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Section 6 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different variant/trim than selected.
Fig 1: Identifying Special Tools (1 Of 3)
G01626989Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 3)
G01626990Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tools (3 Of 3)
G01626991Courtesy of FORD MOTOR CO.
Fig 4: Identifying Material Specification
G01626992Courtesy of FORD MOTOR CO.
CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. In addition, the necessary torques can be found in the General Specifications Chart.

When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.

Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.

Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.

  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
      Fig 5: Installing Rear Case Bushing
      G01626993Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    Fig 6: Installing No. 9 Case Rear Bearing On Case Boss
    G01626994Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES . Internal damage and shift problems may occur.
    Fig 7: Installing Output Shaft And Output Shaft Ring Gear
    G01626995Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 8: Installing No. 8 Bearing
    G01626996Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 9: Installing Direct Clutch
    G01626997Courtesy of FORD MOTOR CO.
    7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
    Fig 10: Installing Reverse Band Support Retaining Ring
    G01626998Courtesy of FORD MOTOR CO.
  7. Install the reverse band support retaining ring.
    8. NOTE: Make sure the band is seated on the anchor pins.
    Fig 11: Installing Reverse Band
    G01626999Courtesy of FORD MOTOR CO.
  8. Install the reverse band.
    9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
      Fig 12: Installing Planetary Assembly And Planetary Gear Support
      G01627000Courtesy of FORD MOTOR CO.
    10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
    Fig 13: Installing Case To Planet Support Spring
    G01627001Courtesy of FORD MOTOR CO.
  10. Install the case to the planet support spring located at the 1 o'clock position.
  11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
      Fig 14: Installing Center Support Retaining Ring
      G01627002Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse sun gear.
    Fig 15: Installing Forward Clutch Sun Gear
    G01627003Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 16: Installing No. 4 Forward Clutch Hub Bearing
    G01627004Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 17: Installing Intermediate Stub Shaft
    G01627005Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 18: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G01627006Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 19: Installing Forward Clutch Assembly
    G01627007Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
      Fig 20: Installing Reverse Clutch Cylinder Assembly
      G01627008Courtesy of FORD MOTOR CO.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
      Fig 21: Installing Overdrive Band
      G01627009Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
      Fig 22: Installing Overdrive Servo Spring
      G01627010Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 23: Verifying Tip Of Piston Assembly Engages Pocket Of Overdrive Band
    G01627011Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 24: Installing Overdrive Servo Retaining Ring
    G01627012Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 25: Installing Intermediate Clutch Pressure Plate
    G01627013Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.
    Fig 26: Installing Intermediate Clutch Pack And Selective Steel Plate
    G01627014Courtesy of FORD MOTOR CO.
  23. Install the intermediate clutch pack and selective steel plate.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

      Fig 27: Selective Steel Plates Specification (1 Of 2)
      G01627015Courtesy of FORD MOTOR CO.
      Fig 28: Selective Steel Plates Specification (2 Of 2)
      G01627016Courtesy of FORD MOTOR CO.
      Fig 29: Measuring Intermediate Clutch Clearance
      G01627017Courtesy of FORD MOTOR CO.
  25. Install the intermediate anti-rattle clip, if equipped.
    Fig 30: Installing Intermediate Anti-Rattle Clip
    G01627018Courtesy of FORD MOTOR CO.
  26. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

      Use the No. 1 thrust washer chart to select the correct washer.

      Fig 31: No. 1 Thrust Washer Chart
      G01627019Courtesy of FORD MOTOR CO.
      Fig 32: Measuring End Clearance For No. 1 Front Pump Thrust Washer
      G01627020Courtesy of FORD MOTOR CO.
  27. Install the No. 1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
      Fig 33: Installing No. 1 Front Pump Support Thrust Washer
      G01627021Courtesy of FORD MOTOR CO.
    28. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 34: Installing An Alignment Pin At Top Of Case
    G01627022Courtesy of FORD MOTOR CO.
  28. Install an alignment pin at the top of the case.
    29. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  29. Install the pump gasket.
    30. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 35: Installing Pump Assembly
    G01627023Courtesy of FORD MOTOR CO.
  30. Install the pump assembly.
  31. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
      Fig 36: Installing Front Pump Bolts
      G01627024Courtesy of FORD MOTOR CO.
  32. Rotate the transmission to the horizontal position.
  33. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
      Fig 37: Installing Parking Pawl
      G01627025Courtesy of FORD MOTOR CO.
  34. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
      Fig 38: Installing New Extension Housing Gasket & Extension Housing
      G01627026Courtesy of FORD MOTOR CO.
  35. Using the special tool, install a new extension housing seal.
    Fig 39: Installing A New Extension Housing Seal
    G01627027Courtesy of FORD MOTOR CO.
  36. Install the output shaft speed (OSS) sensor.
    1. Position the OSS sensor.
    2. Install the bolt.
      Fig 40: Installing Output Shaft Speed (OSS) Sensor
      G01627028Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the manual control lever seal.
    Fig 41: Installing Manual Control Lever Seal
    G01627029Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
  38. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the EPC solenoid bracket and bolt.
      Fig 42: Installing EPC Solenoid
      G01627030Courtesy of FORD MOTOR CO.
  39. Install the manual valve detent lever and parking lever actuating rod.
    Fig 43: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod
    G01627031Courtesy of FORD MOTOR CO.
  40. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
      Fig 44: Installing Manual Control Lever Shaft
      G01627032Courtesy of FORD MOTOR CO.
  41. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the 1-2 accumulator lower spring.
    4. Install the 1-2 accumulator cover and seal.
      Fig 45: Installing 1-2 Accumulator Piston Assembly
      G01627033Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator retaining ring.
    Fig 46: Installing 1-2 Accumulator Retaining Ring
    G01627034Courtesy of FORD MOTOR CO.
    43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
    NOTE: Do not install the reverse servo piston cover and seal at this time.
    Fig 47: Installing Reverse Servo Piston And Rod Assembly
    G01627035Courtesy of FORD MOTOR CO.
  43. Install the reverse servo piston and rod assembly.
  44. Install the special tool.
    • Tighten the bolt.
      Fig 48: Tightening Bolt
      G01627036Courtesy of FORD MOTOR CO.
  45. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
      Fig 49: Installing Special Tool
      G01627037Courtesy of FORD MOTOR CO.
  46. Loosen the bolt until the piston stops against the tool.
    Fig 50: Loosening Bolt
    G01627038Courtesy of FORD MOTOR CO.
  47. Verify that the amount of piston travel on the dial indicator is within specification.
    Fig 51: Verifying Piston Travel
    G01627039Courtesy of FORD MOTOR CO.
  48. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
      Fig 52: Installing Correct Servo Assembly
      G01627040Courtesy of FORD MOTOR CO.
  49. Remove the special tools.
    Fig 53: Removing Special Tools
    G01627041Courtesy of FORD MOTOR CO.
  50. Install the reverse servo piston cover and seal assembly.
    Fig 54: Installing Reverse Servo Piston Cover And Seal Assembly
    G01627042Courtesy of FORD MOTOR CO.
  51. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
      Fig 55: Installing Reverse Servo Retaining Ring
      G01627043Courtesy of FORD MOTOR CO.
  52. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
      Fig 56: Installing 2-3 Accumulator Assembly
      G01627044Courtesy of FORD MOTOR CO.
  53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 57: Applying Regulated Air Pressure To Test Ports
    G01627045Courtesy of FORD MOTOR CO.
    54. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 58: Installing Electrical Connector Into Case
    G01627046Courtesy of FORD MOTOR CO.
  54. Install the electrical connector into the case.
    55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 59: Aligning Main Control Valve Body Alignment Bolts
    G01627047Courtesy of FORD MOTOR CO.
  55. Align the main control valve body alignment bolts and position the main control valve body.
    56. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 60: Installing 11 Long Main Control Valve Body Bolts
    G01627048Courtesy of FORD MOTOR CO.
  56. Loosely install the 11 long main control valve body bolts.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 61: Installing 12 Short Main Control Valve Body Bolts
    G01627049Courtesy of FORD MOTOR CO.
  57. Loosely install the 12 short main control valve body bolts.
  58. Install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring.
    2. Install the bolt.
      Fig 62: Installing Bolt
      G01627050Courtesy of FORD MOTOR CO.
  59. Tighten the bolts in the sequence shown.
    Fig 63: Tightening Bolts
    G01627051Courtesy of FORD MOTOR CO.
  60. Inspect the lead frame for damage.
    • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
      Fig 64: Inspecting Lead Frame For Damage
      G01627052Courtesy of FORD MOTOR CO.
  61. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
      Fig 65: Connecting Molded Lead Frame To Solenoids
      G01627053Courtesy of FORD MOTOR CO.
  62. Install the fluid filter and seal assembly.
    Fig 66: Installing Fluid Filter And Seal Assembly
    G01627054Courtesy of FORD MOTOR CO.
  63. Position the pan magnet onto the fluid pan.
    Fig 67: Positioning Pan Magnet Onto Fluid Pan
    G01627055Courtesy of FORD MOTOR CO.
    64. NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.
  64. Install the fluid pan.
    1. Position the transmission fluid pan.
    2. Install the 14 transmission fluid pan bolts.
      Fig 68: Installing Fluid Pan
      G01627056Courtesy of FORD MOTOR CO.
  65. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
      Fig 69: Installing Digital TR Sensor Bolts
      G01627057Courtesy of FORD MOTOR CO.
    66. NOTE: The tool is designed to fit snugly.
    NOTE: Manual shift lever must be in the neutral position.
    Fig 70: Aligning Digital TR Sensor Slots
    G01627058Courtesy of FORD MOTOR CO.
  66. Using the special tool, align the digital TR sensor slots.
  67. Tighten the bolts.
    Fig 71: Tightening Bolts
    G01627059Courtesy of FORD MOTOR CO.
  68. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 72: Lubricating Converter Hub
    G01627060Courtesy of FORD MOTOR CO.
    69. WARNING: The torque converter can fall out if the transmission is tipped.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
    Fig 73: Installing Torque Converter
    G01627061Courtesy of FORD MOTOR CO.
  69. Using the special tools, install the torque converter.
  70. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 74: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G01627062Courtesy of FORD MOTOR CO.
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