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Home >> Mercury >> 2007 >> Montego Base, AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Continuously Variable Transmission (CVT) >> Disassembly >> Transaxle

Automatic Transmission - Continuously Variable Transmission (CVT): Disassembly: Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0000942
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0000940
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0017494
 Holding Fixture, Transaxle Variator Assembly 307-547 (includes 307-547-1, 307-547-2, 307-547-7, 307-547-8, 307-547-9)
GF0017495
 Variator Socket 307-545
  1. Remove and discard the 4 retainers and remove the transaxle insulator.
    2. Fig 1: Locating Transaxle Insulator Retainers
    G03990976Courtesy of FORD MOTOR CO.
  2. Remove the bolts and remove the rear transaxle mount.
    3. Fig 2: Locating Rear Transaxle Mount Bolts
    G03991049Courtesy of FORD MOTOR CO.
  3. Remove the bolt and remove the transmission fluid level indicator and tube.
    4. Fig 3: Locating Fluid Level Indicator & Tube Bolt
    G03990977Courtesy of FORD MOTOR CO.
  4. Remove the transmission fluid level indicator tube grommet.
    5. Fig 4: Locating Fluid Level Indicator Tube Grommet
    GF0017496Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the torque converter.
    6. Fig 5: Removing/Installing Torque Converter Using Special Tool
    G03991060Courtesy of FORD MOTOR CO.
  6. Make an identifying mark on the torque converter where the pump pilot is located for correct installation.
    7. Fig 6: Identifying Mark On Torque Converter
    GF0017474Courtesy of FORD MOTOR CO.
    CAUTION: Be careful not to cross-thread the bolts while installing the special tool.
  7. Install the special tool onto the transaxle case.
    • Tighten to 55 Nm (41 lb-ft).
    8. Fig 7: Installing Special Tool Onto Transaxle Case
    GF0017475Courtesy of FORD MOTOR CO.
  8. Position the transaxle into the bench fixture.
    9. Fig 8: Positioning Transaxle Into Bench Fixture
    GF0017476Courtesy of FORD MOTOR CO.
  9. Remove the side shaft gear assembly bolts.
    10. Fig 9: Locating Side Shaft Gear Assembly Bolts
    GF0017477Courtesy of FORD MOTOR CO.
  10. Remove the side shaft gear assembly from the case.
    11. Fig 10: Locating Side Shaft Gear Assembly
    GF0017478Courtesy of FORD MOTOR CO.
  11. Remove the transmission fluid pan.
    12. Fig 11: Fluid Pan & Bolts
    GF0017422Courtesy of FORD MOTOR CO.
  12. Remove and discard the transmission fluid pan gasket.
    13. Fig 12: Locating Transaxle Fluid Pan Gasket
    G03990694Courtesy 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.
  13. Remove and discard the transmission fluid filter.
    • Use a suitable seal pick to remove the seal if it is stuck in the case.
    14. Fig 13: Identifying Fluid Filter
    G03990695Courtesy of FORD MOTOR CO.
  14. Remove the main electrical outer shell bolt.
    15. Fig 14: Locating Main Electrical Outer Shell Bolt
    G03990865Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  15. Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
    • Rotate the connector counterclockwise to remove.
    16. Fig 15: Locating Main Electrical Outer Shell Bolt
    GF0017460Courtesy of FORD MOTOR CO.
  16. Remove the electrical connector by lifting it out of the case.
    17. Fig 16: Locating Electrical Connector
    GF0017461Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
  17. Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
    18. 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.
  18. Remove the OSS sensor bolt, sensor and spacer.
    19. Fig 17: Locating OSS Sensor Bolt, Sensor & Spacer
    G03990892Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  19. Remove the 8 bolts from the mechatronic unit.
    20. Fig 18: Mechatronic Unit Bolts
    GF0017462Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  20. Remove the mechatronic unit from the transaxle.
    21. Fig 19: View Of Mechatronic Unit
    G03990870Courtesy of FORD MOTOR CO.
    CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.

    Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.

    Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.

    Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.

    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 of the 5 feed tubes for reassembly.
  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.
    5. Remove and discard the torque converter clutch pressure feed tube.
    22. Fig 20: Identifying Feed Tubes Inside Case
    G03990874Courtesy of FORD MOTOR CO.
  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, secondary pressure feed tube and the main (pump) pressure feed tube.
    3. Discard the torque converter clutch pressure feed tube.
    23. Fig 21: Locating Feed Tube O-Ring Seals
    GF0017463Courtesy of FORD MOTOR CO.
  23. Remove and discard the 26 retaining bolts for the transaxle converter housing.
    24. Fig 22: Locating Transaxle Converter Housing Bolts
    GF0017479Courtesy of FORD MOTOR CO.
  24. Remove the converter housing. It will be necessary to pry the case halves apart.
    25. Fig 23: Prying Case Halves Apart
    GF0017480Courtesy 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.
  25. Remove and discard the converter housing gasket.
    26. Fig 24: Locating Converter Housing Gasket
    GF0017482Courtesy of FORD MOTOR CO.
  26. Remove the differential assembly.
    27. Fig 25: Locating Differential Assembly
    GF0017497Courtesy of FORD MOTOR CO.
  27. Remove the input shaft. Remove and discard the planet carrier thrust washer.
    28. Fig 26: Locating Input Shaft & Planet Carrier Thrust Washer
    GF0017498Courtesy of FORD MOTOR CO.
  28. Remove and discard the O-ring seals and the split ring seal.
    29. Fig 27: Locating O-Ring Seals & Split Ring Seal
    GF0017499Courtesy of FORD MOTOR CO.
    NOTE: There is a selective fit washer under this bearing.
  29. Remove the upper input shaft roller bearing.
    30. Fig 28: Locating Upper Input Shaft Roller Bearing
    GF0017500Courtesy of FORD MOTOR CO.
    NOTE: This is a selective fit washer.
  30. Remove the upper input shaft roller bearing washer.
    31. Fig 29: Locating Upper Input Shaft Roller Bearing Washer
    GF0017501Courtesy of FORD MOTOR CO.
  31. Remove the input shaft roller bearing.
    32. Fig 30: Locating Input Shaft Roller Bearing
    GF0017502Courtesy of FORD MOTOR CO.
  32. Remove the fluid baffle screws and the baffle.
    33. Fig 31: Locating Fluid Baffle Screws & Baffle
    GF0017503Courtesy of FORD MOTOR CO.
  33. Remove the chain lube feed tube retainer screws and the retainer.
    34. Fig 32: Locating Chain Lube Feed Tube Retainer Screws & Retainer
    GF0017504Courtesy of FORD MOTOR CO.
  34. Remove the chain lube feed tube.
    35. Fig 33: Locating Chain Lube Feed Tube
    GF0017505Courtesy of FORD MOTOR CO.
  35. Remove and discard the feed tube O-ring seal.
    36. Fig 34: Locating Feed Tube O-Ring Seal
    GF0017506Courtesy of FORD MOTOR CO.
    NOTE: Note the location of the transaxle range sensor wiring.
  36. Remove the 2 bolts and the manual lever detent spring.
    37. Fig 35: Locating Manual Lever Detent Spring Bolts
    GF0017507Courtesy of FORD MOTOR CO.
    NOTE: The manual valve will need to be in the PARK position in order to remove the valve assembly.
    NOTE: 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.
  37. Remove the 2 bolts for the range selector valve assembly and remove the valve assembly.
    38. Fig 36: Locating Range Selector Valve Assembly Bolts
    GF0017508Courtesy of FORD MOTOR CO.
  38. Remove and discard the sun gear retaining ring.
    39. Fig 37: Locating Sun Gear Retaining Ring
    GF0017509Courtesy of FORD MOTOR CO.
  39. Remove the sun gear and bearing spacer.
    40. Fig 38: Locating Sun Gear & Bearing Spacer
    GF0017510Courtesy of FORD MOTOR CO.
  40. Inspect the sun gear and spacer for damage.
    • If damage is indicated, install a new sun gear and spacer.
    41. Fig 39: Locating Sun Gear & Spacer
    GF0017511Courtesy of FORD MOTOR CO.
  41. Remove the forward clutch assembly.
    42. Fig 40: Locating Forward Clutch Assembly
    GF0017512Courtesy 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.
  42. Using a magnet and a small screwdriver, remove and discard the guide pin retaining ring.
    43. Fig 41: Locating Guide Pin Retaining Ring
    GF0017513Courtesy of FORD MOTOR CO.
  43. Using a magnet, remove the guide pin retaining ring washer.
    44. Fig 42: Locating Guide Pin Retaining Ring Washer
    GF0017514Courtesy of FORD MOTOR CO.
  44. Install the special tool onto the variators.
    45. Fig 43: Installing Special Tool Onto Variators
    GF0017515Courtesy of FORD MOTOR CO.
  45. Secure the special tool with a strap.
    46. Fig 44: Securing Special Tool With A Strap
    GF0017516Courtesy of FORD MOTOR CO.
  46. Remove the special tool.
    47. Fig 45: Installing Special Tool Onto Transaxle Case
    GF0017475Courtesy 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.
    48. Fig 46: Locating End Portion Of Transmission Holding Fixture Tool
    GF0017517Courtesy of FORD MOTOR CO.
  48. Install the transaxle case half and the variator assembly into the bench fixture.
    • Remove the strap.
    49. Fig 47: Locating Safety Strap On Transaxle
    GF0017518Courtesy of FORD MOTOR CO.
    NOTE: The feed tube under the primary cover may stick in the cover or in the case.
  49. Remove and discard the bolts for the primary cover and remove the cover.
    50. Fig 48: Locating Primary Cover Bolts
    GF0017519Courtesy 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.
  50. Remove and discard the primary cover gasket.
    51. Fig 49: Locating Primary Cover Gasket
    GF0017520Courtesy of FORD MOTOR CO.
  51. Remove and discard the O-ring seal from the feed tube and the square cut seal.
    52. Fig 50: Locating Square Cut Seal & O-Ring Seal
    GF0017521Courtesy of FORD MOTOR CO.
    NOTE: If the feed tube is not in the case, it may be stuck in the cover.
  52. Remove the feed tube.
    • If equipped with a primary feed tube that has removable O-ring seals, remove the feed tube and remove and discard the O-ring seals.
    • If equipped with a primary feed tube that has a bonded seal, remove and discard the feed tube.
    53. Fig 51: Locating Feed Tube
    GF0017522Courtesy of FORD MOTOR CO.
  53. Remove and discard the bolts for the secondary cover and remove the cover.
    54. Fig 52: Locating Secondary Cover Bolts
    GF0017523Courtesy 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.
  54. Remove and discard the seal on the secondary feed tube and the gasket from the case.
    55. Fig 53: Locating Feed Tube & Secondary Cover Gasket
    G03990830Courtesy of FORD MOTOR CO.
  55. Remove and discard the secondary feed tube snap ring.
    56. Fig 54: Locating Secondary Feed Tube Snap Ring
    GF0017524Courtesy of FORD MOTOR CO.
    NOTE: The feed tube under the pressure filter cover may stick in the cover or in the case.
  56. Remove the pressure filter cover.
    57. Fig 55: View Of Pressure Filter Case Cover And Bolts
    G03990844Courtesy of FORD MOTOR CO.
    NOTE: If the feed tube is not in the case it may be stuck in the cover.
  57. Remove the high pressure filter feed tube.
    • If equipped with a high pressure filter feed tube that has removable O-ring seals, remove the feed tube and discard the O-ring seals.
    • If equipped with a high pressure filter feed tube that has a bonded seal, remove and discard the feed tube.
    58. Fig 56: Locating High Pressure Filter Feed Tube
    GF0017525Courtesy of FORD MOTOR CO.
  58. Remove and discard the pressure filter.
    59. Fig 57: Locating Pressure Filter
    GF0017526Courtesy of FORD MOTOR CO.
    NOTE: The case half will only need to be removed from the variators if installing a new chain and variator assembly or a new case.
    NOTE: Make sure that the manual control lever is in the PARK position when removing the primary variator nut.
    NOTE: The primary variator nut has been tightened to 500 Nm (369 lb-ft).
  59. Using the special tool, remove and discard the primary variator nut.
    60. Fig 58: Identifying Special Tool (307-545)
    GF0017527Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the manual control lever is in the PARK position when removing the secondary variator nut.
    NOTE: The secondary nut had been tightened to 150 Nm (111 lb-ft).
  60. Using the special tool, remove and discard the secondary variator nut.
    61. Fig 59: Identifying Special Tool (307-545)
    GF0017528Courtesy of FORD MOTOR CO.
    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.
  61. Install the special tools.
    62. Fig 60: Installing Special Tools
    GF0017529Courtesy of FORD MOTOR CO.
    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.
  62. Using the special tools, lift the transaxle case up off the variator assembly.
    63. Fig 61: Lifting Transaxle Case
    GF0017530Courtesy of FORD MOTOR CO.
  63. For the cleaning and inspection of the variators, refer to Variator/Chain and Spur Gear Assembly .
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