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Home >> Mercury >> 2002 >> Cougar 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> In-Vehicle Repair >> Main Control >> Installation

Main Control: Installation

All vehicles 

  1. Install the manual valve.
    Fig 1: Installing Manual Valve
    G02205344Courtesy of FORD MOTOR CO.
    Fig 2: Pushing Solenoid Valve Body Harness Connector Up Through Transaxle Case
    G02205345Courtesy of FORD MOTOR CO.
    2. 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.
  2. Push the solenoid valve body harness connector up through the transaxle case.
  3. Connect the manual valve link to the manual valve.
    Fig 3: Connecting Manual Valve Link To Manual Valve
    G02205346Courtesy of FORD MOTOR CO.
    4. NOTE: Install the bolts in the indicated sequence.
    Fig 4: Installing Mounting Bolts
    G02205347Courtesy of FORD MOTOR CO.
  4. Position the main control valve body and install the mounting bolts.
  5. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
    Fig 5: Loosening Nut On Ball Stud
    G02205348Courtesy of FORD MOTOR CO.
  6. Remove the manual control lever bolt.
    Fig 6: Removing Manual Control Lever Bolt
    G02205349Courtesy of FORD MOTOR CO.
  7. Using the special tool and pin, align the shifter shaft.
    Fig 7: Aligning Shifter Shaft Using Special Tool And Pin
    G02205350Courtesy of FORD MOTOR CO.
  8. Move the manual valve detent lever assembly to the (D) position.
    Fig 8: Moving Manual Valve Detent Lever Assembly To (D) Position
    G02205351Courtesy of FORD MOTOR CO.
  9. Tighten the nut on the ball.
    • Remove the shifter pin from the special tool.
      Fig 9: Tightening Nut On Ball
      G02205352Courtesy of FORD MOTOR CO.
  10. 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: Tightening Detent Nut
      G02205353Courtesy of FORD MOTOR CO.
  11. Using the special tool, check the manual control lever assembly settings.
    Fig 11: Installing Special Tool
    G02205354Courtesy of FORD MOTOR CO.
  12. Install the manual control lever.
    1. Position the manual control lever.
    2. Tighten the bolt.
      Fig 12: Installing Manual Control Lever
      G02205355Courtesy of FORD MOTOR CO.
  13. Install the 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 Manual Valve Detent Lever Positions
      G02205356Courtesy of FORD MOTOR CO.
  14. 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
      G02205357Courtesy of FORD MOTOR CO.
  15. Install the new gasket on the main control cover before positioning.
    Fig 15: Installing Gasket On Main Control Cover
    G02205358Courtesy of FORD MOTOR CO.
    16. NOTE: Tighten the bolts in the indicated sequence.
  16. Install the main control cover.
    • Connect the main control cover vent tube and close clamp.
    • Position main control cover and tighten bolts.
      Fig 16: Positioning Main Control Cover And Tightening Bolts
      G02205359Courtesy of FORD MOTOR CO.
    17. NOTE: Remove the drain pan.
    Fig 17: Connecting Transaxle Cooler Inlet Line
    G02205360Courtesy of FORD MOTOR CO.
  17. Connect the transaxle cooler inlet line.
    18. NOTE: Do not the tighten the TR sensor bolts.
    Fig 18: Installing Transmission Range (TR) Sensor
    G02205361Courtesy of FORD MOTOR CO.
  18. Install the transmission range (TR) sensor and install the bolts loosely.
  19. Tighten the TR sensor bolts. Refer to TRANSMISSION RANGE (TR) SENSOR .
    Fig 19: Tightening TR Sensor Bolts
    G02205362Courtesy of FORD MOTOR CO.
  20. 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: Connecting Transaxle Harness Electrical Connector
      G02205363Courtesy of FORD MOTOR CO.

      Vehicles with air conditioning 

    21. 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 And Installing Screws
    G02205364Courtesy of FORD MOTOR CO.
  21. Position the suction accumulator and install the screws.

    All Vehicles 

  22. Install the battery tray.
    23. 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.
  23. Connect the battery ground cable.
  24. Check the transmission fluid. Add as necessary using clean automatic transmission fluid.
    Fig 22: Identifying Transmission Fluid Dipstick
    G02205365Courtesy of FORD MOTOR CO.
  25. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary.
    Fig 23: Identifying Transaxle Range Selector Lever
    G02205366Courtesy of FORD MOTOR CO.
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