‘Escort 1991/1996 Table of Contents» «Group 17: Automatic Transmissions «Section 17-01: CTX Automatic Transmission» DESCRIPTION AND OPERATION» Description and Operation @ — The CTX transmission (CTX = Continuously Variable Transaxle) is an automatic transmission providing a continuously variable drive ratio over the entire speed range. The drive is transmitted from the engine to the input shaft of the CTX transmission by means of a multi-plate wet clutch. In conventional automatic transmissions the drive is transmitted via a torque converter. ® The CTX transmission has the following specific characteristics, which distinguish it from conventional automatic transmissions: © The continuously variable drive is transmitted through a steel drive belt. This high-strength band is made of disc-shaped steel elements which transfer the power from the engine driven primary cone pulley to the secondary cone pulley. A continuously variable ratio results from a change in the diameter of the path over which the drive belt runs on both cone pulley units. This change in diameter occurs as a result of axial movement of the cone pulley units, which are controlled hydraulically. The hydraulic control takes into account the position of the transmission selector lever, the position of the accelerator pedal and tractive resistances such as gradients and vehicle speed. Like conventional automatic transmissions, the CTX transmission is fitted with an gear-type oil pump (engine speed dependent) and a parking lock mechanism. a) When accelerating, the engine speed may sound higher than expected in relation to the road speed. The impression given is of a slipping clutch in a manual transmission. This is totally normal and characteristic of this transmission. b) When the accelerator pedal is released, the engine speed initially drops faster than the road speed, This also quite normal and demonstrates the fuel-saving characteristics of this transmission. Selector lever positions: P = Park; the transmission is immobilised, Only to be selected when the vehicle is stationary. R = Reverse; only to be selected when the vehicle is stationary. If "R" is selected by mistake during forward drive, a safety control valve will prevent the reverse clutch from becoming engaged at vehicle speeds above 10 km/h. N = Neutral: No drive is transmitted to the front wheels. D = Drive: Normal driving position. The infinitely variable drive ratio is controlled according to the position of the accelerator pedal. While driving, the selector lever can be shifted from "D" to "L" and vice versa. L = Low: This gear should be selected for long hills and down gradients (engine braking effect). The engine can only be started in "P" and "N* Note: Top speed may be reached in “D" and "L”. Towing: shicles fitted with CTX transmission can only be towed with the front wheels raised clear of the ground, Ad caution:‘The handbrake should be applied whenever operations are carried out with the engine running. Service: AX caution: Service: New CTX transmissions are supplied with assembly plugs but are not factory-filled with ATF. Top up new CTX transmissions with about 4 litres of ATF (Tutela Universal CVT) before -ommencing road tests. If fluid is lost as a result of a defect or service/maintenance work, top up the transmission fluid to the maximum mark once the problem has been put right. Fluid level check: Note: {If automatic transmission fluid (Tutela Universal CVT) to Ford Specification WSD-M2C199-A is used, @ sticker with the word *Tutela” written on it is affixed to the top of the transmission to indicate this. This sticker was dispensed with after 10. '97 as Tutela is now the only fluid used. For this reason, only use automatic transmission fluid to Specification WSD-M2C199-A (Tutela) in CTX transmissions which have the sticker or in vehicles built after 10.97 when carrying out maintenance and service work. Tutela must not be mixed with other automatic transmission fluids. Aprecise fluid level reading can only be obtained if the transmission is at operating temperature (transmission fluid 60 - 70°C ) and if the vehicle is parked on flat, level ground with the selector lever in the °N* position Before the road test make sure that the fluid level reaches the ‘Min’ mark with the engine running and the selector lever in position 'N'. Road test: Drive along a straight route, keeping the accelerator pedal slightly depressed until the vehicle speed stops rising. Let the vehicle coast to a stop and move the selector lever to "N' (do not start off again). Carry out the fluid level check within three minutes and, if necessary, top up the fluid to the "MAX" mark, AX caution: Never top up past the "Max" mark, Note: The difference between "Min" and "Max" is about 250 - 300 cm».Petnary Vale Planetary gear carrierRing gear ° Reverse clutch 10 Servo piston ua Secondary Unit * = from '96 model year there is an extra distance ring over the pressure plate, A ‘00 an i oo Lowest ratte Rehaviour under mininun lond, 1,25 tatec-st Bohaviour under minimum load, 1,3 CFE Engagement, full power y r t a tact701294 160 2000 ‘doo ‘000 ‘a0 em Operating curves, CM trananteston teem Description 1 Highest ratio 2 Hove to a higher ratio on overrun 3 Kickdows 4 Kickéown, 1,25 detec SE s Pull. powor:x0 Bogagement, minimue load‘Escort 1991/1996 Table of Contonts» ‘Group 17: Automatic Transmission» ‘Section 17-01; CTX Automatic Transmission» eGenoral Specifications» General Specifications Inbrieante, Adhovives and Sealers Description Fora specitication aor SPH-20166-H ‘putela Universal CVP tranemiseton Fuld vusp-2c199-a Sealant, transmission housing sg-409523-A Vaseline eraciis-2 capacity Bageription Litres ‘rransniseion (with of1 cooler except Zetec) approx. 4,7 © ‘transmission (with ofl cooler Yetec and Zevec-B) approx. 5,0 + O11 cooler Description ‘twin pipe oil cooler im engine radiator water tank only for Zetec; tube Giamater 10mm for ofl cooler ~ feed and return only for Zetec: an air cooled oil cooler is connected in series with a water cooled oil cooler which is rit ineide the engine redietor coolant reservoir Mosouring and Adjusting Shims (in mm) | pescription npat Shaft bifferential Reduetion Gear Hesouring shin - 3.80 2,10 Adjusting shims available 0,75 - 2,08 0,06, 0,10, 0,20 4 2,06 - 3,06 (ineveacing in otepe 12: 4,61 8,0 Gnereasing in ote of 0,08 am) of 0,04 am) Bosring Freload peseription mn pifterential 9,30 Reauction gear 0,02 - 0,07 (deairabie value) 9,05 ‘reanemiesion RatiosDazeription Ratio sunbor of eect Reduction gear 1,6 CVE av 432 wa Reduction gear 1,4 CVM 2V and 1,6 Zetec wat a7) 38 Reduction gear 1,4 CPT and 1,6 zeteo-2 148 aa 34 Differential, all engine variants 3,842 ws Steel belt {all engine variants ~ slow xcept 1,4 cFr) 247 Steal belt [only 1,4 CFT) 2,6 Steel belt (all engine variants ~ rast) 0.45 mole transnission (slow) 1,6 metec-8 14,03 (ihole transmission (fast) 1,6 netoc-# 2.53 hole transmission (elo#) 1,6 Zatae 13,36 vole transmission (fast) 1,6 Zetec aad Speedoneter drive Desertption Number of toot Speedonater Grive yorm wheel an Speedenater drive pinion 9 rorques General on aer.ft Suspension stmt mut as n eanomiseion to engine 4“ 2 Starter motor to transmission 4 30 Starter motor to cylinder block 10 1 Pront engine mounting a 38 Rear left engins mount to body st 2 Rear right engine mount to body 56 a Rear left engine support to cransuission 6 st Rear right engine support to transmission 18 se O41 pipes to transmission a a 012 pipos te radiator and to additional radiator 22 v suspension arm to spindle carrier sa 40 Rear exhaust pipe to flex pipe 40 20Selector cable bracket to transmivsion 40 30 Selector lever assembly n 8 Ground lead to transniseion a a vibration damper to transmission as 93 orgies ‘Teanemineion - disnentie and assemble Ne weft Secondary unit housing cover 28 as ‘sump 8 ‘ O11 strainer 8 5 Valve body to treneniesion, Lot stage 5 2 valve body to transmission, 2nd stage 8 6 Connector te traneniseion 4 w 012 pipe to connector 22 as 041 pips to xadiater 2 a6 041 filler pipe to tranenission 20 as 011 pump to transmission Fa 7 Belt lubrication tube 6 6 gine pitt chamber a 5 Primary pitot chanber 8 6 crown wheel to differential case as a Reduction goar bearing ssp 38 as Primary unit hub nut zo a5 Secondary unit Ib not mo ass Selector shaft retaining bolt 2 u Selector lever to selector shaft uw a Prepoure gauge connection blanking plug a0 1 ‘rangniveion housing bolts 2 1 Start inhibitor switch 12 9‘sEscort 1991/1996 Tablo of Contents» «Group 17: Automatic Transmission» «Section 17-01: CTX Automatic Transmission» ‘«Gonoral Specifications» General Specifications Lubricants, adhesives end sealeze Description Ford specification a0F Boem-2cL66-I ‘qutela Universal CV transniasion fluid wsD-H20199-A Sealant, transmission howsing ‘sgit-400503-a vaseline seaclis-a capacity Doseription Litres ‘ransmission (with oll cooler except Zetec) approx. 4,7 * ‘Transmission (with ofl cooler Zetec and Zateo-8) approx. 5,0 + 012 cooter Doreription twin pipe oll ccoler in engine radiator water tank only for Zetec: tube Gianeter ium for oil cooler ~ feed and return onty fer Zotse: an air cooled of1 coale: inside tho engine radiator coolant rese 1 ie connected in serie with a water coaled oil cooler which ta rit Heasuring and Adjusting Shims (in nm) Description Inpat shart Differential Reduction Gear Meacuring shim - 3,80 220 Aajusting shims available 0,78 ~ 2,08 0,08, 0,10, 0,20 4 2,08 = 3,05 (increasing in steps 121 4,67 5.0 Gnereasing in ste oF 0,08 mn) ‘of 0,04 am) Bearing preload Deceription an pifferontial 0,30 Reduction avar 0,02 = 0,07 (dooirable value) 0.08 ‘Trangntasion RatiosDescription Ratio Sumber of reeth Reduction gear 1.6 Cv av 4,32 2s 133 Reduction gear 1,4 CV 2V and 1,6 fetes aaa ar 38 Reduction gear 1,4 CFI and 1,6 Zetec-E 148 aa ae Differential, sil engine variants 3,842 win Steel belt (all engine variants ~ slow except 1,4 cPz) AT Stoel belt (only 1,4 CPI) 26 Stecl belt (ell engine variants - fast) 0.45 whole transmission (slow) 1,6 nevec-# 14,03 Whole transmiscion (fast) 1,6 Zetoo-# 283 whole transmission (slow) 1,6 zetec 13,36 Whole tranomfosion (fast) 1,6 Zetec 2a Speedoncter arive description Nunbor of beet, Speedomator drive worm wheel a speedoneter drive pinion a9 Torques General wn abe. fe Suspeneion atrut nut as 33 eansniseion to engine a4 22 Starter motor to tranamission 40 30 Starter moter te cylinder bleck 10 7 Pront engine nounting st 38 Rear left engine mount to body s 38 oar right engine nount to body se a Rear left angina support to tranemission oo st Rear right engine support to tranemiesion ae ba 012 pipes te trenemianion 2a a 011 pipes to radiator and to additional radiator a2 a Suspension arn to spindle carrier 5a « Rear exhaust pipe to flex pipe 40 30Selector cable bracket to trananission eo 0 Selector lever assenbly a a Ground lead to trsnemisaton u“ 10 Vibration damper to trensmission 10 38 erques ‘Transmission - diczantle end assenble No eft Secondary unit housing cover a 1 sup ® . bl strainer 3 ‘ Valve body to transmiseion, Jet stage 5 2 valve bedy to transmission, 2nd stage a . connector to transnisasn 2 ae O11 pipe to connector 2 16 011 pipe te radiator 22 16 Olt Filler pipe ¢o tranamieeion 20 2 041 pump to transmission 10 1 Bolt Iubrieation tubs 8 6 Engine pitot chamber 5 ‘ Primary pitot chamber 2 « ceonm wheel to differential case as 85 Reduction gear bearing cap 39 29 Primacy unit hub nut 210 ass Secondary unit hubs mut 20 ass Selector shaft rotaining bolt a a Selector lever to selector shagt a n Pressure gauge connection blanking plug 10 1 ‘Trenaniosion housing bolts 24 a8 Start inhibitor switen 2 ° —«&scort 1991/1996 Table of Contents» «Group 17: Automatic Transmission» «Section 17-04: CTX Automatic Transmission» REMOVAL AND INSTALLATION» Automatic Transmission - Dismantle and Assemble (Transmission Removed) (17 214 8) Special Tools 14-038-01Key, wheel hub 9% 18-025 ADrift, fitting differential bearing 15-048Puller, drive pinion oil seal “SD OP Gr 15-074Drift, removing bearing cones DD a 16-020Drif, fing bearing cones S= EAR 17-032Mounting bracket S 17-036Primary unit locking tool F 15-022 ADial gauge holding fixture 15-042Drif, fitting drive pinion bearing or 15-050 AMain tool remover -_ ro ae 16-018Drift, fitting driveshaft oil seal 16-062Collet for 15-050 A Po Se 47-0340il pump remover \ z 17-036Housing half remover (secondary unit)Escort 1991/1996 Table of Contents» ‘uGroup 17: Automatic Transmission» ‘Section 17-01: CTX Automatic Transmission» «DESCRIPTION AND OPERATION Description and Operation @ = The CTX transmission (CTX = Continuously Variable Transaxle) is an automatic transmission providing a continuously variable drive ratio over the entire speed range. The drive is, transmitted from the engine to the input shaft of the CTX transmission by means of a multi-plate wet clutch. In conventional automatic transmissions the drive is transmitted via a torque converter. © The CTX transmission has the following specific characteristics, which distinguish it from conventional automatic transmissions: © The continuously variable drive is transmitted through a steel drive belt. This high-strength band is made of disc-shaped steel elements which transfer the power from the engine driven primary ‘cone pulley to the secondary cone pulley. A continuously variable ratio results from a change in the diameter of the path over which the drive belt runs on both cone pulley units. This change in diameter occurs as a result of axial movement of the cone pulley units, which are controlled hydraulically. The hydraulic control takes into account the position of the transmission selector lever, the position of the accelerator pedal and tractive resistances such as gradients and vehicle speed. Like conventional automatic transmissions, the CTX transmission is fitted with an gear-type oil pump (engine speed dependent) and a parking lock mechanism. a) When accelerating, the engine speed may sound higher than expected in relation to the road speed. The impression given is of a slipping clutch in a manual transmission. This is totally normal and characteristic of this transmission. b) When the accelerator pedal is released, the engine speed initially drops faster than the road speed. This also quite normal and demonstrates the fuel-saving characteristics of this transmission. Selector lever positions: P = Park; the transmission is immobilised. Only to be selected when the vehicle is stationary. R = Reverse; only to be selected when the vehicle is stationary. If "R” is selected by mistake during forward drive, a safety control valve will prevent the reverse clutch from becoming engaged at vehicle speeds above 10 km/h. N = Neutral: No drive is transmitted to the front wheels. D = Drive: Normal driving position. The infinitely variable drive ratio is controlled according to the position of the accelerator pedal. While driving, the selector lever can be shifted from "D" to "L" and vice versa, L = Low: This gear should be selected for long hills and down gradients (engine braking effect). The engine can only be started in °P" and "N’. Note: Top speed may be reached in“ nd "L" Towing: thicles fitted with CTX transmission can only be towed with the front wheels raised clear of the ground. ZX caution:The handbrake should be applied whenever operations are carried out with the engine running. Service: AX caution: New CTX transmissions are supplied with assembly plugs but are not factory-filled with ATF, Top up new CTX transmissions with about 4 litres of ATF (Tutela Universal CVT) before _ommencing road tests. If fluid is lost as a result of a defect or service/maintenance work, top up the transmission fluid to the maximum mark once the problem has been put right. Fluid level check: Note: if automatic transmission fluid (Tutela Universal CVT) to Ford Specification WSD-M2C199-A is used, a sticker with the word "Tutela” written on it is affixed to the top of the transmission to indicate this. This sticker was dispensed with after 10. '97 as Tutela is now the only fluid used. For this reason, only use automatic transmission fluid to Specification WSD-M2C198-A (Tutela) in CTX transmissions which have the sticker or in vehicles built after 10.97 when carrying out maintenance and service work. Tutela must not be mixed with other automatic transmission fluids. A precise fluid level reading can only be obtained if the transmission is at operating temperature (transmission fluid 60 - 70°C ) and if the vehicle is parked on flat, level ground with the selector lever in the "N" position, Before the road test make sure that the fluid level reaches the 'Min’ mark with the engine running and the selector lever in position 'N’ Road test: Drive along a straight route, keeping the accelerator pedal slightly depressed until the vehicle speed stops rising. Let the vehicle coast to a stop and move the selector lever to "N’ (do not start off again). Carry out the fluid level check within three minutes and, if necessary, top up the fluid fo the "MAX" mark. AX caution: Never top up past the "Max" mark. Note: ‘The difference between "Min" and "Max" is about 260 - 300 cm».jeseription Drive beltRing gear 9 Reverse elute 10 Servo piston n Secondary Unit * = from ‘96 model year there is an extra distance ring over the pressure plate. 4 Pehaviour under minigun load, 1,3 CFE ngagenont, full power 100. eh 180 0 10 100 a wo cy 0 »4 a lact7otas4 ‘pn operating curves, CTX transmission Iten Doeeription 1 Highest ratio 2 Nove te a higher ratio on overrun 3 kickdown, ‘ Kickdews, 1,25 Zetec SE 5 Fuld power: 6 rewest ratio 7 Behaviour under minimus load, 1,25 Zotco SEry mngagenant, minim losd“Escort 1981/1996 Tablo of Contents» ‘xGroup 17: Automatic Transmission» «Section 17-01: CTX Automatic Transmission» ‘sGoneral Specifications» General Specifications Uubricants, Adhesives and Sealers Description Ford specification aor -BSPM-2C156-H ‘putela Univervel CVT transmiselen Auld ‘1s0-H2c199-A Sealant, transmiesion housing soN-4a9523-2 vaseline eescias-a capacity Deceviption Litres ‘ransmiseion (with of1 cooler except Zetec) approx. 4,7 + ‘Teansmigeion (with of] cooler Zetec and tatac-B) approx, 5,0 * 011 cooler Description ‘win pipe of) cooler in engine radiator water tank only for Zetec: tube diameter 10mm tor 011 cooler - teed and return only for Zetec: an air cooled ofl cooler i connected in orice with a water cooled oil inride the engine radiator coolant reservoir cooler which is it Meaeuring and Adjusting chine (in sm) Description input shaft Ditrerential Reduction Gear Nowouring ohim 7 3.80 2.0 Adjusting shins avaliable 0,75 ~ 2,08 0,06, 0,10, 0,20 4 2,06 - 3,06 (increasing in steps 12) 4,6; 5,0 Unereasing in ste bf 0,08 em) of 0,04 mn) Bearing Preload Description - Differential 0,30 Reduction gear 0,02 - 0,07 (Geizable valuo} 0,05 ‘tronenission RatiosDescription Ratio Munber of eoeth Reduction gear 1.5 vit 2v 1,32 33 Reduction gear 1,4 CVI 2V and 1,6 Zetes aa 21/38 Reduction gear 1,4 CFI and 1,6 zetec-E 148 was Differential, a1 engine variants 4.82 win Steel belt (ai) engine variants ~ slow except 1,4 CPT) 2.47 Steel belt {only 1,4 CFI) 26 Steel belt (all engine variants — fast) 2,45 hole transmission (10m) 1,6 Zetec 14,09 Whole tranemicoion (aot) 1,6 Zetoc-E 2.53 whole trensnission (slow) 1,6 detec 13,36 tole transmieeion (fast) 1,6 setec 2a speedometer drive beseription Nuuber of Leet, Speedometer avive worm whoo! a Speedenater drive pinion 2 rorques Gonersit wn abe. fe suspension strut mut © 3s ‘eangmission to engine 4“ 2 Starter notor to transmission 40 30 Starter motor to cylinder block 10 7 Front engine mounting 3 38 Rear left engine mount te body 31 a8 Rear right engine xount to body 56 a Rear left engine eupport to transmission 9 st Rear right engine support to transmission 8 se 041 pipes to transmission 22 ur 042 pipes to radiater end to additional radiator 22 a Suapension arm to spindle carrer 5a 40 Rear exhaust pipe to flex pipe 40 30Selector cable bracket te trananizaion 40 30 Selector lever assonbly u 5 Ground lead so transiniesion u 19 Vibration damper to tranamiesien 129 95 rorquos ‘rancwicaion ~ dicmantle end ascomble Me ae. tt Secondary unit housing cover ey ww sump 5 ° of strainer 5 ‘ valve body te transmission, Ist stage 5 2 Valve body to tranomiesion, 2nd stage 8 6 Connector to transmission 4 18 O11 pipe to connector 22 ae O11 pipe to radiator 22 16 041 tiller pipe to transmission 20 as O42 pump te tranemission 20 7 Belt Lubrication tube ® ‘ Engine pitot chamber e 6 Primary pitot chanber ‘ 6 Crom wheel te differential ease as 85 Reduction gear bearing cap 3 29 Primary unit ub mut 210 ass Secondary unit bub mus 210 198 Selector shaft retaining bolt 3 av Selector lever to selector shaft ” a Pressure gauge connection blanking plus 10 7 ‘rranamission housing: bolts Ea a8 start inhibitor euiten 2 8 ee‘Escort 1991/1996 Tablo of Contents» ‘uGroup 17: Automatic Transmission» «Section 17-01: CTX Automatic Transmission» «General Specifications» General Specifications Iubricants, Adhesives and Soalere Description Fora Specification ane ESM-2C166-H ‘putela Universal CVE tranomizelon Fula visp-1820199-a Sealant, transmission housing pte-469523-a vaseline suenc115-a capacity Desexipeion Litres ‘Dransiiseion (with of1 cooler except Zetec) approx. 4,7 * ranenission (with oll cooler ‘tates and Zetec-B) approx. 5,0 * 042 cooler ‘twin pipe oil cooler in engine radiator water tan only for getes: tube Gianeter 10mm for oll cooler ~ feed and return ineide the engina radiator coolant reservoir only for Zotoot an air cooled oil cooler ie connected in series with a water eeoled ol cooler which te Fit Measuring and Adjusting Shino (in om) bascription Input Shaft Differential Reduction Gear Meseuring chim - 3,80 2.10 Adjusting shims available 0,78 - 2,08 0,06, 0,10, 0,20 ¢ 2,06 - 3,06 (ineraasing in steps 121 4,62 5,0 (increasing in ste of 0,08 mn} of 0,04 mm Boaring preload pif fezential 0,30 Reduction gear 6,02 = 0,07 (desirable value} 0,05 ‘eanentanton Ratiosbeseription Ratio Samber of coeth Reduction gear 1,5 CvH 2 438 as yaa Roduction gear 1,4 CVH 2v and 1,6 Zetec at an 38 Reduction gear 1,4 CFI and 1,6 Zevec-E 148 wae Differontial, a1] engine variante 3,042 wn Steel belt (all engine variants ~ slew except 1,4 CFD) 2.47 Steel belt (only 1,4 CFT) 26 Stool bolt (ell engine variants ~ fast} 0.45 Whole tranemiesion (slow) 1,6 zetacnE 14,03 Whole trananisoion (fast) 1,6 ZetecE asa Whole trananission [slow) 1,6 Zetec aa.3e Uhole transnlzeion [fast) 1,6 Zetec 2-41 Speedowater drive eseription Humber of tect speedometer drive worm wheel 7 Spoedonoter drive pinion w orques ceneral be ibe. te Suspension strut nut 45 33 ‘eenuniesion te engine a0 3 Starter motor to transnission 40 20 Starter motor to cylinder block 10 7 Front engine mounting 5 a8 Roar Left engine mount to body 31 38 Rear right engine mount to body 56 a Rear left engine support to transmieston 69 st Rear right engine support to transmission 78 sa O41 pipes to Eransmiasion 2 v O41 pipes to radiator and to additional radiator 22 a Suspension ar to spindie carrier 5a © Rear oxhaust pipe to flex pipe 40 30Selector cable bracket to transniseion 40 30 Selector lever asseriiy u 8 Ground load to transmesion u 10 Vibration danper to transiission 129 9s Torque: ‘Transtission ~ disuantle and assenme mm awe. te Sacondary unit heusing cover 8 18 samp a 6 oi strainer 8 ‘ Valve body to transmission, Jet stage ° 2 Valve body to tranemiesion, and stage a 6 Connector to transmission 26 a6 01t pips te connector Ey a6 OL pipe to radiator 22 a6 041 filler pipe to transmission 20 as 04 pump to transmission 10 7 Belt Iubeication tubs 8 6 gine pitot chanber 6 6 Primary pitot chanhor 8 ‘ Crown whos! to differential case us a5 Reduction gear bearing cap ey 2 Primary unit Ib nut 220 155 Secondary unit yb mut 20 ass Selector shaft retsining belt a v Selector lever to selector shaft u a Pressure gauge connection blanking plog 10 7 ‘Tranonlasion housing bolts 24 as Start inhibitor switen 2 ° eea&scort 1994/1996 Table of Contents» «Group 17: Automatic Transmission» Section 17-01: CTX Automatic Transmission» «REMOVAL AND INSTALLATION» Automatic Transmission - Dismantle and Assemble (Transmission Removed) (17 214 8) Special Tools aD 14-038-01Key, wheel hub <> Ee 18-025 ADrift, fitting differential bearing 15-048Puller, drive pinion oil seal 15-074Drift, removing bearing cones a 16-020Drift, fitting bearing cones ESQ 47-032Mounting bracket 17-035Primary unit locking tool 15-022 ADial gauge holding fixture OS Qo 15-042Drift, fitting drive pinion bearing 15-050 AMain tool remover i 16-018Drift, fitting driveshaft oil seal 16-062Collet for 15-050 A 7 17-0340 pump remover 3 17-036Housing half remover (secondary unit)“Escort 1991/1996 Table of Contents» ‘xGroup 17: Automatic Transmissions «Section 17-01: CTX Automatic Transmission» “«REMOVAL AND INSTALLATION Valve Body Assembly Dismantle and Assemble (17 234 8) (Valve body assembly removed) co Pzc1701731 Unyout, valve bedy up to model yoar *96) Them beseription 1 Valve body identification tag 2 a Deck 4 cluceh pe Limiting valve 5 clutch pe ‘ Primary valve 7 trol damping valve 8 9196 Nut of the valve body (Hoel year Sealing plug @>P V ag2s Actuating lever a6 Lever with shaft end cane u Bali Fa Ball valve (strong spring) ww Spring plug (weak spring) + 800 stop for details see page for the installation position of the retaining plates, spring plugs and bali valves. e Install clutch pressure valve 4 Put the clutch pressure valve in position. 2 Check end stop (clutch pressure valve body assembly) and clearancew\@ eS 17-037Housing half remover (primary unit) Pe 17-039Sensor shaft remover aan 17-041tInstaller,radial oil seal 147-044Forward clutch piston guide sleeve oD. 17-046Secondary unit dummy spacer OP. 17-048Collet for 15-050 A SF we 21-024-01Adapter for 21-024 21-024Valve spring compressor 17-038Secondary unit puller % 17-040Spring washer compressor A 17-042 AControl piston holding clamp ®. 17-045Reverse clutch piston guide sleeve 17-047Collet for 15-050 A a 17-055Measuring rail, determining shim thickness 21-024-02Adapter for 21-024 21-0510il seal remover Workshop Equipment Deoeription Assembly stand MaterialsDosertption Pord Specification ‘utela Universal CVT transuleeion ciuia | usn-aaci99-a Cleaning agent Paraffin cable ties Sealant, tranenisaioa housing s0H-459529-A Proprietary Tools Doeertpeion Diel indicator gauge 41 wm socket 48 nn socket Focter gauge Depth gauge calliper gauge Dismantle General notes: © Clean the transmission to stop dirt getting in during assembly. Always use vice jaw protectors when working with a vice. © Only use paraffin to clean transmission components, ®@ Do not let the cleaning agent come into contact with the brake bands or the friction plates. © Lay out the parts removed so they can be easily inspected for damage and in a way that will make assembly easy. © If deposits (clutch debris or metal shavings) are detected in the transmission fluid during repairs, the transmission has to be completely dismantled and thoroughly cleaned. © Also carefully clean the oil ines and oil cooler, replace them if dirt build-up is extremely heavy. AX caution: In the case of abraded particles of metal, the valve body, the oil pipes and the oil cooler must be replaced. @ Allclutches at which end float is measured should be pressed together before taking a measurement so as to press out the fluid between the plates. © When using new clutch plates, place these in automatic transmission fluid for 30 minutes prior to fitting. © Lubricate all sliding components with automatic transmission fluid prior to assembly. © Position the thrust washers and needle roller bearings with Vaseline during assembly.Remove the valve body © 7, Rework Special Tool 17-042 and mark it with "A’ Only unscrew the bolts which are highlighted on the illustration. © 8. Unscrew the bolts (x 5) in the valve body assembly. € 9. Tension the spool valve. © Fit the special tool and tighten the knurled screw until finger-tight. AX caution: Only unscrew the bolts highlighted on the illustration.Note: ‘The manual valve may fall out of the valve body assembly. © 10. Remove the valve body 1 Undo the bolts. @ Remove the vaive body assembly. 2 Pull out the manual vaive (fitted underneath the valve body assembly). © 11. Remove secondary pressure adjusting sieeve. @ Remove the dust cap. 1 Slacken the blanking plug one tun. 2 Using a 4 mm Allen key, press the adjusting sleeve in against the spring pressure and hold it in position © Unscrew the blanking plug. o aie eee Esc170#161 12, Remove adjusting sleeve (continued) Withdraw the sleeve with the Allen key. Esct701162— 7© 13. Remove the sensor shaft. 1 Insert the special tool. 2 Withdraw the locking clip. © 14. Remove the gear ratio sensor. 4 Withdraw the sensor shaft. 2 Remove spring 3. Swivel the sensor towards the left and remove it. Remove the engine pitot © 15. Detach the primary unit blanking cover. Remove O-ring. ae eee: © 16. Remove the engine pitot.Note: Do not unscrew the bott 1 Unscrew the engine pitot tube bolt approx. eight turns to block the engine pitot chamber. 2 Unscrew the engine pitot chamber bolts, © Remove the engine pitot tube bolt. © 17. Remove engine pitot (continued), 1 Turn the engine pitot tube anticlockwise as far as it will go. 2 Remove engine pitot chamber. @ Remove engine pitot tube. escsrore7V Remove the oil pump QS caution: Two engine pitot bolts remain in the oil pump. © 18. Release the oll pump. 1 Remove the oil filler pipe. 2 Undo the bolts.© 19. Remove the oil pump. 1 Screw in the threaded pins. 2. Evenly pull out the oll pump. © 20. Remove the oil pump (continued) @ Remove the spring washer. @ Remove the special tool, Esc1701209 © 24. Check the oil pump, @ Remove the seal ring, Note: The oil pump must not be dismantied any further. @ Measure the width of the oil pump ring groove. Max: 2,6 mm.© 22. 2 23, tT esci701170 Detach the secondary unit housing cover. Remove the seal ring Remove secondary unit inner cover. Take off secondary unit inner cover with permanent magnet. Remove the Viton seal ring. Release the primary unit and the secondary unit ce 24 Unscrew the primary unit nut. 1 Insert special tool into forward clutch. 2 Unscrew the nut using a bihexagonal socket (46 mm).ELero1i72 © 25. Unscrew the secondary unit nut, 1 Engage the parking pawl. 2 Unscrew the nut using a bihexagonal socket (41 mm). esci701174 At © 26. Remove the selector shaft. 1 Screw off notched disc and detach gear linkage. 2 Remove selector lever. 3 Unscrew locking screw and push out shaft towards valve body assembly/labyrinth. eLoiraiete — Hu Separate the transmissio1 n housing halves Note: Turn the pitot tube anticlockwise as far as it will go. © 27. Attach the special tool| esctvo17s © 28. Remove the housing bolts. 1 Remove the differential auxiliary plugs, 2 Unscrew all the bolts apart from two opposite each other. © Turn transmission through 90° and unscrew the remaining bolts SS DS Remove the drive belt AX caution: Check that the mark showing the direction of travel of the belt is clearly visible, remark the belt if necessary. = 30. Remove the transmission pitot. 1 Unscrew bolts and remove transmission pitot. 2 Secure drive belt at two points (opposite facing) using cable ties.eLoiraiiaa Note: Make sure the spacer and nut are removed. © 31. Remove the drive belt. Fit spacer together with original nut. Insert pulling device in the groove of the secondary unit and clamp it in place, Prestress the secondary unit as far as possible. Push the drive belt onto the small end of the secondary unit RON © 32. Remove drive belt (continued). © Raise the secondary unit with the drive belt. Note: The secondary unit must not be dismantled any further. © Move the secondary unit with drive belt towards the primary unit until remove the drive belt from the primary unit. © Remove the secondary unit together with the drive belt. possible to© 33. Remove the primary unit with forward gear clutch. © 34. Remove the planetary gear carrier. Remove the thrust washer and the adjusting shim. tis Esci7oita1 YI © 35. Remove the reverse clutch. 4 Remove the snap ring. 2 Remove the plate pack. 1aci7o1282 Note: Only fit the new type of clutch plates when servicing the vehicle, © 36. Clutch plate identification. Note:Immerse clutch plates in Tutela ATF (WSD-M2C198-A) for at least an hour before fitting them, 1 New pattern. 2 Old pattern © 37. Remove the reverse clutch actuating piston, 1 Remove the snap ring. 2 Remove the spring washer. 3. Remove the piston, © 38. Remove the reduction gear bearing cap. 4 Unhook the parking pawl spring and swing the parking pawl back. 2 Undo the bolts. © Prise off the bearing cap. Note: The bearing cup is a sliding fit in the bearing cap. © Press the bearing cup out of the bearing cap.© 39. Remove the reduction gear and the differential. 1 Reduction gear. 2. Differential. eo escr7oites 7H Dismantle the housing halves © 40. Remove the oil seals. 1 From the input shaft. 2 From the axle shaft. 3 From the selector shaft (lever them out with a screwdriver) 42. Withdraw the input shaft needle roller bearing. With a proprietary internal extractor.Note: ‘Only remove the secondary unit roller bearing (paired with bearing inner race, see operation ) ifit is damaged, © 43. Remove the secondary unit roller bearing. Remove the rollers and the bearing cage. @ 44. Remove the reduction gear bearing cup with the spacer. The bearing cup is a sliding fit @ 45. Remove the differential bearing cup with the adjusting shim. Remove the differential bearing cup with the adjusting shim.© 48. Remove the ball bearing and the splash tube. From the primary unit. From the secondary unit Remove the two bearings with a suitable drift. Slacken the pitot tube and remove it. wens +) E9C1701195 J Dismantle the primary unit © 47. Remove the forward clutch. 1 Remove the snap ring. 2 Remove the clutch pack. © 48. Remove the forward clutch actuating piston. 1 Remove the snap ring. 2 Remove the spring washer.Esc1701197 AX caution: The primary unit should only be dismantled as far as described. © 49. Remove the forward clutch actuating piston (continued). 4 Remove the pressure plate and the actuating piston. 2 Remove the seal rit i Ge Dismantle the secondary unit AX caution: The secondary unit should only be dismantled as far as described. Note: Only remove secondary unit roller bearing (paired with bearing inner race, see operation ) if itis damaged. © 50. Pull off the secondary unit bearing inner race. 4 Remove the snap ring, 2 Pulloff the bearing cup.oP O Oo Pzot600624Aajusting shin opeedemater drive pinion brive pinton bearing ‘{(q}—_-| ee ee | Dismantle the differential e rd c 52. Dismantle the differential 1 Insert the thrust element. 2. Pull off the taper roller bearing. 3 Remove the speedometer worm gear. 53. Remove the differential pinions. 4 Turn the pinions 90° in the differential case and remove them. 2 Remove the retaining ring and drive out the shaft Remove the pinions and the plastic thrust washers. 3 Unscrew the bolts five turns and push the crown wheel down evenly off the differential by tapping on the bolt heads. Assemble 54. General note.AX caution: Only use Tutela Universal CVT (WSD-M2C199-A) Automatic Transmission Fluid. Clean all parts carefully and check them for wear and damage. The gaskets, oil seals, O-rings, snap rings and self-locking nuts must not be reused. Coat all moving parts and seals with Tutela ATF (WSD-M2C199-A) before assembly. Immerse lined discs in Tutela ATF (WSD-M2C199-A) for at least 15 minutes before fitting them. lactrores2 Note: Use the new type of clutch plates when repairing the vehicle. © 55. Clutch plate identification Note: Immerse the new type of clutch plates in Tutela ATF (WSD-M2C199-A) for at least an hour before fitting them. 1 New pattern. 2 Old pattern. Pzc1807199 Assemble the differential Note: The spur gear is asymmetrical. Fit with the larger recess and the larger chamfer facing towards the differential housing. © 56. Fitthe differential housing.¢ 57. Fit the spur gear and install the differential pinions. ones 15-0054 evr‘sote4t Pull the crown wheel on using the old bolts. Place the plastic thrust washers and both pinions in their installation positions. Drive in the shaft and secure it in position. Insert the pinions and turn them through 90° in the housing. e 58. Install the taper roller bearing and tighten the crown wheel. 1 Fix the spur gear using new bolts, Torques ‘Spur gear with six holes: 115 Nm Spur gear with eight holes: 85 Nm 2 Insert the speedometer worm gear Note: Do not support the assembly on the lowe in the recesses. rer taper roller bearing 3 Press on the two taper roller bearings. Lae PSAssemble the primary unit 59. Install the forward clutch actuating piston. 1 2 3 4 e Fit the guide sleeve. Fit the two oil seals to the actuating piston Press the actuating piston in, turning it slightly until it meets the stop. Fit the pressure plate. Remove the guide sleeve. © 60. Install the forward clutch actuating piston (continued). © Fit the spring washer. 1 Press the spring washer down. 2 Fitthe snap ring Model year before ‘96. Note: Thrust washer (thicker washer) facing upwards (also see operation ) © 81. Install the forward clutch. 1 Insert the clutch pack. 2 Fitthe snap ring.Model year ‘96 on. Note: Thrust washer (thicker washer) step must be facing upwards (also see operation ).. © 62. Install the forward clutch, 1 Fit the set of clutch plates. 2 Fitthe snap ring. acs703293 Note: The ring groove for the snap ring is offset towards the top (measurement ‘A © 63. Clutch assembly 1 Upto '96 model year; pressure plate without distance ring, 2 Model year '96 on; pressure plate with step and distance ring, 3 Distance ring pzciro1707