Transmission

Transmission

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Removal

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. Remove the ACL (Air Cleaner) assembly and outlet pipe. REFER to Intake Air System Components - Exploded View .

3. Remove the battery tray. REFER to Battery and Battery Tray - Exploded View .

4. Disconnect the selector lever cable end from the manual control lever, remove the 2 bracket bolts and position aside the selector lever cable and bracket.






5. Disconnect the 3 wiring harness retainers from main control cover studbolts.






6. Remove the wiring retainer from the upper transmission-to-engine studbolt.





7. Remove the 3 upper transmission-to-engine bolts.





8. Remove the starter. REFER to Starter Motor - 2.0L GTDI .

9. Remove the starter insulator.





10. NOTICE: Only rotate the engine in a clockwise direction or engine damage will occur.

NOTE: Index mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.





11. Remove the front subframe. REFER to Subframe - Front . When removing the front subframe, it is not necessary to remove the roll restricter through bolt. Remove the 3 roll restrictor bracket bolts and the roll restrictor bracket from the transmission.





12. NOTE: If transmission disassembly or installation of a new transmission is necessary, drain the transmission fluid.
Remove the drain plug and drain the transmission. Install the drain plug.
- Torque: 12 Nm (106 lb-in).





13. Remove the 2 halfshaft bracket nuts and slide the RH halfshaft assembly out of the transmission.

- Position the halfshaft aside and support with a length of mechanics wire.






14. Using 205-832 and 100-001 (T50T-100-A) , separate the halfshaft from the transmission.

- Position the halfshaft aside and support with a length of mechanics wire.






15. Remove the catalytic converter. REFER to Catalytic Converter - 2.0L GTDI , REFER to Catalytic Converter - LH Manifold , REFER to Catalytic Converter - RH Manifold, FWD or REFER to Catalytic Converter - RH Manifold, AWD .

16. Remove the 2 EPAS (Electronic Power Assist Steering) wiring retainers from the back of the transmission.






17. Remove the cowl panel. REFER to Cowl Panel .

18. Install 303-F072 and support the engine and transmission.





19. Remove the transmission support insulator bolt and lower the transmission enough for the transmission support insulator bracket to clear the transmission support insulator.





20. Disconnect the transmission main electrical connector and remove the wiring retainer from the transmission fluid thermal bypass valve bracket.





21. Disconnect the TSS (Turbine Shaft Speed) sensor electrical connector and remove wiring retainer from the transmission fluid thermal bypass valve bracket.





22. Remove the secondary latches from the transmission fluid cooler tubes at the transmission fluid thermal bypass valve.






23. Using 307-569 , disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.






24. Support the transmission with a transmission jack. Secure the transmission to the transmission jack with a safety strap.

25. Remove the 8 lower transmission-to-engine bolts.





26. Separate the transmission from the engine and install 307-566.





27. Remove the transmission from the vehicle.

28. NOTE: It is only necessary to remove the transmission mounted transmission fluid cooler tubes if the transmission is being overhauled or replaced. If the transmission is being removed for access to other components only, it is not necessary to remove the transmission mounted transmission fluid cooler tubes.
Remove and discard the transmission fluid cooler tube bolts.





29. Remove the nuts, the transmission fluid cooler thermal bypass valve and the transmission fluid cooler tubes from the transmission.






30. Inspect the transmission case to be sure that the transmission fluid cooler tube seals and backing rings were removed with the transmission fluid cooler tubes and are not stuck in the transmission case. If the transmission fluid cooler tube seals or backing rings are stuck in the transmission case, remove the seals and backing rings.






31. If the transmission is to be overhauled or if installing a new or re-manufactured transmission, carry out the transmission fluid cooler backflushing and cleaning. REFER to Transmission Fluid Cooler Backflushing and Cleaning .

Installation

NOTICE: Prior to installing a new, re-manufactured or overhauled transmission, the transmission fluid cooler tubes must be cleaned, otherwise transmission failure may occur.

NOTE: Prior to installing a new, re-manufactured or overhauled transmission, flush out the cooler and cooler tubes. REFER to Transmission Fluid Cooler Backflushing and Cleaning .

1. If removed, inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid and install the backing rings and seals on the transmission mounted transmission fluid cooler tubes.










2. If removed, position the transmission fluid cooler thermal bypass valve and transmission mounted transmission fluid cooler tube assembly in place and install the transmission fluid cooler thermal bypass valve bracket nuts.
- Torque: 9 Nm (80 lb-in).





3. If removed, install new transmission mounted transmission fluid cooler tube bolts.
- Torque: 9 Nm (80 lb-in).





4. Lubricate the torque converter pilot hub with Multi-Purpose Grease.






5. NOTICE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.

If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.






6. Support the transmission with a transmission jack. Secure the transmission to the transmission jack with a safety strap.

7. Position the transmission behind the engine and remove 307-566.





8. Align the torque converter stud marked during removal with the flexplate, position the transmission on the dowel pins and install the 8 lower transmission-to-engine bolts.
- Torque: 48 Nm (35 lb-ft).





9. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.






10. Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.






11. Connect the TSS (Turbine Shaft Speed) sensor electrical connector and the wiring retainer on the transmission fluid thermal bypass valve bracket.





12. Connect the transmission main electrical connector and install the wiring retainer on the transmission fluid thermal bypass valve bracket.





13. Using 303-F072 , raise and support the transmission until it contacts the transmission support insulator and install the transmission support insulator bolt.
- Torque: 150 Nm (111 lb-ft).





14. Remove 303-F072.





15. Install the cowl panel. REFER to Cowl Panel .

16. Install the 2 EPAS (Electronic Power Assist Steering) wiring retainers on the transmission.





17. Install the catalytic converter.

18. NOTICE: Make sure to install the correct circlip for this application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.

Install a new circlip.





19. Install 205-461 on the LH (Left Hand) halfshaft seal.





20. NOTICE: The sharp edges on the halfshaft splines can slice or puncture the oil seal. Use care when inserting the halfshaft into the transmission or damage to the seal may occur.

Push the LH (Left Hand) halfshaft into the transmission so the circlip locks into the differential side gear. Pull the halfshaft inner end to make sure the circlip is locked.





21. Install the RH (Right Hand) halfshaft in the transmission and engage the halfshaft splines with the transmission side gears and install the 2 halfshaft bracket nuts.
- Torque: 25 Nm (18 lb-ft).





22. Install the subframe. REFER to Subframe - Front . Install the roll restrictor bracket and the roll restrictor bracket bolts on the transmission.
- Torque: 90 Nm (66 lb-ft).





23. NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.

Install 4 new torque converter nuts.
- Torque: 40 Nm (30 lb-ft).





24. Install the starter insulator.






25. Install the starter. REFER to Starter Motor - 2.0L GTDI .

26. Install the 3 upper transmission-to-engine bolts.
- Torque: 48 Nm (35 lb-ft).





27. Install the wiring retainer on the upper transmission-to-engine studbolt.





28. Install the 3 wiring harness retainers on the main control cover studbolts.





29. Install the selector lever cable bracket and the 2 bolts.
- Torque: 25 Nm (18 lb-ft).





30. Install the battery tray. REFER to Battery and Battery Tray - Exploded View .

31. Install the ACL (Air Cleaner) assembly and outlet pipe. REFER to Intake Air System Components - Exploded View .

32. Adjust the selector lever cable. REFER to Selector Lever Cable Adjustment - 6F35 .

33. Fill the transmission with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid to the correct level. REFER to Transmission Fluid Drain and Refill .

34. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

35. If a new solenoid body is installed, the solenoid body strategy will need to be updated. REFER to Solenoid Body Strategy Download .