Section 300 (Automatic Transmission): Assembly: Transmission: Material

Fig 1: Material Specification

Courtesy of FORD MOTOR CO.

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. In addition to appearing in the section, the necessary torques can be found in the General Specifications Chart.

When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.

Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.

Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.

1. Use the special tools to install the rear case bushing if removed.
   1. Position the rear case bushing and the special tool inside the case.
   2. Assemble the special tools through the back of the case.
   Fig 2: Installing Rear Case Bushing Using Special Tools

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2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
   Fig 3: Placing Transmission In Vertical Position

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CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur.
Fig 4: Installing Output Shaft And Output Shaft Ring Gear
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4. Install the output shaft and output shaft ring gear.
5. Install the No. 8 bearing.
   Fig 5: Installing Bearing

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6. Install the direct clutch.
   Fig 6: Installing Direct Clutch

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NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
Fig 7: Installing Reverse Band Support Retaining Ring
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7. Install the reverse band support retaining ring.
NOTE: Make sure the band is seated on the anchor pins.
Fig 8: Installing Reverse Band
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8. Install the reverse band.
NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
NOTE: The top of the planetary gear support must be below the snap ring groove.
Fig 9: Installing Planetary Assembly And Planetary Gear Support As Unit
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9. Install the planetary assembly and planetary gear support as a unit.
   • Rotate the output shaft to fully seat the planetary assembly.
NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
Fig 10: Installing Case To Planet Support Spring
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10. Install the case to the planet support spring located at the 1 o'clock position.
11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
    Fig 11: Installing Center Support Retaining Ring

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12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse sun gear.
    Fig 12: Installing Forward Clutch Sun Gear

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13. Install the No. 4 forward clutch hub bearing.
    Fig 13: Installing Forward Clutch Hub Bearing

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14. Install the intermediate stub shaft.
    Fig 14: Installing Intermediate Stub Shaft

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15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 15: Installing Forward Clutch Hub

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16. Install the forward clutch assembly.
    Fig 16: Installing Forward Clutch Assembly

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NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
Fig 17: Installing Reverse Clutch Cylinder Assembly
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17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
    Fig 18: Installing Overdrive Band

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19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
    Fig 19: Installing Overdrive Servo Spring

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20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 20: Locating Pocket Of The Overdrive Band

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21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 21: Compressing Overdrive Servo Assembly And Install Overdrive Servo Retaining Ring

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22. Install the intermediate clutch pressure plate.
    Fig 22: Installing Intermediate Clutch Pressure Plate

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NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.
Fig 23: Installing Intermediate Clutch Pack And Selective Steel Plate
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23. Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

       If the intermediate clutch is not within specification, install a correct selective plate.

    Selective Steel Plates

    Fig 24: Selective Steel Plates Specification

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    Fig 25: Installing Special Tool

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25. Install the intermediate anti-rattle clip, if equipped.
    Fig 26: Installing Intermediate Anti-Rattle Clip

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26. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

       Use the No. 1 thrust washer chart to select the correct washer.

       Fig 27: No. 1 Thrust Washer Chart

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    Fig 28: Identifying Special Tool

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27. Install the No. 1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
    Fig 29: Installing Front Pump Support Thrust Washer

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NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
Fig 30: Installing Alignment Pin At Top Of Case
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28. Install an alignment pin at the top of the case.
NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
29. Install the pump gasket.
NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
Fig 31: Installing Pump Assembly
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30. Install the pump assembly.
31. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
    Fig 32: Removing Alignment Pin And Install Front Pump Bolts

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32. Rotate the transmission to the horizontal position.
33. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
    Fig 33: Installing Parking Pawl

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34. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
    Fig 34: Installing New Extension Housing Gasket

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35. Using the special tool, install a new extension housing seal.
    Fig 35: Installing New Extension Housing Seal

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36. Install the output shaft speed (OSS) sensor.
    1. Position the OSS sensor.
    2. Install the bolt.
    Fig 36: Installing Output Shaft Speed (OSS) Sensor

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37. Using the special tool, install the manual control lever seal.
    Fig 37: Installing Manual Control Lever Seal

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NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
Fig 38: Installing EPC Solenoid
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38. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the EPC solenoid bracket and bolt.
39. Install the manual valve detent lever and parking lever actuating rod.
    Fig 39: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod

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40. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
    Fig 40: Installing Manual Control Lever Shaft

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41. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the 1-2 accumulator lower spring.
    4. Install the 1-2 accumulator cover and seal.
    Fig 41: Installing Accumulator Piston Assembly

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42. Install the 1-2 accumulator retaining ring.
    Fig 42: Installing Accumulator Retaining Ring

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NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
NOTE: Do not install the reverse servo piston cover and seal at this time.
Fig 43: Installing Reverse Servo Piston And Rod Assembly
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43. Install the reverse servo piston and rod assembly.
44. Install the special tool.
    • Tighten the bolt.
    Fig 44: Installing Special Tool

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45. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
    Fig 45: Installing Special Tool

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46. Loosen the bolt until the piston stops against the tool.
    Fig 46: Loosening Bolt

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47. Verify that the amount of piston travel on the dial indicator is within specification.
    Fig 47: Identifying Piston Travel Specification On Dial Indicator

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48. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
    Fig 48: Measuring Length Servo Assembly

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49. Remove the special tools.
    Fig 49: Removing Special Tools

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50. Install the reverse servo piston cover and seal assembly.
    Fig 50: Installing Reverse Servo Piston Cover And Seal Assembly

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51. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
    Fig 51: Installing Reverse Servo Retaining Ring

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52. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
    Fig 52: Installing Accumulator Assembly

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53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 53: Applying Regulated Air Pressure To Test Ports

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NOTE: The tab on the electrical connector is secured by main control valve body.
Fig 54: Installing Electrical Connector Into Case
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54. Install the electrical connector into the case.
NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
Fig 55: Aligning Main Control Valve Body Alignment Bolts
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55. Align the main control valve body alignment bolts and position the main control valve body.
NOTE: The main control valve body bolts will be tightened in later steps.
Fig 56: Installing Long Main Control Valve Body Bolts
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56. Loosely install the 11 long main control valve body bolts.
NOTE: The main control valve body bolts will be tightened in later steps.
Fig 57: Installing Short Main Control Valve Body Bolts
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57. Loosely install the 12 short main control valve body bolts.
58. Install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring.
    2. Install the bolt.
    Fig 58: Installing Manual Control Valve Detent Lever Spring

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59. Tighten the bolts in the sequence shown.
    Fig 59: Tightening Bolts In Sequence

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60. Inspect the lead frame for damage.
    • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
    Fig 60: Inspecting Lead Frame For Damage

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61. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    Fig 61: Connecting Molded Lead Frame To Solenoids

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62. Install the fluid filter and seal assembly.
    Fig 62: Installing Fluid Filter And Seal Assembly

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63. Position the pan magnet into the transmission fluid pan.
    Fig 63: Positioning Pan Magnet Into Transmission Fluid Pan

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NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.
Fig 64: Installing Fluid Pan
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64. Install the fluid pan.
    1. Position the transmission fluid pan and gasket.
    2. Install the transmission fluid pan bolts.
65. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
    Fig 65: Installing Digital Transmission Range (TR) Sensor

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NOTE: The tool is designed to fit snugly.
NOTE: Manual shift lever must be in the neutral position.
Fig 66: Aligning Digital TR Sensor Slots
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66. Using the special tool, align the digital TR sensor slots.
67. Tighten the bolts.
    Fig 67: Tightening Bolts

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68. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 68: Locating Converter Hub

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WARNING: The torque converter can fall out if the transmission is tipped.
CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Fig 69: Installing Torque Converter
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69. Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 70: Lubricating Torque Converter Pilot Hub

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