Part 2

Transmission Overhaul

45. NOTICE: Make sure to properly handle the actuator lever as shown or damage may occur.

Install the clutch actuator lever 2.





46. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.

47. Install the 2 clutch actuator lever 2 bolts.
- Tighten to 19 Nm (168 lb-in).





48. NOTICE: Make sure to properly handle the actuator lever as shown or damage may occur.

Install the clutch actuator lever 1.





49. Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.

50. Install the 2 clutch actuator lever 1 bolts.
- Tighten to 19 Nm (168 lb-in).





51. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.

NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown.

NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the spring retainers and actuator levers use the marks made during removal for assembly.

Install the spring retainers and spring retainer bolts.
- Tighten to 26 Nm (19 lb-ft).





52. Remove the clutch actuator lever locks if installed.





53. NOTE: The engagement system bearing unit should be installed easily.

Install the engagement system bearing unit.





54. NOTICE: Do not tilt transaxle after the Z-washers are installed, they may come off center and damage can occur.

Install the Z-washers onto the engagement system bearing unit and center them correctly.





55. If installing a new clutch go to step 74.

56. NOTE: Make sure 307-676 /6 is also installed.

Install 307-676 /1 in a vise.





57. Place the clutch on 307-676 /1 and align one clutch stud with the slotted hole on 307-676 /1.





58. Install 307-676 /3 loosely on the clutch.





59. Install 307-676 /4 on the clutch making sure the legs are inserted in the slots shown.





60. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Turn 307-676 /5 clockwise to the stops and hold.





61. Tighten 307-676 /1 with enough pressure to align the 3 clutch 1 locks.





62. Lock the 3 clutch 1 locks by hand.





63. Install 307-676 /2 loosely on the clutch.





64. Using 307-676 /4, move the clutch self-adjuster counterclockwise to the stop and hold.





65. NOTE: An audible click can be heard when the clutch locks lock.

Using 307-676 /1 and 307-676 /2, compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.





66. Remove 307-676 /1, 307-676 /2 and 307-676 /4.





67. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.

Visually check the locks to make sure they have locked.






68. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.

69. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.0236 in) or less.





70. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.5906 in) or less.





71. Apply a small amount of Motorcraft(R) Dual Clutch Transmission Fluid on the input shaft bearing surface.





72. Apply a small amount of DPS6 Grease on both input shaft splines.





73. Verify the Z-washers are installed correctly.





74. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not operate correctly and damage can occur. If the clutch locks are not locked go to step 2 within this procedure.

NOTE: Install the 1 angled lifting leg as shown.

Using 307-675 /1, 307-675 /2 and 307-675 /4 install the clutch in the transaxle.





75. Remove 307-675 /1, 307-675 /2 and 307-675 /4.

76. Install 307-675 /1 and 307-675 /4 onto the transaxle case.





77. NOTICE: Do not overtighten the special tool or damage can occur.

Using 307-675 /1 and 307-675 /4, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.





78. NOTE: Make sure the hollow input shaft snap ring is fully seated.

Install the new hollow input shaft snap ring.





79. NOTE: Align the index marks on the clutch hub and clutch.

Install the clutch hub.





80. Install the new clutch hub snap ring in the position shown.





81. NOTICE: Do not turn 307-677 more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using 307-677 , release the clutch 1 locks and then the clutch 2 locks by slowly turning 307-677 counterclockwise. An audible click will be heard when the clutch locks are released.





82. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.





83. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.





84. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
- Tighten to 5 Nm (44 lb-in).





85. Install the clutch motor 1 and the 4 clutch motor 1 bolts.
- Tighten to 5 Nm (44 lb-in).





86. NOTICE: Make sure to use the 3.2 mm (0.126 in) input shaft speed sensor 2 shim or damage can occur to the transaxle.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 2.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.

Install the input shaft speed sensor 2.

1. Install the input shaft speed sensor 2 shim.

2. Install the input shaft speed sensor 2.

3. Install the input shaft speed sensor 2 bolt.

- Tighten to 10 Nm (89 lb-in).





87. NOTICE: Make sure to use the 3.5 mm (0.1378 in) input shaft speed sensor 1 shim or damage can occur to the transaxle.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 1.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.

Install the input shaft speed sensor 1.

1. Install the input shaft speed sensor 1 shim.

2. Install the input shaft speed sensor 1.

3. Install the input shaft speed sensor 1 bolt.

- Tighten to 10 Nm (89 lb-in).





88. NOTE: If installing the old OSS (Output Shaft Speed) sensor, install a new O-ring.

Install the OSS (Output Shaft Speed) sensor and the OSS (Output Shaft Speed) sensor bolt.

- Tighten to 10 Nm (89 lb-in).





89. Install the TR (Transmission Range) sensor and the 2 TR (Transmission Range) sensor bolts.

- Tighten to 10 Nm (89 lb-in).





90. Carefully inspect the TCM (Transmission Control Module) and the transaxle bore for debris or damage. Clean and/or repair as needed.





91. NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.

Install new O-rings if the TCM (Transmission Control Module) is being reused.





92. NOTICE: Do not force the TCM (Transmission Control Module) onto the transaxle or damage may occur.

NOTICE: Make sure the TCM (Transmission Control Module) sits flush on the transaxle or damage can occur.

Install the TCM (Transmission Control Module) on the transaxle. Apply light pressure to seat the O-rings. If the TCM (Transmission Control Module) does not push in place with light pressure, remove the TCM (Transmission Control Module) and slightly turn the TCM (Transmission Control Module) shift motor gears and retry installing the TCM (Transmission Control Module) on the transaxle.





93. Install the 4 TCM (Transmission Control Module) bolts.

- Tighten to 27 Nm (20 lb-ft).





94. Install the transaxle wiring harness.