R. Control System/Solenoids/Accumulator Pistons/Cable Harness,
R. Control system/solenoids/accumulator pistons/cable harness, replacement
Special tools: 999 5006, 5033, 5460, 5477, 5562, 998 5972, 8670, 951 2050
Cleanliness:
Important! Cleanliness is extremely important when working on automatic transmissions. Before starting work: Before commencing work, clean the transmission and surrounding area, and ensure that the workplace is free of dust and dirt. Components should preferably be dried with compressed air. Rags or waste which leave lint or threads must not be used under any circumstances! Avoid skin contact with transmission fluid!
Fluid grade: ATF fluid meeting both Dexron IIE and Ford Mercon specifications.
Control system, replacement: R21, R33-R48 Solenoids, inspectionlreplacement: R15-R20, R35-R48
Accumulator pistons, replacement: R22-R32
Wiring harness, inspectionlreplacement: R49-R57
R1
Adjust steering wheel position
Slacken wheel adjusting lever.
Press wheel forward into bottom position and angle upward as far as possible.
Lock wheel in position with lever.
R2
Remove:
- Battery
- Battery shelf
Remove:
- Return hose from control system cover
- Delivery hose at cooler quick-release coupling
Plug hose and oil cooler openings with plastic plugs.
- Cable clamp retaining battery negative lead/cable harness on the transmission or sub-frame.
Tie up lead and harness.
R3
Install:
Support rails 9995033 on fender edges.
Lifting frame 9995006 on support.
Lifting hook 9995460 in torque rod bracket. Pull on hook to relieve load on engine mountings.
R4
Remove:
- Left front wheel
- Front splashguard. Remove both bolts and press splashguard forward sufficiently to release guide spigot at rear edge. Free splashguard at front edge.
- Splashguard under engine. (Early type)
Unbolt EVAP canister holder from subframe
Cut tie securing hoses and hang canister on body. Unhook hose from sub-frame.
R5
Drain transmission oil. Reinstall plug with new seal
Torque: 40 Nm (30 ft. lbs)
Caution! Oil may be extremely hot.
R6
Remove:
- Steering gear nuts
- Oil pipe bracket screws
- Bolt securing front engine mounting to sub-frame
- Bolts securing torque rod support on transmission
- Screw securing cable conduit to front member of subframe. Unhook conduit from frame.
R7
On right-hand drive models:
Remove:
- Steering gear crash guard
- Crash guard/sub-frame nut
R8
Remove linkiball joint from wheel spindle (left side).
Pull down link to expose ball joint. Install protective sleeve 9995562 on ball joint.
If the ball joint is difficult to insert in the wheel spindle tap a chisel in the groove on the spindle.
Disconnect links from anti-roll bar on each side.
Remove sub-frame support plate bolts on each side.
R9
Remove sub-frame from car.
Position hoist 9985972 under sub-frame on left-hand side and raise sufficiently to support frame.
Unscrew bolts (two) between frame and body on right- hand side by 10-15 mm (0.4"-0.6"). Remove bolts on left-hand side.
R10
On right-hand drive models:
Lower sub-frame approx. 100 mm (4").
Ensure that steering gear studs (five) and crash guard plate studs are clear of frame.
Remove bolts in anti-roll bar bearing cap on left-hand side. Slacken bolts on right-hand side until held by just a few threads.
Tie anti-roll bar to steering gear as illustrated.
R11
Lower sub-frame.
NOTE: Ensure that steering gear and guard plate are separated from frame.
Lower sub4rame to expose control system housing.
R12
Place container underneath transmission.
Remove oil pipe.
Undo clip securing oil temperature sensor cable, at point where cable is folded.
Pull out cable and place to one side.
R13
Remove control system cover screws (Torx TX40).
Clean sealing compound residue from threads (M8xl.25).
Remove cover.
Use tool 9995477.
Tap tool carefully into joint between cover and transmission to ensure that cover sealing flange is not distorted. Take care to ensure that oil temperature sensor cables are not damaged.
Remove remains of gasket from cover and transmission loint faces. Use scraper.
NOTE: Ensure that no debris enter transmission. Wash cover thoroughly.
R14
Remove:
Solenoid valve connectors.
Unclip wiring harness from clips on control system.
NOTE: Solenoid S1 and solenoid S2 have two types of cable harness. Refer to information in operation R15-R18.
See operation R21, R33-R48 regarding control system replacement.
Inspection/replacement of solenoids
R15
Solenoid S1
Solenoid S1 is in two variants: early types with the connection to the cable harness from the right and later types with the connection from the left.
Cable harness
The cable harness can be in two lengths, one shorter (early type) and one slightly longer (late type).
R16
The following combinations can occur:
- S1, early type - cable harness, early type, illustration (see operations R14, R20, R35)
- S1, early type - cable harness, late type, illustration (A)
- S1, late type - cable harness, late type, illustration (B).
Only the early versions of S1 and late versions of the cable harness are available as replacement parts, illustration (A).
R17
Solenoid SL
Solenoid SL is in two variants: early types with the connection to the cable harness from the right and later types with the connection from the left.
- Early version and replacement parts, illustration (C)
- Late versions, illustration (D).
SL is only available in the early version as a replacement part, illustration (C)
R18
Check resistance of the solenoids.
Solenoids S1, S2, SL:
Measure resistance between pin in solenoid connector and transmission ground terminal.
The correct resistance should be: 10-15 ohms.
Solenoid STH
Measure resistance between pins in so~enoid connector.
The correct resistance should be: 2-6 ohms.
R19
If solenoid resistances are correct:
Check wiring harness between solenoids and connector on transmission as per R49-R5O.
If solenoid S1, S2 or SL resistanoe is incorrect:
Replace solenoid. See below, operation R20.
If solenoid STH reading is incorrect:
Replace entire control system as per R21. (Solenoid STH is calibrated together with the control system.)
R20
Remove solenoid retaining screws
The illustration shows solenoids SL, S1 and cable harness, early version.
Remove solenoids from control system.
Install new solenoids.
Lubricate solenoid O-rings (S1, S2, SL) with a little vaseline. Install solenoids and tighten screws.
Torque: 10 Nm (7.4 ft. lbs)
See R35-R48 for connection and assembly.
Removal of control system
R21
Remove control system from transmission.
Detach cable harness and connector from solenoids.
Remove seven screws and two in cover.
Remove seals (two) between control system and transmission (see illustration).
NOTE: Ensure that no dirt enters the transmission.
See R33-R48 for installation of control system.
R22
Replacement of accumulator pistons/seals and inspection of valves
Cleanliness
Strict cleanliness is important. The control system is extremely sensitive to dirt. Clean the workplace and tools before commencing work.
Never use rags, waste or paper which leave lint or threads. Dry and clean components with compressed air. If necessary to wipe with a cloth, use a chamois.
Sticking valves and pistons - removal
Under no circumstances may a valve spool or piston which is sticking or seized be prised out. Instead, tap the valve housing with a piece of wood or plastic.
Inaccessible components may often be removed with a magnet.
Inspection after disassembly
Inspect the control system for foreign particles during disassembly. The presence of such particles often provides an indication of a transmission fault.
Measurement(inspection of spring
Spring specifications may be used only to identify the springs during assembly. For example, if the free length of a spring does not coincide exactly with the value specified in the table below, the spring is not necessarily faulty. The acceptability or otherwise of the spring properties can be determined only with the aid of special measuring equipment.
NOTE: Always check the transmission designation and engine type when replacing control system components.
R23
Place control system on clean workbench.
Remove gear selector slide so that it does not fall out and become damaged.
R24
Replacement of accumulator pistons and sealing rings B2/C2
Remove:
- Cover plate and gasket. Check that gasket is intact.
- Control valve, accumulators and spring (1)
- Spring and modulator valve B2 (2)
- Spring and modulator valve C2 (3)
- Accumulator piston C2, with two springs (C2)
- Accumulator piston B2, with two springs (B2). NOTE! Outer spring is attached to piston.
R25
Clean and inspect valves and pistons.
Clean all metallic components thoroughly in a fluid such as petrol, paraffin or trichloroethylene. Dry with compressed air or lint-free rag.
Check that valve spools are not abraded or worn.
Check that there are no abrasion or wear marks on the valves and that they move easily in their bores. If required, the valves may be dressed carefully with extremely fine emery cloth.
R26
Accumulator piston and valve spring specifications
NOTE: See also operation R22 Measurement/inspection of springs.
R27
Replace accumulator piston seals.
Lubricate new seals with ATF oil.
Take care to ensure that seal ends are not damaged!
R28
Reinstall accumulator pistons and springs.
Reinstall valves and springs.
Reinstall cover plate and gasket.
6 screws. Torque: 6.5 Nm (4.8 ft. lbs)
NOTE: Excessive torque may impose stress on system, causing valves to stick.
Replacement of accumulator piston C3
R29
Remove:
- Cover plate and gasket. Check that gasket is intact.
- Spring and modulator valve (1)
- Spring and modulator valve B1 (2)
- Spring and modulator valve C3 (3)
- Accumulator piston C3 and spring (C3)
R30
Clean and inspect valves and pistons.
See R25.
Check that hole in valve (2) is clean.
Blow clean with compressed air.
Accumulator piston and valve spring specifications
NOTE: See also operation R22 Measurement/inspection of springs.
R31
Replace accumulator piston seals.
Lubricate seals with ATF oil.
Take care to ensure that seal ends are not damaged!
R32
Reinstall accumulator piston and spring.
Reinstall valves and springs.
Reinstall cover plate and gasket.
6 screws. Torque: 6.5 Nm .8 ft. lbs)
NOTE: Excessive torque may impose stress on system, causing valves to stick.
R33
Reinstallation of control system
Reinstall gear selector slide in control system as illustrated.
Install new seals in transmission.
Use vaseline to hold seals in position.
R34
Install control system in transmission.
Insert arm on gear selector slide In hole in gear selector cam.
Install screws. Note that screws are of different lengths (measured in mm.).
NOTE: Tighten screws alternately. Torque: 10 Nm (7.4 ft. lbs)
Install cover with new gasket.
Torque: 10 Nm (7.4 ft. lbs)
R35
Connect wiring harness connectors to solenoids.
The illustration shows solenoids SL S1 and cable harness, early version, refer to operations R15-R17 for late version.
Wiring color codes:
Reinstall cable harness and check that harness is correctly positioned.
R36
Check that cover mating surface is level.
Wipe cleaned joint faces on cover and transmission with methylated spirits.
NOTE: Ensure that no dirt enters the transmission.
Place approx. 3 mm (0.12") thick bead of sealing compound (P/N 11611409-6) on cover. Also coat face around screw holes.
R37
Reinstall control system cover on transmission.
Tighten screws (Torx TX4O) diagonally.
Torque: 12 Nm (9 ft. lbs)
Stretch cable up to oil temperature sensor.
Ensure that cable is correctly positioned. Fold cable on top of transmission and secure with clamp.
Install oil pipe.
R38
On right-hand drive models:
Raise sub4rame to approx. 100 mm (4") from the body.
Position steering gear and guard plate in sub-frame.
Install anti-roll bar bolts on left-hand side and tighten both bearing caps.
Torque: 50 Nm (37 ft.lbs)
R39
Reinstall sub-frame.
NOTE! Use new bolts (4 x M14). Lubricate bolt threads.
Commence on left-hand side.
Raise sub-frame on hoist.
NOTE: Ensure that steering gear studs are located in holes in subframe!
Install frame and support plate bolts. Tighten sub-frame bolts first to 105 Nm (77.5 ft. lbs)+120° and then support plate bolts to 50 Nm (37 ft. lbs). Use protractor gauge 9512050.
Transfer hoist to right-hand side and repeat procedure.
R40
Remove lifting hook, lifting beam and support rails.
Install:
Steering gear nuts (five). Use new nuts! Torque: 50 Nm (37 ft. lbs)
Bolt securing front engine mounting to sub-frame. Torque: 50 Nm (37 ft. lbs)
On right-hand drive models:
Guard plate/sub-frame nut (A). Torque: 50 Nm (37 ft. lbs)
R41
Install:
Torque rod support in transmission. Torque: 35 Nm (26ft. lbs) +40°.
NOTE! Early version with M8 screw: Torque: 18 Nm (13.5 ft.lbs) +90° Use protractor gauge 9512050.
NOTE: Use new bolts.
- Both oil pipe brackets. Torque: 25 Nm (19 ft. lbs)
- Cable conduit on sub-frame.
R42
On right-hand drive models:
Install steering gear guard plate.
Two bolts. Torque: 80 Nm (59 ft. lbs)
R43
Install:
- EVAP canister holder and hose on sub-frame. Clip all hoses to frame with a band clamp.
- Splashguard under engine. (Early type)
- The front cover. Press into position at front. Press forward and press upward at rear so that guide spigot is seated in slot. Install screws.
R44
Reinstall link/ball loint to wheel spindle
Remove protective sleeve 9995562.
NOTE: Take care that the ball joint boot is not damaged.
Use new lock nut on bolt. Torque: 50 Nm (37 ft. lbs)
Reinstall links to anti-roll bar.
Use new lock nuts. Torque: 50 Nm (37 ft. lbs)
R45
Install left front wheel.
Lubricate the hub guide for the rim with rust inhibitor 1161030-0.
Tighten the studs lightly. Torque alternately.
Torque: 110 Nm (81 ft. lbs)
NOTE: See also Specifications, Tightening torques
R46
Install:
- Return oil hose to control system cover
- Inlet hose to oil cooler quick-release coupling
- Wiring harness/battery lead clip on control system cover
- Battery shelf
- Battery
R47
Applies only when replacing wiring harness:
Tighten air cleaner (ACL) bracket screws.
Install ACL with inlet pipe and connections.
R48
Check oil level.
See Section H. Oil, check, operations H2-H5. H. Oil Inspection
Check that DTCs have been cleared.
See On-board Diagnostic System section, Diagnostic Test Mode 1. Testing and Inspection
R49
Inspection/replacement of solenoid wiring harness
Remove:
- ACL complete with inlet pipe.
Remove:
- ACL bracket.
Disconnect transmission connector.
Remember rubber seal.
R50
Check wiring harness
Use ohmmeter to measure resistance between transmission connector and end of appropriate solenoid cable. Shake harness gently during measurement to locate possible loose connections. The ohmmeter should indicate 0 ohms.
Replace with new harness as described below if ohmmeter indicates value other than 0.
R51
Remove:
- Gear selector cable
- Lever
- Gear position sensor screw and retainer for harness gland.
R52
Remove:
- Connector screws
- Retainer for grommet for wiring in transmission.
Remove sockets from connector housing.
Remove rubber seal from connector. Insert screwdriver between casing and socket and press catch in. At the same time slide the sockets out of the casing.
R53
Remove socket for wiring to solenoids (5-pin socket).
Free wiring harness from transmissionlcontrol system.
R54
Install new wiring harness with grommet and 0-ring. Reconnect solenoid connectors.
The illustration shows solenoid SL, S1 and cable harness, early version. See operations R15-R17 for late version.
Wiring color codes:
Reinstall cable harness in retainer and check that harness is correctly positioned.
R55
Install:
- Retainer to cable harness grommet
- Gear position sensor bracket screw
- Selector lever. Torque: 16 Nm (12 ft. lbs)
- Gear selector cable with washer and retaining clip. Apply grease 1161241-3 sparingly to lever arm pin.
R56
Reinstall sockets to connector.
Reconnect connector halves.
Ensure that rubber sleeve is in position.
Secure harness and rubber sleeve with cable ties.
Reinstall connector on transmission
Reconnect connector
Remember rubber seal.
R57
See also operations R35-R48.