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Section 474 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G03975426
 Holding Fixture, Transmission 307-262 (T93T-77002-AH)
G03975427
 Adjustment Set, Transmission Band 307-S022 (T71P-77370-A)
G03975428
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G03975429
 Aligner, Torque Converter 307-331 (T95L-7902-A)
G03975430
 Depth Micrometer 303-D026 (D80P-4201-A) or equivalent
G03975431
 Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)
G03975432
 Installer, Transmission Extension Housing Bushing 307-065 (T77L-7697-F)
G03975433
 Installer, Transmission Extension Housing Fluid Seal 307-038 (T74P-77052-A)
G03975434
 Alignment Set, Fluid Pump 307-S039 (T74P-77103-X)
G03975435
 Alignment Gauge, Transmission Fluid Pump 307-431
G03975436
 Alignment Gauge, Transmission Fluid Pump 307-432
G03975437
 Sizer, Piston Seal 307-338 (T95L-70010-G)
G03975438
 Shim Selection Gauge 307-263 (T93T-77003-AH)
G03975174
 Compressor, Servo Cover 307-340 (T95L-77028-A)
G03975440
 Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)
G03975441
 Handle, Torque Converter 307-091 (T81P-7902-C)
G03975442
 Gauge, TSS 307-337 (T95L-70010-F)
G03975443
 Aligner, Valve Body 307-333 (T95L-70010-B)
G03975444
 Aligner, Valve Body 307-334 (T95L-70010-C)
G03975445
 Retainer, Torque Converter 307-346 (T97T-7902-A)
G03975446
 Transmission Fluid Pump Seal Aligner 307-451/1
G03975447
 Transmission Fluid Pump Seal Sizer 307-451/2
G03975448
 Transmission Fluid Pump Seal Installer 307-451/3
MATERIAL ITEM SPECIFICATION

Item Specification
Multi-Purpose Grease D0AZ-19584-AA ESB-M1C93-B
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V

    ALL VEHICLES 

  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    1. Stripped bolt hole threads.
    2. Gasket and mating surfaces for burrs or nicks.
    3. Obstructions to vent and fluid passages.
      • Cracks or warpage.
        Fig 1: Inspecting Transmission Case
        G03975449Courtesy of FORD MOTOR CO.
  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 2: Inspecting Extension Housing For Cracks, Burrs Or Warpage
    G03975450Courtesy of FORD MOTOR CO.
  4. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.
    Fig 3: Inspecting Case Bearing For Damage
    G03975451Courtesy of FORD MOTOR CO.
  5. Install the special tool on the rear of the transmission case.
    Fig 4: Installing Special Tool On Rear Of Transmission Case
    G03975452Courtesy of FORD MOTOR CO.
  6. Attach the fixture arm of the special tool as shown.
    Fig 5: Attaching Fixture Arm Of Special Tool
    G03975453Courtesy of FORD MOTOR CO.
    7. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  7. Install transmission into the special tool.
    • Rotate the transmission so that the fluid pan rail is facing up.
      Fig 6: Installing Transmission Into Special Tool
      G03975454Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the manual control lever shaft seal.
    • Lubricate the manual control lever shaft seal with petroleum jelly.
      Fig 7: Installing Manual Control Lever Shaft Seal
      G03975455Courtesy of FORD MOTOR CO.
  9. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 8: Assembling Manual Valve Inner Lever And Parking Lever Actuating Rod
    G03975456Courtesy of FORD MOTOR CO.
  10. Install the manual control lever shaft.
    Fig 9: Installing Manual Control Lever Shaft
    G03975457Courtesy of FORD MOTOR CO.
    11. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
  11. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
      Fig 10: Installing Manual Control Lever Shaft Spring Pin
      G03975458Courtesy of FORD MOTOR CO.
    12. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 11: Installing Manual Valve Inner Lever And Parking Lever Actuating Rod On To The Manual Control Lever Shaft
    G03975459Courtesy of FORD MOTOR CO.
  12. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.
    13. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 12: Installing Manual Valve Inner Lever Nut On Manual Control Lever Shaft
    G03975460Courtesy of FORD MOTOR CO.
  13. Install the manual valve inner lever nut on the manual control lever shaft and tighten.
    14. CAUTION: The tabs on the No. 11 output shaft thrust washer point into the case. Make sure the thrust washer is correctly seated.
  14. Install the No. 11 output shaft thrust washer.
    • Coat the output shaft thrust washer with petroleum jelly.
      Fig 13: Installing No. 11 Output Shaft Thrust Washer
      G03975461Courtesy of FORD MOTOR CO.
  15. Install the park gear.
    Fig 14: Installing Park Gear
    G03975462Courtesy of FORD MOTOR CO.
  16. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
      Fig 15: Installing Low/Reverse Brake Drum
      G03975463Courtesy of FORD MOTOR CO.
  17. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly.
    • Coat the needle bearing with petroleum jelly.
      Fig 16: Installing No. 10B Needle Bearing Onto Output Shaft Ring Gear And Hub Assembly
      G03975464Courtesy of FORD MOTOR CO.
  18. Install the output shaft through the output shaft park gear.
    Fig 17: Installing Output Shaft Through The Output Shaft Park Gear
    G03975465Courtesy of FORD MOTOR CO.
  19. Install the output shaft ring gear and output shaft hub.
    Fig 18: Installing Output Shaft Ring Gear And Output Shaft Hub
    G03975466Courtesy of FORD MOTOR CO.
    20. CAUTION: Always install a new output shaft retaining ring.
    Fig 19: Installing New Output Shaft Retaining Ring
    G03975467Courtesy of FORD MOTOR CO.
  20. Install a new output shaft retaining ring.
    21. NOTE: Install the output shaft sleeve with the cone facing up.
    Fig 20: Installing Output Shaft Sleeve
    G03975468Courtesy of FORD MOTOR CO.
  21. Install the output shaft sleeve.
  22. Install low/reverse planetary carrier needle bearings.
    1. Install the No. 8 low/reverse planetary carrier needle bearing on the front face of the low/reverse planetary.
    2. Install the No. 9 low/reverse planetary carrier needle bearing on the rear face of the low/reverse planetary.
      • Coat the No. 8 low/reverse planetary carrier needle bearing and No. 9 low/reverse planetary carrier needle bearing with petroleum jelly.
        Fig 21: Installing Low/Reverse Planetary Carrier Needle Bearings
        G03975469Courtesy of FORD MOTOR CO.
    23. CAUTION: Make sure needle bearings stay in place.
    Fig 22: Installing Low/Reverse Planetary Assembly With No. 8 And No. 9 Low/Reverse Planetary Carrier Needle Bearings
    G03975470Courtesy of FORD MOTOR CO.
  23. Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier needle bearings into the output shaft ring gear.
    24. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 23: Installing Low/Reverse Retaining Ring Into Low/Reverse Brake Drum Groove
    G03975471Courtesy of FORD MOTOR CO.
  24. Install the low/reverse retaining ring into the low/reverse brake drum groove.
    25. CAUTION: Make sure band is resting on the two anchor pins in the case.
    Fig 24: Installing Low/Reverse Band Over Low/Reverse Brake Drum
    G03975472Courtesy of FORD MOTOR CO.
  25. Install the low/reverse band over the low/reverse brake drum.
  26. Temporarily install the low/reverse band servo piston and rod to hold the low/reverse band in position.
    Fig 25: Installing Low/Reverse Band Servo Piston And Rod
    G03975473Courtesy of FORD MOTOR CO.
  27. Install the previously assembled forward geartrain assembly.
    Fig 26: Installing Previously Assembled Forward Geartrain Assembly
    G03975474Courtesy of FORD MOTOR CO.
    28. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  28. Rotate the transmission assembly so that the converter housing surface is facing up.
  29. Select the No. 4 intermediate brake drum thrust bearing as follows:
    1. Install the special tool on the case assembly shoulder.
    2. Set the special tool on top as shown.
      Fig 27: Installing Special Tool On Case Assembly Shoulder
      G03975475Courtesy of FORD MOTOR CO.
  30. Calculate the thrust bearing thickness.
    • Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.
      Fig 28: Calculating Thrust Bearing Thickness - Dimension A
      G03975476Courtesy of FORD MOTOR CO.
  31. Place the micrometer on the opposite side of the special tool and repeat the measurement. This is dimension B.
    Fig 29: Placing Micrometer On Opposite Side Of Special Tool - Dimension B
    G03975477Courtesy of FORD MOTOR CO.
  32. Add dimension A and B, divide the total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 in). Record this reading as dimension C.
  33. Place the special tool across the center support. Place the micrometer on the top of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.
      Fig 30: Placing Special Tool Across Center Support - Dimension D
      G03975478Courtesy of FORD MOTOR CO.
  34. Place the special tool on the opposite side of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.
      Fig 31: Placing Special Tool On Opposite Side Of Special Tool - Dimension F
      G03975479Courtesy of FORD MOTOR CO.
  35. Add dimensions D and F, divide the total of D and F by 2. Subtract the special tool thickness 17.78 mm (0.700 in) dimension E. The result is dimension G.
    Fig 32: Subtracting Special Tool Difference - Dimension G
    G03975481Courtesy of FORD MOTOR CO.
  36. Add dimensions C and G. This total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.008-0.021 in).
    NO. 4 THRUST BEARING THICKNESS CHART

    Dimension H Service Part Number Bearing Thickness Identification (Notches)
    3.01-3.15 mm (0.119-0.124 in) XW4Z-7D014-CA 2.65-2.80 mm (0.104-0.110 in) None
    3.17-3.34 mm (0.125-0.132 in) XW4Z-7D014-DA 2.80-2.95 mm (0.110-0.116 in) 1
    3.36-3.54 mm (0.133-0.140 in) XW4Z-7D014-EA 3.00-3.15 mm (0.118-0.124 in) 2
    3.57-3.71 mm (0.141-0.147 in) XW4Z-7D014-FA 3.20-3.35 mm (0.126-0.132 in) 3
  37. Install the intermediate servo actuating lever.
    Fig 33: Installing Intermediate Servo Actuating Lever
    G03975480Courtesy of FORD MOTOR CO.
    38. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 34: Installing Intermediate Band Actuating Lever Shaft Through Intermediate Servo Actuating Lever
    G03975482Courtesy of FORD MOTOR CO.
  38. Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.
  39. Install the intermediate band apply strut on the intermediate servo actuating lever.
    Fig 35: Installing Intermediate Band Apply Strut On The Intermediate Servo Actuating Lever
    G03975483Courtesy of FORD MOTOR CO.
    40. NOTE: Make sure that the intermediate apply strut is aligned with the band notch.
    Fig 36: Installing Intermediate Band
    G03975484Courtesy of FORD MOTOR CO.
  40. Install the intermediate band.
    41. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.
    NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.
    Fig 37: Installing Intermediate Band Anchor Strut And Intermediate Band Adjustment Screw
    G03975485Courtesy of FORD MOTOR CO.
  41. Install the intermediate band anchor strut and the intermediate band adjustment screw.
  42. Install the No. 4 selected intermediate brake drum thrust washer on the center support.
    • Coat the intermediate brake drum thrust washer with petroleum jelly.
      Fig 38: Installing No. 4 Selected Intermediate Brake Drum Thrust Washer On Center Support
      G03975486Courtesy of FORD MOTOR CO.
    43. CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings can result.
    NOTE: Align the center support screw hole with correct case hole.
  43. Install the center support.
    1. Position the center support into the intermediate brake and direct clutch drum.
    2. Temporarily insert the input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
      Fig 39: Installing Center Support.
      G03975487Courtesy of FORD MOTOR CO.
    44. CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
  44. Install the center support retaining ring.
    1. Position the center support retaining ring with the tapered side facing up.
    2. Install the center support retaining ring so that the notch opening is not obstructed.
      Fig 40: Installing Center Support Retaining Ring
      G03975488Courtesy of FORD MOTOR CO.
  45. Install the center support locknut and cage.
    Fig 41: Installing Center Support Locknut And Cage
    G03975489Courtesy of FORD MOTOR CO.
  46. Loosely install the center support-to-case cap screw.
    Fig 42: Installing Center Support-To-Case Cap Screw
    G03975490Courtesy of FORD MOTOR CO.
    47. CAUTION: Carefully route the TSS sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
    NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.
  47. Install the TSS sensor.
    1. Install the TSS sensor.
    2. Install the TSS sensor screw.
      Fig 43: Installing TSS Sensor And Screw
      G03975491Courtesy of FORD MOTOR CO.
    48. CAUTION: Use only the No. 3 center shaft thrust bearing.
    NOTE: The No. 3 center shaft thrust bearing has no notches on the outer race.
    Fig 44: Installing No. 3 Center Shaft Thrust Bearing
    G03975492Courtesy of FORD MOTOR CO.
  48. Install the No. 3 center shaft thrust bearing.
    49. CAUTION: Do not bend the trigger wheel.
    Fig 45: Installing Overdrive Planetary And One-Way Clutch Assembly
    G03975493Courtesy of FORD MOTOR CO.
  49. Install the overdrive planetary and one-way clutch assembly.
    50. CAUTION: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
  50. Using the special tool, check the TSS sensor air gap.
    1. Place the thin blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
      Fig 46: Checking TSS Sensor Air Gap
      G03975494Courtesy of FORD MOTOR CO.
    51. CAUTION: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does, a new overdrive planetary carrier and trigger wheel must be installed.
  51. Using the special tool, check the TSS sensor air gap.
    1. Place the thick blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
      Fig 47: Checking TSS Sensor Air Gap
      G03975495Courtesy of FORD MOTOR CO.
    52. NOTE: Align the clutch plates and front adapter gear.
    Fig 48: Installing Front Brake Drum And Coast Clutch Drum Assembly
    G03975496Courtesy of FORD MOTOR CO.
  52. Install the front brake drum and coast clutch drum assembly.
  53. Install the front servo band lever and front band lever-to-case bracket into the transmission case.
    Fig 49: Installing Front Servo Band Lever And Front Band Lever-To-Case Bracket Into The Transmission Case
    G03975497Courtesy of FORD MOTOR CO.
    54. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.
    Fig 50: Installing Front Band Actuating Lever Shaft Through The Front Servo Band Lever
    G03975498Courtesy of FORD MOTOR CO.
  54. Install the front band actuating lever shaft through the front servo band lever.
  55. Install the front band apply strut.
    Fig 51: Installing Front Band Apply Strut
    G03975499Courtesy of FORD MOTOR CO.
    56. NOTE: If the front band is reused, it must be installed in its original position.
    Fig 52: Installing Front Band Over Front Brake And Coast Clutch Drum
    G03975500Courtesy of FORD MOTOR CO.
  56. Install the front band over the front brake and coast clutch drum.
    57. NOTE: Use the band adjustment screw as a temporary alignment guide.
    Fig 53: Installing Front Band Anchor Strut
    G03975501Courtesy of FORD MOTOR CO.
  57. Install the front band anchor strut.
  58. Install the front band adjusting screw.
    Fig 54: Installing Front Band Adjusting Screw
    G03975502Courtesy of FORD MOTOR CO.
    59. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
  59. Carry out the front end play check procedure as follows:
    • Coat the No. fluid pump inlet thrust washer with petroleum jelly.
    • Install the No. 1 fluid pump inlet thrust washer on the rear of the fluid pump and place the pump into position in the case.
      Fig 55: Carrying Out Front End Play Check
      G03975503Courtesy of FORD MOTOR CO.
    60. CAUTION: The special tool must rest on the gasket surface.
  60. Measure the front end play clearance.
    1. Place the special tool across the case.
    2. Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
      • Read the measurement and subtract the special tool thickness 17.78 mm (0.70 in). This is dimension A.
      • Repeat the measurement at the opposite side of the transmission case. This is dimension B.
      • Add dimensions A and B together and divide by 2. This is front end clearance dimension C.
        Fig 56: Measuring Front End Play Clearance
        G03975504Courtesy of FORD MOTOR CO.
    61. CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
    NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 in).
  61. Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).
    FRONT END PLAY SELECTIVE THRUST WASHER NO. 1 CHART

    Front End Play C 0.18 - 0.70 mm (0.007 - 0.028 in) Without Gasket
    Selective Pump Support Thrust Washer
    Part Number Thickness Color
    F7TZ-7D014-VA 1.35 - 1.40 mm (0.035 - 0.055 in) Blue
    F7TZ-7D014-TA 1.55 - 1.60 mm (0.061 - 0.063 in) White
    F7TZ-7D014-MA 1.75 - 1.80 mm (0.069 - 0.071 in) Green
    F7TZ-7D014-NA 1.85 - 1.90 mm (0.073 - 0.075 in) Red
    F7TZ-7D014-PA 1.95 - 2.00 mm (0.077 - 0.079 in) Beige
    F7TZ-7D014-RA 2.05 - 2.10 mm (0.081 - 0.083 in) Black
    F7TZ-7D014-SA 2.15 - 2.20 mm (0.085 - 0.087 in) Yellow
    62. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 57: Installing No. 1 Thrust Washer Onto Pump
    G03975505Courtesy of FORD MOTOR CO.
  62. Remove the pump and install the No. 1 thrust washer onto the pump. After installing selected front pump thrust washer No. 1, repeat the front end play check. Make sure the end play is correct, then remove the pump for assembly.
  63. Install a new O-ring seal in the fluid pump drive gear.
    Fig 58: Installing O-Ring Seal In Fluid Pump Drive Gear
    G03975506Courtesy of FORD MOTOR CO.
    64. CAUTION: Lubricate the special tool with multi-purpose grease.
    Fig 59: Installing Fluid Pump Drive Gear On Special Tool To Seat The O-Ring Seal
    G03975507Courtesy of FORD MOTOR CO.
  64. Install the fluid pump drive gear on the special tool to seat the O-ring seal. Remove the tool.
    65. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.
    Fig 60: Installing Pump Gears Into Fluid Pump Housing
    G03975508Courtesy of FORD MOTOR CO.
  65. Install the pump gears into the fluid pump housing. Apply multi-purpose grease to the pump gear to prevent scoring at start-up.
    66. CAUTION: Make sure the holes in the plate line up with the holes in the pump.
    Fig 61: Installing Fluid Pump Adapter Plate
    G03975509Courtesy of FORD MOTOR CO.
  66. Install the fluid pump adapter plate.
    67. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.
    NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.
  67. Install the fluid pump on the converter housing.
    • Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.
      Fig 62: Installing Fluid Pump On Converter Housing
      G03975510Courtesy of FORD MOTOR CO.
  68. Loosely install the fluid pump screws.
    Fig 63: Loosely Installing Fluid Pump Screws
    G03975511Courtesy of FORD MOTOR CO.
    69. CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.
    Fig 64: Selecting Gauge From The Special Tool That Is The Snuggest Fit When Placed Over The Fluid Pump
    G03975512Courtesy of FORD MOTOR CO.
  69. Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.
  70. Thread the gauge into the special tool and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.
    Fig 65: Threading Gauge Into Special Tool
    G03975513Courtesy of FORD MOTOR CO.
  71. Tighten the fluid pump bolts in a star pattern and remove the pump alignment handle.
    Fig 66: Tightening Fluid Pump Bolts
    G03975514Courtesy of FORD MOTOR CO.
  72. Install a new fluid pump seal ring.
    • Coat the fluid pump seal ring with petroleum jelly.
      Fig 67: Installing New Fluid Pump Seal Ring
      G03975515Courtesy of FORD MOTOR CO.
    73. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.
  73. Install a new fluid pump gasket.
    • Hold the fluid pump gasket in place with petroleum jelly.
      Fig 68: Installing New Fluid Pump Gasket
      G03975516Courtesy of FORD MOTOR CO.
    74. CAUTION: Be careful not to overstretch the seal ring past the seal ring groove or damage to the seal will occur.
    Fig 69: Installing Fluid Pump Seal Ring
    G03975517Courtesy of FORD MOTOR CO.
  74. Using the special tools, install the fluid pump seal ring.
    75. CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.
    Fig 70: Verifying Seal Is Installed Correctly
    G03975518Courtesy of FORD MOTOR CO.
  75. Verify that the seal is installed correctly.
    76. CAUTION: Failure to correctly size the seal will damage the seal when the torque converter is installed.
    Fig 71: Sizing Seal With Special Tool
    G03975519Courtesy of FORD MOTOR CO.
  76. Using the special tool, size the seal to the correct size. Leave the special tool on the seal for two minutes to obtain the correct seal size.
  77. Install the selected No. 1 fluid pump thrust washer.
    • Coat the fluid pump thrust washer with petroleum jelly.
      Fig 72: Installing Selected No. 1 Fluid Pump Thrust Washer
      G03975520Courtesy of FORD MOTOR CO.
  78. Install the special tools into the transmission case.
    Fig 73: Installing Special Tools Into Transmission Case
    G03975521Courtesy of FORD MOTOR CO.
    79. CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.
    Fig 74: Installing Input Shaft
    G03975522Courtesy of FORD MOTOR CO.
  79. Install the input shaft.
    80. CAUTION: Make sure that the No. 1 fluid pump inlet thrust washer selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
    Fig 75: Installing Fluid Pump And Converter Housing Onto Case
    G03975523Courtesy of FORD MOTOR CO.
  80. Install the fluid pump and converter housing onto the case.
    81. NOTE: Lubricate the O-ring seals on the converter housing screws.
    Fig 76: Installing New Converter Housing-To-Case Screws
    G03975524Courtesy of FORD MOTOR CO.
  81. Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.
  82. Remove the input shaft.
    Fig 77: Removing Input Shaft
    G03975525Courtesy of FORD MOTOR CO.
    83. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  83. Rotate the transmission assembly so the fluid pan rails are facing up.
  84. Assemble the front servo assembly.
    1. Install the front servo cover O-ring seal on the front servo cover. Coat the front servo cover O-ring seal with petroleum jelly.
    2. Install the front servo piston into the front servo cover.
    3. Install the front servo piston spring on the front servo piston.
      Fig 78: Assembling Front Servo Assembly
      G03975526Courtesy of FORD MOTOR CO.
    85. CAUTION: Do not damage the front servo-to-case O-ring seal during installation.
    CAUTION: Do not press the front servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.
    Fig 79: Installing Front Servo Assembly
    G03975527Courtesy of FORD MOTOR CO.
  85. Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.
  86. Assemble the intermediate servo assembly.
    1. Install the intermediate servo cover O-ring seal on the intermediate servo cover. Coat the intermediate servo cover O-ring seal with petroleum jelly.
    2. Install the intermediate servo piston into the intermediate servo cover.
    3. Install the intermediate servo piston spring on the intermediate servo piston.
      Fig 80: Assembling Intermediate Servo Assembly
      G03975528Courtesy of FORD MOTOR CO.
    87. CAUTION: Do not damage servo cover-to-case O-ring seal during installation.
    CAUTION: Do not press the intermediate servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.
    Fig 81: Installing Intermediate Servo Assembly Into Case
    G03975529Courtesy of FORD MOTOR CO.
  87. Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.
    88. CAUTION: Do not allow front band adjustment screw to back out. The band strut can fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 82: Installing New Locknut On Band Adjustment Screw
    G03975530Courtesy of FORD MOTOR CO.
  88. Install a new locknut on the band adjustment screw.
    89. CAUTION: The front servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 83: Tightening Front Band Adjustment Screw
    G03975531Courtesy of FORD MOTOR CO.
  89. Tighten the front band adjustment screw using the special tool and back off the front band adjustment screw exactly 2 turns and hold that position.
  90. Tighten the front band locknut.
    1. Hold the front band adjustment screw stationary.
    2. Tighten the front band locknut.
      Fig 84: Tightening Front Band Locknut
      G03975532Courtesy of FORD MOTOR CO.
    91. CAUTION: Do not allow the intermediate band adjusting screw to back out. The band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 85: Installing A New Nut On The Band Adjustment Screw
    G03975533Courtesy of FORD MOTOR CO.
  91. Install a new nut on the band adjustment screw.
    92. CAUTION: The intermediate servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 86: Tightening Intermediate Band Adjusting Screw
    G03975534Courtesy of FORD MOTOR CO.
  92. Tighten the intermediate band adjusting screw using the special tool and back off the intermediate band adjusting screw exactly 2 turns and hold that position.
  93. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
      Fig 87: Tightening Intermediate Band Locknut
      G03975535Courtesy of FORD MOTOR CO.
    94. CAUTION: Install new O-ring seals on the 16-pin electrical connector. Coat the O-ring seals with petroleum jelly.
    NOTE: Make sure that the tab is in the lock position.
  94. Position the transmission case 16-pin electrical connector into the case bore.
    • Press the transmission case 16-pin electrical connector through the case until a click is heard.
      Fig 88: Pressing Transmission Case 16-Pin Electrical Connector Through Case
      G03975536Courtesy of FORD MOTOR CO.
    95. CAUTION: Do not overstretch the retaining spring.
    Fig 89: Installing 16-Pin Electrical Connector Retaining Spring
    G03975537Courtesy of FORD MOTOR CO.
  95. Install the 16-pin electrical connector retaining spring.
    96. CAUTION: Align the slot on the turbine shaft speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.
  96. Install the TSS sensor electrical connector into the transmission case 16-pin electrical connector.
    1. Connect the TSS sensor electrical connector.
    2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.
      Fig 90: Installing TSS Sensor Electrical Connector Into The Transmission Case 16-Pin Electrical Connector
      G03975538Courtesy of FORD MOTOR CO.
  97. Tighten the center support screw.
    Fig 91: Tightening Center Support Screw
    G03975539Courtesy of FORD MOTOR CO.
  98. Install the special tools into the transmission case.
    Fig 92: Installing Special Tools Into Transmission Case
    G03975540Courtesy of FORD MOTOR CO.
    99. CAUTION: Make sure main control valve body gasket is aligned.
    CAUTION: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.
    Fig 93: Positioning Main Control Valve Body Into Transmission Case
    G03975541Courtesy of FORD MOTOR CO.
  99. Position the main control valve body into the transmission case.
    100. NOTE: The screws will be tightened in later steps.
    Fig 94: Installing Four M6 X 45 mm Screws
    G03975542Courtesy of FORD MOTOR CO.
  100. Loosely install the four M6 x 45 mm screws.
    101. NOTE: The main control valve body screws will be tightened in later steps.
    Fig 95: Installing Two M6 X 35 mm Screws
    G03975543Courtesy of FORD MOTOR CO.
  101. Loosely install the two M6 x 35 mm screws.
    102. NOTE: The main control valve body screw will be tightened in later steps.
    Fig 96: Installing M6 X 30 mm Screw
    G03975544Courtesy of FORD MOTOR CO.
  102. Loosely install the M6 x 30 mm screw.
  103. Remove the special tools.
    Fig 97: Removing Special Tools
    G03975545Courtesy of FORD MOTOR CO.
    104. NOTE: The main control valve body screws will be tightened in later steps.
  104. Loosely install the sixteen M6 x 40 mm screws.
    105. Fig 98: Installing Sixteen M6 X 40 mm Screws
    G03975546Courtesy of FORD MOTOR CO.
  105. Tighten the screws in the sequence shown.
    Fig 99: Valve Body Screws Tightening Sequence
    G03975547Courtesy of FORD MOTOR CO.
  106. Rotate the manual lever into the NEUTRAL position, then install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring on the main control valve body.
    2. Install the screw.
      Fig 100: Installing Manual Control Valve Detent Lever Spring
      G03975548Courtesy of FORD MOTOR CO.
  107. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
    1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
    2. Loosely install the screws.
      Fig 101: Installing Low/Reverse Band Servo Cover And Reverse Servo Separator Plate Cover Gasket
      G03975549Courtesy of FORD MOTOR CO.
  108. Tighten the screws in the sequence shown.
    Fig 102: Servo Cover Screws Tightening Sequence
    G03975550Courtesy of FORD MOTOR CO.
  109. Connect the solenoid electrical connectors.
    1. Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
    2. Connect the torque converter clutch (TCC) solenoids electrical connectors.
    3. Connect the electronic pressure control (EPC) solenoids electrical connectors.
      Fig 103: Connecting Solenoid Electrical Connectors
      G03975551Courtesy of FORD MOTOR CO.
    110. CAUTION: Excessive pressure may break the locating pins.
  110. Install the wiring loom protector and guide.
    • Align the pins in the holes of the solenoid clamps and gently push down.
      Fig 104: Identifying Wire Harness Guide And Protector
      G03914729Courtesy of FORD MOTOR CO.
    111. CAUTION: Make sure that both fluid pan filter O-ring seals are correctly installed on the fluid pan filter prior to installation.
  111. Install the fluid pan filter O-ring seals.
    • Coat the fluid pan filter O-ring seals with clean automatic transmission fluid.
      Fig 105: Installing Fluid Pan Filter O-Ring Seals
      G03975553Courtesy of FORD MOTOR CO.
  112. Install the transmission fluid filter.
    Fig 106: Installing Transmission Fluid Filter
    G03975554Courtesy of FORD MOTOR CO.
  113. Install the transmission fluid pan and transmission fluid pan gasket.
    • Loosely install the screws.
      Fig 107: Installing Transmission Fluid Pan And Transmission Fluid Pan Gasket
      G03975555Courtesy of FORD MOTOR CO.
  114. Tighten the transmission fluid pan screws.
    • Tighten the transmission fluid pan screws in a crisscross sequence.
      Fig 108: Tightening Transmission Fluid Pan Screws
      G03975556Courtesy of FORD MOTOR CO.
  115. Remove the transmission from the bench and place on a flat surface.
    Fig 109: Removing Transmission From Bench
    G03975557Courtesy of FORD MOTOR CO.
  116. Remove the special tools from the transmission case.
    Fig 110: Removing Special Tools From Transmission Case
    G03975558Courtesy of FORD MOTOR CO.
    117. NOTE: Use petroleum jelly to hold the gasket in place.
    Fig 111: Installing New Extension Housing Gasket
    G03975559Courtesy of FORD MOTOR CO.
  117. Install a new extension housing gasket.
    118. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.
  118. Install the parking pawl assembly.
    1. Install the parking pawl shaft into the extension housing.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
      Fig 112: Installing Parking Pawl Assembly
      G03975560Courtesy of FORD MOTOR CO.
    119. CAUTION: Make sure the parking lever actuating rod is correctly seated into the transmission case parking rod guide cup.
  119. Install the extension housing.
    1. Install the extension housing and gasket.
    2. Install the screws.
    3. Install the studs.
      Fig 113: Installing Extension Housing
      G03975561Courtesy of FORD MOTOR CO.
    120. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.
    NOTE: Install the extension housing bushing only if removed in disassembly.
    NOTE: Remove any burrs from the extension housing counterbore.
    Fig 114: Aligning Lube Hole With Lube Groove In Extension Housing
    G03975562Courtesy of FORD MOTOR CO.
  120. Align the lube hole with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear.
    121. CAUTION: Tool will bottom when bushing is in the correct position.
    Fig 115: Installing Extension Housing Bushing
    G03975563Courtesy of FORD MOTOR CO.
  121. Using the special tool, install the extension housing bushing.
  122. Position a new extension housing seal with drain hole in the 6 o'clock position.
    Fig 116: Positioning Extension Housing Seal
    G03975564Courtesy of FORD MOTOR CO.
  123. Using the special tool, install a new extension housing seal.
    Fig 117: Installing A New Extension Housing Seal
    G03975565Courtesy of FORD MOTOR CO.

    124. ALL VEHICLES 

  124. Install the digital transmission range (TR) sensor.
    1. Position the digital TR sensor on the transmission.
    2. Loosely install the screws.
    3. Rotate the manual lever to the NEUTRAL position (two detents rearward).
      Fig 118: Installing Digital Transmission Range (TR) Sensor
      G03975566Courtesy of FORD MOTOR CO.
    125. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
    Fig 119: Aligning Digital TR Sensor
    G03975567Courtesy of FORD MOTOR CO.
  125. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
  126. Install the manual control lever.
    1. Install the lever.
    2. Install the nut.
      Fig 120: Installing Manual Control Lever
      G03975568Courtesy of FORD MOTOR CO.
  127. If equipped, install the transmission servo heat shield and nut.
    Fig 121: Installing Transmission Servo Heat Shield And Nut
    G03975569Courtesy of FORD MOTOR CO.
    128. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.
  128. Install the output shaft speed (OSS) sensor.
    1. Install the sensor.
    2. Install the screw.
      Fig 122: Installing Output Shaft Speed (OSS) Sensor
      G03975570Courtesy of FORD MOTOR CO.
    129. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.
  129. Install the intermediate shaft speed sensor.
    1. Install the intermediate shaft speed sensor.
    2. Install the intermediate shaft speed sensor screw.
      Fig 123: Installing Intermediate Shaft Speed Sensor
      G03975571Courtesy of FORD MOTOR CO.
    130. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
    Fig 124: Installing Input Shaft
    G03975572Courtesy of FORD MOTOR CO.
  130. Install the input shaft.
  131. Using the special tool, check that the fluid pump gear seal ring is seated.
    Fig 125: Checking Fluid Pump Gear Seal Ring Is Seated
    G03975573Courtesy of FORD MOTOR CO.
    132. CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and it rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal can be damaged.
    Fig 126: Lubricating Converter Hub With Clean Automatic Transmission Fluid
    G03975574Courtesy of FORD MOTOR CO.
  132. Lubricate the converter hub with clean automatic transmission fluid.
    133. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions can result in personal injury.
    Fig 127: Installing Torque Converter
    G03975575Courtesy of FORD MOTOR CO.
  133. Use the special tools to install the torque converter by pushing and rotating.
  134. Make sure the torque converter is installed to specification.
    Fig 128: Ensuring Torque Converter Is Installed To Specification
    G03975576Courtesy of FORD MOTOR CO.
  135. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 129: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G03975577Courtesy of FORD MOTOR CO.
  136. Install the special tool on the case.
    Fig 130: Installing Special Tool On Case
    G03975578Courtesy of FORD MOTOR CO.
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