Valve Body: Service and Repair

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.







Removal
1. Disconnect the battery ground cable.
2. Remove the battery tray.
Vehicles with air conditioning





3. CAUTION: Do not place excessive pressure on tubes/hoses (A/C) 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 suction accumulator out of the way to allow enough room for main control cover removal.

Remove the suction accumulator bracket and position the suction accumulator to one side.
^ Loosen the suction accumulator canister holding screw, and remove the suction accumulator from the bracket.
All Vehicles





4. 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.





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





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

Disconnect the transaxle cooler inlet line.





7. NOTE: Remove the bolts in the indicated sequence.

Remove the main control cover.
^ Open clamp and disconnect the main control cover vent tube.
^ Remove the main control bolts and main control cover.





8. Remove the main control cover gasket.





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





10. NOTE: Remove the bolts in the indicated sequence.

Remove the main control valve body bolts.





11. NOTE: Do not damage the manual valve from the manual lever link.

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





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





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

Installation





1. Install the manual valve.





2. NOTE: Inspect solenoid valve body harness connector O-ring seal and install a new as necessary before installing solenoid valve body harness connector in transaxle case.

Push the solenoid valve body harness connector up though the transaxle case.





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





4. NOTE: Install the bolts in the indicated sequence

Position the main control valve body and install the mounting bolts.





5. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.





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





7. Using the special tool and pin, align the shifter shaft.





8. Move the manual valve detent lever assembly to the "D" position.





9. Tighten the nut on the ball.
^ Remove the shifter pin from the special tool.





10. Rotate the special tool until socket can be fitted on nut.
^ Tighten the detent nut.
^ Rotate back to the "D" position and recheck the adjustment.





11. Using the special tool, recheck the manual control lever assembly settings.
12. Rotate the manual lever to the "N" position.





13. Install the manual control lever.
1 Position the manual control lever.
2 Tighten the bolt.





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





15. Install solenoid body wiring harness clip to main control valve body.





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





17. NOTE: Tighten the bolts in the indicated sequence.

Install the main control cover.
^ Connect the main control cover vent tube and close clamp.
^ Position main control cover and tighten bolts.





18. NOTE: Remove the drain pan.

Connect the transaxle cooler inlet line.





19. NOTE: Do not tighten the TR sensor bolts.

Install the transmission range (TR) sensor and install retaining bolts loosely.





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

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





21. Tighten the TR sensor retaining bolts.
1 Install the special tool and align TR sensor slots.
2 Tighten the two bolts.





22. Connect the transaxle harness electrical connector.
1 Install the ground cable.
2 Install the solenoid body electrical connector.
3 Install the TR sensor electrical connector.
4 Install the wiring harness clip.
Vehicles with air conditioning





23. CAUTION: Do not place excessive pressure on tubes/hoses (A/C) 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 suction accumulator out of the way to allow enough room for main control cover removal.

Position the suction accumulator and install retaining screws.
All Vehicles
24. Install the battery tray.

25. 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 miles) or more to relearn the strategy.

Connect the battery ground cable.





26. Check the transmission fluid, add as necessary use Motorcraft MERCON or MERCON V automatic transmission fluid or equivalent meeting FORD specification.





27. Start the engine and move the transaxle range selector lever through all gear positions. Refill . necessary.