Section 511 (Automatic Transmission): Assembly: Transmission

Courtesy of FORD MOTOR CO.	Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
Courtesy of FORD MOTOR CO.	Installer, Shifter Fluid Seal 307-559
Courtesy of FORD MOTOR CO.	Handle, Torque Converter 307-091 (T81P-7902-C)
Courtesy of FORD MOTOR CO.	Installer, Extension Seal 307-560
Courtesy of FORD MOTOR CO.	Installer, Front Pump Fluid Seal - 4x2 Output 307-556
Courtesy of FORD MOTOR CO.	Retaining Ring Pliers 307-343 (T95P-77001-AHR)
Courtesy of FORD MOTOR CO.	Aligner, Valve Body 307-334 (T95L-70010-C)
Courtesy of FORD MOTOR CO.	Installer, Needle Bearing 307-558
Courtesy of FORD MOTOR CO.	Remover, Transmission Fluid Pump 307-553
Courtesy of FORD MOTOR CO.	Handle, Driver 205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	End Play Gauge, Transmission 307-534
Courtesy of FORD MOTOR CO.	Installer, Ball Bearing 307-557
Courtesy of FORD MOTOR CO.	Installer, Needle Bearing 307-558

Disassembled Views 

Fig 1: Exploded View Of Transmission Assembly Components (1 Of 3)

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Fig 2: Exploded View Of Transmission Assembly Components (2 Of 3)

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Fig 3: Exploded View Of Transmission Assembly Components (3 Of 3)

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Fig 4: Part Description Table (1 Of 3)

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Fig 5: Part Description Table (2 Of 3)

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Fig 6: Part Description Table (3 Of 3)

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4x4 vehicles 

1. Using the special tool, install the rear bearing.
   Fig 7: Locating Special Tool To Install Rear Bearing

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2. Install the snap ring.
   Fig 8: Locating Snap Ring

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3. Using the special tool, install the rear bearing spacer.
   Fig 9: Installing Rear Bearing Spacer

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4. Install the rear bearing spacer snap ring.
   Fig 10: Locating Rear Bearing Spacer Snap Ring

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4x2 vehicles 

5. Using the special tool, install the rear bearing.
   Fig 11: Installing Rear Bearing

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6. Install the snap ring.
   Fig 12: Locating Snap Ring

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7. Using the special tool, install the second rear bearing.
   Fig 13: Locating Second Rear Bearing

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8. Install the rear bearing spacer snap ring.
   Fig 14: Locating Rear Bearing Spacer Snap Ring

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All vehicles 

9. Place the transmission in the vertical position.
10. Install the shim on the end of the output shaft.
    Fig 15: Locating Shim On End Of Output Shaft

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11. Install the planet carrier hub and output shaft assembly.
    Fig 16: Locating Planet Carrier Hub & Output Shaft Assembly

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12. Install the silver shim on the planet carrier hub and output shaft assembly.
    Fig 17: Locating Silver Shim On Planet Carrier Hub

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13. Position the park pawl pin into the case.
    Fig 18: Locating Park Pawl Pin Into Case Position

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14. Position the park pawl into the case and push the park pawl pin in to hold the park pawl and spring in position.
    Fig 19: Locating Park Pawl & Spring Position

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15. Install the park pawl pin bolt.
    • Tighten to 35 N.m (26 lb-ft).
      Fig 20: Locating Park Pawl Pin Bolt

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All vehicles 

16. Install the roller bearing in the bottom of the carrier.
    Fig 21: Locating Roller Bearing In Bottom Of Carrier

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17. Install the roller bearing race in the bottom of the carrier.
    Fig 22: Locating Roller Bearing Race

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18. Snap the top and the bottom roller bearings onto the sun gear.
    Fig 23: Locating Roller Bearings Onto Sun Gear

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NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque converter housing.
Fig 24: Locating Sun Gear Into Planet Assembly
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19. Install the sun gear into the planet assembly.
20. Install the low/reverse sun gear.
    Fig 25: Locating Low/Reverse Sun Gear

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21. Install the low/reverse bearing race.
    Fig 26: Locating Low/Reverse Bearing Race

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22. Install the planet carrier.
    Fig 27: Locating Planet Carrier

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23. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates, and ending with the wave spring plate on the top.
    Fig 28: Locating Low/Reverse Clutch Plates

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24. If not done previously, install the roller bearing onto the center support.
    Fig 29: Locating Roller Bearing Onto Center Support

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NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.
Fig 30: Locating Center Support Into Case
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25. Install the center support into the case.
26. Using the special tool, install the center support snap ring. Tap the snap ring into the case to make sure that it is seated into the case.
    Fig 31: Installing Center Support Snap Ring

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NOTE: Rotate case 180 degrees.
27. Using the special tool, lift up on the output shaft and record the reading. The reading should be within the specification.
    • End play specification is 0.15-0.35 mm (0.006-0.013 inches).
    • If the end play is not within specification, install a new transmission.
      Fig 32: Measuring End Play

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28. Install the roller bearing if not previously installed on the direct clutch drum.
    Fig 33: Locating Roller Bearing

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29. Install the direct clutch drum.
    Fig 34: Locating Direct Clutch Drum

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30. Install the roller bearing on the direct clutch assembly.
    Fig 35: Locating Roller Bearing

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31. Install the forward and overdrive clutch assembly.
    Fig 36: Locating Overdrive Clutch Assembly

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32. Install the pump washer.
    Fig 37: Locating Pump Washer

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33. Install the special tool into the case.
    Fig 38: Installing Special Tool Into Case

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34. Using the special tools, install the front pump.
    Fig 39: Installing Front Pump

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NOTE: Make sure that the fluid filter seal has been removed, if it has not been removed, use a suitable pick to remove the seal.
Fig 40: Locating Seal
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35. Make sure that the pump is correctly aligned with the case.
36. Loosely install the new front pump bolts with new washers.
    Fig 41: Locating Front Pump Bolts With Washers

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37. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern.
    • Tighten to 10 N.m (89 lb-in).
      Fig 42: Locating Front Pump Bolt

      Courtesy of FORD MOTOR CO.
38. Install the special tool onto the input shaft to measure end play.
    • Tighten the wing nut.
      Fig 43: Locating Wing Nut

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39. Install the remaining special tool.
    • Push down on the special tool and zero out the dial indicator.
    • Lift up on the special tool and record the measurement 0.2-0.4 mm (0.008-0.015 inches). If the measurement is not within specification install a new transmission.
      Fig 44: Installing Special Tool

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40. Install the park rod actuating plate.
    • Tighten to 10 N.m (89 lb-in).
      Fig 45: Locating Park Rod Actuating Plate

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41. Position a new manual control lever seal in place.
    Fig 46: Locating Manual Control Lever Seal

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42. Using the special tool, install a new manual control lever shaft seal.
    Fig 47: Installing Manual Control Lever Shaft Seal

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43. Position the manual lever and park rod in place.
    • Push down on the park pawl and slide the park rod in place.
      Fig 48: Locating Park Pawl & Slide Park Rod

      Courtesy of FORD MOTOR CO.
44. Install the manual lever in the case.
    1. Slide the manual lever in the case.
    2. Position the spacer in place while sliding the manual lever into the spacer.
    3. Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
    4. Install the roll pin.
       Fig 49: Identifying Manual Valve Inner Lever & Roll Pin

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45. Install the 4 rubber feed tubes for the center support.
    Fig 50: Locating Rubber Feed Tubes

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46. Install the rubber adapter.
    Fig 51: Locating Rubber Adapter

    Courtesy of FORD MOTOR CO.
NOTE: The mechatronic assembly will not lay flush on the case, this is normal, the retaining bolts will pull the mechatronic assembly down.
Fig 52: Locating Mechatronic Bolts
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47. Loosely install the 10 mechatronic bolts.
48. Tighten the bolts in the sequence shown in Fig 53.
    • Tighten to 8 N.m (71 lb-in).
      Fig 53: Identifying Tightening Sequence Of Bolts

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49. Install new O-rings on the outer shell of the bulkhead electrical connector.
    Fig 54: Locating O-Rings On Outer Shell

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CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Fig 55: Locating Outer Shell Of Bulkhead Electrical Connector (1 Of 2)
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50. With the release tab up, push the outer shell of the bulkhead electrical connector into the transmission.
51. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place.
    Fig 56: Locating Outer Shell Of Bulkhead Electrical Connector And Tab

    Courtesy of FORD MOTOR CO.
52. Install a new fluid pan and tighten the bolts in a crisscross pattern.
    • Tighten to 8 N.m (71 lb-in).
      Fig 57: Locating Fluid Pan Bolts

      Courtesy of FORD MOTOR CO.
53. Install the torque converter.
    Fig 58: Locating Torque Converter

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4x4 vehicles 

54. Position a new output shaft seal in place.
    Fig 59: Locating Output Shaft Seal

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55. Using the special tool, install the output shaft seal.
    Fig 60: Installing Output Shaft Seal

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56. Install the extension housing and the 11 bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 61: Locating Extension Housing Bolts

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4x2 vehicles 

57. Position the output shaft seal in place.
    Fig 62: Locating Output Shaft Seal Position

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58. Using the special tool, install the output shaft seal.
    Fig 63: Installing Output Shaft Seal

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59. Install the rear transmission mount bracket.
    • Tighten to 65 N.m (48 lb-ft)
      Fig 64: Locating Transmission Mount Bracket Bolts

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60. Install the anti-click washer over the output shaft.
61. Install the output shaft flange.
    Fig 65: Locating Output Shaft Flange

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62. Install a new output shaft flange nut.

• After installing the new nut, it must be staked at the slots to prevent it from coming loose.
• Tighten to 120 N.m (89 lb-ft).
  Fig 66: Locating Output Shaft Flange Nut

  Courtesy of FORD MOTOR CO.