LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2003 >> Explorer Sport 4.0 K, 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Forward Geartrain >> Assembly

Forward Geartrain: Assembly

  1. Install the forward clutch cylinder thrust bearing (No. 5) on the forward clutch cylinder assembly.
    • Use petroleum jelly to hold the forward clutch cylinder thrust bearing (No. 5) in place.
    Fig 1: Installing Forward Clutch Cylinder Thrust Bearing (No. 5)
    G01299934Courtesy of FORD MOTOR CO.
  2. Install the forward clutch cylinder assembly into the intermediate brake and direct clutch drum assembly.
    Fig 2: Installing Forward Clutch Cylinder Assembly
    G01299935Courtesy of FORD MOTOR CO.
  3. Install the forward ring gear hub thrust bearing (No. 6A) with the tabs facing up.
    Fig 3: Installing Forward Ring Gear Hub Thrust Bearing (No. 6A)
    G01299936Courtesy of FORD MOTOR CO.
  4. Install the forward clutch thrust washer (No. 6B) into the forward ring gear hub.
    • Use petroleum jelly to hold the forward clutch thrust washer (No. 6B) in place.
    Fig 4: Installing Forward Clutch Thrust Washer (No. 6B)
    G01299937Courtesy of FORD MOTOR CO.
    5. NOTE: Make sure the forward ring gear hub thrust bearing (No. 6A) and forward clutch thrust washer (No. 6B) are inside the forward ring gear.
    Fig 5: Installing Forward Ring Gear Into Forward Clutch Cylinder
    G01299938Courtesy of FORD MOTOR CO.
  5. Install the forward ring gear into the forward clutch cylinder.
    6. CAUTION: Black oxidized color of thrust bearing must face up towards the planetary assembly.
    Fig 6: Installing Forward Planetary Thrust Bearing (No. 7)
    G01299939Courtesy of FORD MOTOR CO.
  6. Install the forward planetary thrust bearing (No. 7) into the forward ring gear.
    7. NOTE: The forward planetary assembly is serviced with a 6 pinion assembly in all applications.
    Fig 7: Installing Forward Planetary Assembly
    G01299940Courtesy of FORD MOTOR CO.
  7. Install the forward planetary assembly into the forward ring gear.
    8. NOTE: There is not a bushing inside the forward sun gear or washer on the back of the input shell.
    NOTE: If the sun gear or input shell is damaged carry out the following steps. If not, install the input shell and forward sun gear assembly into planetary gearset.
    NOTE: Make sure the forward sun gear aligns with the forward planetary assembly. Ensure the input shell aligns with the intermediate brake and direct clutch.
    Fig 8: Inspecting Sun Gear And Input Shell
    G01299941Courtesy of FORD MOTOR CO.
  8. Inspect sun gear and input shell for damage or wear. If sun gear or input shell are damaged, install new as necessary. Install the input shell and forward sun gear assembly into planetary gearset.
  9. Remove the rear retaining ring, sun gear and the retaining ring from the sun gear.
    1. Remove the rear retaining ring.
    2. Remove the sun gear.
    Fig 9: Removing Rear Retaining Ring
    G01299942Courtesy of FORD MOTOR CO.
  10. Remove the front retaining ring from the sun gear.
    Fig 10: Removing Front Retaining Ring From Sun Gear
    G01299943Courtesy of FORD MOTOR CO.
  11. Install a new retaining ring onto the sun gear.
    Fig 11: Installing A New Retaining Ring Onto Sun Gear
    G01299944Courtesy of FORD MOTOR CO.
  12. Install the sun gear into the input shell.
    Fig 12: Installing Sun Gear Into Input Shell
    G01299945Courtesy of FORD MOTOR CO.
  13. Install a new rear retaining ring.
    Fig 13: Installing A New Rear Retaining Ring
    G01299946Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals