Assembly

Torque Converter Housing, Reverse Clutch and Pump Assembly - Assembly








Special Tool(s)





Material

Assembly
Pump Assembly

NOTE: The pump assembly cannot be taken apart. It must be installed new as an assembly.

Clean and inspect all pump parts, install new parts as required.





1. Install the special tool into a soft jawed vice.





2. Set the pump assembly onto the special tool to correctly align the pump.





3. Install the special tool into the center of the special tool to keep the pump centered.





4. Install the special tool onto the top of the pump.





5. Install the pump gasket. Note the location of the bleed slots in the gasket.





6. Install the special tools. Note the location of the bleed slot in the gasket.





7. Install new O-ring seals onto the feed tube.





8. NOTE: Lubricate the inner and outer seals in clean CVT automatic transmission fluid.

Install the feed tube into the pump cover.





9. NOTE: Partially install the stator support and loosely install 2 bolts for alignment.

Using the special tool, install the stator support.





10. Install the remaining bolts. Tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.).





11. Position the stator support bearing in place.





12. Using the special tool, install the stator support bearing.





13. From the opposite side of the case, install the pump assembly into the transaxle case.





14. Loosely install the pump bolts.





15. Remove the special tools and loosely install the remaining bolts.





16. Tighten in the sequence shown.
^ Tighten to 16 Nm (12 ft. lbs.).





17. Remove the special tool.





18. Remove the special tool.





19. NOTE: Lubricate the inner and outer seals in clean CVT automatic transmission fluid.

Position the pump dust cover in place.





20. Install the special tools.





21. Using the special tools, install the pump dust cover.





22. Install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





23. Using the special tool, install a new pump seal.

Reverse clutch

CAUTION: MERCON, MERCON V and 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.

NOTE: Soak all of the new clutch plates in clean CVT automatic transmission fluid.

NOTE: To correctly select the selective snap ring, the reverse clutch assembly will need to be assembled incorrectly.

NOTE: Clean and inspect all reverse clutch parts, install new parts as required.





24. NOTE: Lubricate the seals in clean CVT automatic transmission fluid.

Install new inner and outer O-ring seals.





25. Install the reverse clutch piston.





26. Install the return spring.





27. Using the special tool, install the return spring retainers.





28. NOTE: The new clutch plates must be installed in the following order. Do not install the wave spring at this time.

Install a steel plate, a friction plate, a second steel plate, a second friction plate, a third steel plate, a third friction plate and the pressure plate.





29. Install the reverse clutch plate snap ring.





30. Install the special tool. Zero out the special tool.

31. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure that the clutch snap ring is in and completely seated. Failure to follow these instruction may result in personal injury.

Using compressed air, air up on the clutch plates until they contact the reverse clutch snap ring and record the measurement. Enter this measurement in the following table on line labeled A. Repeat this 3 times and take the average of the 3 readings.





32. NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.33-1.53 mm (0.052-0.060 inch).

Selecting selective snap ring.
^ Add line A to B, then subtract line C and enter this total on line D.
^ Line D is the actual clearance with the snap ring used during this measurement.
^ If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.





Reverse Clutch Selective Snap Ring





33. Remove the reverse clutch pack snap ring.





34. Remove the reverse clutch plates: steel and friction.





35. Install the reverse clutch wave spring.





36. Install the ring gear assembly.





37. Install the reverse clutch plates, steel and friction, alternating between steel and friction, starting with a steel plate.





38. Install the reverse clutch pressure plate.





39. Install the reverse clutch pack snap ring.

Case housing

NOTE: The bearing race and shim will be installed in the case during the assembly of the transaxle after differential set up.





40. Inspect the bearing race and shim for damage. If damage is indicated install a new race. If new differential bearing is installed, a new bearing race should also be installed.





41. Using the special tools, install the roller bearing and race as an assembly.





42. Using the special tools, install the roller bearing and race as an assembly.





43. Install new O-ring seals onto the feed tube.





44. Using new sealing washers, install the bolt onto the lube tube





45. Lubricate the O-ring seals with clean CVT automatic transmission fluid and install the lube tube into the case.
^ Tighten to 10 Nm (89 inch lbs.).