Ford Fusion: Automatic Transmission - 6-Speed Automatic Transmission – 6F35 / Main Control Valve Body. Overhaul

Special Tool(s) / General Equipment

	307-636 Alignment Pins- Valve Body TKIT-2008ET-FLM TKIT-2008ET-ROW
Flat Headed Screw Driver
Magnetic Socket
Long Nose Pliers

Main Control Valve Body and Solenoid Body

1. Remove the solenoid body-to-valve body bolts and separate the solenoid body from the valve body.
   

1. Remove the separator plate-to-solenoid body bolts and remove and discard the separator plate.
   

Main Control Valve Body

1. 
   Remove the check balls, solenoid damper and the spring.
   
   1. Check balls
      
   2. Solenoid damper and spring
      

1. Remove the manual valve.
   

1. NOTICE: Remove the valves by tapping the valve body on the palm of the hand to slide the valves out of the bores or by threading a 4-mm bolt into the valves and pulling them out. If it is necessary to use a pick, use extreme caution to prevent damaging the valves or valve bores. If necessary, disassemble parts of the main control valve body in small groups. Arrange the parts as they are removed to avoid mixing similar pieces.

   NOTE: The bypass valve is held in with a spring-loaded retainer. Be careful not to lose the retainer when removing it.

   Compress the valve springs with a screwdriver and remove the retainers with a magnet. Use a pick to remove the bypass valve retainer. Remove the individual valves and springs from the main control valve body by tapping the valve body on the palm of the hand to slide the valves out of the bores. If needed, use a 4-mm bolt to thread into the valves to remove the valves.
   Use the General Equipment: Flat Headed Screw Driver
   Use the General Equipment: Magnetic Socket

1. NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do not move freely, install a new assembly.

   Clean the valves, springs and main control valve body.
   

1. NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do not move freely, install a new assembly.

   Install the valve body valves, springs and retaining clips in the main control valve body. For valve and spring locations
   Refer to: Main Control Valve Body (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Description and Operation).
   

1. Install the manual valve in the valve body.
   

1. 
   Install the check balls, spring and the solenoid damper.
   
   1. Check balls
      
   2. Solenoid damper and spring
      

Solenoid Body

1. 
   Remove the solenoid body dampers and springs.
   
   1. Damper pistons and springs
      
   2. Elastomeric damper
      

1. Compress the valve springs and remove the retainers with a magnet. Remove the individual valves and springs from the solenoid body by tapping it on the palm of the hand to slide the valves out of the bores.
   Use the General Equipment: Flat Headed Screw Driver
   Use the General Equipment: Magnetic Socket

1. NOTICE: Be careful not to bend or twist the transmission internal wiring harness frame or solenoid terminals when removing the transmission internal wiring harness frame or damage can occur.

   Remove the screws and carefully remove the transmission internal wiring harness frame from the solenoids by lifting it straight up evenly.
   

1. NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to mark the solenoids to the ports they were originally in can result in mixing the solenoids and cause damage to the transmission or a harsh shift.

   Using a paint marker, number the solenoids and the solenoid body to correspond with the ports from which the solenoids are located in the solenoid body
   

1. Remove the solenoid retaining pins.
   Use the General Equipment: Long Nose Pliers

1. Remove the solenoids from the solenoid body.
   

1. NOTICE: Be careful not to wash the numbers from the solenoids or the solenoid body. Failure to install the solenoids in the ports they were originally in can result in damage to the transmission or a harsh shift.

   NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do not move freely during assembly, install a new solenoid body.

   Clean and inspect the solenoid body, solenoids and valve assemblies for damage.
   

1. Inspect the solenoid screens for debris that may restrict fluid flow through the screen.
   

1. NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to install the solenoids in the ports they were originally in can result in damage to the transmission or a harsh shift.

   If new solenoid(s) are not being installed, position the solenoids in their corresponding solenoid body ports.
   

1. NOTE: If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s). The TCC solenoid, SSA and SSC are all normally low pressure solenoids. The LPC solenoid, SSB and SSD are all normally high pressure solenoids. SSE is not a Variable Force Solenoid (VFS); it is an ON/OFF solenoid.

   1. LPC solenoid (normally high) part number 7G383
      
   2. SSC (normally low) part number 7G136
      
   3. TCC solenoid (normally low) part number 7G136
      
   4. SSE (normally closed [OFF]) part number 7G484
      
   5. SSA (normally low) part number 7G136
      
   6. SSB (normally high) part number 7G383
      
   7. SSD (normally high) part number 7G383
      
   8. Solenoid body part number 7G391
      

1. If installing new solenoids, note the color of the plastic nozzle and the large O-ring. High pressure solenoids, such as the LPC solenoid, SSB and SSD, have black plastic nozzles and orange O-rings. Low pressure solenoids, such as the TCC solenoid, SSA and SSC, have brown plastic nozzles and green O-rings. The solenoids can only be replaced with the same color solenoid.
   

1. Determine the part number suffix by checking the solenoid service band number etched on the side of the solenoid. The band number is next to the two-dimensional matrix barcode on the side of the solenoid and will be a 1, 2, 3, 4 or 5. Determine the part number suffix and match the new solenoid base part number and suffix with the old solenoid.
   
   1. = (B)
      
   2. = (C)
      
   3. = (D)
      
   4. = (E)
      
   5. = (F)
      

1. Install the solenoid(s) in the solenoid body.
   

1. Install the solenoid retaining pin(s).
   

1. Install the special tools in the solenoid body to align the transmission internal wiring harness frame for installation.
   Use Special Service Tool: 307-636  Alignment Pins- Valve Body.

1. NOTICE: Be careful not to bend or twist the transmission internal wiring harness frame or solenoid terminals when removing the transmission internal wiring harness frame or damage can occur.

   Position the transmission internal wiring harness frame on the guide pins and carefully install the transmission internal wiring harness frame by pushing it straight down into the solenoids.
   

1. Install the transmission internal wiring harness frame screws.
   Torque: 31 lb.in (3.5 Nm)

1. NOTICE: If the valves do not move freely during assembly, install a new solenoid body. Failure to install a new solenoid body can result in a harsh shift or damage to the transmission.

   Install the solenoid body valves, springs and retaining clips in the solenoid body. For valve and spring locations
   Refer to: Main Control Valve Body (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Description and Operation).
   Use the General Equipment: Flat Headed Screw Driver

1. 
   Install the solenoid body dampers and springs.
   
   1. Damper pistons and springs
      
   2. Elastomeric damper
      

Main Control Valve Body and Solenoid Body

1. Install the new separator plate and the separator plate-to-solenoid body bolts.
   Torque: 89 lb.in (10 Nm)

1. Position the solenoid body assembly on the valve body and install the solenoid body-to-valve body bolts.
   Torque: 89 lb.in (10 Nm)