Automatic Transmission: Disassembly: Transmission

Fig 1: Identifying Special Tools (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 2)

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1. Remove the special tool.
   Fig 3: Removing Special Tool

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2. Using the special tools, remove torque converter.
   Fig 4: Removing Torque Converter

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3. Using the special tool, mount the transmission to the bench.
   Fig 5: Mounting Transmission To Bench

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NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
4. Remove the transmission fluid pan and transmission fluid pan gasket.
   1. Remove the bolts.
   2. Remove the transmission fluid pan and transmission fluid pan to case gasket.
      Fig 6: Removing Bolts

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5. Clean the transmission fluid pan and pan magnet.
   Fig 7: Cleaning Transmission Fluid Pan And Pan Magnet

   Courtesy of FORD MOTOR CO.
CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
Fig 8: Removing Fluid Filter And Grommet
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6. Remove the fluid filter and grommet.
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
7. Disconnect the molded lead frame from the solenoids.
   1. Disconnect the shift solenoid SSA and SSB.
   2. Disconnect the torque converter clutch (TCC).
   3. Disconnect the electronic pressure control (EPC) solenoid.
   4. Disconnect the bulkhead inter-connector.
      Fig 9: Disconnecting Shift Solenoid SSA And SSB

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8. Remove the output shaft speed (OSS) sensor.
   1. Remove the bolt.
   2. Remove the OSS sensor.
      Fig 10: Removing Bolt

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9. Remove the digital transmission range (TR) sensor.
   1. Remove the bolts.
   2. Remove the digital TR sensor.
      Fig 11: Removing Digital TR Sensor

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10. Remove the manual control valve detent lever spring.
    1. Remove the bolt.
    2. Remove the manual control valve detent lever spring.
       Fig 12: Removing Bolt

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11. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 13: Removing 24 Main Control Valve Body Bolts

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12. Remove the discard the pump outlet screen.
    Fig 14: Removing Pump Outlet Screen

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NOTE: Use a shop cloth to protect the transmission case surface.
Fig 15: Removing Manual Lever Shaft Retaining Pin
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13. Remove the manual lever shaft retaining pin.
14. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
      Fig 16: Removing Manual Lever Shaft Inner Nut

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15. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
       Fig 17: Removing Parking Lever Actuating Rod

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CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged the new seal may leak.
Fig 18: Removing Manual Control Lever Shaft Seal
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16. Remove the manual control lever shaft seal.
17. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
       Fig 19: Removing EPC Solenoid

       Courtesy of FORD MOTOR CO.
18. Remove the 2-3 accumulator spring retainer.
    Fig 20: Removing 2-3 Accumulator Spring Retainer

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19. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
       Fig 21: Removing 2-3 Accumulator Piston

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20. Using the special tool, remove the reverse band servo retaining ring.
    Fig 22: Removing Reverse Band Servo Retaining Ring

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21. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
       Fig 23: Removing Reverse Servo Assembly

       Courtesy of FORD MOTOR CO.
NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
Fig 24: Compressing Piston Spring
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22. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
23. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
       Fig 25: Removing Overdrive Servo Piston

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24. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 26: Compressing 1-2 Accumulator Cover And Removing Retaining Ring

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25. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the 1-2 accumulator lower spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
       Fig 27: Removing 1-2 Accumulator Upper Spring

       Courtesy of FORD MOTOR CO.
26. Using the special tools, remove the extension housing seal.
    Fig 28: Removing Extension Housing Seal

    Courtesy of FORD MOTOR CO.
NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
27. Remove the extension housing.
    1. Remove the four bolts and two nuts.
    2. Remove the extension housing and the extension housing gasket.
       Fig 29: Removing Four Bolts And Two Nuts

       Courtesy of FORD MOTOR CO.
28. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
       Fig 30: Removing Parking Pawl

       Courtesy of FORD MOTOR CO.
29. Rotate the transmission to the vertical position with the output shaft towards the floor.
CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
Fig 31: Pushing Connector Out Through Bottom Of Case
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30. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
31. Using the special tools, remove the front pump seal.
    Fig 32: Removing Front Pump Seal

    Courtesy of FORD MOTOR CO.
NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
Fig 33: Removing Bolts
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32. Remove the bolts.
33. Using the special tools, remove the front pump support.
    Fig 34: Removing Front Pump Support

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34. Remove the discard the pump gasket.
35. Remove the intermediate anti-rattle clip, if equipped.
    Fig 35: Removing Intermediate Anti-Rattle Clip

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CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
36. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
      Fig 36: Removing Forward Clutch Assembly

      Courtesy of FORD MOTOR CO.
37. Disengage and remove the overdrive band.
    Fig 37: Removing Overdrive Band

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38. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 38: Removing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing

    Courtesy of FORD MOTOR CO.
39. Remove the intermediate stub shaft.
    Fig 39: Removing Intermediate Stub Shaft

    Courtesy of FORD MOTOR CO.
40. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 40: Aligning Reverse Sun Shell

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41. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
      Fig 41: Removing Reverse Clutch Sun Gear

      Courtesy of FORD MOTOR CO.
42. Remove the center support retaining ring and note location for assembly.
    Fig 42: Removing Center Support Retaining Ring

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43. Remove the case to planet support spring.
    Fig 43: Removing Case To Planet Support Spring

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44. Remove the planetary gear support and planetary as an assembly.
    Fig 44: Removing Planetary Gear Support And Planetary

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45. Remove the reverse clutch band.
    Fig 45: Removing Reverse Clutch Band

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46. Remove the retaining ring.
    Fig 46: Removing Retaining Ring

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47. Remove the direct clutch pack.
    Fig 47: Removing Direct Clutch Pack

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48. Remove the No. 8 bearing.
    Fig 48: Removing No. 8 Bearing

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49. Remove the output shaft, output shaft ring gear assembly and direct clutch.
    Fig 49: Removing Output Shaft, Output Shaft Ring Gear Assembly And Direct Clutch

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50. Remove the No. 9 case rear bearing.
    Fig 50: Removing No. 9 Case Rear Bearing

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51. Inspect and if necessary, use the special tools to remove the rear case bushing.
    Fig 51: Removing Rear Case Bushing

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