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Hydraulic Pressure Accumulator > < Automated Gearshift System

Transit 2000.5 (01.2000-05.2006)

Manual Transmission/Transaxle Automated Gearshift System - Hydraulic Pressure Unit (HPU) Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

Disconnect Tool, Hydraulic Line

308-440 (16-099)

Worldwide Diagnostic System

418-F224
General Equipment
Brake hose clamp
Transmission jack
Two M10 x 100 mm bolts
Materials
Name
Specification
Hydraulic fluid
N052146-VX00 

Removal

  1. WARNING:
    WARNING:The gearshift system accumulator pressure must be released before attempting any repairs. Failure to follow this instruction may result in personal injury.
    Using worldwide diagnostic system (WDS), release the pressure in the hydraulic pressure accumulator.

  1. Remove the transmission control module (TCM) fuse.
    • Remove the battery junction box (BJB) cover.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. WARNING:
    WARNING:Make sure that the gearshift system is not pressurized. Failure to follow this instruction may result in personal injury.
    Using a suitable brake hose clamp, clamp the hydraulic fluid reservoir hose.

  1. NOTE:
    NOTE:Do not remove the driveshaft.
    NOTE:
    NOTE:Support the driveshaft.
    Remove the driveshaft center bearing retaining bolts.

  1. Loosely install two M10 x 100 mm bolts.
    • Lower the driveshaft.

  1. Using a suitable transmission jack, support the front axle crossmember.

  1. Loosen the front axle crossmember retaining nuts by three turns (left-hand side shown).

  1. Remove the front axle crossmember retaining bolts (left-hand side shown).

  1. Using the transmission jack, lower the front axle crossmember 50 mm.

  1. Disconnect the hydraulic pressure unit (HPU) and clutch actuator position sensor electrical connectors.

  1. Disconnect the gearshift actuator and HPU valves electrical connectors.

  1. Detach the gearshift actuator and HPU electrical connectors from the HPU retaining bracket.

  1. WARNING:
    WARNING:Wear protective safety goggles when cleaning components with compressed air. Failure to follow this instruction may result in personal injury.
    Thoroughly clean the HPU surface and dry using dry regulated compressed air.

  1. Disconnect the HPU hydraulic fluid supply hose.

  1. CAUTION:
    CAUTION:Do not use the special tool as a lever.
    CAUTION:
    CAUTION:Plug the HPU to prevent fluid loss and dirt ingress.
    Using the special tool, disconnect the gearshift hydraulic fluid lines from the HPU.
    • Slide the special tool into the connection to release the line.

  1. Detach the HPU from the retaining bracket.

  1. Remove the HPU.

Installation
  1. Install the hydraulic pressure unit (HPU).

  1. Attach the HPU to the retaining bracket.

  1. NOTE:
    NOTE:Make sure that the gearshift hydraulic fluid line snap rings are correctly engaged.
    Connect the gearshift hydraulic fluid lines to the HPU.

  1. Connect the HPU hydraulic fluid supply hose.

  1. Remove the brake hose clamp from the hydraulic fluid reservoir hose.

  1. Bleed the HPU (bleed nipple shown without a bleed tube and bleed jar for clarity) in the following sequence.
    1. Remove the HPU bleed nipple dust cap.
    1. Loosen the bleed nipple until hydraulic fluid flows.
    1. Tighten the bleed nipple.
    1. Install the bleed nipple dust cap.

  1. Connect the gearshift actuator and HPU valves electrical connectors.

  1. Attach the gearshift actuator and HPU electrical connectors to the HPU retaining bracket.

  1. Connect the HPU and clutch actuator position sensor electrical connectors.

  1. Using a suitable transmission jack, raise the front axle crossmember.

  1. Install the front axle crossmember retaining bolts (left-hand side shown).

  1. Tighten the front axle crossmember retaining nuts (left-hand side shown).

  1. Remove the transmission jack.

  1. Install the driveshaft center bearing retaining bolts.
  1. Lower the vehicle.

  1. Install the transmission control module (TCM) fuse.
    • Install the battery junction box (BJB) cover.

  1. Fill the gearshift hydraulic fluid reservoir with hydraulic fluid to the MAX mark.
  1. Using worldwide diagnostic system (WDS), bleed the gearshift system.
  1. Using WDS, allow the TCM to relearn the clutch parameters.

  1. Check the fluid level in the gearshift hydraulic fluid reservoir and top up to the MAX mark with hydraulic fluid if necessary.

Hydraulic Pressure Accumulator > < Automated Gearshift System