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Automatic Transmission - 6R80: Assembly: Transmission

Special Tools

Illustration Tool Name Tool Number
GF0022683Courtesy of FORD MOTOR CO.
 Aligner, Valve Body 307-334 (T95L-70010-C)
GF0000024Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0017679Courtesy of FORD MOTOR CO.
 End Play Gauge, Transmission 307-534
GF0001106Courtesy of FORD MOTOR CO.
 Handle, Driver 205-153 (T80T-4000-W)
GF0000942Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0022685Courtesy of FORD MOTOR CO.
 Installer, Ball Bearing 307-557
GF0022506Courtesy of FORD MOTOR CO.
 Installer, Fluid Pump Seal 307-556
GF0022684Courtesy of FORD MOTOR CO.
 Installer, Needle Bearing 307-558
GF0022516Courtesy of FORD MOTOR CO.
 Installer, Shifter Fluid Seal 307-559
GF0022505Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Fluid Seal 307-560
GF0022323Courtesy of FORD MOTOR CO.
 Remover, Transmission Fluid Pump 307-553
GF0006856Courtesy of FORD MOTOR CO.
 Retaining Ring Pliers 307-343 (T95P-77001-AHR)
Material

Item Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC (US); CXT-10-LV12 (Canada)		 MERCON® LV
Multi-Purpose Grease
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151		 ESB-M1C93-B
Fig 1: Disassembled Views
GF0027447Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transmission Assembly Disassembled Views (2 Of 3)
GF0027448Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transmission Assembly Disassembled Views (3 Of 3)
GF0027449Courtesy of FORD MOTOR CO.
Item Part Number Description
1 N800750-S437 Flex plate-to-torque converter nut (4 required)
2 7902 Torque converter
3 7A103 Pump assembly
4 7A248 Front pump oil seal
5 7N877 Torque converter pump retaining ring
6 7B031 Front pump outer oil seal
7 7R166 Front oil pump bearing assembly
8 7N817 Bushing converter stator support
9 7N134 Front pump-to-case bolts (13 required)
10 7A103 Front pump assembly
11 7R078 Bolt - attaches stator support to pump adapter assembly (6 required)
12 W707871-S300 Bolt - attaches pump to pump adapter assembly (11 required)
13 7B261 Converter stator support bushing
14 7G427 Front bushing forward clutch drum
15 7Z463 Clutch support fluid seal
16 7L323 Front pump support seal
17 7G428 Forward clutch rear bushing
18 7D014 Front pump support thrust washer
19 7A511 Forward clutch assembly (clutch A)
20 7J011 Forward clutch cylinder and hub assembly
21 7G242 Forward clutch inner piston seal
22 7F227 Forward clutch outer piston seal
23 7L140 Forward clutch piston
24 7F230 Forward clutch piston retaining spring
25 7J032 Forward clutch balance piston assembly
26 7F227 Forward clutch balance piston outer seal
27 7H365 Forward clutch balance piston snap ring
28 7N572 Forward clutch cushion spring
29 7E314 Forward clutch steel plates (externally splined) (number model dependent)
30 7B164 Forward clutch friction plates (internally splined) (number model dependent)
31 7B421 Pressure plate retaining snap ring
32 7G231 Front planetary sun gear (No. 1)
33 7H375 Bearing (T1)
34 7H579 Front planetary carrier assembly snap ring
35 7G218 Front planetary carrier assembly
36 7H578 Plate transmission fluid collector
37 7L495 Bearing (T2)
38 7L668 Overdrive clutch assembly (clutch E)
39 7G091 Turbine shaft seals (2 required)
40 7J006 Input shaft
41 7C232 Fluid distributor sleeve
42 7B256 Output shaft bushing
43 7J008 Overdrive clutch piston outer seal
44 7G007 Overdrive clutch piston inner seal
45 7G418 Overdrive clutch piston
46 7N529 Overdrive clutch piston spring
47 7J009 Balance piston outer seal
48 7J029 Overdrive balance piston
49 7J010 Balance piston snap ring
50 7N572 Clutch cushion plate
51 7B442 Overdrive clutch steel plates (externally splined) (number model dependent)
52 7B164 Overdrive clutch friction plates (internally splined) (number model dependent)
53 7C576 Overdrive pressure plate
54 7M157 Overdrive clutch retaining ring
55 7A453 Bearing (T3)
56 7F351 Intermediate clutch shaft
57 7H375 Bearing (T4)
58 7D065 Sun gear bushings (2 required) (part of 7R193)
59 7R193 Sun gear hub and shaft assembly
60 7F236 Direct clutch hub
61 7H076 Direct clutch cylinder retaining ring
62 7C108 Direct clutch assembly (clutch B)
63 7B421 Direct clutch pressure plate retaining ring
64 7B477 Direct clutch pressure plate
65 7B164 Direct clutch friction plates (internally splined) (number model dependent)
66 7E314 Direct clutch steel plates (externally splined) (number model dependent)
67 7N572 Direct clutch cushion plate
68 7D283 Bearing (T5)
69 7H363 Direct clutch balance piston snap ring
70 7D427 Direct clutch piston spring retainer
71 7B488 Direct clutch piston return spring
72 7B492 Direct clutch piston retaining ring
73 7H359 Direct clutch balance piston
74 7C000 Direct clutch balance seal
75 7F254 Direct clutch piston
76 7C000 Direct clutch piston outer seal
77 7F234 Direct clutch piston inner seal
78 7H240 Direct clutch hub bushings (part of 7F281) (2 required)
79 7C486 Gear shaft tube sleeve
80 7F360 Direct clutch cylinder
81 7B399 Shell cylinder seals (2 required)
82 7L327 Center support retaining ring
83 7F388 Intermediate clutch assembly (clutch C)
84 7B421 Intermediate clutch pressure plate retaining ring
85 7E314 Intermediate clutch pressure plate
86 7E314 Intermediate clutch steel plates (externally splined) (number model dependent)
87 7B164 Intermediate clutch friction plates (internally splined) (number model dependent)
88 7H136 Intermediate clutch pressure plate spring
89 7N169 Intermediate clutch retaining ring
90 7B043 Intermediate clutch ring
91 7C151 Intermediate clutch piston spring
92 7J015 Intermediate clutch piston
93 7F225 Intermediate clutch piston inner seal
94 7F224 Intermediate clutch piston outer seal
95 7F373 Bearing (T6)
96 7B314 Center shaft sleeve (part of 7G033)
97 7J114 Center support keys (2 required)
98 7J135 Center support seals (4 required)
99 7G033 Support assembly
100 7G446 Low/reverse clutch piston center seal
101 7G444 Low/reverse clutch piston inner seal
102 7G445 Low/reverse clutch piston outer seal
103 7D343 Low/reverse clutch piston
104 7D405 Low/reverse clutch piston return spring
105 7G494 Low/reverse clutch piston retaining ring
106 7N572 Clutch disc cushion plate
107 7E314 Low/reverse clutch steel plates (externally splined) (number model dependent)
108 7B164 Low/reverse clutch friction plates (internally splined) (number model dependent)
109 7E314 Low/reverse clutch pressure plate (select fit)
110 7H286 Gear thrust shim (select fit)
111 7C041 Bearing (T7)
112 7H580 Sun gear No. 2
113 7D235 Thrust bearing outer race
114 7D234 Bearing (T8)
115 7A348 Sun gear No. 3
116 7D234 Bearing (T9)
117 7193 Bearing race (T9)
118 7G224 Rear planetary carrier assembly
119 7H583 Fluid collar rear planetary plate (part of 7G224)
120 7A153 Output shaft ring gear assembly
121 7M152 Bearing (T10)
122 7B256 Output shaft bushing (part of 7096)
123 7096 Output shaft parking gear assembly (rear wheel drive [RWD])
124 7096 Output shaft parking gear assembly (four wheel drive [4WD])
125 7N194 Output shaft retaining ring
126 7006 Transmission case assembly (model dependent)
127 7E389 Transmission case fluid fill plug assembly
128 7E380 Transmission case fluid fill plug
129 7E390 Transmission case fluid fill seal
130 7E049 Transmission oil level indicator
131 7034 Transmission case vent assembly (model dependent)
132 7A415 Output shaft bearing assembly
133 7030A Output shaft retaining ring
134 7E413 Bearing (T11) (4WD only)
135 7R205 Output shaft bearing (RWD only)
136 7A433 Output shaft spacer (4WD only)
137 7030B Output shaft bearing retainer shim
138 7N135 Anti-click washer
139 7052 Extension housing seal (RWD)
140 7052 Extension housing seal (4WD)
141 7A021 Output shaft flange (RWD)
142 7K440 Output shaft flange retaining nut (RWD)
143 7E332 Manual valve detent spring
144 W711235-S300 Manual valve detent spring retaining screw and washer
145 7D410 Parking pawl actuating rod
146 7A441 Parking pawl
147 7D070 Parking pawl return spring
148 7D071 Parking pawl shaft
149 7H398 Plug assembly transmission case housing
150 7G101 Parking pawl abutment
151 W711235-S300 Parking pawl abutment retaining screw and washer
152 W708455-S441 Manual control lever nut
153 7A256 Manual control lever
154 7B498 Manual control lever shaft seal
155 7C493 Manual control lever shaft
156 7C257 Manual control lever shaft spacer
157 7A115 Manual valve detent lever assembly
158 7G100 Manual valve detent lever retaining pin
159 7H322 Thermal bypass valve
160 7F401 Front pump adapter seal
161 7A100 Main control valve body assembly
162 7A091 Upper main control valve body assembly
163 7Z490 Main control valve body separator plate
164 7G423 Lower main control valve body
165 14C247 Control module assembly
166 7H585 Bulkhead connector sleeve
167 - Transmission fluid filter seal (part of 7G186)
168 7G186 Transmission fluid filter
169 - Transmission fluid pan magnet
170 7A191 Transmission fluid pan gasket
171 7A194 Transmission fluid pan
172 W500214-S437 Transmission fluid pan bolts

All vehicles 

  1. If removed, position the rear case roller bearing in the case.
    2. Fig 4: Locating Rear Case Roller Bearing
    GF0022804Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the roller bearing.
    3. Fig 5: Installing Roller Bearing Using Special Tools (205-153, 307-558)
    GF0022805Courtesy of FORD MOTOR CO.
  3. Install the snap ring.
    4. Fig 6: Locating Inner Bearing Snap Ring
    GF0022758Courtesy of FORD MOTOR CO.

    Rear wheel drive (RWD) vehicles 

  4. Using the special tools, install the rear case roller bearing in the case.
    5. Fig 7: Installing Rear Case Roller Bearing Using Special Tools (205-153, 307-557)
    GF0022690Courtesy of FORD MOTOR CO.
  5. Install the roller bearing snap ring.
    6. Fig 8: Locating Rear Bearing Spacer Snap Ring
    GF0022580Courtesy of FORD MOTOR CO.

    Four wheel drive (4WD) vehicles 

  6. Using the special tools, install the rear bearing spacer.
    7. Fig 9: Installing Rear Bearing Spacer Using Special Tools (205-153, 307-558)
    GF0022806Courtesy of FORD MOTOR CO.
  7. Install the rear bearing spacer snap ring.
    8. Fig 10: Locating Rear Bearing Spacer Snap Ring
    GF0022585Courtesy of FORD MOTOR CO.

    All vehicles 

  8. Place the transmission in the vertical position.
  9. Install the planet carrier hub and output shaft assembly.
    10. Fig 11: Locating Planet Carrier Hub & Output Shaft Assembly
    GF0022577Courtesy of FORD MOTOR CO.
  10. Install the silver shim (caged bearing) on the planet carrier hub and output shaft assembly.
    11. Fig 12: Locating Silver Shim On Planet Carrier Hub
    GF0022692Courtesy of FORD MOTOR CO.
  11. Position the park pawl pin into the case.
    12. Fig 13: Positioning Park Pawl Pin Into Case
    GF0022693Courtesy of FORD MOTOR CO.
  12. Position the park pawl into the case and push the park pawl pin in to hold the park pawl and spring in position.
    13. Fig 14: Locating Park Pawl Pin, Park Pawl & Spring
    GF0022589Courtesy of FORD MOTOR CO.
  13. Install the park pawl pin bolt.
    • Tighten to 35 Nm (26 lb-ft).
    14. Fig 15: Locating Park Pawl Pin Bolt
    GF0022588Courtesy of FORD MOTOR CO.

    4WD vehicles 

  14. Position a new output shaft seal in place.
    15. Fig 16: Positioning Output Shaft Seal In Place
    GF0022807Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the output shaft seal.
    16. Fig 17: Installing Output Shaft Seal Using Special Tool (307-560)
    GF0022740Courtesy of FORD MOTOR CO.

    RWD vehicles 

  16. Install the anti-click washer.
    17. Fig 18: Locating Anti-Click Washer
    GF0022756Courtesy of FORD MOTOR CO.
  17. Position a new output shaft seal in place.
    18. Fig 19: Locating Output Shaft Seal
    GF0022578Courtesy of FORD MOTOR CO.
  18. Using the special tool, install the output shaft seal.
    19. Fig 20: Installing Output Shaft Seal Using Special Tool (307-556)
    GF0022808Courtesy of FORD MOTOR CO.
  19. Install the output shaft flange.
    20. Fig 21: Locating Output Shaft Flange
    GF0027436Courtesy of FORD MOTOR CO.
  20. Install a new output shaft flange nut.
    • Tighten to 60 Nm (44 lb-ft).
    • After installing the new nut, it must be staked at the slots to prevent it from coming loose.
    21. Fig 22: Locating Output Shaft Flange Nut
    GF0027435Courtesy of FORD MOTOR CO.
  21. Install the rear transmission mount bracket.
    • Tighten to 48 Nm (35 lb-ft).
    22. Fig 23: Locating Transmission Mount Bracket Bolts
    GF0027434Courtesy of FORD MOTOR CO.

    All vehicles 

  22. Install the roller bearing race in the bottom of the carrier.
    23. Fig 24: Locating Roller Bearing Race
    GF0022573Courtesy of FORD MOTOR CO.
  23. Snap the top and the bottom roller bearings onto the sun gear.
    24. Fig 25: Sun Gear Top & Bottom Roller Bearings
    GF0022572Courtesy of FORD MOTOR CO.
    NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque converter housing.
  24. Install the sun gear into the planet assembly.
    25. Fig 26: Locating Sun Gear In Planet Assembly
    GF0022755Courtesy of FORD MOTOR CO.
  25. Install the low/reverse sun gear.
    26. Fig 27: Locating Low/Reverse Sun Gear
    GF0022754Courtesy of FORD MOTOR CO.
  26. Install the planet carrier.
    27. Fig 28: Locating Low/Reverse Clutch Pack
    GF0022568Courtesy of FORD MOTOR CO.
    NOTE: Inspect the friction and steel plates for damage. If damaged, install new components as necessary. If no damage is indicated, the friction and steel plates can be reused.
  27. 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.
    28. Fig 29: Locating Direct Clutch Assembly
    GF0022565Courtesy of FORD MOTOR CO.
    NOTE: Inspect and install new thrust bearings as required.
  28. Install the low/reverse thrust bearing (T7).
    29. Fig 30: Locating Low/Reverse Bearing Race
    GF0022569Courtesy of FORD MOTOR CO.
  29. Install the select fit thrust gear shim on the T7 thrust bearing.
    30. 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.
  30. Install the center support into the case.
    31. Fig 31: Locating Center Support Into Case
    GF0022695Courtesy of FORD MOTOR CO.
    NOTE: Rotate case to the horizontal position.
  31. 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.
    32. Fig 32: Removing/Installing Center Support Snap Ring Using Special Tool (307-343)
    GF0022752Courtesy of FORD MOTOR CO.

    4WD vehicles 

  32. Using the special tool, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.006-0.013 in).
    • If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
    33. Fig 33: Checking End Play
    GF0022809Courtesy of FORD MOTOR CO.

    RWD vehicles 

  33. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.
    34. Fig 34: Identifying Special Tool (100-002)
    GF0045156Courtesy of FORD MOTOR CO.
  34. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).
    • If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
    35. Fig 35: Identifying Special Tool (100-002)
    GF0045157Courtesy of FORD MOTOR CO.

    All vehicles 

  35. Install the roller bearing if not previously installed on the direct clutch drum.
    36. Fig 36: Locating Roller Bearing
    GF0022810Courtesy of FORD MOTOR CO.
  36. Install the direct clutch drum.
    37. Fig 37: Locating Direct Clutch Drum
    GF0022567Courtesy of FORD MOTOR CO.
  37. Install the bearing on the direct clutch assembly.
    38. Fig 38: Locating Caged Roller Bearing
    GF0022750Courtesy of FORD MOTOR CO.
  38. Install the forward and overdrive clutch assembly.
    39. Fig 39: Locating Forward And Overdrive Clutch Assembly
    GF0022699Courtesy of FORD MOTOR CO.
  39. Install the pump washer.
    40. Fig 40: Locating Pump Washer
    GF0022700Courtesy of FORD MOTOR CO.
  40. Install the special tool into the case.
    41. Fig 41: Installing Special Tool (307-334) Into Case
    GF0022811Courtesy of FORD MOTOR CO.
  41. If the pump assembly was not disassembled and assembled, install a new pump outer diameter front pump O-ring seal.
    42. Fig 42: Locating Pump Outer Diameter Front Pump O-Ring Seal
    GF0022800Courtesy of FORD MOTOR CO.
  42. Using the special tool, install the front pump seal.
    43. Fig 43: Installing Front Pump Seal Using Special Tool (307-556)
    GF0022682Courtesy of FORD MOTOR CO.
  43. Using the special tools, install the front pump.
    44. Fig 44: Install Front Pump Using Special Tools (307-334, 307-553)
    GF0022812Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the transmission fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.
    NOTE: Add 0.118L (4 oz.) of clean transmission fluid to prime the pump.
  44. Make sure that the pump is correctly aligned with the case.
    45. Fig 45: Locating Seal
    GF0022703Courtesy of FORD MOTOR CO.
  45. Loosely install the new front pump bolts with the new washers.
    46. Fig 46: Identifying Special Tools (307-334, 307-553)
    GF0022813Courtesy of FORD MOTOR CO.
  46. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
    47. Fig 47: Locating Front Pump Bolts
    GF0022561Courtesy of FORD MOTOR CO.
  47. Install the special tool onto the input shaft to measure end play.
    • Tighten the wing nut.
    48. Fig 48: Installing Special Tool (307-534) Onto Input Shaft
    GF0017722Courtesy of FORD MOTOR CO.
  48. 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 in). If the measurement is not within specification install a new pump washer.
    • Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.
    49. Fig 49: Identifying Special Tools (100-002, 307-534)
    GF0022814Courtesy of FORD MOTOR CO.
  49. Install the park pawl abutment.
    • Tighten to 10 Nm (89 lb-in).
    50. Fig 50: Locating Park Rod Actuating Plate
    GF0022519Courtesy of FORD MOTOR CO.
  50. Position a new manual control lever seal in place.
    51. Fig 51: Locating Manual Control Lever Seal
    GF0022521Courtesy of FORD MOTOR CO.
  51. Using the special tool, install a new manual control lever shaft seal.
    52. Fig 52: Installing Manual Control Lever Shaft Seal Using Special Tool (307-559)
    GF0022742Courtesy of FORD MOTOR CO.
  52. Position the manual lever and park rod in place.
    • Push down on the park pawl and slide the park rod in place.
    53. Fig 53: Park Pawl & Park Rod
    GF0022706Courtesy of FORD MOTOR CO.
  53. Install the manual control lever in the case.
    1. Slide the manual control lever in the case.
    2. Position the spacer in place while sliding the manual control lever into the spacer.
    3. Position the manual valve inner detent lever while sliding the manual control lever and lining up the roll pin hole.
    4. Install the roll pin.
    54. Fig 54: Identifying Manual Lever, Spacer, Manual Valve Inner Lever, Roll Pin
    GF0027450Courtesy of FORD MOTOR CO.
  54. Install the 4 rubber feed tubes for the center support.
    1. Black feed tube.
    2. Green feed tube.
    3. Blue feed tube.
    55. Fig 55: Locating Rubber Feed Tubes
    GF0022732Courtesy of FORD MOTOR CO.
  55. Install the thermal bypass valve into the case.
    56. Fig 56: Locating Thermal Bypass Valve
    GF0022734Courtesy of FORD MOTOR CO.
  56. Install the rubber adapter.
    57. Fig 57: Locating Rubber Adapter
    GF0022733Courtesy of FORD MOTOR CO.
    NOTE: The mechatronic assembly will not lay flush on the case, this is normal, the bolts will pull the mechatronic assembly down.
  57. Loosely install the 11 mechatronic bolts.
    1. Align the manual valve and control lever linkage.
    58. Fig 58: Locating Mechatronic Assembly Bolts
    GF0022735Courtesy of FORD MOTOR CO.
    NOTE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.
  58. Tighten the bolts in the sequence shown.
    • Tighten to 6 Nm (53 lb-in).
    59. Fig 59: Tightening Mechatronic Bolts In Sequence
    GF0022744Courtesy of FORD MOTOR CO.
    NOTE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.
  59. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
    60. Fig 60: Locating Outer Shell Of Bulkhead Electrical Connector And Release Tab
    GF0022554Courtesy of FORD MOTOR CO.
  60. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.
    61. Fig 61: Locating Outer Shell Of Bulkhead Electrical Connector And Tab
    GF0022524Courtesy of FORD MOTOR CO.
  61. Install a new transmission fluid filter.
    62. Fig 62: Locating Transmission Fluid Filter
    GF0022493Courtesy of FORD MOTOR CO.
    NOTE: The transmission fluid pan gasket can be reused if not damaged.
  62. Install a new transmission fluid pan gasket if required.
    63. Fig 63: Identifying Transmission Fluid Pan Gasket
    GF0045151Courtesy of FORD MOTOR CO.
  63. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
    • Tighten to 14 Nm (10 lb-ft).
    64. Fig 64: Identifying Transmission Fluid Pan
    GF0045150Courtesy of FORD MOTOR CO.
  64. Install the torque converter.
    65. Fig 65: Removing/Installing Torque Converter Using Special Tool (307-091)
    GF0022745Courtesy of FORD MOTOR CO.
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