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

Pump Assembly 

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.

1. Install the special tool into a soft-jawed vice.
   Fig 1: Identifying Special Tool (307-544-1)

   Courtesy of FORD MOTOR CO.
2. Set the pump assembly onto the special tool to correctly align the pump.
   Fig 2: Setting Pump Assembly Onto Special Tool (307-544-1)

   Courtesy of FORD MOTOR CO.
3. Install the special tool into the center of the special tool to keep the pump centered.
   Fig 3: Identifying Special Tool (307-544-2)

   Courtesy of FORD MOTOR CO.
4. Install the special tool onto the top of the pump.
   Fig 4: Identifying Special Tool (307-544-2, 307-544-4A)

   Courtesy of FORD MOTOR CO.
5. Install the pump gasket. Note the location of the bleed slots in the gasket.
   Fig 5: Locating Pump Gasket

   Courtesy of FORD MOTOR CO.
6. Install the special tools. Note the location of the bleed slot in the gasket.
   Fig 6: Identifying Special Tools (307-544-3)

   Courtesy of FORD MOTOR CO.
7. 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: Locating O-Ring Seals

   Courtesy of FORD MOTOR CO.
NOTE:
1. Lubricate the inner and outer seals in clean CVT transmission fluid.
2. 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: Identifying Feed Tube Into Pump Cover
Courtesy of FORD MOTOR CO.
8. Install the feed tube into the pump cover.
NOTE: Partially install the stator support and loosely install 2 bolts for alignment.
Fig 9: Identifying Special Tools (205-153, 307-540-1)
Courtesy of FORD MOTOR CO.
9. Using the special tool, install the stator support.
10. Install the remaining bolts. Tighten the bolts in a crisscross pattern.
    • Tighten to 14 N.m (10 lb-ft).
    Fig 10: Locating Bolts

    Courtesy of FORD MOTOR CO.
11. Using the special tool, install the stator support bearing.
    Fig 11: Identifying Special Tools (205-153, 307-540-1)

    Courtesy of FORD MOTOR CO.
12. From the opposite side of the case, install the pump assembly into the transaxle case.
    Fig 12: Locating Pump Assembly Using Special Tools (307-544-3)

    Courtesy of FORD MOTOR CO.
13. Loosely install the pump bolts.
    Fig 13: Locating Pump Bolts Using Special Tools (307-544-3) As Guides

    Courtesy of FORD MOTOR CO.
14. Remove the special tools and loosely install the remaining bolts.
    Fig 14: Locating Bolts

    Courtesy of FORD MOTOR CO.
15. Tighten in the sequence shown.
    • Tighten to 16 N.m (12 lb-ft).
    Fig 15: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
16. Remove the special tool.
    Fig 16: Identifying Special Tools (307-544-2, 307-544-4)

    Courtesy of FORD MOTOR CO.
17. Remove the special tool.
    Fig 17: Identifying Special Tool (307-544-4A)

    Courtesy of FORD MOTOR CO.
18. Using the special tool, install a new pump seal.
    Fig 18: Installing Pump Seal Using Special Tool (307-524)

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner and outer seals in clean CVT transmission fluid.
Fig 19: Locating Pump Dust Cover
Courtesy of FORD MOTOR CO.
19. Position the pump dust cover in place.
20. Install the special tools.
    Fig 20: Identifying Special Tools (307-127)

    Courtesy of FORD MOTOR CO.
21. Using the special tools, install the pump dust cover.
    Fig 21: Identifying Special Tools (307-127, 307-542)

    Courtesy of FORD MOTOR CO.
22. Install the bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 22: Locating 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:

    1. Pre-soak all of the new clutch plates in clean CVT transmission fluid.
    2. To correctly select the selective snap ring, the reverse clutch assembly will need to be assembled incorrectly.
    3. Clean and inspect all reverse clutch parts, install new parts as required.
NOTE: Lubricate the seals in clean CVT transmission fluid.
Fig 23: Locating Inner & Outer O-Ring Seals
Courtesy of FORD MOTOR CO.
23. Install new inner and outer O-ring seals.
24. Install the reverse clutch piston.
    Fig 24: Locating Reverse Clutch Piston

    Courtesy of FORD MOTOR CO.
25. Install the return spring.
    Fig 25: Locating Return Spring

    Courtesy of FORD MOTOR CO.
26. Using the special tool, install the return spring retainers.
    Fig 26: Locating Return Spring Retainers Using Special Tool (307-525)

    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: Locating Clutch Plates
Courtesy of FORD MOTOR CO.
27. 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.
28. Install the reverse clutch plate snap ring.
    Fig 28: Locating Reverse Clutch Plate Snap Ring

    Courtesy of FORD MOTOR CO.
29. Install the special tool. Zero out the special tool.
    Fig 29: Identifying Special Tool (100-002)

    Courtesy of FORD MOTOR CO.
30. 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.
    Fig 30: Locating Case Hole

    Courtesy of FORD MOTOR CO.
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).
31. Select the selective snap ring.
    SELECTIVE SNAP RING CHART
    
    

    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 CHART
    
    

    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)

32. Remove the reverse clutch pack snap ring.
    Fig 31: Locating Reverse Clutch Pack Snap Ring

    Courtesy of FORD MOTOR CO.
33. Remove the reverse clutch plates, steel and friction.
    Fig 32: Locating Reverse Clutch Plates, Steel & Friction

    Courtesy of FORD MOTOR CO.
34. Install the reverse clutch wave spring.
    Fig 33: Locating Reverse Clutch Wave Spring

    Courtesy of FORD MOTOR CO.
35. Install the ring gear assembly.
    Fig 34: Locating Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
36. Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
    Fig 35: Identifying Reverse Clutch Plates, Steel & Friction

    Courtesy of FORD MOTOR CO.
37. Install the reverse clutch pressure plate.
    Fig 36: Locating Reverse Clutch Pressure Plate

    Courtesy of FORD MOTOR CO.
38. Install the reverse clutch pack snap ring.
    Fig 37: Locating 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.
39. 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.
    Fig 38: Locating Bearing Race & Shim

    Courtesy of FORD MOTOR CO.
40. Using the special tools, install the roller bearing and race as an assembly.
    Fig 39: Identifying Special Tools (205-153, 307-536)

    Courtesy of FORD MOTOR CO.
41. Using the special tools, install the roller bearing and race as an assembly.
    Fig 40: Identifying Special Tools (205-153, 307-535)

    Courtesy of FORD MOTOR CO.
42. 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: Locating O-Ring Seals

    Courtesy of FORD MOTOR CO.
43. Using new sealing washers, install the bolt onto the lube tube.
    Fig 42: Locating Sealing Washers & Bolt

    Courtesy of FORD MOTOR CO.
44. 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 N.m (89 lb-in).
    Fig 43: Locating Stator Needle Bearing Lube Tube

    Courtesy of FORD MOTOR CO.