Friday, March 9, 2012

How to replace Transaxle on Ford and Mercury Vehicles?

The details for ford and mercury car models.


Transaxle Removal & Installation
6-SPEED TRANSAXLE?6F50
SOLENOID BODY STRATEGY


Instructions are as follows :----

6-Speed Transaxle-6F50



Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
  3. Disconnect the engine breather from the Air Cleaner (ACL) assembly.
  4. Remove the ACL assembly bracket bolts.
  5. Disconnect the brake booster vacuum hose from the ACL outlet pipe.
  6. Loosen the ACL outlet pipe clamp at the Throttle Body (TB) and remove the ACL and ACL outlet pipe assembly.
  7. Remove the battery.
  8. Detach the wiring harness retainers from the battery tray.
  9. Remove the lower battery tray bracket bolts.
  10. Remove the upper battery tray bolt and nut and remove the battery tray and bracket.
  11. Remove the upper intake manifold. Refer to Intake Manifold.
  12. Disconnect the selector lever cable end from the manual control lever.
  13. Remove the selector lever cable bracket bolts and position aside the selector lever cable and bracket.
  14. Remove the starter motor positive terminal cover.
  15. Remove the starter terminals from the starter.
  16. Disconnect the wiring harness fastener from the starter motor studbolt.
  17. Remove the bolt, studbolt and the starter.
  18. If equipped, remove the 2 auxiliary coolant pump bracket nuts and position the auxiliary coolant pump aside.
  19. Disconnect the transaxle electrical connector and remove the wiring harness fastener from the main control cover stud.
  20. Position the coolant hoses aside from the transmission fluid filler tube.
  21. Remove the transmission fluid level indicator.
  22. Remove the nut, rotate the transmission fluid filler tube counterclockwise 90 degrees and remove the transmission fluid filler tube.
  23. Remove the top torque converter housing bolts.
  24. Install the Engine Lift Eye onto the LH cylinder head.
  25. Install the Engine Support Bar and Engine Spreader Bar to support the engine.

    Click image to see an enlarged view
    Fig. Installing engine support tools
  26. Remove the front wheels.
  27. Remove the pushpin fasteners and the RH splash shield.
  28. Remove the screws, pushpin fasteners and the front splash shield.
  29. Remove the transmission fluid drain plug and allow the transmission fluid to drain.
  30. Install the transmission fluid drain plug. Tighten to 80 inch lbs. (9 Nm).
  31. Remove the 3 power steering tube bracket bolts from the LH side of the subframe and position the power steering tube aside.
  32. Remove the RH and LH front halfshaft. Refer to Halfshaft.
  33. Inspect the halfshaft hubs for wear or damage and install a new halfshaft, if necessary.
  34. Inspect the differential seal surface.
  35. Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
  36. Inspect the differential side gear splines.
  37. Remove the Y-pipe nuts and disconnect the exhaust hanger. Discard the gasket and nuts.
  38. Remove the nuts and the Y-pipe assembly. Discard the nuts.
  39. Remove and discard the nuts and bolts from the steering rack. Position the steering rack aside and support it using a suitable length of mechanic's wire.
  40. Remove and discard the sway bar bolts. Position the sway bar aside and support it using a suitable length of mechanic's wire.
  41. Remove the bolts from the roll restrictor bracket.
On All-Wheel Drive (AWD) vehicles, perform the following steps:
  1. Index-mark the driveshaft, remove and discard the bolts. Position the driveshaft aside.
  2. Disconnect the RH catalyst monitor electrical connector.
  3. Remove the catalytic converter support bracket bolts.
  4. Remove the 4 RH catalytic converter nuts and the RH catalytic converter.
  5. Remove the bolts and the Power Transfer Unit (PTU) support bracket.
    NOTE
    A new halfshaft seal must be installed anytime the RH halfshaft is removed.
  6. Remove the seal deflector and the intermediate shaft seal.
  7. Remove the PTU bolts and the PTU.
On all vehicles, perform the following steps:
  1. Support the subframe using the Powertrain Lift.
  2. Remove the subframe bracket-to-body bolts.
  3. Remove the rear subframe bolts and the subframe brackets.
  4. Remove the front subframe bolts.
  5. Remove the subframe.
  6. Remove the 2 fasteners and the torque converter inspection cover.
  7. Remove and discard the 3 torque converter bolts.
  8. Remove the secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  9. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
  10. Remove the transaxle support insulator through bolt.
  11. Remove the flagnut.
  12. Release the tension from the through bolt to remove it from the transaxle mount.
  13. Lower the transaxle from the mount about 50.8 mm (2 in).
  14. Remove the nuts, the bolt and the transaxle support insulator bracket.
  15. Using the Transmission Jack Adapter, support the transaxle.
  16. Remove the remaining torque converter housing bolts and remove the transaxle from the vehicle.
  17. Remove the manual control lever.
  18. Remove and discard the transmission fluid cooler tube bolts.
  19. Remove the nuts, pull the transmission fluid cooler thermal bypass valve and the transmission fluid cooler tubes straight up and remove the assembly from the transaxle.
  20. 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.
  21. If the transaxle is to be overhauled or if installing a new or re-manufactured transaxle, carry out transmission fluid cooler backflushing and cleaning.
To install :

NOTE
Prior to installation of a new, re-manufactured or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure may occur.


NOTE
Prior to installation of a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes.

  1. 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.
  2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the nuts. Tighten to 80 inch lbs. (9 Nm).
  3. Install new transmission fluid cooler tube bolts. Tighten to 80 inch lbs. (9 Nm).
    NOTE
    Make sure that when installing the manual control lever, it is fully seated onto the manual control lever shaft. Damage to the manual control lever shaft will occur and the lever will come loose.


    NOTE
    Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
  4. Install the manual control lever and the nut. Tighten to 13 ft. lbs. (18 Nm).
  5. Lubricate the torque converter pilot hub with grease.
    NOTE
    If the transaxle is not positioned on the dowel pins, damage to the transaxle may occur.
  6. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
  7. Using the Transmission Jack Adapter, support the transaxle.
  8. Position the transaxle in place and install the lower torque converter housing bolts. Tighten to 35 ft. lbs. (48 Nm).
  9. Install the transaxle support insulator bracket, the nuts and the bolt. Tighten to 46 ft. lbs. (63 Nm).
  10. Raise the transaxle and install the transaxle support insulator through bolt. Tighten to 129 ft. lbs. (175 Nm).
  11. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
  12. Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  13. Install 3 new torque converter bolts. Tighten to 41 ft. lbs. (55 Nm).
  14. Install the inspection cover and the 2 fasteners.
On All-Wheel Drive (AWD) vehicles, perform the following steps:
  1. Position the Power Transfer Unit (PTU) in place and install the bolts. Tighten to 66 ft. lbs. (90 Nm).
  2. Install a new cover seal.
  3. Position the PTU support bracket in place and install the bolts. Tighten to 52 ft. lbs. (70 Nm).
  4. Position the RH catalytic converter in place and loosely install the 4 nuts.
  5. Install the RH catalytic converter support bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
  6. Tighten the 4 RH catalytic converter nuts. Tighten to 30 ft. lbs. (40 Nm).
  7. Connect the RH catalyst monitor electrical connector.
  8. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install new driveshaft bolts. Tighten to 52 ft. lbs. (70 Nm).
On all vehicles, perform the following steps:
  1. Loosely install the RH and LH front subframe bolts.
  2. Position the RH and LH subframe support brackets in place and loosely install the bracket bolts.
  3. Loosely install the RH and LH rear subframe bolts.
  4. Tighten the RH and LH front subframe bolts. Tighten to 111 ft. lbs. (150 Nm).
  5. Tighten the RH and LH rear subframe bolts. Tighten to 111 ft. lbs. (150 Nm).
  6. Tighten the RH and LH subframe support bracket bolts. Tighten to 41 ft. lbs. (55 Nm).
  7. Position the roll restrictor in place and install the bolts. Tighten to 66 ft. lbs. (90 Nm).
  8. Position the stabilizer bar in place and install new bolts. Tighten to 35 ft. lbs. (48 Nm).
  9. Position the power steering rack in place and install new bolts and nuts. Tighten to 86 ft. lbs. (117 Nm).
  10. Position the exhaust Y-pipe assembly in place and install the new nuts. Tighten to 30 ft. lbs. (40 Nm).
  11. Install the exhaust hanger and the exhaust flange nuts. Tighten to 30 ft. lbs. (40 Nm).
  12. Install the RH and LH halfshafts. Refer to Halfshafts.
  13. Position the power steering tube in place on the LH side of the subframe and install the 3 power steering tube bracket bolts. Tighten to 80 inch lbs. (9 Nm).
  14. Install the front splash shield, the screws and the pushpin fasteners.
  15. Install the RH splash shield and the pushpin fasteners.
  16. Remove the Engine Support Bar and Engine Spreader Bar.
  17. Remove the Engine Lift Eye from the LH cylinder head.
  18. Install the top torque converter housing bolts. Tighten to 35 ft. lbs. (48 Nm).
  19. Install the transmission fluid filler tube and the nut. Tighten to 97 inch lbs. (11 Nm).
  20. Install the transmission fluid level indicator.
  21. Route the coolant hoses to the correct position on the transmission fluid filler tube.
  22. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.
  23. If equipped, position the auxiliary coolant pump on the transaxle studs and install the 2 nuts. Tighten to 15 ft. lbs. (20 Nm).
  24. Install the starter, the bolt and studbolt. Tighten to 19 ft. lbs. (26 Nm).
  25. Install the wiring harness fastener on the starter motor studbolt.
  26. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal. Tighten the starter battery terminal nut to 106 inch lbs. (12 Nm). Tighten the starter solenoid terminal nut to 53 inch lbs. (6 Nm).
  27. Install the starter motor positive terminal cover.
  28. Position the selector lever cable and bracket in place and install the bolts. Tighten to 106 inch lbs. (12 Nm).
  29. Place the selector lever in DRIVE.
  30. Place the manual control lever in DRIVE.
  31. Rotate the manual control lever clockwise until it stops.
  32. Rotate the manual control lever counterclockwise one detent until it stops.
  33. Unlock the selector lever cable adjuster by sliding the locking tab over.
  34. Slide the cable end forward or backward to align it with the manual lever.
  35. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
  36. Slide the release tab back to lock the adjuster.
  37. Install the upper intake manifold. Refer to Intake Manifold.
  38. Install the battery tray and bracket, install the battery tray bolt and the nut. Tighten to 80 inch lbs. (9 Nm).
  39. Install the lower battery tray bracket bolts. Tighten to 80 inch lbs. (9 Nm).
  40. Attach the pin-type wiring harness fasteners to the battery tray.
  41. Install the battery.
  42. Position the Air Cleaner (ACL) assembly in place and install the ACL assembly bracket bolts. Tighten to 97 inch lbs. (11 Nm).
  43. Connect the brake booster vacuum hose to the ACL outlet pipe.
  44. Tighten the ACL outlet pipe clamp at the Throttle Body (TB). Tighten to 44 inch lbs. (5 Nm).
  45. Connect the engine breather to the ACL assembly.
  46. Connect the Mass Air Flow (MAF) sensor electrical connector.
  47. Install the front wheels.
  48. Fill with clean transmission fluid to the correct level.
  49. If a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to Solenoid Body Strategy.

Solenoid Body Strategy



Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009

NOTE
Special Tool(s) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Solenoid Body Identification Procedure
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Using the scan tool, select Powertrain, Transmission and Transmission Solenoid Body Identification from the toolbox icon and follow the instructions displayed on the scan tool.
    1. The solenoid body identification screen displays solenoid body identification information:
    2. Solenoid body identification - 7-digit
    3. Solenoid body strategy - 13-digit
    4. The next screen displays the current solenoid body identification and strategy data file stored in the PCM. If the solenoid body strategy field is blank, the module contains a partial transmission solenoid body strategy. This is due to a corrupt or missing file at the time the programmable parameters were completed.
    5. Compare the solenoid body identification and strategy (if available) to the solenoid body service tag or the replacement solenoid body tag located on top of the transaxle case.

      Click image to see an enlarged view
      Fig. Original Solenoid Body Service Tag


      Click image to see an enlarged view
      Fig. Replacement Solenoid Body Service Tag
  2. If the solenoid body identification and strategy on the scan tool match the solenoid body service tag or replacement tag, then the solenoid body identification and strategy are correct for this transaxle and a solenoid body strategy download is not required. If the solenoid body service tag or replacement tag is missing or damaged so that it is not readable or does not match the identification or strategy on the scan tool, remove the main control cover. The 7-digit identification number and the 13-digit strategy number are stamped on the solenoid body.
    NOTE
    If the solenoid body information does not match the module information, transaxle damage or drivability concerns can occur.
  3. Inspect the solenoid body identification and strategy stamped on the solenoid body and compare this to the solenoid body service tag on the transaxle case. If the solenoid body identification and strategy stamped on the solenoid body does not match the solenoid body service tag or if the solenoid body identification and strategy stamped on the solenoid body match the solenoid body service tag on the transaxle case but do not match the solenoid body identification and strategy numbers displayed on the scan tool, a solenoid body strategy data download is required.

    Click image to see an enlarged view
    Fig. Original Solenoid Body Service Tag
Solenoid Body Strategy Data Download
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Using the scan tool, select module programming and programmable parameters under the toolbox icon and select transmission. Follow the instructions displayed on the scan tool.
  2. There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from the solenoid body.
    NOTE
    If the solenoid body information is not correct, transaxle damage or drivability concerns can occur.
  3. Enter the solenoid body identification and strategy.
  4. The scan tool will verify that the numbers entered are valid and display a message if the information is not valid.
  5. The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician may proceed with downloading the file to the PCM. If the file is not present, the scan tool will need to be connected to the Professional Technician Society (PTS) server to download the file onto the scan tool.
  6. Verify that the file is present on the scan tool. If the file is present, go to Step 8. If the file is not present, continue with this procedure.
  7. Connect the scan tool to the PTS server. The screen will display a progress bar when connecting to the network.
  8. Follow the instructions on the network to download the strategy file to the scan tool. The screen will display a progress bar when downloading the strategy file to the scan tool and display a message if it is downloaded successfully.
  9. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com. If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be downloaded.
  10. Reconnect the scan tool to the vehicle.
  11. Follow the instructions displayed on the scan tool.
  12. If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields from the solenoid body to the replacement solenoid body tag provided with the solenoid body service kit and place it over the existing identification tag.
The scan tool will automatically download the strategy file or partial strategy file to the PCM and will display a progress bar while downloading. The scan tool will display a message when it is finished downloading the data that states that the file was downloaded successfully.

NOTE
If a drive cycle is not completed, the customer may feel erratic shifts and drivability concerns.

  1. Test drive the vehicle. Refer to Solenoid Body Strategy Drive Cycle.
Solenoid Body Strategy Drive Cycle
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
Carry out the drive cycle after downloading the solenoid body strategy data file to the PCM.

NOTE
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.


NOTE
The engine and transaxle must be at normal operating temperature.

  1. Bring the transaxle to normal operating temperature.
  2. With the engine running and the brake applied, move the selector lever through the gears in the following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times. If any engagements feel soft or harsh, repeat this procedure.
  3. Drive the vehicle and accelerate at a moderate throttle so that the upshifts occur at 2,000 rpm up to 80 km/h (50 mph) and brake moderately to a stop. Repeat this pattern 2 times.
  4. Drive the vehicle and accelerate at a moderate throttle so that the upshifts occur at 3,000 rpm up to 80 km/h (50 mph) and brake moderately to a stop. Repeat this pattern 2 times.
  5. With the engine running and the brake applied, move the selector lever through the gears in the following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times.

This details will help.
Thanks.




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