Main Controls: Installation

Install the manual valve.

Fig 1: Installing Manual Valve

NOTE: Inspect solenoid valve body harness connector O-ring seal and install new as necessary before installing solenoid valve body harness connector in transaxle case.

Fig 2: Inspecting Solenoid Valve Body Harness Connector O-Ring

Push the solenoid valve body harness connector up through the transaxle case.
Connect the manual valve link to the manual valve.

Fig 3: Connecting Manual Valve Link To Manual Valve
Position the main control valve body and install the mounting bolts.
NOTE: Install the bolts in the indicated sequence.

Fig 4: Installing Mounting Bolts In Sequence
Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.

Fig 5: Loosening Nut On Ball Stud
Remove the manual control lever bolt.

Fig 6: Removing Manual Control Lever Bolt
Using the special tool and pin, align the shifter shaft.

Fig 7: Aligning Shifter Shaft
Move the manual valve detent lever assembly to the "D" position.

Fig 8: Moving Manual Valve Detent Lever Assembly To "D" Position
Tighten the nut on the ball.
- Remove the shifter pin from the special tool.
Fig 9: Removing Shifter Pin
Rotate the special tool until the socket can be fitted on nut.
- Tighten the detent nut.
- Rotate back to the "D" position and check the adjustment.
Fig 10: Rotating Special Tool Until Socket Can Be Fitted On Nut
Using the special tool, check the manual control lever assembly settings.

Fig 11: Check Manual Control Lever Assembly
Install the manual control level.
1. Position the manual control lever.
2. Tighten the bolt.
Fig 12: Installing Manual Control Level
Install and rotate the manual valve detent lever assembly to the NEUTRAL position.
1. Low 1
2. Low 2
3. Drive
4. Neutral
5. Reverse
6. Park
Fig 13: Identifying Low 1 (1), Low 2 (2), Drive (3), Neutral (4), Reverse (5) & Park (6)
Connect the shift cable to the control lever.
1. Install the shift cable.
2. Install the bolts.
Fig 14: Connecting Shift Cable To Control Lever
Install new gasket on the main control cover before positioning.

Fig 15: Install New Gasket
Tighten the bolts in the indicated sequence. Install the main control cover.
- Connect the main control cover vent tube and close clamp.
- Position main control cover and tighten bolts.
Fig 16: Tightening Bolts In Sequence

NOTE: Remove the drain pan:

Fig 17: Connect Transaxle Cooler Inlet Line

Connect the transaxle cooler inlet line.

NOTE: Do not tighten the TR sensor bolts.

Fig 18: Installing Transmission Range (TR) Sensor

Install the transmission range (TR) sensor and install the bolts loosely.
Tighten the TR sensor bolts.

Fig 19: Tightening TR Sensor Bolts
Connect the transaxle harness electrical connector.
1. Install the ground cable.
2. Install the solenoid body electrical connector.
3. Install the TR sensor electrical connector.
4. Install the wiring harness clip.
Fig 20: Installing Transaxle Harness Electrical Connector
On vehicles with air conditioning, position the suction accumulator and install the screws.
CAUTION: Do not place excessive pressure on tubes/hoses (A/C) and fittings when disconnecting and reconnecting A/C components. Excessive pressure may cause component damage and A/C system leaks.

NOTE: On some vehicles, it may be necessary to disconnect and position the suction accumulator out of the way to allow enough room for main control cover removal.

Fig 21: Positioning Suction Accumulator Out Of The Way
On all vehicles, install the battery tray.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy.

Connect the battery ground cable.
Check the transmission fluid, add as necessary. Use Motorcraft MERCON® multi-purpose transmission fluid or equivalent meeting MERCON® specification.

Fig 22: Checking Transmission Fluid
Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary.