This procedure replaces the torque converter clutch (TCC) solenoid in the 6R80 automatic transmission by removing the transmission pan, valve body, and accessing the solenoid pack.

Warnings

Tools required

Parts

• Torque converter clutch solenoid × 1 — BC3Z-7G383-A or equivalent
• Transmission pan gasket × 1 — Use OEM specification
• Valve body gasket kit × 1 — Use OEM specification
• Transmission filter × 1 — FL-910 or equivalent
• Transmission drain plug crush washer × 1 — Use OEM specification if equipped

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Allow transmission to cool if recently operated
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove front skid plate if equipped
5. Place large drain pan under transmission pan area
6. Disconnect negative battery terminal

Procedure

1. 1

   Drain transmission fluid
   If equipped with drain plug, loosen and remove transmission drain plug allowing fluid to drain completely. If no drain plug is present, carefully loosen one corner of the transmission pan bolts to create a drain point, controlling flow rate by how far you loosen the bolts. Allow fluid to drain into pan.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove transmission pan
   Remove all transmission pan bolts in a criss-cross pattern, working from outer bolts inward. Carefully lower pan and gasket, being prepared for additional fluid to spill. Inspect pan for metal debris or excessive clutch material. Clean pan thoroughly with brake cleaner and inspect magnet for abnormal material.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)
3. 3

   Remove transmission filter
   Remove the transmission filter by pulling straight down to disconnect from valve body. The filter is typically held by a press-fit seal. Inspect the filter screen for debris and contamination. Discard old filter.
4. 4

   Disconnect electrical connectors
   Locate all electrical connectors on the valve body. There are multiple solenoid connectors and the main transmission harness connector. Press release tabs and carefully disconnect all electrical connectors. Note routing and positions for reassembly.
   ⚠Do not pull on wires. Press connector release tabs firmly and pull only on connector bodies.
5. 5

   Remove valve body bolts
   Remove all valve body mounting bolts. There are approximately 15-20 bolts of varying lengths securing the valve body. Keep bolts organized by location as they are different lengths. Note the position of any wiring harness clips or brackets attached to valve body bolts.
   ℹ️Valve body bolts are different lengths. Keep them organized to ensure correct reassembly.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Lower valve body assembly
   Carefully lower the valve body assembly, being aware that internal springs may create resistance. The valve body is heavy and contains many internal passages. Support it with both hands and lower it carefully to avoid dropping check balls or spring-loaded components. Place valve body on clean work surface with the solenoid side facing up.
   ⚠Valve body weighs approximately 15-20 pounds. Support properly to avoid dropping.
7. 7

   Access solenoid body assembly
   With valve body removed and solenoid side facing up, locate the solenoid body assembly. The TCC solenoid is integrated into the solenoid body pack. Remove the bolts securing the solenoid body to the valve body separator plate.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
8. 8

   Replace TCC solenoid
   Remove the old TCC solenoid from the solenoid body assembly. The solenoid will have O-ring seals that must be removed. Install new TCC solenoid ensuring O-rings are properly seated and lubricated with clean MERCON LV fluid. Verify solenoid is fully seated in its bore.
   ℹ️Lubricate all O-rings with clean transmission fluid before installation to prevent damage during assembly.
9. 9

   Reinstall solenoid body to valve body
   Install new gaskets from valve body gasket kit. Position solenoid body assembly back onto valve body separator plate, ensuring all passages align correctly. Install and tighten solenoid body bolts to specification in a criss-cross pattern.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
10. 10

    Reinstall valve body assembly
    Carefully lift valve body assembly back into position in transmission case. Align all passages and ensure manual valve engages properly with manual shift linkage. Install all valve body mounting bolts finger-tight first, then torque in a criss-cross pattern from center outward. Use appropriate torque specification based on bolt size.
    ⚠Ensure manual valve is properly engaged with shift linkage before tightening bolts.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Reconnect electrical connectors
    Reconnect all electrical connectors to valve body solenoids and main harness. Ensure each connector clicks into place and is fully seated. Verify wiring harness is routed correctly and will not contact rotating components.
12. 12

    Install new transmission filter
    Install new transmission filter by pressing firmly upward into valve body until fully seated. The filter should snap into place and be secure with no movement.
13. 13

    Install transmission pan
    Clean transmission pan mating surface and case mating surface thoroughly. Install new transmission pan gasket. Position pan onto transmission case, ensuring gasket stays in place. Install all pan bolts finger-tight, then torque in criss-cross pattern starting from center and working outward.
    ⚠Over-tightening pan bolts can warp the pan and cause leaks. Use torque wrench.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)
14. 14

    Install drain plug if equipped
    If transmission has drain plug, install new crush washer on drain plug and install plug into transmission pan. Torque to specification.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)
15. 15

    Refill transmission fluid
    Lower vehicle. Locate transmission dipstick tube. Using transmission fluid pump or funnel with long tube, add approximately 6-7 quarts of Motorcraft MERCON LV ATF initially. Start engine and allow to idle in Park. Shift through all gear ranges, pausing 3 seconds in each position. Return to Park and check fluid level with engine running at operating temperature. Add fluid as needed to bring to proper level on dipstick. Total capacity is approximately 11 quarts but actual fill amount depends on fluid retained in torque converter and cooler system.
    ⚠Do not overfill transmission. Check level with engine running at operating temperature in Park on level ground.

Reassembly

1. Reinstall front skid plate if equipped and torque mounting bolts to specification
2. Reconnect negative battery terminal
3. Clear any diagnostic trouble codes that may have been set during service
4. Road test vehicle through all gear ranges to verify proper transmission operation

Verification

• Check for transmission fluid leaks around pan and drain plug after initial startup
• Verify transmission shifts smoothly through all gears with no slipping or harsh engagement
• Confirm torque converter lockup engages properly at highway speeds (typically 40+ mph in top gear)
• Monitor transmission fluid level after road test and adjust as needed
• Verify no diagnostic trouble codes related to TCC solenoid or transmission performance
• Recheck fluid level after vehicle reaches normal operating temperature

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