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Transaxle - 2.5L Duratec-VE (VE6) > < Transmission Control Module (TCM)

Mondeo 2001 (10.2000-02.2007)

Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic Transmission (5F31J) - Transaxle—2.0L Duratorq-TDCi (Puma) Diesel Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Support Bar, Engine

303-290A (21-140)

Adapter for 303-290A

303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Securing straps
Transmission jack
Steel straight edge
Materials
Name
Specification
Grease
WSD-M1C230-A 

Removal

  1. Remove the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the battery tray.
    • Remove the clips.

  1. Remove the engine upper cover.
    • Remove the oil level indicator.

  1. Remove the strut and spring assembly top mount brace cover on both sides.

  1. Loosen the strut and spring assembly top mount nuts by four turns on both sides.

  1. Disconnect the mass air flow (MAF) sensor electrical connector.

  1. Remove the air cleaner.
    1. Disconnect the air cleaner intake pipe.
    1. Disconnect the positive crankcase ventilation (PCV) hose.
    1. Disconnect the turbocharger air intake pipe.
    1. Disconnect the vacuum hose.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the selector lever cable cover.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in the "D" (DRIVE) position.
    Detach the selector lever cable from the selector shaft lever.
    1. Detach the selector lever cable from the selector shaft lever pin.
    1. Detach the selector lever cable from the selector lever cable bracket.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Remove the charge air cooler intake hose.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Remove and discard the center bearing cap and locknuts.
    • Discard the O-ring seal.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Discard the O-ring seal.

  1. Detach the heater pipe from the transaxle.

  1. Remove the torque converter retaining nuts.
    • Remove the cover.
    • Rotate the engine to gain access to the nuts.
    • Discard the nuts.
  1. Lower the vehicle.

  1. Disconnect the vent hose from the transaxle.

  1. Detach the cable bracket from the transaxle.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.

  1. Detach the ground cable from the transaxle.

  1. Remove the transaxle left-hand upper retaining bolt.

  1. Remove the transaxle right-hand upper retaining bolt.
    • Detach the vacuum reservoir bracket.

  1. Remove the bulkhead cover.

  1. Install the special tools.

  1. Remove the engine rear mount.
    • Discard the center nut.

  1. Remove the engine rear mount bracket.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:Plug the fluid cooler pipes to prevent oil loss or dirt ingress.
    Disconnect the fluid cooler pipes from the transaxle.
    • Allow the fluid to drain into a suitable container.

  1. Disconnect the transaxle electrical connectors.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand and lower retaining bolts.

  1. WARNING:
    WARNING:Make sure the torque converter remains in the torque converter housing.
    NOTE:
    NOTE:Use a suitable wooden block to protect the transaxle.
    NOTE:
    NOTE:Secure the transaxle with securing straps.
    Using a suitable transmission jack remove the transaxle.
  1. NOTE:
    NOTE:Make a note of the position of the dowel pins in the engine flange, to aid installation.
    Lower the transaxle.

Installation

  1. CAUTION:
    CAUTION:The torque converter hub must remain at the correct installation depth throughout the whole installation procedure.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Lay a steel straight edge across the transaxle flange.
    1. Check the installation depth between the steel straight edge and the drive plate stud.

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the entire installation procedure.
    NOTE:
    NOTE:Secure the transaxle with securing straps.
    NOTE:
    NOTE:Use a suitable wooden block to protect the transaxle.
    NOTE:
    NOTE:The torque converter studs must be aligned with the engine drive plate holes before any transaxle bolts are installed.
    NOTE:
    NOTE:Make sure that the dowel pins are correctly installed in the engine flange.
    Using a suitable transmission jack install the transaxle.
  1. Remove the securing straps.

  1. Tighten the transaxle left-hand and lower retaining bolts.

  1. Tighten the transaxle right-hand retaining bolts.

  1. Connect the transaxle electrical connectors.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    • Rotate the engine to gain access to the nuts.
    • Install the cover.

  1. Attach the heater pipe to the transaxle.

  1. Connect the fluid cooler pipes to the transaxle.
  1. Lower the vehicle.

  1. Install the engine rear mount bracket.

  1. NOTE:
    NOTE:Install a new engine rear mount center retaining nut.
    Install the engine rear mount.

  1. Remove the special tools.

  1. Install the bulkhead cover.

  1. Install the transaxle right-hand upper retaining bolts.
    • Attach the vacuum reservoir bracket.

  1. Install the transaxle left-hand upper retaining bolt.

  1. Attach the ground cable to the transaxle.

  1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. Attach the cable bracket to the transaxle.

  1. Connect the vent hose to the transaxle.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    CAUTION:
    CAUTION:Lubricate the O-ring seal with grease.
    NOTE:
    NOTE:Install a new O-ring seal.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Lubricate the O-ring seal with grease.
    NOTE:
    NOTE:Install a new O-ring seal.
    NOTE:
    NOTE:Install a new center bearing cap and new locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

  1. Install the charge air cooler intake hose.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in the "D" (DRIVE) position.
    Attach the selector lever cable to the selector shaft lever.
    1. Attach the selector lever cable to the selector lever cable bracket.
    1. Attach the selector lever cable to the selector shaft lever pin.

  1. Open the yellow locking clip on the select lever cable adjustment mechanism.
  1. Adjust the selector lever cable. For additional information, refer to Section  307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.
  1. Lower the vehicle.

  1. Install the air cleaner.
    1. Connect the air cleaner intake pipe.
    1. Connect the positive crankcase ventilation (PCV) hose.
    1. Connect the turbocharger air intake pipe.
    1. Connect the vacuum hose.

  1. Connect the mass air flow (MAF) sensor electrical connector.

  1. Tighten the strut and spring assembly top mount nuts on both sides.

  1. Install the strut and spring assembly top mount brace cover on both sides.

  1. Install the engine upper cover.
    • Install the oil level indicator.

  1. Install the battery tray.
    • Install the clips.
  1. Install the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. CAUTION:
    CAUTION:If a new transaxle is being installed, a new transmission fluid oil cooler and new transmission fluid cooler tubes must be installed.
    Install a new transmission fluid cooler and new transmission fluid cooler tubes if necessary. For additional information, refer to Section  307-02A Transmission/Transaxle Cooling / 307-02B Transmission/Transaxle Cooling.
  1. Fill the transaxle with transmission fluid.
    For additional information, refer to Transmission Fluid Drain and Refill in this section.
  1. NOTE:
    NOTE:Only carry out the following step when a new transaxle has been installed.
    Using worldwide diagnostic system (WDS), reset the transmission control module (TCM).
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Transaxle - 2.5L Duratec-VE (VE6) > < Transmission Control Module (TCM)