Automatic Transaxle - 6 Speed: Removal & Installation Mercury Montego III

Removal

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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 transmission fluid drain plug and allow the fluid to drain.
3. Disconnect the transmission fluid cooler tubes at the transaxle.
4. Disconnect the transmission fluid cooler tube bracket and position the tubes aside.
5. Remove the transmission fluid pan bolts and remove the pan.
6. Remove the sealer off the fluid pan.
7. Disconnect the wire harness from the solenoids. Remove the wire harness from the clamps. Disconnect the 8 solenoid connectors and the 2 speed sensor connectors.
8. Remove the 2 speed sensor wires from the solenoid clamp.
9. Remove the bolt and the lock plate and pull out the transmission fluid temperature (TFT) sensor.
10. Remove the 2 bolts, suction cover and gasket.
11. Remove the 6 main control valve body bolts in the sequence shown.
12. Remove the main control valve body.

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1. Connect the manual valve link and position the main control valve body in place.
2. Loosely install the 6 main control valve body bolts.
3. Install the suction cover gasket, cover and loosely install the 2 bolts.
4. Tighten the 8 bolts to 10 Nm (89 lb-in) in the sequence shown.
5. Lubricate the O-ring and install the transmission fluid temperature sensor. Tighten to 10 Nm (89 lb-in).
6. Connect the 2 speed sensor wires.
7. Connect the wire harness to the solenoids. Install the wire harness into the clamps. Connect the 8 solenoid connectors and the 2 speed sensor connectors.
8. Install a bead of sealer to the fluid pan.
9. Install the fluid pan. Tighten to 13 Nm (10 lb-ft).
10. Connect the transmission fluid cooler tubes to the transaxle. Tighten to 10 Nm (89 lb-in).
11. Connect the transmission fluid cooler tube bracket to the transaxle. Tighten to 10 Nm (89 lb-in).
12. Install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft).
13. Remove the transmission fluid fill plug.
14. Fill the transaxle with approximately 4.7L (5 quarts) of clean automatic transmission fluid.
15. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).
16. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
17. Wipe the fluid level indicator cap and remove the fluid level indicator.
18. Wipe the fluid level indicator with a clean cloth.
19. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

1. Remove the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
2. Using a suitable awl, poke a small hole in the seal.
3. Using a suitable dent puller and slide hammer, remove the LH differential fluid seal.

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1. Position the new differential fluid seal in place.
2. Using the special tool, install the outer differential fluid seal.
3. Install the LH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
4. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
5. Wipe the fluid level indicator cap and remove the fluid level indicator.
6. Wipe the fluid level indicator with a clean cloth.
7. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.
8. Remove the transmission fluid fill plug.
9. Fill the transaxle with clean automatic transmission fluid.
10. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).

1. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
2. Using the special tools, remove the differential fluid seal.

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1. Position the new differential fluid seal in place.
2. Using the special tool, install the outer differential fluid seal.
3. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232996) .
4. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
5. Wipe the fluid level indicator cap and remove the fluid level indicator.
6. Wipe the fluid level indicator with a clean cloth.
7. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper-most mark on the fluid level indicator. Only fill to the upper-most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.
8. Remove the transmission fluid fill plug.
9. Fill the transaxle with clean automatic transmission fluid.
10. Install the fluid fill plug. Tighten to 39 Nm (29 lb-ft).

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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.

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

Installation

1. Clean the rear transaxle mount bolts using a wire brush and apply new threadlock and sealer to the threads.
2. Position the transaxle mount in place and install the bolts. Tighten to 55 Nm (41 lb-ft).
3. Install the rear transaxle mount. Tighten to 90 Nm (66 lb-ft).