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6R80 In-Vehicle Repair




Mechatronic Assembly





Removal

Mechatronic assembly

NOTICE: The only solenoid that is serviceable in the mechatronic assembly is Shift Solenoid E (SSE). If the mechatronic assembly is being removed due to a faulty SSE, follow the specific steps in this procedure to install a new SSE. If the mechatronic assembly is being removed due to a faulty solenoid other than SSE, a new mechatronic assembly must be installed.

NOTE: For vehicles equipped with a 4.6L or 5.4L engine and a new or existing mechatronic assembly is installed, the Transmission Control Module (TCM) will need to be programed with the latest calibration.

NOTE: For vehicles equipped with a 6.2L engine, the PCM replaces the TCM.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. NOTICE: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur.

Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on the connector.





3. Remove the transmission fluid fill plug transmission 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.





4. Remove the transmission fluid pan and allow the transmission fluid to drain.





5. Remove the transmission fluid pan gasket.





6. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.

Remove and discard the transmission fluid filter.





7. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer.





8. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector terminals or the exposed solenoid tabs on the transmission bulkhead electrical connector. Electrostatic discharge may occur and may cause damage to the Transmission Control Module (TCM).

With the release tab down, pull the outer shell of the transmission bulkhead electrical connector out of the mechatronic assembly.





9. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector pins or the exposed solenoid tabs on the transmission bulkhead electrical connector. Electrostatic discharge may occur and may cause damage to the Transmission Control Module (TCM).

Pull the transmission bulkhead electrical connector out of the transmission case.





10. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of the transmission case. Damage to the valve will occur if the valve falls out.

Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and the bypass valve.





Shift Solenoid E (SSE)

11. Remove the 6 long bolts from the molded leadframe.





12. NOTE: TCM molded leadframe shown, PCM molded leadframe similar.
Carefully separate the molded leadframe from the mechatronic assembly.

1. Molded leadframe

2. Mechatronic assembly





13. Remove the 8 solenoid bracket bolts and the solenoid bracket.





14. Remove the Shift Solenoid E (SSE).





Installation

SSE

1. Install the SSE.





2. Position the solenoid bracket in place and install the 8 bolts.
- Tighten to 6 Nm (53 lb-in).





3. NOTE: The TR switch pin must be aligned with the manual control valve during installation.

NOTE: TCM molded leadframe shown, PCM molded leadframe similar.
Position the molded leadframe on the mechatronic assembly.

1. Molded leadframe

2. Mechatronic assembly

3. TR switch pin





4. Install the 6 long bolts into the molded leadframe. Tighten the bolts in the sequence shown.
- Tighten to 6 Nm (53 lb-in).





Mechatronic assembly

5. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place.

1. Black feed tubes

2. Green feed tube

3. Blue feed tube





6. Verify the rubber adapter is in place.





7. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass valve in the transmission case.





8. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. Electrostatic discharge may occur and may cause damage to the Transmission Control Module (TCM).

Position the mechatronic assembly in place and loosely install the 11 bolts.

1. Align the manual valve and control lever linkage.





9. Tighten the mechatronic bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in).





10. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector pins or the exposed solenoid tabs on the transmission bulkhead electrical connector. Electrostatic discharge may occur and may cause damage to the Transmission Control Module (TCM).

With the release tab down and unlocked, push the outer shell of the transmission bulkhead electrical connector into the transmission. Make sure that the transmission bulkhead electrical connector is fully seated into the mechatronic assembly.





11. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector in place. Make sure that the locking tab is securely locked.





12. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.

If required, install a new transmission fluid filter.





13. NOTE: The transmission fluid pan gasket can be reused if not damaged.

Install a new transmission fluid pan gasket, if required.





14. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).





15. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to lock it in place.





16. Make sure the transmission fluid is 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 Transmission Fluid Drain and Refill.

17. For vehicles equipped with a 4.6L or 5.4L engine, if a new or existing mechatronic assembly is installed, the TCM will need to be programmed with the latest calibration.

18. Perform Road Test - Adaptive Drive Cycle after downloading the latest calibration. For additional information, refer to Shift Point Road Test Shift Point Road Test.

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