LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2009 >> Flex SE >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> In-Vehicle Repair >> Solenoid Body Assembly >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Solenoid Body Assembly: Installation

    NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
    NOTE: 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.
    NOTE: 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.
    Fig 1: Locating Solenoid Body Filter Assembly
    G06067689Courtesy of FORD MOTOR CO.
  1. Install a new solenoid body filter assembly by pushing it straight down on to the alignment tabs.
    2. NOTE: 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.
  2. 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
      Fig 2: Identifying Solenoid Body Bolts
      G06067690Courtesy of FORD MOTOR CO.
  3. Tighten the solenoid body bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 3: Identifying Solenoid Body Bolts Tightening Sequence
      G06067691Courtesy of FORD MOTOR CO.
  4. Route the OSS  sensor wiring harness and connect the electrical connector.
    Fig 4: Identifying OSS Sensor Wiring Harness And Electrical Connector
    G06067692Courtesy of FORD MOTOR CO.
  5. Connect the TR  sensor electrical connector.
    1. Connect the electrical connector.
    2. Slide the locking tab over.
      Fig 5: Identifying TR Sensor Electrical Connector
      G06067693Courtesy of FORD MOTOR CO.
  6. Connect the TSS  sensor electrical connector.
    Fig 6: Locating TSS Sensor Electrical Connector
    G06067694Courtesy of FORD MOTOR CO.
  7. Inspect the transaxle side cover seal for damage and install new if necessary.
    Fig 7: Locating Cover Seal
    G06067695Courtesy of FORD MOTOR CO.
    8. NOTE: Inspect the 20-pin solenoid body connector seal to make sure that the seal is on the inside of the main control cover or a transmission fluid leak will occur.
    NOTE: Install the studbolts in the locations noted during disassembly.
  8. Install the main control cover and loosely install the 14 bolts.
    1. Bolt location
    2. Studbolt location
      Fig 8: Identifying Main Control Cover Bolts Tightening Sequence
      G06067696Courtesy of FORD MOTOR CO.
  9. Tighten the main control cover bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 9: Identifying Main Control Cover Bolts Tightening Sequence
      G06067697Courtesy of FORD MOTOR CO.
  10. Wipe the surface of the existing solenoid body strategy tag on top of the transaxle case clean and install the new solenoid body strategy tag (supplied with the solenoid body service kit) over it.
    Fig 10: Wiping Surface Of Existing Solenoid Body Strategy Tag
    G06067963Courtesy of FORD MOTOR CO.
  11. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the thermal bypass valve nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 11: Locating Transmission Fluid Cooler Thermal Bypass Valve And Transmission Fluid Cooler Tube Assembly Nuts
      G06067698Courtesy of FORD MOTOR CO.
  12. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.
    Fig 12: Locating Transaxle Electrical Connector
    G06067678Courtesy of FORD MOTOR CO.
  13. 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.
    Fig 13: Identifying Transmission Fluid Cooler Tube Backing Ring And Seal
    G06067701Courtesy of FORD MOTOR CO.
    ITEM DESCRIPTION CHART

    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
  14. Position the transmission fluid cooler tube in place and install a new bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 14: Locating Transmission Fluid Cooler Tube
      G06067675Courtesy of FORD MOTOR CO.
  15. Tighten the transmission fluid cooler tube fitting.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 15: Locating Transmission Fluid Cooler Tube Fitting
      G06067674Courtesy of FORD MOTOR CO.
    16. NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or 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.
  16. Install the manual control lever and the nut.
    • Tighten to 18 Nm (159 lb-in).
      Fig 16: Locating Nut And Manual Control Lever
      G06067677Courtesy of FORD MOTOR CO.
    17. NOTE: Coolant hoses removed for clarity.
  17. Install the transmission fluid filler tube and the nut.
    • Tighten to 11 Nm (97 lb-in).
      Fig 17: Locating Transmission Fluid Filler Tube
      G06067673Courtesy of FORD MOTOR CO.
    18. NOTE: Coolant hoses removed for clarity.
    Fig 18: Locating Transmission Fluid Level Indicator
    G06067672Courtesy of FORD MOTOR CO.
  18. Install the transmission fluid level indicator.
  19. Route the coolant hoses to their position on the transmission fluid filler tube.
    Fig 19: Locating Coolant Hoses
    G06067815Courtesy of FORD MOTOR CO.
  20. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
      Fig 20: Positioning Manual Control Lever
      G06067707Courtesy of FORD MOTOR CO.
  21. Unlock the selector lever cable adjuster by sliding the locking tab over.
    Fig 21: Unlocking Selector Lever Cable Adjuster
    G06067708Courtesy of FORD MOTOR CO.
  22. Slide the cable end forward or backward to align it with the manual control lever.
    Fig 22: Sliding Cable End
    G06067709Courtesy of FORD MOTOR CO.
  23. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 23: Locating Manual Control Lever
    G06067710Courtesy of FORD MOTOR CO.
  24. Slide the release tab back to lock the adjuster.
    Fig 24: Sliding Release Tab Back To Lock Adjuster
    G06067711Courtesy of FORD MOTOR CO.
  25. Position the ACL  assembly in place and install the 2 ACL  assembly bracket bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 25: Locating ACL Assembly Bracket Bolts
      G06067666Courtesy of FORD MOTOR CO.
  26. Tighten the ACL  outlet pipe clamp at the TB  .
    • Tighten to 5 Nm (44 lb-in).
      Fig 26: Locating ACL Outlet Pipe Clamp
      G06067667Courtesy of FORD MOTOR CO.
  27. Connect the engine breather to the ACL  assembly.
    Fig 27: Locating Engine Breather
    G06067665Courtesy of FORD MOTOR CO.
  28. Connect the MAF  sensor electrical connector.
    Fig 28: Locating Mass Air Flow (MAF) Sensor Electrical Connector
    G06067664Courtesy of FORD MOTOR CO.
  29. Fill with clean transmission fluid to the correct level.
  30. Download a new solenoid body strategy to the PCM. For additional information, refer to SOLENOID BODY STRATEGY .
scientia non olet · About LEMON Manuals