Automatic Transmission - Overhaul: Assembly: Transmission

Fig 1: Identifying Special Tools (1 Of 4)

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Fig 2: Identifying Special Tools (2 Of 4)

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Fig 3: Identifying Special Tools (3 Of 4)

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Fig 4: Identifying Special Tools (4 Of 4)

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CAUTION: If the clutch plates or the intermediate band are replaced, soak the new parts in the specified automatic transmission fluid (ATF) for at least two hours before assembly. Apply the specified ATF to all seal rings, rotating parts, O-rings and sliding parts.

NOTE: Clean all bearings thoroughly in solvent and blow dry with compressed air. Inspect the bearings for pitting and rough operation. Replace as necessary.

NOTE: All O-rings, seals, and gaskets must be replaced with new ones.

1. Prior to installation, inspect the transmission case for damage, cracks, or wear. Replace as necessary.
2. Use (A) Valve Body Guide Pins to align the torque converter stator support. Use (B) Step Plate to press the (C) torque converter stator support into the converter housing.
   Fig 5: Pressing Torque Converter Stator Support Into Converter Housing

   Courtesy of FORD MOTOR CO.
3. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the bearing cup into the converter housing.
   Fig 6: Installing Bearing Cup Into Converter Housing

   Courtesy of FORD MOTOR CO.
NOTE: Tighten the torque converter stator support bolts evenly and gradually.
Fig 7: Installing Eight Bearing Cover Bolts
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4. Install the eight bearing cover bolts.
5. Install the (A) idler gear (7F475) and (B) output shaft (7060) as an assembly.
   • Install the idler gear and output shaft by tapping them in with a plastic hammer.
   Fig 8: Installing Idler Gear & Output Shaft

   Courtesy of FORD MOTOR CO.
NOTE: Tighten the bearing housing bolts evenly and gradually.
Fig 9: Installing Bearing Housing Onto Converter Housing
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6. Install the bearing housing onto the converter housing.
   1. Install the bearing housing onto the converter housing.
   2. Install the bolts.
7. Install a new bearing housing roll pin.
   • Align the holes on the idler gear shaft with the mark on the bearing housing. Tap the roll pin in using a 5/32 inch pin punch and hammer.
   Fig 10: Installing New Bearing Housing Roll Pin

   Courtesy of FORD MOTOR CO.
8. Install the differential (4026).
   Fig 11: Installing Differential

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NOTE: Move the manual shaft and verify that the parking pawl operates.
Fig 12: Installing Parking Pawl Assembly
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9. Install the parking pawl (7A441) assembly.
   1. Install the parking pawl.
   2. Install the parking pawl shaft (7D071).
   3. Install the parking pawl return spring (7D070).
   4. Install the parking pawl shaft E-clip.
10. Install the detent lever spring and actuator support.
    • Install the actuator support.
    • Install new actuator support bolts.
    • Install the detent lever spring.
    Fig 13: Installing Detent Lever Spring & Actuator Support

    Courtesy of FORD MOTOR CO.
11. Install the detent lever. Attach the detent lever spring to the detent lever.
    Fig 14: Installing Detent Lever Spring To Detent Lever

    Courtesy of FORD MOTOR CO.
12. Install the manual shaft plate and the lever holder.
    1. Install the lever holder.
    2. Install the manual shaft plate.
    3. Install the lever holder nut.
    Fig 15: Installing Manual Shaft Plate & Lever Holder

    Courtesy of FORD MOTOR CO.
13. Install the manual shaft.
    • Push the manual shaft into the manual shaft plate.
    Fig 16: Installing Manual Shaft

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14. Install the manual shaft washer and nut.
    Fig 17: Installing Manual Shaft Washer & Nut

    Courtesy of FORD MOTOR CO.
15. Install the output shell. Set the thrust bearing onto the output shell.
    • The output shell thrust washer outer diameter is 72.1 mm (2.84 in).
    Fig 18: Installing Output Shell

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16. Apply a small bead of Silicone Gasket and Sealant to the surfaces of the (A) converter housing and transmission case. Carefully install new (B) O-rings.
    Fig 19: Applying Silicone Gasket & Installing New O-Rings

    Courtesy of FORD MOTOR CO.
NOTE: Tighten the transmission bolts evenly and gradually.
Fig 20: Attaching Transmission Case To The Converter Housing
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17. Attach the transmission case to the converter housing and install the transmission case bolts.
18. Install Turbine Shaft Holder.
    Fig 21: Installing Turbine Shaft Holder.

    Courtesy of FORD MOTOR CO.
19. Install the (A) turbine shaft and direct clutch assembly with the (B) thrust bearing between the direct clutch and output shell.
    • Assemble the turbine shaft and direct clutch assembly.
    • Install the turbine shaft and direct clutch assembly into the transmission case.
    Fig 22: Installing Turbine Shaft & Direct Clutch Assembly

    Courtesy of FORD MOTOR CO.
20. Install the ring gear to the output shell.
    • Install the ring gear with the external gear side down.
    Fig 23: Installing Ring Gear To Output Shell

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21. Install the ring gear retainer snap ring.
    Fig 24: Installing Ring Gear Retainer Snap Ring

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NOTE: Install the carrier hub into the 3-4 clutch cylinder by rotating it to align the carrier hub with the 3-4 clutch pack.
NOTE: Hold the turbine shaft with one hand to keep it from rotating while installing the carrier hub.
Fig 25: Installing Carrier Hub Assembly
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22. Install the carrier hub assembly.
    1. Use petroleum jelly to install the thrust washer to the carrier hub assembly.
    2. Install the thrust bearing between the carrier hub assembly and the direct clutch assembly.
    3. Install the carrier hub assembly.
23. Install the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.
    Fig 26: Installing Low/Reverse Clutch Pressure Plate & Low/Reverse Clutch Disc Pack

    Courtesy of FORD MOTOR CO.
24. Install the low/reverse clutch pressure plate snap ring.
    Fig 27: Installing Low/Reverse Clutch Pressure Plate Snap Ring

    Courtesy of FORD MOTOR CO.
25. Install the wave washer.
    Fig 28: Installing Wave Washer

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CAUTION: The one-way clutch can be installed improperly. Be certain that after installing the one-way clutch, you can rotate the carrier by hand in a counterclockwise direction while working from the rear side of the transmission. If the one-way clutch is installed improperly, gear ranges may not function or the gear train may lock up. This may cause overheating of the transmission and unnecessary overhauling of the unit.
Fig 29: Installing One-Way Clutch
Courtesy of FORD MOTOR CO.
26. Install the one-way clutch horizontally. Use the rear sun gear to rotate the carrier counterclockwise while installing the one-way clutch.
27. Install the one-way clutch and one-way clutch retaining snap ring.
    Fig 30: Installing One-Way Clutch Retaining Snap Ring

    Courtesy of FORD MOTOR CO.
28. Adjust the servo piston stem.
    1. Mark the servo piston stem at the point that it exits the transmission case.
    2. Apply compressed air through the fluid passage. If the stroke exceeds 1.0-1.7 mm (0.0394-0.0669 in) replace it with the appropriate length servo piston stem. Refer to Fig 32.
    Fig 31: Adjusting Servo Piston Stem

    Courtesy of FORD MOTOR CO.
    Fig 32: Servo Piston Stem Lengths

    Courtesy of FORD MOTOR CO.
29. Install the (A) anchor strut and the (B) anchor strut shaft into the transmission case.
    Fig 33: Installing Anchor Strut & Anchor Strut Shaft Into Transmission Case

    Courtesy of FORD MOTOR CO.
30. Install the 2-4 band into the transmission.
    • Interlock one end of the 2-4 band and the anchor strut.
    • Interlock the other end of the 2-4 band to the servo apply pin.
    Fig 34: Installing 2-4 Band Into Transmission

    Courtesy of FORD MOTOR CO.
NOTE: Use petroleum jelly to hold the thrust bearing and thrust washer in position.
Fig 35: Installing Primary Sun Gear & One-Way Clutch Assembly
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31. Install the (A) primary sun gear and one-way clutch assembly.
    • Verify that the (B) thrust bearing and the (C) thrust washer are installed in the correct positions.
    • Install the primary sun gear and one-way clutch assembly while rotating it.
32. Install the (A) forward/coast/reverse clutch assembly.
    • Verify that the (B) thrust bearing is installed in the correct position.
    • Install the forward and reverse clutch drum assembly while rotating it.
    Fig 36: Installing Forward/Coast/Reverse Clutch Assembly

    Courtesy of FORD MOTOR CO.
33. Rotate the rear sun gear, the one-way clutch, and the reverse clutch drum assembly to line up to the clutch pack and gears.
34. Carefully install the turbine shaft snap ring into the bottom ring groove of the turbine shaft.
    Fig 37: Installing Turbine Shaft Snap Ring Into Bottom Ring Groove Of Turbine Shaft

    Courtesy of FORD MOTOR CO.
35. Remove Turbine Shaft Holder.
    Fig 38: Removing Turbine Shaft Holder

    Courtesy of FORD MOTOR CO.
NOTE: If the clearance is greater than the specification, recheck/reassemble the clutch pack(s) as needed.
Fig 39: Measuring Height Difference Between Reverse Clutch Drum & Transmission Case
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36. Measure the height difference between the reverse clutch drum and the transmission case.
NOTE: Use petroleum jelly to hold the thrust bearing in position.
Fig 40: Installing Reverse Clutch Drum Thrust Bearing
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37. Install the reverse clutch drum thrust bearing.
38. Set the thickest thrust washer, 2.2 mm (0.087 in) onto the oil pump. Set the oil pump onto the forward/coast/reverse clutch drum assembly.
    Fig 41: Setting Thickest Thrust Washer Onto Oil Pump

    Courtesy of FORD MOTOR CO.
NOTE: Take several measurements and calculate the average value.
Fig 42: Measuring Clearance Between Transmission Case & Oil Pump
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Fig 43: Thrust Washer Chart
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39. Use the following procedure to adjust the total end play and select a suitable bearing race.
    • Measure the clearance between the transmission case and the oil pump. Select a suitable thrust washer from the following chart:
40. Remove the oil pump.
    Fig 44: Removing Oil Pump

    Courtesy of FORD MOTOR CO.
NOTE: Use petroleum jelly to hold the thrust washer in position.
Fig 45: Placing Thrust Washer & New Oil Pump Gasket Onto Oil Pump
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41. Place the selected (A) thrust washer and a new (B) oil pump gasket onto the oil pump.
NOTE: Tighten the oil pump bolts evenly and gradually in a crosshatch pattern.
Fig 46: Installing Oil Pump Onto Forward & Reverse Clutch Drum Assembly
Courtesy of FORD MOTOR CO.
42. Install the oil pump onto the forward and reverse clutch drum assembly.
43. Install the (A) solenoid connector with a new O-ring in the transmission case, then connect the (B) solenoid electrical connector.
    Fig 47: Installing Solenoid Connector With A New O-Ring In Transmission Case & Connecting Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
44. Position the main valve body to the transmission case. Align the (A) manual valve with the (B) pin on the manual valve detent lever.
    Fig 48: Aligning Manual Valve With The Pin On The Manual Valve Detent Lever

    Courtesy of FORD MOTOR CO.
NOTE: Tighten the main control valve body bolts evenly and gradually.
Fig 49: Installing Main Control Valve Body Bolts & New Filter
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45. Install the main control valve body bolts and a new filter. Connect the solenoid electrical connectors.
    • Bolt length (measured from below the head)

      A: 30 mm (1.18 in).

      C: 50 mm (1.97 in).

46. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the bolt.
    Fig 50: Installing EPC Solenoid

    Courtesy of FORD MOTOR CO.
NOTE: Tighten the transmission oil pan bolts evenly and gradually.
NOTE: Apply a thin coat of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to each side of the new gasket.
Fig 51: Installing Oil Pan & New Oil Pan Gasket
Courtesy of FORD MOTOR CO.
47. Install the oil pan and new oil pan gasket.
48. Install the turbine shaft speed (TSS) sensor.
    1. Install the sensor.
    2. Install the bolt.
    Fig 52: Installing Turbine Shaft Speed Sensor

    Courtesy of FORD MOTOR CO.
49. Install the vehicle speed sensor (VSS).
    Fig 53: Installing Vehicle Speed Sensor

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50. Install the transmission range (TR) sensor.
    1. Rotate the manual shaft to the N position.
    2. Turn the TR sensor so that the Neutral mark is in line with the flat, straight surfaces on either side of the manual shaft.
    3. Hand-tighten the TR sensor, then tighten the TR sensor mounting bolts.
    Fig 54: Installing Transmission Range Sensor

    Courtesy of FORD MOTOR CO.
51. Install the manual shaft lever.
    1. Position the manual shaft lever.
    2. Install the spring washer and manual control lever nut.
    Fig 55: Installing Manual Shaft Lever

    Courtesy of FORD MOTOR CO.
52. Install a new O-ring on the fluid filler tube, then install the fluid filler tube and dipstick assembly.
    Fig 56: Installing Fluid Filler Tube & Dipstick Assembly

    Courtesy of FORD MOTOR CO.
53. Install the fluid cooler line.
    1. Install the check ball.
    2. Install the drain back valve spring.
    3. Install the fluid cooler line washers.
    4. Install the fluid cooler line bolt.
    5. Install the fluid cooler line nut.
    Fig 57: Installing Fluid Cooler Line

    Courtesy of FORD MOTOR CO.
54. Install the oil pump shaft.
    Fig 58: Installing Oil Pump Shaft

    Courtesy of FORD MOTOR CO.
55. Install a new converter turbine shaft seal on the turbine shaft.
    • The converter turbine shaft seal inner diameter is 20 mm (0.787 in).
    Fig 59: Installing New Converter Turbine Shaft Seal On Turbine Shaft

    Courtesy of FORD MOTOR CO.
CAUTION: If a new torque converter is being installed or the torque converter has been drained and washed, pour 0.5L (0.53 qt) of Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON into the torque converter before installation. Hold the torque converter in an erect position when filling it with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON.
NOTE: The torque converter should slide into the transmission easily. Do not force the torque converter into the transmission.
Fig 60: Installing Torque Converter Into Converter Housing
Courtesy of FORD MOTOR CO.
56. Install the torque converter into the converter housing while rotating it to align the splines.
57. To ensure that the torque converter is installed properly, measure the distance between the torque converter and the edge of the converter housing.
    Fig 61: Identifying Distance Between Torque Converter & Edge Of Converter Housing

    Courtesy of FORD MOTOR CO.
58. Remove the transmission from Bench Mounted Holding Fixture.
    Fig 62: Removing Transmission From Bench Mounted Holding Fixture

    Courtesy of FORD MOTOR CO.