Secondary Variator Cover

Secondary Variator Cover





Special Tool(s)





Material

Removal

CAUTION: MERCON, MERCON V, MERCON 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. With the vehicle in NEUTRAL, position it on a hoist.





2. Remove the fluid cooler tube bracket from the transaxle.





3. CAUTION: When disconnecting the fluid cooler tubes pull straight up to prevent damage to the fluid cooler tubes.

NOTE: The axle shaft has been removed for clarity.

Disconnect the transmission fluid cooler tubes from the transaxle.





4. Remove and discard the 4 transmission fluid cooler tube seals.





5. Remove only the 3 retainers and carefully position the insulator aside to gain access to the secondary variator cover.





6. Remove and discard the bolts for the secondary cover and remove the cover.





7. Remove and discard the square cut seal from the secondary cover.





8. CAUTION: Do not remove the retaining clip that holds the feed tube in place. This will cause the tube to fall into the case.

Remove and discard the seal on the feed tube and the gasket from the secondary cover.

Installation





1. 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.





2. Install a new square cut seal in the secondary cover.





3. Using new bolts, install the secondary cover. Tighten the bolts in 2 stages:
^ Stage 1: Tighten bolts to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten bolts 90 degrees.





4. Carefully position the insulator over the retaining pins and install the 3 retainers.





5. Install 4 new transmission fluid cooler tube seals.





6. CAUTION: Make sure the fluid cooler tubes are installed straight or the tubes will be damaged.

Connect the transmission fluid cooler tubes to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).





7. Install the fluid cooler tube bracket to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).





8. If more fluid is needed, remove the fluid fill plug.
9. Fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.





10. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.).