A/T - Various Noises From The CVT Transmission
TSB 06-11-406/12/06
CONTINUOUSLY VARIABLE TRANSAXLE (CVT) NOISE DIAGNOSIS
FORD:
2005-2006 Five Hundred, Freestyle
MERCURY:
2005-2006 Montego
ISSUE
Some 2005-2006 Freestyle/Five Hundred/Montego vehicles equipped with a continuously variable transaxle (CVT) may exhibit noise under various driving conditions.
ACTION
Use the following Service Procedure to identify and repair specific CVT transmission noises.
SERVICE PROCEDURE
It is important to understand normal operating characteristics of the CVT, what type, location, and speeds of noise.
NOTE
DO NOT ATTEMPT REPAIR IF THE NOISE IS COMPARABLE TO A SIMILARLY EQUIPPED VEHICLE.
1. For whine/thump/knock noise in park or neutral, go to Possible Cause Step 1.
2. For tick noise on deceleration from 20 MPH (32 Km/h) to a stop, go to Possible Cause Step 2.
3. For whine noise on deceleration, go to Possible Cause Step 3.
4. For other noise concerns, refer to Other Concerns: Noise/Vibration - Forward or Reverse in Workshop Manual, Section 307-01A for a complete list of possible noise sources.
Possible Cause
1. Whine/thump/knock in park and neutral with engine running that goes away when vehicle is put into drive. Noise may come back when vehicle starts to move. This may be caused by machining of the input shaft or flat spots on the roller bearing. For diagnosis first use chassis ears to pinpoint the noise to transaxle area. If the noise is from the transaxle, monitor Turbine Shaft Speed (TSS_SRC) PID using scan tool. If the noise goes away as TSS_SRC goes to 0, when vehicle is put in gear, replace input shaft and bearing following instruction in Workshop Manual, Section 307-01A.
2. Tick noise on deceleration from 20 MPH (32 Km/h) to a stop. This may be caused by the differential ring gear. For front wheel drive (FWD), if the noise is isolated to the final drive area of the transmission, replace the differential assembly and transfer gear. If the vehicle is an all wheel drive (AWD), remove the power transfer unit (PTU) assembly, reinstall the halfshafts, disconnect the differential electronic module (DEM) and road test. If the noise goes away, the condition is isolated to the AWD system (not CVT related). If the noise is still present, replace the transaxle differential and transfer gear. Refer to Workshop Manual, Section 307-01A for procedures to shim the differential assembly and set proper preload. All replacement differential assemblies are serviced with bearings installed. AWD differentials are serviced with the inner seal installed. Outer bearing races are not packaged with replacement differential/bearing assemblies and will also require replacement.
3. Gear whine during coast down or deceleration. This may be caused by the transfer gear assembly. If noise follows the criteria below, replace the transfer gear.
^ 69th order noise from 42-35 MPH (68-56 Km/h) (loudest at around 37 MPH (59 Km/h))
^ 69th order noise from 32-25 MPH (51-40 Km/h) (loudest at around 27 MPH (43 Km/h))
^ 138th order noise from 11-16 MPH (18-26 Km/h) (loudest at around 15 MPH (24 Km/h))
NOTE
THE TRANSFER GEAR DUST SEAL AND 0-RING WILL ALSO NEED TO BE REPLACED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061104A 2005-2006 Five Hundred, 8.1 Hrs.
Freestyle FWD: Replace
The Input Shaft And
Bearing Includes Time To
Remove And Install
Transmission (Do Not Use
With 7000A, 7000A2,
7000A12, 7000A38,
7000F10, 7191A, 7091A1,
7228A, 3329A, 7OOOAZJ,
7003B)
061104B 2005-2006 Five Hundred, 8.3 Hrs.
Freestyle FWD: Replace
Transaxle Differential And
Transfer Gear Includes
Time To Remove And
Install Transmission (Do
Not Use With 7000A,
7000A2, 7000A12,
7000A38, 7000F10, 7191A,
7091A1, 7228A, 3329A,
7000AZJ, 7003B)
061104C 2005-2006 Five Hundred, 1.4 Hrs.
Freestyle FWD: Replace
Side Shaft Gear Assembly
(Do Not Use With 7000A,
7000A2, 7000A12,
7000A38, 7000F10, 7191A,
7091A1, 7228A, 3329A,
7000AZJ, 7003B)
061104D 2005-2006 Five Hundred, 8.6 Hrs.
Freestyle, Montego AWD:
Replace The Input Shaft
And Bearing Includes Time
To Remove And Install
Power Transfer Unit, And
Transmission (Do Not Use
With 7000A, 7000A2,
7000A12, 7000A38,
7000F10, 7191A, 7091A1,
7228A, 3329A, 7000AZJ,
7003B)
061104E 2005-2006 Five Hundred, 8.8 Hrs.
Freestyle, Montego AWD:
Replace Transaxle
Differential And Transfer
Gear Includes Time To
Remove And Install Power
Transfer Unit, And
Transmission (Do Not Use
With 7000A, 7000A2,
7000A12, 7000A38,
7000F10, 7191A, 7091A1,
7228A, 3329A, 7000AZJ,
7003B)
061104F 2005-2006 Five Hundred, 2.7 Hrs.
Freestyle, Montego AWD:
Replace Side Shaft Gear
Assembly Includes Time
To Remove And Install
The Power Transfer Unit
(Do Not Use With 7000A
7000A2, 7000A12,
7000A38, 7000F10, 7191A,
7091A1, 7228A, 3329A,
7000AZJ, 7003B)
MT061104 Claim Additional Labor Actual
Required as Actual Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7015 (USE WITH LABOR
OPERATION A AND D) 42
7F465 (USE WITH LABOR
OPERATION B) 42
7H348 (USE WITH LABOR
OPERATION C, E, AND F) 42
Disclaimer