14B07 – Transmission Inspection and Repair – 2013-2014 Ford C-Max & Fusion Hybrid

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November 9, 2015

Customer Satisfaction Program 14B07
Certain 2013 through 2014 Model Year C-Max Hybrid and Fusion Hybrid Vehicles
Transmission Inspection and Repair

 

PROGRAM TERMS

This program will be in effect through May 31, 2016.  There is no mileage limit for this program.

 

URGENCY / EXPIRATION DATE

This Customer Satisfaction Program has an expiration date of May 31, 2016 to encourage dealers and customers to have this service performed as soon as possible.

We recommend dealers utilize their FSA VIN Lists name and address (available on December 4, 2015) to contact customers with affected vehicles.  This will help minimize the number of vehicles that may exhibit transfer shaft gear assembly-to-damper housing contact, which requires a more extensive repair.

 

AFFECTED VEHICLES

VehicleModel YearAssembly PlantBuild Dates
Fusion Hybrid2013-2014HermosilloNovember 30, 2012 through January 21, 2014
C-Max Hybrid2013-2014MichiganAugust 8, 2012 through June 17, 2014

 

REASON FOR THIS PROGRAM

Under certain driving conditions, the transfer shaft gear assembly bearing may fail prematurely.  This can result in thumping, rubbing, or grinding noises from the transmission, and may be accompanied by the illumination of the powertrain fault indicator (wrench light) in the instrument cluster.

 

SERVICE ACTION

Dealers are to disassemble and inspect the transmission for damage or excessive wear, then either repair or replace the transmission as needed.  This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE:  Technical Assistance Center prior approval is not required if the transmission requires replacement under this program.

 

OWNER NOTIFICATION MAILING SCHEDULE

Owner Letters are expected to be mailed the week of November 16, 2015.  Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

 

STOCK VEHICLES

Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

SOLD VEHICLES

  • Owners of affected vehicles will be directed to dealers for repairs.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.  

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this service action.

 

OWNER REFUNDS

  • FordeBay Motor Company is offering a refund for owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. This refund offer expires January 31, 2016.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the date of the Owner Notification Letter. There is no expiration date for emergency repair refunds.  Non-covered repairs, or those judged by FordeBay to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with transmission replacement caused by transfer shaft gear assembly bearing failure.

 

RENTAL VEHICLES

If you have a unique circumstance which may require a rental vehicle, please contact the SSSC via the SSSC Web Contact Site.

 

PARTS REQUIREMENTS

For simplicity, parts requirements for Fusion Hybrid vehicles and C-Max Hybrid vehicles have been separated into different tables.  Each table contains three sections as follows:

See Page 2 for Fusion Hybrid parts and Page 3 for C-Max Hybrid parts.

Transmission Inspection and Repair

Part NumberDescription – Fusion Vehicles OnlyOrder Quantity
Use the parts below for both transmission repair and transmission replacement
W714878-S439Steering shaft bolt (4/package, 1 needed)1
W520215-S440 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightOuter tie rod end nut (4/package, 2 needed)1
W705606-S440 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightLower stabilizer bar link nut (2/package, 2 needed)1
W500545-S439 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightLower ball joint bolt (4/package, 2 needed)1
W520214-S442 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightLower ball joint nut (1/package, 2 needed)2
W716457-S439Subframe bolts (4/package, 4 needed)1
BB5Z-4B422-BLH halfshaft circlip1
W520102-S442RH halfshaft bearing support nuts (4/package, 2 needed)1
Use the additional parts below for transmission repair only (passed inspection)
FG9Z-7H348-BTransmission end cover service kit1
DG9Z-7048-AInput shaft seal1
BB5Z-1S177-C RH output seal1
9L8Z-1177-GLH output seal1
ZC-30-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft silicone gasket remover1
TA-29 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft ultra silicone sealant1
ZC-31-B 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft metal surface prep wipes (25 per package, 2 needed)1
XT-10-QLVC 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft automatic transmission fluid (1 quart bottles – 6 quarts needed for flushing the transmission cooler and lines and 5 quarts needed for refilling the transmission after repairs)11
Use the additional parts below for transmission replacement only (failed inspection)
DM5Z-7000-KAutomatic transmission assembly1
XT-10-QLVC 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft automatic transmission fluid (1 quart bottles – 6 quarts needed for flushing the transmission cooler, 3 quarts allowed for topping off the transmission)9

 

Transmission Inspection and Repair

Part NumberDescription – C-Max Vehicles OnlyOrder Quantity
Use the parts below for both transmission repair and transmission replacement
CV6Z-9448-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightExhaust manifold gasket1
W704474-S437 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightExhaust manifold stud (4/package, 7 needed)2
W713095-S437 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightExhaust manifold nut (4/package, 7 needed)2
CV6Z-9450-B 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightExhaust flange gasket1
W520103-S442eBayExhaust flange nuts (4/package, 2 needed)1
DS7Z-19B596-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightRefrigerant hose seal kit1
AE5Z-4B422-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightLH halfshaft circlip1
CV6Z-3B477-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightHalfshaft nut and washer (1/package, 2 needed)2
W520102-S442RH halfshaft bearing support nuts (4/package, 2 needed)1
W715491-S442Lower ball joint bolt (4/package, 2 needed)1
W520415-S442Lower ball joint nut (4/package, 2 needed)1
VC-3DIL-B 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft orange antifreeze/coolant (1 gallon pre-diluted)2
Use the additional parts below for transmission repair only (passed inspection)
FG9Z-7H348-BTransmission end cover service kit1
DG9Z-7048-AInput shaft seal1
BB5Z-1S177-C RH output seal1
9L8Z-1177-GLH output seal1
ZC-30-A 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft silicone gasket remover1
TA-29 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft ultra silicone sealant1
ZC-31-B 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft metal surface prep wipes (25 per package, 2 needed)1
XT-10-QLVC 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft automatic transmission fluid (1 quart bottles – 6 quarts needed for flushing the transmission cooler and lines and 5 quarts needed for refilling the transmission after repairs)11
Use the additional parts below for transmission replacement only (failed inspection)
DM5Z-7000-KAutomatic transmission assembly1
XT-10-QLVC 14B07 - Transmission Inspection and Repair - 2013-2014 Ford C-Max & Fusion Hybrid | small lightMotorcraft automatic transmission fluid (1 quart bottles – 6 quarts needed for flushing the transmission cooler, 3 quarts allowed for topping off the transmission)9

 

CERTAIN 2013 – 2014 MODEL YEAR C-MAX HYBRID AND FUSION HYBRID VEHICLES — TRANSMISSION INSPECTION AND REPAIR

 

OVERVIEW

Under certain driving conditions, the transfer shaft gear assembly bearing may fail prematurely. This can result in thumping, rubbing, or grinding noises from the transmission, and may be accompanied by the illumination of the powertrain fault indicator (wrench light) in the instrument cluster. Dealers are to disassemble and inspect the transmission for damage or excessive wear, then either repair or replace the transmission as needed.

 

SERVICE PROCEDURE

  1. Remove the transmission assembly. Please follow the Workshop Manual (WSM) procedures in Section 307-01.
  2. Flush transmission fluid cooling system. Please follow the WSM procedures in Section 307-02.
  3. Follow the Transmission – Disassembly and Inspection Procedure starting on Page 2.
    • – Is contact or wear present on damper housing or any of the gears or bearings?
      • – No – Proceed to Transmission – Repair and Assembly Procedure starting on Page 4.
      • – Yes – Install a new transmission assembly. Please follow the WSM procedures in Section 307-01.

 

Transmission – Disassembly and Inspection Procedure

  1. Remove the bolts and the damper housing. See Figure 1.
damper housing

FIGURE 1

 

  1. Remove the transfer shaft gear assembly, traction motor drive gear assembly, final drive input gear assembly, and the differential carrier gear assembly. See Figure 2.
transfer shaft gear assembly, traction motor drive gear assembly, final drive input gear assembly, and the differential carrier gear assembly

FIGURE 2

 

  1. Inspect the damper housing for contact or wear from the transfer shaft gear assembly. See Figure 3. Also inspect all gears and bearings (removed in Step 2) for damage or excessive wear. Are any concerns present?
    • No – Proceed to Transmission – Repair and Assembly Procedure starting on Page 4.
    • Yes – Install a new transmission assembly. Please follow the WSM procedures in Section 307-01.
INSPECTION

FIGURE 3

 

Transmission – Repair and Assembly Procedure

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  1. Using the special tools, remove and discard the transmission side transfer gear bearing cup. See Figure 4.
    • Use Special Service Tools: 308-001 Remover, Pilot Bearing and 307-163 Remover, Stator Case Bearing.
transmission side transfer gear bearing cup

FIGURE 4

 

  1. Remove and discard the LH halfshaft seal. See Figure 5.
    • Use the General Equipment: Punch.
LH halfshaft seal

FIGURE 5

 

  1. Remove the retainers and the transmission fluid oil sump baffle. See Figure 6.
transmission fluid oil sump baffle

FIGURE 6

 

  1. Remove and discard the RH halfshaft seal. See Figure 7.
    • Use the General Equipment: Punch.
RH halfshaft seal

FIGURE 7

 

  1. Remove and discard the input shaft oil seal. See Figure 8.
    • Use the General Equipment: Punch.
input shaft oil seal

FIGURE 8

 

  1. Remove and discard the damper housing side transfer gear bearing cup. See Figure 9.
    • Use Special Service Tool: 308-001 Remover, Pilot Bearing and 307-163 Remover, Stator Case Bearing.
damper housing side transfer gear bearing cup

FIGURE 9

 

  1. Remove and discard the transfer shaft preload shim. See Figure 10.
damper housing side transfer gear bearing cup

FIGURE 10

 

  1. Install 307-586 Remover, Differential Bearing Cup onto the damper housing bearing cup. See Figure 11.
    1. Position the 307-586 Remover, Differential Bearing Cup in the damper housing with the tabs on the 307-586 Remover, Differential Bearing Cup aligned with the slots in the damper housing.
    2. Expand the 307-586 Remover, Differential Bearing Cup by hand.
    3. While holding the 307-586 Remover, Differential Bearing Cup in the expanded position with the tabs in the slots of the damper housing, tighten the nut.
damper housing side differential bearing cup

FIGURE 11

 

  1. Remove and discard the damper housing side differential bearing cup. See Figure 12.
    • Use Special Service Tool: 307-586 Remover, Differential Bearing Cup.
    • Use the General Equipment: Hydraulic Press.
damper housing side differential bearing cup

FIGURE 12

 

  1. Remove and discard the differential preload shim. See Figure 13.
differential preload shim

FIGURE 13

 

  1. Remove and discard the upper differential bearing using a Bearing Puller and Step Plate. See Figure 14.
    • Use Special Service Tool: 204-069 Remover/Installer, Front Wheel Hub.
    • Use the General Equipment: Puller.
upper differential bearing

FIGURE 14

 

  1. Install the new upper differential bearing. See Figure 15.
    • Use Special Service Tool: 307-587 Installer and Guide, Differential Bearing.
    • Use the General Equipment: Hydraulic Press.
upper differential bearing

FIGURE 15

 

  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 transmission mating faces are clean and free of foreign material. Please follow RTV Sealing Surface Cleaning and Preparation in WSM Section 303-00 – Engine System – General Information, General Procedures. See Figures 16 and 17.

NOTE: Do not apply metal surface prep at this time. This should be applied just before the silicone sealant is applied, during assembly.

Make sure that the transmission mating faces are clean and free of foreign material

FIGURE 16

 

Make sure that the transmission mating faces are clean and free of foreign material

FIGURE 17

 

  1. Install the new transmission case side transfer shaft bearing cup. See Figure 18.
    • Use Special Service Tool: 205-153 Handle and 307-693 Installer, Transfer Gear Bearing Cup.
transmission case side transfer shaft bearing cup

FIGURE 18

 

  1. Install the new transfer shaft gear assembly and the differential carrier gear assembly. See Figure 19.
transfer shaft gear assembly and the differential carrier gear assembly

FIGURE 19

 

  1. Place the new differential bearing cup and the new transfer shaft bearing cup on the bearings. See Figure 20.
differential bearing cup and transfer shaft bearing cup

FIGURE 20

 

  1. Install the special tools on top of the bearing cups. See Figure 21.
    • Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing and 307-692 Tool, Transfer Gear Preload.
Install the special tools on top of the bearing cups

FIGURE 21

 

NOTE: Make sure that the silicone has been cleaned off the machined surface of the transmission case and the damper housing before installing the 307-591/3 Shim Gauge, Differential/Transfer Gear Bearing (4 spacers) or the preload measurement may be inaccurate.

  1. Install the special tools, placing the spacers on the studs. See Figures 22 and 23.
Install the special tools, placing the spacers on the studs

FIGURE 22

 

Install the special tools, placing the spacers on the studs

FIGURE 23

 

  1. Install the damper housing on the special tools. See Figure 24.
damper housing

FIGURE 24

 

  1. Install the nuts on the studs. See Figure 25.
    • Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.
    • Tighten to 18 lb.ft (24 Nm).
Install the nuts on the studs

FIGURE 25

 

  1. Rotate the transfer shaft and the differential several times to seat the bearing cups. See Figure 26.
Rotate the transfer shaft and the differential several times to seat the bearing cups

FIGURE 26

 

  1. Using a feeler gauge, measure and record the smallest and largest preload gap on the 307-591/1 Shim Gauge, Differential/Transfer Gear Bearing. Average the two measurements to get the measurement needed when referring to the shim chart for proper shim selection. See Figure 27.

NOTE: Measurements and shim thicknesses are not the same.

measure and record the smallest and largest preload gap

FIGURE 27

 

  1. Using a feeler gauge measure and record the smallest and largest preload gap on the 307-692 Tool, Transfer Gear Preload. Average the two measurements to get the measurement needed when referring to the shim chart for proper shim selection. See Figure 28.

NOTE: Measurements and shim thicknesses are not the same.

measure and record the smallest and largest preload gap

FIGURE 28

 

  1. Install the new transfer shaft preload shim. See Figure 29.
transfer shaft preload shim

FIGURE 29

 

  1. Using the special tools, install the new damper housing side transfer gear bearing cup. See Figure 30.
    • Use Special Service Tool: 205-153 Handle and 307-693 Installer, Transfer Gear Bearing Cup.
damper housing side transfer gear bearing cup

FIGURE 30

 

  1. Install the new differential preload shim. See Figure 31.
differential preload shim

FIGURE 31

 

  1. Using the special tools, install the new damper housing side differential bearing cup. See Figure 32.
    • Use Special Service Tool: 204-029 Drawbar, 307-541 Installer, Transfer Gear Bearing and 307-576 Installer, Bearing Cup.
damper housing side differential bearing cup

FIGURE 32

 

  1. Using the special tool, install the new input shaft oil seal. See Figure 33.
    • Use Special Service Tool: 307-672 Installer, Input Guide and Seal.
input shaft oil seal

FIGURE 33

 

  1. Using the special tool, install the new RH halfshaft seal. See Figure 34.
    • Use Special Service Tool: 205-153 Handle and 307-626 Installer, Differential Seal.
RH halfshaft seal

FIGURE 34

 

  1. Install the transmission fluid oil sump baffle and the retainers. See Figure 35.
    • Tighten to 97 lb.in (11 Nm).
transmission fluid oil sump baffle

FIGURE 35

 

  1. Using the special tool, install the new LH halfshaft seal. See Figure 36.
    • Use Special Service Tool: 205-153 Handle and 307-626 Installer, Differential Seal.
LH halfshaft seal

FIGURE 36

 

  1. Install the differential carrier gear assembly. See Figure 37.
differential carrier gear assembly

FIGURE 37

 

  1. Install the final drive input gear assembly. See Figure 38.
final drive input gear assembly

FIGURE 38

 

  1. Install the new transfer shaft gear assembly and the traction motor drive gear assembly. See Figure 39.
transfer shaft gear assembly and the traction motor drive gear assembly

FIGURE 39

 

NOTE: Before applying silicone sealant, finish cleaning the transmission case mating surfaces and apply the metal surface prep. Follow the RTV Sealing Surface Cleaning and Preparation procedures in WSM Section 303-00 – Engine System – General Information, General Procedures.

  1. NOTE: Make sure silicone is applied to the shoulder on the inner bolt hole.

Apply Ultra Silicone Sealant / TA-29 to the transmission case assembly. See Figure 40.

Apply Ultra Silicone Sealant / TA-29

FIGURE 40

 

  1. NOTE: Tighten in a crisscross pattern.

Install the damper housing and the bolts. See Figure 41.

  • Tighten to 18 lb.ft (25 Nm).
damper housing

FIGURE 41

 

  1. Place tape over transmission mount boss holes to prevent any debris lodged in the holes from falling into transmission during removal. See Figure 42.
TAPE COVERING HOLES

FIGURE 42

 

  1. Remove the transmission case end cover bolts. Remove and discard the transmission case end

    cover assembly. See Figure 43.
transmission case

FIGURE 43

 

  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 transmission mating faces are clean and free of foreign material. Please follow RTV Sealing Surface Cleaning and Preparation in WSM Section 303-00 – Engine System – General Information, General Procedures. See Figure 44.

Make sure that the transmission mating faces are clean and free of foreign material

FIGURE 44

 

  1. Apply Ultra Silicone Sealant / TA-29 to the transmission case assembly. See Figure 45.
Apply Ultra Silicone Sealant / TA-29

FIGURE 45

 

  1. Install the new transmission case end cover assembly and the bolts. See Figure 46.
    • Tighten to 18 lb.ft (25 Nm).
transmission case

FIGURE 46

 

 

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