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In-Vehicle Repair: Solenoids: Installation

  1. Inspect the solenoid(s) for damage.
    Fig 1: Inspecting Solenoid For Damage
    G06097103Courtesy of FORD MOTOR CO.
  2. If a new solenoid is not being installed, install the solenoid(s) into the bore from which it was removed.
  3. If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s). The Torque Converter Clutch (TCC) solenoid, Shift Solenoid A (SSA) and Shift Solenoid C (SSC) are all normally low pressure solenoids. The Line Pressure Control (LPC) solenoid, Shift Solenoid B (SSB) and Shift Solenoid D (SSD) are all normally high pressure solenoids. Shift Solenoid E (SSE) is not a VFS, it is an ON/OFF solenoid.
    Item Part Number Description
    1 7G136 SSA (normally low)
    2 7G383 SSB (normally high)
    3 7G136 SSC (normally low)
    4 7G383 SSD (normally high)
    5 7G484 SSE (normally closed [OFF])
    6 7G136 TCC solenoid (normally low)
    7 7G383 LPC solenoid (normally high)
    Fig 2: Identifying SSA, SSB, SSC, SSD, SSE, TCC And LPC
    G06097104Courtesy of FORD MOTOR CO.
  4. If installing a new LPC solenoid, SSB or SSD, note the color of the electrical terminal area of the solenoid. The color will be blue or green and the solenoid can only be replaced with the same color solenoid. If a new solenoid with that color is not available, install a new solenoid body, refer to SOLENOID BODY ASSEMBLY .
    Fig 3: Locating Color Of Electrical Terminal Area Of Solenoid
    G06376795Courtesy of FORD MOTOR CO.
  5. Determine the part number suffix by checking the solenoid service band number etched on the side of the solenoid. The band number is the third digit on the side of the solenoid and will be a 1, 2, 3, 4 or 5. Use the following table to determine the part number suffix and match the new solenoid base part number and suffix with the old solenoid. Install the solenoid in the solenoid body.
    Solenoid Band Number Part Number Suffix
    1 B
    2 C
    3 D
    4 E
    5 F
    Fig 4: Locating Solenoid Band Number
    G06096814Courtesy of FORD MOTOR CO.
  6. Install the solenoid retaining pin(s).
    Fig 5: Installing Solenoid Retaining Pin
    G06097102Courtesy of FORD MOTOR CO.
  7. Install the Leadframe Guide Pins in the solenoid body to align the lead frame for installation.
    Fig 6: Identifying Leadframe Guide Pins
    G06097075Courtesy of FORD MOTOR CO.
  8. Position the leadframe on the Leadframe Guide Pins and carefully install the leadframe by pushing straight down into the solenoids.
  9. Remove the Leadframe Guide Pins.
    Fig 7: Identifying Leadframe Guide Pins
    G06097075Courtesy of FORD MOTOR CO.
  10. Install the 5 leadframe screws.
    Fig 8: Locating Leadframe Screws
    G06097077Courtesy of FORD MOTOR CO.
  11. Connect the OSS sensor electrical connector.
    Fig 9: Locating OSS Sensor Electrical Connector
    G08023179Courtesy of FORD MOTOR CO.
  12. Connect the TR sensor electrical connector.
    Fig 10: Locating TR Sensor Electrical Connector
    G06097012Courtesy of FORD MOTOR CO.
  13. Install the main control cover grommet.
    Fig 11: Locating Main Control Cover Grommet
    G06097011Courtesy of FORD MOTOR CO.
  14. Clean the main control cover sealing surface and inspect for damage.
    Fig 12: Locating Main Control Cover Sealing Surface
    G06096992Courtesy of FORD MOTOR CO.
  15. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 13: Locating Main Control Sealing Surface Of Transaxle Case
    G06096993Courtesy of FORD MOTOR CO.
  16. Position the main control cover in place.
    Fig 14: Locating Main Control Cover
    G06096994Courtesy of FORD MOTOR CO.
    17. NOTE: Inspect the 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.
  17. Tighten the 8 main control cover bolts and 5 stud bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 15: Locating Main Control Cover Bolts And Stud Bolts
      G06096991Courtesy of FORD MOTOR CO.
  18. 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 16: Locating Transmission Fluid Cooler Tube Bracket Nuts
      G06096988Courtesy of FORD MOTOR CO.
  19. Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts.
    Fig 17: Locating Transaxle Electrical Wiring Harness Retainers On Main Control Cover Stud Bolts
    G06096990Courtesy of FORD MOTOR CO.
  20. Connect the transaxle electrical connector.
    Fig 18: Locating Transaxle Electrical Connector
    G06096997Courtesy of FORD MOTOR CO.
  21. 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) .
  22. Install the underbody cover and the screws.
    Fig 19: Locating Underbody Cover And Screws
    G06257240Courtesy of FORD MOTOR CO.
  23. Fill the transaxle with clean transmission fluid.
    Fig 20: Locating Transmission Fluid Level Indicator
    G06096977Courtesy of FORD MOTOR CO.
  24. Start the engine and move the range selector lever into each gear position.
  25. 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.
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