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Transmission Reassembly

NOTE: Exploded views of internal parts, thrust washer and thrust bearing locations can be found in Fig 7-Fig 9 . Lubricate all parts with transmission fluid during reassembly. Thrust washers, thrust bearings and gaskets should be held in place with petroleum jelly.
  1. With transmission mounted in fixture, rotate bellhousing to face upward. Install inner and outer seals on low-reverse clutch piston. Using appropriate spring compressor, install low-reverse clutch piston. Remove spring compressor.
  2. Install low-reverse clutch piston return spring assembly, output shaft hub and inner race. Ensure lubrication hole of inner race is in 5 o'clock position. See Fig 1 and Fig 2 . Using 2 5/16-24, 3" long bolts with nuts, compress low-reverse piston return spring. See Fig 3. Install 3 bolts in remaining one-way clutch inner race bolt holes and remove 2 compression bolts. Install remaining 2 bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  3. Install reverse clutch hub and low-reverse one-way clutch. Rotate transmission to horizontal position. Apply petroleum jelly to parking gear thrust washer No. 13, and place on rear of case. Slide parking gear onto output shaft with thrust surface forward. Install output shaft. Apply coat of petroleum jelly to thrust bearing No. 12 and install onto rear surface of output shaft hub. Install output shaft hub and ring gear. See Fig 1. Install NEW retaining ring on output shaft.
  4. Rotate transmission with bellhousing facing upward. Install cushion spring into reverse clutch case bore. Install reverse clutch pack (5 or 6 plate assembly depending on model) starting with an external spline steel plate. Alternate external spline steel plates with internal spline friction plates. Install reverse clutch pressure plate and retaining ring. Ensure retaining ring is installed with opening between 12 and 3 o'clock position. Clearance measurement is not required.
  5. Install reverse planet assembly into hub with No. 11 and No. 10B thrust washers. See Fig 7. Install reverse planet retaining ring into low-reverse hub. Ensure retaining ring is securely seated in groove.
    6. NOTE: Thrust washer No.8 is model dependent. See COMPONENT PART NUMBERS  table.
  6. Using Clutch Remover-Installer (T89T-70010-E), install intermediate brake drum, forward clutch and input shell assembly into case as a unit. See Fig 4. It may be necessary to rotate output shaft to seat reverse sun gear. Remove installer.
    7. NOTE: When installing intermediate servo piston, ensure that intermediate servo rod is making contact in correct position and location on band assembly. If intermediate band and servo rod fall out of position during transmission reassembly, a possible fault with manual 2nd may occur.
  7. Install intermediate band with one ear on anchor pin. Install servo spring, piston and rod assembly and retaining plate. Install intermediate clutch pressure plate (thickest plate). Install intermediate clutch pack starting with internal spline plate. Install intermediate pressure apply plate with blank area (no teeth) in 6 and 12 o'clock positions.
    8. NOTE: Remove cast iron seal rings from center support to allow easy insertion into intermediate brake drum.
  8. Install center support without thrust washer into intermediate brake drum. Measure clearance between center support and intermediate brake drum. Note reading as measurement "A". See Fig 5.
  9. To determine center support thickness (measurement "B"), hold thrust washer against center support. Place depth micrometer over drilled hole. Extend depth micrometer probe until flush with thrust washer surface and note reading. See Fig 6. Use the following equation: "A" - "B" = "C"  .
  10. Ensure measurement "C" is .032-.081" (.81-2.06 mm). This verifies components are correctly installed. If thrust washer clearance is not within specification, this indicates improper assembly, missing parts or parts out of specification. Correct before continuing reassembly. If clearance is within specifications, remove center support and reinstall cast iron seal rings onto center support.
  11. Align fluid feed holes in center support with holes in case for fluid feed bolts, and install center support. Install intermediate clutch return spring with dished surface inward. Ensure one spring locator leg is located at 6 o'clock position and properly located in center support circular rib.
    12. NOTE: Intermediate-overdrive clutch cylinder and retaining ring will not be fully seated until intermediate clutch return spring is compressed fully. DO NOT attempt to force cylinder or ring into position before completing this step.
  12. Install intermediate-overdrive clutch cylinder. DO NOT angle clutch cylinder when installing. Align cylinder threaded feed hole with hole in case. Install large retaining ring over intermediate-overdrive clutch cylinder with ring opening at bottom of case for proper oil drainback. Large retaining ring will not be able to seat into case ring groove until intermediate-overdrive clutch cylinder is fully seated into case. See Figure.
  13. Install Spring Compressor Plate (T89T-70010-F) and Spring Fixture (T89T-70010-C) onto intermediate-overdrive clutch cylinder. Tighten center bolt on clutch spring compressor bar to 62 INCH lbs. (7 N.m). See Figure. When intermediate-overdrive clutch cylinder is fully seated into case, finger tighten 3 NEW fluid feed bolts into intermediate-overdrive clutch cylinder. DO NOT fully tighten fluid feed bolts at this time.
    14. NOTE: Coast clutch cylinder Tool Installer (307-S383) must be used to install coast clutch cylinder/center shaft assembly, or damage may occur.
  14. Install intermediate-overdrive clutch cylinder retaining ring into case ring groove. Remove spring compressor. No clearance measurement is required. Coat thrust bearing No. 5 with petroleum jelly and install on rear face of coast clutch cylinder/center shaft assembly. Install coast clutch cylinder/center shaft assembly.
  15. Install overdrive clutch pack, starting with a steel plate. Install pressure plate with dot facing outward and toward top of case. Install selective retaining ring with opening at bottom of case. Using a feeler gauge, measure clutch pack clearance. Ensure clearance is .027-.052" (.69-1.32 mm) on 2-plate clutch. On 3-plate clutch, clearance should be .032-.058" (.81-1.47 mm).
  16. If clearance is not within specification, install correct selective retaining ring. Selective retaining rings are available in thicknesses of .077-.081" (1.96-2.06 mm), .098-.102" (2.49-2.59 mm), .118-.122" (3.00-3.10 mm) and .138-.142" (3.51-3.61 mm).
  17. Lightly coat oil pump gasket with petroleum jelly to hold it in place and install pump gasket into case. Install input shaft long splined end first into case. Apply petroleum jelly to thrust washer No. 1 and thrust bearing No. 2A and install onto pump. See Fig 7. Install appropriate alignment pin into transmission case to aid pump installation. Lubricate outer pump "O" ring and install pump. Ensure filter inlet tube bore is in 6 o'clock position.
  18. Fully seat pump into case using hand pressure only. DO NOT use bolts to draw pump into case. Remove alignment pin. Install pump bolts and NEW seal washers. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove input shaft.
  19. Using appropriate seal driver, install manual lever seal. Install manual lever shaft and retaining pin, with pin just below case surface. Install TR sensor with 2 bolts and washer. DO NOT tighten bolts at this time. Install manual lever detent spring. Tighten bolt to specification.
  20. Install manual detent lever, parking pawl actuating rod and nut. Tighten nut to specification. Ensure manual valve detent spring is positioned correctly on inner detent lever. Using appropriate TR sensor adjuster, align TR sensor to Neutral gear position. Tighten bolts to specification.
  21. Install parking pawl, parking pawl shaft and parking pawl return spring on rear face. Ensure parking pawl return spring end rests on inside surface of case. If removed, install parking pawl actuating abutment with NEW Torx bolt and tighten to specification. Attach parking rod guide plate with 2 bolts and washers. Tighten bolts to specification.
  22. Ensure parking rod guide plate dimple is facing inward and parking rod is in guide plate slot. Install gasket on extension housing. Install extension housing and wiring harness bracket on rear of case. Tighten bolts to specification. See TORQUE SPECIFICATIONS . On 4WD vehicles, the 2 bottom extension housing bolts are longer.
    23. CAUTION: Intermediate-overdrive clutch cylinder feed bolt torque is lower than 2 center support feed bolts. Ensure proper torque specification is used. See TORQUE SPECIFICATIONS .
  23. Rotate transmission with pan surface facing upward. Intermediate-overdrive clutch cylinder feed bolt should be tightened to 71-124 INCH lbs. (8-14 N.m) and 2 center support feed bolts to 97-144 INCH lbs. (11-16 N.m). Install 8 rubber check balls, and EPC steel check ball and spring into case pockets. See Figure.
  24. Install case-to-separator plate gasket. Ensure correct placement of EPC steel check ball and spring. Install separator plate. Attach reinforcing plate with 3 bolts. Ensure the word UP on reinforcing plate faces up. Tighten bolts to specification. Install NEW separator-to-main control valve body gasket.
  25. Install solenoid screen into separator plate. Turn and lock solenoid screen. Install accumulator control body over studs. Install 2 nuts and 11 bolts finger tight. Lower main control valve body over studs. Align manual valve with manual lever. Install 2 nuts and 14 bolts finger tight.
  26. Ensure case connector bore is coated with petroleum jelly prior to installing solenoid valve body. Install solenoid valve body over stud. Install 9 Torx bolts and one nut finger tight. Tighten all accumulator control body, upper and lower main control valve body and solenoid valve body nuts and bolts to specification.
  27. Install NEW filter and seal assembly. Lubricate seal with ATF. Press filter into place. Install pan magnet on dimple in bottom of pan. Install NEW pan gasket on pan. Install oil pan and tighten bolts to specification. See TORQUE SPECIFICATIONS .
  28. If removed, install short fluid inlet tube into case. Use stripe or rib on side of tube for alignment. Stripe should be farthest outboard when installed. Rib should face toward front. Reinstall input shaft, long splined end first. Install torque converter. Using straightedge, ensure converter crankshaft pilot is inset from converter housing.
Fig 1: Exploded View Of Low-Reverse One-Way Clutch
G96E04236Courtesy of FORD MOTOR CO.
Fig 2: Locating Inner Race Lubrication Hole
G96C04240Courtesy of FORD MOTOR CO.
Fig 3: Compressing Low-Reverse Piston Return Spring
G98D01355Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing Input Shell
G92G15293Courtesy of FORD MOTOR CO.
Fig 5: Measuring Thrust Washer Clearance
G96A04362Courtesy of FORD MOTOR CO.
Fig 6: Measuring Center Support Thickness
G96I04361Courtesy of FORD MOTOR CO.
Fig 7: Locating Thrust Washers & Bearings
G99J50863Courtesy of FORD MOTOR CO.
Fig 8: Exploded View Of 4R100 Automatic Transmission (1 Of 2)
G00026027Courtesy of FORD MOTOR CO.
Fig 9: Legend For Exploded View Of 4R100 Automatic Transmission (2 Of 2)
G00026028Courtesy of FORD MOTOR CO.
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