Fluid Line/Hose: Service and Repair

Transmission Fluid Cooler Tubes

Transmission Fluid Cooler Tubes (Part 1):

Transmission Fluid Cooler Tubes (Part 2):

Removal

NOTICE: MERCON(R) V, MERCON(R) SP, Motorcraft Premium Automatic Transmission Fluid, Motorcraft Continuously Variable Chain Type Transmission Fluid and FNR5 Automatic 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. Disconnect the Mass Air How (MAF) sensor electrical connector.





3. Disconnect the engine breather from the Air Cleaner (ACL) assembly.





4. Remove the 2 ACL assembly bolts.





5. Loosen the ACL outlet pipe clamp at the Throttle Body (B) and remove the ACL and ACL outlet pipe assembly.





6. Remove the battery.
7. Detach the wiring harness retainers from the battery tray.





8. Remove the 2 lower battery tray bracket bolts.





9. Remove the upper battery tray bolt and nut and remove the battery tray and bracket.





10. Compress the constant tension clamps and remove the transmission fluid cooler tubes from the transmission fluid cooler.





11. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.





12. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve and remove the bypass valve-to-cooler transmission fluid cooler tubes.





13. Remove and discard the 2 transmission fluid cooler tube bolts.





14. Loosen the 2 transmission fluid cooler tube fittings and remove the 2 transmission fluid cooler tubes from the thermal bypass valve and the transaxle.





15. Inspect the transaxle case to be sure that the transmission fluid cooler tube seals and backing rings were removed with the transmission fluid cooler tubes and are not stuck in the transaxle case. If the transmission fluid cooler tube seals or backing rings are stuck in the transaxle case, remove the seals and backing rings.





16. Remove the 2 transmission thermal bypass valve nuts and the transmission thermal bypass valve.





Installation
1. Position the transmission fluid cooler thermal bypass valve in place and install the 2 thermal bypass valve nuts.
^ Tighten to 9 Nm (80 lb-in).





2. Inspect the transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals, if necessary. Lubricate the transmission fluid cooler tube seals with clean transmission fluid and install the backing rings and seals on the transmission fluid cooler tubes.





3. Position the 2 transmission fluid cooler tubes on the transaxle and tighten the 2 transmission fluid cooler tube fittings.
^ Tighten to 25 Nm (18 lb-ft).





4. Install 2 new transmission fluid cooler tube bolts.
^ Tighten to 9 Nm (80 lb-in).





5. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.





6. Install the 2 secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.





7. Compress the constant tension clamps and install the transmission fluid cooler tubes on the transmission fluid cooler.





8. Install the battery tray and bracket, install the battery tray bolt and the nut.
^ Tighten to 9 Nm (80 lb-in).





9. Install the 2 lower battery tray bracket bolts.
^ Tighten to 9 Nm (80 lb-in).





10. Attach the wiring harness retainers to the battery tray.





11. Install the battery.
12. Position the ACL assembly in place and install the 2 ACL assembly bolts.
^ Tighten to 11 Nm (97 lb-in).





13. Tighten the ACL outlet pipe clamp at the TB.
^ Tighten to 5 Nm (44 lb-in).





14. Connect the engine breather to the ACL assembly.





15. Connect the MAF sensor electrical connector.





16. Check the transmission fluid level and add transmission fluid as necessary.