Mechatronic Assembly
Mechatronic AssemblySpecial Tool(s):
Material:
Removal
CAUTION: MERCON (R), MERCON (R) V, 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.
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 bulkhead electrical connector.
^ Rotate the electrical connector counterclockwise to disconnect.
4. Remove the transmission fluid pan drain plug and allow the continuously variable transaxle (CVT) transmission fluid to drain.
5. Remove the transmission fluid pan bolts and the transmission fluid pan.
6. Remove and discard the transmission 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 transmission 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. 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. CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.
Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.
Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.
Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.
NOTE: The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
NOTE: Note the location and size of the 5 feed tubes for reassembly.
Remove all of the 5 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.
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, secondary pressure feed tube and the main (pump) pressure feed tube.
3 Discard the torque converter clutch pressure feed tube.
Installation
1. CAUTION: Lubricate all of the O-ring seals with clean continuously variable transmission (CVT) transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the feed tubes into the transaxle case half or internal damage to the transaxle will occur.
For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals on the feed tubes.
1 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, secondary pressure feed tube and main (pump) pressure feed tube.
2. For transaxles built before December 6, 2005, lubricate all of the O-ring seals with clean CVT transmission fluid.
1 Clutch supply feed tube
2 Primary feed tube (longer tube)
3 Secondary feed tube (longer tube)
4 Main pressure feed tube (shorter tube)
5 Torque converter clutch feed tube
3. For transaxles built after December 6, 2005, lubricate all of the bonded seals on the feed tubes with clean CVT transmission fluid.
1 Clutch supply feed tube
2 Primary feed tube (short tube)
3 Secondary feed tube (short tube)
4 Main pressure feed tube (short tube)
5 Torque converter clutch feed tube
4. NOTE: Note the location of the 5 feed tubes.
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.
5 Install a new torque converter clutch pressure feed tube.
5. 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.
6. Tighten the mechatronic bolts in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten an additional 40 degrees (1/8 turn).
7. 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.
8. Rotate the outer shell connector in place and install the bolt.
^ Tighten to 6 Nm (53 inch lbs.).
9. Connect the electrical connectors.
10. CAUTION: Make sure that the transmission fluid filter pickup tube seal was removed from the bore when the transmission fluid filter was removed. Failure to remove the seal prior to installing the new transmission fluid filter will result in transaxle failure.
CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the transmission fluid filter is not correctly installed, internal transaxle damage will occur.
Install a new transmission fluid filter and seal assembly.
11. Make sure that the transmission fluid filter is seated over one of the mechatronic bolts.
12. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
Install a new transmission fluid pan gasket.
13. Install the transmission fluid pan and the bolts.
Tighten in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs.).
14. Install the transmission fluid pan drain plug.
^ Tighten to 25 Nm (18 ft. lbs.).
15. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Connect the transaxle bulkhead electrical connector.
16. Fill the transaxle with approximately 4.7L (5 quarts) of clean CVT transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
17. 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.