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Transmission Reassembly

NOTE: Lubricate all parts with transmission fluid during reassembly. Thrust washers and gaskets should be held in place with petroleum jelly. See Figure for location of thrust washers & bearings.
  1. Before installing center support into case, install new high clutch seals on support hub. It is necessary to size these seals. Apply liberal amount of petroleum jelly to center support hub and seals.
    NOTE: If sizing is not done, the seals may be cut or rolled over when entering intermediate brake drum cavity.
  2. Use overdrive brake drum for sizing. Carefully rotate center support while inserting it into drum housing. Observe seals as they enter cavity to ensure that they DO NOT  roll over or get cut.
  3. Ensure center support is seated fully into overdrive drum. Allow assembly to stand for several minutes for seals to seat in grooves. Set aside until required for reassembly.
    NOTE: If new output shaft is being installed, ensure correct shaft is used. The shaft for the 4.0L model does not have a lubrication hole.
  4. Position No. 11 thrust washer in rear of case. Install collector body in rear of case. Install output shaft. Install governor on collector body. Tighten bolts to specifications. See TORQUE SPECIFICATIONS .
  5. Position No. 10 thrust washer into case from front. Using Clutch Replacement Guide (T74P-77193-A), install low-reverse brake drum (guide not required on 4.0L models). Install output shaft ring gear and new snap ring. On 4.0L models, install output shaft sleeve. On all models, install No. 9 thrust washer, reverse planet assembly and No. 8 thrust washer.
  6. On all models except 4.0L, install snap ring in drum to hold planet assembly. On all models, install low-reverse band as marked at disassembly. Replace piston "O" ring and install low-reverse servo piston assembly to hold band in position. See Figure.
    CAUTION: DO NOT  mix any of the servo piston assemblies or covers as transmission failure may occur.
  7. Replace piston "O" ring and install intermediate servo piston assembly. Install piston cover and snap ring. Replace piston "O" ring and install overdrive servo piston assembly. Install piston cover and snap ring.
  8. Install intermediate servo apply lever and shaft into case. Install complete forward clutch and reverse-high clutch assemblies. Turn transmission so output shaft points downward. Install intermediate band and apply strut. Install intermediate band anchor strut. Temporarily install input shaft.
  9. Check transmission rear end play to determine amount of space between thrust washer surface of overdrive center support and intermediate brake drum. The No. 4 thrust washer is used to obtain end play of .012-.022" (.30-.56 mm). Use steps 10) through 13) for this procedure.
  10. Fabricate a depth gauge from an overdrive center support, if available. See Fig 1. Drill a 1/8" (3 mm) hole through thrust washer surface of center support. This will allow a measurement to be taken between thrust surfaces of support and intermediate brake drum.
  11. Place Depth Micrometer (D80P-4201-A) over drilled hole. Extend micrometer probe until it is flush with thrust washer surface of fixture and record reading. Install fabricated depth gauge fixture into intermediate brake drum. See Fig 2.
    Fig 1: Fabricated Depth Gauge Fixture
    G92B14432Courtesy of FORD MOTOR CO.
    Fig 2: Measuring Rear End Play
    G92C14433Courtesy of FORD MOTOR CO.
  12. Gently wiggle input shaft to allow center support fixture to slide into intermediate brake drum. Ensure it is fully seated. Place depth micrometer over drilled hole. Extend micrometer probe until it bottoms against thrust washer surface. Note reading. Subtract reading obtained in step 11) from this reading.
  13. Remove micrometer and measure again 180 degrees from first location. Repeat steps 11) and 12). Average these 2 measurements to obtain final reading. Select thrust washer to obtain correct end play specification. See END PLAY SELECTIVE THRUST WASHER . End play should be .012-.022" (.30-.56 mm).
    END PLAY SELECTIVE THRUST WASHER

    Average Reading In. (mm) Thrust Washer Thickness In. (mm) Thrust Washer Part No.
    .057-.064 (1.46-1.65) .055 (1.4) 89 DT-7D014-HA
    .065-.073 (1.66-1.85) .055 (1.4) 89 DT-7D014-AA
    .074-.077 (1.87-1.95) .063 (1.6) 89 DT-7D014-BA
    .078-.081 (1.96-2.05) .067 (1.7) 89 DT-7D014-CA
    .082-.085 (2.06-2.15) .071 (1.8) 89 DT-7D014-DA
    .086-.089 (2.16-2.25) .075 (1.9) 89 DT-7D014-EA
    .090-.093 (2.26-2.35) .079 (2.0) 89 DT-7D014-FA
    .094-.096 (2.36-2.45) .083 (2.1) 89 DT-7D014-GA
    .097-.104 (2.46-2.65) .087 (2.2) 89 DT-7D014-MA
    .105-.112 (2.66-2.84) .094 (2.4) 89 DT-7D014-JA
    .113-.119 (2.86-3.05) .102 (2.6) 89 DT-7D014-KA
    .120-.124 (3.06-3.15) .110 (2.8) 89 DT-7D014-LA
  14. If average reading is outside of specifications, this indicates improper reassembly, missing parts or parts outside of specifications. Correct before continuing reassembly. If within specifications, remove depth gauge, fixture and input shaft. Install selected No. 4 thrust washer on center support and retain with petroleum jelly.
  15. Insert input shaft (short splines down), through intermediate brake drum and into splines of forward clutch cylinder. Carefully place center support into case. DO NOT  seat it into intermediate brake drum. Ensure it is square with case and 5 mm Allen bolt retainer nut aligns with hole in case.
  16. DO NOT  apply any pressure to center support. Gently wiggle input shaft, allowing center support to slide into intermediate brake drum of its own weight. Perform this operation until support is fully seated. Position No. 3 thrust washer on top of center support.
  17. Install snap ring to retain center support. Snap ring taper should face front of transmission. Ends of snap ring should be positioned in wide shallow cavity located in the 5 o'clock position. Install 5 mm Allen head bolt that retains center support to case. Two types of snap rings are used. Orient snap ring as shown. See Fig 3.
    Fig 3: Installing Center Support Snap Ring
    G92D14434Courtesy of FORD MOTOR CO.
  18. Install sun gear and adapter into overdrive planet assembly and one-way clutch. Take care to center needle bearing race inside of planetary assembly. Ensure it stays centered and is positioned with lip upward (toward sun gear).
  19. Install overdrive planet assembly and one-way clutch into case. Install overdrive drum assembly. Install overdrive bracket, apply lever and shaft. Install overdrive band (tagged at disassembly), and apply strut. Install anchor strut.
  20. Ensure needle bearing race in overdrive planetary assembly is centered and overdrive clutch is fully seated. Place No. 1 selective washer on top of overdrive clutch drum and temporarily install pump assembly (without gasket) into case. Ensure pump assembly is fully seated in case and pump body is below level of case gasket surface.
    NOTE: Check for damaged or missing front pump support seal. Replace if necessary.
  21. Mount a dial indicator on oil pump with tip resting on transmission housing. See Fig 4. Zero dial indicator and swing indicator around so plunger contacts oil pump.
    Fig 4: Checking End Play
    G92E14435Courtesy of FORD MOTOR CO.
  22. Record dial indicator reading. Move dial indicator assembly to opposite side of pump (180 degrees). Take another end play reading. Average the 2 readings.
  23. End play range is .007-.025" (.18-.64 mm). If end play exceeds limits, replace No. 1 selective thrust washer. See END PLAY SELECTIVE THRUST WASHER .
  24. After end play check has been completed, remove oil pump and No. 1 selective thrust washer. Mark installed position of oil pump gears in relation to one another and remove.
  25. Using Seal Replacer (T78L-77248-AH), install new oil pump seal. Position separator plate on converter housing. Place pump gears into pump housing. The inside edge of small gear has a chamfer on one side. This chamfer must face toward front of transmission.
  26. The larger gear has a dimple on one side which must face toward rear of transmission. Position pump assembly onto separator plate and converter housing. Install bolts finger tight.
    NOTE: The rough appearance of pump stator casting is not a flaw. DO NOT  replace casting due to this appearance.
  27. To prevent seal leakage, pump gear breakage or bushing failure, align pump in converter housing with Pump Alignment Set (T74P-77103-X). Select smallest I.D. sleeve which will fit completely over pump shaft. Outside diameter of sleeve will center pump in converter housing.
  28. Install 5 new Allen bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Remove alignment tool. Install input shaft into pump. Install converter into pump gears. Rotate converter to check for free movement. Remove converter and input shaft.
  29. Coat converter housing gasket with petroleum jelly and position on converter housing. Install seal ring on converter housing. Position No. 1 selected thrust washer on rear of pump. Align converter housing and pump to transmission case. Install bolts with new "O" rings and tighten to specification.
  30. Install new lock nut on OVERDRIVE band adjusting screw. Tighten adjusting screw to 120 INCH lbs. (14 N.m). Back off exactly 2 turns (3 1/2 turns on all 1990-91 4.0L vehicles; these vehicles were equipped with a "double wrap" type OVERDRIVE band). Hold adjusting screw and tighten lock nut to 35-45 ft. lbs. (47-61 N.m). Repeat procedure for INTERMEDIATE band. Air pressure tests may be performed to ensure proper transmission operation. See AIR PRESSURE TESTS  under TESTING.
  31. Install shift lever oil seal using Shift Lever Seal Replacer (T74P-77498-A). Install internal shift linkage, external manual control lever and centering pin. Tighten nut to 30-40 ft. lbs. (41-54 N.m). Install "O" ring, kickdown lever and 13 mm nut. Install Neutral switch using Neutral Switch Socket (T74P-77247-A).
  32. Install converter clutch solenoid connector. Install throttle valve, rod, vacuum diaphragm, retaining clamp and bolt. Tighten to specification. Ensure throttle valve moves freely in its bore.
  33. Align valve body to separator plate and gasket using tapered punches. Use a small amount of petroleum jelly to hold gasket in place. Install 2 bolts and tighten to 53-71 INCH lbs. (6-8 N.m). Attach and lock "Z" link to manual valve. Carefully ease valve body into case using care not to bend "Z" link. See Fig 5.
    Fig 5: Connecting Internal Linkage
    G92F14436Courtesy of FORD MOTOR CO.
    NOTE: Valve body bolts are of different lengths. Ensure each bolt is installed in its correct location.
  34. Install and finger tighten bolts "A" and "B". See Figure. Position solenoid retainer onto solenoid. Install and tighten remaining bolts except filter screen bolt. Remove bolt "A" and install detent spring.
  35. Connect solenoid wires. Install reverse servo piston assembly into bore along with Servo Check Spring (D4ZZ-70031-A). Ensure piston rod is seated correctly in reverse band apply end. Install Servo Rod Selecting Gauge (T74P-77190-A) with new servo cover gasket. See Fig 6.
    Fig 6: Selecting Servo Piston & Rod
    G92G14437Courtesy of FORD MOTOR CO.
  36. Tighten select guide adjusting screw to 35 INCH lbs. (4 N.m). Install dial indicator onto case. Position indicator tip on one of 3 servo piston pads accessible through cut-out of guide. Zero dial indicator.
  37. Back out adjusting screw until servo piston bottoms out on guide. Record distance servo piston moved. Servo piston travel should be .120-.220" (3.05-5.59 mm). See Fig 7.
  38. If piston travel is greater than specification, use next longest piston and rod. If less than specification, use next shorter piston and rod. Rods are identified by their number of grooves. Rods with 2 grooves are shortest in length; rods with no grooves are medium in length; rods with 1 groove are longest.
  39. Install selected piston and rod. Recheck piston travel. If correct, remove guide and auxiliary spring. Reinstall servo assembly, accumulator spring, gasket and cover. Install servo cover bolts and tighten to specification.
    Fig 7: Measuring Rear Servo Piston Travel
    G92H14438Courtesy of FORD MOTOR CO.
  40. Install new "O" rings on filter screen and lube with petroleum jelly. Install filter screen and bolt. Install oil pan with new gasket. Tighten pan bolts to specification in 2 steps. Refer to TORQUE SPECIFICATIONS .
  41. Install parking pawl and return spring in extension housing and preload. Using new gasket, install extension housing. Ensure operating parking rod is correctly seated in extension guide cup. Install and tighten bolts.
  42. Install input shaft and torque converter. Ensure torque converter is properly installed. When installation is correct, measurement between torque converter pilot nose and front face of housing will be .402-.568" (11.12-14.30 mm).
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