*Valve body replaced, problem solved*
I was able to get the valve body changed out on my 2006 Fusion. I managed to take some pictures along the way,
http://www.fordfusionclub.com/album.php?albumid=10025. Took 3 hours to remove and replace, then had to wait 24 hours for the form-a-gasket to cure prior to filling the transmission with fluid. A final hour to finish assembly, and clean up.
Total cost:
Valve body - $1265 (-$275 core) = $990
MOTORCRAFT XT8QAW - 4 qt = $45
Permatex Gasket = $8
T55 Torx = $1
Total cost = $1044
Tools required:
Flat screwdriver
T40 Torx for cover bolts
T55 Torx for fill plug ($1 at local hardware store)
10mm Hex for drain plug
12mm socket
10mm socket
~9/32 socket
Started out by removing the air intake tube, just disconnect one electrical connection and loosen the band clamp. This allowed access to the fill plug. I wanted to make sure I could access as other blogs showed that otherwise filling the transmission would be pretty messy. I was also able to remove the air filter base by just pulling up on it to unseat the three vibration mounts and then disconnect the two tabs on the inlet tube near the fender.
Once that was out of the way, you have clear access to the fill plug and the top of the valve body cover bolts. Make sure you can remove the fill plug. Mine was on pretty tight for a fill plug. Once you can remove it, then go ahead and drain the transmission.
Next removed the front air dam under the front bumper. There are 5 screws (might be 9/32 socket, mine were rusted) and three plastic buttons. Need to remove the center of the plastic button then the remaining part will come free. With this out of the way, you gain access to the trans cooler lines and the remaining cover bolts. Have your drain pan under the cover as you pry off the cover from the form - a- gasket.
Once the cover is removed you can disconnect all connectors. The solenoid connectors are pretty difficult to remove, I used a small screwdriver to push them out. Undo the 6 bolts and the two suction cover bolts, and more oil will come draining out. The valve body can now be eased out of the transmission.
Installation is just the reverse. Create a new gasket and install the cover back on. Tighen the drain plugs and cooler hoses. Replace the air dam and filter housing.
Fill the transmission. I had to add right about 3.75 qts. I put in 3 qts, started the engine to warm everything up. Shifted through the gears with the brake on, then checked the fluid level. Added the balance of fluid to top it off.
Took the car out for a drive, able to simulate passing cars, no issues at all. Shifts smooth as the day I bought the car. I have only put about 10 miles on the car so far. If I have any problems I will report back.