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Section 166 (Automatic Transmission - CVT): Disassembly: Transaxle: Disassembly

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.
  1. Remove and discard the 4 retainers and remove the transaxle insulator.
    Fig 1: Removing Retainers And Transaxle Insulator
    G03990976Courtesy of FORD MOTOR CO.
  2. Remove the bolts and remove the rear transaxle mount.
    Fig 2: Removing Bolts And Rear Transaxle Mount
    G03991049Courtesy of FORD MOTOR CO.
  3. Remove the bolt and remove the fluid level indicator and tube.
    Fig 3: Removing Bolt And Fluid Level Indicator And Tube
    G03990977Courtesy of FORD MOTOR CO.
  4. Remove the fluid level indicator tube grommet.
    Fig 4: Removing Fluid Level Indicator Tube Grommet
    G03991059Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the torque converter.
    Fig 5: Removing/Installing Torque Converter Using Special Tool
    G03991060Courtesy of FORD MOTOR CO.
  6. Make an identifying mark on the torque converter where the pump pilot is located for correct installation.
    Fig 6: Identifying Mark On Torque Converter
    G03991061Courtesy of FORD MOTOR CO.
    7. CAUTION: Be careful not to cross-thread the bolts while installing the special tool.
  7. Install the special tool onto the transaxle case.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 7: Installing Special Tool Onto Transaxle Case
      G03991062Courtesy of FORD MOTOR CO.
  8. Position the transaxle into the bench fixture.
    Fig 8: Positioning Transaxle Into Bench Fixture
    G03991063Courtesy of FORD MOTOR CO.
  9. Remove the side shaft gear assembly bolts.
    Fig 9: Removing Side Shaft Gear Assembly Bolts
    G03991064Courtesy of FORD MOTOR CO.
  10. Remove the side shaft gear assembly from the case.
    Fig 10: Removing Side Shaft Gear Assembly From Case
    G03991065Courtesy of FORD MOTOR CO.
  11. Remove the transaxle fluid pan.
    Fig 11: Removing Transaxle Fluid Pan
    G03991066Courtesy of FORD MOTOR CO.
  12. Remove and discard the transaxle fluid pan gasket.
    Fig 12: Removing Transaxle Fluid Pan Gasket
    G03990694Courtesy of FORD MOTOR CO.
    13. NOTE: Check the transaxle case to see if the filter pickup tube seal is stuck in the case. If the pickup tube seal is in the case it will need to be removed.
  13. Remove and discard the fluid filter.
    • Use a suitable seal pick to remove the seal if it is stuck in the case.
      Fig 13: Identifying Fluid Filter
      G03990695Courtesy of FORD MOTOR CO.
  14. Remove the main electrical outer shell bolt.
    Fig 14: Removing Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
    15. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  15. Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
    • Rotate the connector counterclockwise to remove.
      Fig 15: Rotating Connector Counterclockwise
      G03990866Courtesy of FORD MOTOR CO.
  16. Remove the electrical connector by lifting it out of the case.
    Fig 16: Removing Electrical Connector
    G03990867Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
    Fig 17: Disconnecting Electrical Connectors
    G03990868Courtesy of FORD MOTOR CO.
  17. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
    18. CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping the sensor a specific distance from the differential gears.
    Fig 18: Removing OSS Sensor Bolt, Sensor And Spacer
    G03990892Courtesy of FORD MOTOR CO.
  18. Remove the OSS sensor bolt, sensor and spacer.
    19. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    NOTE: The 8 bolts that hold the mechatronic unit to the case are a different size Torx® bolt.
    Fig 19: Removing Bolts From Mechatronic Unit
    G03990869Courtesy of FORD MOTOR CO.
  19. Remove the 8 bolts from the mechatronic unit.
    20. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 20: Removing Mechatronic Unit From Transaxle
    G03990870Courtesy of FORD MOTOR CO.
  20. Remove the mechatronic unit from the transaxle.
    21. NOTE: The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
    NOTE: Note the location and size of the 5 feed tubes for reassembly.
  21. Remove all of the 5 feed tubes.
    1. Remove the clutch (manual valve) supply feed tube.
    2. Remove the primary pressure feed tube.
    3. Remove the secondary pressure feed tube.
    4. Remove the main (pump) pressure feed tube (smaller tube).
    5. Remove and discard the torque converter clutch pressure feed tube.
      Fig 21: Removing Feed Tubes
      G03990874Courtesy of FORD MOTOR CO.
  22. Remove and discard all of the seals on the feed tubes.
    1. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
    2. Remove and discard the O-ring seals from the primary pressure feed tube.
    3. Remove and discard the O-ring seals from the secondary pressure feed tube.
    4. Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube).
    5. Discard the torque converter clutch pressure feed tube.
      Fig 22: Removing Seals On Feed Tubes
      G03990872Courtesy of FORD MOTOR CO.
  23. Remove and discard the 26 retaining bolts for the transaxle converter housing.
    Fig 23: Removing Retaining Bolts For Transaxle Converter Housing
    G03991078Courtesy of FORD MOTOR CO.
  24. Remove the converter housing. It will be necessary to pry the case halves apart.
    Fig 24: Removing Converter Housing
    G03991079Courtesy of FORD MOTOR CO.
    25. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
    Fig 25: Removing Converter Housing Gasket
    G03991080Courtesy of FORD MOTOR CO.
  25. Remove and discard the converter housing gasket.
  26. Remove the differential assembly.
    Fig 26: Removing Differential Assembly
    G03991081Courtesy of FORD MOTOR CO.
  27. Remove the input shaft. Remove and discard the planet carrier thrust washer.
    Fig 27: Removing Input Shaft
    G03991082Courtesy of FORD MOTOR CO.
  28. Remove and discard the O-ring seals and the split ring seal.
    Fig 28: Removing O-Ring Seals And Split Ring Seal
    G03991083Courtesy of FORD MOTOR CO.
    29. NOTE: There is a selective fit washer under this bearing.
    Fig 29: Removing Upper Input Shaft Roller Bearing
    G03991084Courtesy of FORD MOTOR CO.
  29. Remove the upper input shaft roller bearing.
    30. NOTE: This is a selective fit washer.
    Fig 30: Removing Upper Input Shaft Roller Bearing Washer
    G03991085Courtesy of FORD MOTOR CO.
  30. Remove the upper input shaft roller bearing washer.
  31. Remove the input shaft roller bearing.
    Fig 31: Removing Input Shaft Roller Bearing
    G03991086Courtesy of FORD MOTOR CO.
  32. Remove the fluid baffle screws and the baffle.
    Fig 32: Removing Fluid Baffle Screws And Baffle
    G03991087Courtesy of FORD MOTOR CO.
  33. Remove the chain lube feed tube retainer screws and the retainer.
    Fig 33: Removing Chain Lube Feed Tube Retainer Screws And Retainer
    G03991088Courtesy of FORD MOTOR CO.
  34. Remove the chain lube feed tube.
    Fig 34: Removing Chain Lube Feed Tube
    G03991089Courtesy of FORD MOTOR CO.
  35. Remove and discard the feed tube O-ring seal.
    Fig 35: Removing Feed Tube O-Ring Seal
    G03991090Courtesy of FORD MOTOR CO.
    36. NOTE: Note the location of the transaxle range sensor wiring.
    Fig 36: Removing Bolts And Manual Lever Detent Spring
    G03991091Courtesy of FORD MOTOR CO.
  36. Remove the 2 bolts and the manual lever detent spring.
    37. NOTE: The manual valve will need to be in the PARK position in order to remove the valve assembly.
    NOTE: It may require some rocking movement back and forth in order to get the valve off the O-ring seals on the clutch feed tube.
    Fig 37: Removing Bolts For Range Selector Valve Assembly
    G03991092Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts for the range selector valve assembly and remove the valve assembly.
  38. Remove and discard the sun gear retaining ring.
    Fig 38: Removing Sun Gear Retaining Ring
    G03991093Courtesy of FORD MOTOR CO.
  39. Remove the sun gear and bearing spacer.
    Fig 39: Removing Sun Gear And Bearing Spacer
    G03991094Courtesy of FORD MOTOR CO.
  40. Inspect the sun gear and spacer for damage.
    • If damage is indicated, install a new sun gear and spacer.
      Fig 40: Installing Sun Gear And Spacer
      G03991095Courtesy of FORD MOTOR CO.
  41. Remove the forward clutch assembly.
    Fig 41: Removing Forward Clutch Assembly
    G03991096Courtesy of FORD MOTOR CO.
    42. CAUTION: Be careful when removing the retaining ring that it does not fall into the case, damage to the case will result.
    Fig 42: Removing Guide Pin Retaining Ring
    G03991097Courtesy of FORD MOTOR CO.
  42. Using a magnet and a small screwdriver, remove and discard the guide pin retaining ring.
  43. Using a magnet, remove the guide pin retaining ring washer.
    Fig 43: Removing Guide Pin Retaining Ring Washer
    G03991098Courtesy of FORD MOTOR CO.
  44. Install the special tool onto the variators.
    Fig 44: Installing Special Tool Onto Variators
    G03991099Courtesy of FORD MOTOR CO.
  45. Secure the special tool with a strap.
    Fig 45: Securing Special Tool With A Strap
    G03991100Courtesy of FORD MOTOR CO.
  46. Remove the special tool.
    Fig 46: Removing Special Tool
    G03991062Courtesy of FORD MOTOR CO.
  47. Remove the end portion of the transmission holding fixture tool that fits into the bench fixture. Install the end portion onto the variator holding fixture so it can be mounted into the bench fixture.
    Fig 47: Installing End Portion Onto Variator Holding Fixture
    G03991102Courtesy of FORD MOTOR CO.
  48. Install the transaxle case half and the variator assembly into the bench fixture.
    • Remove the strap.
      Fig 48: Removing Strap
      G03991103Courtesy of FORD MOTOR CO.
    49. NOTE: The feed tube under the primary cover may stick in the cover or in the case.
    Fig 49: Removing Bolts For Primary Cover
    G03991104Courtesy of FORD MOTOR CO.
  49. Remove and discard the bolts for the primary cover and remove the cover.
    50. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
    Fig 50: Removing Primary Cover Gasket
    G03991105Courtesy of FORD MOTOR CO.
  50. Remove and discard the primary cover gasket.
  51. Remove and discard the O-ring seal from the feed tube and the square cut seal.
    Fig 51: Removing O-Ring Seal
    G03991106Courtesy of FORD MOTOR CO.
    52. NOTE: If the feed tube is not in the case, it may be stuck in the cover.
    Fig 52: Removing Feed Tube From Case
    G03991107Courtesy of FORD MOTOR CO.
  52. Remove the feed tube from the case.
  53. Remove and discard the bolts for the secondary cover and remove the cover.
    Fig 53: Removing Bolts For Secondary Cover
    G03991108Courtesy of FORD MOTOR CO.
    54. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
    Fig 54: Removing Seal On Secondary Feed Tube And Gasket
    G03990830Courtesy of FORD MOTOR CO.
  54. Remove and discard the seal on the secondary feed tube and the gasket from the case.
  55. Remove and discard the secondary feed tube snap ring.
    Fig 55: Removing Secondary Feed Tube Snap Ring
    G03991110Courtesy of FORD MOTOR CO.
    56. NOTE: The feed tube under the pressure filter cover may stick in the cover or in the case.
    Fig 56: Removing Pressure Filter Cover
    G03990844Courtesy of FORD MOTOR CO.
  56. Remove the pressure filter cover.
    57. NOTE: If the feed tube is not in the case it may be stuck in the cover.
    Fig 57: Removing Pressure Filter Feed Tube
    G03991112Courtesy of FORD MOTOR CO.
  57. Remove the pressure filter feed tube.
  58. Remove and discard the O-ring seals from the feed tube.
    Fig 58: Removing O-Ring Seals From Feed Tube
    G03990808Courtesy of FORD MOTOR CO.
  59. Remove and discard the pressure filter.
    Fig 59: Removing Pressure Filter
    G03991114Courtesy of FORD MOTOR CO.
    60. NOTE: The case half will only need to be removed from the variators if installing a new chain and variator assembly or a new case.
    NOTE: Make sure that the manual control lever is in the PARK position when removing the primary variator nut.
    NOTE: The primary variator nut has been torqued to 500 Nm (369 lb-ft).
    Fig 60: Removing Primary Variator Nut
    G03991115Courtesy of FORD MOTOR CO.
  60. Using the special tool, remove and discard the primary variator nut.
    61. NOTE: Make sure that the manual control lever is in the PARK position when removing the secondary variator nut.
    NOTE: The secondary nut had been torqued to 150 Nm (111 lb-ft).
    Fig 61: Removing Secondary Variator Nut
    G03991116Courtesy of FORD MOTOR CO.
  61. Using the special tool, remove and discard the secondary variator nut.
    62. CAUTION: The chain and variators are a matched set of components. All 3 components (chain, primary variator and secondary variator) are installed as an assembly. Do not attempt to install an individual component. Transmission failure will result.
    NOTE: The short variator insert goes on top of the primary variator.
    Fig 62: Installing Special Tools
    G03991117Courtesy of FORD MOTOR CO.
  62. Install the special tools.
    63. CAUTION: In order for the cover to be removed evenly from the variators, both of the bolts must be turned 1/4 turn at a time. Failure to follow this instruction will cause damage to the variators and case.
    Fig 63: Lifting Transaxle Case
    G03991118Courtesy of FORD MOTOR CO.
  63. Using the special tools, lift the transaxle case up off the variator assembly.
  64. For the cleaning and inspection of the variators, refer to VARIATOR/CHAIN AND SPUR GEAR ASSEMBLY .
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