Removing / Installing The Transmission, AW50-42
Removing / installing the transmission
Special tools:
115 8147 TORQUE SOCKET 1/2" 19 MM 115 8147 Torque Socket 1/2" 19 mm
951 2661 Replaced by 9512834 951 2661 Replaced by 9512834
998 5972 JACK 998 5972 Jack
999 5006 LIFTING BAR 999 5006 Lifting Bar
999 5396 PUNCH 999 5396 Punch
999 5460 Lifting hook 999 5460 Lifting Hook
999 5463 FIXTURE 999 5463 Fixture
999 5488 PLUGS 999 5488 Plugs
999 5633 Replaced by 9995681 999 5633 Replaced By 9995681
999 5972 FIXTURE 999 5972 Fixture
Removing
Introduction
Caution! Cleanliness is extremely important when working on automatic transmissions.Make sure that the workplace is free of dirt and dust. Always use clean containers.Clean around connectors, oil filler pipe and draining plug.
Warning! Avoid skin contact with transmission fluid.
Removing components in the engine compartment
Remove:
- Engine cover
- Battery
- Air cleaner (ACL) housing
- Battery shelf
Disconnecting components in the engine compartment
Disconnect:
- Fresh air intake with connections and connector from intake manifold.
Fold the hose to one side and place on the fusebox
- Gear selector cable from transmission
- Ground lead from transmission.
Disconnecting transmission connectors
Cut off cable harness tie straps.
Disconnect connector bracket from mounting on transmission.
Separate connectors halves.
Removing transmission-engine-starter motor screws
Remove:
- Oil cooler pipe nut.
Remove:
- Dipstick and plug opening.
- Screws between transmission-engine and transmission-starter motor (five screws)
Installing hoist
Install:
- Lifting beam 999 5006 LIFTING BAR 999 5006 Lifting Bar
- Lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook
Locate the lifting beam directly above the lifting eyelet on the engine
Raise the lifting hook a little.
Removing front wheel and splash guards
Remove:
- Front wheels
- Front and rear splash guards under the engine
- Splash guard in wheel arch (left-hand side).
Removing components left and right-hand sides:
Remove:
- Brake hose from spring strut mounting
- ABS cable from mountings in the wheel arch and on the spring strut
Remove spring strut-stub axle nuts. Leave the screws in place.
Disconnecting drive shaft, left-hand side
Remove on left-hand side:
- Drive shaft from transmission enough to free the circlip from the [1][2]differential drive. Use tool 999 5633 Replaced by 9995681 999 5633 Replaced By 9995681.
Removing, left-hand side:
Ensure that the steering wheel is in its neutral position.
Remove the stub axle from the spring strut.
Fold out the stub axle and pull the drive shaft out from transmission.
Caution! Take care not to damage the sealing ring in the transmission.
Secure the stub axle with one of the screws.
Secure drive shaft with a tie strap. Protect the end of the drive shaft from dirt.
Knock out the right drive shaft enough to free the circlip from the [1][2]differential drive. Use tool 999 5396 PUNCH 999 5396 Punch. The tool has been modified according to Workshop Guide.
Install plug 999 5488 PLUGS 999 5488 Plugs.
Removing heat deflector plate and member
Remove:
- Heat deflector plate from bracket on engine
- Heat deflector plate bracket.
- Longitudinal member under engine.
Removing right-hand side
Pull drive shaft out of transmission.
Remove stub axle from spring strut, turn the stub axle (steering left) while pulling the drive shaft out of the transmission.
Caution! Take care not to damage the sealing ring in the transmission.
Let drive shaft rest against front axle member.
Install plug 999 5488 PLUGS 999 5488 Plugs.
Tie up the stub axle so as not to stretch the brake hose.
Remove:
- Front and rear transmission brackets
- Screw on exhaust pipe mounting.
Disconnecting oil pipes
Disconnect oil pipe connections from transmission and push to one side.
Ensure that no dirt gets into the transmission and hoses.
Seal all openings with plastic plugs.
Removing torque converter screws
(6 screws). Use Torx socket TX50.
Open the hatch in the right fender liner and turn crankshaft with a socket.
Lowering engine
Remove upper transmission mounting screws.
Lower engine until the gap between the lifting beam and lifting eyelet is approx. 170 mm. See illustration.
Note! Ensure that cables and hoses are not trapped or stretched.
Connecting fixture
Install universal tool 999 5972 FIXTURE 999 5972 Fixture and transmission fixture 999 5463 FIXTURE 999 5463 Fixture on the mobile jack.
Install transmission fixture on transmission with two M10x35 screws.
At the same time install bearing plate (number 9995463-1) on fixture. The bearing plate has been modified according to Workshop Guide.
Bring mobile jack lightly into contact.
Removing engine-transmission screws
Remove the remaining screws between the engine and transmission (six screws).
Removing transmission
Carefully remove the transmission from the engine.
Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft. Use hole in torque converter cover to press the torque converter.
Turn the transmission a little and remove it.
Caution! Take care not to damage the ring on the carrier plate for the flywheel sensor.
Cleaning and inspection
Checking the transmission
Inspect the transmission and the electrical connections.
Carefully clean round the oil pipe connections.
Check that the torque converter cover mating surfaces are clean.
When replacing the transmission:
- Transfer the connector bracket to the new transmission.
- Install the torque converter lock plate on the old transmission.
Checking the carrier plate
Check:
- That the carrier plate is not damaged or cracked
- That the mating surfaces between the transmission and the engine are clean
- That the guide bushings are intact and in place.
- That the torque converter bushing in the crankshaft is intact.
Flushing the oil cooler
Place a container under the oil cooler return line.
Connect a lubricant gun and hose to the oil cooler pressure pipe.
Flush the oil cooler with ATF oil.
Checking the position of the torque converter
Ensure that the torque converter is as far in towards the transmission as it will go.
Check with a ruler. The distance between the cover and retaining tabs must be approximately approximately 14 mm.
Apply a light coating of grease to the torque converter guide studs and in the holes for the guide bushings on the torque converter cover.
Installing
Installing transmission
Use mobile jack and transmission fixture to adjust the height and angle.
Locate transmission on engine.
Caution! Take care not to damage the ring on the carrier plate for the flywheel sensor.
Reinstall screws (six screws). Tighten alternately to a light pressure. Then tighten alternately.
Tightening torque: 50 Nm.
Caution! Check carefully when tightening screws that the guide bushings locate correctly in their guide holes and that the torque converter cover is in contact with the engine before tightening.
Remove fixture and mobile jack from transmission.
Lifting engine and transmission
Lower the car.
Raise engine and transmission
Locate and install the upper transmission mounting (3 screws).
Tighten screws.
Tightening torque: 50 Nm.
Remove lifting hook and lifting beam.
Installing transmission-engine screws
Install:
- Other transmission-starter motor screws (two screws)
Tightening torque: 50 Nm
- Other transmission-engine screws (three screws).
Tightening torque: 50 Nm.
Note! Two screws hold the bracket to the engine coolant hose.
- Clamp the engine coolant hose to the bracket
Installing torque converter screws
Caution! Use new screws, Torx TX50.
Locate torque converter on carrier plate by turning engine with the crankshaft pulley nut (accessible through fender liner hatch).
Install all screws loosely (six screws). Tighten screws until heads are in contact with the carrier plate.
Then tighten to 35 Nm. Socket Torx TX 50.
Caution! Remove socket from crankshaft when the work is complete.
Installing front and rear brackets
Check drive shaft position. Check carefully that it is below the rear bracket when installing.
Install:
- Front and rear mounting brackets to transmission housing.
Tightening torque: 67 Nm
- Screw on exhaust pipe mounting.
Installing left/right drive shafts
Install drive shafts in [1][2]differential housing.
Hint: Use mobile jack 998 5972 JACK 998 5972 Jack as a support under the control arm.
At the same time locate stub axles on spring strut. Install screws loosely. The nuts will be installed later.
Caution! Take care not to damage boots and sealing rings.Press in drive shafts properly.
Checking drive shafts
Check that drive shafts are locked into place in the [1][2]differential drive by carefully pulling the drive shaft constant velocity joints.
Installing longitudinal member
Install:
- c member under engine (four screws).
Front edge, long screws
Rear edge, short screws
Tightening torque: 70 Nm.
Longitudinal member-engine, two screws with new lock nuts. Tighten the rear nut first, then the front.
Tightening torque: 50 Nm.
- Heat deflector plate bracket, two screws.
Tightening torque: 50 Nm.
- Heat deflector plate, three screws.
Installing oil pipes
Install lower pipe. Use a new O-ring.
Install the upper pipe (return line) with its mounting in the control system cover.
Install connector loosely. The pipe cap nut is tightened later.
Tightening stub axle/installing ABS and brake lines
Install:
- New lock nuts stub axle-spring strut.
Tightening torque: 90 Nm.
- ABS line on wheel arch and spring strut
- Brake hose with mounting clip on spring strut.
Installing splash guards and wheels
Install:
- Splash guard in the left wheel arch
- Splash guards under the transmission/engine
- Wheels.
See Installing wheels, AW50-42 Installing Wheels.
- Hub cap.
Installing, continued
Lower the car.
Tighten return oil pipe cap nut on control system cover.
Install:
- Oil dipstick pipe with new O-ring.
Tightening torque : 25 Nm
- Bracket with transmission connectors. Connect all connectors. Secure wiring from control system in bracket.
- Ground lead to transmission.
Installing gear selector cable
Adjust the gear selector cable and install to transmission.
Installing other components
Install:
- Battery shelf
- Fresh air hose and connectors
- Preheating hose
- Air cleaner (ACL) housing assembly
- Engine cover
- Battery.
Finishing
Checking transmission oil level
Caution! Only automatic transmission fluid which meets both Dexron IIE and Ford Mercon standards may be used.
Note! When oil and transmission are cold and the engine is off the correct oil level is only a few mm up the dipstick.
Check oil level when transmission and oil are hot
Note! Check the oil level when the oil temperature is approx. +80°C.
The gear selector should be in position P and the engine idling.
See Checking oil level, AW50-42 Checking Oil Level.
Checking diagnostic trouble codes (DTCs)
Check, remedy and erase diagnostic trouble codes (DTCs).
Test driving
Test drive with mode selector in all three positions (E, W, S)
Checking oil level
See Checking transmission oil level. See also Checking oil level, AW50-42 Checking Oil Level.
Checking diagnostic trouble codes (DTCs) after test driving the car
Check that no diagnostic trouble codes (DTCs) have been stored. Remedy and erase diagnostic trouble codes (DTCs).
Filling in Diagnostic and Check lists
Note! Before replacing the transmission, fill in Diagnostics/check list Diagnostics/Check List Diagnostics/check list Diagnostics/Check List.
Returning the transmission. (Only when replacing the entire transmission assembly)
Return the old transmission unit.
In order to accurately analyze faults, information is required about all symptoms which have caused the unit to be replaced. This information must be reported on the "Diagnosis and Check List" form which has been provided.
Make sure form has been filled out accurately
Note clearly all fault symptoms under the heading "Customer Complaints". Fill in the results after test driving the car.
Place the completed form in a plastic folder behind the torque converter so that it will not fall out.
The different sections of the form are to be used as follows:
- The white copy goes with the transmission
- The yellow copy is sent to the importer
- The pink copy is kept by the issuing party.