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Main Control Valve Body: Installation

  1. Install the new separator plate and the 2 separator bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 1: Locating Bolts And Separator Plate
      G06097482Courtesy of FORD MOTOR CO.
    2. NOTE: If cleaning the main control assembly or inspecting the valves, refer to MAIN CONTROL VALVE BODY . If installing a new main control assembly, continue with this procedure.
  2. Install the solenoid body assembly onto the main control valve body. Install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 2: Locating Solenoid Body Assembly Bolts
      G06097133Courtesy of FORD MOTOR CO.
  3. Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle case separator plate.
    Fig 3: Locating Main Control-To-Transaxle Case Separator Plate
    G06097132Courtesy of FORD MOTOR CO.
    4. NOTE: Make sure that the manual lever pin (part of the TR sensor) is correctly installed in the manual valve.
    Fig 4: Locating Manual Lever Pin In Manual Valve
    G06097136Courtesy of FORD MOTOR CO.
  4. Install the main control.
    5. NOTE: Make sure not to pinch the Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses when installing the main control.
    NOTE: Install the different length bolts in the locations noted during disassembly.
  5. Install the main control stud nut and 22 main control valve body bolts. Tighten in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      Fig 5: Locating Main Control Bolts And Nut
      G06097131Courtesy of FORD MOTOR CO.
  6. Connect the OSS sensor electrical connector.
    Fig 6: Locating OSS Sensor Electrical Connector
    G08023179Courtesy of FORD MOTOR CO.
  7. Connect the TR sensor electrical connector.
    Fig 7: Locating TR Sensor Electrical Connector
    G06097012Courtesy of FORD MOTOR CO.
  8. Install the main control-to-main control cover grommet.
    Fig 8: Locating Main Control Cover Grommet
    G06097011Courtesy of FORD MOTOR CO.
  9. Clean the main control cover sealing surface.
    Fig 9: Locating Main Control Cover Sealing Surface
    G06096992Courtesy of FORD MOTOR CO.
  10. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 10: Locating Main Control Sealing Surface Of Transaxle Case
    G06096993Courtesy of FORD MOTOR CO.
  11. Position the main control cover in place.
    Fig 11: Locating Main Control Cover
    G06096994Courtesy of FORD MOTOR CO.
    12. NOTE: Inspect the main control-to-main control cover grommet to make sure that the seal 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.
  12. Tighten the 8 main control cover bolts and 5 stud bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 12: Locating Main Control Cover Bolts And Stud Bolts
      G06096991Courtesy of FORD MOTOR CO.
  13. Position the transmission fluid cooler tube bracket and transmission fluid cooler tube assembly in place and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 13: Locating Transmission Fluid Cooler Tube Bracket Nuts
      G06096988Courtesy of FORD MOTOR CO.
  14. Connect the transaxle electrical wiring harness retainers to the main control cover studbolts.
    Fig 14: Locating Transaxle Electrical Wiring Harness Retainers On Main Control Cover Stud Bolts
    G06096990Courtesy of FORD MOTOR CO.
  15. Connect the transaxle electrical connector.
    Fig 15: Locating Transaxle Electrical Connector
    G06096997Courtesy of FORD MOTOR CO.
  16. Install the underbody cover and the screws.
    Fig 16: Locating Underbody Cover And Screws
    G06257240Courtesy of FORD MOTOR CO.
  17. Install the ACL assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L or INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) .
  18. Fill the transaxle with clean transmission fluid.
    Fig 17: Locating Transmission Fluid Level Indicator
    G06096977Courtesy of FORD MOTOR CO.
  19. Start the engine and move the range selector lever into each gear position.
  20. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
  21. If a new solenoid body is installed, the solenoid body strategy and solenoid body identification will need to be updated. For additional information, refer to SOLENOID BODY STRATEGY .
  22. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will have to be reflashed with a new solenoid body strategy and identification data file. For additional information, refer to SOLENOID BODY STRATEGY .
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