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Home >> Mercury >> 2002 >> Cougar 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Pump Assembly >> Assembly

Pump Assembly: Assembly

    NOTE: The identification dot on the pump driven gear must face downward.
    Fig 1: Installing Pump Driven Gear
    G02198662Courtesy of FORD MOTOR CO.
  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
      G02198663Courtesy of FORD MOTOR CO.
  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 And Pump Body Face
      G02198664Courtesy of FORD MOTOR CO.
  4. Install the special tool.
    Fig 4: Installing Special Tool
    G02198665Courtesy of FORD MOTOR CO.
  5. Align the pump support assembly. Fill the pump gear cavity with clean automatic transmission fluid 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: Installing Pump Support
      G02198666Courtesy of FORD MOTOR CO.
    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 Six Pump Support Bolts
    G02198667Courtesy of FORD MOTOR CO.
  6. Install the six pump support bolts.
    7. NOTE: Make sure that the white tripe on the pump seal is visible around the pump body circumference.
    Fig 7: Installing Pump Seal On Pump Body
    G02198668Courtesy of FORD MOTOR CO.
  7. Install the pump seal on the pump body.
    8. NOTE: Make sure the pump support seal rings are overlapped correctly.
    Fig 8: Installing Seven Pump Support Seal Rings
    G02198669Courtesy of FORD MOTOR CO.
  8. Install the seven pump support seal rings.
  9. Measure the pump rotation 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 Rotation Torque
        G02198670Courtesy of FORD MOTOR CO.
  10. Install the No.1 pump support thrust bearing.
    • Lubricate the seal rings with clean automatic transmission fluid.
      Fig 10: Installing No.1 Pump Support Thrust Bearing
      G02198671Courtesy of FORD MOTOR CO.
  11. Install the forward/coast/direct clutch cylinder and reverse clutch drum on the pump support.
    12. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can 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.
  12. Check the following passages of the forward/coast/direct clutch cylinder and reverse clutch drum with moisture-free compressed air, regulated to 276 kPa (40 psi).
    1. Reverse clutch passage.
    2. Forward clutch passage.
    3. Direct clutch passage.
    4. Coast clutch passage.
      • Converter bypass (located on the bottom).
        Fig 11: Checking Forward/Coast/Direct Clutch Cylinder And Reverse Clutch Drum
        G02198672Courtesy of FORD MOTOR CO.
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