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Automatic Transmission - Cd4E: Assembly: Transaxle: Assembly

  1. Prepare the transaxle for assembly by proceeding with the following steps:
    • Clean all parts (except the friction plates, seals and intermediate/overdrive band) in solvent.
    • Dry all parts with moisture-free regulated compressed air (do not use shop towels).
    • Lubricate all internal parts (including friction plates) with clean automatic transmission fluid.
    • Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
      • Drive sprocket thrust washers.
      • Driven sprocket thrust bearing shims.
      • Differential case thrust bearing shims.
      • Low/reverse clutch pressure plates.
    • During assembly, use petroleum jelly to hold the parts in place (do not use grease).
    • Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
  2. Install intermediate and overdrive band assembly into the transaxle case.
    3. Fig 1: Band Assembly
    GF0025120Courtesy of FORD MOTOR CO.
    NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle. Lubricate the seal rings with clean automatic transmission fluid.
  3. Install the pump assembly into the case.
    4. Fig 2: Pump Assembly
    GF0025121Courtesy of FORD MOTOR CO.
    NOTE: Tighten the bolts in the indicated sequence.
  4. Install the pump assembly bolts.
    • Tighten to 11 Nm (8 lb-ft).
    5. Fig 3: Pump Assembly Bolt Torque Sequence
    GF0025122Courtesy of FORD MOTOR CO.
  5. Using the special tools, install the low/reverse clutch piston.
    • Lubricate seals and piston bore with clean automatic transmission fluid.
    6. Fig 4: Installing Low/Reverse Clutch Piston
    GF0025123Courtesy of FORD MOTOR CO.
  6. Install the low/reverse clutch return spring assembly.
    7. Fig 5: Low/Reverse Clutch Return Spring Assembly
    GF0025124Courtesy of FORD MOTOR CO.
  7. Install a new low/reverse clutch return spring retaining ring.
    8. Fig 6: Low/Reverse Clutch Return Spring Retaining Ring
    GF0024932Courtesy of FORD MOTOR CO.
    CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
  8. Install the low/reverse clutch wave spring.
    9. Fig 7: Identifying Thick, 10-Wave Low/Reverse Clutch Wave Spring With Specification
    GF0025125Courtesy of FORD MOTOR CO.
  9. Install the low/reverse clutch plates.
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the thin 8-wave low/reverse clutch cushion spring.
    4. Install the low/reverse clutch pressure plate.
    10. Fig 8: Identifying Low/Reverse Clutch Plates
    GF0025126Courtesy of FORD MOTOR CO.
  10. Install the special tool.
    11. Fig 9: Installing Special Tool
    GF0025127Courtesy of FORD MOTOR CO.
  11. Measure the clearance between the low/reverse clutch pressure plate and the transmission end play gauge.
    • Take a second measurement on the opposite side.
    • Average the 2 measurements to get the clearance.
    • If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
    • Pressure plate sizes:
      • 2.57-2.46 mm (0.101-0.097 in).
      • 2.36-2.26 mm (0.092-0.089 in).
      • 2.16-2.06 mm (0.085-0.081 in).
    12. Fig 10: Measuring Clearance Between Low/Reverse Clutch Pressure Plate And Transmission End Play Gauge With Specification
    GF0025128Courtesy of FORD MOTOR CO.
    NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.
  12. Remove the special tool, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring and the low/reverse clutch internal spline clutch plates (friction).
    1. Low/reverse clutch pressure plate.
    2. Low/reverse clutch external spline clutch plates (steel).
    3. Low/reverse clutch wave spring.
    4. Low/reverse clutch internal spline clutch plates (friction).
    13. Fig 11: Identifying Low/Reverse Clutch Pressure Plate, Low/Reverse Clutch External Spline Clutch Plates (Steel)
    GF0025129Courtesy of FORD MOTOR CO.
  13. Install the No. 1 pump support thrust bearing assembly.
    14. Fig 12: Locating No. 1 Pump Support Thrust Bearing Assembly
    GF0025130Courtesy of FORD MOTOR CO.
    NOTE: Remove the seal sizer from forward/coast/direct clutch cylinder.
  14. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
    15. Fig 13: Forward/Coast/Direct Clutch Cylinder Assembly & Reverse Clutch Drum Assembly
    GF0025131Courtesy of FORD MOTOR CO.
  15. Install the turbine shaft.
    16. Fig 14: Turbine Shaft
    GF0025132Courtesy of FORD MOTOR CO.
  16. Install the No. 4 turbine shaft thrust bearing.
    17. Fig 15: No. 4 Turbine Shaft Thrust Bearing
    GF0025133Courtesy of FORD MOTOR CO.
  17. Install the forward one-way clutch and low/intermediate sun gear assembly.
    18. Fig 16: Forward One-Way Clutch & Low/Intermediate Sun Gear Assembly
    GF0025134Courtesy of FORD MOTOR CO.
  18. Install the No. 5 low/intermediate sun gear thrust bearing.
    19. Fig 17: No. 5 Low/Intermediate Sun Gear Thrust Bearing
    GF0025135Courtesy of FORD MOTOR CO.
  19. Install the low/intermediate carrier assembly.
    20. Fig 18: Low/Intermediate Carrier Assembly
    GF0025136Courtesy of FORD MOTOR CO.
  20. Install the No. 6 low/intermediate carrier thrust bearing.
    21. Fig 19: No. 6 Low/Intermediate Carrier Thrust Bearing
    GF0025137Courtesy of FORD MOTOR CO.
  21. Install the low/intermediate ring gear assembly.
    22. Fig 20: Low/Intermediate Ring Gear Assembly
    GF0025138Courtesy of FORD MOTOR CO.
  22. Install the No. 7 reverse/overdrive sun gear thrust bearing.
    23. Fig 21: No. 7 Reverse/Overdrive Sun Gear Thrust Bearing
    GF0025139Courtesy of FORD MOTOR CO.
  23. Install the reverse/overdrive sun gear and shell assembly.
    24. Fig 22: Reverse/Overdrive Sun Gear & Shell Assembly
    GF0025140Courtesy of FORD MOTOR CO.
  24. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
    25. Fig 23: Reverse/Overdrive Carrier Assembly & No. 8 Thrust Bearing
    GF0025141Courtesy of FORD MOTOR CO.
  25. Install the thick, 10-wave low/reverse clutch wave spring.
    26. Fig 24: Identifying Thick, 10-Wave Low/Reverse Clutch Wave Spring
    GF0025125Courtesy of FORD MOTOR CO.
  26. Install the low/reverse clutch plates (model dependent).
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the low/reverse clutch pressure plate previously selected.
    27. Fig 25: Identifying Low/Reverse Clutch Plates
    GF0025142Courtesy of FORD MOTOR CO.
  27. Install the thin, 8-wave low/reverse clutch wave spring.
    28. Fig 26: Locating Thin, 8-Wave Low/Reverse Clutch Wave Spring
    GF0025143Courtesy of FORD MOTOR CO.
    NOTE: Do not use a thrust plate with the mechanical diode one-way clutch.
  28. Install the mechanical diode one-way clutch with the rubber isolators in the positions indicated.
    29. Fig 27: Locating Mechanical Diode One-Way Clutch With Rubber Isolators
    GF0025144Courtesy of FORD MOTOR CO.
    NOTE: Make sure to position the low one-way clutch retaining ring as shown.
  29. Install the low one-way clutch retaining ring.
    30. Fig 28: Low One-Way Clutch Retaining Ring
    GF0025145Courtesy of FORD MOTOR CO.
  30. Install the manual valve detent lever actuating rod assembly.
    • Install the parking cam actuator lever.
    31. Fig 29: Parking Lever Actuating Rod & Parking Cam Actuator Lever Assembly
    GF0024912Courtesy of FORD MOTOR CO.
  31. Install the manual valve detent lever.
    32. Fig 30: Parking Lever Actuation Rod At Manual Valve Detent Lever
    GF0024913Courtesy of FORD MOTOR CO.
  32. Install the special tools.
    • Tighten to 13 Nm (10 lb-ft).
    33. Fig 31: Installing Special Tools
    GF0025146Courtesy of FORD MOTOR CO.
  33. Install the special tool with short spacers.
    34. Fig 32: Installing Special Tool With Short Spacers
    GF0025147Courtesy of FORD MOTOR CO.
  34. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
    • Record this as dimension A.
    35. Fig 33: Measuring Distance From Top Of Special Tool To No. 12 Driven Sprocket Bearing Surface Area
    GF0025148Courtesy of FORD MOTOR CO.
  35. Using the special tools, measure the distance from the top of the special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
    • Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension B.
    • Remove the special tools.
    36. Fig 34: Measuring Distance From Top Of Special Tool To Bearing Surface On Reverse/Overdrive Carrier Assembly
    GF0025149Courtesy of FORD MOTOR CO.
  36. Subtract dimension B from dimension A to get dimension C.
  37. Use dimension C to select the correct No. 11 driven sprocket shim.
    • Select a shim from the driven sprocket shim chart.
      DRIVEN SPROCKET ALIGNMENT SHIM NO. 11

      Shim Size mm Inch
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim AB: 2.20-2.10 0.086-0.082
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim BB: 2.02-1.92 0.079-0.075
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim CB: 1.85-1.75 0.072-0.068
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim DB: 1.67-1.57 0.065-0.061
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim EB: 1.50-1.40 0.059-0.052
      Transaxle case to driven sprocket/final drive sun gear thrust bearing shim FB: 1.32-1.22 0.051-0.048
      Distance measured during gauging procedure and appropriate thrust bearing shim AB: 14.34-14.1 0.564-0.557
      Distance measured during gauging procedure and appropriate thrust bearing shim BB: 14.16-14.00 0.557-0.551
      Distance measured during gauging procedure and appropriate thrust bearing shim CB: 13.99-13.83 0.551-0.544
      Distance measured during gauging procedure and appropriate thrust bearing shim DB: 13.82-13.66 0.544-0.537
      Distance measured during gauging procedure and appropriate thrust bearing shim EB: 13.65-13.49 0.537-0.531
      Distance measured during gauging procedure and appropriate thrust bearing shim FB: 13.48-13.32 0.531-0.524
  38. Install and lubricate the following:
    1. Lubricate the needles and seals in the No. 18 driven sprocket bearing.
    2. Install the selected No. 11 driven sprocket shim.
    3. Install the No. 12 driven sprocket bearing.
    39. Fig 35: Identifying Needles & Seals In No. 18 Driven Sprocket Bearing
    GF0025150Courtesy of FORD MOTOR CO.
  39. Install the No. 9 reverse/overdrive ring gear thrust bearing.
    40. Fig 36: No. 9 Reverse/Overdrive Ring Gear Thrust Bearing
    GF0025151Courtesy of FORD MOTOR CO.
    NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
  40. Install the reverse/overdrive ring gear assembly.
    41. Fig 37: Reverse/Overdrive Ring Gear Assembly
    GF0025152Courtesy of FORD MOTOR CO.
  41. Install the special tools.
    • Tighten to 13 Nm (10 lb-ft).
    42. Fig 38: Installing Special Tools
    GF0025153Courtesy of FORD MOTOR CO.
  42. Install the special tool with short spacers.
    43. Fig 39: Installing Special Tool With Short Spacers
    GF0025147Courtesy of FORD MOTOR CO.
  43. Using the special tools, measure the distance from the top of the special tool to the face of the reverse/overdrive ring gear assembly surface area.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension A.
    • Remove the special tools.
    44. Fig 40: Measuring Distance From Top Of Special Tool To Face Of Reverse/Overdrive Ring Gear Assembly Surface Area
    GF0025154Courtesy of FORD MOTOR CO.
  44. Subtract 25.4 mm (1.00 in) thickness of the special tool and the thickness of the short spacers.
    • This is the dimension B.
  45. Subtract dimension A from dimension B.
    • This is dimension C.
  46. Select No. 10 thrust washer from the drive sprocket thrust washer chart.
    • Use dimension C to select the No. 10 drive sprocket thrust washer.
      DRIVE SPROCKET ALIGNMENT NO. 10 THRUST WASHER

      No.10 Thrust Washer mm Inch
      Drive sprocket-to-converter housing thrust washer AA: 1.51-1.41 0.059-0.052
      Drive sprocket-to-converter housing thrust washer BA: 1.77-1.67 0.069-0.065
      Drive sprocket-to-converter housing thrust washer CA: 2.03-1.93 0.079-0.075
      Drive sprocket-to-converter housing thrust washer DA: 2.29-2.19 0.090-0.086
      Distance measured during gauging procedure and appropriate thrust washer AA: 1.12-0.86 0.044-0.033
      Distance measured during gauging procedure and appropriate thrust washer BA: 0.85-0.60 0.033-0.023
      Distance measured during gauging procedure and appropriate thrust washer CA: 0.59-0.34 0.023-0.013
      Distance measured during gauging procedure and appropriate thrust washer DA: 0.33-0.08 0.012-0.003
  47. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
    48. Fig 41: No. 10 Drive Sprocket Thrust Washer
    GF0025155Courtesy of FORD MOTOR CO.
  48. Remove the reverse/overdrive ring gear assembly.
    49. Fig 42: Reverse/Overdrive Ring Gear Assembly
    GF0025152Courtesy of FORD MOTOR CO.
  49. Install the filter and seal assembly.
    50. Fig 43: Filter & Seal Assembly
    GF0025156Courtesy of FORD MOTOR CO.
    NOTE: Refer to the following illustration for correct tool usage.
  50. Install the special tool in the filter eyelet and transaxle hole.
    51. Fig 44: Special Tool
    GF0025157Courtesy of FORD MOTOR CO.
    Fig 45: Special Tool
    GF0025158Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
  51. Using the special tool, install the filter recirculating regulator exhaust seal.
    52. Fig 46: Installing Filter Recirculating Regulator Exhaust Seal
    GF0025159Courtesy of FORD MOTOR CO.
  52. Install the chain pan in the transaxle case.
    53. Fig 47: Chain Pan
    GF0025160Courtesy of FORD MOTOR CO.
  53. Assemble and install the drive chain assembly.
    1. Drive chain (copper colored link facing upward).
    2. Driven sprocket assembly.
    3. Reverse/overdrive ring gear assembly.
      • Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
    54. Fig 48: Identifying Drive Chain Assembly Components
    GF0025161Courtesy of FORD MOTOR CO.
  54. Install the chain pan cover by snapping it into place.
    55. Fig 49: Chain Pan Cover
    GF0025162Courtesy of FORD MOTOR CO.
  55. Install the No. 13 driven sprocket thrust bearing.
    56. Fig 50: No. 13 Driven Sprocket Thrust Bearing
    GF0025163Courtesy of FORD MOTOR CO.
    NOTE: The all wheel drive differential is shown. The front wheel drive differential may or may not have splines.
  56. Install the final drive carrier and differential assembly.
    57. Fig 51: Final Drive Carrier & Differential Assembly
    GF0025164Courtesy of FORD MOTOR CO.
    NOTE: Plastic washers should be placed between bolt heads and special tool.
  57. Install the special tools.
    1. Install the special tool.
    2. Install the special tool and bolts.
      • Tighten to 13 Nm (10 lb-ft).
    58. Fig 52: Installing Special Tools & Bolts
    GF0025165Courtesy of FORD MOTOR CO.
  58. Using the special tools, measure the distance from the top of the special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
    • The special tools must be relocated to carry out the second measurement.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension B.
    59. Fig 53: Measuring Distance From Top Of Special Tool To Shim Surface Area Of Final Drive Carrier
    GF0025166Courtesy of FORD MOTOR CO.
  59. Use combined thickness of the special tool with long spacers 177.8 mm (7.0 in) as dimension A.
  60. Subtract dimension B from dimension A. This is dimension C.
  61. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
    DIFFERENTIAL END PLAY NO. 14 SHIM

    If Dimension C is: Use No. 14 Differential Shim:
    130.76 to 130.46 mm (5.148 to 5.136 in) 1.08 to 0.98 mm
    (0.042 to 0.038 in)
    130.45 to 130.16 mm (5.136 to 5.124 in) 1.38 to 1.28 mm
    (0.054 to 0.050 in)
    130.15 to 129.87 mm (5.124 to 5.113 in) 1.67 to 1.57 mm
    (0.065 to 0.061 in)
    129.86 to 129.57 mm (5.113 to 5.101 in) 1.97 to 1.87 mm
    (0.077 to 0.073 in)
    129.56 to 129.27 mm (5.101 to 5.089 in) 2.27 to 2.17 mm
    (0.089 to 0.085 in)
  62. Install the differential bearing assembly.
    1. Install the No. 14 differential bearing shim (selective fit).
    2. Install the No. 15 differential bearing.
    63. Fig 54: No. 14 Differential Bearing Shim & No. 15 Differential Bearing
    GF0025167Courtesy of FORD MOTOR CO.
    NOTE: Check for correct alignment of the lube tube on the converter housing.
  63. Install the torque converter housing onto the transaxle case.
    • Position and install the split flange gasket.
    64. Fig 55: Torque Converter Housing
    GF0025168Courtesy of FORD MOTOR CO.
    NOTE: Tighten the bolts in the indicated sequence.
  64. Install the torque converter housing-to-transaxle case bolts.
    • Tighten to 23 Nm (17 lb-ft).
    65. Fig 56: Torque Converter Housing-To-Transaxle Case Bolts Torque Sequence
    GF0025169Courtesy of FORD MOTOR CO.
    NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.
  65. Lubricate the assembly with clean transmission fluid.
    1. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
    2. Install the intermediate and overdrive servo apply rod and piston assembly.
    3. Install the overdrive servo apply rod spring.
    66. Fig 57: Servo Piston Assembly
    GF0025170Courtesy of FORD MOTOR CO.
  66. Install the special tool.
    67. Fig 58: Installing Special Tool
    GF0025171Courtesy of FORD MOTOR CO.
    NOTE: Struts on the special tool fit into the servo cover retaining ring groove.
  67. Assemble the special tool.
    1. Install the struts.
    2. Install the bar.
    3. Install the bolts.
    4. Install the center bolt.
      • Tighten to 4 Nm (35 lb-in).
    68. Fig 59: Assembling Special Tool Into Servo Cover Retaining Ring Groove
    GF0025172Courtesy of FORD MOTOR CO.
  68. Using the special tool, measure the distance to the bar of special tool.
    • Record this as dimension A.
    69. Fig 60: Measuring Distance To Bar Of Special Tool
    GF0025173Courtesy of FORD MOTOR CO.
  69. Back off the center bolt of the special tool until the piston movement stops.
    70. Fig 61: Center Bolt Of The Special Tool
    GF0025174Courtesy of FORD MOTOR CO.
  70. Using the special tool, measure the dimension to the bar of the special tool, record as dimension B.
    • Subtract dimension A from B to find the travel.
    • If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
      INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

      Part Number Number of Rings Rod Length
      F3RP-7H188-CB 0 108.1 mm
      (4.25 in)
      F3RP-7H188-BB 1 107.1 mm
      (4.21 in)
      F3RP-7H188-AB 2 105.7 mm
      (4.16 in)
    71. Fig 62: Measuring Dimension To Bar Of Special Tool With Specification
    GF0025175Courtesy of FORD MOTOR CO.
  71. Wipe the servo piston and the servo cover cap with a lint-free cloth.
    72. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.
  72. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attaches to the servo rod.
  73. Squeeze the servo piston lip to check for flexibility. If the lip feels brittle, install a new piston.
  74. Inspect the servo retainer spring for cracks, breaks or deformation.
  75. Install the special tool.
    76. Fig 63: Identifying Special Tool
    GF0024799Courtesy of FORD MOTOR CO.
    CAUTION: If the case is stamped WG, install a wide-groove snap ring or damage to the servo will result.
    CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.
  76. The WG stamp is located on the case toward the passenger side of the overdrive servo. The letters WG are etched into the case and hard to see.
    77. Fig 64: Locating Stamped Area
    GF0025176Courtesy of FORD MOTOR CO.
    NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
  77. Tighten the special tool bolt.
    • Install the servo cover retaining ring, using retaining ring pliers.
    78. Fig 65: Special Tool Bolt
    GF0024800Courtesy of FORD MOTOR CO.
  78. Loosen the special tool bolt.
    • When spring tension is released, remove the special tool.
    79. Fig 66: Special Tool Bolt
    GF0024800Courtesy of FORD MOTOR CO.
    CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.
    NOTE: If any leaks occur, make sure the special tool is correctly seated.
  79. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 276 kPa (40 psi) of moisture-free regulated compressed air.
    1. Reverse clutch test port.
    2. Forward clutch test port.
    3. Direct clutch test port.
    4. Low/reverse clutch test port.
    5. Servo release test port.
    6. Servo apply test port.
    7. Transmission air test plate.
      • If air leakage is detected, disassemble the transaxle and locate source of leakage.
    80. Fig 67: Inspecting Hydraulic Circuits Using Special Tools
    GF0025177Courtesy of FORD MOTOR CO.
  80. Install the thermostatic fluid level control valve.
    1. Position the thermostatic fluid level control valve.
    2. Install the bracket.
    3. Install the thermostatic fluid level control valve bracket bolt.
      • Tighten to 12 Nm (9 lb-ft).
    81. Fig 68: Installing Thermostatic Fluid Level Control Valve
    GF0025178Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
  81. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
    82. Fig 69: Solenoid Body Electrical Connector O-Ring Seal
    GF0025179Courtesy of FORD MOTOR CO.
    CAUTION: Handle main control valve body with care to prevent manual valve damage.
  82. Connect the manual valve.
    1. Lift the main control away from the case.
    2. Connect the Z-link to the manual valve.
    83. Fig 70: Locating Z-Link To Manual Valve
    GF0025180Courtesy of FORD MOTOR CO.
    NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.
  83. Install the main control valve body mounting bolts.
    • Tighten to 10 Nm (89 lb-in).
    84. Fig 71: Main Control Valve Body Mounting Bolt Tightening Sequence
    GF0024776Courtesy of FORD MOTOR CO.
  84. Install the manual control lever.
    • Tighten to 27 Nm (20 lb-ft).
    85. Fig 72: Locating Manual Control Lever
    GF0025181Courtesy of FORD MOTOR CO.
  85. Rotate the manual valve detent lever assembly to the NEUTRAL position.
    1. Low 1.
    2. Low 2.
    3. Drive.
    4. Neutral.
    5. Reverse.
    6. Park.
    86. Fig 73: Identifying Manual Valve Detent Lever Assembly Positions
    GF0025182Courtesy of FORD MOTOR CO.
  86. Position the transmission range (TR) sensor.
    87. Fig 74: Transmission Range (TR) Sensor
    GF0025183Courtesy of FORD MOTOR CO.
  87. Using the special tool, align the TR sensor and tighten the bolts.
    • Tighten to 11 Nm (8 lb-ft).
    88. Fig 75: Aligning TR Sensor Using Special Tools
    GF0024764Courtesy of FORD MOTOR CO.
    NOTE: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary.
  88. Install the main control cover gasket.
    89. NOTE: Tighten the bolts and studs in the indicated sequence.
    NOTE: The cooler bypass valve studs are in locations 3 and 11.
  89. Install the main control valve body cover and bolts.
    • Tighten to 13 Nm (10 lb-ft).
    90. Fig 76: Identifying Main Control Cover Bolts Tightening Sequence
    GF0024774Courtesy of FORD MOTOR CO.
  90. Install the vent tube.
    91. Fig 77: Locating Vent Tube
    GF0025184Courtesy of FORD MOTOR CO.
  91. Install a new transmission filler tube grommet.
    92. Fig 78: Transmission Filler Tube Grommet
    GF0025185Courtesy of FORD MOTOR CO.
  92. Install the transmission filler tube assembly.
    1. Install the tube.
    2. Install the transmission filler tube bolt.
      • Tighten to 8 Nm (71 lb-in).
      • Install the fluid level indicator.
    93. Fig 79: Transmission Filler Tube & Bolt
    GF0025186Courtesy of FORD MOTOR CO.
  93. Install a new O-ring seal on the turbine shaft speed (TSS) sensor and install the sensor.
    1. Using petroleum jelly on the O-ring seal, position the TSS sensor into the case.
    2. Install the TSS sensor bolt.
      • Tighten to 12 Nm (9 lb-ft).
    94. Fig 80: TSS Sensor & Bolt
    GF0025187Courtesy of FORD MOTOR CO.
  94. Using the special tool, install the LH differential seal.
    95. Fig 81: Installing LH Differential Seal Using Special Tools
    GF0024787Courtesy of FORD MOTOR CO.
  95. If the vehicle is equipped with a power transfer unit (PTU), use the special tools to install the RH differential seal.
    96. Fig 82: Installing RH Differential Seal Using Special Tools (1 Of 2)
    GF0024791Courtesy of FORD MOTOR CO.
  96. If the vehicle is not equipped with a PTU, use the special tools to install the RH differential seal.
    97. Fig 83: Installing RH Differential Seal Using Special Tools (2 Of 2)
    GF0024792Courtesy of FORD MOTOR CO.
    NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
  97. Using the special tool, install the torque converter fluid seal.
    • Coat the torque converter seal garter spring with petroleum jelly.
    98. Fig 84: Installing Torque Converter Fluid Seal Using Special Tools
    GF0025188Courtesy of FORD MOTOR CO.
  98. Using a small amount of pipe sealant on the threads, install the transaxle drain plug.
    • Tighten to 25 Nm (18 lb-ft).
    99. Fig 85: Transaxle Drain Plug
    GF0024762Courtesy of FORD MOTOR CO.
    NOTE: Check for correct rotation of the pump driveshaft.
  99. Install the pump driveshaft.
    100. Fig 86: Pump Assembly Driveshaft
    GF0024886Courtesy of FORD MOTOR CO.
  100. Using the special tool, install the torque converter.
    101. Fig 87: Installing/Removing Torque Converter Using Special Tools
    GF0024881Courtesy of FORD MOTOR CO.
    NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.
  101. Check the installation depth of the torque converter.
    1. Lay a straightedge on the transaxle converter housing.
    2. Check the clearance between the straightedge and the pilot hub.
      • Clearance is 17 mm (0.66 in).
    102. Fig 88: Checking Installation Depth Of Torque Converter
    GF0025189Courtesy of FORD MOTOR CO.
  102. Remove the transaxle from the special tool.
    103. Fig 89: Securing Transaxle To Bench
    GF0024885Courtesy of FORD MOTOR CO.
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