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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.
      Fig 1: Installing TR Sensor In Transaxle Case
      G06067866Courtesy of FORD MOTOR CO.
  2. Using the Manual Lever Retaining Pin Installer, install a new TR  sensor locking pin.
    Fig 2: Installing TR Sensor Locking Pin
    G06067867Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure that the manual pin (part of the TR  sensor) is correctly installed in the manual valve.
    Fig 3: Locating TR Sensor Wiring Harnesses And Main Control Valve Body
    G06067686Courtesy of FORD MOTOR CO.
  3. Position the TSS  , OSS  and TR  sensor wiring harnesses aside and install the main control valve body.
  4. Inspect the manual pin to make sure it is correctly installed in the manual control valve. If it is not, pull the valve body off the transaxle case. Correctly install the manual pin in the manual control valve and position the valve body in place.
    Fig 4: Locating Manual Pin
    G06067687Courtesy of FORD MOTOR CO.
  5. Install the TR  sensor detent spring and the bolts. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 5: Locating TR Sensor Detent Spring And Bolts
      G06067688Courtesy of FORD MOTOR CO.
    6. 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 can 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 6: Locating Solenoid Body Filter Assembly
    G06067689Courtesy of FORD MOTOR CO.
  6. Install a new solenoid body filter assembly by pushing it straight down on to the alignment tabs.
    7. 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.
  7. Install the solenoid body and the 11 bolts.
    1. 42 mm (1.653 in) bolt
    2. 63 mm (2.48 in) bolts
    3. 80 mm (3.149 in) bolts
    4. 95 mm (3.74 in) bolts
      Fig 7: Identifying Solenoid Body And Bolts
      G06067690Courtesy of FORD MOTOR CO.
  8. Tighten the solenoid body bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 8: Locating Solenoid Body Bolts
      G06067691Courtesy of FORD MOTOR CO.
  9. Route the OSS  sensor wiring harness and connect the electrical connector.
    Fig 9: Locating OSS Sensor Wiring Harness And Electrical Connector
    G06067692Courtesy of FORD MOTOR CO.
  10. Connect the TR  sensor electrical connector.
    1. Connect the electrical connector.
    2. Slide the locking tab over.
      Fig 10: Locating TR Sensor Electrical Connector
      G06067693Courtesy of FORD MOTOR CO.
  11. Connect the TSS  sensor electrical connector.
    Fig 11: Locating TSS Sensor Electrical Connector
    G06067694Courtesy of FORD MOTOR CO.
  12. Inspect the transaxle main control cover seal for damage and install new if necessary.
    Fig 12: Locating Transaxle Main Control Cover Seal
    G06067695Courtesy of FORD MOTOR CO.
    13. 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 resulting in transmission damage.
    NOTE: Install the studbolts in the locations noted during disassembly.
  13. Install the main control cover and loosely install the bolts.
    1. Bolt location
    2. Studbolt location
      Fig 13: Identifying Main Control Cover Bolts
      G06067696Courtesy of FORD MOTOR CO.
  14. Tighten the main control cover bolts in the sequence shown in illustration.
    • Tighten to 12 Nm (106 lb-in).
      Fig 14: Identifying Main Control Cover Bolts Tighten Sequence
      G06067697Courtesy of FORD MOTOR CO.
  15. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 15: Locating Transmission Fluid Cooler Tube Bracket Nuts
      G06502385Courtesy of FORD MOTOR CO.
  16. Connect the transaxle electrical connector.
    Fig 16: Locating Transaxle Electrical Connector
    G06501212Courtesy 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.
    Fig 17: Identifying Backing Ring And Seal
    G06067701Courtesy of FORD MOTOR CO.
    ITEM DESCRIPTION

    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
  18. Position the transmission fluid cooler tube in place and install a new bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 18: Locating Transmission Fluid Cooler Tube Bolt
      G06067675Courtesy of FORD MOTOR CO.
  19. Tighten the transmission fluid cooler tube fitting.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 19: Locating Transmission Fluid Cooler Tube
      G06067674Courtesy of FORD MOTOR CO.
    20. 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.
  20. Install the manual control lever and the nut.
    • Tighten to 18 Nm (159 lb-in).
      Fig 20: Locating Manual Control Lever And Nut
      G06067677Courtesy of FORD MOTOR CO.
  21. 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 21: Rotating Manual Control Lever Counterclockwise
      G06067707Courtesy of FORD MOTOR CO.
  22. Unlock the selector lever cable adjuster by sliding the locking tab over.
    Fig 22: Identifying Selector Lever Cable Adjuster Unlocked
    G06067708Courtesy of FORD MOTOR CO.
  23. Slide the cable end forward or backward to align it with the manual control lever.
    Fig 23: Aligning Manual Control Lever
    G06067709Courtesy of FORD MOTOR CO.
  24. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 24: Connecting Selector Lever Cable End To Manual Control Lever
    G06067710Courtesy of FORD MOTOR CO.
  25. Slide the release tab back to lock the adjuster.
    Fig 25: Releasing Tab Back To Lock Adjuster
    G06067711Courtesy of FORD MOTOR CO.
  26. Position the ACL  assembly in place and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
      Fig 26: Locating ACL Assembly Bracket Bolt
      G06502358Courtesy of FORD MOTOR CO.
  27. Tighten the ACL  outlet pipe clamp at the TB  .
    • Tighten to 5 Nm (44 lb-in).
      Fig 27: Locating ACL Outlet Pipe Clamp
      G06067667Courtesy of FORD MOTOR CO.
  28. Connect the engine breather to the ACL  assembly.
    Fig 28: Locating Engine Breather From ACL Assembly
    G06067665Courtesy of FORD MOTOR CO.
  29. Connect the brake booster vacuum hose to the ACL  assembly.
    Fig 29: Locating Brake Booster Vacuum Hose
    G06502356Courtesy of FORD MOTOR CO.
  30. Connect the MAF  sensor electrical connector and connect the electrical harness fastener.
    Fig 30: Locating MAF Sensor Electrical Connector And Electrical Harness Fastener
    G06502400Courtesy of FORD MOTOR CO.
  31. Fill with clean transmission fluid to the correct level.
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