Primary Variator Cover

Primary Variator Cover

Special 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.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 bolts for the rear transaxle mount.





3. Install a suitable transmission jack to support the transaxle.
4. Remove the upper transaxle mount bolts and the mount.





5. NOTE: When removing the cover, the feed tube may stick in the cover or the case.

Remove and discard the bolts for the primary cover and remove the cover.





6. Remove and discard the primary cover gasket.





7. NOTE: The primary cover feed tube (2) may remain in the cover or the case when the cover is removed.

NOTE: Some transaxles may have a primary cover feed tube (2) with bonded seal material covering the tube or O-ring seals on the tube. Either can be used for the primary cover feed tube (2) .

Remove and discard seals.
1 Remove and discard the O-ring on the smaller feed tube.
2 If equipped with feed tube having a bonded seal covering the tube, remove and discard feed tube. If equipped with feed tube and O-ring seals, remove the tube and discard O-ring seals.





8. Remove the retaining clip and the primary cover feed tube.





9. Remove and discard the 2 square cut seals, the O-ring seal and the retaining clip from the primary cover feed tube.





Installation

1. NOTE: The new retaining clip must be installed on the feed tube prior to installing the square cut seals.

Lubricate the O-ring seal in clean continuously variable transaxle (CVT) transmission fluid and install a new seal and a new retaining clip on the feed tube.





2. Install the special tool onto the feed tube.





3. NOTE: Be careful not to overextend the seals when installing, damage to the seals will occur.

Using the special tool, install 2 new square cut seals.





4. Lubricate the O-ring seal in clean CVT transmission fluid and install the feed tube into the primary cover and install the clip.





5. NOTE: Some transaxles may have a primary cover feed tube (2) with bonded seal material covering the tube or O-ring seals on the tube. Either can be used for the primary cover feed tube (2).

Install seals and primary cover feed tube.
1 Lubricate the small O-ring seal with clean CVT transmission fluid and install on the small feed tube.
2 If equipped with a feed tube having a bonded seal covering the tube, lubricate a new feed tube containing bonded seal with clean CVT transmission fluid and install the tube. If equipped with a feed tube and O-rings, install new O-rings on the feed tube and lubricate the O-rings with clean CVT transmission fluid and install the feed tube.





6. Install a new primary cover gasket.





7. Using new bolts, install the primary cover.
Tighten the bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten to 4 Nm (35 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.





8. Clean the rear transaxle mount bolts using a wire brush and apply new threadlock to the threads.
9. Position the mount onto the subframe and install the rear transaxle support insulator.
^ Tighten to 55 Nm (41 ft. lbs.).





10. Install the 2 bolts for the rear transaxle mount.
^ Tighten to 90 Nm (66 ft. lbs.).





11. If more CVT transmission fluid is needed, remove the fluid fill plug.





12. Fill the transaxle with clean CVT transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
13. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.).