Automatic Transmission - CVT: Assembly: Transaxle: Material

MATERIAL SPECIFICATION

Item	Specification
Motorcraft Continuously Variable Chain Type Transmission Fluid XT-7-QCFT	WSS-M2C933-A
Multi-Purpose Grease XG-4 and/or XG-5	ESB-M1C93-B
Threadlock 262 TA-26	WSK-M2G351-A6

CAUTION: MERCON®, MERCON® V and MERCON®SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

CAUTION: Prior to installing the transaxle case onto the variator assembly, make sure that the manual valve feed tube is correctly installed in the case. Damage to the manual valve feed and variator could occur if not correctly installed.

Fig 1: Positioning Transaxle Case Onto Variators

Courtesy of FORD MOTOR CO.

Position the transaxle case onto the variators.
Install the spacer washer to the special tool.

Fig 2: Installing Spacer Washer To Special Tool
Courtesy of FORD MOTOR CO.
Assembly the remaining components of the special tool.

Fig 3: Assembling Remaining Components Of Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: The special tools must be installed as shown or damage to the case will occur.

CAUTION: Make sure that when installing the case onto the variators, the case is NOT in park. If the case is in park damage to the case will occur.

NOTE: The windows in the special tools must be facing you so that when pressing the case down you can see when to stop.

Fig 4: Installing Special Tools On Top Of Case

Courtesy of FORD MOTOR CO.

Install the special tools on the top of the case in the position shown.
Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.

Fig 5: Identifying Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: This step must be followed exactly. Do not use any air tools when installing the case. Do not turn one forcing screw more than the other unless indicated. Failure to follow this instruction will result in damage to the case.

Press the transaxle case down onto the variator assembly.
1. Hold the transaxle case level. Turn the secondary forcing screw 2 complete turns.
2. Turn both forcing screws at the same time evenly until the case just contacts the variators.
  
  Fig 6: Identifying Forcing Screws
  Courtesy of FORD MOTOR CO.
Install a new primary nut.

Fig 7: Installing Primary Nut
Courtesy of FORD MOTOR CO.
Install a new secondary nut.

Fig 8: Installing Secondary Nut
Courtesy of FORD MOTOR CO.

NOTE: In order to tighten the variator nuts the manual control lever must be in park to prevent the variators from turning.

Make sure that the manual control lever is in the PARK position.
Using the special tools, tighten the primary variator nut in 2 stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 500 Nm (369 lb-ft).
  
  Fig 9: Tightening Primary Variator Nut
  Courtesy of FORD MOTOR CO.
Using the special tools, tighten the secondary variator nut in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten to 150 Nm (111 lb-ft).
  
  Fig 10: Tightening Secondary Variator Nut
  Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean continuously variable transmission (CVT) automatic transmission fluid and install the O-ring seals on the primary cover feed tube.

Fig 11: Installing O-Ring Seals On Primary Cover Feed Tube
Courtesy of FORD MOTOR CO.
Install the primary cover feed tube into the case.

Fig 12: Installing Primary Cover Feed Tube Into Case
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install a new square cut seal and the O-ring seal.

Fig 13: Installing Square Cut Seal And O-Ring Seal
Courtesy of FORD MOTOR CO.
Install a new primary cover gasket.

Fig 14: Installing Primary Cover Gasket
Courtesy of FORD MOTOR CO.
Using new bolts, install the primary cover and tighten in the sequence shown in 2 stages:
- Stage 1: Tighten to 4 Nm (35 lb-in).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 15: Installing Primary Cover
  Courtesy of FORD MOTOR CO.

NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.

Fig 16: Installing Secondary Cover Gasket

Courtesy of FORD MOTOR CO.

Lubricate the new O-ring with clean automatic transmission fluid and install the O-ring seal on the feed tube. Install a new secondary cover gasket.
If not previously done, install a new square cut seal in the secondary cover.

Fig 17: Installing Square Cut Seal
Courtesy of FORD MOTOR CO.
Using new bolts, install the secondary cover and tighten in the sequence shown in 2 stages:
- Stage 1: Tighten to 4 Nm (35 lb-in).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 18: Installing Secondary Cover
  Courtesy of FORD MOTOR CO.
Install a new pressure filter.

Fig 19: Installing Pressure Filter
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the pressure filter feed tube.

Fig 20: Installing O-Ring Seals On Pressure Filter Feed Tube
Courtesy of FORD MOTOR CO.
Install the pressure filter feed tube.

Fig 21: Installing Pressure Filter Feed Tube
Courtesy of FORD MOTOR CO.
Install the pressure filter case cover.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Installing Pressure Filter Case Cover
  Courtesy of FORD MOTOR CO.
Install the safety strap on the transaxle.

Fig 23: Installing Safety Strap On Transaxle
Courtesy of FORD MOTOR CO.
Install the special tool onto the transaxle case.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 24: Installing Special Tool Onto Transaxle Case
  Courtesy of FORD MOTOR CO.

NOTE: Be careful when installing the guide plate that it does not fall into the case. If guide plate falls into the case, case disassembly will need to carried out.

Fig 25: Installing Guide Pin Retaining Ring Plate

Courtesy of FORD MOTOR CO.

Using a magnet, carefully install the guide pin retaining ring plate.
Install the C-clip onto the special tool.

Fig 26: Installing C-Clip Onto Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install the guide pin retaining ring.

Fig 27: Installing Guide Pin Retaining Ring
Courtesy of FORD MOTOR CO.
If not previously done, lubricate the new seals with clean CVT automatic transmission fluid and install the O-ring seals in the case.

Fig 28: Installing O-Ring Seals In Case
Courtesy of FORD MOTOR CO.

NOTE: When installing the range selector valve assembly make sure that the pin from the manual valve lever is correctly installed into the range selector valve assembly.

Fig 29: Installing Range Selector Valve Assembly

Courtesy of FORD MOTOR CO.

Loosely install the range selector valve assembly.
Install the bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 30: Installing Bolts
  Courtesy of FORD MOTOR CO.
Make sure that when routing the range selector valve assembly wiring harness it is between the bolt holes and is pressed into the case retainers.

Fig 31: Identifying Range Selector Valve Assembly Wiring Harness
Courtesy of FORD MOTOR CO.

NOTE: Be careful not to pinch wire harness when installing detent spring.

Install the manual lever detent spring.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 32: Installing Manual Lever Detent Spring
  Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seal with clean CVT automatic transmission fluid and install the O-ring seal on the chain lube tube.

Fig 33: Installing O-Ring Seal On Chain Lube Tube
Courtesy of FORD MOTOR CO.
Install the chain lube tube into the case.

Fig 34: Installing Chain Lube Tube Into Case
Courtesy of FORD MOTOR CO.
Install the fluid feed transfer tube retainer bracket.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 35: Installing Fluid Feed Transfer Tube Retainer Bracket
  Courtesy of FORD MOTOR CO.
Install the transmission fluid baffle.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 36: Installing Transmission Fluid Baffle
  Courtesy of FORD MOTOR CO.
Install new forward clutch primary shaft seals.

Fig 37: Installing Forward Clutch Primary Shaft Seals
Courtesy of FORD MOTOR CO.
Install the forward clutch drum without the clutch plates installed.

Fig 38: Installing Forward Clutch Drum Without Clutch Plates
Courtesy of FORD MOTOR CO.

NOTE: Note the recess in the top of the sun gear and the slight groove on the face of the gear teeth are facing up.

Fig 39: Installing Sun Gear

Courtesy of FORD MOTOR CO.

Install the sun gear.
Install the sun gear spacer.

Fig 40: Installing Sun Gear Spacer
Courtesy of FORD MOTOR CO.
Install a new sun gear snap ring.

Fig 41: Installing Sun Gear Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: The clutch pack stack is made without the wave plate only.

Install all plates and pressure plate but not the wave spring.
Install the forward clutch snap ring.

Fig 42: Installing Forward Clutch Snap Ring
Courtesy of FORD MOTOR CO.
Install the special tool. Zero out the special tool.

Fig 43: Installing Special Tool
Courtesy of FORD MOTOR CO.
Lift up on the clutch plates by inserting a screwdriver in the clutch pack and record the measurement. Enter this measurement in the following table on the line labeled A.

Fig 44: Lifting Up On Clutch Plates
Courtesy of FORD MOTOR CO.

NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.39-1.68 mm (0.055-0.066 inch).

Select the selective snap ring.

SNAP RING SPECIFICATION

Description	Reading
A
B	+ 0.51 mm (0.02 in)
C	- 1.40 mm (0.055 in)
(D) Clearance

Add line A to B, then subtract line C and enter this total on line D.
Line D is the actual clearance of the snap ring used during this measurement.
If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.

Forward Clutch Selective Snap Ring

Remove the forward clutch pack snap ring.

FORWARD CLUTCH SELECTIVE SNAP RING SPECIFICATION

Part Number	Snap Ring Thickness
7B421	2.00 mm (0.078 in)
7B421	1.80 mm (0.070 in)
7B421	1.60 mm (0.062 in)
7B421	1.40 mm (0.055 in)
7B421	1.20 mm (0.047 in)
7B421	1.00 mm (0.039 in)

Fig 45: Removing Forward Clutch Pack Snap Ring

Courtesy of FORD MOTOR CO.

Remove the forward clutch plates, steel and friction.

Fig 46: Removing Forward Clutch Plates, Steel And Friction
Courtesy of FORD MOTOR CO.
Install the forward clutch wave spring.

Fig 47: Installing Forward Clutch Wave Spring
Courtesy of FORD MOTOR CO.
Install the forward clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.

Fig 48: Installing Forward Clutch Plates, Steel And Friction, Alternating Between Steel And Friction
Courtesy of FORD MOTOR CO.
Install the forward clutch pressure plate.

Fig 49: Installing Forward Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Install the forward clutch pack snap ring.

Fig 50: Installing Forward Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.
Install the forward clutch roller cage bearing.

Fig 51: Installing Forward Clutch Roller Cage Bearing
Courtesy of FORD MOTOR CO.

NOTE: This is a selective fit washer for the input shaft set up.

Fig 52: Installing Forward Clutch Upper Bearing Washer

Courtesy of FORD MOTOR CO.

Install the forward clutch upper bearing washer.
Install the forward clutch upper roller bearing.

Fig 53: Installing Forward Clutch Upper Roller Bearing
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals and split ring seal.

Fig 54: Installing O-Ring Seals And Split Ring Seal
Courtesy of FORD MOTOR CO.
Install the input shaft and a new planet carrier thrust washer.

Fig 55: Installing Input Shaft And A New Planet Carrier Thrust Washer
Courtesy of FORD MOTOR CO.
Install the differential assembly in the case.

Fig 56: Installing Differential Assembly
Courtesy of FORD MOTOR CO.
Install the bearing race onto the differential assembly.

Fig 57: Installing Bearing Race Onto Differential Assembly
Courtesy of FORD MOTOR CO.
Compress the special tool and hand-tighten the bolt.

Fig 58: Compressing Special Tool
Courtesy of FORD MOTOR CO.
Install the special tools onto the case.

Fig 59: Installing Special Tools Onto Case
Courtesy of FORD MOTOR CO.
Position the case onto the special tools and install the bolts.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 60: Positioning Case Onto Special Tools
  Courtesy of FORD MOTOR CO.
Loosen the top bolt of the special tool. Using a feeler gauge measure the opening.

Fig 61: Loosening Top Bolt Of Special Tool
Courtesy of FORD MOTOR CO.
Measure the thickness of the bearing shim that came out when the race was removed. The thickness of the bearing shim should match the measured opening of the special tool. If the measurements do not match use a new selective bearing race shim.

Differential Bearing Race Selective Shim

Install the selective bearing race shim into the housing.

DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION

Part Number	Selective Shim Thickness
7F119	1.00 mm (0.039 inch)
7F119	1.05 mm (0.041 inch)
7F119	1.10 mm (0.043 inch)
7F119	1.15 mm (0.045 inch)
7F119	1.20 mm (0.047 inch)
7F119	1.25 mm (0.049 inch)
7F119	1.30 mm (0.051 inch)
7F119	1.35 mm (0.053 inch)
7F119	1.40 mm (0.055 inch)
7F119	1.45 mm (0.047 inch)
7F119	1.50 mm (0.059 inch)
7F119	1.55 mm (0.061 inch)
7F119	1.60 mm (0.063 inch)
7F119	1.65 mm (0.065 inch)
7F119	1.70 mm (0.067 inch)
7F119	1.75 mm (0.068 inch)
7F119	1.80 mm (0.070 inch)
7F119	1.85 mm (0.072 inch)
7F119	1.90 mm (0.074 inch)
7F119	1.95 mm (0.076 inch)
7F119	2.00 mm (0.078 inch)
7F119	2.05 mm (0.080 inch)
7F119	2.10 mm (0.081 inch)

Fig 62: Installing Selective Bearing Race Shim Into Housing

Courtesy of FORD MOTOR CO.

Position the new bearing race in place.

Fig 63: Positioning New Bearing Race
Courtesy of FORD MOTOR CO.
Install the special tools on this side of the case.

Fig 64: Installing Special Tools
Courtesy of FORD MOTOR CO.
Install the remaining special tools from the other side of the case. Using the special tools, install the bearing race.

Fig 65: Installing Remaining Special Tools
Courtesy of FORD MOTOR CO.
Install a new converter housing gasket.

Fig 66: Installing Converter Housing Gasket
Courtesy of FORD MOTOR CO.

NOTE: This is not a final torque. For this step only you can reuse the old bolts that were removed.

Position the converter housing in place. Install only 8 bolts evenly around the case to do the input shaft end play. It may be necessary to remove the install the correct shim. Tighten the bolts in a crisscross sequence.
- Tighten bolts to 8 Nm (71 lb-in).
  
  Fig 67: Tightening Bolts
  Courtesy of FORD MOTOR CO.
Install the special tool to measure the input shaft end play.
- Tighten the wing nut.
  
  Fig 68: Tightening Wing Nut
  Courtesy of FORD MOTOR CO.
Install the remaining special tool.
- Push down on the special tool and zero out the dial indicator.
- Lift up on the special tool and record the measurement 0.22-0.53 mm (0.008-0.021 inch) If the measurement is not within specification install a new input shaft bearing spacer. For additional information, refer to FORWARD CLUTCH .
  
  Fig 69: Installing Remaining Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.

Position the converter housing in place. Install new converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts. Starting at No. 1, tighten the bolts in a counterclockwise rotation.
- Stage 1: Tighten bolts to 2 Nm (18 lb-in).
- Stage 2: Tighten bolts to 8 Nm (71 lb-in).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 70: Installing Converter Housing Bolts
  Courtesy of FORD MOTOR CO.
Install the side shaft gear assembly.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 71: Installing Side Shaft Gear Assembly
  Courtesy of FORD MOTOR CO.
Position the output shaft seal in place.

Fig 72: Positioning Output Shaft Seal
Courtesy of FORD MOTOR CO.
Using the special tool, install the output shaft seal.

Fig 73: Installing Output Shaft Seal
Courtesy of FORD MOTOR CO.
Position the output shaft seal in place.

Fig 74: Positioning Output Shaft Seal
Courtesy of FORD MOTOR CO.
Using the special tool, install the output shaft seal.

Fig 75: Installing Output Shaft Seal
Courtesy of FORD MOTOR CO.
Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the feed tubes.
1. Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
2. Install new O-ring seals on the primary pressure feed tube.
3. Install new O-ring seals on the secondary pressure feed tube.
4. Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).
  
  Fig 76: Installing O-Ring Seals On Feed Tubes
  Courtesy of FORD MOTOR CO.

CAUTION: If not done previously, lubricate all of the O-ring seals with clean CVT automatic transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the mechatronic assembly or internal damage to the transaxle will occur.

NOTE: Note the location of the 5 feed tubes.

Lubricate the seals with clean transmission fluid and install all of the feed tubes into the case.
1. Align the inner tube and install the clutch (manual valve) supply feed tube.
2. Install the primary pressure feed tube.
3. Install the secondary pressure feed tube.
4. Install the main (pump) pressure feed tube (smaller tube).
5. Install a new torque converter clutch pressure feed tube.
  
  Fig 77: Installing Feed Tubes Into Case
  Courtesy of FORD MOTOR CO.

CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

Fig 78: Positioning Mechatronic Unit Onto Case

Courtesy of FORD MOTOR CO.

Position the mechatronic unit onto the case.
Tighten the mechatronic bolts in 2 stages.
- Stage 1: Tighten the bolts in the sequence shown to 5 Nm (44 lb-in).
- Stage 2: Tighten the bolts in the sequence shown 40 degrees (1/8 turn).
  
  Fig 79: Tightening Mechatronic Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Fig 80: Installing Electrical Connector Into Case

Courtesy of FORD MOTOR CO.

Lubricate the O-ring seal with clean CVT automatic transmission fluid and install the electrical connector into the case.

CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Rotate the outer shell connector in place and install the bolt.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 81: Installing Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping a specific distance from the differential gears.

Install the OSS sensor spacer, sensor and bolt.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 82: Installing OSS Sensor Spacer, Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Connect the electrical connectors.

Fig 83: Connecting Electrical Connectors
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the fluid filter pickup tube seal has been removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.

CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.

Fig 84: Identifying Fluid Filter

Courtesy of FORD MOTOR CO.

Lubricate the O-ring seal that is on the new filter with clean CVT automatic transmission fluid and install the fluid filter.
Make sure that the filter is seated over one of the mechatronic bolts.

Fig 85: Identifying Mechatronic Bolts
Courtesy of FORD MOTOR CO.
Install a new transaxle fluid pan gasket.

Fig 86: Installing Transaxle Fluid Pan Gasket
Courtesy of FORD MOTOR CO.
Make sure that the magnets in the pan are in the correct location prior to installing the transmission fluid pan.

Fig 87: Identifying Location Of Magnets In Pan
Courtesy of FORD MOTOR CO.
Install the transaxle fluid pan. Tighten the bolts in the sequence indicated.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 88: Installing Transaxle Fluid Pan
  Courtesy of FORD MOTOR CO.

CAUTION: Do not set the torque converter in the pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.

Fig 89: Identifying Location Of Index Slot In Pump

Courtesy of FORD MOTOR CO.

Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.
Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.

Fig 90: Removing/Installing Torque Converter Using Special Tool
Courtesy of FORD MOTOR CO.
Using 4 new retainers, install the transaxle insulator.

Fig 91: Installing Transaxle Insulator
Courtesy of FORD MOTOR CO.
Install a new fluid tube indicator grommet.

Fig 92: Installing Fluid Tube Indicator Grommet
Courtesy of FORD MOTOR CO.
Install the fluid level indicator and tube.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 93: Installing Fluid Level Indicator And Tube
  Courtesy of FORD MOTOR CO.
Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
Position the transaxle mount in place and install the upper retaining bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 94: Identifying Upper Transaxle Mount Retaining Bolts
  Courtesy of FORD MOTOR CO.