Ford Fusion Manuals

Ford Fusion: Automatic Transmission - 6-Speed Automatic Transmission – 6F35 / Transmission. Overhaul

Special Tool(s) / General Equipment

Ford Fusion. Transmission. Overhaul 100-001 (T50T-100-A)
Slide Hammer
Ford Fusion. Transmission. Overhaul 100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
Ford Fusion. Transmission. Overhaul 205-153 (T80T-4000-W)
Handle
Ford Fusion. Transmission. Overhaul 211-061 (T78P-3504-N1)
Remover, Roll Pin
Ford Fusion. Transmission. Overhaul 303-D011 (D80L-100-G)
Actuator Pin (Dia 3/16)
Ford Fusion. Transmission. Overhaul 303-D019 (D80L-100-Q)
Collet, 3/4 to 7/8
Ford Fusion. Transmission. Overhaul 307-003 (T57L-500-B)
Holding Fixture, Transmission
Ford Fusion. Transmission. Overhaul 307-091
Handle, Torque Converter
TKIT-2009TC-F
Ford Fusion. Transmission. Overhaul 307-300
Gauge Bar, Shim Selection
TKIT-1994-LMH/MH2
TKIT-1994-F
TKIT-1994-FLM/FM
Ford Fusion. Transmission. Overhaul 307-566
Retainer, Torque Converter
TKIT-2006C-FFMFLM
TKIT-2006C-LM
TKIT-2006C-ROW
Ford Fusion. Transmission. Overhaul 307-574
Forward Clutch Spring Compressor
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Ford Fusion. Transmission. Overhaul 307-578
Input Shaft Support Seal Installer (Back Plate, Multiple rings)
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Ford Fusion. Transmission. Overhaul 307-581
Manual lever seal installer
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Ford Fusion. Transmission. Overhaul 307-584
2-6 Spring Compressor
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Ford Fusion. Transmission. Overhaul 307-589
Overdrive clutch and balance piston service set
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Ford Fusion. Transmission. Overhaul 307-625
Fixture, Bench Mounting
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-626
Installer, Differential Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-627
Installer, Converter Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-628
Protector, Low Reverse Piston Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-629
Protector, Low Reverse / 1-2-3-4 Piston Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-630
Center Support Piston Spring Tool
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-632
Protector, 2-6 Piston Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-633
2-6 Piston return spring Comp
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-635
Protector, Turbine Shaft Seal
TKIT-2008ET-FLM
TKIT-2008ET-ROW
Ford Fusion. Transmission. Overhaul 307-691
Tester, Torque Convertor Leak
Ford Fusion. Transmission. Overhaul 307-718
Installer, Axle Seal
TKIT-2013B-FL
TKIT-2013B-ROW
Ford Fusion. Transmission. Overhaul 307-723
Installer, Turbine Seal
TKIT-2014A-FL
Ford Fusion. Transmission. Overhaul 307-732
Tool Kit, Torque Converter Flusher
Flat Headed Screw Driver
Magnetic Socket
Hydraulic Press
Long Nose Pliers
Puller
Punch

Materials

Name Specification
Motorcraft® Ultra Silicone Sealant
TA-29
WSS-M4G323-A8
 
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC
WSS-M2C938-A
MERCON® LV,
 

All vehicles

  1. For information on component views and base part numbers.
    Refer to: Transmission Description (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Description and Operation).
  1. NOTE: Use M10 x 1.5 x 25mm bolts to attach the special tool to the transmission case.

    Install the special tool.
    Use Special Service Tool: 307-732  Tool Kit, Torque Converter Flusher. , 307-625  Fixture, Bench Mounting.
Ford Fusion. Transmission. Overhaul
  1. Mount the transmission to the bench-mounted holding fixture.
    Use Special Service Tool: 307-003 (T57L-500-B)  Holding Fixture, Transmission. , 307-625  Fixture, Bench Mounting.
Ford Fusion. Transmission. Overhaul
  1. Remove the special tool.
    Use Special Service Tool: 307-566  Retainer, Torque Converter.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.

    Using the special tools, remove the torque converter from the transmission.
    Use Special Service Tool: 307-091  Handle, Torque Converter.
Ford Fusion. Transmission. Overhaul

  1. A new or remanufactured torque converter must be installed if one or more of the following statements are true:
    • The sealing surface has a groove worn from the seal.
    • A torque converter malfunction has been determined based on complete diagnostic procedures.
    • The torque converter stud or studs, threaded pads, impeller hub or bushing are damaged.
    • The torque converter exhibits external discoloration (due to overheating).
    • There is evidence of water or antifreeze contamination.
Ford Fusion. Transmission. Overhaul

Flush The Torque Converter With The Transmission Cooling System Heated Flusher

  1. NOTE: Use transmission fluid specified for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail, which will affect the operation of the transmission.

    The torque converter must be flushed every time the transmission is overhauled. It is mandatory that proper equipment and procedures be followed when flushing the torque converter. The flushing equipment used MUST:
    • Maintain the transmission fluid at 140°F or above
    • Pulsate the transmission fluid during cleaning
    • Have a GPM flow meter
    • Have a filter with a rating of 100 micron or less
    • Have air purge capability before and after flushing
  1. If equipment meeting the specifications above is not available, the torque converter must be flushed by hand. Go to Flush The Torque Converter By Hand steps later in this procedure.
  1. Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.
  1. Turn on the heater and allow the transmission fluid in the transmission cooling system heated flusher 15-30 minutes to heat up to 60°C (140°F) before using.
  1. Place the torque converter in an arbor press. Support the torque converter on the mounting pads.
Ford Fusion. Transmission. Overhaul
  1. Using the special tools, assemble the correct turbine shaft simulator to the torque converter flush main hub and place it on the torque converter hub.
    Use Special Service Tool: 307-732  Tool Kit, Torque Converter Flusher.
Ford Fusion. Transmission. Overhaul
  1. Using the special tool, install the slotted cap.
    Use Special Service Tool: 307-691  Tester, Torque Convertor Leak.
Ford Fusion. Transmission. Overhaul
  1. Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.
Ford Fusion. Transmission. Overhaul

  1. Connect the flush machine to the main hub.
    1. Red hose on top.
    1. Blue hose on bottom.
Ford Fusion. Transmission. Overhaul
  1. Follow the equipment instructions to purge transmission fluid from the torque converter prior to starting the flushing procedure.
  1. Ford Fusion. Transmission. Overhaul  WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.

    NOTE: Maintain visual contact with torque converter during the entire flush procedure. Immediately stop the flush machine if a leak develops. Repeat set up steps to reseal the tool to the converter hub and continue flushing.

    Forward flush the converter for 15 minutes.
  1. Monitor GPM flow meter periodically during the flush procedure. Flow rate above 2.0 gallons per minute is required to break up and dislodge any contamination trapped behind the TCC plate. Service flush machine filter(s) if flow rate drops below 2 GPM.
  1. Follow the equipment instructions to purge the torque converter.
  1. Ford Fusion. Transmission. Overhaul  WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.

    Allow torque converter and equipment to cool for 30 minutes before handling.
  1. Disconnect the hoses and remove the special tools.

Flush The Torque Converter By Hand

NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.

NOTE: Only flush the torque converter by hand when the transmission cooling system heated flusher is not available.

  1. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
  1. Examine the transmission fluid for contaminants. The transmission fluid must be free of metallic contaminants. If metallic contaminants are present, do not continue with hand flushing. The torque converter must be flushed with the transmission cooling system heated flusher.
  1. Drain the remaining transmission fluid from the torque converter.
  1. Using only the recommended transmission fluid, add 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. Thoroughly drain the transmission fluid.

Auto-Start-Stop

NOTE: On some vehicles the transmission fluid auxiliary pump is removed during the transmission removal.

  1. NOTICE: Do not use power tools to remove the transmission fluid auxiliary pump bolts or damage can occur.


    Remove the bolts and the transmission fluid auxiliary pump.
    1. Apply heat to the bolts to soften the Loctite®.
    1. Remove and discard the bolts.
Ford Fusion. Transmission. Overhaul
  1. Remove the transmission fluid auxiliary pump gasket.
Ford Fusion. Transmission. Overhaul
  1. Remove the transmission fluid auxiliary pump supply tube assembly.
Ford Fusion. Transmission. Overhaul

All vehicles

  1. NOTE: Note the location of the stud bolts for assembly.

    Remove the main control cover bolts and the main control cover.
Ford Fusion. Transmission. Overhaul
  1. Disconnect the OSS sensor electrical connector.
Ford Fusion. Transmission. Overhaul
  1. Disconnect the TR sensor electrical connector.
Ford Fusion. Transmission. Overhaul
  1. Remove the main control-to-cover seal.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: If the transmission internal wiring harness frame has melted due to overheat condition the transmission and cooler must be replaced.

    NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.

    Remove the main control nut and the main control-to-transmission case bolts and remove the main control assembly.
Ford Fusion. Transmission. Overhaul
  1. Inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it.
    Refer to: Main Control Valve Body (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Overhaul).
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the main control-to-transmission case separator plate.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transmission case seals.
Ford Fusion. Transmission. Overhaul
  1. Remove the TSS sensor bolt and the TSS sensor.
Ford Fusion. Transmission. Overhaul
  1. Remove the TR sensor detent spring bolt and the TR sensor detent spring.
Ford Fusion. Transmission. Overhaul
  1. Remove the OSS sensor bolt and the OSS sensor.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the location of the stud bolts for assembly.

    Remove the torque converter housing bolts.
Ford Fusion. Transmission. Overhaul
  1. Pry the torque converter housing loose from the transmission case.
Ford Fusion. Transmission. Overhaul
  1. Remove the torque converter housing from the transmission case.
Ford Fusion. Transmission. Overhaul
  1. Remove the No. 15 differential thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the differential assembly.
Ford Fusion. Transmission. Overhaul
  1. Check that the bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear. Install a new differential, if necessary.
Ford Fusion. Transmission. Overhaul
  1. Remove the differential sun gear.
Ford Fusion. Transmission. Overhaul
  1. Inspect the differential sun gear for damage or wear and install new, as necessary.
Ford Fusion. Transmission. Overhaul
  1. NOTE: If the transmission plastic baffle has melted due to overheat condition the transmission and cooler must be replaced.

    Remove the differential transmission fluid baffle.
Ford Fusion. Transmission. Overhaul
    1. Remove the No. 13 thrust washer.
    1. Remove the No. 11 drive sprocket thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Simultaneously remove the drive and driven sprockets and the chain.
Ford Fusion. Transmission. Overhaul
  1. Remove the drive chain from the drive and driven sprockets.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
    • Check for stretching or tightness of the chain links.
    • Check that the chain moves freely.
Ford Fusion. Transmission. Overhaul

  1. Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
    • Chain teeth
    • Spline teeth
    • Thrust bearing surfaces
    • Bearing
Ford Fusion. Transmission. Overhaul
  1. Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
Ford Fusion. Transmission. Overhaul

  1. Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
    • Chain teeth
    • Spline teeth
    • Thrust washer surface
Ford Fusion. Transmission. Overhaul

  1. Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if necessary.
    • Park gear teeth
    • Spline teeth
    • Thrust washer surface
    • Thrust bearing surface
    • Bearing surfaces
    • Needle bearing
Ford Fusion. Transmission. Overhaul
  1. Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
Ford Fusion. Transmission. Overhaul
  1. Install the drive chain on the drive and driven sprockets.
Ford Fusion. Transmission. Overhaul
    1. Remove the No. 12 driven sprocket thrust bearing.
    1. Remove the No. 10 front sun gear and shell assembly thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the fluid reservoir bolts and the fluid reservoir.
Ford Fusion. Transmission. Overhaul
  1. Remove the transmission fluid baffle bolts and the transmission fluid baffle.
Ford Fusion. Transmission. Overhaul
  1. Remove the park pawl pin and spring.
Ford Fusion. Transmission. Overhaul
  1. Remove the park pawl.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).

    NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.

    Remove the forward (1, 2, 3, 4) clutch snap ring.
Ford Fusion. Transmission. Overhaul
  1. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
Ford Fusion. Transmission. Overhaul
  1. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
Ford Fusion. Transmission. Overhaul
  1. Remove the front planetary sun gear and shell assembly.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, as necessary.
    • Gear teeth
    • Shell-to-clutch pack surfaces
    • Thrust bearing surfaces
Ford Fusion. Transmission. Overhaul
  1. Remove the front planetary carrier/rear ring gear assembly.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the front planetary carrier/rear ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing
    • Thrust bearing surfaces
    • Ring gear teeth
Ford Fusion. Transmission. Overhaul
    1. Remove the No. 7 thrust bearing.
    1. Remove the No. 8 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the center planetary carrier/front ring gear assembly.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the center planetary carrier/front ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing surfaces
    • Ring gear teeth
Ford Fusion. Transmission. Overhaul
  1. Remove the center planetary sun gear.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
Ford Fusion. Transmission. Overhaul
    1. Remove the No. 5 thrust bearing.
    1. Remove the No. 6 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the center support assembly.
Ford Fusion. Transmission. Overhaul
  1. Remove the rear planetary carrier/center ring gear assembly.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the rear planetary carrier/center ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing surfaces
    • Thrust bearing
Ford Fusion. Transmission. Overhaul
  1. Remove the low/reverse wave spring, clutch pack and pressure plate.
Ford Fusion. Transmission. Overhaul
  1. Inspect the low/reverse clutch pack and pressure plate surface for damage or excessive wear and install new, if necessary.
Ford Fusion. Transmission. Overhaul
  1. Remove the low One-Way Clutch (OWC).
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Do not clean in water or with water-based solvents. Damage to the component may occur.

    NOTE: The low One-Way Clutch (OWC) should not be disassembled.

    Clean and inspect the low One-Way Clutch (OWC) for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new low One-Way Clutch (OWC).
Ford Fusion. Transmission. Overhaul
  1. Inspect the intermediate (2, 6) clutch surface for damage. If the surface is burned or worn excessively, install a new low One-Way Clutch (OWC).
Ford Fusion. Transmission. Overhaul
  1. NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.

    Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
Ford Fusion. Transmission. Overhaul
  1. Inspect the intermediate (2, 6) clutch surface for damage or excessive wear and install new, if necessary.
Ford Fusion. Transmission. Overhaul

  1. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, if necessary.
    • Sun gear teeth
    • Shell-to-clutch pack surfaces
    • Bearing surfaces
Ford Fusion. Transmission. Overhaul
  1. Remove the pressure plate and the wave spring.
Ford Fusion. Transmission. Overhaul
  1. Inspect the pressure plate surface for damage or excessive wear and install new, if necessary.
Ford Fusion. Transmission. Overhaul
  1. Remove the No. 3 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive/direct clutch assembly.
Ford Fusion. Transmission. Overhaul
  1. NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.

    Remove the No. 1 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the intermediate (2, 6) clutch apply ring.
Ford Fusion. Transmission. Overhaul
  1. Remove the clutch support tower bolts and the clutch support tower.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the location of the snap ring gap for assembly.

    Remove the intermediate (2, 6) clutch return spring snap ring.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the position of the return spring for assembly.

    Remove the intermediate (2, 6) clutch return spring.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the position of the intermediate clutch piston for assembly.

    Remove the intermediate (2, 6) clutch piston.
    Use the General Equipment: Long Nose Pliers
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the clutch feed seals.
Ford Fusion. Transmission. Overhaul
  1. Remove the manual control lever nut and the manual control lever from the manual control shaft.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transmission case causing damage to the transmission case.

    Using the special tool, pull the manual control shaft pin out of the manual control shaft.
    Use Special Service Tool: 211-061 (T78P-3504-N1)  Remover, Roll Pin.
Ford Fusion. Transmission. Overhaul
  1. Remove the manual control shaft.
Ford Fusion. Transmission. Overhaul
  1. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the manual control shaft seal.
    Use the General Equipment: Flat Headed Screw Driver
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the LH halfshaft seal.
Ford Fusion. Transmission. Overhaul
    • NOTICE: If the LH transmission case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transmission case bushing and a new LH halfshaft must be installed, or excessive noise or transmission failure can occur.

      Clean and inspect the LH transmission case bushing and the bushing surface on the LH halfshaft for damage or excessive wear. If the LH transmission case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components.
      Refer to: Transmission Case (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Disassembly and Assembly of Subassemblies).
    • NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

      Make sure that the mating faces are clean and free of foreign material.
      Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
Ford Fusion. Transmission. Overhaul
  1. Remove the pump-to-torque converter housing bolts and the pump and filter assembly.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the RH halfshaft seal.
Ford Fusion. Transmission. Overhaul
    • Inspect the torque converter housing and the differential ring gear for damage or excessive wear. If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear.
      Refer to: Transmission Case (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Disassembly and Assembly of Subassemblies).
    • NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

      Make sure that the mating faces are clean and free of foreign material.
      Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the orientation of the transmission fluid filter to the fluid pump assembly.

    Rotate the transmission fluid filter 90 degrees clockwise and pull the transmission fluid filter out of the pump assembly.
Ford Fusion. Transmission. Overhaul
  1. Remove the magnet from the transmission fluid filter and discard the transmission fluid filter.
Ford Fusion. Transmission. Overhaul
  1. Assemble the special tools and remove and discard the input shaft seal.
    Use Special Service Tool: 100-001 (T50T-100-A)  Slide Hammer. , 303-D011 (D80L-100-G)  Actuator Pin (Dia 3/16). , 303-D019 (D80L-100-Q)  Collet, 3/4 to 7/8.
Ford Fusion. Transmission. Overhaul
  1. Remove the pump assembly-to-torque converter housing O-ring seal.
Ford Fusion. Transmission. Overhaul
  1. Remove the torque converter hub seal snap ring.
Ford Fusion. Transmission. Overhaul
  1. Using a dent puller, remove the torque converter hub seal.
    Use the General Equipment: Puller
Ford Fusion. Transmission. Overhaul
  1. Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Loosen the pump bolts.
Ford Fusion. Transmission. Overhaul
  1. Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
Ford Fusion. Transmission. Overhaul
  1. Remove the pump bolts and separate the pump assembly halves.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The dot on the inner pump gear faces up.

    Remove the pump gears.
Ford Fusion. Transmission. Overhaul
  1. Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a magnet.
    Use the General Equipment: Flat Headed Screw Driver
    Use the General Equipment: Magnetic Socket
Ford Fusion. Transmission. Overhaul
  1. Install a M4 bolt in the valve and remove the main pressure regulator valve assembly.
Ford Fusion. Transmission. Overhaul
  1. Compress the TCC control valve spring with a screw driver and remove the retainer with a magnet.
    Use the General Equipment: Flat Headed Screw Driver
    Use the General Equipment: Magnetic Socket
Ford Fusion. Transmission. Overhaul
  1. Remove the TCC control valve assembly.
Ford Fusion. Transmission. Overhaul
  1. Clean and dry all of the pump assembly components.
  1. Inspect the inner and the outer pump gears for damage or excessive wear and install new, if necessary.
Ford Fusion. Transmission. Overhaul

  1. Inspect the pump housing for damage or excessive wear and install new, as necessary.
    • Inner and outer pump gear to pump housing surface.
Ford Fusion. Transmission. Overhaul
  1. Inspect the torque converter hub bushing for damage or excessive wear and install new, as necessary.
Ford Fusion. Transmission. Overhaul

    1. Inspect the aluminum pump housing near the TCC control valve for scoring or blockage.
    1. Using a straight edge, inspect the aluminum pump housing near the TCC control valve for evidence of any surface warping possibly causing internal pressure leaks. Inspect the hydraulic passages for blockage.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Make sure the valves and the pump housing are clean and dry.

    Install the TCC control valve and the main pressure regulator valve in the pump housing. Verify each valve moves freely in the pump housing bore and falls out under its own weight.
Ford Fusion. Transmission. Overhaul
  1. Using a straight edge, inspect the pump housing for evidence of surface warping at the case to pump seal area.
Ford Fusion. Transmission. Overhaul
  1. Inspect the stator bushing for damage or excessive wear and install new, as necessary.
Ford Fusion. Transmission. Overhaul
  1. Inspect the turbine shaft support bushing for wear or scoring that might cause pressure leaks and install new, as necessary.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The TCC control valve retainer is shown assembled in the pump body, the main pressure regulator valve retainer is similar.

    Assemble the TCC control valve assembly and main pressure regulator valve assembly and install the valves in the pump. Compress the valve springs with a screw driver and install the retainers.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The dot on the inner pump gear faces up.

    Install the pump gears.
Ford Fusion. Transmission. Overhaul
  1. Position the stator support on the pump housing and install the pump bolts hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Install the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Tighten the pump bolts.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Transmission. Overhaul
  1. Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
Ford Fusion. Transmission. Overhaul
  1. Install a new torque converter hub seal on the special tool.
    Use Special Service Tool: 307-627  Installer, Converter Seal.
Ford Fusion. Transmission. Overhaul
  1. Using the special tool, install a new torque converter hub seal.
    Use Special Service Tool: 307-627  Installer, Converter Seal.
Ford Fusion. Transmission. Overhaul
  1. Install the torque converter hub seal snap ring.
Ford Fusion. Transmission. Overhaul
  1. Install a new pump assembly-to-torque converter housing O-ring seal.
Ford Fusion. Transmission. Overhaul
  1. Install a new input shaft seal on the special tool.
    Use Special Service Tool: 307-723  Installer, Turbine Seal.
Ford Fusion. Transmission. Overhaul
  1. Using the special tool, install the input shaft seal.
    Use Special Service Tool: 307-723  Installer, Turbine Seal.
Ford Fusion. Transmission. Overhaul
  1. Install a new O-ring on a new transmission fluid filter and lubricate it with transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. Install the magnet on the transmission fluid filter.
Ford Fusion. Transmission. Overhaul

  1. Install the new transmission fluid filter.
    1. Position the transmission fluid filter in the pump assembly.
    1. Rotate the transmission fluid filter counterclockwise 90 degrees.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.

    NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.

    Using the special tool and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer.
    Use Special Service Tool: 307-630  Center Support Piston Spring Tool.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Remove the low/reverse clutch return spring.
Ford Fusion. Transmission. Overhaul
  1. Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the low/reverse clutch piston.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.

    Using the special tool and a press, compress the forward (1,2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer.
    Use Special Service Tool: 307-630  Center Support Piston Spring Tool.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Remove the return spring from the forward (1, 2, 3, 4) clutch piston.
Ford Fusion. Transmission. Overhaul
  1. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the forward (1, 2, 3, 4) clutch piston.
Ford Fusion. Transmission. Overhaul
  1. Clean and inspect the center support for damage. Install a new center support if necessary.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.

    Install the special tools on the forward clutch piston side of the center support.
    Use Special Service Tool: 307-628  Protector, Low Reverse Piston Seal. , 307-629  Protector, Low Reverse / 1-2-3-4 Piston Seal.
Ford Fusion. Transmission. Overhaul
  1. Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly.
Ford Fusion. Transmission. Overhaul
  1. Position the forward (1, 2, 3, 4) clutch piston on the special tools and push it down into the center support.
    Use Special Service Tool: 307-628  Protector, Low Reverse Piston Seal. , 307-629  Protector, Low Reverse / 1-2-3-4 Piston Seal.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.

    Install the forward (1, 2, 3, 4) clutch piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Using the special tools and a press, compress the forward (1,2, 3, 4) clutch return spring and install the snap ring retainer and the snap ring.
    Use Special Service Tool: 307-630  Center Support Piston Spring Tool.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Inspect the snap ring to be sure it is seated in the groove on the center support.
    Use the General Equipment: Flat Headed Screw Driver
Ford Fusion. Transmission. Overhaul
  1. Turn the center support over and install the special tools on the low/reverse piston side of the center support.
    Use Special Service Tool: 307-628  Protector, Low Reverse Piston Seal.
Ford Fusion. Transmission. Overhaul
  1. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly.
Ford Fusion. Transmission. Overhaul
  1. Position the low/reverse clutch piston on the special tools and push it down into the center support.
    Use Special Service Tool: 307-628  Protector, Low Reverse Piston Seal.
Ford Fusion. Transmission. Overhaul
  1. Install the low/reverse piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Using the special tools and a press, compress the low/reverse clutch return spring and install the snap ring retainer and the snap ring.
    Use Special Service Tool: 307-630  Center Support Piston Spring Tool.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Inspect the snap ring to be sure it is seated in the groove on the center support.
    Use the General Equipment: Flat Headed Screw Driver
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the 4 Teflon® seals.
Ford Fusion. Transmission. Overhaul
  1. Clean and inspect the clutch support tower for damage. Install a new clutch support tower if damaged.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the clutch support tower and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove.
    Use Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Install a new Teflon® seal on the special tool.
    Use Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Install the special tool 307-578/2 over 307-578/3. Using the special 307-578/2, slide the Teflon® seal over the clutch support tower and into the groove.
    Use Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Remove tools and repeat steps for the other 3 Teflon® seals.
    Use Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the clutch support tower to size the 4 Teflon® seals.
    Use Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Remove the input shaft snap ring.
Ford Fusion. Transmission. Overhaul
  1. Remove the input shaft.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive (4, 5, 6) clutch hub.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive (4, 5, 6) clutch hub, No. 2 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive (4, 5, 6) clutch snap ring.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive (4, 5, 6) clutch pressure plate and clutch assembly.
Ford Fusion. Transmission. Overhaul
  1. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
Ford Fusion. Transmission. Overhaul
  1. Install the special tools on the balance piston.
    Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
Ford Fusion. Transmission. Overhaul
  1. Using a press, compress the overdrive (4, 5, 6) clutch return spring and remove the snap ring.
    Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the balance piston.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive (4, 5, 6) piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Install the clutch support tower in the transmission case and install the clutch support tower bolts.
    Torque: 106 lb.in (12 Nm)
Ford Fusion. Transmission. Overhaul
  1. Remove the special tool.
    Remove Special Service Tool: 307-578  Input Shaft Support Seal Installer (Back Plate, Multiple rings).
Ford Fusion. Transmission. Overhaul
  1. Install the No. 1 overdrive/direct clutch assembly thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Position the overdrive/direct clutch assembly in the transmission case.
Ford Fusion. Transmission. Overhaul
  1. Apply compressed air to the overdrive (4, 5, 6) clutch piston port and remove the overdrive (4, 5, 6) clutch piston.
Ford Fusion. Transmission. Overhaul
  1. Remove the overdrive/direct clutch assembly from the transmission case.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the overdrive (4, 5, 6) clutch piston seal from the overdrive/direct clutch assembly.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the seals from the overdrive (4, 5, 6) clutch piston.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.


    Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    1. Remove the snap ring.
      Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
      Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Remove the direct (3, 5, R) clutch cylinder.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the direct (3, 5, R) clutch piston.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the position of the return spring for assembly. The flat side faces down.

    Remove the direct (3, 5, R) clutch piston return spring.
Ford Fusion. Transmission. Overhaul

  1. Remove the direct (3, 5, R) clutch snap ring.
    1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
    1. Using a tool, compress the snap ring.
    1. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    1. Remove the snap ring.
Ford Fusion. Transmission. Overhaul
  1. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
Ford Fusion. Transmission. Overhaul
  1. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
Ford Fusion. Transmission. Overhaul
  1. Remove and discard the direct (3, 5, R) clutch piston seals.
Ford Fusion. Transmission. Overhaul
  1. Clean and inspect the overdrive/direct clutch assembly for damage or excessive wear and install new components as necessary.
Ford Fusion. Transmission. Overhaul
  1. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
Ford Fusion. Transmission. Overhaul
  1. Install the direct (3, 5, R) clutch wave spring.
Ford Fusion. Transmission. Overhaul
  1. Soak the direct (3, 5, R) clutch pack in transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. Install the direct (3, 5, R) clutch assembly and pressure plate.
Ford Fusion. Transmission. Overhaul

  1. Install the direct (3, 5, R) clutch snap ring.
    1. Compress the snap ring.
    1. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
    1. Release the tension on the snap ring.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.

    Install the direct (3, 5, R) clutch piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
Ford Fusion. Transmission. Overhaul
  1. Install the direct (3, 5, R) clutch cylinder.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.


    Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    1. Install the snap ring.
      Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
      Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Install new seals on the overdrive (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
Ford Fusion. Transmission. Overhaul
  1. Install a new overdrive (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
Ford Fusion. Transmission. Overhaul
  1. Position the overdrive (4, 5, 6) clutch piston in place.
Ford Fusion. Transmission. Overhaul
  1. Using the special tools, install the overdrive (4, 5, 6) clutch piston into the overdrive/direct clutch assembly by hand.
    Use Special Service Tool: 307-589  Overdrive clutch and balance piston service set.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.

    Install the overdrive (4, 5, 6) clutch piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Lubricate the seals on a new balance piston and position the piston in place.
Ford Fusion. Transmission. Overhaul
  1. Install the special tools on the balance piston.
    Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
Ford Fusion. Transmission. Overhaul
  1. Using a press, compress the overdrive (4, 5, 6) clutch return spring and install the snap ring.
    Use Special Service Tool: 307-584  2-6 Spring Compressor. , 307-589  Overdrive clutch and balance piston service set.
    Use the General Equipment: Hydraulic Press
Ford Fusion. Transmission. Overhaul
  1. Install the No. 2 thrust bearing.
Ford Fusion. Transmission. Overhaul
  1. Install the overdrive (4, 5, 6) clutch hub.
Ford Fusion. Transmission. Overhaul
  1. Soak the overdrive (4, 5, 6) clutch pack in transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. Install the overdrive (4, 5, 6) clutch pack.
Ford Fusion. Transmission. Overhaul
  1. Install the overdrive (4, 5, 6) clutch pressure plate.
Ford Fusion. Transmission. Overhaul
  1. Install the overdrive (4, 5, 6) clutch snap ring.
Ford Fusion. Transmission. Overhaul
  1. Install the input shaft.
Ford Fusion. Transmission. Overhaul
  1. While holding the input shaft in place, install the snap ring.
Ford Fusion. Transmission. Overhaul
  1. Position the overdrive/direct clutch assembly in the transmission case, install the special tool or a dial indicator and position the plunger on the overdrive (4, 5, 6) clutch pressure plate.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. NOTE: The dial indicator plunger is positioned on the overdrive (4, 5, 6) clutch pressure plate.

    Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator. The clearance should be between 1.71 mm (0.067 in) and 3.61 mm (0.142 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. Remove the special tool, overdrive/direct clutch assembly and the No. 1 overdrive/direct clutch assembly thrust bearing.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. Assemble the special tools. Install a new LH halfshaft seal on the special tool.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-626  Installer, Differential Seal.
Ford Fusion. Transmission. Overhaul
  1. Using the special tools, install the new LH halfshaft seal in the transmission case.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-626  Installer, Differential Seal.
Ford Fusion. Transmission. Overhaul
  1. Install a new manual control shaft seal on the special tool.
    Use Special Service Tool: 307-581  Manual lever seal installer.
Ford Fusion. Transmission. Overhaul
  1. Using the special tool, install the new manual control shaft seal in the transmission case.
    Use Special Service Tool: 307-581  Manual lever seal installer.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool.
    Use Special Service Tool: 307-632  Protector, 2-6 Piston Seal.
Ford Fusion. Transmission. Overhaul
  1. Lubricate the seals on the intermediate (2, 6) clutch piston with transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.

    Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transmission case.
Ford Fusion. Transmission. Overhaul

  1. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transmission case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Inner double tabs
    1. Bleed hole
    1. Outer tabs
Ford Fusion. Transmission. Overhaul
  1. Remove the intermediate (2, 6) clutch piston return spring.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the intermediate (2, 6) clutch piston. Push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
    Use Special Service Tool: 307-584  2-6 Spring Compressor.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transmission can occur.


    Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Inner double tabs
    1. Bleed hole
    1. Outer tabs
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3,4) clutch hydraulic ports are located.


    Position the snap ring in place. Align the gap of the snap ring to face the front of the transmission.
    1. Snap ring
    1. Snap ring gap
    1. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transmission case)
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the transmission case to center the intermediate (2, 6) clutch return spring.
    Use Special Service Tool: 307-633  2-6 Piston return spring Comp.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the snap ring.
    Use Special Service Tool: 307-633  2-6 Piston return spring Comp.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the transmission case.
    Use Special Service Tool: 307-574  Forward Clutch Spring Compressor.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.

    Using the special tools, install the intermediate (2, 6) clutch snap ring in the groove.
    Use Special Service Tool: 307-574  Forward Clutch Spring Compressor. , 307-633  2-6 Piston return spring Comp.
Ford Fusion. Transmission. Overhaul
  1. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.

    Install the No. 1 thrust bearing with the flat side facing up.
Ford Fusion. Transmission. Overhaul
  1. Install the overdrive/direct clutch assembly.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.

    Install the No. 3 thrust bearing with the flat side facing down.
Ford Fusion. Transmission. Overhaul
  1. Install the direct/intermediate clutch hub and rear sun gear assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the intermediate (2, 6) wave spring assembly.
Ford Fusion. Transmission. Overhaul
  1. Soak the intermediate (2, 6) clutch assembly in transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul

  1. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    1. Steel plate
    1. Friction plate
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the transmission case.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth gauge, measure and record as measurement A, the distance from the special tool to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the transmission case step above the intermediate (2, 6) clutch.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and check to see if it is within range of 0.240mm (0.009 in) and 2.60 mm (0.102 in)  
  1. Remove the top intermediate (2, 6) clutch friction and steel plate.
Ford Fusion. Transmission. Overhaul
  1. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.


    Install the top intermediate (2, 6) clutch friction and steel plate correctly back in the transmission case.
    1. Friction plate
    1. Steel plate
Ford Fusion. Transmission. Overhaul
  1. Install the One-Way Clutch (OWC) assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the rear planetary carrier/center ring gear assembly.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the One-Way Clutch (OWC).

    Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the One-Way Clutch (OWC) and install the low/reverse pressure plate.
Ford Fusion. Transmission. Overhaul
  1. Soak the low/reverse clutch in transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul

  1. Align the low/reverse clutch pack with the pressure plate and install it in the transmission case temporarily reversing the wave spring and top steel plate.
    1. Steel plate.
    1. Wave spring.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the side of the center support with the long support legs.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth gauge, measure and record as measurement A, the distance from the top of the special tool to the contact surface of the low/reverse clutch piston.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the leg surface of the center support.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Subtract measurement B from measurement A and record as measurement C.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and record as measurement C  
  1. Install the special tool on the transmission case.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth micrometer, measure and record as measurement D, the distance from the special tool to the top of the One-Way Clutch (OWC).
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Using a depth gauge, measure and record as measurement E, the distance from the top of special tool to the top of the low/reverse clutch at 3 different points and average the 3 distances.
    Use Special Service Tool: 307-300  Gauge Bar, Shim Selection.
Ford Fusion. Transmission. Overhaul
  1. Subtract measurement E from measurement D and record as measurement F.
    Description Reading
    Measurement D  
    Measurement E  
    Subtract measurement E from measurement D and record as measurement F  
  1. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement C  
    Measurement F  
    Subtract measurement F from measurement C and check to see if it is within range of 0.406mm (0.015 in) and 2.000 mm (0.078 in)  
  1. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.


    Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transmission case.
    • Wave spring
    • Steel plate
Ford Fusion. Transmission. Overhaul
  1. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transmission.


    Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transmission case.
    1. Long center support legs face down
    1. Feed holes face the front of the transmission case
Ford Fusion. Transmission. Overhaul
    1. Install the No. 5 thrust bearing
    1. Install the No. 6 thrust bearing
Ford Fusion. Transmission. Overhaul
  1. Install the center planetary sun gear.
Ford Fusion. Transmission. Overhaul
  1. Install the center carrier/front ring gear assembly.
Ford Fusion. Transmission. Overhaul
    1. Install the No. 7 thrust bearing
    1. Install the No. 8 thrust bearing
Ford Fusion. Transmission. Overhaul
  1. Install the front planetary/rear ring gear assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the forward (1, 2, 3, 4) clutch wave spring.
Ford Fusion. Transmission. Overhaul
  1. Soak the forward (1, 2, 3, 4) clutch pack in transmission fluid.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Transmission. Overhaul
  1. Install the forward (1, 2, 3, 4) clutch pack.
Ford Fusion. Transmission. Overhaul
  1. Install the forward (1, 2, 3, 4) clutch pressure plate.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transmission.

    Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.
Ford Fusion. Transmission. Overhaul
  1. Seat the snap ring in the snap ring groove.
    Use the General Equipment: Flat Headed Screw Driver
Ford Fusion. Transmission. Overhaul
  1. Install the special tool or a dial indicator on the transmission case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. Install the new low/reverse and forward (1, 2, 3, 4) clutch main control-to-transmission case seals.
Ford Fusion. Transmission. Overhaul
  1. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transmission for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
    Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Make sure the front planetary sun gear and shell assembly is fully engaged into both forward clutch friction plates.

    Install the front planetary sun gear and shell assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the park pawl.
Ford Fusion. Transmission. Overhaul
  1. Install the park pawl pin and spring.
Ford Fusion. Transmission. Overhaul
  1. Install the park pawl actuator rod in the TR sensor. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transmission case.
Ford Fusion. Transmission. Overhaul
  1. Install the manual control shaft and align the manual control shaft pin holes.
Ford Fusion. Transmission. Overhaul
  1. Install the manual control shaft pin.
    Use the General Equipment: Punch
Ford Fusion. Transmission. Overhaul
  1. NOTICE: 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.

    Install the manual control lever and the manual control lever nut.
    Torque: 18 lb.ft ( 24 Nm)
Ford Fusion. Transmission. Overhaul
  1. Install the 5 new clutch feed seals.
Ford Fusion. Transmission. Overhaul
  1. Position the transmission fluid baffle in place and install the transmission fluid baffle bolts.
    Torque: 106 lb.in (12 Nm)
Ford Fusion. Transmission. Overhaul
  1. Position the fluid reservoir in place and install the fluid reservoir bolts.
    Torque: 106 lb.in (12 Nm)
Ford Fusion. Transmission. Overhaul
    1. Install the No. 12 thrust bearing
    1. Install the No. 10 thrust bearing
Ford Fusion. Transmission. Overhaul
    1. Simultaneously install the drive/driven sprocket and chain assembly.
    1. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
Ford Fusion. Transmission. Overhaul
    1. Install the No. 13 thrust washer
    1. Install the No. 11 thrust bearing
Ford Fusion. Transmission. Overhaul
  1. Install the differential transmission fluid baffle.
Ford Fusion. Transmission. Overhaul
  1. Install the differential sun gear.
Ford Fusion. Transmission. Overhaul
  1. Install the differential assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the No. 15 thrust bearing
Ford Fusion. Transmission. Overhaul
  1. Install the special tool on the input shaft.
    Use Special Service Tool: 307-635  Protector, Turbine Shaft Seal.
Ford Fusion. Transmission. Overhaul
  1. NOTE: FWD Vehicles.

    Assemble the special tools and install a new RH halfshaft seal on the special tool.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-718  Installer, Axle Seal.
Ford Fusion. Transmission. Overhaul
  1. NOTE: FWD Vehicles.

    Using the special tools, install the new RH halfshaft seal.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-718  Installer, Axle Seal.
Ford Fusion. Transmission. Overhaul
  1. NOTE: AWD Vehicles.

    Assemble the special tools and install a new RH halfshaft seal on the special tool.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-718  Installer, Axle Seal.
Ford Fusion. Transmission. Overhaul
  1. NOTE: AWD Vehicles.

    Using the special tools, install the new RH halfshaft seal.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-718  Installer, Axle Seal.
Ford Fusion. Transmission. Overhaul
  1. Install the pump and filter assembly in the torque converter housing and install the pump-to-torque converter housing bolts.
    Torque: 26 lb.ft (35 Nm)
Ford Fusion. Transmission. Overhaul
  1. NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.

    Apply silicone to the sealing surface of the transmission case.
    Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)
Ford Fusion. Transmission. Overhaul
  1. Install the torque converter housing on the transmission case.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.

    Install the torque converter housing bolts and the torque converter housing stud bolt.
    Torque: 24 lb.ft (32 Nm)
Ford Fusion. Transmission. Overhaul
  1. Remove the special tool.
    Remove Special Service Tool: 307-635  Protector, Turbine Shaft Seal.
Ford Fusion. Transmission. Overhaul
  1. Install the TSS sensor and the TSS sensor bolt.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Transmission. Overhaul
  1. Install the OSS sensor and the OSS sensor bolt.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Transmission. Overhaul
  1. Install the new main control-to-transmission case separator plate and align it on the stud and the guide pin.
Ford Fusion. Transmission. Overhaul
  1. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.

    Position the main control assembly in place and align the manual valve on the TR sensor.
Ford Fusion. Transmission. Overhaul
  1. Install the main control nut hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Install the short main control-to-transmission case bolts hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Install the long main control-to-transmission case bolts hand-tight.
Ford Fusion. Transmission. Overhaul
  1. Tighten the main control-to-transmission case bolts and the main control nut in a crisscross pattern.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Transmission. Overhaul
  1. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the TR sensor detent spring bolt.
    Torque: 115 lb.in (13 Nm)
Ford Fusion. Transmission. Overhaul
  1. NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.

    Install the main control-to-cover seal.
Ford Fusion. Transmission. Overhaul
  1. Connect the TR sensor electrical connector.
Ford Fusion. Transmission. Overhaul
  1. Connect the OSS sensor electrical connector.
Ford Fusion. Transmission. Overhaul
  1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
Ford Fusion. Transmission. Overhaul
  1. Apply silicone to the main control sealing surface of the transmission case.
    Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)
Ford Fusion. Transmission. Overhaul
  1. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.

    Install the main control cover and the main control cover bolts and stud bolts.
    Torque: 106 lb.in (12 Nm)
Ford Fusion. Transmission. Overhaul

Auto-Start-Stop


  1. Clean and inspect the transmission fluid auxiliary pump supply tube and check ball.
    1. Check ball (part of the transmission fluid auxiliary pump supply tube)
Ford Fusion. Transmission. Overhaul
  1. Install the transmission fluid auxiliary pump supply tube assembly.
Ford Fusion. Transmission. Overhaul
  1. Install the transmission fluid auxiliary pump gasket.
Ford Fusion. Transmission. Overhaul
  1. Install the transmission fluid auxiliary pump and the new bolts.
    Torque: 115 lb.in (13 Nm)
Ford Fusion. Transmission. Overhaul

All vehicles

  1. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.

    Using the special tools, install the torque converter.
    Use Special Service Tool: 307-091  Handle, Torque Converter.
Ford Fusion. Transmission. Overhaul
  1. Install the special tool.
    Use Special Service Tool: 307-566  Retainer, Torque Converter.
Ford Fusion. Transmission. Overhaul
  1. Remove the transmission from the bench-mounted holding fixture.
    Use Special Service Tool: 307-003 (T57L-500-B)  Holding Fixture, Transmission. , 307-625  Fixture, Bench Mounting.
Ford Fusion. Transmission. Overhaul
  1. Remove the special tool.
    Use Special Service Tool: 307-625  Fixture, Bench Mounting.
Ford Fusion. Transmission. Overhaul

    Main Control Valve Body. Overhaul

    Special Tool(s) / General Equipment 307-636Alignment Pins- Valve BodyTKIT-2008ET-FLMTKIT-2008ET-ROW Flat Headed Screw Driver Magnetic Socket Long Nose Pliers Main Control Valve Body and Solenoid Body Remove the solenoid body-to-valve body bolts and separate the solenoid body from the valve body...

    Transmission Case. Disassembly and Assembly of Subassemblies

    Special Tool(s) / General Equipment 205-153 (T80T-4000-W) Handle 206-084Installer, Wheel Speed Sensor RingTKIT-2003-FLM/LMTKIT-2003D-F 307-664Case Bushing InstallerTKIT-2009OP-FLMTKIT-2009OP-ROW Flat Headed Screw Driver Hydraulic Press Materials Name Specification Loctite® 6481835922 WSK-M2G349-A4  DISASSEMBLY NOTE: The transm..

    Other information:

    Ford Fusion 2013–2020 Service Manual: Instrument Panel and Interior Switches Illumination - System Operation and Component Description. Description and Operation


    System Operation System Diagram Item Description 1 FDIM 2 BCM 3 DDM 4 RDM 5 PDM 6 RDM 7 Headlamp Switch 8 Dimmable Components 9 GWM 10 Non-Dimmable Components 11 Non-Dimmable Components 12 Non-Dimmable Components 13 Non-Dimmable Components 14 Light Sensor 15 FCIM 16 APIM 17 ACM ..

    Ford Fusion 2013–2020 Service Manual: Rear Door Tweeter Speaker. Removal and Installation


    Removal NOTE: Removal steps in this procedure may contain installation details. Remove the rear door trim panel. Refer to: Rear Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Release the tabs and remove the front door tweeter speaker. Disconnect the electrical connector. Installation To inst..

    Categories

    Manual Climate Control

    Ford Fusion. Manual Climate Control

    Note: Depending on your vehicle option package, the controls may look different from what you see here.

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