Manual Control Lever Shaft Seal: Installation

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Using the Manual Lever Seal Installer, install a new manual control lever shaft seal.

Fig 1: Installing Manual Control Lever Shaft Seal Using Manual Lever Seal Installer
Courtesy of FORD MOTOR CO.
Install the manual control lever shaft in the transaxle case and through the TR sensor.

Fig 2: Locating Manual Control Lever Shaft
Courtesy of FORD MOTOR CO.
Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the manual control lever shaft out and correctly install the manual pin in the manual valve and position the manual control lever shaft in place.

Fig 3: Locating Manual Pin In Manual Valve
Courtesy of FORD MOTOR CO.
Using a suitable tool, install a new TR sensor roll pin.

Fig 4: Installing TR Sensor Locking Pin
Courtesy of FORD MOTOR CO.
Install the TR sensor detent spring and the bolt.
- Tighten to 13 Nm (115 lb-in).
  
  Fig 5: Locating TR Sensor Detent Spring And Bolt
  Courtesy of FORD MOTOR CO.
Connect the TR sensor electrical connector.

Fig 6: Locating TR Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Clean the main control cover sealing surface.

Fig 7: Locating Main Control Cover Sealing Surface
Courtesy of FORD MOTOR CO.
Apply silicone to the main control sealing surface of the transaxle case.

Fig 8: Locating Main Control Sealing Surface Of Transaxle Case
Courtesy of FORD MOTOR CO.
Position the main control cover in place.

Fig 9: Locating Main Control Cover
Courtesy of FORD MOTOR CO.

NOTE: Inspect the main control-to-main control cover grommet to make sure that the seal is on the inside of the main control cover. Transmission fluid leak will occur.

NOTE: Install the stud bolts in the locations noted during disassembly.

Tighten the 8 main control cover bolts and 5 stud bolts.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 10: Locating Main Control Cover Bolts And Stud Bolts
  Courtesy of FORD MOTOR CO.
Position the transmission fluid cooler tube bracket and transmission fluid cooler tube assembly in place and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 11: Locating Transmission Fluid Cooler Tube Bracket Nuts
  Courtesy of FORD MOTOR CO.
Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts.

Fig 12: Locating Transaxle Electrical Wiring Harness Retainers On Main Control Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Connect the transaxle electrical connector.

Fig 13: Locating Transaxle Electrical Connector
Courtesy of FORD MOTOR CO.
Install the underbody cover and the screws.

Fig 14: Locating Underbody Cover And Screws
Courtesy of FORD MOTOR CO.

NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.

NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.

Install the manual control lever and the nut.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 15: Locating Manual Control Lever With Mounting Nut
  Courtesy of FORD MOTOR CO.
Connect the selector lever cable end to the manual control lever with the manual control lever and selector lever in DRIVE. Check selector lever cable adjustment. For additional information, refer to AUTOMATIC TRANSAXLE EXTERNAL CONTROLS - AISIN AW21/6F35

Fig 16: Locating Selector Lever Cable End On Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the ACL assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L or INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) .
Fill the transaxle with clean transmission fluid.

Fig 17: Locating Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
Start the engine and move the range selector lever into each gear position.
Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.