LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2007 >> Freestyle Limited, AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Continuously Variable Transmission (CVT) >> In-Vehicle Servicing >> Mechatronic Assembly >> Installation

Mechatronic Assembly: Installation

    CAUTION: Lubricate all of the O-ring seals with clean continuously variable transmission (CVT) transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the feed tubes into the transaxle case half or internal damage to the transaxle will occur.
  1. For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals on the feed tubes.
    1. Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
    2. Install new O-ring seals on the primary pressure feed tube, secondary pressure feed tube and main (pump) pressure feed tube.
    2. Fig 1: Locating O-Ring Seals On Feed Tubes
    GF0017464Courtesy of FORD MOTOR CO.
  2. For transaxles built before December 6, 2005, lubricate all of the O-ring seals with clean CVT transmission fluid.
    1. Clutch supply feed tube
    2. Primary feed tube (longer tube)
    3. Secondary feed tube (longer tube)
    4. Main pressure feed tube (shorter tube)
    5. Torque converter clutch feed tube
    3. Fig 2: Feed Tubes
    GF0017465Courtesy of FORD MOTOR CO.
  3. For transaxles built after December 6, 2005, lubricate all of the bonded seals on the feed tubes with clean CVT transmission fluid.
    1. Clutch supply feed tube
    2. Primary feed tube (short tube)
    3. Secondary feed tube (short tube)
    4. Main pressure feed tube (short tube)
    5. Torque converter clutch feed tube
    4. Fig 3: Feed Tubes
    GF0017466Courtesy of FORD MOTOR CO.
    NOTE: Note the location of the 5 feed tubes.
  4. Install all of the feed tubes into the case.
    1. Align the inner tube and install the clutch (manual valve) supply feed tube.
    2. Install the primary pressure feed tube.
    3. Install the secondary pressure feed tube.
    4. Install the main (pump) pressure feed tube.
    5. Install a new torque converter clutch pressure feed tube.
    5. Fig 4: Identifying Feed Tubes Inside Case
    G03990874Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  5. Position the mechatronic unit onto the case.
    6. Fig 5: View Of Mechatronic Unit
    G03990870Courtesy of FORD MOTOR CO.
  6. Tighten the mechatronic bolts in the sequence shown, in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten an additional 40 degrees (1/8 turn).
    7. Fig 6: Tightening Mechatronic Unit Bolts In Sequence
    GF0017467Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  7. Install the electrical connector into the case.
    8. Fig 7: Locating Electrical Connector
    GF0017461Courtesy of FORD MOTOR CO.
  8. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 Nm (53 lb-in).
    9. Fig 8: Locating Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
  9. Connect the electrical connectors.
    10. CAUTION: Make sure that the transmission fluid filter pickup tube seal was removed from the bore when the transmission fluid filter was removed. Failure to remove the seal prior to installing the new transmission fluid filter will result in transaxle failure.
    CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the transmission fluid filter is not correctly installed, internal transaxle damage will occur.
  10. Install a new transmission fluid filter and seal assembly.
    11. Fig 9: Identifying Fluid Filter
    G03990695Courtesy of FORD MOTOR CO.
  11. Make sure that the transmission fluid filter is seated over one of the mechatronic bolts.
    12. Fig 10: Transmission Fluid Filter Seated Over One Of The Mechatronic Bolts
    G03990711Courtesy of FORD MOTOR CO.
    CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
  12. Install a new transmission fluid pan gasket.
    13. Fig 11: Locating Transaxle Fluid Pan Gasket
    G03990694Courtesy of FORD MOTOR CO.
  13. Install the transmission fluid pan and the bolts. Tighten in the sequence shown.
    • Tighten to 12 Nm (9 lb-ft).
    14. Fig 12: Tightening Transmission Fluid Pan Bolts In Sequence
    GF0017423Courtesy of FORD MOTOR CO.
  14. Install the transmission fluid pan drain plug.
    • Tighten to 25 Nm (18 lb-ft).
    15. Fig 13: Locating Drain Plug
    GF0017421Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  15. Connect the transaxle bulkhead electrical connector.
    16. Fig 14: Locating Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.
  16. Fill the transaxle with approximately 4.7L (5 quarts) of clean CVT transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to Transmission Fluid Level Check and Setting .
  17. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
scientia non olet · About LEMON Manuals