Part 1
TransaxleSpecial Tool(s):
Special Tool(s):
Special Tool(s):
Material:
CAUTION: MERCON (R), MERCON (R) V and MERCON (R) 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.
1. CAUTION: Prior to installing the transaxle case onto the variator assembly, make sure that the manual valve feed tube is correctly installed in the case. Damage to the manual valve feed and variator could occur if not correctly installed.
Position the transaxle case onto the variators.
2. Install the spacer washer to the special tool.
3. Assemble the remaining components of the special tool.
4. CAUTION: The special tools must be installed as shown or damage to the case will occur.
CAUTION: Make sure that when installing the case onto the variators, the case is NOT in PARK. If the case is in PARK damage to the case will occur.
NOTE: The windows in the special tools must be facing you so that when pressing the case down, you can see when to stop.
Install the special tools on the top of the case in the position shown.
5. Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.
6. CAUTION: This step must be followed exactly. Do not use any air tools when installing the case. Do not turn one forcing screw more than the other unless indicated. Failure to follow this instruction will result in damage to the case.
Press the transaxle case down onto the variator assembly.
1 Hold the transaxle case level. Turn the secondary forcing screw 2 complete turns.
2 Turn both forcing screws evenly, at the same time, until the case just contacts the variators.
7. Install a new primary nut.
8. Install a new secondary nut.
9. NOTE: In order to tighten the variator nuts, the manual control lever must be in PARK to prevent the variators from turning.
Make sure that the manual control lever is in the PARK position.
10. Using the special tools, tighten the primary variator nut in 2 stages.
^ Stage 1: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 2: Tighten to 500 Nm (369 ft. lbs.).
11. Using the special tools, tighten the secondary variator nut in 2 stages.
^ Stage 1: Tighten to 30 Nm (22 ft. lbs.).
^ Stage 2: Tighten to 150 Nm (111 ft. lbs.).
12. Lubricate with clean continuously variable transaxle (CVT) transmission fluid.
^ If equipped with a primary feed tube that has removable O-ring seals, install new O-rings on the primary feed tube. Lubricate the seals with clean CVT) transmission fluid and install the feed tube into the case.
^ If equipped with a primary feed tube that has bonded seals, lubricate a new feed tube with clean CVT transmission fluid and install the feed tube into the case.
13. Lubricate the new O-ring seal with clean CVT transmission fluid and install a new square cut seal and the O-ring seal.
14. Install a new primary cover gasket.
15. Using new bolts, install the primary cover and tighten in the sequence shown, in 2 stages:
^ Stage 1: Tighten to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.
16. NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.
Lubricate the new O-ring with clean CVT transmission fluid and install the O-ring seal on the feed tube. Install a new secondary cover gasket.
17. If not previously done, install a new square cut seal in the secondary cover.
18. Using new bolts, install the secondary cover and tighten in the sequence shown, in 2 stages:
^ Stage 1: Tighten to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.
19. Install a new pressure filter.
20. Lubricate with clean CVT transmission fluid.
^ If equipped with a high pressure filter feed tube that has removable O-ring seals, install new O-rings on the feed tube. Lubricate the O-ring seals with clean CVT transmission fluid and install the feed tube into the case.
^ If equipped with a high pressure filter feed tube that has bonded seals, lubricate a new feed tube with clean CVT transmission fluid and install the feed tube into the case.
21. Install the pressure filter case cover.
^ Tighten to 10 Nm (89 inch lbs.).
22. Install the safety strap on the transaxle.
23. Install the special tool onto the transaxle case.
^ Tighten to 55 Nm (41 ft. lbs.).
24. NOTE: Be careful when installing the guide plate that it does not fall into the case. If the guide plate falls into the case, the case will need to disassembled.
Using a magnet, carefully install the guide pin retaining ring plate.
25. Install the C-clip onto the special tool.
26. Using the special tool, install the guide pin retaining ring.
27. If not previously done, lubricate the new seals with clean CVT transmission fluid and install the O-ring seals in the case.
28. NOTE: When installing the range selector valve assembly, make sure that the pin from the manual valve lever is correctly installed into the range selector valve assembly.
Loosely install the range selector valve assembly.
29. Install the bolts.
^ Tighten to 5 Nm (44 inch lbs.).
30. Make sure when routing the range selector valve assembly wiring harness that it is between the bolt holes and is pressed into the case retainers.
31. NOTE: Be careful not to pinch the wire harness when installing the detent spring.
Install the manual lever detent spring.
^ Tighten to 10 Nm (89 inch lbs.).
32. Lubricate the new O-ring seal with clean CVT transmission fluid and install the O-ring seal on the chain lube tube.
33. Install the chain lube tube into the case.
34. Install the fluid feed transfer tube retainer bracket.
^ Tighten to 10 Nm (89 inch lbs.).
35. Install the transmission fluid baffle.
^ Tighten to 5 Nm (44 inch lbs.).
36. Install the new forward clutch primary shaft seals.
37. Install the forward clutch drum without the clutch plates installed.
38. NOTE: Note the recess in the top of the sun gear and the slight groove on the face of the gear teeth are facing up.
Install the sun gear.
39. Install the sun gear spacer.
40. Install a new sun gear snap ring.
41. NOTE: The clutch pack stack is made without the wave plate only.
Install all plates and the pressure plate, but not the wave spring.
42. Install the forward clutch snap ring.
43. Install the special tool and zero it out.
44. Lift up on the clutch plates by inserting a screwdriver in the clutch pack and record the measurement. Enter this measurement in the following table on the line labeled A.
45. NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.39-1.68 mm (0.055-0.066 inch).
Select the selective snap ring.
^ Add line A to line 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 specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.
Forward Clutch Selective Snap Ring:
46. Remove the forward clutch pack snap ring.
47. Remove the forward clutch plates, steel and friction.
48. Install the forward clutch wave spring.
49. Install the forward clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
50. Install the forward clutch pressure plate.
