Section 1 (Automatic Transmission): Assembly: Transaxle: Assembly

WARNING: This page is about a different variant/trim than selected.

Using the special tool, install the final drive input gear bearing.
1. Install the final drive input gear bearing.
2. Install the special tool.
  
  Fig 1: Identifying Special Tool (205-005)
  Courtesy of FORD MOTOR CO.
Using an arbor press and the special tools, seat the final drive input gear bearing.

Fig 2: Identifying Special Tools (205-005, 205-090)
Courtesy of FORD MOTOR CO.
Install a new collapsible spacer.

Fig 3: Locating Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the special tool, position the final drive input gear.

Fig 4: Locating Final Drive Input Gear
Courtesy of FORD MOTOR CO.

CAUTION: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case.
Rotate the transaxle 180 degrees.
Using the special tools, install the final drive input gear bearing.

Fig 5: Identifying Special Tools (205-024, 307-256)
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Using the special tool, lock the final drive input gear.

Fig 6: Identifying Special Tool (307-413) Into Final Drive Input Gear
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
NOTE: A high tightening torque specification of 400 Nm (295 lb-ft) is necessary to crush the collapsible spacer for correct bearing preload.

NOTE: If the preload is too high, a new collapsible spacer must be installed.
Using the special tools, tighten the nut to achieve the preload specification.

Fig 7: Identifying Special Tools (307-414, 307-420)
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
NOTE: Make sure that the final drive rotates.
Unlock the special tool.

Fig 8: Unlocking Special Tool
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
CAUTION: Make sure the bearing preload is between 0.4-0.7 Nm (3.5-6.2 lb-in).

NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.
Using the special tools, measure the rotating torque.
- Rotational torque is 0.4-0.7 Nm (3.5-6.2 lb-in).
  
  Fig 9: Identifying Special Tools (307-414, 307-420)
  Courtesy of FORD MOTOR CO.
After achieving the correct torque, remove the special tools and stake the nut to prevent movement.

Fig 10: Locating Seal
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Position the transfer shaft gears in the transaxle case.

Fig 11: Locating Transfer Shaft Gears
Courtesy of FORD MOTOR CO.
Install the parking pawl return spring.

Fig 12: Locating Parking Pawl Return Spring
Courtesy of FORD MOTOR CO.
Connect the spring.
1. Install the parking pawl abutment.
2. Install the lever.
3. Install the pin.
4. Connect the spring.
  
  Fig 13: Identifying Parking Pawl Abutment
  Courtesy of FORD MOTOR CO.
Install the parking pawl assembly cover and bolts.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 14: Locating Parking Pawl Assembly Cover And Bolts
  Courtesy of FORD MOTOR CO.
Install the differential case assembly.

Fig 15: Locating Differential Case Assembly
Courtesy of FORD MOTOR CO.
Position the bearing cups.

Fig 16: Locating Bearing Cups
Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 17: Identifying Special Tools (307-417, 308-164)
Courtesy of FORD MOTOR CO.

CAUTION: Do not use the bolts from special service kit 308-164 they will not work. Use only the bolts from the special service kit 308-161.

NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.
Using the special tools, assemble the transaxle for end play measurement.
1. Position the converter housing.
2. Install the special tool bolts and seat the case cover flat.
  - Tighten to 5 Nm (44 lb-in).
    
    Fig 18: Identifying Special Tool (308-161)
    Courtesy of FORD MOTOR CO.
Remove the converter housing.
1. Remove bolts.
2. Remove the converter housing.
Fig 19: Identifying Converter Housing Bolts
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 20: Identifying Special Tools (307-417, 308-164)
Courtesy of FORD MOTOR CO.
Remove the bearing cups.

Fig 21: Locating Bearing Cups
Courtesy of FORD MOTOR CO.

NOTE: If the plunger is above the contact surface, the reading will be incorrect.
To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim. For additional information, refer to SPECIFICATIONS in this article.

Fig 22: Identifying Special Tool (307-417)
Courtesy of FORD MOTOR CO.

NOTE: If the plunger is above the contact surface, the reading will be incorrect.
To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim. For additional information, refer to SPECIFICATIONS in this article.

Fig 23: Identifying Special Tool (307-417)
Courtesy of FORD MOTOR CO.
Using the special tool, install the correct transfer shaft shim and bearing cup into the converter housing.

Fig 24: Identifying Special Tool (205-153, 307-418)
Courtesy of FORD MOTOR CO.
Using the special tool, install the correct differential shaft shim and differential case bearing cup into the converter housing.

Fig 25: Identifying Special Tool (205-118, 205-153)
Courtesy of FORD MOTOR CO.
Apply a 1 mm (0.04 in) thick bead of sealer to the case half.

Fig 26: Identifying Area Applying Sealer
Courtesy of FORD MOTOR CO.
Position the converter housing on the transaxle case and install the bolts.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 27: Locating Converter Housing Bolts
  Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive band servo piston return spring.

Fig 28: Locating Intermediate/Overdrive Band Servo Piston Return Spring
Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive servo piston.

Fig 29: Locating Intermediate/Overdrive Servo Piston
Courtesy of FORD MOTOR CO.
Install the O-ring seal.

Fig 30: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.

NOTE: The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.
Install the intermediate/overdrive band servo piston cover.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 31: Locating Intermediate/Overdrive Band Servo Piston Cover Bolts
  Courtesy of FORD MOTOR CO.
Install the shifter assembly and bolt.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 32: Locating Shifter Assembly And Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring with clean automatic transmission fluid prior to assembly.
Install the new O-rings on the manual lever shaft.

Fig 33: Identifying O-Rings On Manual Lever Shaft
Courtesy of FORD MOTOR CO.
Install the manual lever shaft.

Fig 34: Locating Manual Lever Shaft
Courtesy of FORD MOTOR CO.

NOTE: The roll pin does not need to sit flush with the shifter assembly.
Install a new manual lever shaft roll pin.

Fig 35: Locating Manual Lever Shaft Roll Pin
Courtesy of FORD MOTOR CO.
Loosely install the transmission range (TR) sensor.

Fig 36: Locating Transmission Range (TR) Sensor
Courtesy of FORD MOTOR CO.

NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.
Install the thinner and longer neutral drive accumulator springs.

Fig 37: Locating Longer Neutral Drive Accumulator Springs
Courtesy of FORD MOTOR CO.
Install the neutral drive accumulator piston.

Fig 38: Locating Neutral Drive Accumulator Piston
Courtesy of FORD MOTOR CO.
Install the 1-2 accumulator springs.

Fig 39: Locating Accumulator Springs
Courtesy of FORD MOTOR CO.
Install the 1-2 accumulator piston.

Fig 40: Locating Accumulator Piston
Courtesy of FORD MOTOR CO.
Inspect the seals. Lubricate the seals in clean automatic transmission fluid. Install the transaxle internal harness electrical connector.

Fig 41: Locating Transaxle Internal Harness Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Make sure that the manual valve is in the manual control valve shift lever.

NOTE: Do not fully tighten the bolts at this stage.
Install the main control valve body.

Fig 42: Locating Main Control Valve Body
Courtesy of FORD MOTOR CO.
Tighten the main control valve body retaining bolts.
- Tighten the bolts in the sequence shown.
  - Tighten to 9 Nm (80 lb-in).
    
    Fig 43: Identifying Tightening Sequence For Main Control Valve Body Retaining Bolts
    Courtesy of FORD MOTOR CO.
NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.
Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt.
1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
3. Solenoid SSD; Color L (Blue).
4. Solenoid PCA; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
6. Solenoid SSB; Color B (Black).
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Locating Ground Wire Bolt
  Courtesy of FORD MOTOR CO.
Install the fluid filter.

Fig 45: Locating Fluid Filter
Courtesy of FORD MOTOR CO.
Connect the transmission fluid temperature (TFT) sensor.

Fig 46: Locating Transmission Fluid Temperature (TFT) Sensor
Courtesy of FORD MOTOR CO.

NOTE: Do not use more than the specified amount of sealer on the pan or internal transaxle damage could occur.
Apply a bead 1.5 mm (0.06 in) diameter of sealer to the transmission fluid pan.

Fig 47: Identifying Area Applying Sealer To Transmission Fluid Pan
Courtesy of FORD MOTOR CO.
Install the transmission fluid pan.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 48: Locating Transmission Fluid Pan Bolts
  Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Install the low/reverse clutch piston.

Fig 49: Locating Low/Reverse Clutch Piston
Courtesy of FORD MOTOR CO.

NOTE: Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.
Install the low/reverse clutch return spring.

Fig 50: Locating Low/Reverse Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the wave spring.

Fig 51: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Install the low one-way clutch inner race.

Fig 52: Locating Low One-Way Clutch Inner Race
Courtesy of FORD MOTOR CO.

NOTE: The opening of the retaining ring must be at the 10 o'clock position.
Install the low one-way clutch retaining ring.

Fig 53: Locating Low One-Way Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
Install the low/reverse plates and pressure plate.

Fig 54: Locating Low/Reverse Plates And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the low reverse clutch plate selective retaining ring.
- Check the clutch clearance.
  
  Fig 55: Locating Low Reverse Clutch Plate Selective Retaining Ring
  Courtesy of FORD MOTOR CO.
NOTE: Make sure that the snap ring is installed before installing the planet assembly.
Install the planet assembly.

Fig 56: Locating Planet Assembly
Courtesy of FORD MOTOR CO.

CAUTION: The edge of the planet assembly must fit flush with the transaxle case.
Inspect the planet assembly installation.

Fig 57: Identifying Planet Assembly Installation Position
Courtesy of FORD MOTOR CO.

CAUTION: The planet assembly must only rotate counterclockwise.
Check to make sure that the one way clutch is correctly installed.
- Rotate the planet assembly clockwise and counterclockwise.
  
  Fig 58: Rotating Planet Assembly Clockwise
  Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive drum assembly.

Fig 59: Locating Intermediate/Overdrive Drum Assembly
Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive band.

Fig 60: Locating Intermediate/Overdrive Band
Courtesy of FORD MOTOR CO.
Install the direct clutch cylinder thrust bearing with the rollers facing up.

Fig 61: Locating Direct Clutch Cylinder Thrust Bearing With Rollers Facing Up
Courtesy of FORD MOTOR CO.
Install new end cover-to-case seals.

Fig 62: Locating Cover-To-Case Seals
Courtesy of FORD MOTOR CO.
Install new end cover seals.

Fig 63: Locating Cover Seals
Courtesy of FORD MOTOR CO.
Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater.

Fig 64: Identifying Shim Thickness Specification
Courtesy of FORD MOTOR CO.

CAUTION: Failure to support the transaxle end cover in the center can result in inaccurate measurements.
Measure the gap between the transaxle end cover and the transaxle assembly.
1. Position the transaxle end cover on the transaxle assembly.
2. Support the transaxle end cover in the center.
3. Measure the gap between the transaxle end cover and the transaxle assembly.
  
  Fig 65: Identifying Transaxle Cover
  Courtesy of FORD MOTOR CO.
Remove the transaxle end cover.

Fig 66: Locating Transaxle Cover Bolts
Courtesy of FORD MOTOR CO.

NOTE: The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.001-0.020 in).

NOTE: The correct shim thickness is between minimum and maximum.
Choose and install the correct direct clutch hub bearing shim:
- Line 1: total amount of shim thickness used during transaxle end cover mock up.
- Line 2: measure the gap between transaxle end cover and transaxle case.
- Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.
- Line 4: subtract 0.25 mm (0.001 in) from Line 3 for maximum shim thickness.
- Subtract 0.50 mm (0.020 in) from Line 3 for the minimum thickness shim.
  
  Fig 67: Locating Bearing Shim:
  Courtesy of FORD MOTOR CO.
CAUTION: Applying too much sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.
Apply a 1 mm (0.04 in) bead of sealer to the transaxle end cover.

Fig 68: Applying Sealer To Transaxle Cover
Courtesy of FORD MOTOR CO.
Install the transaxle end cover.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 69: Locating Transaxle Cover Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, collapse the intermediate/overdrive band.
- Tighten to 5 Nm (44 lb-in), then back out three 1/2 turns.
  
  Fig 70: Identifying Special Tool (307-416)
  Courtesy of FORD MOTOR CO.
Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.

Fig 71: Seating Nut Against Transaxle Case
Courtesy of FORD MOTOR CO.
Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown.

Fig 72: Using Special Tool To Select Intermediate/Overdrive Band Bolt
Courtesy of FORD MOTOR CO.

NOTE: Apply thread sealer to the bolt.
Install the intermediate/overdrive band anchor bolt.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 73: Locating Intermediate/Overdrive Band Anchor Bolt
  Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Install the forward clutch hub.

Fig 74: Locating Forward Clutch Hub
Courtesy of FORD MOTOR CO.
Install the forward clutch assembly.

Fig 75: Locating Forward Clutch Assembly
Courtesy of FORD MOTOR CO.
Install the forward clutch thrust washer.

Fig 76: Locating Forward Clutch Thrust Washer
Courtesy of FORD MOTOR CO.
Install new fluid pump seals and lubricate with clean automatic transmission fluid.

Fig 77: Locating Fluid Pump Seals
Courtesy of FORD MOTOR CO.
Install the fluid pump (do not force the pump down at this time).

Fig 78: Locating Fluid Pump
Courtesy of FORD MOTOR CO.
Install the fluid pump bolts.
- Use the bolts to seat the fluid pump.
- Tighten the bolts in a crisscross pattern.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 79: Locating Fluid Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 80: Locating Output Shaft Speed (OSS) Sensor
  Courtesy of FORD MOTOR CO.
NOTE: Apply thread sealer to the bolt.
Install the turbine shaft speed (TSS) sensor.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 81: Locating Turbine Shaft Speed (TSS) Sensor
  Courtesy of FORD MOTOR CO.
Using the special tool, align the TR sensor and tighten the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 82: Aligning TR Sensor Using Special Tool (307-415)
  Courtesy of FORD MOTOR CO.
CAUTION: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt.
Install the manual control lever.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 83: Locating Manual Control Lever
  Courtesy of FORD MOTOR CO.
Install the vent cap past the second detent notch.

Fig 84: Locating Vent Cap
Courtesy of FORD MOTOR CO.
Using the special tool, install the LH halfshaft seal.

Fig 85: Identifying Special Tool (205-153, 205-259) Into LH Halfshaft Seal
Courtesy of FORD MOTOR CO.
Using the special tool, install the RH halfshaft seal.

Fig 86: Identifying Special Tool (205-153, 307-572) Into RH Halfshaft Seal
Courtesy of FORD MOTOR CO.
Install the differential opening cover.

Fig 87: Locating Differential Opening Cover
Courtesy of FORD MOTOR CO.
Install the torque converter.

Fig 88: Locating Torque Converter
Courtesy of FORD MOTOR CO.
Using the special tool, secure the torque converter.

Fig 89: Identifying Special Tool (307-346) Into Torque Converter
Courtesy of FORD MOTOR CO.
Remove the special tool from the transaxle.

Fig 90: Identifying Special Tool (307-410) On Transaxle
Courtesy of FORD MOTOR CO.