Primary and Secondary Variator Covers: 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.

Primary variator cover

NOTE: The new retaining clip must be installed on the feed tube prior to installing the square cut seals.

Fig 1: Installing O-Ring Seal And A New Retaining Clip On Forward Clutch Feed Tube

Courtesy of FORD MOTOR CO.

Install a new O-ring seal and a new retaining clip on the forward clutch feed tube.
Install the special tool onto the forward clutch feed tube.

Fig 2: Installing Special Tool Onto Forward Clutch Feed Tube
Courtesy of FORD MOTOR CO.

NOTE: Be careful not to overextend the seals when installing, damage to the seals will occur.

Fig 3: Installing Square Cut Seals

Courtesy of FORD MOTOR CO.

Using the special tool, install 2 new square cut seals.

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.

Fig 4: Installing Forward Clutch Feed Tube Into Primary Cover

Courtesy of FORD MOTOR CO.

Lubricate the O-ring seals in clean continuously variable transaxle (CVT) transmission fluid, install the forward clutch feed tube into the primary cover and install the retaining clip.
Install a new primary variator cover feed tube with bonded seals.

Fig 5: Installing Primary Variator Cover Feed Tube With Bonded Seals
Courtesy of FORD MOTOR CO.

Secondary variator cover

Install a new square cut seal on the secondary cover.

Fig 6: Installing Square Cut Seal On Secondary Cover
Courtesy of FORD MOTOR CO.