Automatic Transmission - CVT: Disassembly: Transaxle

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Handle, Torque Converter 307-091 (T81P-7902-C)
Courtesy of FORD MOTOR CO.	Holding Fixture, Transmission 307-003 (T57L-500-B)
Courtesy of FORD MOTOR CO.	Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9)
Courtesy of FORD MOTOR CO.	Variator Socket 307-545

1. Remove and discard the 4 retainers and remove the transaxle insulator.
   Fig 1: Locating Transaxle Insulator Retainers

   Courtesy of FORD MOTOR CO.
2. Remove the bolts and remove the rear transaxle mount.
   Fig 2: Locating Rear Transaxle Mount Bolts

   Courtesy of FORD MOTOR CO.
3. Remove the bolt and remove the fluid level indicator and tube.
   Fig 3: Locating Fluid Level Indicator & Tube Bolt

   Courtesy of FORD MOTOR CO.
4. Remove the fluid level indicator tube grommet.
   Fig 4: Locating Fluid Level Indicator Tube Grommet

   Courtesy of FORD MOTOR CO.
5. Using the special tool, remove the torque converter.
   Fig 5: Identifying Special Tool (307-091) On Torque Converter

   Courtesy of FORD MOTOR CO.
6. Make an identifying mark on the torque converter where the pump pilot is located for correct installation.
   Fig 6: Locating Mark On Torque Converter

   Courtesy of FORD MOTOR CO.
CAUTION: Be careful not to cross-thread the bolts while installing the special tool.
Fig 7: Identifying Special Tool (307-003)
Courtesy of FORD MOTOR CO.
7. Install the special tool onto the transaxle case.
   • Tighten to 55 N.m (41 lb-ft).
8. Position the transaxle into the bench fixture.
   Fig 8: Positioning Transaxle Into Bench Fixture Using Special Tool (307-003)

   Courtesy of FORD MOTOR CO.
9. Remove the side shaft gear assembly bolts.
   Fig 9: Locating Side Shaft Gear Assembly Bolts

   Courtesy of FORD MOTOR CO.
10. Remove the side shaft gear assembly from the case.
    Fig 10: Locating Side Shaft Gear Assembly

    Courtesy of FORD MOTOR CO.
11. Remove the transaxle fluid pan.
    Fig 11: Locating Transaxle Fluid Pan

    Courtesy of FORD MOTOR CO.
12. Remove and discard the transaxle fluid pan gasket.
    Fig 12: Locating Transaxle Fluid Pan Gasket

    Courtesy of FORD MOTOR CO.
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.
Fig 13: Locating Fluid Filter
Courtesy of FORD MOTOR CO.
13. Remove and discard the fluid filter.
    • Use a suitable seal pick to remove the seal if it is stuck in the case.
14. Remove the main electrical outer shell bolt.
    Fig 14: Locating Main Electrical Outer Shell Bolt

    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 15: Locating Electrical Connector (1 Of 3)
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15. Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
    • Rotate the connector counterclockwise to remove.
16. Remove the electrical connector by lifting it out of the case.
    Fig 16: Locating Electrical Connector (2 Of 3)

    Courtesy of FORD MOTOR CO.
CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
Fig 17: Locating Electrical Connector (3 Of 3)
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17. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping the sensor a specific distance from the differential gears.
Fig 18: Locating OSS Sensor Bolt, Sensor & Spacer
Courtesy of FORD MOTOR CO.
18. Remove the OSS sensor bolt, sensor and spacer.
CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
NOTE: The 8 bolts that hold the mechatronic unit to the case are a different size Torx® bolt.
Fig 19: Locating Mechatronic Unit Bolts
Courtesy of FORD MOTOR CO.
19. Remove the 8 bolts from the mechatronic unit.
CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Fig 20: Locating Mechatronic Unit
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20. Remove the mechatronic unit from the transaxle.
NOTE:
1. The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
2. Note the location and size of the 5 feed tubes for reassembly.
Fig 21: Identifying Feed Tubes
Courtesy of FORD MOTOR CO.
21. 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.
22. 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 22: Locating O-Ring Seals

    Courtesy of FORD MOTOR CO.
23. Remove and discard the 26 retaining bolts for the transaxle converter housing.
    Fig 23: Locating Transaxle Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
24. Remove the converter housing. It will be necessary to pry the case halves apart.
    Fig 24: Prying Case Halves Apart

    Courtesy of FORD MOTOR CO.
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 25: Locating Converter Housing Gasket
Courtesy of FORD MOTOR CO.
25. Remove and discard the converter housing gasket.
26. Remove the differential assembly.
    Fig 26: Locating Differential Assembly

    Courtesy of FORD MOTOR CO.
27. Remove the input shaft. Remove and discard the planet carrier thrust washer.
    Fig 27: Locating Input Shaft & Planet Carrier Thrust Washer

    Courtesy of FORD MOTOR CO.
28. Remove and discard the O-ring seals and the split ring seal.
    Fig 28: Locating O-Ring Seals & Split Ring Seal

    Courtesy of FORD MOTOR CO.
NOTE: There is a selective fit washer under this bearing.
Fig 29: Locating Upper Input Shaft Roller Bearing
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29. Remove the upper input shaft roller bearing.
NOTE: This is a selective fit washer.
Fig 30: Locating Upper Input Shaft Roller Bearing Washer
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30. Remove the upper input shaft roller bearing washer.
31. Remove the input shaft roller bearing.
    Fig 31: Locating Input Shaft Roller Bearing

    Courtesy of FORD MOTOR CO.
32. Remove the fluid baffle screws and the baffle.
    Fig 32: Locating Fluid Baffle Screws & Baffle

    Courtesy of FORD MOTOR CO.
33. Remove the chain lube feed tube retainer screws and the retainer.
    Fig 33: Locating Chain Lube Feed Tube Retainer Screws & Retainer

    Courtesy of FORD MOTOR CO.
34. Remove the chain lube feed tube.
    Fig 34: Locating Chain Lube Feed Tube

    Courtesy of FORD MOTOR CO.
35. Remove and discard the feed tube O-ring seal.
    Fig 35: Locating Feed Tube O-Ring Seal

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the transaxle range sensor wiring.
Fig 36: Locating Manual Lever Detent Spring Bolts
Courtesy of FORD MOTOR CO.
36. Remove the 2 bolts and the manual lever detent spring.
NOTE:
1. The manual valve will need to be in the PARK position in order to remove the valve assembly.
2. It may require some rocking movement back and forth in order to get the valve off the O-ring seals on the clutch feed tube.
Fig 37: Locating Range Selector Valve Assembly Bolts
Courtesy of FORD MOTOR CO.
37. Remove the 2 bolts for the range selector valve assembly and remove the valve assembly.
38. Remove and discard the sun gear retaining ring.
    Fig 38: Locating Sun Gear Retaining Ring

    Courtesy of FORD MOTOR CO.
39. Remove the sun gear and bearing spacer.
    Fig 39: Locating Sun Gear & Bearing Spacer

    Courtesy of FORD MOTOR CO.
40. Inspect the sun gear and spacer for damage.
    • If damage is indicated, install a new sun gear and spacer.
    Fig 40: Locating Sun Gear & Spacer

    Courtesy of FORD MOTOR CO.
41. Remove the forward clutch assembly.
    Fig 41: Locating Forward Clutch Assembly

    Courtesy of FORD MOTOR CO.
CAUTION: Be careful when removing the retaining ring that it does not fall into the case, damage to the case will result.
Fig 42: Locating Guide Pin Retaining Ring
Courtesy of FORD MOTOR CO.
42. Using a magnet and a small screwdriver, remove and discard the guide pin retaining ring.
43. Using a magnet, remove the guide pin retaining ring washer.
    Fig 43: Locating Guide Pin Retaining Ring Washer

    Courtesy of FORD MOTOR CO.
44. Install the special tool onto the variators.
    Fig 44: Identifying Special Tool (307-547-1)

    Courtesy of FORD MOTOR CO.
45. Secure the special tool with a strap.
    Fig 45: Locating Special Tool (307-547-1) With Strap

    Courtesy of FORD MOTOR CO.
46. Remove the special tool.
    Fig 46: Identifying Special Tool (307-003)

    Courtesy of FORD MOTOR CO.
47. Remove the end portion of the transmission holding fixture tool that fits into the bench fixture. Install the end portion onto the variator holding fixture so it can be mounted into the bench fixture.
    Fig 47: Locating End Portion Of Transmission Holding Fixture Tool

    Courtesy of FORD MOTOR CO.
48. Install the transaxle case half and the variator assembly into the bench fixture.
    • Remove the strap.
    Fig 48: Locating Transaxle Case Half & Variator Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The feed tube under the primary cover may stick in the cover or in the case.
Fig 49: Locating Primary Cover Bolts
Courtesy of FORD MOTOR CO.
49. Remove and discard the bolts for the primary cover and remove the cover.
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 50: Locating Primary Cover Gasket
Courtesy of FORD MOTOR CO.
50. Remove and discard the primary cover gasket.
51. Remove and discard the O-ring seal from the feed tube and the square cut seal.
    Fig 51: Locating O-Ring Seal

    Courtesy of FORD MOTOR CO.
NOTE: If the feed tube is not in the case, it may be stuck in the cover.
Fig 52: Locating Feed Tube
Courtesy of FORD MOTOR CO.
52. Remove the feed tube from the case.
53. Remove and discard the bolts for the secondary cover and remove the cover.
    Fig 53: Locating Secondary Cover Bolts

    Courtesy of FORD MOTOR CO.
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 54: Locating Secondary Feed Tube & Gasket
Courtesy of FORD MOTOR CO.
54. Remove and discard the seal on the secondary feed tube and the gasket from the case.
55. Remove and discard the secondary feed tube snap ring.
    Fig 55: Locating Secondary Feed Tube Snap Ring

    Courtesy of FORD MOTOR CO.
NOTE: The feed tube under the pressure filter cover may stick in the cover or in the case.
Fig 56: Locating Pressure Filter Cover Bolts
Courtesy of FORD MOTOR CO.
56. Remove the pressure filter cover.
NOTE: If the feed tube is not in the case it may be stuck in the cover.
Fig 57: Locating Pressure Filter Feed Tube
Courtesy of FORD MOTOR CO.
57. Remove the pressure filter feed tube.
58. Remove and discard the O-ring seals from the feed tube.
    Fig 58: Locating O-Ring Seals

    Courtesy of FORD MOTOR CO.
59. Remove and discard the pressure filter.
    Fig 59: Locating Pressure Filter

    Courtesy of FORD MOTOR CO.
NOTE:
1. The case half will only need to be removed from the variators if installing a new chain and variator assembly or a new case.
2. Make sure that the manual control lever is in the PARK position when removing the primary variator nut.
3. The primary variator nut has been torqued to 500 N.m (369 lb-ft).
Fig 60: Identifying Special Tool (307-545)
Courtesy of FORD MOTOR CO.
60. Using the special tool, remove and discard the primary variator nut.
NOTE:
1. Make sure that the manual control lever is in the PARK position when removing the secondary variator nut.
2. The secondary nut had been torqued to 150 N.m (111 lb-ft).
Fig 61: Identifying Special Tool (307-545)
Courtesy of FORD MOTOR CO.
61. Using the special tool, remove and discard the secondary variator nut.
CAUTION: The chain and variators are a matched set of components. All 3 components (chain, primary variator and secondary variator) are installed as an assembly. Do not attempt to install an individual component. Transmission failure will result.
NOTE: The short variator insert goes on top of the primary variator.
Fig 62: Identifying Special Tools (307-547-3, 307-547-4, 307-547-5, 307-547-6)
Courtesy of FORD MOTOR CO.
62. Install the special tools.
CAUTION: In order for the cover to be removed evenly from the variators, both of the bolts must be turned 1/4 turn at a time. Failure to follow this instruction will cause damage to the variators and case.
Fig 63: Identifying Special Tools (307-547-2, 307-547-3, 307-547-4, 307-547-5, 307-547-6)
Courtesy of FORD MOTOR CO.
63. Using the special tools, lift the transaxle case up off the variator assembly.
64. For the cleaning and inspection of the variators, refer to VARIATOR/CHAIN AND SPUR GEAR ASSEMBLY .