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Section 1459 (Automatic Transmission - Cd4E): Disassembly: Transaxle: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Clean the transaxle assembly to prevent the entry of dirt when reassembling.
  1. Inspect transaxle during disassembly.
  2. Remove the special tool.
    Fig 1: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
    3. CAUTION: Do not tilt the torque converter when removing it. This can damage the torque converter hub.
    NOTE: The torque converter is filled with fluid. Position it on a table so that fluid will drain out of the torque converter into a drain pan.
    Fig 2: Identifying Installation Special Tool
    G04620092Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the torque converter.
  4. Remove the turbine shaft speed (TSS) sensor.
    1. Remove the bolt.
    2. Remove the TSS sensor.
      Fig 3: Identifying Turbine Shaft Speed Sensor
      G04620093Courtesy of FORD MOTOR CO.
  5. Remove and discard the TSS and OSS sensor O-ring seals.
    Fig 4: Identifying O-Ring Seals
    G04620094Courtesy of FORD MOTOR CO.
  6. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the TR sensor from the manual valve detent lever shaft.
      Fig 5: Identifying Transmission Range (TR) Sensor
      G04620095Courtesy of FORD MOTOR CO.
  7. Using the special tool, secure the transaxle to the bench.
    Fig 6: Securing Transaxle To Bench
    G04620096Courtesy of FORD MOTOR CO.
  8. Position the drain pan under the transaxle, remove the drain plug, and drain the transmission fluid.
    Fig 7: Identifying Transaxle Drain Plug
    G03900626Courtesy of FORD MOTOR CO.
  9. Remove the pump assembly driveshaft.
    Fig 8: Locating Pump Assembly Driveshaft
    G04620098Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove and discard the torque converter impeller hub seal.
    Fig 9: Removing Torque Converter Impeller Hub Seal Using Special Tools
    G04620099Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the LH differential seal.
    Fig 10: Removing LH Differential Seal Using Special Tools
    G04620100Courtesy of FORD MOTOR CO.
  12. If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal.
    Fig 11: Removing RH Differential Seal Using Special Tools (1 Of 2)
    G04620101Courtesy of FORD MOTOR CO.
  13. If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal.
    Fig 12: Removing RH Differential Seal Using Special Tools (2 Of 2)
    G04620102Courtesy of FORD MOTOR CO.
  14. Remove the transaxle fluid filler tube bolt.
    Fig 13: Locating Transaxle Fluid Filler Tube Bolt
    G04620103Courtesy of FORD MOTOR CO.
  15. Remove the transaxle fluid filler tube.
    Fig 14: Removing Transaxle Fluid Filler Tube
    G04620104Courtesy of FORD MOTOR CO.
  16. Remove and discard the transaxle filler tube grommet.
    Fig 15: Locating Transaxle Filler Tube Grommet
    G04620105Courtesy of FORD MOTOR CO.
  17. Remove the main control cover bolts, studs and cover.
    Fig 16: Locating Main Control Cover Bolts
    G04620106Courtesy of FORD MOTOR CO.
  18. Remove the gasket.
    Fig 17: Locating Main Control Cover Gasket
    G04620107Courtesy of FORD MOTOR CO.
  19. Inspect the fitting of the main control cover vent tube for blockage.
  20. Remove the main control valve body bolts.
    Fig 18: Identifying Main Control Valve Body Mounting Bolt Tightening Sequence
    G04620108Courtesy of FORD MOTOR CO.
  21. Disconnect the manual valve link from the manual valve when lifting the main control valve body from the case.
    Fig 19: Locating Manual Valve Link From Manual Valve
    G04620109Courtesy of FORD MOTOR CO.
    22. CAUTION: Do not pull on solenoid body electrical connector wires, or use a hammer on the electrical connector.
  22. Remove the solenoid body electrical connector.
    • Release the retaining tabs and push the connector through the transaxle case.
      Fig 20: Locating Solenoid Body Electrical Connector
      G04620110Courtesy of FORD MOTOR CO.
  23. Support the manual valve and remove the main control.
    Fig 21: Locating Main Control
    G04620111Courtesy of FORD MOTOR CO.
  24. Remove the thermostatic fluid level control valve bracket.
    1. Remove the bolt.
    2. Remove the bracket.
      Fig 22: Identifying Thermostatic Fluid Level Control Valve Bracket
      G04620112Courtesy of FORD MOTOR CO.
  25. Remove the thermostatic fluid level control valve.
    Fig 23: Locating Thermostatic Fluid Level Control Valve
    G04620113Courtesy of FORD MOTOR CO.
    26. WARNING: The servo and servo cover are under high spring force. Use caution when removing servo cover. Failure to follow these instructions can result in personal injury.
    CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case can occur. Use only snap ring pliers to remove the retaining ring.
  26. Using the special tool, remove the servo assembly.
    1. Install the special tool.
    2. Compress the servo assembly by tightening the bolt.
    3. Remove the retaining ring.
      Fig 24: Identifying Installation Special Tool
      G04620114Courtesy of FORD MOTOR CO.
  27. Remove the servo cover assembly.
  28. Remove the intermediate and overdrive servo piston and return spring.
    29. NOTE: If the bonded seal is damaged, install a new servo assembly.
  29. Inspect the intermediate and overdrive servo assembly and bore for damage or wear.
    1. Servo cover with bonded seal.
    2. Cushion spring
    3. Servo apply rod
    4. Servo return spring
      • Case servo bore
        Fig 25: Identifying Intermediate & Overdrive Servo Assembly Components
        G04620115Courtesy of FORD MOTOR CO.
    30. NOTE: Position the transaxle with the torque converter housing facing upward.
    Fig 26: Locating Torque Converter Housing Bolts
    G04620116Courtesy of FORD MOTOR CO.
  30. Remove the 20 bolts.
    31. NOTE: Place the torque converter housing on the engine flange side after removal to prevent damage to the lube tube.
  31. Separate the torque converter housing from the transaxle case.
    • Remove and discard the transaxle split flange gasket.
      Fig 27: Separating Torque Converter Housing From Transaxle Case
      G04620117Courtesy of FORD MOTOR CO.
  32. Remove the differential bearing and shim.
    1. Remove the No. 15 differential bearing.
    2. Remove the No. 14 differential bearing shim.
      Fig 28: Identifying Differential Bearing & Shim Components
      G04620118Courtesy of FORD MOTOR CO.
    33. NOTE: The all wheel drive differential is shown. The front wheel drive differential may or may not have splines.
    Fig 29: Locating Drive Carrier & Differential Assembly
    G04620119Courtesy of FORD MOTOR CO.
  33. Remove the final drive carrier and differential assembly.
  34. Remove the No. 13 driven sprocket thrust bearing.
    Fig 30: Locating Driven Sprocket Thrust Bearing
    G04620120Courtesy of FORD MOTOR CO.
  35. Unclip and remove the chain pan cover.
    Fig 31: Locating Chain Pan Cover
    G04620121Courtesy of FORD MOTOR CO.
    36. NOTE: The driven sprocket thrust washer may adhere to the converter housing.
    Fig 32: Locating Driven Sprocket Thrust Washer
    G04620122Courtesy of FORD MOTOR CO.
  36. Remove the No. 10 driven sprocket thrust washer from the reverse/overdrive ring gear assembly.
  37. Remove the chain drive, reverse/overdrive ring gear and driven sprocket assembly.
    Fig 33: Removing Chain Drive
    G04620123Courtesy of FORD MOTOR CO.
  38. Separate the drive chain assembly from the driven sprocket assembly and reverse/overdrive ring gear assembly.
    Fig 34: Identifying Reverse/Overdrive Ring Gear Assembly
    G04620124Courtesy of FORD MOTOR CO.
    39. NOTE: Inspect the magnet located on the chain pan for excessive metal particles.
    Fig 35: Locating Chain Pan
    G04620125Courtesy of FORD MOTOR CO.
  39. Remove the chain pan (with the magnet retained) from the transaxle case.
  40. Assemble the special tools.
    Fig 36: Identifying Assembling Special Tools
    G04620126Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove and discard fluid filter recirculating regulator exhaust seal.
    Fig 37: Removing Fluid Filter Recirculating Regulator Exhaust Seal Using Special Tools
    G04620127Courtesy of FORD MOTOR CO.
  42. Remove the fluid filter and seal assembly.
    1. Discard the fluid filter.
    2. Discard the fluid filter seal.
      Fig 38: Identifying Fluid Filter & Seal Assembly
      G04620128Courtesy of FORD MOTOR CO.
  43. Remove the No. 12 driven sprocket bearing.
    Fig 39: Locating Driven Sprocket Bearing
    G04620129Courtesy of FORD MOTOR CO.
  44. Remove the No. 11 driven sprocket shim (selective fit).
    Fig 40: Locating Driven Sprocket Shim
    G04620130Courtesy of FORD MOTOR CO.
  45. Disconnect the parking lever actuating rod from the parking cam actuator lever assembly.
    Fig 41: Locating Parking Lever Actuating Rod
    G04620131Courtesy of FORD MOTOR CO.
  46. Disconnect the parking lever actuation rod from the manual valve detent lever, and remove the parking lever actuation rod.
    Fig 42: Locating Manual Valve Detent Lever
    G04620132Courtesy of FORD MOTOR CO.
    47. NOTE: The thrust bearing may adhere to the reverse/overdrive sprocket.
    Fig 43: Locating No. 9 Reverse/Overdrive Ring Gear Thrust Bearing
    G04620133Courtesy of FORD MOTOR CO.
  47. Remove the No. 9 reverse/overdrive ring gear thrust bearing.
    48. NOTE: The thrust bearing is part of the reverse/overdrive carrier assembly.
    Fig 44: Identifying Reverse/Overdrive Carrier Assembly
    G04620134Courtesy of FORD MOTOR CO.
  48. Remove the reverse/overdrive carrier assembly with captured No. 8 thrust bearing.
  49. Remove the reverse/overdrive sun gear and shell assembly.
    Fig 45: Locating Reverse/Overdrive Sun Gear & Shell Assembly
    G04620135Courtesy of FORD MOTOR CO.
    50. NOTE: The thrust bearing may adhere to the reverse/overdrive sun gear and shell.
    Fig 46: Locating Shell Thrust Bearing
    G04620136Courtesy of FORD MOTOR CO.
  50. Remove the reverse/overdrive sun gear and No. 7 shell thrust bearing.
  51. Remove the low/intermediate ring gear assembly.
    Fig 47: Locating Low/Intermediate Ring Gear Assembly
    G04620137Courtesy of FORD MOTOR CO.
    52. NOTE: The low/intermediate carrier thrust bearing may adhere to the low/intermediate ring gear.
    Fig 48: Locating Low/Intermediate Carrier Thrust Bearing
    G04620138Courtesy of FORD MOTOR CO.
  52. Remove the No. 6 low/intermediate carrier thrust bearing.
  53. Remove the low/intermediate carrier assembly.
    Fig 49: Locating Low/Intermediate Carrier Assembly
    G04620139Courtesy of FORD MOTOR CO.
  54. Remove the No. 5 low/intermediate sun gear thrust bearing and tag for installation.
    Fig 50: Locating Sun Gear Thrust Bearing
    G04620140Courtesy of FORD MOTOR CO.
  55. Remove the forward one-way clutch and low/intermediate sun gear.
    Fig 51: Locating Forward One-Way Clutch & Low/Intermediate Sun Gear
    G04620141Courtesy of FORD MOTOR CO.
    56. NOTE: The turbine shaft thrust bearing may adhere to the forward one-way clutch and low/intermediate sun gear.
    Fig 52: Locating Turbine Shaft Thrust Bearing
    G04620142Courtesy of FORD MOTOR CO.
  56. Remove the No. 4 turbine shaft thrust bearing.
  57. Remove the turbine shaft assembly.
    Fig 53: Locating Turbine Shaft Assembly
    G04620143Courtesy of FORD MOTOR CO.
  58. Remove the forward/coast/direct cylinder assembly and reverse clutch drum assembly from the transaxle.
    Fig 54: Locating Reverse Clutch Drum Assembly
    G04620144Courtesy of FORD MOTOR CO.
    59. NOTE: The pump support thrust bearing assembly may adhere to the reverse clutch drum assembly.
    Fig 55: Locating Pump Support Thrust Bearing
    G04620145Courtesy of FORD MOTOR CO.
  59. Remove the No. 1 pump support thrust bearing and tag for installation.
  60. Remove the low one-way clutch retaining ring.
    Fig 56: Locating Clutch Retaining Ring
    G04620146Courtesy of FORD MOTOR CO.
  61. If equipped with a sprag-type one-way clutch, remove the low one-way clutch thrust plate.
    Fig 57: Locating Clutch Thrust Plate
    G04620147Courtesy of FORD MOTOR CO.
  62. If equipped with a mechanical diode, there is no thrust plate.
    Fig 58: Identifying Transfer Equipped With Mechanical Diode
    G04620148Courtesy of FORD MOTOR CO.
    63. NOTE: The low one-way clutch assembly should be removed as an assembly.
    Fig 59: Locating Low One-Way Clutch Assembly
    G04620149Courtesy of FORD MOTOR CO.
  63. Remove the low one-way clutch assembly.
  64. Remove the thin, 8-wave low/reverse clutch wave spring.
    Fig 60: Locating Wave Low/Reverse Clutch Wave Spring
    G04620150Courtesy of FORD MOTOR CO.
  65. Remove the low/reverse clutch plates.
    • Inspect the friction plates for partially stripped, broken or bent spline teeth, burnt, worn or flaked-off friction material and warped or bent friction discs.
    • Inspect the steel plates for heat discoloration or warpage.
      Fig 61: Locating Steel Plates
      G04620151Courtesy of FORD MOTOR CO.
  66. Remove the thick, 10-wave low/reverse clutch wave spring.
    Fig 62: Locating 10-Wave Low/Reverse Clutch Wave Spring
    G04620152Courtesy of FORD MOTOR CO.
  67. Remove the low/reverse clutch return spring retaining ring.
    Fig 63: Locating Low/Reverse Clutch Return Spring Retaining Ring
    G04620153Courtesy of FORD MOTOR CO.
  68. Remove the low/reverse clutch return spring assembly.
    Fig 64: Locating Low/Reverse Clutch Return Spring Assembly
    G04620154Courtesy of FORD MOTOR CO.
    69. NOTE: Rotate the low/reverse clutch piston while pulling upward.
    Fig 65: Locating Low/Reverse Clutch Piston
    G04620155Courtesy of FORD MOTOR CO.
  69. Remove the low/reverse clutch piston.
    70. NOTE: Position the transaxle so the pump assembly is facing upward.
    Fig 66: Locating Pump Assembly Bolts
    G04620156Courtesy of FORD MOTOR CO.
  70. Remove the pump assembly bolts.
  71. Using the special tools, remove the pump assembly.
    1. Install the special tool.
    2. Assemble the special tools.
    3. Using the special tools, remove the pump assembly.
      Fig 67: Removing Pump Assembly Using Special Tools
      G04620157Courtesy of FORD MOTOR CO.
  72. Remove the intermediate and overdrive band assembly from the case.
    • Inspect the intermediate and overdrive band assembly for damage and wear.
      Fig 68: Identifying Overdrive Band Assembly
      G04620158Courtesy of FORD MOTOR CO.
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