GENERAL SPECIFICATIONS
| Item | Specification |
|---|
| Fluid |
| CAUTION: MERCON®, MERCON® V and MERCON®SP are not interchangeable with the Motorcraft Continuously Variable Chain Type Transmission Fluid. The use of any other fluid or cleaning agents will cause internal transaxle damage. Refer to the Owner/Schedule Maintenance Guide to determine the correct service interval for the specific vehicle. |
| CAUTION: The transmission fluid used for continuously variable transaxle (CVT) and 6-speed transaxles are unique. Do not use water-based cleaners to clean or flush the cooler tubes or transmission damage will occur. Mineral spirits can be used to clean the cooler tubes, providing the cooler tubes are flushed with clean automatic transmission fluid and blown dry with shop air. Use only clean automatic transmission fluid designated for the transmission and torque converter being serviced. |
| CAUTION: The use of cleaning solvents and petroleum lubricants should not be used on this transaxle. They may contaminate the CVT fluid and cause internal transaxle damage. Only clean CVT fluid should be used to clean and assemble this transaxle. |
| Motorcraft Continuously Variable Chain Type Transmission Fluid XT-7-QCFT | WSS-M2C933-A |
| Fluid Capacities |
| All | 9.6L (10 quarts) (approximate dry fill capacities) |
| Lubricants |
| Multi-Purpose Grease XG-4 and/or XL-5 | ESB-M1C93-B |
| Constant Velocity Joint Grease XG-5 | WSS-M1C258-A1 |
| CAUTION |
|---|
| MERCON®, MERCON® V and MERCON®SP are not interchangeable with the Motorcraft Continuously Variable Chain Type Transmission Fluid. The use of any other fluid or cleaning agents will cause internal transaxle damage. Refer to the Owner/Schedule Maintenance Guide to determine the correct service interval for the specific vehicle. |
| CAUTION |
|---|
| The transmission fluid used for continuously variable transaxle (CVT) and 6-speed transaxles are unique. Do not use water-based cleaners to clean or flush the cooler tubes or transmission damage will occur. Mineral spirits can be used to clean the cooler tubes, providing the cooler tubes are flushed with clean automatic transmission fluid and blown dry with shop air. Use only clean automatic transmission fluid designated for the transmission and torque converter being serviced. |
| CAUTION |
|---|
| The use of cleaning solvents and petroleum lubricants should not be used on this transaxle. They may contaminate the CVT fluid and cause internal transaxle damage. Only clean CVT fluid should be used to clean and assemble this transaxle. |
INPUT SHAFT END PLAY SPECIFICATION
| Item | Specification |
|---|
| Clearance | 0.22-0.53 mm (0.008-0.021 inch) |
| Input shaft bearing spacer thickness | 1.50 mm (0.05 inch) 1.60 mm (0.06 inch) 1.70 mm (0.06 inch) 1.80 mm (0.07 inch) 1.90 mm (0.07 inch) 2.00 mm (0.07 inch) 2.10 mm (0.08 inch) 2.20 mm (0.08 inch) 2.30 mm (0.09 inch) 2.40 mm (0.09 inch) 2.50 mm (0.09 inch) 2.60 mm (0.1 inch) 2.70 mm (0.1 inch) 2.80 mm (0.11 inch) 2.90 mm (0.11 inch) |
INPUT SHAFT END PLAY SPECIFICATION
DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION
| Part Number | Selective Shim Thickness |
|---|
| 7F119 | 1.00 mm (0.039 inch) |
| 7F119 | 1.05 mm (0.041 inch) |
| 7F119 | 1.10 mm (0.043 inch) |
| 7F119 | 1.15 mm (0.045 inch) |
| 7F119 | 1.20 mm (0.047 inch) |
| 7F119 | 1.25 mm (0.049 inch) |
| 7F119 | 1.30 mm (0.051 inch) |
| 7F119 | 1.35 mm (0.053 inch) |
| 7F119 | 1.40 mm (0.055 inch) |
| 7F119 | 1.45 mm (0.047 inch) |
| 7F119 | 1.50 mm (0.059 inch) |
| 7F119 | 1.55 mm (0.061 inch) |
| 7F119 | 1.60 mm (0.063 inch) |
| 7F119 | 1.65 mm (0.065 inch) |
| 7F119 | 1.70 mm (0.067 inch) |
| 7F119 | 1.75 mm (0.068 inch) |
| 7F119 | 1.80 mm (0.070 inch) |
| 7F119 | 1.85 mm (0.072 inch) |
| 7F119 | 1.90 mm (0.074 inch) |
| 7F119 | 1.95 mm (0.076 inch) |
| 7F119 | 2.00 mm (0.078 inch) |
| 7F119 | 2.05 mm (0.080 inch) |
| 7F119 | 2.10 mm (0.081 inch) |
DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION
TORQUE SPECIFICATIONS
| Description | Nm | Lb-ft | Lb-in |
|---|
| Transmission fluid pan bolts | 12 | 9 | |
| Transmission fluid drain plug | 25 | 18 | |
| Transmission fluid fill plug | 35 | 26 | |
| Transmission fluid level indicator tube | 10 | | 89 |
| Pressure filter cover bolts | 10 | | 89 |
| Primary variator cover bolts (1) | | | |
| Secondary variator cover bolts (1) | | | |
| Mechatronic bolts (1) | | | |
| Rear driveshaft-to-power transfer unit (PTU) bolts | 25 | 18 | |
| Rear driveshaft cross brace bolts | 30 | 22 | |
| Torque converter retaining nuts | 36 | 27 | |
| Transaxle-to-engine retaining bolts | 40 | 30 | |
| Transaxle roll restrictor (2) | 40 | 30 | |
| Transaxle roll restrictor upper roll restrictor brace (2) | 48 | 35 | |
| Shift cable bracket bolts | 25 | 18 | |
| Starter motor bolts | 26 | 19 | |
| Starter motor electrical connector (B+) | 12 | 9 | |
| Starter motor electrical connector (small) | 5 | | 44 |
| Ground wire bolt | 12 | 9 | |
| PTU retaining bolts | 90 | 66 | |
| PTU bracket-to-engine | 55 | 41 | |
| Catalytic converter bracket bolts | 40 | 30 | |
| Catalytic converter bolts | 40 | 30 | |
| Exhaust pipe bolts and nuts | 40 | 30 | |
| Exhaust gas recirculation (EGR) tube | 40 | 30 | |
| Engine knock sensor | 10 | | 89 |
| Transmission fluid cooler tube bracket | 10 | | 89 |
| Transmission fluid cooler tube-to-pressure filter cover | 10 | | 89 |
| Subframe bolts | 90 | 66 | |
| Subframe bracket bolts | 48 | 35 | |
| Rear transaxle mount-to-transaxle bolts (2) | 55 | 41 | |
| Rear transaxle mount-to-subframe bolts | 90 | 66 | |
| Rear motor mount nut | 70 | 52 | |
| Front motor mount | 70 | 52 | |
| Lower stabilizer mount bolt | 70 | 52 | |
| Power steering bolts | 133 | 98 | |
| Power steering line retaining bolts | 7 | | 62 |
| Stabilizer link nuts | 55 | 41 | |
| Transaxle range selector valve | 5 | | 44 |
| Fluid feed transfer tube retaining bracket | 10 | | 89 |
| Transmission fluid baffle | 5 | | 44 |
| Transaxle converter housing (1) | | | |
| Side shaft assembly | 23 | 17 | |
| Transaxle electrical connector outer shell | 6 | | 53 |
| Output shaft speed (OSS) sensor bolt | 8 | | 71 |
| Pump cover seal | 10 | | 89 |
| Stator support bolts | 14 | 10 | |
| Pump housing bolts | 16 | 12 | |
| (1) Refer to the PROCEDURE . (2) When reinstalling fasteners originally coated with threadlock, clean the bolt threads with a wire brush prior to applying new threadlock. Apply threadlock to threads of the bolt. |
| (1) | Refer to the PROCEDURE . |
| (2) | When reinstalling fasteners originally coated with threadlock, clean the bolt threads with a wire brush prior to applying new threadlock. Apply threadlock to threads of the bolt. |
Torque Converter
The converter consists of the impeller, the turbine wheel, the reactive element (stator) and the fluid used to transmit the torque. The impeller is driven by the engine and imparts a circular flow to the fluid in the converter. The angle of the fluid flow is deflected when it strikes the turbine wheel. The fluid leaves the turbine wheel close to the hub, and passes through the stator, where it is again deflected and enters the impeller at an angle. The change in the direction of fluid flow at the stator generates a reaction torque that increases the torque at the turbine. The ratio between turbine torque and impeller torque is the torque conversion ratio. The greater the speed difference between the impeller and the turbine, the greater the increase in torque; this increase reaches a maximum when the turbine is stationary. As turbine speed rises, the increase in torque lessens. When the turbine is running at about 85 percent of the impeller speed, the increase in torque drops to one, that is to say turbine and impeller torques are identical. The stator, which bears against the gearbox housing via a one-way clutch and the stator shaft, can then revolve freely in the fluid flow, and the freewheel is overrun. From this moment, the converter operates purely as a fluid coupling. During the torque conversion phase, the stator is stationary and bears against the housing through the freewheel.
Torque Converter Clutch
The torque converter clutch is a device that eliminates slip in the torque converter and therefore helps to keep fuel consumption to a minimum.
Torque Converter Operation Test
Note. The torque converter clutch will not engage if the transmission fluid temperature is below 0°C (32°F).
- Using the special tool, make sure that the transmission fluid temperature is within specification 43°C-47°C (109°F-117°F).
- Accelerate the vehicle to 35-60 km/h (22-37 mph) and maintain a consistent speed.
- Release the accelerator pedal to close the throttle and press the accelerator to partially open the throttle while monitoring the special tool engine speed and TCC PID 194D. The TCC PID on the special will read 0 when the TCC clutch is released, and 1 when the TCC is applied. The engine speed will increase when the TCC is released and decrease when the TCC is applied.
- If these actions do not occur, refer to «DIAGNOSIS BY SYMPTOM»(ref-233028-S04141298392006052400000) in this section.
PINPOINT TEST D: TORQUE CONVERTER CLUTCH
- D1 ELECTRONIC DIAGNOSTICS Check to make sure the transaxle harness connector is fully seated, pins are fully engaged in the connector and in good condition before proceeding. Connect the scan tool. Drive the vehicle with a steady speed up to and above 24 km/h (15 mph). Monitor PID: (PCE/TCC). The TCC commanded pressure should be greater than 400 kPa (44 psi) and the turbine shaft speed should be equal to engine speed. Is the lockup commanded pressure greater than 400 kPa (44 psi) and the turbine speed equal to engine speed? Yes : CLEAR all DTCs. ROAD TEST to verify if concern is still present. Concern could be intermittent. No : INSTALL a new torque converter.
Fluid Leakage in Torque Converter Area
In diagnosing and correcting fluid leaks in the torque converter area, use the following procedures to locate the exact cause of the leakage. Leakage at the front of the transaxle, as evidenced by fluid around the torque converter housing, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of the leak before removing the transaxle from the vehicle. The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the illustration. The 5 steps following correspond with the numbers in the illustration.
Scheme 198
Scheme 198: Fluid Leakage in Torque Converter Area
- Fluid leaking by the converter hub seal lip will tend to move along the drive hub and onto the back of the torque converter. Except in the case of a total seal failure, fluid leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near the outside diameter of the housing.
- Fluid leakage by the outside diameter of the converter hub seal and the case will follow the same path that leaks by the inside diameter of the converter hub seal follow.
- Fluid leakage from the converter cover weld or the converter-to-flexplate stud weld will appear at the outside diameter of the torque converter on the back face of the flexplate and in the converter housing only near the flexplate. If a converter-to-flexplate stud or converter cover weld leak is suspected, install a new torque converter.
- Fluid leaking from the pump cover, pump cover bolts or the torque converter hub seal inside the converter housing will flow down the back of the torque converter housing. Leakage may be from loose or missing pump cover bolts, defective pump cover seal or defective torque converter hub seal.
- Engine oil leaks are sometimes incorrectly diagnosed as transaxle converter hub seal leaks. The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the concern. Leakage at the valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block, causing oil to be present in or at the bottom of the torque converter housing. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing. Leakage at the crankshaft rear oil seal will work back to the flexplate and then into the torque converter housing. Leakage at the oil pressure sensor. Cracks in the block. Leakage from the engine oil pan.
Torque Converter Operation Concerns: No Apply
| Possible Component | Reference/Action |
|---|
| 240 - ROUTINE |
| Incorrect Pressures | |
| Low pressure | Check pressure PIDs. If low, check main control valve body. |
| Mechatronic Assembly | |
| Bolts out of torque specification | Check bolt specification. |
| PC solenoid B - damaged, not functioning | GO to PINPOINT TEST E . |
| Torque converter clutch seal - damaged | Inspect for damage. Repair as required. |
Torque Converter Operation Concern: Cycling/Shudder/Chatter
| Possible Component | Reference/Action |
|---|
| 242 - ROUTINE |
| Fluid | |
| Fluid condition | Inspect fluid condition. If burnt, drain fluid. Install new fluid and fluid filter assembly. Bring vehicle to normal operating temperature. |
| Incorrect Pressures | |
| Low pressure | Check pressure PIDs. |
| Torque converter clutch seal - damaged | Inspect for damage. Repair as required. |
- A new torque converter must be installed if one or more of the following statements is true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter stud or studs, impeller hub or bushing are damaged. Discoloration or distortion of cover (due to overheating). Evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes: Major metallic failure. Multiple clutches or clutch plate failures. Sufficient component wear which results in metallic contamination. Internal torque converter contamination present. For additional information refer to «TORQUE CONVERTER CONTAMINATION INSPECTION»(ref-233028-S12160823102006052400000) .
