the wire harness from the roll restrictor.
15. Remove the positive crankcase ventilation (PCV) hose.
16. Disconnect the vacuum hoses from the throttle body.
17. Remove the bolt for the power steering line bracket and position aside.
18. Remove the plastic electrical cover for the starter motor electrical connectors.
19. Disconnect the 2 starter motor electrical connectors.
20. Remove the 2 bolts for the starter and the starter.
21. Remove the 2 retaining bolts and remove the roll restrictor and position aside.
22. Disconnect the ground wire.
23. Remove the 4 upper transaxle bolts.
24. If a transaxle exchange or overhaul is required, the transmission fluid must be drained. Remove the drain plug and allow the fluid to drain.
25. Remove the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
26. If removed, install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft).
27. Remove and discard the 2 nuts for the front exhaust pipe.
28. Remove and discard the 2 nuts for the rear exhaust pipe.
29. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
30. If equipped, disconnect the engine block heater electrical connector.
31. Position the heat shield for the knock sensor (KS) aside.
32. Remove the bolt and the KS.
33. Disconnect the KS wire harness from the transaxle.
34. Remove the transaxle-to-engine bolt.
35. Remove the bolt for the power steering hose.
36. Install the lower half of the lifting hook.
37. Install the upper half of the lifting hook.
38. Disconnect the vapor tube from the canister purge valve.
39. Remove the bolt for the power steering hose.
40. Install the special tool to the RH cylinder head.
41. Remove and discard the 2 bolts for the catalytic converter.
42. Install the special tool to the LH cylinder head.
43. Install the special tools to support the engine assembly.
44. Install the special tools to the LH (front) cylinder head.
45. Install the special tools to the RH (rear) cylinder head.
46. Install the special tools into the lifting hook near the EGR valve.
47. Disconnect the lower radiator hose from the retainers and position the hose aside.
48. Remove the 4 bolts retaining the power steering line to the subframe.
49. Disconnect the wire harness from the LH front of the subframe.
50. Remove the bolts and nuts for the power steering rack. Using mechanic's wire, hold the power steering rack up and out of the way.
51. Disconnect the HO2S electrical connector from the subframe.
52. Disconnect the 3 pushpins and position the splash shield aside.
53. Remove the nut for the front motor mount.
54. Remove the 2 bolts for the lower stabilizer mount.
55. Remove the nut for the rear motor mount.
56. Remove and discard the bolts for the rear transaxle mount.
57. Remove the 2 bolts for the LH rear subframe mount.
58. Remove the 2 bolts for the RH rear subframe mount.
59. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
60. Using a suitable powertrain lift, remove the 4 subframe bolts and the subframe.
61. Disconnect the HO2S electrical connector.
62. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
63. Remove the 2 pushpins and the rubber access plug.
64. Remove and discard the 4 torque converter nuts.
65. Disconnect the transmission fluid cooler tube bracket from the transaxle.
66. Disconnect the transmission fluid cooler tubes from the transaxle.
67. Position a suitable high-lift transmission jack under the transmission.
68. Remove the 3 transaxle-to-engine bolts.
69. Remove the transaxle from under the vehicle.
70. If installing a new transaxle, the fluid cooler tubes will need to be backflushed and cleaned. Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer to «TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING»(ref-233010-S37274369852006052400000) .
71. If the transaxle is to be overhauled or if installing a new transaxle, a new transmission fluid cooler will need to be installed. For additional information, refer to «TRANSAXLE/TRANSMISSION COOLING»(ref-233053) .
72. If installing a new transaxle, remove the rear transaxle mount.

SPECIAL TOOL(S) CHART Slide Hammer 307-005 (T59L100-B) Remover, Input Shaft Oil Seal 308-375 Converter Seal Installer 307-548

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SPECIAL TOOL(S) CHART Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent Engine Lifting Bracket Set 307-1140 Support Bar, Engine 303-290A Adapters for 303-290A 303-290A-01 Adapter for 303-290A (Support Leg) 303-290A-03A Adapter for 303-290A (Lifting Hook) 303-290A-12