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Transmission Disassembly

NOTE: Thrust washer No. 8 is model dependent. See COMPONENT PART NUMBERS .
NOTE: For exploded views of internal parts, thrust washer and thrust bearing locations, see Figure-Figure .
  1. Remove torque converter. Remove transfer case (if equipped). Remove Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensors. Mount transmission in appropriate holding fixture. Remove input shaft. Thoroughly clean solenoid body connector area to avoid contamination. Remove oil pan and gasket. Remove filter and "O" ring assembly. DO NOT damage bore in aluminum pump.
  2. Remove accumulator body and main control valve body retaining bolts and nuts. Note bolt locations for reassembly. Do not remove 2 center bolts that secure upper and lower valve bodies together during disassembly. See Figure. Remove solenoid body Torx retaining bolts and one nut.
  3. Push up on solenoid body connector while removing solenoid body. To remove solenoid screen from separator plate, rotate solenoid screen to align tabs on screen with notches in separator plate and pull outward. See Figure. Remove separator reinforcing plate. EPC check ball is spring loaded under separator plate. Remove separator plate and 2 gaskets. Remove steel EPC check ball and spring. Discard gasket.
  4. Remove 8 rubber check balls. DO NOT damage rubber check balls. See Fig 1. Using a plastic or rubber-headed hammer, tap gently on intermediate servo assembly piston. Downward force will cause servo to be released from case bore. Remove 3 feed bolts and discard.
    5. CAUTION: DO NOT use a screwdriver to pry out oil pump. This may cause severe damage to transmission case. When removing coast clutch/center shaft assembly, special tool (307-S383) must be used or damage to overdrive one-way clutch may occur.
  5. Rotate transmission so bellhousing is facing upward. Remove 9 pump retaining bolts. Discard washers. Using 2 slide hammers, remove pump, gasket and pump support thrust washer. Remove thrust bearing assembly between front pump and sun gear. Using Coast Clutch Installation Tool (307-S383), lift out coast clutch, overdrive ring gear and center shaft assembly.
    6. NOTE: Ensure No. 5 thrust bearing is not remaining on center shaft or center support.
  6. Remove No. 5 thrust bearing. Remove overdrive clutch pressure plate retaining ring. Remove overdrive pressure plate and clutch pack. Tag clutch plates for reassembly. Install Clutch Spring Compressor (T89T-70010-C) into case. See Fig 2.
  7. Tighten center bolt to 65 INCH lbs. (7.3 N.m). Remove large retaining ring. Remove spring compressor. Remove intermediate/overdrive clutch cylinder assembly. Remove intermediate return spring, center support and center support thrust washer.
  8. Remove intermediate pressure plate and clutch plates. Tag clutch plates for reassembly. Remove intermediate band. Using Clutch Remover/Replacer (T89T-70010-E), remove direct clutch, forward clutch and input shell. Hooks on crossbar MUST be rotated into notches on input shell. See Fig 3.
    9. CAUTION: Use caution when removing output shaft retaining ring. Output shaft can drop out of case when retaining ring is removed.
  9. Using large screwdriver, remove reverse planet assembly retaining ring. Remove reverse planet assembly and 2 planet carrier thrust washers. Remove and discard output shaft retaining ring.
  10. Remove rear ring gear and hub assembly and thrust bearing No. 12. Remove reverse clutch hub and one-way clutch assembly. Using large screwdriver, remove reverse clutch retaining ring. Remove reverse pressure plate and clutch pack. Tag clutch plates for reassembly.
  11. Rotate transmission so pan surface faces up. Remove 8 extension housing bolts. Remove extension housing and gasket and discard gasket.
  12. Remove output shaft, parking gear and output shaft thrust bearing No. 13. Remove plastic orifice plug from rear of case and discard. See Fig 4. Remove 5 retaining bolts from low-reverse one way clutch inner race. Remove reverse clutch return spring assembly and low-reverse one-way clutch inner race.
    13. NOTE: Reinstall reverse clutch pressure plate and selective retaining ring to restrain reverse clutch piston during removal.
  13. Using compressed air in low-reverse clutch feed port, blow out low-reverse clutch piston against pressure plate. See Figure. Remove selective retaining ring, low-reverse clutch pressure plate and low-reverse clutch piston from case.
    14. NOTE: If Torx head bolt retaining parking pawl abutment is removed, it must be discarded and replaced with NEW bolt.
  14. Rotate transmission so pan surface faces downward. Remove parking pawl return spring, pin and parking pawl from case. Remove parking rod guide plate. Remove Torx head bolt and parking pawl abutment (if necessary).
  15. Using side cutters or remover tool, remove manual lever shaft retaining pin from case. Remove inner detent lever nut, while holding lever with crescent wrench. Remove inner detent lever and parking pawl actuating rod assembly from manual lever.
  16. Remove Transmission Range (TR) sensor and manual lever. Remove manual valve detent spring. Using slide hammer, remove manual lever seal. Remove short lube inlet tube, if required using channel lock pliers.
Fig 1: Locating Valve Body Check Balls In Case
G98C01350Courtesy of FORD MOTOR CO.
Fig 2: Compressing Intermediate/Overdrive Cylinder Assembly
G94H38585Courtesy of FORD MOTOR CO.
Fig 3: Removing Direct Clutch & Input Shell Assembly
G99G50852Courtesy of FORD MOTOR CO.
Fig 4: Location Of Rear Orifice Lube Plug
G99H50853Courtesy of FORD MOTOR CO.
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