In-Vehicle Repair

Special Tools:

REMOVAL
1. Remove the battery tray.

2. Remove the A/C accumulator bracket and position the accumulator aside.
- Loosen the accumulator canister holding screw, and remove the accumulator from the bracket.

CAUTION: Use extreme care not to place excessive pressure on A/C lines and fittings when disconnecting and reconnecting A/C components. Excessive pressure may cause component damage and A/C system leaks.

NOTE: On some vehicles, it may be necessary to disconnect and position the A/C accumulator out of the way to allow enough room for main control cover removal.

3. Disconnect the transaxle wiring harness electrical connector.
1 Remove the solenoid body electrical connector.
2 Remove the Transmission Range (TR) sensor electrical connector.
3 Remove the wiring harness retaining clip.

4. Disconnect the transmission shift cable and bracket.
1 Remove the bracket bolts.
2 Remove the cable.

5. Disconnect the transaxle cooler inlet line.

NOTE: Position a suitable drain pan under the main control cover.

6. Remove the main control bolts and main control cover.

7. Remove the main control cover gasket.

8. Remove the solenoid body wiring harness clip from the main control valve body assembly.

9. Remove the main control valve body bolts.

10. Lift the main control valve body while disconnecting the manual valve link.

NOTE: Use caution not to damage the manual valve from the manual lever link.

11. Remove the solenoid body harness connector.
1 Push the solenoid valve body electrical connector down through the transaxle case.
2 Depress the retaining tabs.
- Remove the harness connector.

12. Ensure the manual valve control lever does not fall out while removing from vehicle.

INSTALLATION

1. Install the manual valve.

2. Push the solenoid valve body harness connector up though the transaxle case.
1 Inspect the O-ring.
2 Squeeze the retaining tabs and install the electrical connector.

NOTE: Inspect solenoid valve body harness connector O-ring and replace if necessary before installing solenoid valve body harness connector in transaxle case.

3. Connect the manual valve link to the manual valve.

4. Position the main control valve body and install the mounting bolts in sequence.

5. Loosen the ball stud on the manual valve detent lever.

6. Disconnect the shift cable from the manual lever.
1 Remove the manual lever retaining bolt.
2 Remove the manual lever.

7. Install the Shifter Shaft Alignment Tool.
1 Tighten manual valve detent lever ball stud hand tight.
2 Rotate the control shaft until the alignment tool fits into the hole in the case.

8. Rotate the manual valve detent lever to the D position.
9. Remove the Shifter Shaft Alignment Tool.

10. Tighten the manual lever detent lever ball stud.
11. Rotate the manual lever to the N position.

12. Install the manual control lever.
1 Position the manual control lever.
2 Tighten the manual control lever retaining bolt.

13. Connect the shift cable to the control lever.
1 Install the shift cable.
2 Install the shift cable bolts.

14. Install solenoid body wiring harness clip to main control valve body assembly.

15. Install new gasket on the main control cover before positioning in place.

16. Position main control cover and tighten bolts in sequence.

17. Connect the transaxle cooler inlet line.

NOTE: Remove the drain pan.

18. Install the Transmission Range (TR) sensor and install retaining bolts loosely.

NOTE: Do not tighten the TR sensor bolts.

19. Rotate the manual valve detent lever assembly to the Neutral position.
1 Low 1
2 Low 2
3 Drive
4 Neutral
5 Reverse
6 Park

NOTE: If necessary, move the manual control lever to N position for TR sensor adjustment.

20. Tighten the TR sensor retaining bolts.
1 Install the Transmission Range (TR) Sensor Alignment Tool and align TR sensor slots with tool.
2 Tighten the two TR sensor bolts.

21. Connect the transaxle harness electrical connector.
1 Install the battery ground cable.
2 Install the solenoid body electrical connector.
3 Install the TR sensor electrical connector.
4 Install the wiring harness clip.

22. Position the A/C accumulator and install retaining screws.

CAUTION: Use extreme care not to place excessive pressure on A/C lines and fittings when disconnecting and reconnecting A/C components. Excessive pressure may cause component damage and A/C system leaks.

NOTE: On some vehicles, it may be necessary to disconnect and position the A/C accumulator out of the way to allow enough room for main control cover removal.

23. Install the battery tray.

24. Connect the battery ground cable.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 Km (10 mi) or more to relearn the strategy.

25. Check the transmission fluid, add as required use Motorcraft MERCON Multi-purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

26. Start the engine and move the transaxle range selector lever through all gear positions. Refill as required.