307-01 Câmbio automático 6R80

Automatic Transmission/Transaxle – Vehicles With: 307-01-1 307-01-1 6-Speed Automatic Transaxle - 6R80 . SECTION 307-01 Automatic Transmission/Transaxle – Vehicles With: 6-Speed Automatic Transaxle - 6R80 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS DESCRIPTION AND OPERATION Transmission Description (Component Location)............................................................... Transmission Description (Overview)................................................................................. 6R80 Transmission............................................................................................................. Major Components ............................................................................................................ Multi-Plate Clutch .............................................................................................................. Shift Overlap Control ......................................................................................................... Hydraulic Systems.............................................................................................................. Fluid Pump ..................................................................................................................... Fluid Filter....................................................................................................................... Single Planetary Gearset ............................................................................................... Ravigenaux Planetary Gearset ...................................................................................... Output Shaft ................................................................................................................... GENERAL PROCEDURES Transmission Fluid Cooler - Backflushing and Cleaning.................................................... Transmission Fluid Drain and Refill.................................................................................... Adding additional transmission fluid................................................................................... Removing transmission fluid............................................................................................... Transmission Fluid Level Check......................................................................................... REMOVAL Transmission – 2WD......................................................................................................... Transmission – 4WD......................................................................................................... INSTALLATION Transmission – 2WD......................................................................................................... Transmission – 4WD......................................................................................................... PAGE 307-01-2 307-01-4 307-01-4 307-01-5 307-01-5 307-01-5 307-01-6 307-01-6 307-01-6 307-01-6 307-01-6 307-01-6 307-01-7 307-01-8 307-01-11 307-01-12 307-01-14 307-01-16 307-01-21 307-01-26 307-01-31

Automatic Transmission/Transaxle – Vehicles With: 307-01-2 307-01-2 6-Speed Automatic Transaxle - 6R80 DESCRIPTION AND OPERATION Transmission Description œ Component Location Major Components of 6R80 Transmission 2 1 4 6 E128656 3 5 8 7 10 11 12

Automatic Transmission/Transaxle – Vehicles With: 307-01-3 307-01-3 6-Speed Automatic Transaxle - 6R80 DESCRIPTION AND OPERATION Item Description 1 Torque converter 2 Front pump assembly 3 Forward clutch (A) (quantity model dependant) 4 Front planetary gearset 5 Overdrive (O/D) clutch (E) 6 Direct clutch (B) (quantity model dependant) Item Description 7 Intermediate clutch (C) (quantity model dependant) 8 Low/reverse clutch (D) Rear planetary gearset 10 Transmission case 11 Main control assembly 12 Transmission fluid filter

Automatic Transmission/Transaxle – Vehicles With: 307-01-4 307-01-4 6-Speed Automatic Transaxle - 6R80 DESCRIPTION AND OPERATION Transmission Description œ Overview 6R80 Transmission E128660 This transmission has an internal thermal bypass valve contained within the case. This transmission uses planetary gears with hydraulic electronic controls. The Transmission Control Module (TCM) and the main control valve body units form a composite element that is installed as a single unit inside the automatic transmission. This transmission has the following features: ‡ Six forward speeds ‡ Torque converter with an integral converter clutch ‡ Electronic shift and pressure controls ‡ Single planetary gear set ‡ Double planetary gear set ‡ Two fixed multi-disc clutches ‡ Three multi-plate clutches All hydraulic functions are directed by electronic solenoids to control the following: ‡ Engagement feel ‡ Shift feel ‡ Shift scheduling ‡ Modulated Torque Converter Clutch (TCC) applications This transmission has a mechatronic unit which contains: ‡ Transmission Control Module (TCM) ‡ Turbine Shaft Speed (TSS) sensor ‡ Output Shaft Speed (OSS) sensor ‡ An internal P, R, N, D selector shaft position sensor ‡ Transmission Fluid Temperature (TFT) sensor Engine power reaches the transmission by a torque converter with an integral clutch. The 6 forward gears and one reverse gear are obtained from 2 planetary gearsets. This automatic transmission is a 6-speed HOHFWURQLFDOO\ FRQWUROOHG WUDQVPLVVLRQ FRPSULVLQJ the basic elements, main control valve body unit,

Automatic Transmission/Transaxle – Vehicles With: 307-01-5 307-01-5 6-Speed Automatic Transaxle - 6R80 DESCRIPTION AND OPERATION torque converter, 1 solenoid valve and 6 pressure regulators. Gear selection is achieved by the control of automatic transmission fluid flow to operate various internal clutches. The TCM operates the electrical components and provides for the control of gear selection shift pressure, which increases refinement and torque converter slip. In the event of a system fault, the TCM also provides for Failure Mode Effect Management to maintain maximum functional operation of the transmission with a minimum reduction in driver, passenger or vehicle safety. In the event of a total loss of control or electrical power, the basic transmission functions P, R, N and D are retained. Also 3rd or 5th gear is retained by the hydraulic system. The gear retained is dependent upon the gear selected at the time of the failure. Major Components This transmission has the following major components: ‡ Transmission case with integral torque converter housing and extension housing ‡ Torque converter ‡ Fluid pump ‡ Three drive clutches: œ Forward clutch (A) œ Direct clutch (B) œ Overdrive (O/D) clutch (E) ‡ Two brake clutches: œ Intermediate clutch (C) œ Low/reverse clutch (D) ‡ Two planetary gearsets: œ Front single planetary gearset (1 sun gear, 1 carrier, 1 ring gear) œ Rear Ravigenaux planetary gearset (2 sun gears, 1 carrier with 2 sets of pinion gears and 1 ring gear) ‡ Main control (mechatronic assembly): œ Upper valve body œ Lower valve body œ Transmission Control Module (TCM) œ Transmission Range (TR) sensor œ Turbine Shaft Speed (TSS) sensor œ Output Shaft Speed (OSS) sensor NOTE: Friction and steel plate quantity will vary based on engine displacement. Refer to the Clutch Plate Quantity Chart in the Specifications portion of this section. In addition to the torque converter, the other shift elements are: ‡ three rotating multi-plate clutches: forward (A), direct (B) and overdrive (E). ‡ two fixed multi-disc brakes: intermediate (C) and low/reverse (D). All gear shifts from 1st to 6th or from 6th to 1st are power-on overlapping shifts. That is, during the shift, one of the clutches must continue to transmit the drive at lower main pressure until the other clutch is able to accept the input torque. The shift elements, clutches or brakes are engaged hydraulically. The transmission fluid pressure builds up between the cylinder and the piston, pressing the clutches together. The purpose of these shift elements is to carry out in-load shifts with no interruption to traction. Multi-plate clutches; forward, direct and overdrive, supply power from the engine to the planetary geartrain. Multi-disc brakes, intermediate and low/reverse, press against the transmission housing in order to achieve a torque reaction effect. Multi-Plate Clutch Clutches; O/D (E), forward (A) and direct (B) are balanced in terms of dynamic pressure. That is, their pistons are exposed to the transmission fluid flow on both sides, in order to prevent pressure buildup in the clutch as speed increases. This equalization process is achieved by a baffle plate and pressure-free transmission fluid supply by a lubricating passage, through which the space between piston and baffle plate is filled with transmission fluid. The advantages of this dynamic pressure equalization are: ‡ Reliable clutch engagement and release in all speed ranges. ‡ Improved shift refinement. Shift Overlap Control The electro-hydraulic shift action is obtained by means of various valves in the TCM and main control valve body, actuated by pressure regulators. They engage or disengage the relevant clutches or brakes at the correct moments.

Automatic Transmission/Transaxle – Vehicles With: 307-01-6 307-01-6 6-Speed Automatic Transaxle - 6R80 DESCRIPTION AND OPERATION Hydraulic Systems Fluid Pump The torque converter is supported in the fluid pump by a needle roller bearing. The fluid pump is driven directly from the engine by the torque converter shell and supplies transmission fluid to the transmission and the hydraulic control unit. The fluid pump draws in transmission fluid through a transmission fluid filter and delivers it at high pressure to the main pressure valve in the main control valve body unit. The valve adjusts the pressure and returns excess transmission fluid to the transmission fluid pan. Fluid Filter All transmission fluid that is picked up from the transmission fluid pan passes through the transmission fluid filter. The transmission fluid filter and its accompanying seal are part of the transmission fluid path from the pan to the transmission fluid pump. Single Planetary Gearset The single planetary gear O/D carrier is driven by the input shaft. The single planetary gear set consists of the following components: ‡ One sun gear ‡ Four planetary gears meshing with the sun gear ‡ One planetary carrier ‡ One ring gear Ravigenaux Planetary Gearset The Ravigenaux planetary gearset is splined to the output shaft and consists of the following components: ‡ Two sun gears of different sizes ‡ Three short planetary gear pinions meshing with the sun gears ‡ Three long planetary gear pinions meshing with the sun gears ‡ One planetary carrier ‡ One ring gear Output Shaft The output shaft provides torque to the driveshaft and rear axle assembly. It is driven by the ring gear of the planetary gearset.

Automatic Transmission/Transaxle – Vehicles With: 307-01-7 307-01-7 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES Transmission Fluid Cooler - Backflushing and Cleaning Special Tool(s) Transmission Heated Cooler Line Flusher 222-00007, 222-00004 E128862 WARNING: 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; this will affect the operation of the transmission. NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Transmission Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the machine. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. NOTE: If the Transmission Heated Cooler Line Flusher or equivalent is not available, install a new transmission fluid cooler and/or an auxiliary transmission fluid cooler will be required. NOTE: If the vehicle is equipped with an in-line transmission fluid filter, remove and discard the in-line filter. 1. Check and top off the fluid level of the cooler line flusher with transmission fluid. 2. Allow the transmission fluid in the cooler line flusher 15-30 minutes to heat up to 60°C (140°F) before using. 3. If equipped, remove and discard the in-line transmission fluid filter. E128858 4. Install the line adapters into the transmission fluid cooler tubes. 5. Attach the cooler line flusher red line to the transmission fluid cooler pressure tube quick connect fitting. 6. Attach the cooler line flusher blue line to the transmission fluid cooler return tube quick connect fitting. 7. Follow the equipment instructions to purge the transmission fluid cooler tubes and cooler prior to starting the flushing procedure. 8. Allow the transmission fluid cooling system to backflush for 10-15 minutes, then flush the transmission fluid cooler in a normal flow direction for an additional 10-15 minutes.

Automatic Transmission/Transaxle – Vehicles With: 307-01-8 307-01-8 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES Transmission Fluid Drain and Refill Special Tool(s) Rubber Tip Air Nozzle 100-D009 (D93L-7000-A) ST2467-A Fluid Transporter/Evacuator/Injector 307-D465 ST2715-A Adapter, Fluid Level and Fill Plug 307-437 E129427 Vacuum Pump Kit 416-D002 (D95L-7559-A) Integrated Diagnostic System (IDS) Vehicle Communication Module, with appropriate ST1269-A adapters or equivalent diagnostic tool Materials Name Specification Transmission Fluid 0(5&21Š9 Drain 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill plug. Remove the transmission fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. E128906 3. Remove the transmission fluid pan and allow the transmission fluid to drain. E128907 4. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. E129417

Automatic Transmission/Transaxle – Vehicles With: 307-01- 307-01- 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES 5. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. ‡ Tighten to 12NM E128907 Refill WARNING: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. CAUTIONS: This procedure contains the air purge steps required to purge air from the transmission fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. The vehicle should not be driven if the transmission fluid level is low as internal failure could result. The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. 1. NOTE: The transmission will need 3.3L (3.5 qt) of transmission fluid added to the transmission as an initial fill if: th•e transmission has been overhauled. a• new mechatronic assembly has been installed. th•e transmission fluid pan or transmission fluid filter have been removed. Using the Transmission Fluid Fill Tube, add 3.3L (3.5 qt) of transmission fluid to the transmission through the transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure.transmission fluid 2. Check the transmission fluid level cold. ‡ The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90°F-110°F). ‡ Using the scan tool and with the engine running, place the selector lever in each gear position and hold approximately 5 seconds. Place the selector lever in PARK, with the engine at idle (600-750 rpm). 3. Separate the transmission fluid level indicator from the transmission fluid fill plug. E129418 4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. E129425

Automatic Transmission/Transaxle – Vehicles With: 307-01-10 307-01-10 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES 5. Add transmission fluid to the cold level location as shown in the illustration. E129419 6. Install the transmission fluid fill plug. ‡ Tighten to 35 Nm E128906 7. While driving the vehicle, use the scan tool to verify that the TFT has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the transmission fluid cooling system, eliminating any trapped air in the transmission fluid cooling system. ‡ With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 80ºC-85ºC (176ºF-185ºF). 8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. E128906 9. Separate the transmission fluid level indicator from the transmission fluid fill plug. E129418 10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. E129425 11. Using the scan tool verify that the TFT is between 80ºC-85ºC (176ºF-185ºF). The

Automatic Transmission/Transaxle – Vehicles With: 307-01-11 307-01-11 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES transmission fluid level must be at the upper level of the crosshatch mark. E129428 12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. ‡ Tighten to 35 Nm Adding additional transmission fluid 1. NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. Install the Transmission Fluid Fill Tube into the transmission fluid fill hole. 307-570 E129421 2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid. 307-D465 E129422 3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the transmission. 307-D465 E129423 4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube. ‡ Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the Transmission Fluid Fill Tube from the transmission case. 307-570 307-D465 E129420

Automatic Transmission/Transaxle – Vehicles With: 307-01-12 307-01-12 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES 5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/ pressure hose from the Transporter Fluid Evacuator/ Injector. Transmission fluid will immediately start flowing out of the Transporter Fluid Evacuator/Injector into the transmission. 307-D465 100-D009 E129424 6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 307-D465 E129423 7. Using the scan tool, verify that the TFT is between 80ºC-85ºC (176ºF-185ºF). The transmission fluid level must be at the upper level of the crosshatch mark. E129428 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. ‡ Tighten to 35 Nm E128906 Removing transmission fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the Transporter Fluid Evacuator/Injector

Automatic Transmission/Transaxle – Vehicles With: 307-01-13 307-01-13 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES and the Vacuum Pump Kit to extract any excessive transmission fluid. 416-D002 307-D465 E129426 2. Using the scan tool, verify that the TFT is between 80ºC-85ºC (176ºF-185ºF). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. E129428 3. Install the transmission fluid fill plug. ‡ Tighten to 35 Nm E128906

Automatic Transmission/Transaxle – Vehicles With: 307-01-14 307-01-14 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES Transmission Fluid Level Check WARNING: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler or transmission fluid cooler tubes has been carried out, the vehicle must be driven to get the transmission fluid to a temperature of 88ºC (190ºF) in order to purge the air from the transmission fluid cooling system. 1. With the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK. 2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. For additional information, refer to Section 100-02. 3. E128713 4. E128714 5. E128715 6. E128716 7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. For additional information, refer to Transmission Fluid Drain and Refill in this section

Automatic Transmission/Transaxle – Vehicles With: 307-01-15 307-01-15 6-Speed Automatic Transaxle - 6R80 GENERAL PROCEDURES Tighten to 35 Nm (26 lb-ft). E128713

Automatic Transmission/Transaxle – Vehicles With: 307-01-16 307-01-16 6-Speed Automatic Transaxle - 6R80 REMOVAL Transmission – 2WD Removal 1. Refer to: Driveshaft - 2WD (205-01 Driveshaft, Removal and Installation). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 4. Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, General Procedures). 5. Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures). 6. Torque: 21 Nm x2 E128920 7.

Automatic Transmission/Transaxle – Vehicles With: 307-01-17 307-01-17 6-Speed Automatic Transaxle - 6R80 REMOVAL E128925 8. Torque: 19 Nm x4 E128913 9. WARNING: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Torque: 15 Nm x2 E128909

Automatic Transmission/Transaxle – Vehicles With: 307-01-18 307-01-18 6-Speed Automatic Transaxle - 6R80 REMOVAL 10.Torque: 22 Nm E132699 2 E135454 13.NOTE: Make sure that the transmission jack makes contact on the outer ribs of the fluid pan. 11. Torque: 21 Nm x2 E135453 12.Torque: 29 Nm 60 303-1310 1 x6 2

Automatic Transmission/Transaxle – Vehicles With: 307-01-19 307-01-19 6-Speed Automatic Transaxle - 6R80 REMOVAL NOTE: Make sure that the transmission is securely fastened to the transmission jack. x4 E128926 15.NOTE: The top 2 transmission-to-engine bolts need to be removed prior to removing the remaining bolts. E128845 14.Torque: 45 Nm x2

Automatic Transmission/Transaxle – Vehicles With: 307-01-20 307-01-20 6-Speed Automatic Transaxle - 6R80 REMOVAL NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 40 Nm x3 x2 E128927 16.NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 40 Nm x3 E128928 17.Slide the transmission back far enough to install the Torque Converter Retainer. 307-346 E128929 18.If the transmission is being disassembled to install new parts, or if a new or remanufactured transmission is being installed, the transmission fluid cooler, the auxiliary transmission fluid cooler (if equipped) and the transmission fluid cooler tubes must be cleaned and backflushed to keep contaminants from entering the transmission. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.

Automatic Transmission/Transaxle – Vehicles With: 307-01-21 307-01-21 6-Speed Automatic Transaxle - 6R80 REMOVAL Transmission – 4WD Removal 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Refer to: Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). 4. Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, General Procedures). 5. Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures). 6. Torque: 21 Nm x2 E128920 7.

Automatic Transmission/Transaxle – Vehicles With: 307-01-22 307-01-22 6-Speed Automatic Transaxle - 6R80 REMOVAL E129076 8. Torque: 19 Nm x4 E128913 9. WARNING: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Torque: 15 Nm x2 E128909

Automatic Transmission/Transaxle – Vehicles With: 307-01-23 307-01-23 6-Speed Automatic Transaxle - 6R80 REMOVAL 10.Torque: 22 Nm E132699 2 E135454 13.NOTE: Make sure that the transmission jack makes contact on the outer ribs of the fluid pan. 11. Torque: 21 Nm x2 E135453 12.Torque: 29 Nm 60 303-1310 1 x6 2

Automatic Transmission/Transaxle – Vehicles With: 307-01-24 307-01-24 6-Speed Automatic Transaxle - 6R80 REMOVAL NOTE: Make sure that the transmission is securely fastened to the transmission jack. x4 E128926 15.NOTE: The top 2 transmission-to-engine bolts need to be removed prior to removing the remaining bolts. E128845 14.Torque: 45 Nm x2

Automatic Transmission/Transaxle – Vehicles With: 307-01-25 307-01-25 6-Speed Automatic Transaxle - 6R80 REMOVAL NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 40 Nm x3 x2 E128927 16.NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 40 Nm x3 E128928 17.Slide the transmission back far enough to install the Torque Converter Retainer. 307-346 E128929 18.If the transmission is being disassembled to install new parts, or if a new or remanufactured transmission is being installed, the transmission fluid cooler, the auxiliary transmission fluid cooler (if equipped) and the transmission fluid cooler tubes must be cleaned and backflushed to keep contaminants from entering the transmission. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.

Automatic Transmission/Transaxle – Vehicles With: 307-01-26 307-01-26 6-Speed Automatic Transaxle - 6R80 INSTALLATION Transmission – 2WD Installation Materials Name Specification Automatic Transmission WSS-M2C938-A / 7U7J- Oil C-ML5 M2C938-AA Contact Grease WSB-M1C239-A / YS5J-M1C239-AA 1. CAUTION: Prior to installation of the transmission, the torque converter pilot hub must be lubricated with multipurpose grease or damage to the torque converter or the engine crankshaft can occur. Lubricate the torque converter pilot hub with multipurpose grease. Material: Contact Grease (WSB-M1C239-A / YS5J-M1C239-AA) grease E129224 2. CAUTION: Prior to installation of the transmission, the torque converter pilot hub must be lubricated with multipurpose grease or damage to the torque converter or the engine crankshaft can occur. Remove the Torque Converter Retainer. 307-346 E128929 3. CAUTION: The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft. NOTE: Make sure that the transmission jack makes contact on the outer ribs of the transmission fluid pan. NOTE: Make sure that the transmission is securely fastened to the transmission jack. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle. 4. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine. With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.

Automatic Transmission/Transaxle – Vehicles With: 307-01-27 307-01-27 6-Speed Automatic Transaxle - 6R80 INSTALLATION 5. NOTE: LH shown, RH similar. Torque: 49 Nm x3 E128928 x4 E128926 8. Torque: 49 Nm 6. Torque: 49 Nm x3 x2 E128927 7. Torque: 45 Nm x2

Automatic Transmission/Transaxle – Vehicles With: 307-01-28 307-01-28 6-Speed Automatic Transaxle - 6R80 INSTALLATION 2 E135454 9. Torque: 49 Nm x2 E135453 303-1310 60 1 x6 2 10.Torque: 18 Nm E132699 11. WARNING: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual

Automatic Transmission/Transaxle – Vehicles With: 307-01-29 307-01-29 6-Speed Automatic Transaxle - 6R80 INSTALLATION control lever and the selector lever cable bracket. Torque: 25 Nm E128925 x2 E128909 12.

Automatic Transmission/Transaxle – Vehicles With: 307-01-30 307-01-30 6-Speed Automatic Transaxle - 6R80 INSTALLATION 13.Torque: 26 Nm x2 E128920 14.NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck in the case. NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler tubes prior to installing. Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes. E129227 15.Install the transmission fluid cooler tube bracket bolt. Torque: 26 Nm x4 E128913 16.Refer to: Driveshaft - 2WD (205-01 Driveshaft, Removal and Installation). 17.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 18.Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission/Transaxle External Controls, General Procedures). 19.Program the Transmission Control Module (TCM) with the latest calibration. 20.Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, General Procedures). Material: Automatic Transmission Oil C-ML5 (WSS-M2C938-A / 7U7J-M2C938-AA) transmission fluid

Automatic Transmission/Transaxle – Vehicles With: 307-01-31 307-01-31 6-Speed Automatic Transaxle - 6R80 INSTALLATION Transmission – 4WD Installation Materials Name Specification Contact Grease WSB-M1C239-A / YS5J-M1C239-AA 1. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 2. CAUTION: Prior to installation of the transmission, the torque converter pilot hub must be lubricated with multipurpose grease or damage to the torque converter or the engine crankshaft can occur. Lubricate the torque converter pilot hub with multipurpose grease. Material: Contact Grease (WSB-M1C239-A / YS5J-M1C239-AA) grease E129224 3. CAUTION: The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft. NOTE: Make sure that the transmission jack makes contact on the outer ribs of the transmission fluid pan. NOTE: Make sure that the transmission is securely fastened to the transmission jack. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle. 307-346 E128929 4. NOTE: The top 2 transmission-to-engine bolts need to be removed prior to removing the remaining bolts. NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 49 Nm x3 x2 E128927 5. NOTE: The top 2 transmission-to-engine bolts need to be removed prior to removing the remaining bolts.

Automatic Transmission/Transaxle – Vehicles With: 307-01-32 307-01-32 6-Speed Automatic Transaxle - 6R80 INSTALLATION NOTE: The top left bolt secures the fuel line bracket to the transmission case. Torque: 49 Nm x4 E128926 7. Torque: 49 Nm x3 E128928 6. Torque: 45 Nm x2

Automatic Transmission/Transaxle – Vehicles With: 307-01-33 307-01-33 6-Speed Automatic Transaxle - 6R80 INSTALLATION 2 E135454 8. Torque: 49 Nm x2 E135453 303-1310 60 1 x6 2 9. Torque: 18 Nm E132699 10.NOTE: Make sure that the transmission jack makes contact on the outer ribs of the fluid pan.

Automatic Transmission/Transaxle – Vehicles With: 307-01-34 307-01-34 6-Speed Automatic Transaxle - 6R80 INSTALLATION NOTE: Make sure that the transmission is securely fastened to the transmission jack. E128845 11. NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck in the case. NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler tubes prior to installing. Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes. E129227 12.Torque: 26 Nm x4 E128913 13. WARNING: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever. Pull back on the selector lever cable end to make sure that the selector lever cable end is securely installed onto the manual control lever. Torque: 26 Nm x2 E128909 14.Torque: 26 Nm x2 E128920

Automatic Transmission/Transaxle – Vehicles With: 307-01-35 307-01-35 6-Speed Automatic Transaxle - 6R80 INSTALLATION 15. E129076 16.Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission/Transaxle External Controls, General Procedures). 17.Program the Transmission Control Module (TCM (transmission control module)) with the latest calibration. 18.Refer to: Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). 19.Refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, General Procedures). 20.Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures). 21.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).