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Mechatronic Assembly: Installation

    CAUTION: Lubricate all of the O-ring seals with clean continuously variable transmission (CVT) automatic transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the feed tubes into the transaxle case half or internal damage to the transaxle will occur.
  1. Lubricate the new O-ring seals with clean CVT automatic transmission fluid and install the O-ring seals on the feed tubes.
    1. Align the inner tube and 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 1: Installing Seals On Feed Tubes
      G03990873Courtesy of FORD MOTOR CO.
    2. CAUTION: 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.
  2. Lubricate the O-ring seals with clean CVT automatic 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 2: Installing Feed Tubes Into Case
      G03990874Courtesy of FORD MOTOR CO.
    3. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 3: Positioning Mechatronic Unit Onto Case
    G03990870Courtesy of FORD MOTOR CO.
  3. Position the mechatronic unit onto the case.
  4. Tighten the mechatronic bolts in sequence in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten an additional 40 degrees (1/8 turn).
      Fig 4: Tightening Mechatronic Bolts
      G03990876Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 5: Installing Electrical Connector Into Case
    G03990867Courtesy of FORD MOTOR CO.
  5. Install the electrical connector into the case.
  6. Rotate the outer shell connector in place and install the bolt.
    • Tighten to 6 Nm (53 lb-in).
      Fig 6: Installing Bolt
      G03990865Courtesy of FORD MOTOR CO.
  7. Connect the electrical connectors.
    Fig 7: Connecting Electrical Connectors
    G03990868Courtesy of FORD MOTOR CO.
    8. CAUTION: Make sure that the fluid filter pickup tube seal was 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 8: Identifying Fluid Filter
    G03990695Courtesy of FORD MOTOR CO.
  8. Install a new fluid filter and seal assembly.
  9. Make sure that the filter is seated over one of the mechatronic bolts.
    Fig 9: Identifying Mechatronic Bolts
    G03990711Courtesy of FORD MOTOR CO.
    10. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
    NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
    Fig 10: Removing Transaxle Fluid Pan Gasket
    G03990694Courtesy of FORD MOTOR CO.
  10. Install a new fluid pan gasket.
  11. Install the fluid pan and the bolts. Tighten in the sequence shown.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 11: Installing Fluid Pan And Bolts
      G03990712Courtesy of FORD MOTOR CO.
  12. Install the fluid pan drain plug.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 12: Locating Fluid Pan Drain Plug
      G03990683Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 13: Identifying Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.
  13. Connect the transaxle bulk head electrical connector.
  14. Fill the transaxle with approximately 4.7 L (5 quarts) of clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK AND SETTING  in this section.
  15. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
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