Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2008 Ford Fusion FWD L4-2.3LFACTORY OEM SERVICE PROCEDURE
Transmission Position Sensor/Switch: Service and Repair
IN-VEHICLE REPAIR
Transmission Range (TR) Sensor
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the transmission range (TR) sensor electrical connector and the selector lever cable end.
3. NOTE: Failure to hold the selector lever, while loosening or tightening the manual control lever, will transmit rotational torque to the TR switch causing internal damage.
Remove the TR sensor (the automatic transaxle is removed for clarity).
1 Remove the nut and the manual control lever.
2 Remove the bolts and the TR sensor.
Installation
1. NOTE: Failure to hold the selector lever, while loosening or tightening the manual control lever, will transmit rotational torque to the TR switch causing internal damage.
NOTE: Do not fully tighten the bolts at this time.
Install the TR sensor and loosely install the bolts (the automatic transaxle is removed for clarity).
2. Using the special tool, align the TR sensor and tighten the bolts.
^ Tighten to 10 Nm (89 lb-in).
3. CAUTION: Do not use air tools on this nut. Hold the manual control lever while tightening the manual control lever nut, or damage to the manual control lever shaft or the transmission range (TR) sensor could occur.
Install the manual control lever.
^ Tighten to 22 Nm (16 lb-ft).
4. CAUTION: Check to make sure the manual control lever is in position "2" (same as "D" position).
Adjust the manual control lever to TR sensor D position.
1 L (LOW)
2 D (DRIVE)
3 N (NEUTRAL)
4 R (REVERSE)
5 P (PARK)
^ When in position D, the marks on the manual control lever line up with the marks on the TR sensor.
5. Connect the selector lever cable and the TR sensor electrical connector.
Transmission Range (TR) Sensor
Special Tool(s):
Transmission Range (TR) Sensor:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the transmission range (TR) sensor electrical connector and the selector lever cable end.
3. NOTE: Failure to hold the selector lever, while loosening or tightening the manual control lever, will transmit rotational torque to the TR switch causing internal damage.
Remove the TR sensor (the automatic transaxle is removed for clarity).
1 Remove the nut and the manual control lever.
2 Remove the bolts and the TR sensor.
Installation
1. NOTE: Failure to hold the selector lever, while loosening or tightening the manual control lever, will transmit rotational torque to the TR switch causing internal damage.
NOTE: Do not fully tighten the bolts at this time.
Install the TR sensor and loosely install the bolts (the automatic transaxle is removed for clarity).
2. Using the special tool, align the TR sensor and tighten the bolts.
^ Tighten to 10 Nm (89 lb-in).
3. CAUTION: Do not use air tools on this nut. Hold the manual control lever while tightening the manual control lever nut, or damage to the manual control lever shaft or the transmission range (TR) sensor could occur.
Install the manual control lever.
^ Tighten to 22 Nm (16 lb-ft).
4. CAUTION: Check to make sure the manual control lever is in position "2" (same as "D" position).
Adjust the manual control lever to TR sensor D position.
1 L (LOW)
2 D (DRIVE)
3 N (NEUTRAL)
4 R (REVERSE)
5 P (PARK)
^ When in position D, the marks on the manual control lever line up with the marks on the TR sensor.
5. Connect the selector lever cable and the TR sensor electrical connector.
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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