Fluid Pump Installation

Fluid Pump

Special Tool(s):

Material:

CAUTION: MERCON (R), MERCON (R) V and 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. NOTE: The fluid pump assembly cannot be disassembled. It is serviced as an assembly only.

Install the special tool into a soft-jawed vise.

2. Set the fluid 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. Remove the pump with the special tools installed from the soft-jawed vise. Carefully turn the pump over. Do not let the special tools move or drop. If the tools fall out or move, the alignment procedure must be carried out again.
6. Install the pump gasket. Note the location of the bleed slots in the gasket.

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

8. Lubricate the new O-ring seals with clean continuously variable transaxle (CVT) transmission fluid. Install the O-ring seals onto the feed tube.

9. Lubricate the inner and outer seals in clean CVT transmission fluid. Install the feed tube into the pump cover.

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

11. Loosely install the 6 fluid pump bolts.

12. Remove the special tools and loosely install the remaining 2 fluid pump bolts.

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

14. Remove the special tool.

15. Using the special tool, install a new fluid pump seal.

16. Lubricate the inner and outer seals in clean CVT transmission fluid, then position the pump dust cover in place.

17. Install the special tools.

18. Using the special tools, install a new pump dust cover.

19. Install the pump dust cover bolts.
^ Tighten to 10 Nm (89 inch lbs.).

20. Lubricate the seals in clean CVT transmission fluid. Install new inner and outer O-ring seals.

21. Install the reverse clutch piston.

22. Install the return spring.

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

24. Install the reverse clutch wave spring.

25. Install the ring gear assembly.

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

27. Install the reverse clutch pressure plate.

28. Install the reverse clutch pack snap ring.

29. Install the new O-ring seal on the clutch feed tube and lubricate with clean CVT automatic transmission fluid.

30. Install a new clutch feed sealing sleeve into the range selector valve assembly.

31. Make sure when routing the range selector valve assembly wiring harness that it is still pressed into the case retainers and out of the way.

32. Install a new O-ring seal on the input shaft and lubricate it with clean CVT transmission fluid.

33. Install a new converter housing gasket.

34. NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.

Position the converter housing in place. Install new transaxle converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts. Starting at No. 1, tighten the bolts in a counterclockwise rotation.
^ Stage 1: Tighten bolts to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten bolts to 8 Nm (71 inch lbs.).
^ Stage 3: Tighten an additional 90 degrees.

35. Install the side shaft gear assembly.
^ Tighten to 35 Nm (26 ft. lbs.).

36. Position the output shaft seal in place.

37. 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.

For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean CVT transmission fluid. Install the O-ring seals on the feed tubes (late build vehicles).
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.

38. 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

39. 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

40. 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.

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

NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

Position the mechatronic unit onto the case.

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

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

Lubricate the O-ring seal with clean CVT transmission fluid and install the electrical connector into the case.

44. 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 place and install the bolt.
^ Tighten to 6 Nm (53 inch lbs.).

45. Connect the electrical connectors.

46. 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. Lubricate the seal that is on the new filter with clean CVT transmission fluid and install the fluid filter.

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

48. Install a new transmission fluid pan gasket.

49. Make sure that the magnet in the pan is in the correct location prior to installing the transmission fluid pan.

50. Install the transmission fluid pan. Tighten the bolts in the sequence indicated.
^ Tighten to 12 Nm (9 ft. lbs.).

51. CAUTION: Do not set the torque converter in the fluid pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.

Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.

52. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.

53. Using 4 new retainers, install the transaxle insulator.

54. Install the fluid level indicator.

55. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
56. Position the transaxle mount in place and install the upper bolts.
^ Tighten to 55 Nm (41 ft. lbs.).

57. Install the transaxle.