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Section 291 (Automatic Transmission): Disassembly: Transaxle: Disassembly

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: If, during repair work, abrasive particles are found in the transaxle fluid (particles from the clutch or metal chips or foreign material), the transaxle must be disassembled completely and thoroughly cleaned. Also, clean the fluid pipes, fluid cooler and torque converter carefully. In the case of extreme soiling of the fluid pipes, install a new fluid cooler and torque converter.
    NOTE: In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid.
  1. Inspect the transaxle during disassembly.
  2. Remove the output shaft speed (OSS) sensor.
    1. Remove the bolt.
    2. Remove the OSS.
    Fig 1: Removing Output Shaft Speed (OSS) Sensor
    G01612706Courtesy of FORD MOTOR CO.
  3. Remove the turbine shaft speed (TSS) sensor.
    Fig 2: Removing Turbine Shaft Speed (TSS) Sensor
    G01612707Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not use air tools.
    Fig 3: Removing Manual Control Lever
    G01612708Courtesy of FORD MOTOR CO.
  4. While holding the lever, remove the manual control lever.
  5. Remove the transmission range (TR) sensor.
    Fig 4: Removing Transmission Range (TR) Sensor
    G01612709Courtesy of FORD MOTOR CO.
  6. Remove the special tool.
    Fig 5: Removing Special Tool
    G01612710Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not tilt the torque converter when removing it, to prevent damaging the torque converter hub.
    NOTE: The torque converter is filled with fluid. Drain into a suitable container.
    Fig 6: Removing Torque Converter
    G01612711Courtesy of FORD MOTOR CO.
  7. Using the special tool, remove the torque converter.
  8. Using the special tool, mount the transaxle to a bench.
    Fig 7: Mounting Transaxle To Bench
    G01612712Courtesy of FORD MOTOR CO.
  9. Remove the bolts.
    Fig 8: Removing Bolts
    G01612713Courtesy of FORD MOTOR CO.
  10. Using the two 10 mm bolts, remove the fluid pump.
    Fig 9: Removing Fluid Pump
    G01612714Courtesy of FORD MOTOR CO.
  11. Remove the fluid pump seals.
    Fig 10: Removing Fluid Pump Seals
    G01612715Courtesy of FORD MOTOR CO.
  12. Remove the forward clutch thrust washer.
    Fig 11: Removing Forward Clutch Thrust Washer
    G01612716Courtesy of FORD MOTOR CO.
  13. Remove the forward clutch assembly.
    Fig 12: Removing Forward Clutch Assembly
    G01612717Courtesy of FORD MOTOR CO.
    14. NOTE: Small levers will aid in the removal of the forward clutch hub.
    Fig 13: Removing Forward Clutch Hub
    G01612718Courtesy of FORD MOTOR CO.
  14. Remove the forward clutch hub.
  15. Rotate the transaxle 180 degrees.
  16. Remove the end cover.
    Fig 14: Removing End Cover
    G01612719Courtesy of FORD MOTOR CO.
  17. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
  18. Remove the direct clutch hub bearing shim.
    Fig 15: Removing Direct Clutch Hub Bearing Shim
    G01612720Courtesy of FORD MOTOR CO.
  19. Remove the end cover seals.
    Fig 16: Removing End Cover Seals
    G01612721Courtesy of FORD MOTOR CO.
  20. Remove the end cover to case seals.
    Fig 17: Removing End Cover To Case Seals Bolts
    G01612722Courtesy of FORD MOTOR CO.
  21. Remove the direct clutch cylinder thrust bearing.
    Fig 18: Removing Direct Clutch Cylinder Thrust Bearing
    G01612723Courtesy of FORD MOTOR CO.
  22. Remove the intermediate/overdrive band anchor bolt.
    Fig 19: Removing Intermediate/Overdrive Band Anchor Bolt
    G01612724Courtesy of FORD MOTOR CO.
  23. Remove the intermediate/overdrive band.
    Fig 20: Removing Intermediate/Overdrive Band
    G01612725Courtesy of FORD MOTOR CO.
  24. Remove the intermediate/overdrive drum assembly.
    Fig 21: Removing Intermediate/Overdrive Drum Assembly
    G01612726Courtesy of FORD MOTOR CO.
  25. Remove the planet gear assembly.
    Fig 22: Removing Planet Gear Assembly
    G01612727Courtesy of FORD MOTOR CO.
  26. Remove the low/reverse clutch plate retaining ring.
    Fig 23: Removing Low/Reverse Clutch Plate Retaining Ring
    G01612728Courtesy of FORD MOTOR CO.
  27. Remove the low/reverse clutch plates, pressure plate and bevel ring.
    Fig 24: Removing Low/Reverse Clutch Plates, Pressure Plate And Bevel Ring
    G01612729Courtesy of FORD MOTOR CO.
  28. Remove the low one-way clutch retaining ring.
    Fig 25: Removing Low One-Way Clutch Retaining Ring
    G01612730Courtesy of FORD MOTOR CO.
  29. Remove the low one-way clutch inner race.
    Fig 26: Removing Low One-Way Clutch Inner Race
    G01612731Courtesy of FORD MOTOR CO.
  30. Remove the low/reverse clutch return spring.
    Fig 27: Removing Low/Reverse Clutch Return Spring
    G01612732Courtesy of FORD MOTOR CO.
  31. Remove the low/reverse clutch piston.
    Fig 28: Removing Low/Reverse Clutch Piston
    G01612733Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the transaxle fluid pan.
    Fig 29: Removing Transaxle Fluid Pan
    G01612734Courtesy of FORD MOTOR CO.
  33. Clean the silicone from the transaxle fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
  34. Disconnect the transmission fluid temperature (TFT) sensor.
    Fig 30: Disconnecting Transmission Fluid Temperature (TFT) Sensor
    G01612735Courtesy of FORD MOTOR CO.
  35. Remove the fluid filter.
    Fig 31: Removing Fluid Filter
    G01612736Courtesy of FORD MOTOR CO.
    36. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.
    Fig 32: Disconnecting Electrical Connectors
    G01612737Courtesy of FORD MOTOR CO.
  36. Remove the ground wire bolt, disconnect the electrical connectors and remove the wire harness.
    1. Solenoid SSC; Color N (Neutral).
    2. Solenoid SSE; Color G (Green).
    3. Solenoid SSD; Color L (Blue).
    4. Solenoid EPC; Color B (Black).
    5. Solenoid SSA; Color N (Neutral).
    6. Solenoid SSB; Color B (Black).
    37. NOTE: Note the locations of the longer bolts.
    Fig 33: Removing Main Control Valve Body Bolts
    G01612738Courtesy of FORD MOTOR CO.
  37. Remove the 13 main control valve body bolts.
    38. NOTE: Squeeze the tabs on the side of the electrical connector.
    Fig 34: Removing Transaxle Internal Harness Electrical Connector
    G01612739Courtesy of FORD MOTOR CO.
  38. Remove the transaxle internal harness electrical connector.
    39. NOTE: Each accumulator has two springs. All four springs are different sizes.
    NOTE: Note the size and location of the accumulator springs to aid assembly.
    Fig 35: Removing Accumulator Pistons And Springs
    G01612740Courtesy of FORD MOTOR CO.
  39. Remove the accumulator pistons and springs.
  40. Remove the manual lever shaft roll pin.
    Fig 36: Removing Manual Lever Shaft Roll Pin
    G01612741Courtesy of FORD MOTOR CO.
  41. Remove the manual lever shaft.
    Fig 37: Removing Manual Lever Shaft
    G01612742Courtesy of FORD MOTOR CO.
  42. Remove the O-ring seals from the manual lever shaft.
    Fig 38: Removing O-Ring Seals From Manual Lever Shaft
    G01612743Courtesy of FORD MOTOR CO.
  43. Remove the control lever assembly.
    Fig 39: Removing Control Lever Assembly
    G01612744Courtesy of FORD MOTOR CO.
    44. CAUTION: The intermediate/overdrive band servo cover plate is spring loaded. The bolts should be removed evenly until plate is unloaded, then remove the bolts.
    Fig 40: Removing Intermediate/Overdrive Piston Servo Cover
    G01612745Courtesy of FORD MOTOR CO.
  44. Remove the intermediate/overdrive piston servo cover.
    1. Remove the bolts.
    2. Remove the intermediate/overdrive piston servo cover.
  45. Remove the O-ring seal.
    Fig 41: Removing O-Ring Seal
    G01612746Courtesy of FORD MOTOR CO.
  46. Remove the intermediate/overdrive servo piston.
    Fig 42: Removing Intermediate/Overdrive Servo Piston
    G01612747Courtesy of FORD MOTOR CO.
  47. Remove the intermediate/overdrive servo piston return spring.
    Fig 43: Removing Intermediate/Overdrive Servo Piston Return Spring
    G01612748Courtesy of FORD MOTOR CO.
  48. Rotate the transaxle 180 degrees.
  49. Remove the bolts and separate the converter housing from the transaxle case.
    Fig 44: Separating Converter Housing From The Transaxle Case
    G01612749Courtesy of FORD MOTOR CO.
  50. Remove the differential assembly.
    Fig 45: Removing Differential Assembly
    G01612750Courtesy of FORD MOTOR CO.
  51. Remove the parking pawl assembly cover.
    1. Remove the bolts.
    2. Remove the parking pawl assembly cover.
    Fig 46: Removing Parking Pawl Assembly Cover
    G01612751Courtesy of FORD MOTOR CO.
  52. Remove the parking pawl abutment.
    1. Unclip the spring.
    2. Remove the pin.
    3. Remove the lever.
    4. Remove the parking pawl abutment.
    Fig 47: Removing Parking Pawl Abutment
    G01612752Courtesy of FORD MOTOR CO.
  53. Remove the spring.
    Fig 48: Removing Spring
    G01612753Courtesy of FORD MOTOR CO.
  54. Remove the transfer shaft gears.
    Fig 49: Removing Transfer Shaft Gears
    G01612754Courtesy of FORD MOTOR CO.
  55. Using the special tool, lock the final drive input gear.
    Fig 50: Locking Final Drive Input Gear
    G01612755Courtesy of FORD MOTOR CO.
  56. Rotate the transaxle 180 degrees.
    57. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
    Fig 51: Removing Final Drive Input Gear Bearing Retainer Nut
    G01612756Courtesy of FORD MOTOR CO.
  57. Using the special tools, remove the final drive input gear bearing retainer nut.
  58. Remove the special tools.
  59. Rotate the transaxle 180 degrees.
  60. Remove the special tool.
    Fig 52: Removing Special Tool
    G01612757Courtesy of FORD MOTOR CO.
    61. CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.
  61. Rotate the transaxle 180 degrees.
  62. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
    Fig 53: Removing Final Drive Input Gear Bearing
    G01612758Courtesy of FORD MOTOR CO.
  63. Remove and discard the collapsible spacer.
    Fig 54: Removing Collapsible Spacer
    G01612759Courtesy of FORD MOTOR CO.
    64. WARNING: Wear eye protection when working with the chisel as the cutting operation may produce splinters. Failure to follow this instruction may result in personal injury.
    Fig 55: Removing Final Drive Input Gear Bearing
    G01612760Courtesy of FORD MOTOR CO.
  64. Using a suitable chisel, remove the final drive input gear bearing.
  65. Using the special tools, remove the final drive input gear bearing inner race.
    Fig 56: Removing Final Drive Input Gear Bearing Inner Race
    G01612762Courtesy of FORD MOTOR CO.
  66. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.
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