Overhaul Automatic Transmission: Disassembly: Transmission

Fig 1: Special Tool(s) (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 2: Special Tool(s) (2 Of 4)

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Fig 3: Special Tool(s) (3 Of 4)

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Fig 4: Special Tool(s) (4 Of 4)

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All vehicles 

1. Place the transmission on a workbench.
Fig 5: 5R55W/S Transmission
Courtesy of FORD MOTOR CO.
NOTE: Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.
2. If vehicle is equipped, and installation of a new or remanufactured torque converter is necessary, remove the torque converter adapter plate.
Fig 6: Marking Torque Converter Stud
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3. If the adapter plate has been removed use the special tools to remove the torque converter.
Fig 7: Using Torque Converter Handles Without Adapter Plate
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WARNING: The torque converter is heavy, especially when full of fluid.
NOTE: If not installing a new torque converter leave the adapter plate bolted to the torque converter.
4. Using the special tools, remove the torque converter and adapter plate as an assembly.
Fig 8: Using Torque Converter Handles With Adapter Plate
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5. Remove the input shaft.
Fig 9: Removing Input Shaft
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6. Remove the sensors.
Fig 10: Removing Sensors
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7. Remove the outer manual control lever.
Fig 11: Removing Manual Control Lever
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8. Remove the digital transmission range (TR) sensor.
   Fig 12: Removing Digital TR Sensor

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   4x2 applications 

9. Using the special tools, remove the extension housing seal.
Fig 13: Removing Extension Housing Seal
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CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
Fig 14: Removing Extension Housing
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10. Remove the extension housing.

    4x4 applications 

11. Using the special tools, remove the extension housing seal.
Fig 15: Removing Extension Housing Seal
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CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
Fig 16: Removing Extension Housing
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12. Remove the extension housing.

    All applications 

NOTE: The 4x2 is shown, the 4x4 is similar.
13. Remove the parking pawl assembly and discard the gasket.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    4. Remove and discard the gasket.
Fig 17: Removing Parking Pawl Assembly
Courtesy of FORD MOTOR CO.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If not damaged, the gasket should be reused.
14. Remove the 16 transmission fluid pan screws, fluid pan, and gasket.
Fig 18: Removing Fluid Pan
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15. Remove the transmission fluid filter and seal assembly and discard.
Fig 19: Removing Transmission Fluid Filter
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16. Remove the manual control valve detent spring.
Fig 20: Removing Manual Control Valve Detent Spring
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17. Remove the reverse servo assembly.
Fig 21: Removing Reverse Servo Assembly
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CAUTION: Do not damage solenoid body connector pins.
18. Remove the solenoid body assembly by lifting on the body and pushing the connector from the other side of the case.
Fig 22: Removing Solenoid Body
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19. Remove the main control valve body, separator plate, and gasket.
Fig 23: Removing Main Control Valve Body
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20. Using the special tools, remove the converter hub seal.
Fig 24: Removing Converter Hub Seal
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CAUTION: Failure to loosen the OD band adjusting screw prior to pump removal may cause damage to the pump and OD band.
CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
21. Remove the locknuts, and loosen the OD band adjusting screw.
Fig 25: Removing Band Adjusting Locknuts
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22. Remove the overdrive anchor strut.
Fig 26: Removing Overdrive Anchor Strut
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CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.
23. Remove and discard the screws.
Fig 27: Removing Pump Screws
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24. Install the special tool.
Fig 28: Installing Transmission Fluid Pump Remover
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25. Using the special tools, remove the pump.
Fig 29: Removing Transmission Fluid Pump
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CAUTION: Servo cover is under spring tension.
26. Using the special tool, remove the intermediate servo cover retaining ring and cover.
Fig 30: Removing Intermediate Servo Cover
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27. Remove the intermediate band servo piston and spring.
Fig 31: Removing Intermediate Band Servo Piston
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CAUTION: Servo cover is under spring tension.
28. Using the special tool, remove the overdrive servo cover retaining ring and cover.
Fig 32: Removing Overdrive Servo Cover
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29. Remove the front band servo piston and spring.
Fig 33: Removing Front Band Servo Piston
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30. Remove the screw.
Fig 34: Removing Band Adjusting Screw
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NOTE: Tag and identify parts for reassembly.
31. Compress the overdrive band and remove the apply strut.
Fig 35: Removing Overdrive Apply Strut
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CAUTION: Identify the anchor and apply ends of the overdrive band.
NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Fig 36: Removing Overdrive Band
Courtesy of FORD MOTOR CO.
32. Remove and inspect the overdrive band. Check the following conditions for installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
33. Remove the overdrive brake and coast clutch drum.
Fig 37: Removing Overdrive Brake & Coast Clutch Drum
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CAUTION: Do not bend the trigger wheel.
NOTE: The No. 2 thrust bearing is in this assembly.
34. Remove the planetary gear overdrive carrier.
Fig 38: Removing Planetary Gear Overdrive Carrier
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35. Remove the overdrive planet thrust bearing (No. 2).
Fig 39: Removing Overdrive Planet Thrust Bearing
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36. Remove the overdrive ring gear, overdrive one-way clutch assembly, and center shaft as an assembly.
Fig 40: Removing Overdrive Ring Gear, Overdrive One-Way Clutch Assembly & Center Shaft
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NOTE: Tag and identify the center shaft thrust bearing (No.3) for assembly.
37. Remove the No. 3 center shaft thrust bearing.
Fig 41: Removing Center Shaft Thrust Bearing
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CAUTION: The center support locknut could fall into the remaining assembly if not removed.
38. Remove the screw.
Fig 42: Removing Screw
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39. Remove the locknut and cage.
Fig 43: Removing Locknut & cage
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40. Remove the center support retaining ring.
Fig 44: Removing Center Support Retaining Ring
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NOTE: When removing the center support, pull evenly around the center support web.
41. Remove the center support.
Fig 45: Removing Center Support
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NOTE: Tag and identify the No.4 intermediate brake drum thrust bearing.
42. Remove the intermediate brake drum thrust bearing (No. 4).
Fig 46: Removing Intermediate Brake Drum Thrust Bearing
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43. Remove the intermediate band anchor strut.
Fig 47: Removing Intermediate Band Anchor Strut
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CAUTION: Identify the anchor and apply ends of the intermediate band.
NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
44. Remove and inspect the intermediate band. Check the following conditions for installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
Fig 48: Removing Intermediate Band
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45. Remove the intermediate band apply strut.
Fig 49: Removing Intermediate Band Apply Strut
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46. Remove the screw.
Fig 50: Removing Band Adjusting Screw
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NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
47. Remove the direct clutch drum.
Fig 51: Removing Direct Clutch Drum
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48. Remove the No. 5 forward clutch cylinder thrust bearing, tag and identify.
Fig 52: Removing Forward Clutch Cylinder Thrust Bearing
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NOTE: The No. 6A thrust bearing may come out with the cylinder. Tag for reassembly.
49. Remove the forward clutch cylinder.
Fig 53: Removing Forward Clutch Cylinder
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NOTE: The No. 6A forward ring gear hub thrust bearing may have come out with the forward clutch cylinder.
50. Remove the No. 6A forward ring gear hub thrust bearing.
Fig 54: Removing Forward Ring Gear Hub Thrust Bearing
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NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
51. Remove the forward ring gear and hub as an assembly.
Fig 55: Removing Forward Ring Gear & Hub
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52. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
Fig 56: Removing Forward Clutch Thrust Washer
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NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
53. Remove the No. 7 forward planet thrust bearing.
Fig 57: Removing Forward Planet Thrust Bearing
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54. Remove the forward planetary assembly.
Fig 58: Removing Forward Planetary Assembly
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55. Remove the input shell and sun gear assembly.
Fig 59: Removing Input Shell & Sun Gear Assembly
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56. Remove the spacer.
Fig 60: Removing Spacer
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NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
57. Remove the thrust bearing.
Fig 61: Removing Low/Reverse Planetary Carrier Thrust Bearing
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58. Remove the retaining ring.
Fig 62: Removing Retaining Ring
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59. Remove low/reverse planetary assembly.
Fig 63: Removing Low/Reverse Planetary Assembly
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NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
60. Remove the thrust bearing.
Fig 64: Removing Low/Reverse Planetary Carrier Thrust Bearing
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NOTE: Use slots located around the outside of the sleeve.
61. Using a small pick, remove the output shaft sleeve.
Fig 65: Removing Output Shaft Sleeve
Courtesy of FORD MOTOR CO.
WARNING: The output shaft may fall out after removing the snap ring. Failure to follow these instructions may result in personal injury.
CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
62. While holding the output shaft, remove and discard the output shaft retaining ring.
Fig 66: Removing Output Shaft Retaining Ring
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63. Remove the output shaft ring gear and hub.
Fig 67: Removing Output Shaft Ring Gear & Hub
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64. Remove the No. 10 low intermediate sun gear bearing.
Fig 68: Removing Low/Intermediate Sun Gear Bearing
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CAUTION: Do not pry on the outer edge of the case damage to the gasket sealing surface could occur.
NOTE: It may be necessary to grind flat spots on the edges of the reverse band actuating lever shaft in order to remove it.
65. Using a pair of vice grips, hold the flat spots on the reverse band actuating lever shaft, wiggle it back and forth and remove the reverse band actuating lever shaft.
Fig 69: Removing Reverse Band Actuating Lever Shaft
Courtesy of FORD MOTOR CO.
66. Remove the reverse band actuating lever assembly.
Fig 70: Removing Reverse Band Actuating Lever Assembly
Courtesy of FORD MOTOR CO.
NOTE: The inner race of the rear one-way clutch is not removable. It is repaired in the case.
67. Remove the low/reverse brake drum and one-way clutch assembly by rotating it clockwise.
Fig 71: Removing Low/Reverse Brake Drum & One-Way Clutch Assembly
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68. Remove the reverse band.
Fig 72: Removing Reverse Band
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69. Remove the output shaft and park gear.
Fig 73: Removing Output Shaft
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NOTE: Tag and identify the No. 11 output shaft thrust washer.
70. Remove the output shaft thrust washer.
Fig 74: Removing Output Shaft Thrust Washer
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CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.
71. Remove the nut.
Fig 75: Removing Manual Lever Shaft Nut
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72. Remove the manual lever shaft retaining pin.
Fig 76: Removing Manual Lever Shaft Retaining Pin
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73. Remove the manual control lever shaft.
Fig 77: Removing Manual Control Lever Shaft
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74. Disconnect the manual valve inner lever from the parking lever actuating rod.
Fig 78: Disconnecting Manual Valve Inner Lever
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75. Remove the manual valve inner lever.
Fig 79: Removing Manual Valve Inner Lever
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76. Remove the parking lever actuating rod.
Fig 80: Removing Parking Lever Actuating Rod
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CAUTION: Do not damage the bore.
77. Remove the manual control lever seal.

Fig 81: Removing Manual Control Lever Seal

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