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Section 231 (Automatic Transaxle/Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2003 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools (1 Of 3)
G01564109Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 3)
G01564110Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tools (3 Of 3)
G01564111Courtesy of FORD MOTOR CO.
NOTE: Refer to the Disassembled Views for component location and orientation.
  1. Using the special tools, remove the torque converter from the transmission.
    Fig 4: Removing Torque Converter From Transmission
    G01564112Courtesy of FORD MOTOR CO.
    2. CAUTION: The turbine shaft speed sensor (TSS) must be removed or damage to the sensors will occur.
  2. Remove the turbine shaft sensor (TSS).
    1. Remove the bolt.
    2. Remove the turbine shaft sensor (TSS).
      Fig 5: Removing Turbine Shaft Sensor
      G01564113Courtesy of FORD MOTOR CO.
    3. CAUTION: The output shaft speed sensor (OSS) will need to be removed or damage to the sensors will occur.
  3. Remove the output shaft speed sensor (OSS).
    1. Remove the bolt.
    2. Remove the output shaft speed sensor (OSS).
      Fig 6: Removing Output Shaft Speed Sensor
      G01564114Courtesy of FORD MOTOR CO.
  4. Mount the transmission to a suitable stand.
    5. CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.
    Fig 7: Removing Input Shaft
    G01564115Courtesy of FORD MOTOR CO.
  5. Remove the input shaft.
    6. CAUTION: The sealing washers may fall off the cooler line case fittings.
    NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
  6. Remove the cooler bypass valve.
    1. Remove the cooler line case fittings.
    2. Remove the cooler bypass valve.
      Fig 8: Removing Cooler Bypass Valve
      G01564116Courtesy of FORD MOTOR CO.
  7. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the transmission range (TR) sensor.
      Fig 9: Removing Transmission Range Sensor
      G01564117Courtesy of FORD MOTOR CO.
    8. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 10: Removing Transmission Fluid Pan And Gasket
    G01564118Courtesy of FORD MOTOR CO.
  8. Remove the transmission fluid pan and the gasket.
    9. CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
    NOTE: After removal, discard the filter and seal assembly.
    Fig 11: Removing Filter And Seal Assembly
    G01564119Courtesy of FORD MOTOR CO.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
  10. Remove the bolts, nuts and the accumulator body.
    Fig 12: Removing Accumulator Body
    G01564120Courtesy of FORD MOTOR CO.
    11. NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
  11. Remove the main control valve body.
    1. Do not remove the two lower-to-upper main control valve body assembly bolts.
      Fig 13: Removing Main Control Valve Body
      G01564121Courtesy of FORD MOTOR CO.
  12. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 14: Removing Solenoid Body Assembly
    G01564122Courtesy of FORD MOTOR CO.
  13. Remove the solenoid screen assembly by rotating and pulling.
    Fig 15: Removing Solenoid Screen Assembly
    G01564123Courtesy of FORD MOTOR CO.
    14. CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
    Fig 16: Removing Separator Plate Reinforcing Plate And Valve Body Separator Plate
    G01564124Courtesy of FORD MOTOR CO.
  14. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
    15. NOTE: The steel EPC check ball has a 0.5 mm (0.02 in) diameter and is smaller than the other check balls.
    Fig 17: Removing Steel EPC Check Ball And Spring
    G01564125Courtesy of FORD MOTOR CO.
  15. Remove the steel EPC check ball and spring.
    16. CAUTION: Use care not to damage the rubber check balls. Transmission shift problems can occur.
    Fig 18: Removing Rubber Check Balls
    G01564126Courtesy of FORD MOTOR CO.
  16. Using a small screwdriver, carefully remove the eight rubber check balls.
  17. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 19: Locating Intermediate Band Servo Assembly Piston
    G01564127Courtesy of FORD MOTOR CO.
    18. CAUTION: After removal, discard the feedbolts. The bolts will not retain torque specification if reused.
    Fig 20: Removing Feedbolts
    G01564128Courtesy of FORD MOTOR CO.
  18. Remove and discard the feedbolts.
  19. Remove the pump bolts and discard the washers.
    Fig 21: Removing Pump Bolts
    G01564129Courtesy of FORD MOTOR CO.
    20. NOTE: The special tools should be installed into the pump threaded holes as shown.
    Fig 22: Removing Pump
    G01564130Courtesy of FORD MOTOR CO.
  20. Using the special tools, remove the pump.
    21. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
  21. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
      Fig 23: Removing No. 1 Pump Thrust Washer
      G01564131Courtesy of FORD MOTOR CO.
    22. CAUTION: The coast clutch, overdrive ring gear, centershaft assembly must be removed as an assembly, using special service tool or damage to the overdrive one-way clutch can occur.
    Fig 24: Removing Centershaft Assembly
    G01564132Courtesy of FORD MOTOR CO.
  22. Using the special tool remove the coast clutch, overdrive ring gear, centershaft assembly.
    23. NOTE: The No. 5 thrust bearing may remaining on the center shaft or the center support.
    Fig 25: Removing No. 5 Overdrive Center Shaft Thrust Bearing Assembly
    G01564133Courtesy of FORD MOTOR CO.
  23. Remove the No. 5 overdrive center shaft thrust bearing assembly.
  24. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 26: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring
    G01564134Courtesy of FORD MOTOR CO.
    25. NOTE: Tag the parts for identification during installation.
    Fig 27: Removing Overdrive Clutch Pressure Plate
    G01564135Courtesy of FORD MOTOR CO.
  25. Remove the overdrive clutch pressure plate and the clutch pack.
  26. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 28: Removing Intermediate/Overdrive Cylinder Retaining Ring
    G01564136Courtesy of FORD MOTOR CO.
    27. CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
    Fig 29: Removing Intermediate/Overdrive Cylinder Assembly
    G01564137Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/overdrive cylinder assembly.
  28. Remove the intermediate clutch piston return spring.
    Fig 30: Removing Intermediate Clutch Piston Return Spring
    G01564138Courtesy of FORD MOTOR CO.
    29. CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.
    Fig 31: Removing Center Support Assembly
    G01564139Courtesy of FORD MOTOR CO.
  29. Carefully remove the center support assembly.
  30. Remove the No. 6 center support thrust washer.
    Fig 32: Removing No. 6 Center Support Thrust Washer
    G01564140Courtesy of FORD MOTOR CO.
    31. NOTE: Tag the parts for identification during installation.
  31. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate.
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
      Fig 33: Removing Intermediate Clutch Rear Pressure Plate
      G01564141Courtesy of FORD MOTOR CO.
  32. Remove the intermediate band.
    Fig 34: Removing Intermediate Band
    G01564142Courtesy of FORD MOTOR CO.
    33. NOTE: When installing the special tool, each leg of the tool must be rotated separately to engage notches on the input shell prior to tightening the top cross bar.
    Fig 35: Removing Direct Clutch, Forward Clutch And Input Shell
    G01564143Courtesy of FORD MOTOR CO.
  33. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
  34. Remove the reverse planet retaining ring.
    Fig 36: Removing Reverse Planet Retaining Ring
    G01564144Courtesy of FORD MOTOR CO.
  35. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 37: Removing Reverse Planet Assembly, No. 10B And No. 11 Reverse Planet Carrier Thrust Washers
    G01564145Courtesy of FORD MOTOR CO.
    36. WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
    Fig 38: Removing Output Shaft Retaining Ring
    G01564146Courtesy of FORD MOTOR CO.
  36. Remove the output shaft retaining ring.
  37. Remove the output shaft ring gear and hub assembly.
    Fig 39: Removing Output Shaft Ring Gear And Hub Assembly
    G01564147Courtesy of FORD MOTOR CO.
    38. WARNING: Use care not to drop the output shaft while rotating the transmission.
  38. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
      Fig 40: Removing Low/Reverse One Way Clutch Assembly
      G01564148Courtesy of FORD MOTOR CO.
  39. Using the special tools, remove the extension housing seal.
    Fig 41: Removing Extension Housing Seal
    G01564149Courtesy of FORD MOTOR CO.
  40. Using the special tool, remove the extension housing bushing.
    Fig 42: Removing Extension Housing Bushing
    G01564150Courtesy of FORD MOTOR CO.
  41. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 43: Removing And Discarding Extension Housing Gasket
    G01564151Courtesy of FORD MOTOR CO.
    42. NOTE: Be sure not to damage the output shaft drive sprocket speed sensor wheel or the park gear.
    NOTE: The parking gear and output shaft drive sprocket speed sensor wheel are a press fit to the output shaft.
    Fig 44: Removing Output Shaft
    G01564152Courtesy of FORD MOTOR CO.
  42. Remove the output shaft.
  43. Remove the No. 13 thrust bearing.
    Fig 45: Removing No. 13 Thrust Bearing
    G01564153Courtesy of FORD MOTOR CO.
  44. Remove the plastic orifice lube plug form the rear of the case and discard.
    Fig 46: Removing Plastic Orifice Lube Plug Form Rear Of Case
    G01564154Courtesy of FORD MOTOR CO.
  45. Remove the five bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 47: Removing Low/Reverse One-Way Clutch Inner Race Retaining Bolts
    G01564155Courtesy of FORD MOTOR CO.
  46. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 48: Removing Low/Reverse One-Way Clutch Inner Race And Reverse Clutch Return Spring Assembly
    G01564156Courtesy of FORD MOTOR CO.
  47. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to retain the reverse clutch piston.
    Fig 49: Removing Reverse Clutch Piston
    G01564157Courtesy of FORD MOTOR CO.
  48. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 50: Applying Air Pressure Into Reverse Clutch Feed Port
    G01564158Courtesy of FORD MOTOR CO.
  49. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 51: Removing Reverse Clutch Pressure Plate Retainer Snap Ring, Pressure Plate And Clutch Piston
    G01564159Courtesy of FORD MOTOR CO.
  50. If required, remove the parking rod guide plate.
    Fig 52: Removing Parking Rod Guide Plate
    G01564160Courtesy of FORD MOTOR CO.
  51. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
      Fig 53: Removing Parking Pawl
      G01564161Courtesy of FORD MOTOR CO.
    52. CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.
    Fig 54: Removing Parking Pawl Abutment
    G01564162Courtesy of FORD MOTOR CO.
  52. If required, remove the parking pawl abutment.
    53. NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
    Fig 55: Removing Manual Lever Shaft Retaining Pin
    G01564163Courtesy of FORD MOTOR CO.
  53. Using the special tool, remove the manual lever shaft retaining pin.
    54. CAUTION: Use care not to damage the manual control lever bore.
    NOTE: The manual control lever and manual control lever shaft are one piece.
  54. Remove the manual control lever shaft assembly.
      NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
      Fig 56: Removing Manual Control Valve Detent Lever Spring
      G01564164Courtesy of FORD MOTOR CO.
  55. Using the special tool, remove the manual control lever seal.
    Fig 57: Removing Manual Control Lever Seal
    G01564165Courtesy of FORD MOTOR CO.
    56. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 58: Identifying Special Tools
    G01564166Courtesy of FORD MOTOR CO.
  56. If required, remove the short fluid inlet tube.
  57. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
  58. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
  59. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the helicoil kit.
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