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Fluid Pump

Special Tools

Illustration Tool Name Tool Number
GF0017638
 Aligner, Transaxle Pump 307-544 (includes 307-544/1, 307-544/2, 307-544/3 and 307-544/4A)
GF0017642
 Alignment Pins, Transmission Main Control Body 307-127 (T94P-77000-P)
GF0017639
 Installer, Front Pump Seal 307-524
GF0017641
 Installer, Pump Cover 307-542
GF0017471
 Piston Spring Compressor 307-525
GF0000940
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0000942
 Handle, Torque Converter 307-091 (T81P-7902-C)
Material

Item Specification
Motorcraft Continuously Variable Chain Type Transmission Fluid
XT-7-QCFT (US); CXT-7-LCF12 (Canada)		 WSS-M2C933-A
Threadlock 262
TA-26		 WSK-M2G351-A6
CAUTION: MERCON®, MERCON® V and MERCON® 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.
    NOTE: The fluid pump assembly cannot be disassembled. It is serviced as an assembly only.
  1. Install the special tool into a soft-jawed vise.
    2. Fig 1: Installing Special Tool Into Soft-Jawed Vice
    GF0017643Courtesy of FORD MOTOR CO.
  2. Set the fluid pump assembly onto the special tool to correctly align the pump.
    3. Fig 2: Setting Pump Assembly Onto Special Tool
    GF0017644Courtesy of FORD MOTOR CO.
  3. Install the special tool into the center of the special tool to keep the pump centered.
    4. Fig 3: Installing Special Tool Into Center Of Special Tool
    GF0017645Courtesy of FORD MOTOR CO.
  4. Install the special tool onto the top of the pump.
    5. Fig 4: Special Tools
    GF0017733Courtesy of FORD MOTOR CO.
  5. Remove the pump with the special tools installed from the soft-jawed vise. Carefully turn the pump over. Do not let the special tools move or drop. If the tools fall out or move, the alignment procedure must be carried out again.
  6. Install the pump gasket. Note the location of the bleed slots in the gasket.
    7. Fig 5: Locating Pump Gasket
    GF0017734Courtesy of FORD MOTOR CO.
  7. Install the special tools. Note the location of the bleed slot in the gasket.
    8. Fig 6: Installing Special Tools
    GF0017648Courtesy of FORD MOTOR CO.
  8. Lubricate the new O-ring seals with clean continuously variable transaxle (CVT) transmission fluid. Install the O-ring seals onto the feed tube.
    9. Fig 7: Locating O-Ring Seals
    G03990808Courtesy of FORD MOTOR CO.
  9. Lubricate the inner and outer seals in clean CVT transmission fluid. Install the feed tube into the pump cover.
    10. Fig 8: Installing Feed Tube Into Pump Cover
    GF0017649Courtesy of FORD MOTOR CO.
  10. From the opposite side of the case, install the fluid pump assembly into the transaxle case.
    11. Fig 9: Installing Pump Assembly Into Transaxle Case
    GF0017653Courtesy of FORD MOTOR CO.
  11. Loosely install the 6 fluid pump bolts.
    12. Fig 10: Installing Pump Bolts
    GF0017654Courtesy of FORD MOTOR CO.
  12. Remove the special tools and loosely install the remaining 2 fluid pump bolts.
    13. Fig 11: Installing Remaining Bolts
    GF0017655Courtesy of FORD MOTOR CO.
  13. Tighten in the sequence shown.
    • Tighten to 16 Nm (12 lb-ft).
    14. Fig 12: Tightening Bolts In Sequence
    GF0017656Courtesy of FORD MOTOR CO.
  14. Remove the special tool.
    15. Fig 13: Identifying Special Tools
    GF0017735Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new fluid pump seal.
    16. Fig 14: Installing Pump Seal
    GF0017659Courtesy of FORD MOTOR CO.
  16. Lubricate the inner and outer seals in clean CVT transmission fluid, then position the pump dust cover in place.
    17. Fig 15: Locating Inner & Outer Seals
    GF0017660Courtesy of FORD MOTOR CO.
  17. Install the special tools.
    18. Fig 16: Installing Special Tools
    GF0017661Courtesy of FORD MOTOR CO.
  18. Using the special tools, install a new pump dust cover.
    19. Fig 17: Installing Pump Dust Cover
    GF0017662Courtesy of FORD MOTOR CO.
  19. Install the pump dust cover bolts.
    • Tighten to 10 Nm (89 lb-in).
    20. Fig 18: Locating Pump Dust Cover Bolts
    GF0017663Courtesy of FORD MOTOR CO.
  20. Lubricate the seals in clean CVT transmission fluid. Install new inner and outer O-ring seals.
    21. Fig 19: Locating Reverse Clutch Piston Inner & Outer O-Ring Seals
    GF0017489Courtesy of FORD MOTOR CO.
  21. Install the reverse clutch piston.
    22. Fig 20: Locating Reverse Clutch Piston
    GF0017664Courtesy of FORD MOTOR CO.
  22. Install the return spring.
    23. Fig 21: Locating Return Spring
    GF0017487Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the return spring retainers.
    24. Fig 22: Locating Return Spring Retainers Using Special Tool (307-525)
    GF0017486Courtesy of FORD MOTOR CO.
  24. Install the reverse clutch wave spring.
    25. Fig 23: Locating Reverse Clutch Wave Spring
    GF0017669Courtesy of FORD MOTOR CO.
  25. Install the ring gear assembly.
    26. Fig 24: Locating Ring Gear Assembly
    GF0017670Courtesy of FORD MOTOR CO.
  26. Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.
    27. Fig 25: Locating Reverse Clutch Plates, Steel & Friction
    GF0017665Courtesy of FORD MOTOR CO.
  27. Install the reverse clutch pressure plate.
    28. Fig 26: Locating Reverse Clutch Pressure Plate
    GF0017672Courtesy of FORD MOTOR CO.
  28. Install the reverse clutch pack snap ring.
    29. Fig 27: Locating Reverse Clutch Pack Snap Ring
    GF0017666Courtesy of FORD MOTOR CO.
  29. Install the new O-ring seal on the clutch feed tube and lubricate with clean CVT automatic transmission fluid.
    30. Fig 28: Locating Clutch Feed Tube O-Ring Seal
    GF0017483Courtesy of FORD MOTOR CO.
  30. Install a new clutch feed sealing sleeve into the range selector valve assembly.
    31. Fig 29: Locating Clutch Feed Sealing Sleeve
    GF0017481Courtesy of FORD MOTOR CO.
  31. Make sure when routing the range selector valve assembly wiring harness that it is still pressed into the case retainers and out of the way.
    32. Fig 30: Locating Range Selector Valve Assembly Wiring Harness
    GF0017687Courtesy of FORD MOTOR CO.
  32. Install a new O-ring seal on the input shaft and lubricate it with clean CVT transmission fluid.
    33. Fig 31: Locating O-Ring Seal On Input Shaft
    GF0017736Courtesy of FORD MOTOR CO.
  33. Install a new converter housing gasket.
    34. Fig 32: Locating Converter Housing Gasket
    GF0017482Courtesy of FORD MOTOR CO.
    NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.
  34. Position the converter housing in place. Install new transaxle converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts. Starting at No. 1, tighten the bolts in a counterclockwise rotation.
    • Stage 1: Tighten bolts to 2 Nm (18 lb-in).
    • Stage 2: Tighten bolts to 8 Nm (71 lb-in).
    • Stage 3: Tighten an additional 90 degrees.
    35. Fig 33: Positioning Converter Housing In Place
    GF0017724Courtesy of FORD MOTOR CO.
  35. Install the side shaft gear assembly.
    • Tighten to 35 Nm (26 lb-ft).
    36. Fig 34: Locating Side Shaft Gear Assembly Bolts
    GF0017477Courtesy of FORD MOTOR CO.
  36. Position the output shaft seal in place.
    37. Fig 35: Positioning Output Shaft Seal
    GF0017725Courtesy of FORD MOTOR CO.
    CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.

    Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.

    Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.

    Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.

  37. For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean CVT transmission fluid. Install the O-ring seals on the feed tubes (late build vehicles).
    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.
    38. Fig 36: Locating O-Ring Seals On Feed Tubes
    GF0017464Courtesy of FORD MOTOR CO.
  38. 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
    39. Fig 37: Feed Tubes
    GF0017465Courtesy of FORD MOTOR CO.
  39. 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
    40. Fig 38: Feed Tubes
    GF0017466Courtesy of FORD MOTOR CO.
    NOTE: Note the location of the 5 feed tubes.
  40. 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.
    41. Fig 39: 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.
    NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.
  41. Position the mechatronic unit onto the case.
    42. Fig 40: View Of Mechatronic Unit
    G03990870Courtesy of FORD MOTOR CO.
  42. Tighten the mechatronic bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 40 degrees (1/8 turn).
    43. Fig 41: 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.
  43. Lubricate the O-ring seal with clean CVT transmission fluid and install the electrical connector into the case.
    44. Fig 42: Locating Electrical Connector
    GF0017461Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  44. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 Nm (53 lb-in).
    45. Fig 43: Locating Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
  45. Connect the electrical connectors.
    46. CAUTION: Make sure that the fluid filter pickup tube seal was removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.
    CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.
  46. Lubricate the seal that is on the new filter with clean CVT transmission fluid and install the fluid filter.
    47. Fig 44: Identifying Fluid Filter
    G03990695Courtesy of FORD MOTOR CO.
  47. Make sure that the filter is seated over one of the mechatronic bolts.
    48. Fig 45: Locating Mechatronic Bolts
    G03990711Courtesy of FORD MOTOR CO.
  48. Install a new transmission fluid pan gasket.
    49. Fig 46: Locating Transaxle Fluid Pan Gasket
    G03990694Courtesy of FORD MOTOR CO.
  49. Make sure that the magnet in the pan is in the correct location prior to installing the transmission fluid pan.
    50. Fig 47: Locating Magnet In Pan
    GF0017729Courtesy of FORD MOTOR CO.
  50. Install the transmission fluid pan. Tighten the bolts in the sequence indicated.
    • Tighten to 12 Nm (9 lb-ft).
    51. Fig 48: Tightening Transmission Fluid Pan Bolts In Sequence
    GF0017423Courtesy of FORD MOTOR CO.
    CAUTION: Do not set the torque converter in the fluid pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.
  51. Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
    52. Fig 49: Identifying Location Of Index Slot In Pump
    GF0017730Courtesy of FORD MOTOR CO.
  52. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.
    53. Fig 50: Removing/Installing Torque Converter Using Special Tool
    G03991060Courtesy of FORD MOTOR CO.
  53. Using 4 new retainers, install the transaxle insulator.
    54. Fig 51: Locating Transaxle Insulator Retainers
    G03990976Courtesy of FORD MOTOR CO.
  54. Install the fluid level indicator.
    55. Fig 52: Locating Fluid Level Indicator
    GF0017473Courtesy of FORD MOTOR CO.
  55. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  56. Position the transaxle mount in place and install the upper bolts.
    • Tighten to 55 Nm (41 lb-ft).
    57. Fig 53: Identifying Upper Transaxle Mount Retaining Bolts
    G03991478Courtesy of FORD MOTOR CO.
  57. Install the transaxle. For additional information, refer to Transaxle - All Wheel Drive (AWD)  or Transaxle - Front Wheel Drive (FWD) .
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