Transmission Control Systems: Service and Repair

INTERNAL HARNESS SERVICE

Removal
1. If equipped, turn the air suspension switch off.
2. Disconnect the battery ground cable.
3. Raise the vehicle on a hoist.
4. Disconnect vehicle harness from transmission case (16 pin) connector.
5. Drain the transmission fluid.

6. NOTE: The main control assembly does not need to be removed.





Remove the transmission fluid filter.
1 Remove the screw.
2 Remove the transmission fluid filter.





7. Remove main control valve body wire loom.
- Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps.





8. Disconnect the solenoid electrical connectors.
1 Disconnect the SSA/SS1, SSB/SS2, SSC/SS3, and the SSD/SS4 electrical connectors.
2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector.
3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector.

9. CAUTION:
- The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve.
- Shift solenoids may pop out of their bore. This may damage the solenoids.





Remove the EPC and SSB/SS2 solenoids.
1 Remove the solenoid clamp screws.
2 Remove the solenoid clamp.
3 Remove the EPC and SSB/SS2 solenoids.

10. CAUTION: Do not pry on the other wires or damage the connector case surface.





Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case (16 pin) electrical connector.
1 Disconnect the TSS sensor electrical connector.
2 Remove from the TSS sensor wire locator.

11. CAUTION: Do not overstretch the retaining spring.





Remove the transmission case (16 pin) electrical connector retaining spring

12. CAUTION: Do not damage the connector or harness





Remove the transmission case (16 pin) electrical connector.
- Compress the tabs on the transmission case (16 pin) electrical connector
- Push the transmission case (16 pin) electrical connector out of transmission case.


Installation

1. NOTE:
- Make sure the tab is in the lock position.
- Install new O-rings on the transmission case (16 pin) electrical connector.





Install the transmission case (16 pin) electrical connector.
- Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly.





2. Press the transmission case (16 pin) electrical connector through the case until a click is heard.

3. CAUTION: Align the slot on the Turbine Shaft Speed (TSS) sensor electrical connector with the slot in the 16 pin case connector.





Install the TSS sensor wire
1 Install TSS sensor wire into (16 pin) case connector.
2 Install TSS sensor wire into the locator.

4. CAUTION: Do not overstretch the retaining spring.





Install the transmission case (16 pin) electrical connector retaining spring.





5. Install the Electronic Pressure Control (EPC) and SSB/SS2 solenoids.

6. CAUTION: The solenoid clamp must be installed in the Torque Converter Clutch (TCC) and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug.





Install the solenoid clamp.
1 Position the solenoid clamp on the main control valve body.
2 Install the solenoid clamp screw.





7. Connect the SSA/SS1 and SSC/SS3 shift(SS) solenoid electrical connectors.





8. Connect the TCC, SSD/SS4, SSB/SS2, and EPC solenoid electrical connectors.

9. CAUTION: Excessive pressure may break the retaining pins.





Install the wire harness guide and protector.
- Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness guide and protector





10. Install the transmission fluid filter.
1 Install the transmission fluid filter.
2 Install the screw.





11. Install the transmission fluid pan .
1 Position a new transmission fluid pan gasket on the transmission fluid pan.
2 Align and install the transmission fluid pan.
- Loosely install the transmission fluid pan screws.





12. Tighten the transmission fluid pan screws.
13. Connect vehicle harness to transmission (16 pin) connector. Make sure lock is fully engaged.
14. Lower the vehicle.
15. Connect the battery ground cable.
16. If equipped with air suspension, reactivate the system by turning on the air suspension switch.
17. Fill the transmission to the proper fluid level and check for proper transmission operation.
- Use Mercon V(R) Automatic Transmission Fluid XT-S-QM meeting Ford specification Mercon V(R).