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Home >> Ford >> 2000 >> ZX2 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 192 (Automatic Transmission - CVT) >> Disassembly And Assembly Of Subassemblies >> Variator/Chain and Spur Gear Assembly >> Assembly
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Variator/Chain and Spur Gear Assembly: Assembly

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, install the spur gear onto the variator assembly.
    Fig 1: Installing Spur Gear Onto Variator Assembly
    G03991249Courtesy of FORD MOTOR CO.
  2. If removed, press the gear onto the variator assembly and install the snap ring.
    Fig 2: Pressing Gear Onto Variator Assembly
    G03991247Courtesy of FORD MOTOR CO.
  3. Install the secondary variator assembly into the special tool.
    Fig 3: Installing Secondary Variator Assembly Into Special Tool
    G03991245Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not overcompress the secondary variator. Do not exceed the torque specification listed. Damage to the tool or variator will occur.
  4. Install the special tool and open up the secondary variator assembly.
    • Tighten to 7 Nm (62 lb-in).
      Fig 4: Installing Special Tool
      G03991244Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not let the variator chain hang free without some support. Damage to the chain will occur.
    NOTE: While installing the primary variator it is acceptable to rest the chain on the primary variator portion of the special tool.
    Fig 5: Positioning Variator Chain
    G03991240Courtesy of FORD MOTOR CO.
  5. Position the variator chain in place.
    6. CAUTION: Do not let the variator chain hang free without some support. Damage to the chain will occur.
    NOTE: While installing the primary variator it is acceptable to rest the chain on the primary variator portion of the special tool.
    Fig 6: Positioning Primary Variator On Special Tool
    G03991239Courtesy of FORD MOTOR CO.
  6. Position the primary variator on the special tool.
  7. Carefully position the chain around the primary variator.
    Fig 7: Positioning Chain Around Primary Variator
    G03991238Courtesy of FORD MOTOR CO.
  8. Once the chain is around the primary variator, lift up slightly and slide the variator over until it drops into the holding fixture.
    Fig 8: Installing Chain
    G03991256Courtesy of FORD MOTOR CO.
  9. Install both chain guides.
    Fig 9: Installing Both Chain Guides
    G03991237Courtesy of FORD MOTOR CO.
  10. Remove the special tool.
    Fig 10: Removing Special Tool
    G03991236Courtesy of FORD MOTOR CO.
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