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Transaxle Disassembly

NOTE: For exploded view of transaxle components, see Fig 1 -Fig 4 . Transaxle may no longer have speedometer drive and driven gears.
  1. Remove torque converter. Mount transaxle in appropriate holding fixture. Place transaxle in vertical position and drain fluid.
  2. Place transaxle in horizontal position. On Windstar, remove output shaft sensor. On all models, remove speedometer cover bolts, cover and seal. Discard seal. Lift speedometer drive gear assembly and bearing from case. Bearing sits on top of speedometer drive gear.
  3. Remove bolts from overdrive servo cover. Servo cover is under pressure and must be retained when removing bolts. Mark and remove cover, piston assembly and spring. Discard "O" ring from cover. Remove low-intermediate servo cover bolts. Mark and remove cover, piston assembly and spring. Remove and discard gasket.
  4. Install Step Plate Adapter (D80L-630-3) into right-hand output shaft opening. Hold adapter in position with grease. Screw Seal Remover (T74P-6700-A) into metal seal protector. Tighten screw on end of seal remover until metal seal protector is removed. Reinstall remover and repeat procedure to remove seal.
  5. Remove bolts from Transmission Range (TR) sensor and remove sensor. Remove dipstick tube and dipstick from case. Remove 9 chain cover bolts from inside torque converter housing.
  6. Using a slide hammer and appropriate seal puller, remove converter oil seal from torque converter housing. Rotate transaxle to vertical position. Remove side cover bolts. Remove cover and discard gasket.
  7. Using both hands, disconnect electrical connectors from Transmission Fluid Temperature (TFT) sensor and solenoids. See Figure . DO NOT pull on wires. Compress tabs on both sides of bulkhead connector from inside of chain cover and remove connector and wiring.
    8. CAUTION: Do not remove 4 bolts holding oil pump and valve body together. Do not remove 6 oil pump cover bolts.
    Fig 1: Exploded View Of AX4S Transaxle Valve Body Components
    G96H04327Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of AX4S Transaxle Case Assembly
    G00025113Courtesy of FORD MOTOR CO.
    Fig 3: Exploded View Of AX4S Transaxle Internal Components (1 Of 2)
    G00025114Courtesy of FORD MOTOR CO.
    Fig 4: Exploded View Of AX4S Transaxle Internal Components (2 Of 2)
    G98H01159Courtesy of FORD MOTOR CO.
  8. Disconnect manual linkage. Mark and remove 22 oil pump and valve body assembly bolts, noting length and location. DO NOT remove 2 hex head bolts marked "A". 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 transaxle pan. Remove and discard fluid filter. Loosen reverse clutch anchor pin nut and remove bolt. See Fig 6 .
  11. Place transaxle in vertical position. Remove and discard left output shaft circlip. Screw Seal Remover (T74P-6700-A) into metal seal protector. Tighten screw of seal remover until metal seal protector is removed. Repeat procedure to remove seal.
  12. Remove Transmission Speed Sensor (TSS) from chain cover. Mark and remove 16 chain cover bolts. Note length and location of bolts for reassembly reference. Chain cover is under spring pressure. Remove carefully. See Fig 5 . Note location of accumulator springs and tag to ensure reassembly to original location. Mark and remove No. 1 plastic thrust washer from chain cover. Mark and remove No. 3 metal thrust washer from chain cover.
  13. Simultaneously lift both sprockets out with chain assembly. Remove cast iron sealing ring from input shaft sprocket. Mark and remove thrust washers No. 2 and 4 from drive and driven sprocket supports. Thrust washers may stick to bottom side of sprockets. Inspect drive sprocket support bearing. Using slide hammer puller, replace drive sprocket support bearing, if necessary.
  14. Using Pin Remover (D81P-3504-N), remove lock pin and 2 roll pins from manual shaft. Be careful not to damage machined surfaces. Slide shaft out and pry shaft seal from case. See Fig 7 .
  15. Remove driven sprocket support assembly. See Fig 8 . Remove 5 Teflon seals from support assembly. Mark and remove No. 5 selective thrust washer. Washer may stay on support assembly during removal.
    Fig 5: Removing Chain Cover
    G92F12828Courtesy of FORD MOTOR CO.
    Fig 6: Locating Oil Transfer Tubes & Reverse Clutch Anchor Pin Bolt
    G99H50739Courtesy of FORD MOTOR CO.
    Fig 7: Removing Manual Shaft & Seal
    G92G12829Courtesy of FORD MOTOR CO.
    Fig 8: Removing Driven Sprocket Support
    G92J12830Courtesy of FORD MOTOR CO.
  16. Using a wire hook, if necessary, remove selective thrust washer No. 8 and thrust bearing No. 9. Remove plastic overdrive band retainer and overdrive band. Remove intermediate circuit screen. See Fig 2 . Clean screen with compressed air. Replace filter tube lip seal.
    17. NOTE: For complete transaxle disassembly, reverse clutch apply fluid transfer tube and rear lube fluid transfer tube MUST be removed prior to removing the reverse clutch or differential. All fluid tubes removed must be replaced during reassembly.
  17. Position transaxle with oil pan up. Remove reverse clutch apply tube, oil filter bolt and bracket. See Fig 6 . Remove transfer tube support bracket bolts and brackets. If necessary, use Tube Remover (T94P-77001-CH) and a slide hammer to remove transfer tubes. Tubes are retained with Loctite.
  18. Remove 2 park pawl actuating rod bracket bolts. Remove park pawl actuating rod by lifting to clear bracket and lower from case. Remove park pawl shaft return pin. Use magnet to remove park pawl shaft. Remove park pawl and return spring. Remove reverse clutch anchor pin bolt and lock nut. See Fig 6 .
  19. Place transaxle in vertical position. Install Front Clutch Loading Tool (T86P-70389-A). Install hook portion of tool on inner diameter of reverse clutch cylinder. See Fig 9 . Lift front sun gear and shell assembly out of case. Grasp outer diameter with fingertips and slide clutch assembly out of case.
  20. Grasp front planetary shaft and lift out both front and rear planetary assemblies. Lift out rear sun gear and drum assembly. Remove low-intermediate band.
  21. Remove final drive assembly snap ring from case using a screwdriver inserted through side of case. Lift out final drive assembly using output shaft. See Fig 10 .
  22. Remove differential carrier thrust washer No. 18 and thrust bearing No. 19. Remove final drive ring gear from case. Thrust washer may remain on final drive next to speedometer gear, if equipped. Remove and discard rear lube tube seal using a 3/8" rod or drift. Tap seal toward inside of case. If case replacement is necessary, remove Torx bolts and converter support from old case.
Fig 9: Removing Front Sun Gear & Shell Assembly
G98J01160Courtesy of FORD MOTOR CO.
Fig 10: Removing Final Drive Assembly
G92B12832Courtesy of FORD MOTOR CO.
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