Valve Body: Service and Repair

Mechatronic Assembly





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.

CAUTION: If a new transaxle or a mechatronic main control valve body assembly is installed, the transmission control module (TCM) will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.





3. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Disconnect the transaxle bulk head electrical connector.
^ Rotate the electrical connector counterclockwise to disconnect.





4. Remove the fluid pan drain plug and allow the fluid to drain.





5. Remove the fluid pan bolts and the fluid Dan.





6. Remove the fluid pan gasket.





7. NOTE: Check the transaxle case to see if the filter pickup tube seal is stuck in the case. If the pickup tube seal is in the case it will need to be removed.

Remove and discard the fluid filter.
^ Use a suitable seal pick to remove the seal if it is stuck in the case.





8. Remove the main electrical outer shell bolt.





9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
^ Rotate the connector counterclockwise to remove.





10. Remove the electrical connector by lifting it out of the case.





11. CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.

Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.





12. NOTE: The - bolts that hold the mechatronic unit to the case are a different size Torrid bolt.

Remove the 8 bolts from the mechatronic unit.





13. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Remove the mechatronic unit from the transaxle.





14. NOTE: Note the location and size of the 5 feed tubes.

Remove all of the feed tubes.
1 Remove the clutch (manual valve) supply feed tube.
2 Remove the primary pressure feed tube.
3 Remove the secondary pressure feed tube.
4 Remove the main (pump) pressure feed tube (smaller tube).
5 Remove and discard the torque converter clutch pressure feed tube.





15. Remove and discard all of the seals on the feed tubes
1 Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
2 Remove and discard the O-ring seals from the primary pressure feed tube.
3 Remove and discard the O-ring seals from the secondary pressure feed tube.
4 Remove and discard the O-ring seals from the main (pump) pressure feed tube (smaller tube).
5 Discard the torque converter clutch pressure feed tube.

Installation





1. Install new O-ring seals on the feed tubes.
1 Align the inner tube and install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
2 Install new O-ring seals on the primary pressure feed tube.
3 Install new O-ring seals on the secondary pressure feed tube.
4 Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).





2. CAUTION: Lubricate all of the O-ring seals with clean CVT automatic transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the mechatronic assembly or internal damage to the transaxle will occur.

NOTE: Note the location of the 5 feed tubes.

Lubricate the O-ring seals with clean CVT automatic transmission fluid and install all of the feed tubes into the case.
1 Align the inner tube and install the clutch (manual valve) supply feed tube.
2 Install the primary pressure feed tube.
3 Install the secondary pressure feed tube.
4 Install the main (pump) pressure feed tube (smaller tube).
5 Install a new torque converter clutch pressure feed tube.





3. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Position the mechatronic unit onto the case.





4. Tighten the mechatronic bolts in 2 stages.
^ Stage 1: Tighten the bolts in the sequence shown to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten the bolts in the sequence shown 40 degrees (1/8 turn).





5. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Install the electrical connector into the case.





6. Rotate the outer shell connector in place and install the bolt.
^ Tighten to 6 Nm (53 inch lbs.).





7. Connect the electrical connectors.





8. CAUTION: Make sure that the fluid filter pickup tube seal was removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.

CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.

Install a new fluid filter and seal assembly.





9. Make sure that the filter is seated over one of the mechatronic bolts.





10. Install a new fluid pan gasket.





11. Install the fluid pan and the bolts. Tighten in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs.).





12. Install the fluid pan drain plug.
^ Tighten to 25 Nm (18 ft. lbs.).





13. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Connect the transaxle bulk head electrical connector.
14. Fill the transaxle with approximately 4.7 Liters (5 quarts) of clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
15. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.