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Digital Transmission Range (TR) Sensor: Installation

  1. Install the TR sensor.
    1. Position the park pawl actuating rod in the TR sensor.
    2. Install the TR sensor in the transaxle case.
    2. Fig 1: Identifying TR Sensor In Transaxle Case
    GF0031687Courtesy of FORD MOTOR CO.
  2. Using the special tool, install a new TR sensor locking pin.
    3. Fig 2: Installing TR Sensor Locking Pin Using Special Tool (307-592)
    GF0031688Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
  3. Position the TSS, OSS and TR sensor wiring harnesses aside and install the main control valve body.
    4. Fig 3: Locating TSS, OSS & TR Sensor Wiring Harnesses
    GF0031654Courtesy of FORD MOTOR CO.
  4. Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the valve body off the transaxle case. Correctly install the manual pin in the manual valve and position the valve body in place.
    5. Fig 4: Identifying Manual Pin
    GF0031655Courtesy of FORD MOTOR CO.
  5. Install the TR sensor detent spring and the 10 bolts. Tighten the bolts in the sequence shown.
    • Tighten to 12 Nm (9 lb-ft).
    6. Fig 5: Tightening TR Sensor Detent Spring Bolts In Sequence
    GF0031656Courtesy of FORD MOTOR CO.
    CAUTION: Do not handle the solenoid body in the lead frame area or by the screens of the solenoid body filter or damage to the solenoid body can occur.
    CAUTION: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transaxle will occur if the solenoid body is not correctly aligned.
    CAUTION: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transaxle will occur if the filter passages are not clean.
  6. Install a new solenoid body filter assembly by pushing it straight down on to the alignment tabs.
    7. Fig 6: Identifying Solenoid Body Filter Assembly
    GF0031652Courtesy of FORD MOTOR CO.
    CAUTION: Make sure not to pinch the turbine shaft speed (TSS), output shaft speed (OSS) or transmission range (TR) sensor wiring harnesses when installing the solenoid body. Damage to the wiring harness will occur.
    NOTE: Install the different length bolts in the locations noted during disassembly.
  7. Install the solenoid body and the 11 bolts.
    1. 42 mm (1.65 in) bolt
    2. 63 mm (2.48 in) bolts
    3. 80 mm (3.14 in) bolts
    4. 95 mm (3.74 in) bolts
    8. Fig 7: Locating Solenoid Body Bolts
    GF0031657Courtesy of FORD MOTOR CO.
  8. Tighten the solenoid body bolts in the sequence shown.
    • Tighten to 12 Nm (9 lb-ft).
    9. Fig 8: Tightening Solenoid Body Bolts In Sequence
    GF0031658Courtesy of FORD MOTOR CO.
  9. Route the OSS sensor wiring harness and connect the electrical connector.
    10. Fig 9: Locating OSS Sensor Wiring Harness & Electrical Connector
    GF0031659Courtesy of FORD MOTOR CO.
  10. Connect the TR sensor electrical connector.
    1. Connect the electrical connector.
    2. Slide the locking tab over.
    11. Fig 10: Identifying TR Sensor Electrical Connector
    GF0031660Courtesy of FORD MOTOR CO.
  11. Connect the TSS sensor electrical connector.
    12. Fig 11: Identifying TSS Sensor Electrical Connector
    GF0031661Courtesy of FORD MOTOR CO.
  12. Inspect the transaxle main control cover seal for damage and install new if necessary.
    13. Fig 12: Inspecting Transaxle Main Control Cover Seal For Damage
    GF0031662Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the 20-pin solenoid body connector seal to make sure that the seals is on the inside of the main control cover. Transmission fluid leak will occur.
    NOTE: Install the stud bolts in the locations noted during disassembly.
  13. Install the main control cover and loosely install the 14 bolts.
    1. Bolt location
    2. Stud bolt location
    14. Fig 13: Locating Main Control Cover Bolts
    GF0031663Courtesy of FORD MOTOR CO.
  14. Tighten the main control cover bolts in the sequence shown.
    • Tighten to 12 Nm (9 lb-ft).
    15. Fig 14: Tightening Main Control Cover Bolts In Sequence
    G00541235Courtesy of FORD MOTOR CO.
  15. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    16. Fig 15: Identifying Transmission Fluid Cooler Tube Assembly & Nuts
    GF0031665Courtesy of FORD MOTOR CO.
  16. Connect the transaxle electrical connector.
    17. Fig 16: Identifying Transaxle Control Electrical Connector
    GF0031384Courtesy of FORD MOTOR CO.
  17. Inspect the transmission fluid cooler tube backing ring and seal for damage and install a new backing ring or seal if necessary. Lubricate the transmission fluid cooler tube seal with clean transmission fluid and install the backing ring and seal on the transmission fluid cooler tube.
    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
    18. Fig 17: Identifying Transmission Fluid Cooler Tube Backing Ring & Seal
    GF0031666Courtesy of FORD MOTOR CO.
  18. Position the transmission fluid cooler tube in place and install a new bolt.
    • Tighten to 9 Nm (80 lb-in).
    19. Fig 18: Identifying Transmission Fluid Cooler Tube Bolt
    GF0031645Courtesy of FORD MOTOR CO.
  19. Tighten the transmission fluid cooler tube fitting.
    • Tighten to 25 Nm (18 lb-ft).
    20. Fig 19: Identifying Transmission Fluid Cooler Tube Fitting From Thermal Bypass Valve
    GF0031644Courtesy of FORD MOTOR CO.
  20. Install the manual control lever and the nut.
    • Tighten to 18 Nm (13 lb-ft).
    21. Fig 20: Identifying Manual Control Lever & Nut
    GF0031683Courtesy of FORD MOTOR CO.
  21. Connect the selector lever cable end to the manual control lever.
    22. Fig 21: Locating Selector Lever Cable End From Manual Lever
    GF0031682Courtesy of FORD MOTOR CO.
  22. Install the transmission fluid filler tube and the nut.
    • Tighten to 11 Nm (8 lb-ft).
    23. Fig 22: Identifying Transmission Fluid Filler Tube
    GF0031643Courtesy of FORD MOTOR CO.
  23. Install the transmission fluid level indicator.
    24. Fig 23: Identifying Transmission Fluid Level Indicator
    GF0031642Courtesy of FORD MOTOR CO.
  24. Route the coolant hoses in the transmission fluid filler tube.
    25. Fig 24: Identifying Coolant Hoses From Transmission Fluid Filler Tube
    GF0031641Courtesy of FORD MOTOR CO.
  25. Position the air cleaner assembly in place and install the bolt.
    • Tighten to 11 Nm (8 lb-ft).
    26. Fig 25: Locating Air Cleaner Assembly Bracket Bolt
    GF0031639Courtesy of FORD MOTOR CO.
  26. Tighten the air cleaner outlet pipe clamp at the throttle body (TB).
    • Tighten to 5 Nm (44 lb-in).
    27. Fig 26: Locating Air Cleaner Outlet Pipe Clamp
    GF0031640Courtesy of FORD MOTOR CO.
  27. Connect the engine breather to the air cleaner assembly.
    28. Fig 27: Locating Engine Breather
    GF0031638Courtesy of FORD MOTOR CO.
  28. Connect the brake booster vacuum hose to the air cleaner assembly.
    29. Fig 28: Locating Brake Booster Vacuum Hose
    GF0031637Courtesy of FORD MOTOR CO.
  29. Connect the MAF sensor electrical connector and connect the electrical harness fastener.
    30. Fig 29: Locating Mass Air Flow (MAF) Sensor Electrical Connector & Wiring Harness Fastener
    GF0031636Courtesy of FORD MOTOR CO.
  30. Fill with clean transmission fluid to the correct level.
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