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

WARNING: This page is about a different variant/trim than selected.
    CAUTION: If, during repair work, abrasive particles are found in the transmission fluid (particles from the clutch or metal chips or foreign material), the transaxle must be disassembled completely and thoroughly cleaned. Also, clean the fluid tubes, 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.
    3. Fig 1: Locating Output Shaft Speed (OSS) Sensor
    GF0039771Courtesy of FORD MOTOR CO.
  3. Remove the turbine shaft speed (TSS) sensor.
    4. Fig 2: Locating Turbine Shaft Speed (TSS) Sensor
    GF0039772Courtesy of FORD MOTOR CO.
    CAUTION: Do not use air tools.
  4. While holding the manual control lever, remove the manual control lever bolt.
    5. Fig 3: Locating Manual Control Lever
    GF0039773Courtesy of FORD MOTOR CO.
  5. Remove the transmission range (TR) sensor.
    6. Fig 4: Locating Transmission Range (TR) Sensor
    GF0039774Courtesy of FORD MOTOR CO.
  6. Remove the special tool.
    7. Fig 5: Identifying Special Tool
    GF0039764Courtesy of FORD MOTOR CO.
  7. Remove the rubber vent cap.
    8. Fig 6: Locating Rubber Vent Cap
    GF0039775Courtesy of FORD MOTOR CO.
    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.
  8. Using the special tool, remove the torque converter.
    9. Fig 7: Identifying Special Tool
    GF0039776Courtesy of FORD MOTOR CO.
  9. Remove the differential opening cover.
    10. Fig 8: Locating Differential Opening Cover
    GF0039763Courtesy of FORD MOTOR CO.
  10. Remove the LH and RH axle seals.
  11. Using the special tool, mount the transaxle to a bench.
    12. Fig 9: Identifying Special Tool
    GF0039777Courtesy of FORD MOTOR CO.
  12. Remove the bolts.
    13. Fig 10: Locating Torque Converter Bolts
    GF0039778Courtesy of FORD MOTOR CO.
  13. Using the two 10-mm (50 mm [2 in] long) bolts, remove the fluid pump.
    14. Fig 11: Locating Fluid Pump Bolts
    GF0039779Courtesy of FORD MOTOR CO.
  14. Remove the fluid pump seals.
    15. Fig 12: Locating Fluid Pump Seals
    GF0039780Courtesy of FORD MOTOR CO.
  15. Remove the forward clutch thrust washer.
    16. Fig 13: Locating Clutch Thrust Washer
    GF0039781Courtesy of FORD MOTOR CO.
  16. Remove the forward clutch assembly.
    17. Fig 14: Locating Clutch Assembly
    GF0039782Courtesy of FORD MOTOR CO.
    NOTE: Small levers will aid in the removal of the forward clutch hub.
  17. Remove the forward clutch hub.
    18. Fig 15: Locating Clutch Hub
    GF0039783Courtesy of FORD MOTOR CO.
  18. Rotate the transaxle 180 degrees.
  19. Remove the end cover.
    20. Fig 16: Locating Transaxle Cover Bolts
    GF0039784Courtesy of FORD MOTOR CO.
  20. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
  21. Remove the direct clutch hub bearing shim.
    22. Fig 17: Locating Clutch Hub Bearing Shim
    GF0039785Courtesy of FORD MOTOR CO.
  22. Remove the end cover seals.
    23. Fig 18: Locating Cover Seals
    GF0039786Courtesy of FORD MOTOR CO.
  23. Remove the end cover-to-case seals.
    24. Fig 19: Locating Cover-To-Case Seals
    GF0039787Courtesy of FORD MOTOR CO.
  24. Remove the direct clutch cylinder thrust bearing.
    25. Fig 20: Locating Clutch Cylinder Thrust Bearing
    GF0039788Courtesy of FORD MOTOR CO.
  25. Remove the intermediate/overdrive band anchor bolt.
    26. Fig 21: Locating Intermediate/Overdrive Band Anchor Bolt
    GF0039789Courtesy of FORD MOTOR CO.
  26. Remove the intermediate/overdrive band.
    27. Fig 22: Locating Intermediate/Overdrive Band
    GF0039790Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/overdrive drum assembly.
    28. Fig 23: Locating Intermediate/Overdrive Drum Assembly
    GF0039791Courtesy of FORD MOTOR CO.
  28. Remove the planet gear assembly.
    29. Fig 24: Locating Planet Gear Assembly
    GF0039792Courtesy of FORD MOTOR CO.
  29. Remove the low/reverse clutch plate retaining ring.
    30. Fig 25: Locating Low/Reverse Clutch Plate Retaining Ring
    GF0039793Courtesy of FORD MOTOR CO.
  30. Remove the low/reverse clutch plates, pressure plate and wave spring.
    31. Fig 26: Locating Low/Reverse Clutch Plates, Pressure Plate And Wave Spring
    GF0039794Courtesy of FORD MOTOR CO.
  31. Remove the low one-way clutch retaining ring.
    32. Fig 27: Locating Low One-Way Clutch Retaining Ring
    GF0039795Courtesy of FORD MOTOR CO.
  32. Remove the low one-way clutch inner race.
    33. Fig 28: Locating Low One-Way Clutch Inner Race
    GF0039796Courtesy of FORD MOTOR CO.
  33. Remove the low/reverse clutch return spring.
    34. Fig 29: Locating Low/Reverse Clutch Return Spring
    GF0039797Courtesy of FORD MOTOR CO.
  34. Remove the low/reverse clutch piston.
    35. Fig 30: Locating Low/Reverse Clutch Piston
    GF0039798Courtesy of FORD MOTOR CO.
  35. Using a suitable tool, remove the transmission fluid pan.
    • Remove the bolts.
    • Using a suitable tool, remove the transmission fluid pan.
    36. Fig 31: Locating Transmission Fluid Pan Bolts
    GF0039715Courtesy of FORD MOTOR CO.
  36. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
  37. Disconnect the transmission fluid temperature (TFT) sensor.
    38. Fig 32: Locating Transmission Fluid Temperature (TFT) Sensor
    GF0029777Courtesy of FORD MOTOR CO.
  38. Remove the transmission fluid filter.
    39. Fig 33: Locating Fluid Filter
    GF0029778Courtesy of FORD MOTOR CO.
    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.
  39. 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 PCA, Color B (Black).
    5. Solenoid SSA, Color N (Neutral).
    6. Solenoid SSB, Color B (Black).
    40. Fig 34: Locating Ground Wire Bolt
    GF0029779Courtesy of FORD MOTOR CO.
    NOTE: Note the locations of the longer bolts.
  40. Remove the 13 main control valve body bolts.
    41. Fig 35: Locating Main Control Valve Body Bolts
    GF0039799Courtesy of FORD MOTOR CO.
    NOTE: Squeeze the tabs on the side of the electrical connector.
  41. Remove the transaxle internal harness electrical connector.
    42. Fig 36: Locating Transaxle Internal Harness Electrical Connector
    GF0039800Courtesy of FORD MOTOR CO.
    NOTE: Each accumulator piston has 2 springs inside of them, totaling 4 springs. All 4 springs are different sizes. The accumulator piston bore and accumulator pistons are a match as to depth. Some of the accumulator piston may have steps. Take note of the size, depth and location of the accumulator pistons and the spring sizes to aid assembly.
  42. Remove the accumulator pistons and springs.
    43. Fig 37: Locating Accumulator Pistons And Springs
    GF0039801Courtesy of FORD MOTOR CO.
  43. Remove the manual lever shaft roll pin.
    44. Fig 38: Locating Manual Lever Shaft Roll Pin
    GF0039802Courtesy of FORD MOTOR CO.
  44. Remove the manual lever shaft.
    45. Fig 39: Locating Manual Lever Shaft
    GF0039803Courtesy of FORD MOTOR CO.
  45. Remove the O-ring seals from the manual lever shaft.
    46. Fig 40: Locating O-Ring Seals
    GF0039804Courtesy of FORD MOTOR CO.
  46. Remove the control lever assembly.
    47. Fig 41: Locating Control Lever Assembly Bolts
    GF0039805Courtesy of FORD MOTOR CO.
    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.
  47. Remove the 3 intermediate/overdrive piston servo cover bolts and the servo cover.
    48. Fig 42: Locating Intermediate/Overdrive Piston Servo Cover Bolts
    GF0039806Courtesy of FORD MOTOR CO.
  48. Remove the O-ring seal.
    49. Fig 43: Locating O-Ring Seal
    GF0039807Courtesy of FORD MOTOR CO.
  49. Remove the intermediate/overdrive servo piston.
    50. Fig 44: Locating Intermediate/Overdrive Servo Piston
    GF0039808Courtesy of FORD MOTOR CO.
  50. Remove the intermediate/overdrive servo piston return spring.
    51. Fig 45: Locating Intermediate/Overdrive Servo Piston Return Spring
    GF0039809Courtesy of FORD MOTOR CO.
  51. Rotate the transaxle 180 degrees.
  52. Remove the bolts and separate the converter housing from the transaxle case.
    53. Fig 46: Locating Converter Housing Bolts
    GF0039810Courtesy of FORD MOTOR CO.
  53. Remove the differential assembly.
    54. Fig 47: Locating Differential Assembly Gear
    GF0039811Courtesy of FORD MOTOR CO.
  54. Remove the parking pawl assembly cover.
    • Remove the bolts and the parking pawl assembly cover.
    55. Fig 48: Locating Parking Pawl Assembly Cover Bolts
    GF0039812Courtesy of FORD MOTOR CO.
  55. Remove the parking pawl abutment.
    1. Unclip the spring.
    2. Remove the pin.
    3. Remove the lever.
    4. Remove the parking pawl abutment.
    56. Fig 49: Locating Parking Pawl Abutment
    GF0039813Courtesy of FORD MOTOR CO.
  56. Remove the spring.
    57. Fig 50: Locating Spring
    GF0039814Courtesy of FORD MOTOR CO.
  57. Remove the transfer shaft gears.
    58. Fig 51: Locating Transfer Shaft Gears
    GF0039815Courtesy of FORD MOTOR CO.
  58. Using the special tool, lock the final drive input gear.
    59. Fig 52: Identifying Special Tool
    GF0039816Courtesy of FORD MOTOR CO.
  59. Rotate the transaxle 180 degrees.
    60. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
  60. Using the special tools, remove the final drive input gear bearing retainer nut.
    61. Fig 53: Identifying Special Tools
    GF0039817Courtesy of FORD MOTOR CO.
  61. Remove the special tools.
  62. Rotate the transaxle 180 degrees.
  63. Remove the special tool.
    64. Fig 54: Identifying Special Tools
    GF0039816Courtesy of FORD MOTOR CO.
    CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.
  64. Rotate the transaxle 180 degrees.
  65. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
    66. Fig 55: Locating Final Drive Input Gear
    GF0039818Courtesy of FORD MOTOR CO.
  66. Remove and discard the collapsible spacer.
    67. Fig 56: Locating Collapsible Spacer
    GF0039819Courtesy of FORD MOTOR CO.
    WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
  67. Using a suitable chisel, remove the final drive input gear bearing.
    68. Fig 57: Locating Final Drive Input Gear Bearing
    GF0039820Courtesy of FORD MOTOR CO.
  68. Using the special tools, remove the final drive input gear bearing inner race.
    69. Fig 58: Identifying Special Tools
    GF0039821Courtesy of FORD MOTOR CO.
  69. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.
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