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Section 1155 (Automatic Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) CHART

G03985044
 Air Test Plate and Gaskets
307-433-1, 307-433-2, 307-433-3
G03948850
 Remover, Input Shaft Oil Seal
308-375
G03985217
 Remover, Transmission Fluid Pump
307-397
G03912866
 Holding Fixture, Transmission
307-003 (T57L-500-B)
G03885061
 Slide Hammer
100-001 (T50T-100-A)
G03922675
 Remover, Torque Converter Fluid Seal
307-309 (T94P-77001-BH)
G03997617
 Compressor, Servo Cover
307-402
G03914889
 Handle, Torque Converter
307-091 (T81P-7902-C)

    All vehicles 

  1. Place the transmission on a workbench.
    Fig 1: Placing Transmission On Workbench
    G03948492Courtesy of FORD MOTOR CO.
  2. If vehicle is equipped, and installation of a new or remanufactured torque converter is necessary, remove the torque converter adapter plate.
    Fig 2: Removing Torque Converter Adapter Plate
    G03948858Courtesy of FORD MOTOR CO.
  3. If the adapter plate has been removed use the special tools to remove the torque converter.
    Fig 3: Removing Torque Converter
    G03948859Courtesy of FORD MOTOR CO.
    4. WARNING: The torque converter is heavy, especially when full of fluid.
    NOTE: If not installing a new torque converter leave the adapter plate bolted to the torque converter.
    Fig 4: Removing Torque Converter And Adapter Plate As An Assembly
    G03948860Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the torque converter and adapter plate as an assembly.
  5. Remove the input shaft.
    Fig 5: Removing Input Shaft
    G03948861Courtesy of FORD MOTOR CO.
  6. Remove the sensors.
    Fig 6: Removing Sensors
    G03948862Courtesy of FORD MOTOR CO.
  7. Remove the outer manual control lever.
    Fig 7: Removing Outer Manual Control Lever
    G03948621Courtesy of FORD MOTOR CO.
  8. Remove the digital transmission range (TR) sensor.
    Fig 8: Removing Digital Transmission Range (TR) Sensor
    G03948700Courtesy of FORD MOTOR CO.

    9. 4x2 applications 

  9. Using the special tools, remove the extension housing seal.
    Fig 9: Removing Extension Housing Seal
    G03948865Courtesy of FORD MOTOR CO.
    10. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 10: Removing Extension Housing
    G03948866Courtesy of FORD MOTOR CO.
  10. Remove the extension housing.

    11. 4x4 applications 

  11. Using the special tools, remove the extension housing seal.
    Fig 11: Removing Extension Housing Seal
    G03948867Courtesy of FORD MOTOR CO.
    12. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 12: Removing Extension Housing
    G03948680Courtesy of FORD MOTOR CO.
  12. Remove the extension housing.

    13. All applications 

    NOTE: 4x2 shown, 4x4 similar.
  13. Remove the parking pawl assembly and discard the gasket.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    4. Remove and discard the gasket.
      Fig 13: Removing Parking Pawl Assembly
      G03948869Courtesy of FORD MOTOR CO.
    14. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If not damaged, the gasket should be reused.
    Fig 14: Identifying Transmission Fluid Pan And Gasket
    G03948629Courtesy of FORD MOTOR CO.
  14. Remove the 16 transmission fluid pan screws, fluid pan and gasket.
  15. Remove the transmission fluid filter and seal assembly and discard.
    Fig 15: Identifying Transmission Fluid Filter Mounting Screws
    G03948630Courtesy of FORD MOTOR CO.
  16. Remove the manual control valve detent spring.
    Fig 16: Removing Manual Control Valve Detent Spring
    G03948872Courtesy of FORD MOTOR CO.
    17. WARNING: The upper and lower servo covers are under spring tension. Use care when removing the piston and cover assembly. Failure to follow these instruction can result in personal injury.
    Fig 17: Removing Reverse Servo Assembly
    G03948644Courtesy of FORD MOTOR CO.
  17. Remove the reverse servo assembly.
    18. CAUTION: Do not damage solenoid body connector pins.
    Fig 18: Locating Solenoid Body Mounting Screws
    G03948643Courtesy of FORD MOTOR CO.
  18. Remove the solenoid body assembly by lifting on the body and pushing the connector from the other side of the case.
  19. Remove the main control valve body, separator plate and gasket.
    Fig 19: Removing Main Control Valve Body, Separator Plate And Gasket
    G03948646Courtesy of FORD MOTOR CO.
  20. Using the special tools, remove the converter hub seal.
    Fig 20: Removing Converter Hub Seal
    G03948876Courtesy of FORD MOTOR CO.
    21. CAUTION: Failure to loosen the OD band adjusting screw prior to pump removal may cause damage to the pump and OD band.
    CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 21: Locating Locknuts
    G03948877Courtesy of FORD MOTOR CO.
  21. Remove the locknuts, and loosen the OD band adjusting screw.
  22. Remove and tag the overdrive anchor strut for assembly.
    Fig 22: Removing And Tag Overdrive Anchor Strut For Assembly
    G03948878Courtesy of FORD MOTOR CO.
    23. CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.
    Fig 23: Locating Screws
    G03948879Courtesy of FORD MOTOR CO.
  23. Remove and discard the screws.
  24. Install the special tool.
    Fig 24: Installing Special Tool
    G03948880Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the pump.
    Fig 25: Removing Pump
    G03948881Courtesy of FORD MOTOR CO.
    26. CAUTION: Servo cover is under spring tension.
    Fig 26: Removing Intermediate Servo Cover Retaining Ring And Cover
    G03948882Courtesy of FORD MOTOR CO.
  26. Using the special tool, remove the intermediate servo cover retaining ring and cover.
  27. Remove the intermediate Dana servo piston and spring.
    Fig 27: Locating Intermediate Band Servo Piston And Spring
    G03948883Courtesy of FORD MOTOR CO.
    28. CAUTION: Servo cover is under spring tension.
    Fig 28: Removing Overdrive Servo Cover Retaining Ring And Cover
    G03948884Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the overdrive servo cover retaining ring and cover.
  29. Remove the front band servo piston and spring.
    Fig 29: Locating Front Band Servo Piston And Spring
    G03948885Courtesy of FORD MOTOR CO.
  30. Remove the screw.
    Fig 30: Locating Screw
    G03948886Courtesy of FORD MOTOR CO.
    31. NOTE: Tag and identify parts for reassembly.
    Fig 31: Identifying Apply Strut
    G03948887Courtesy of FORD MOTOR CO.
  31. Compress the overdrive band and remove the apply strut.
    32. CAUTION: Identify the anchor and apply ends of the overdrive band.
    NOTE: The new overdrive band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  32. Remove and inspect the overdrive band. Check the following conditions for installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
      Fig 32: Identifying Overdrive Band
      G03948888Courtesy of FORD MOTOR CO.
  33. Remove the overdrive brake and coast clutch drum.
    Fig 33: Identifying Overdrive Brake And Coast Clutch Drum
    G03948889Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not bend the trigger wheel.
    NOTE: The No. 12 thrust bearing is in this assembly.
    Fig 34: Identifying Planetary Gear Overdrive Carrier
    G03948890Courtesy of FORD MOTOR CO.
  34. Remove the planetary gear overdrive carrier.
  35. Remove the overdrive planet thrust bearing (No. 2).
    Fig 35: Identifying Overdrive Planet Thrust Bearing
    G03948891Courtesy of FORD MOTOR CO.
  36. Remove the overdrive ring gear, overdrive one-way clutch assembly, and center shaft as an assembly.
    Fig 36: Identifying Overdrive Ring Gear
    G03948892Courtesy of FORD MOTOR CO.
    37. NOTE: Tag and identify the center shaft thrust bearing (No. 3) for assembly.
    Fig 37: Identifying Center Shaft Thrust Bearing
    G03948893Courtesy of FORD MOTOR CO.
  37. Remove the No. 3 center shaft thrust bearing.
    38. CAUTION: The center support locknut could fall into the remaining assembly if not removed.
    Fig 38: Locating Bolt
    G03948894Courtesy of FORD MOTOR CO.
  38. Remove the screw.
  39. Remove the locknut and cage.
    Fig 39: Locating Center Support Locknut And Cage
    G03948895Courtesy of FORD MOTOR CO.
  40. Remove the center support retaining ring.
    Fig 40: Identifying Center Support Retaining Ring
    G03948896Courtesy of FORD MOTOR CO.
    41. NOTE: The center support is repaired as an assembly. Any damage requires installing a new component.
    NOTE: When removing the center support, pull evenly around the center support web.
    Fig 41: Removing Center Support
    G03948897Courtesy of FORD MOTOR CO.
  41. Remove the center support.
  42. Inspect the center support assembly for wear or damage.
    1. Inspect the thrust surfaces for wear or damage.
    2. Inspect the center support sealing surface.
    3. Inspect the fluid passage for blockage or damage.
      Fig 42: Inspecting Fluid Passage For Blockage
      G03948898Courtesy of FORD MOTOR CO.
  43. Inspect the seal rings for damage.
    Fig 43: Identifying Seal Rings
    G03948899Courtesy of FORD MOTOR CO.
  44. Inspect the bearing for missing rollers or damage.
    Fig 44: Inspecting Bearing For Missing Rollers Or Damage
    G03948900Courtesy of FORD MOTOR CO.
  45. Inspect the direct clutch feed hole for blockage or damage.
    1. Rotate the center support bearing to locate the direct clutch feed hole.
    2. Inspect the direct clutch feed hole for blockage or damage.
      Fig 45: Inspecting Direct Clutch Feed Hole For Blockage Or Damage
      G03948901Courtesy of FORD MOTOR CO.
    46. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 46: Identifying Intermediate Brake Drum Thrust Washer
    G03948902Courtesy of FORD MOTOR CO.
  46. Remove the intermediate brake drum thrust bearing (No. 4).
  47. Remove and tag the intermediate band anchor strut for assembly.
    Fig 47: Identifying Intermediate Band Anchor Strut
    G03948903Courtesy of FORD MOTOR CO.
    48. CAUTION: Identify the anchor and apply ends of the intermediate band.
    NOTE: The new intermediate band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  48. Remove and inspect the intermediate band. Check the following conditions for installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
      Fig 48: Identifying Intermediate Band
      G03948904Courtesy of FORD MOTOR CO.
  49. Remove and tag the intermediate band apply strut for assembly.
    Fig 49: Installing Intermediate Band Apply Strut
    G03948905Courtesy of FORD MOTOR CO.
  50. Remove the screw.
    Fig 50: Locating Screw
    G03949148Courtesy of FORD MOTOR CO.
    51. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
    Fig 51: Identifying Direct Clutch Drum
    G03948907Courtesy of FORD MOTOR CO.
  51. Remove the direct clutch drum.
  52. Remove the No. 5 forward clutch cylinder thrust bearing, tag and identify.
    Fig 52: Identifying Thrust Bearing
    G03948908Courtesy of FORD MOTOR CO.
    53. NOTE: The No. 6A thrust bearing may come out with the cylinder. Tag for reassembly.
    Fig 53: Identifying Forward Clutch Cylinder
    G03948909Courtesy of FORD MOTOR CO.
  53. Remove the forward clutch cylinder.
    54. NOTE: The No. 6A forward ring gear hub thrust bearing may have come out with the forward clutch cylinder.
    Fig 54: Identifying Forward Ring Gear Hub Thrust Bearing
    G03948910Courtesy of FORD MOTOR CO.
  54. Remove the No. 6A forward ring gear hub thrust bearing.
    55. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
    Fig 55: Identifying Forward Ring Gear And Hub
    G03948911Courtesy of FORD MOTOR CO.
  55. Remove the forward ring gear and hub as an assembly.
  56. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
    Fig 56: Identifying Forward Clutch Thrust Washer
    G03948912Courtesy of FORD MOTOR CO.
    57. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
    Fig 57: Identifying Forward Planet Thrust Bearing
    G03948913Courtesy of FORD MOTOR CO.
  57. Remove the No. 7 forward planet thrust bearing.
  58. Remove the forward planetary assembly.
    Fig 58: Identifying Forward Planetary Assembly
    G03948914Courtesy of FORD MOTOR CO.
  59. Remove the input shell and sun gear assembly.
    Fig 59: Identifying Input Shell And Sun Gear Assembly
    G03948915Courtesy of FORD MOTOR CO.
  60. Remove the spacer.
    Fig 60: Removing Spacer
    G03948916Courtesy of FORD MOTOR CO.
    61. NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
    Fig 61: Identifying Thrust Bearing
    G03948917Courtesy of FORD MOTOR CO.
  61. Remove the thrust bearing.
  62. Remove the retaining ring.
    Fig 62: Identifying Thrust Bearing
    G03948917Courtesy of FORD MOTOR CO.
  63. Remove low/reverse planetary assembly.
    Fig 63: Identifying Low/Reverse Planetary Assembly
    G03948919Courtesy of FORD MOTOR CO.
    64. NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
    Fig 64: Identifying Thrust Bearing
    G03948920Courtesy of FORD MOTOR CO.
  64. Remove the thrust bearing.
    65. NOTE: Use slots located around the outside of the sleeve.
    Fig 65: Identifying Output Shaft Sleeve
    G03949124Courtesy of FORD MOTOR CO.
  65. Using a small pick, remove the output shaft sleeve.
    66. WARNING: The output shaft may fall out after removing the snap ring. Failure to follow these instructions may result in personal injury.
    CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 66: Identifying Output Shaft Retaining Ring
    G03948922Courtesy of FORD MOTOR CO.
  66. While holding the output shaft, remove and discard the output shaft retaining ring.
  67. Remove the output shaft ring gear and hub.
    Fig 67: Identifying Output Shaft Ring Gear
    G03948923Courtesy of FORD MOTOR CO.
  68. Remove the No. 10 low intermediate sun gear bearing.
    Fig 68: Identifying Low Intermediate Sun Gear Bearing
    G03948924Courtesy of FORD MOTOR CO.
    69. CAUTION: Do not pry on the outer edge of the case damage to the gasket sealing surface could occur.
    NOTE: It may be necessary to grind flat spots on the edges of the reverse band actuating lever shaft in order to remove it.
    Fig 69: Identifying Reverse Band Actuating Lever Shaft
    G03985297Courtesy of FORD MOTOR CO.
  69. Using a pair of vice grips, hold the flat spots on the reverse band actuating lever shaft, wiggle it back and forth and remove the reverse band actuating lever shaft.
  70. Remove the reverse band actuating lever assembly.
    Fig 70: Identifying Reverse Band Actuating Lever
    G03948926Courtesy of FORD MOTOR CO.
    71. NOTE: The inner race of the rear one-way clutch is not removable. It is repaired in the case.
    Fig 71: Identifying Low/Reverse Brake Drum
    G03948927Courtesy of FORD MOTOR CO.
  71. Remove the low/reverse brake drum and one-way clutch assembly by rotating it clockwise.
    72. NOTE: The reverse one-way clutch is part of the reverse brake drum assembly. Install a new reverse brake drum as an assembly only.
  72. Inspect the reverse brake drum assembly and install a new reverse brake drum assembly if damaged.
    1. Inspect the reverse brake drum sprags.
    2. Inspect the reverse brake drum rollers.
    3. Inspect the reverse brake drum.
      Fig 72: Inspecting Reverse Brake Drum Sprags
      G03948928Courtesy of FORD MOTOR CO.
  73. Remove the reverse band.
    Fig 73: Identifying Low/Reverse Band
    G03948929Courtesy of FORD MOTOR CO.
  74. Remove the output shaft and park gear.
    Fig 74: Removing Output Shaft And Park Gear
    G03948930Courtesy of FORD MOTOR CO.
    75. NOTE: Tag and identify the No. 11 output shaft thrust washer.
    Fig 75: Removing Output Shaft Thrust Washer
    G03948931Courtesy of FORD MOTOR CO.
  75. Remove the output shaft thrust washer.
    76. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.
    Fig 76: Removing Nut
    G03948932Courtesy of FORD MOTOR CO.
  76. Remove the nut.
  77. Remove the manual lever shaft retaining pin.
    Fig 77: Removing Manual Lever Shaft Retaining Pin
    G03948933Courtesy of FORD MOTOR CO.
  78. Remove the manual control lever shaft.
    Fig 78: Removing Manual Control Lever Shaft
    G03948934Courtesy of FORD MOTOR CO.
  79. Disconnect the manual valve inner lever from the parking lever actuating rod.
    Fig 79: Locating Manual Valve Inner Lever At Parking Lever Actuating Rod
    G03948935Courtesy of FORD MOTOR CO.
  80. Remove the manual valve inner lever.
    Fig 80: Identifying Manual Control Valve Inner Lever
    G03948936Courtesy of FORD MOTOR CO.
  81. Remove the parking lever actuating rod.
    Fig 81: Identifying Parking Lever Actuating Rod
    G03948937Courtesy of FORD MOTOR CO.
    82. CAUTION: Do not damage the bore.
    Fig 82: Locating Manual Control Lever Seal
    G03948938Courtesy of FORD MOTOR CO.
  82. Remove the manual control lever seal.
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