Part 1 Of 2

TRANSAXLE

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tool(s)

CAUTION: MERCON(R), MERCON(R) V and MERCON(R) SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

1. CAUTION: Prior to installing the transaxle case onto the variator assembly, make sure that the manual valve feed tube is correctly installed in the case. Damage to the manual valve feed and variator could occur if not correctly installed.

Position the transaxle case onto the variators.

2. Assembly the remaining components of the special tool.

3. CAUTION: The special tools must be installed as shown or damage to the case will occur.

NOTE: The windows in the special tools must be facing you so that when pressing the case down you can see when to stop.

Install the special tools, on the top of the case in the position shown.

4. Slowly turn the forcing screws of the special tool until they just contact the cone shaped installers.

5. CAUTION: This step must be followed exactly. Do not use any air tools when installing the case. Do not turn one forcing screw more than the other unless indicated. Failure to follow this will result in damage to the case.

Press the transaxle case down onto the variator assembly.
1 Hold the transaxle case level. Turn the secondary forcing screw 2 complete turns.
2 Turn both forcing screws at the same time evenly until the case just contacts the variators.

6. Install a new primary nut.

7. Install a new secondary nut.
8. Make sure that the manual control lever is in the PARK position.

9. Using the special tools, tighten the primary variator nut in 2 stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 500 Nm (369 lb-ft).

10. Using the special tools, tighten the secondary variator nut in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten to 150 Nm (111 lb-ft).

11. Install new O-ring seals on the primary cover feed tube.

12. Install the primary cover feed tube into the case.

13. Install a new square cut seal and O-ring seal.

14. Install a new primary cover gasket.

15. Using new bolts, install the primary cover. Tighten the bolts in 2 stages:
- Stage 1: Tighten bolts to 4 Nm (35 lb-in).
- Stage 2: Tighten bolts 90 degrees.

16. NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.

Install a new O-ring seal on the feed tube and install a new secondary cover gasket.

17. If not previously done, install a new square cut seal in the secondary cover.

18. Using new bolts, install the secondary cover. Tighten the bolts in 2 stages:
- Stage 1: Tighten bolts to 4 Nm (35 lb-in).
- Stage 2: Tighten bolts 90 degrees.

19. Install a new pressure filter.

20. Install new O-ring seals on the feed tube.

21. NOTE: Lubricate the O-ring seals in clean CVT automatic transmission fluid.

Install the pressure filter feed tube.

22. Install the pressure filter case cover.
- Tighten to 10 Nm (89 lb-in).

23. Install the special tool onto the transaxle case.
- Tighten to 55 Nm (41 lb-ft).

24. NOTE: Be careful when installing the guide plate that it does not fall into the case. If guide plate falls into the case, case disassembly will need to carried out.

Using a magnet, carefully install the guide pin retaining ring plate.

25. Install the C-clip onto the special tool.

26. Using the special tool, install the guide pin retaining ring.

27. If not previously done, install 2 new O-ring seals in the case.

28. NOTE: When installing the range selector valve assembly make sure that the pin from the manual valve lever is correctly installed into the range selector valve assembly.

Loosely install the range selector valve assembly.

29. Install the bolts.
- Tighten to 6 Nm (53 lb-in).

30. Make sure that when routing the range selector valve assembly wiring harness it is between the bolt holes and is pressed into the case retainers.

31. NOTE: Be careful not to pinch wire harness when installing detent spring.

Install the manual lever detent spring.
- Tighten to 8 Nm (71 lb-in).