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TSB 06-11-4 CVT Noise

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BlueLtd2
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TSB 06-11-4 CVT Noise

Post by BlueLtd2 » Thu Oct 04, 2007 8:05 am

TSB
06-11-4 CONTINUOUSLY VARIABLE TRANSAXLE (CVT) NOISE DIAGNOSIS

Publication Date: May 22, 2006

FORD: 2005-2006 Five Hundred, Freestyle
MERCURY: 2005-2006 Montego


ISSUE:
Some 2005-2006 Freestyle/Five Hundred/Montego vehicles equipped with a continuously variable transaxle (CVT) may exhibit noise under various driving conditions.

ACTION:
Use the following Service Procedure to identify and repair specific CVT transmission noises.

SERVICE PROCEDURE

It is important to understand normal operating characteristics of the CVT, what type, location, and speeds of noise.

NOTE: DO NOT ATTEMPT REPAIR IF THE NOISE IS COMPARABLE TO A SIMILARLY EQUIPPED VEHICLE.



For whine/thump/knock noise in park or neutral, go to Possible Cause Step 1.
For tick noise on deceleration from 20 MPH (32 Km/h) to a stop, go to Possible Cause Step 2.
For whine noise on deceleration, go to Possible Cause Step 3.
For other noise concerns, refer to Other Concerns: Noise/Vibration - Forward or Reverse in Workshop Manual, Section 307-01A for a complete list of possible noise sources.
Possible Cause

Whine/thump/knock in park and neutral with engine running that goes away when vehicle is put into drive. Noise may come back when vehicle starts to move. This may be caused by machining of the input shaft or flat spots on the roller bearing. For diagnosis first use chassis ears to pinpoint the noise to transaxle area. If the noise is from the transaxle, monitor Turbine Shaft Speed (TSS_SRC) PID using scan tool. If the noise goes away as TSS_SRC goes to 0, when vehicle is put in gear, replace input shaft and bearing following instruction in Workshop Manual, Section 307-01A.
Tick noise on deceleration from 20 MPH (32 Km/h) to a stop. This may be caused by the differential ring gear. For front wheel drive (FWD), if the noise is isolated to the final drive area of the transmission, replace the differential assembly and transfer gear. If the vehicle is an all wheel drive (AWD), remove the power transfer unit (PTU) assembly, reinstall the halfshafts, disconnect the differential electronic module (DEM) and road test. If the noise goes away, the condition is isolated to the AWD system (not CVT related). If the noise is still present, replace the transaxle differential and transfer gear. Refer to Workshop Manual, Section 307-01A for procedures to shim the differential assembly and set proper preload. All replacement differential assemblies are serviced with bearings installed. AWD differentials are serviced with the inner seal installed. Outer bearing races are not packaged with replacement differential/bearing assemblies and will also require replacement.
Gear whine during coast down or deceleration. This may be caused by the transfer gear assembly. If noise follows the criteria below, replace the transfer gear.
69th order noise from 42-35 MPH (68-56 Km/h) (loudest at around 37 MPH (59 Km/h))
69th order noise from 32-25 MPH (51-40 Km/h) (loudest at around 27 MPH (43 Km/h))
138th order noise from 11-16 MPH (18-26 Km/h) (loudest at around 15 MPH (24 Km/h))
NOTE: THE TRANSFER GEAR DUST SEAL AND O-RING WILL ALSO NEED TO BE REPLACED.




PART NUMBER PART NAME
7F9Z-7015-A Input Shaft
5F9Z-7025-A Bearing
5F9Z-7F465-AA Diff Assy AWD
5F9Z-7F465-BA Diff Assy FWD
5F9Z-4222-BA Diff Bearing Race
5F9Z-4222-CA Diff Bearing Race
7F9Z-7H348-A Side Shaft Gear Assy 5.19
7F9Z-7H348-B Side Shaft Gear Assy 5.54
5F9Z-7J309-AA Dust Cap
5F9Z-7L280-CA O-ring


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME
061104A 2005-2006 Five Hundred, Freestyle FWD: Replace The Input Shaft And Bearing Includes Time To Remove And Install Transmission (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 8.1 Hrs.
061104B 2005-2006 Five Hundred, Freestyle FWD: Replace Transaxle Differential And Transfer Gear Includes Time To Remove And Install Transmission (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 8.3 Hrs.
061104C 2005-2006 Five Hundred, Freestyle FWD: Replace Side Shaft Gear Assembly (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 1.4 Hrs.
061104D 2005-2006 Five Hundred, Freestyle, Montego AWD: Replace The Input Shaft And Bearing Includes Time To Remove And Install Power Transfer Unit, And Transmission (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 8.6 Hrs.
061104E 2005-2006 Five Hundred, Freestyle, Montego AWD: Replace Transaxle Differential And Transfer Gear Includes Time To Remove And Install Power Transfer Unit, And Transmission (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 8.8 Hrs.
061104F 2005-2006 Five Hundred, Freestyle, Montego AWD: Replace Side Shaft Gear Assembly Includes Time To Remove And Install The Power Transfer Unit (Do Not Use With 7000A, 7000A2, 7000A12, 7000A38, 7000F10, 7191A, 7091A1, 7228A, 3329A, 7000AZJ, 7003B) 2.7 Hrs.
MT061104 Claim Additional Labor Required as Actual Time Actual TIme

DEALER CODING
BASIC PART NO. CONDITION CODE
7015 (Use With Labor Operation A And D) 42
7F465 (Use With Labor Operation B) 42
7H348 (Use With Labor Operation C, E, And F) 42

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NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.


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