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Home >> Mercury >> 2001 >> Cougar Base, 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle >> Disassembly And Assembly Of Subassemblies >> Pump Assembly >> Assembly

Pump Assembly: Assembly

    NOTE: The identification dot on the pump driven gear must be facing downward.
    Fig 1: Installing Pump Driven Gear
    G02164512
  1. Install the pump driven gear.
  2. Install the pump drive gear assembly.
    1. Install the pump drive gear.
    2. Install the pump drive gear insert.
    Fig 2: Installing Pump Drive Gear Assembly
    G02164513
  3. Using the special tool, measure the clearance between each gear and the pump body face.
    • If the clearance exceeds specification, install a new pump assembly.
    Fig 3: Measuring Clearance Between Each Gear & Pump Body Face
    G02164514
  4. Install the special tool.
    Fig 4: Installing Special Tool
    G02164515
  5. Align the pump support assembly.
    • Fill the pump gear cavity with MERCON® Multi-purpose automatic transmission fluid or equivalent meeting MERCON® specification to the top of the gears.
    • Align the pump guide screws.
    1. Install the pump body.
    2. Install the pump body separator plate.
    3. Install the pump body separator plate gasket onto the pump body.
    4. Install the pump support.
    Fig 5: Aligning Pump Support Assembly
    G02164516
    6. NOTE: Install the four pump support bolts in the pump support holes, and remove the special tool. Then install the last two bolts.
    Fig 6: Installing 6 Pump Support Bolts
    G02164517
  6. Install the six pump support bolts.
    7. NOTE: Make sure that the white stripe on the pump seal is visible around the pump body circumference.
    Fig 7: Installing Pump Seal On Pump Body
    G02164518
  7. Install the pump seal on the pump body.
    8. NOTE: Make sure the pump support seal rings are overlapped correctly.
    Fig 8: Installing 7 Pump Support Seal Rings
    G02164519
  8. Install the seven pump support seal rings.
  9. Measure the pump rotational torque.
    1. Install the pump drive shaft.
    2. Measure the pump rotational torque.
    3. Remove the pump drive shaft.
    • If rotational torque exceeds the specification, disassemble and inspect the pump assembly for contamination or incorrect end clearance.
    Fig 9: Measuring Pump Rotational Torque
    G02164520
  10. Install the No. 1 pump support thrust bearing.
    • Lubricate the seal rings with MERCON® Multi-purpose automatic transmission fluid or equivalent meeting MERCON® specification.
    Fig 10: Installing No. 1 Pump Support Thrust Bearing
    G02164521
  11. Install the forward/coast/direct clutch cylinder and reverse clutch drum on the pump support.
    12. WARNING: Air pressure must not exceed 1.38 bar (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions may result in personal injury.
    NOTE: With each application of air, you should hear the clutch pack apply. A hissing or high pitched squeal indicates that a seal is damaged or torn. Inspect to find the source and repair as necessary.
    Fig 11: Checking Passages Of Forward/Coast/Direct Clutch Cylinder & Reverse Clutch Drum With Moisture-Free Compressed Air
    G02164522
  12. Check the following passages of the forward/coast/direct clutch cylinder and reverse clutch drum with moisture-free compressed air, regulated to 2.76 bar (40 psi).
    1. Reverse clutch passage
    2. Forward clutch passage
    3. Direct clutch passage
    4. Coast clutch passage
    5. Converter by-pass
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