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Solenoid Body Assembly: Installation

  1. Install the new separator plate and the 2 separator bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 1: Locating Bolts And Separator Plate
      G06097482Courtesy of FORD MOTOR CO.
    2. NOTE: If cleaning the solenoid body assembly or inspecting the valves, refer to SOLENOID BODY ASSEMBLY . If installing a new solenoid body assembly, continue with this procedure.
  2. Install the solenoid body onto the main control valve body. Install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 2: Locating Solenoid Body Assembly Bolts
      G06097133Courtesy of FORD MOTOR CO.
  3. Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle case separator plate.
    Fig 3: Locating Main Control-To-Transaxle Case Separator Plate
    G06097132Courtesy of FORD MOTOR CO.
    4. NOTE: Make sure that the manual lever pin (part of the TR sensor) is correctly installed in the manual valve.
    Fig 4: Locating Manual Lever Pin In Manual Valve
    G06097136Courtesy of FORD MOTOR CO.
  4. Install the main control.
    5. NOTE: Make sure not to pinch the Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses when installing the main control.
    NOTE: Install the different length bolts in the locations noted during disassembly.
  5. Install the main control stud nut and 22 main control valve body bolts. Tighten in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      Fig 5: Locating Main Control Bolts And Nut
      G06097131Courtesy of FORD MOTOR CO.
  6. Route the OSS sensor wiring harness and connect the electrical connector.
    Fig 6: Locating OSS Sensor Electrical Connector
    G08023179Courtesy of FORD MOTOR CO.
  7. Connect the TR sensor electrical connector.
    Fig 7: Locating TR Sensor Electrical Connector
    G06097012Courtesy of FORD MOTOR CO.
  8. Install the main control cover grommet.
    Fig 8: Locating Main Control Cover Grommet
    G06097011Courtesy of FORD MOTOR CO.
  9. Clean the main control cover sealing surface.
    Fig 9: Locating Main Control Cover Sealing Surface
    G06096992Courtesy of FORD MOTOR CO.
  10. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 10: Locating Main Control Sealing Surface Of Transaxle Case
    G06096993Courtesy of FORD MOTOR CO.
  11. Position the main control cover in place.
    Fig 11: Locating Main Control Cover
    G06096994Courtesy of FORD MOTOR CO.
    12. NOTE: Inspect the main control-to-main control cover grommet to make sure that the seal is on the inside of the main control cover or a transmission fluid leak will occur.
    NOTE: Install the stud bolts in the locations noted during disassembly.
  12. Tighten the 8 main control cover bolts and 5 stud bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 12: Locating Main Control Cover Bolts And Stud Bolts
      G06096991Courtesy of FORD MOTOR CO.
  13. Position the transmission fluid cooler tube bracket and transmission fluid cooler tube assembly in place and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 13: Locating Transmission Fluid Cooler Tube Bracket Nuts
      G06096988Courtesy of FORD MOTOR CO.
  14. Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts.
    Fig 14: Locating Transaxle Electrical Wiring Harness Retainers On Main Control Cover Stud Bolts
    G06096990Courtesy of FORD MOTOR CO.
  15. Connect the transaxle electrical connector.
    Fig 15: Locating Transaxle Electrical Connector
    G06096997Courtesy of FORD MOTOR CO.
  16. Install the underbody cover and the screws.
    Fig 16: Locating Underbody Cover And Screws
    G06257240Courtesy of FORD MOTOR CO.
  17. Install the ACL assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L or INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) .
  18. Fill the transaxle with clean transmission fluid.
    Fig 17: Locating Transmission Fluid Level Indicator
    G06096977Courtesy of FORD MOTOR CO.
  19. Start the engine and move the range selector lever into each gear position.
  20. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
  21. Download a new solenoid body strategy to the PCM. For additional information, refer to SOLENOID BODY STRATEGY .
  22. Using the scan tool, select Module Programming and Programmable Parameters under the tool box icon and select Transmission. Follow the instructions displayed on the scan tool.

    There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from the solenoid body.

    23. NOTE: If the solenoid body information is not correct, transaxle damage or driveability concerns can occur.
  23. Enter the solenoid body identification and strategy.

    The scan tool will verify that the numbers entered are valid and display a message if the information is not valid.

    The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician may proceed with downloading the file to the PCM. If the file is not present, the scan tool will need to be connected to the Professional Technician Society (PTS) server to download the file onto the scan tool.

  24. Verify that the file is present on the scan tool. If the file is present, go to Step 25. If the file is not present, continue with this procedure.
  25. Connect the scan tool to the PTS server.

    The screen will display a progress bar when connecting to the network.

  26. Follow the instructions on the network to download the strategy file to the scan tool.

    The screen will display a progress bar when downloading the strategy file to the scan tool and display a message if it is downloaded successfully.

  27. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.

    If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be downloaded.

  28. Reconnect the scan tool to the vehicle.
  29. Follow the instructions displayed on the scan tool.
  30. If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields from the solenoid body to the replacement solenoid body tag provided with the solenoid body service kit and place it over the existing identification tag.

    The scan tool will automatically download the strategy file or partial strategy file to the PCM and will display a progress bar while downloading. The scan tool will display a message when it is finished downloading the data that states that the file was downloaded successfully.

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