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Freestyle CVT Repair In Progress

Posted: Sun Apr 21, 2019 8:38 pm
by fuxxy
Just cracked open my CVT30 in my 2005 Freestyle, was experiencing the helicopter noise. Followed the TSB and monitored the PID for the input shaft, and it performed exactly as the TSB stated. Helicopter noise in Park and Neutral, switched to Drive and noise went away as TSS_SRC went to zero. As the car started moving, TSS_SRC increased, and the noise followed in sync.

My input shaft is not scored in the "normal" place (Reference: viewtopic.php?t=6245#p43697 )

On my Freestyle, I was missing the O-Ring at the end of the input shaft. Once I got in the case, the smaller needle cage bearing on the input shaft is scored, along with both the inner and outer races.

(Parts that need replacing) TURNS OUT I NEED HELP FIGURING OUT THE NEWEST REVISIONS
Input Shaft - (Ford P/N 5F9Z-7015-AA)
Caged Input Bearing - WIT# 232
Flat Input Bearing - WIT# 230
Drive Pulley -
Input Shaft O-Ring (unless its included in Master Kit) - 5F9Z-7H497-EA
Master Gasket Set - WIT K8200L (https://www.buffaloengine.com/catalog/p ... master-kit)
Pan Filter - A206010A - (https://www.buffaloengine.com/catalog/p ... t30-filter)
Torque Converter - FM3301 (https://www.buffaloengine.com/catalog/p ... -converter)



Now for the questions:
Is this failure in line with all the other threads that are experiencing the bigger 'roller' bearing failure further up the input shaft (and therefore all caused from the same issue)?

Re: Freestyle CVT Repair In Progress

Posted: Sun Apr 21, 2019 8:39 pm
by fuxxy
More Pics

Re: Freestyle CVT Repair In Progress

Posted: Sun Apr 21, 2019 8:40 pm
by fuxxy
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Re: Freestyle CVT Repair In Progress

Posted: Sun Apr 21, 2019 8:40 pm
by fuxxy
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Re: Freestyle CVT Repair In Progress

Posted: Mon Apr 22, 2019 5:39 am
by jas88
I am no help, I just yanked mine out and put in a 6-speed. Mine did not have the helicopter noise, it just moaned loudly like a bad PS pump. However, it still worked perfectly. I took it apart looking for the source of the noise but to no avail. I can only figure it was the TC.

Good luck on your repair.

Re: Freestyle CVT Repair In Progress

Posted: Tue Apr 23, 2019 6:44 pm
by fuxxy
Anyone else have suggestions what should be replaced while i have the trans out and apart??

Re: Freestyle CVT Repair In Progress

Posted: Tue Apr 23, 2019 9:16 pm
by fuxxy
Found a video explaining common problems and causes.

https://m.youtube.com/watch?feature=you ... 5KYAV19RpE

These guys suggest a design flaw in the torque convertor is causing the input shaft o-ring failures.

Re: Freestyle CVT Repair In Progress

Posted: Mon May 27, 2019 6:08 am
by fuxxy
Rebuild is finished, but still having an issue.

Engine starts and idles flawlessly. Fluids topped off. Foot on the brake, shift out of park. Instantly hear a "thump", and engine stops, just like dumping a clutch at idle. Shift to Neutral, crank engine back up. Shift to Drive, same thing - engine jerks and stops instantly.

I installed a rebuilt torque converter from Torco, and im wondering if the torque converter is stuck in lockup.

Are there any tests known that I can use to diagnose if its the torque converter vs. the mechatronic?

Re: Freestyle CVT Repair In Progress

Posted: Wed May 29, 2019 11:46 pm
by xvert
fuxxy wrote:
Mon May 27, 2019 6:08 am
Rebuild is finished, but still having an issue...
I installed a rebuilt torque converter from Torco, and im wondering if the torque converter is stuck in lockup.

Are there any tests known that I can use to diagnose if its the torque converter vs. the mechatronic?
In theory, the torque converter cannot be guilty. I would replace the yellow solenoid TCC (ZF 0501213960) and check the valve body.

Re: Freestyle CVT Repair In Progress

Posted: Mon Jun 03, 2019 4:31 pm
by fuxxy
Removed and cleaned the valve body THOROUGHLY. Verified all valves slide freely, no debris in the valve body. Doublechecked seals on solenoids, both seals for each solenoid "engages" snugly to the valve body. Cleaned contacts on solenoids. Replaced Mechatronics assembly and refilled trans with fluid.

CVT is now able to be placed in gear with engine at idle, however I have more problems now.
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