Replace all shift solenoids in the 6R80 automatic transmission by removing the transmission pan, valve body, and solenoid pack assembly.

Warnings

Tools required

Parts

• Transmission pan gasket × 1 — BC3Z-7A191-A or equivalent
• Transmission filter × 1 — BC3Z-7A098-A
• Shift solenoid pack (complete set for 6R80) × 1 — BC3Z-7G383-F or individual solenoids
• Valve body gasket kit × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow transmission to cool completely (minimum 2 hours after operation)
3. Raise vehicle using floor jack and support on jack stands at frame rails
4. Remove engine skid plate if equipped (four bolts)
5. Place drain pan under transmission pan

Procedure

1. 1

   Drain transmission fluid
   Locate the transmission drain plug on the bottom of the pan. Remove the drain plug using appropriate socket and allow fluid to drain completely into drain pan. Inspect drained fluid for metal particles or debris that may indicate transmission damage. Once drained, reinstall drain plug with new crush washer.
   Torque spec

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

   Remove transmission pan
   Remove all transmission pan bolts in a criss-cross pattern, starting from the center and working outward. Gently tap the pan with a rubber mallet to break the gasket seal. Lower the pan carefully as residual fluid will drain. Remove and discard the old gasket from both the pan and transmission case mating surfaces.
3. 3

   Remove transmission filter
   Locate the transmission filter attached to the valve body. Remove the filter retaining bolts and carefully pull the filter straight down to avoid damaging the seal bore. Inspect the filter for debris or metal particles. Discard the old filter and O-ring.
4. 4

   Document and remove valve body
   Take detailed photos of all electrical connectors, check ball locations, and separator plate position. Disconnect all solenoid harness connectors by pressing release tabs gently. Remove valve body mounting bolts in the sequence specified (there are approximately 20 bolts of varying lengths). Note bolt locations as they are different lengths. Carefully lower the valve body assembly, keeping it level to prevent check balls from falling out of their bores.
   ⚠The separator plate contains check balls that will fall out if tilted. Keep the valve body horizontal during removal.
5. 5

   Remove separator plate and gaskets
   With the valve body removed, carefully lift the separator plate away from the transmission case. Note the location of all check balls (typically 5-7 balls of various sizes). Use a magnet or parts tray to keep check balls organized by location. Remove all old gaskets from the separator plate and transmission case. Clean all mating surfaces with brake cleaner and lint-free rags.
6. 6

   Remove old shift solenoids
   Locate all shift solenoids on the valve body. The 6R80 has seven solenoids: SSA, SSB, SSC, SSD, SSE, TCC solenoid, and intermediate clutch solenoid. Remove the bolts securing each solenoid to the valve body. Carefully pull each solenoid straight out to avoid damaging the valve body bores. Note the orientation and position of each solenoid.
7. 7

   Inspect and clean valve body
   Thoroughly inspect all valve body passages for debris, varnish, or damage. Clean all passages with brake cleaner and compressed air if available. Inspect solenoid bores for scoring or wear. Check all springs and check valves for proper operation. Replace any damaged components.
8. 8

   Install new shift solenoids
   Lubricate new solenoid O-rings with MERCON LV ATF. Install each new solenoid into its correct position on the valve body, ensuring proper orientation. Press each solenoid firmly into its bore until fully seated. Install solenoid retaining bolts and tighten to specification. Verify each solenoid is secure and properly aligned.
   Torque spec

   Sensor Bolts14 Nm (10 lb-ft)
9. 9

   Reinstall separator plate assembly
   Install new gaskets on the transmission case, ensuring they are properly aligned with all bolt holes and passages. Carefully position all check balls in their correct locations according to your photos and documentation. Place the separator plate over the check balls, keeping it level to prevent ball displacement. Install another gasket on top of the separator plate.
10. 10

    Install valve body
    Carefully raise the valve body assembly into position, keeping it level and aligned with all passages. Start all valve body mounting bolts by hand, ensuring correct bolt lengths in their respective holes. Tighten bolts in a criss-cross pattern from the center outward. Reconnect all solenoid harness connectors, ensuring each clicks into place securely.
    ⚠Use the 34 Nm (25 lb-ft) specification for valve body mounting bolts. Do not overtighten as this can warp the valve body.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
11. 11

    Install new transmission filter
    Install new O-ring on the filter neck, lubricating with MERCON LV ATF. Push the filter straight up into the valve body until fully seated. Install filter retaining bolts and tighten securely.
12. 12

    Clean and install transmission pan
    Thoroughly clean the transmission pan with brake cleaner, removing all old gasket material and debris. Inspect the magnet in the pan and clean it. Clean the transmission case mating surface with plastic scraper and brake cleaner. Install new gasket on the pan. Position the pan against the transmission case, ensuring the gasket stays in place. Install all pan bolts hand-tight first, then torque in a criss-cross pattern from the center outward.
    Torque spec

    Pan Bolts20 Nm (15 lb-ft)
13. 13

    Refill transmission fluid
    Reinstall engine skid plate if equipped. Lower the vehicle to level ground. Remove the transmission dipstick. Using a transmission fluid pump and funnel, add approximately 6 quarts of Motorcraft MERCON LV ATF through the dipstick tube. Start the engine and allow it to idle. With the engine running and parking brake engaged, move the shifter through all gear positions, pausing 3 seconds in each position. Return to Park.
14. 14

    Check and adjust fluid level
    With the engine at idle and transmission in Park, check the fluid level on the dipstick. The fluid should be in the cold range. Add additional fluid as needed to reach the proper level. Total capacity is approximately 11 quarts, but actual fill amount depends on how much was retained in the torque converter and cooler lines. Do not overfill.
    ⚠Overfilling can cause fluid aeration and transmission damage. Add fluid in small increments and recheck frequently.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm transmission pan has no leaks after initial fill
3. Ensure all tools and parts have been removed from under the vehicle
4. Reinstall any skid plates or protective covers

Verification

• Start engine and verify no leaks from transmission pan or drain plug
• With engine at operating temperature, recheck fluid level and adjust if necessary to hot range on dipstick
• Test drive vehicle through all gears, verifying smooth shifts with no slipping, flaring, or harshness
• Scan for diagnostic trouble codes with OBD-II scanner to confirm all solenoids are functioning properly
• After test drive, recheck fluid level and inspect for leaks
• Monitor transmission operation over the next 100 miles for proper shift quality and fluid level

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