Ford Fusion: Automatic Transmission - 6-Speed Automatic Transmission – 6F35 / Transmission Range (TR) Sensor. Removal and Installation

Special Tool(s) / General Equipment

Removal

1. Remove the main control cover.
   Refer to: Main Control Cover - 1.5L EcoBoost (118kW/160PS) – I4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   Refer to: Halfshaft Seal RH - AWD (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   Refer to: Main Control Cover - 2.0L EcoBoost (184kW/250PS) – MI4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   

1. Disconnect the selector lever cable end from the manual control lever.
   

1. Remove the manual control lever nut and the manual control lever.
   

1. Disconnect the TR sensor electrical connector.
   

1. Remove the TR sensor detent spring bolt and the TR sensor detent spring.
   

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 .

   NOTE: If the roll pin remover does not pull the roll pin far enough to clear the manual shaft, the roll pin can be pulled from the TR sensor with a pair of locking pliers.

   Using the roll pin remover, remove and discard the TR sensor roll pin.
   

1. If the roll pin did not clear the manual shaft by pulling it with a roll pin remover, remove the roll pin from the TR sensor with a pair of locking pliers.
   Use the General Equipment: Locking Pliers

1. 
   Remove the TR sensor in the following sequence.
   
   1. Hold the TR sensor in place and slide the manual shaft outward until the manual shaft is out of the transmission case.
      
   2. Remove the TR sensor from the transmission, leaving the park pawl actuating rod attached to the TR sensor.
      

Installation

1. NOTICE: It is possible to mis-align the TR sensor actuator rod in the transmission and still install the manual shaft. Inspect the area of the TR sensor actuator rod guide after the TR sensor is installed in the transmission case to be sure that it correctly rests over the park pawl and in the guide.

   
   Install the TR sensor.
   
   1. Install the TR sensor and park pawl actuating rod in the transmission case.
      
   2. Install the manual shaft in the transmission case through the TR sensor.
      

1. Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the manual control lever shaft out and correctly install the manual pin in the manual valve and position the manual control lever shaft in place.
   

1. Install a new TR sensor locking pin.
   Use the General Equipment: Punch

1. Install the TR sensor detent spring and the bolt.
   Torque: 115 lb.in (13 Nm)

1. Connect the TR sensor electrical connector.
   

1. Install the main control cover.
   Refer to: Main Control Cover - 1.5L EcoBoost (118kW/160PS) – I4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   Refer to: Halfshaft Seal RH - AWD (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   Refer to: Main Control Cover - 2.0L EcoBoost (184kW/250PS) – MI4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
   

1. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.

   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 nut.
   Torque: 18 lb.ft (24 Nm)

1. Connect the selector lever cable end to the manual control lever with the manual control lever and selector lever in DRIVE. Check selector lever cable adjustment.
   Refer to: Selector Lever Cable Adjustment - 1.5L EcoBoost (118kW/160PS) – I4 (307-05A Automatic Transmission External Controls - 6-Speed Automatic Transmission – 6F35, General Procedures).
   Refer to: Selector Lever Cable Adjustment - 2.0L EcoBoost (184kW/250PS) – MI4 (307-05A Automatic Transmission External Controls - 6-Speed Automatic Transmission – 6F35, General Procedures).
   Refer to: Selector Lever Cable Adjustment - 2.5L Duratec (125kW/170PS) (307-05A Automatic Transmission External Controls - 6-Speed Automatic Transmission – 6F35, General Procedures).