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Transaxle Disassembly

  1. Remove torque converter. Mount transaxle in a appropriate holding fixture. Place transaxle in vertical position and drain fluid.
  2. Place transaxle in horizontal position. Remove 3 (8 mm) bolts from overdrive servo piston cover. See Fig 1 . Servo piston cover is under pressure and must be retained when removing bolts. Mark and remove cover, piston assembly and spring. Discard "O" ring from cover.
  3. Remove dipstick tube and discard grommet. Remove TR sensor. Remove TSS sensor and discard "O" rings. Remove VSS (if applicable). See Fig 1 and Fig 2 .
  4. Screw front cover Seal Remover (T74P-6700-A) into metal seal and protector of left differential output shaft seal. Tighten screw on end of seal remover until metal seal protector is removed. Reinstall remover and repeat procedure to remove seal.
    Fig 1: Exploded View Of AX4N Transaxle Case Components
    G00025104Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of AX4N Transaxle Valve Body & Turbine Shaft Components
    G96B04051Courtesy of FORD MOTOR CO.
  5. Install Step Plate Adapter (D80L-630-A) into right-hand output shaft opening. Hold adapter in position with grease. Screw front cover Seal Remover (T74P-6700-A) into metal seal and protector of right output shaft seal on top of step plate adapter. Tighten screw on end of seal remover until metal seal protector is removed. Reinstall remover and repeat procedure to remove seal.
  6. Using a slide hammer and Converter Seal Remover (T94P-77001-BH), remove converter hub seal from input shaft. Remove 7 chain cover bolts from inside torque converter housing, (5 of 7 bolts are recessed Torx head style).
  7. Rotate transaxle to vertical position. Remove valve body cover and discard gasket. Disconnect wiring to valve body solenoids and TFT sensor. See Figure .
    8. CAUTION: Do not remove oil pump and valve body assembly bolts indicated. See Figure .
  8. Using a 9 mm wrench on flats of manual shaft, rotate shaft clockwise to position manual linkage in low detent (manual valve all the way in). Remove 23 valve body retaining bolts, noting length and position of bolts for reassembly reference . See Figure .
  9. Rotate valve body clockwise and remove manual valve link from manual valve. Disconnect manual valve link from detent lever. Remove oil pump and valve body assembly.
  10. Pull oil pump drive shaft out of case and remove 4 Teflon seals from shaft. Discard seals. Remove 18 chain cover bolts and shift cable stud from center outward, noting length and location of bolts for reassembly reference.
    11. CAUTION: Chain cover is under spring pressure. Remove carefully. See Fig 3 .
    Fig 3: Removing Chain Cover
    G96D04052Courtesy of FORD MOTOR CO.
    Fig 4: Identifying Accumulator Springs
    G96F04053Courtesy of FORD MOTOR CO.
  11. Note location of accumulator springs and tag to ensure reassembly to original location. See Fig 4 . Plastic sprocket thrust washers may stick to chain cover or chain sprocket when chain cover is removed. Mark and remove plastic thrust washer No. 1. Mark and remove plastic thrust washer No. 3.
    12. CAUTION: Chain and sprocket may have very sharp edges.
  12. Simultaneously lift both sprockets off with chain assembly. Mark and remove thrust washers No. 2 and 4 from drive and driven sprocket supports. Thrust washers may stick to bottom side of sprockets.
  13. Using vise-grip pliers, remove 3 roll pins from manual shaft. Be careful not to damage machined surfaces. Slide manual shaft and linkage from case. See Fig 5 . Remove parking lever actuating rod and pry manual shaft seal from case.
    Fig 5: Removing Manual Shaft
    G96H04054Courtesy of FORD MOTOR CO.
  14. Remove oil pan and discard gasket. Remove magnet from oil pan. Remove oil filter screen and lip seal and discard. Remove oil transfer tube retaining brackets. If necessary, use Tube Remover (T94P-77001-CH) and a slide hammer to remove all oil transfer tubes. Discard oil transfer tube seals. See Fig 6 .
    Fig 6: Oil Tube Locations
    G96I04342Courtesy of FORD MOTOR CO.
  15. Remove parking pawl actuator bracket. Remove reverse clutch assembly locator bolt. See Fig 6 . Remove N-D accumulator cover. Remove N-D accumulator piston, shaft assembly and springs.
  16. Compress coast band servo and remove snap ring. See Fig 6 . Remove driven sprocket support assembly. See Fig 7 . Selective thrust washer No. 5 and No. 8, and thrust bearing No. 9 may stick to driven sprocket support when removed. Remove selective thrust washer No. 8 and thrust bearing No. 9 if still in case. See Fig 8 .
    Fig 7: Removing Driven Sprocket Support
    G96A04055Courtesy of FORD MOTOR CO.
    Fig 8: Exploded View Of AX4N Transaxle Internal Components (1 Of 2)
    G96J04050Courtesy of FORD MOTOR CO.
    Fig 9: Exploded View Of AX4N Transaxle Internal Components (2 Of 2)
    G98D07060Courtesy of FORD MOTOR CO.
  17. Remove plastic overdrive band retainer and overdrive band. Rotate transaxle to vertical position. Install Front Clutch Loading Tool (T86P-70389-A) with Extended Front Clutch Loading Tool Screw (T94P-77001-HH) on sun gear and shell assembly. Install hook portion of loading tool screw into one of the lube holes of sun gear and shell assembly. Position notched block over edge of assembly and tighten handle. Using loading tool, lift assembly out of case. See Fig 10 .
  18. Using same tool combination, remove reverse clutch and planet assembly. Lift out low-intermediate drum, sun gear and one-way clutch assembly. Remove coast band. Remove low-intermediate clutch selective snap ring.
  19. Remove low-intermediate clutch pack pressure plate, friction plates, steel plates and cushion spring. Remove selective snap ring and record thickness and type of bevel at snap ring ends. Thickness of selective snap ring can be determined by type of bevel at ring end. See Fig 11 . Discard snap ring.
    Fig 10: Removing Sun Gear & Shell Assembly
    G98D07055Courtesy of FORD MOTOR CO.
    Fig 11: Identifying Low-Intermediate Clutch Selective Snap Rings
    G96C04056Courtesy of FORD MOTOR CO.
  20. Inspect transaxle case and rear planetary support assembly for damage due to removal of low-intermediate clutch bottom selective snap ring. Remove final drive/differential and rear planetary gear support assembly from transaxle using differential output shaft.
  21. Differential carrier thrust washer No. 18 may come out with final drive/differential and rear planetary gear support assembly. Remove differential carrier thrust washer No. 18 and differential carrier thrust bearing No. 19.
  22. Remove final drive gear from case. Using slide hammer, remove drive sprocket support bearing. See Fig 12 . If transaxle case is being replaced, remove stator support. Remove parking pawl shaft roll pin. Using slide hammer, remove parking pawl shaft plug from case. See Fig 1 . Use magnet to remove parking pawl shaft. Remove parking pawl and return spring.
Fig 12: Removing Drive Sprocket Support Bearing
G96E04057Courtesy of FORD MOTOR CO.
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