Torque Converter Housing, Reverse Clutch and Pump Assembly - Assembly: Assembly

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

Pump Assembly

NOTE: The pump assembly cannot be taken apart. It must be installed new as an assembly.

Fig 1: Installing Special Tool Into Soft-Jawed Vice

Courtesy of FORD MOTOR CO.

Inspect the pump for contamination, if contamination is present a new pump must be installed. The new pump assembly comes with a new seal. The seal will need to be removed and discarded in order to align and install the pump into the case.
Install the special tool into a soft-jawed vice.
Set the pump assembly onto the special tool to correctly align the pump.

Fig 2: Setting Pump Assembly Onto Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool into the center of the special tool to keep the pump centered.

Fig 3: Installing Special Tool Into Center Of Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool onto the top of the pump.

Fig 4: Installing Special Tool Onto Top Of Pump
Courtesy of FORD MOTOR CO.
Install the pump gasket. Note the location of the bleed slots in the gasket.

Fig 5: Installing Pump Gasket
Courtesy of FORD MOTOR CO.
Install the special tools. Note the location of the bleed slot in the gasket.

Fig 6: Installing Special Tools
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean continuously variable transaxle (CVT) transmission fluid and install the O-ring seals onto the feed tube.

Fig 7: Installing O-Ring Seals Onto Feed Tube
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the inner and outer seals in clean CVT transmission fluid.

NOTE: The installation of the pump into the case is done in a later step. Do not install the pump into the case at this time.

Fig 8: Installing Feed Tube Into Pump Cover

Courtesy of FORD MOTOR CO.

Install the feed tube into the pump cover.

NOTE: Partially install the stator support and loosely install 2 bolts for alignment.

Fig 9: Installing Stator Support

Courtesy of FORD MOTOR CO.

Using the special tool, install the stator support.
Install the remaining bolts. Tighten the bolts in a crisscross pattern.
- Tighten to 14 Nm (10 lb-ft).
  
  Fig 10: Installing Remaining Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, install the stator support bearing.

Fig 11: Installing Stator Support Bearing
Courtesy of FORD MOTOR CO.
From the opposite side of the case, install the pump assembly into the transaxle case.

Fig 12: Installing Pump Assembly Into Transaxle Case
Courtesy of FORD MOTOR CO.
Loosely install the pump bolts.

Fig 13: Installing Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the special tools and loosely install the remaining bolts.

Fig 14: Installing Remaining Bolts
Courtesy of FORD MOTOR CO.
Tighten in the sequence shown.
- Tighten to 16 Nm (12 lb-ft).
  
  Fig 15: Tightening Sequence Of Bolts
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 16: Removing Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 17: Removing Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install a new pump seal.

Fig 18: Installing Pump Seal
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the inner and outer seals in clean CVT transmission fluid.

Fig 19: Positioning Pump Dust Cover

Courtesy of FORD MOTOR CO.

Position the pump dust cover in place.
Install the special tools.

Fig 20: Installing Special Tools
Courtesy of FORD MOTOR CO.
Using the special tools, install the pump dust cover.

Fig 21: Installing Pump Dust Cover
Courtesy of FORD MOTOR CO.
Install the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Installing Bolts
  Courtesy of FORD MOTOR CO.

Reverse clutch

CAUTION: MERCON®, MERCON® V and MERCON®SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

NOTE: Pre-soak all of the new clutch plates in clean CVT transmission fluid.

NOTE: To correctly select the selective snap ring, the reverse clutch assembly will need to be assembled incorrectly.

NOTE: Clean and inspect all reverse clutch parts, install new parts as required.

NOTE: Lubricate the seals in clean CVT transmission fluid.

Fig 23: Installing Inner And Outer O-Ring Seals

Courtesy of FORD MOTOR CO.

Install new inner and outer O-ring seals.
Install the reverse clutch piston.

Fig 24: Installing Reverse Clutch Piston
Courtesy of FORD MOTOR CO.
Install the return spring.

Fig 25: Installing Return Spring
Courtesy of FORD MOTOR CO.
Using the special tool, install the return spring retainers.

Fig 26: Installing Return Spring Retainers
Courtesy of FORD MOTOR CO.

NOTE: The new clutch plates must be installed in the following order. Do not install the wave spring at this time.

Fig 27: Installing Clutch Plates

Courtesy of FORD MOTOR CO.

Install a steel plate, a friction plate, a second steel plate, a second friction plate, a third steel plate, a third friction plate and the pressure plate.
Install the reverse clutch plate snap ring.

Fig 28: Installing Reverse Clutch Plate Snap Ring
Courtesy of FORD MOTOR CO.
Install the special tool. Zero out the special tool.

Fig 29: Installing Special Tool
Courtesy of FORD MOTOR CO.

WARNING: Air pressure must not exceed 172 kPa (25 psi). Wear safety glasses when using compressed air and make sure that the clutch snap ring is in and completely seated. Failure to follow these instructions may result in personal injury.

Fig 30: Measuring Clutch Snap Ring Clearance

Courtesy of FORD MOTOR CO.

Using compressed air, apply air to the case so the clutch plates contact the reverse clutch snap ring and record the measurement. Enter this measurement in the following table on the line labeled A. Repeat this step 3 times and take the average of the 3 readings.

NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.33--1.53 mm (0.052--0.060 inch).

Select the selective snap ring.

SNAP RING SPECIFICATION

Description	Reading
A
B	+ 0.54 mm (0.02 in)
C	- 1.50 mm (0.059 in)
(D) Clearance

Add line A to B, then subtract line C and enter this total on line D.
Line D is the actual clearance of the snap ring used during this measurement.
If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.

Reverse Clutch Selective Snap Ring

Remove the reverse clutch pack snap ring.

REVERSE CLUTCH SELECTIVE SNAP RING SPECIFICATION

Part Number Snap	Ring Thickness
7H365	2.00 mm (0.07 in)
7H365	1.80 mm (0.07 in)
7H365	1.60 mm (0.06 in)
7H365	1.40 mm (0.05 in)
7H365	1.20 mm (0.04 in)
7H365	1.00 mm (0.03 in)

Fig 31: Removing Reverse Clutch Pack Snap Ring

Courtesy of FORD MOTOR CO.

Remove the reverse clutch plates, steel and friction.

Fig 32: Removing Reverse Clutch Plates, Steel And Friction
Courtesy of FORD MOTOR CO.
Install the reverse clutch wave spring.

Fig 33: Reverse Clutch Wave Spring
Courtesy of FORD MOTOR CO.
Install the ring gear assembly.

Fig 34: Removing Ring Gear Assembly
Courtesy of FORD MOTOR CO.
Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.

Fig 35: Installing Reverse Clutch Plates, Steel And Friction, Alternating Between Steel And Friction
Courtesy of FORD MOTOR CO.
Install the reverse clutch pressure plate.

Fig 36: Installing Reverse Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Install the reverse clutch pack snap ring.

Fig 37: Installing Reverse Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.

Case housing

NOTE: The bearing race and shim will be installed in the case during the assembly of the transaxle after differential set up.

Fig 38: Inspecting Bearing Race And Shim

Courtesy of FORD MOTOR CO.

Inspect the bearing race and shim for damage. If damage is indicated install a new race. If new differential bearing is installed, a new bearing race should also be installed.
Using the special tools, install the roller bearing and race as an assembly.

Fig 39: Installing Roller Bearing And Race
Courtesy of FORD MOTOR CO.
Using the special tools, install the roller bearing and race as an assembly.

Fig 40: Installing Roller Bearing And Race
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals onto the secondary shaft and stator needle bearing lube tube.

Fig 41: Installing O-Ring Seals Onto Secondary Shaft And Stator Needle Bearing Lube Tube
Courtesy of FORD MOTOR CO.
Using new sealing washers, install the bolt onto the lube tube.

Fig 42: Installing Bolt Onto Lube Tube
Courtesy of FORD MOTOR CO.
Lubricate the O-ring seals with clean CVT transmission fluid and install the secondary shaft and stator needle bearing lube tube into the case.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 43: Installing Secondary Shaft And Stator Needle Bearing Lube Tube Into Case
  Courtesy of FORD MOTOR CO.