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Mechatronic Assembly: Removal

CAUTION: MERCON®, MERCON®V, 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: If a new transaxle or a mechantronic main control valve body assembly is installed, the transmission control module (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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    3. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  3. Disconnect the transaxle bulk head electrical connector.
    • Rotate the electrical connector counterclockwise to disconnect.
      Fig 1: Identifying Transaxle Bulkhead Electrical Connector
      G03990860Courtesy of FORD MOTOR CO.
  4. Remove the fluid pan drain plug and allow the fluid to drain.
    Fig 2: Locating Fluid Pan Drain Plug
    G03990683Courtesy of FORD MOTOR CO.
  5. Remove the fluid pan bolts and the fluid pan.
    Fig 3: Removing Fluid Pan Bolts And Fluid Pan
    G03990693Courtesy of FORD MOTOR CO.
  6. Remove and discard the fluid pan gasket.
    Fig 4: Removing Transaxle Fluid Pan Gasket
    G03990694Courtesy of FORD MOTOR CO.
    7. NOTE: Check the transaxle case to see if the filter pickup tube seal is stuck in the case. If the pickup tube seal is in the case it will need to be removed.
  7. Remove and discard the fluid filter.
    • Use a suitable seal pick to remove the seal if it is stuck in the case.
      Fig 5: Identifying Fluid Filter
      G03990695Courtesy of FORD MOTOR CO.
  8. Remove the main electrical outer shell bolt.
    Fig 6: Removing Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
    9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  9. Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
    • Rotate the connector counterclockwise to remove.
      Fig 7: Rotating Connector Counterclockwise
      G03990866Courtesy of FORD MOTOR CO.
  10. Remove the electrical connector by lifting it out of the case.
    Fig 8: Removing Electrical Connector
    G03990867Courtesy of FORD MOTOR CO.
    11. CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
    Fig 9: Disconnecting Electrical Connectors
    G03990868Courtesy of FORD MOTOR CO.
  11. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
    12. NOTE: The 8 bolts that hold the mechatronic unit to the case are a different size Torx® bolt.
    Fig 10: Removing Bolts From Mechatronic Unit
    G03990869Courtesy of FORD MOTOR CO.
  12. Remove the 8 bolts from the mechatronic unit.
    13. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 11: Removing Mechatronic Unit From Transaxle
    G03990870Courtesy of FORD MOTOR CO.
  13. Remove the mechatronic unit from the transaxle.
    14. NOTE: The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
    NOTE: Note the location and size of the 5 feed tubes for reassembly.
  14. Remove all of the 5 feed tubes.
    1. Remove the clutch (manual valve) supply feed tube.
    2. Remove the primary pressure feed tube.
    3. Remove the secondary pressure feed tube.
    4. Remove the main (pump) pressure feed tube (smaller tube).
    5. Remove and discard the torque converter clutch pressure feed tube.
      Fig 12: Removing Feed Tubes
      G03990874Courtesy of FORD MOTOR CO.
  15. Remove and discard all of the seals on the feed tubes.
    1. Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
    2. Remove and discard the O-ring seals from the primary pressure feed tube.
    3. Remove and discard the O-ring seals from the secondary pressure feed tube.
    4. Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube).
    5. Discard the torque converter clutch pressure feed tube.
      Fig 13: Removing All Of Seals On Feed Tubes
      G03990872Courtesy of FORD MOTOR CO.
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