Secondary Variator Cover

Secondary 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 transmission fluid cooler tube bracket from the transaxle.





3. CAUTION: When disconnecting the transmission fluid cooler tubes pull straight up to prevent damage to the transmission fluid cooler tubes.

NOTE: The axle shaft has been removed for clarity.

Disconnect the transmission fluid cooler tubes from the transaxle.





4. Remove and discard the 4 transmission fluid cooler tube seals.





5. Remove only the 3 retainers and carefully position the insulator aside to gain access to the secondary variator cover.





6. Remove and discard the bolts for the secondary cover and remove the cover.





7. Remove and discard the square cut seal from the secondary cover.





8. CAUTION: Do not remove the retaining clip that holds the feed tube in place. This will cause the tube to fall into the case.

Remove and discard the seal on the feed tube and the gasket from the secondary cover.





Installation

1. NOTE: Make sure that the snap ring is on the feed tube prior to installing the cover.

Lubricate the O-ring with clean continuously variable transmission (CVT) transmission fluid and install the O-ring seal on the feed tube and install a new secondary cover gasket.





2. Install a new square cut seal in the secondary cover.





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





4. Carefully position the insulator over the retaining pins and install the 3 retainers.





5. Lubricate the 4 new seals in clean CVT transmission fluid and install transmission fluid cooler tube seals.





6. CAUTION: Make sure the transmission fluid cooler tubes are pushed in straight or the tubes and/or O-ring seals will be damaged.

Connect the transmission fluid cooler tubes to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).





7. Install the transmission fluid cooler tube bracket to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).





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





9. If required, top off the transaxle with clean CVT transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.

10. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.).