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Home >> Lincoln >> 2006 >> Zephyr >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - 6 Speed >> In-Vehicle Repair >> Main Control Valve Body >> Installation

Main Control Valve Body: Installation

    CAUTION: When installing the main control valve body, place the wire harness in the open space of the separate plate being careful not to pinch the harness. Damage to the harness will occur.
    Fig 1: Locating Manual Control Lever
    G04681473Courtesy of FORD MOTOR CO.
  1. Connect the manual valve link and position the main control valve body in place.
  2. Loosely install the 6 main control valve body bolts.
    Fig 2: Identifying Main Control Valve Body Bolts
    G04681474Courtesy of FORD MOTOR CO.
  3. Install the suction cover gasket, cover and loosely install the 2 bolts.
    Fig 3: Identifying Bolts And Suction Cover Gasket
    G04681475Courtesy of FORD MOTOR CO.
  4. Tighten the 8 bolts to 10 Nm (89 lb-in) in the sequence shown.
    Fig 4: Identifying Main Control Valve Body Bolts Tightening Sequence
    G04681477Courtesy of FORD MOTOR CO.
  5. Lubricate the O-ring and install the transmission fluid temperature sensor.
    • Tighten to 10 Nm (89 lb-in).
    Fig 5: Identifying Transmission Fluid Temperature Sensor, Bolt And Lock Plate
    G04681478Courtesy of FORD MOTOR CO.
  6. Connect the 2 speed sensor wires.
    7. Fig 6: Identifying Speed Sensor Wires
    G04681476Courtesy of FORD MOTOR CO.
  7. Connect the wire harness to the solenoids.
    1. Install the wire harness into the clamps.
      • Connect the 8 solenoid connectors and the 2 speed sensor connectors.
        Fig 7: Locating Solenoid Connectors And Speed Sensor Connectors
        G04681479Courtesy of FORD MOTOR CO.
  8. Install a bead of sealer to the fluid pan.
    Fig 8: Locating Fluid Pan Sealer
    G04681480Courtesy of FORD MOTOR CO.
  9. Using new pan bolts, install the fluid pan.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 9: Locating Transmission Fluid Pan Bolts
      G04681481Courtesy of FORD MOTOR CO.
    10. NOTE: Lubricate the new O-rings with clean automatic transmission fluid and install them onto the fluid cooler tubes.
  10. Connect the transmission fluid cooler tubes to the transaxle.
    • Tighten to 10 Nm (89 lb-in).
      Fig 10: Locating Transmission Fluid Cooler Tube Bolts
      G04681482Courtesy of FORD MOTOR CO.
  11. Install the transmission fluid drain plug.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 11: Locating Transmission Fluid Drain Plug
      G04681483Courtesy of FORD MOTOR CO.
  12. If equipped, install the splash shield and the 7 screws.
    Fig 12: Locating Screws On Splash Shield
    G04681484Courtesy of FORD MOTOR CO.
  13. Remove the transmission fluid fill plug.
    Fig 13: Locating Transmission Fluid Fill Plug
    G04681485Courtesy of FORD MOTOR CO.
  14. Fill the transaxle with approximately 4.7L (5 quarts) of clean automatic transmission fluid.
  15. Install the fluid fill plug.
    • Tighten to 39 Nm (29 lb-ft).
      Fig 14: Locating Transmission Fluid Fill Plug
      G04681486Courtesy of FORD MOTOR CO.
  16. With the transaxle in (P) PARK, the vehicle on a level surface, the engine at idle (680-780 RPM) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
  17. Wipe the fluid level indicator cap and remove the fluid level indicator.
  18. Wipe the fluid level indicator with a clean cloth.
    19. NOTE: In order to get an accurate fluid level reading, the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the WDS, verify that the transaxle is at normal operating temperature 60°C - 70°C (140°F - 158°F), prior to adjusting the transmission fluid level.
    Fig 15: Locating Fluid Level Indicator
    G04681487Courtesy of FORD MOTOR CO.
  19. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper most mark on the fluid level indicator. Only fill to the upper most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.
    20. NOTE: The correct transmission fluid level at normal operating temperature of 60°C - 70°C (140°F - 158°F) is between the top 2 marks on the fluid level indicator.
    Fig 16: Locating Marks On Fluid Level Indicator
    G04681488Courtesy of FORD MOTOR CO.
  20. Fill the transaxle to the correct fluid level.
    21. NOTE: The correct transmission fluid level at cool operating temperature of 15°C - 25°C (59°F - 77°F), is at the bottom mark on the fluid level indicator.
    Fig 17: Locating Bottom Mark On Fluid Level Indicator
    G04681489Courtesy of FORD MOTOR CO.
  21. If the transmission fluid temperature is low, fill the fluid to the cold range on the fluid level indicator. Recheck the fluid level when the transaxle has reached the normal operating temperature.
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