Automatic Transmission (6F35): Disassembly: Transaxle

SPECIAL TOOLS CHART

	Handle, Torque Converter 307-091 (T81P-7902-C)
	Holding Fixture 307-625
	Installer, Wheel Speed Sensor Ring 206-084/2
	Remover, Roll Pin 211-061 (T78P-3504-N1)
	Retainer, Torque Converter 307-566

1. Install the Holding Fixture 307-625.
   Fig 1: Identifying Holding Fixture 307-625

   Courtesy of FORD MOTOR CO.
2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.
   Fig 2: Installing Transaxle On Bench-Mounted Holding Fixture

   Courtesy of FORD MOTOR CO.
3. Remove the Torque Converter Retainer 307-566.
   Fig 3: Identifying Torque Converter Retainer 307-566

   Courtesy of FORD MOTOR CO.
4. Install the Torque Converter Handle 307-091.
   Fig 4: Identifying Torque Converter Handle 307-091

   Courtesy of FORD MOTOR CO.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 5: Removing Torque Converter From Transaxle Using Torque Converter Handle 307-091
Courtesy of FORD MOTOR CO.
5. Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
NOTE: Note the location of the stud bolts for assembly.
Fig 6: Locating Bolts And Main Control Cover
Courtesy of FORD MOTOR CO.
6. Remove the 13 bolts and the main control cover.
7. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
   Fig 7: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Disconnect the Transmission Range (TR) sensor electrical connector.
   Fig 8: Locating TR Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Remove the solenoid body-to-main control cover grommet.
   Fig 9: Locating Solenoid Body-To-Main Control Cover Grommet

   Courtesy of FORD MOTOR CO.
NOTE: Note the location of the short and long main control bolts for reassembly.
Fig 10: Locating Nut, Torx Bolts And Main Control Assembly
Courtesy of FORD MOTOR CO.
10. Remove the nut and the 22 Torx bolts and remove the main control assembly.
11. Remove and discard the main control-to-transaxle case separator plate.
    Fig 11: Locating Main Control-To-Transaxle Case Separator Plate

    Courtesy of FORD MOTOR CO.
12. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center support seals.
    1. Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal.
    2. Low/reverse clutch transaxle case-to-center support seal.
       Fig 12: Identifying Forward (1, 2, 3, 4) Clutch Transaxle Case-To-Center Support Seal And Low/Reverse Clutch Transaxle Case-To-Center Support Seal

       Courtesy of FORD MOTOR CO.
13. Remove the internal cooler bypass spring, sleeve and valve.
    Fig 13: Locating Internal Cooler Bypass Spring, Sleeve And Valve

    Courtesy of FORD MOTOR CO.
14. Remove the bolt and the Turbine Shaft Speed (TSS) sensor.
    Fig 14: Locating Bolt And Turbine Shaft Speed (TSS) Sensor

    Courtesy of FORD MOTOR CO.
15. Remove the bolt and the TR sensor detent spring.
    Fig 15: Locating Bolt And TR Sensor Detent Spring

    Courtesy of FORD MOTOR CO.
16. Remove the bolt and the OSS sensor.
    Fig 16: Locating Bolt And OSS Sensor

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the stud bolts for assembly.
Fig 17: Locating Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
17. Remove the 17 torque converter housing bolts.
18. Using a suitable tool, pry the torque converter housing loose from the transaxle case.
    Fig 18: Prying Torque Converter Housing Loose From Transaxle Case

    Courtesy of FORD MOTOR CO.
19. Remove the torque converter housing from the transaxle case.
    Fig 19: Locating Torque Converter Housing

    Courtesy of FORD MOTOR CO.
20. Remove the No. 15 differential thrust bearing.
    Fig 20: Removing No. 15 Differential Thrust Bearing

    Courtesy of FORD MOTOR CO.
21. Remove the differential.
    Fig 21: Removing Differential

    Courtesy of FORD MOTOR CO.
22. Remove the differential planetary sun gear.
    Fig 22: Locating Differential Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
23. Remove the No. 13 thrust washer.
    Fig 23: Locating No. 13 Thrust Washer

    Courtesy of FORD MOTOR CO.
24. Remove the No. 11 drive sprocket thrust bearing.
    Fig 24: Locating No. 11 Drive Sprocket Thrust Bearing

    Courtesy of FORD MOTOR CO.
25. Simultaneously remove the drive and driven sprockets and the chain.
    Fig 25: Locating Chain, Drive And Driven Sprockets

    Courtesy of FORD MOTOR CO.
26. Remove the No. 12 driven sprocket thrust bearing.
    Fig 26: Locating No. 12 Driven Sprocket Thrust Bearing

    Courtesy of FORD MOTOR CO.
27. Remove the No. 10 front sun gear and shell assembly thrust bearing.
    Fig 27: Locating No. 10 Front Sun Gear And Shell Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
28. Remove the 2 bolts and the transmission fluid reservoir.
    Fig 28: Locating Bolts And Transmission Fluid Reservoir

    Courtesy of FORD MOTOR CO.
29. Remove the 2 bolts and the transmission fluid baffle.
    Fig 29: Locating Bolts And Transmission Fluid Baffle

    Courtesy of FORD MOTOR CO.
30. Remove the park pawl pin and spring.
    Fig 30: Removing Park Pawl Pin And Spring

    Courtesy of FORD MOTOR CO.
31. Remove the park pawl.
    Fig 31: Locating Park Pawl

    Courtesy of FORD MOTOR CO.
NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).
NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
Fig 32: Locating Forward (1, 2, 3, 4) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
32. Remove the forward (1, 2, 3, 4) clutch snap ring.
33. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
    Fig 33: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate, Clutch Assembly And Wave Spring

    Courtesy of FORD MOTOR CO.
34. Remove the front sun gear and shell assembly.
    Fig 34: Locating Front Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
35. Remove the front planetary carrier/rear ring gear assembly.
    Fig 35: Locating Front Planetary Carrier/Rear Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
36. Remove the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
       Fig 36: Identifying No. 7 And No. 8 Thrust Bearings

       Courtesy of FORD MOTOR CO.
37. Remove the center planetary carrier/front ring gear assembly.
    Fig 37: Locating Center Planetary Carrier/Front Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
38. Remove the center planetary sun gear.
    Fig 38: Locating Center Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
39. Remove the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
       Fig 39: Identifying No. 5 And No. 6 Thrust Bearings

       Courtesy of FORD MOTOR CO.
40. Remove the center support assembly.
    Fig 40: Locating Center Support Assembly

    Courtesy of FORD MOTOR CO.
41. Remove the rear planetary carrier/center ring gear assembly.
    Fig 41: Locating Rear Planetary Carrier/Center Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
42. Remove the low/reverse wave spring, clutch pack and pressure plate.
    Fig 42: Locating Low/Reverse Wave Spring, Clutch Pack And Pressure Plate

    Courtesy of FORD MOTOR CO.
43. Remove the low One-Way Clutch (OWC).
    Fig 43: Locating Low One-Way Clutch (OWC)

    Courtesy of FORD MOTOR CO.
NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Fig 44: Removing Intermediate (2, 6) Clutch From Assembly
Courtesy of FORD MOTOR CO.
44. Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
45. Remove the pressure plate and the wave spring.
    Fig 45: Locating Pressure Plate And Wave Spring

    Courtesy of FORD MOTOR CO.
46. Remove the No. 3 thrust bearing.
    Fig 46: Locating No. 3 Thrust Bearing

    Courtesy of FORD MOTOR CO.
47. Remove the overdrive/direct clutch assembly.
    Fig 47: Locating Overdrive/Direct Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
Fig 48: Locating No. 1 Thrust Bearing
Courtesy of FORD MOTOR CO.
48. Remove the No. 1 thrust bearing.
49. Remove the intermediate (2, 6) clutch apply ring.
    Fig 49: Locating Intermediate (2, 6) Clutch Apply Ring

    Courtesy of FORD MOTOR CO.
50. Remove the 3 bolts and the clutch support tower.
    Fig 50: Locating Bolts And Clutch Support Tower

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the snap ring gap for assembly.
Fig 51: Locating Intermediate (2, 6) Clutch Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
51. Remove the intermediate (2, 6) clutch return spring snap ring.
NOTE: Note the position of the return spring for assembly.
Fig 52: Locating Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
52. Remove the intermediate (2, 6) clutch return spring.
NOTE: Note the position of the intermediate clutch piston for assembly.
Fig 53: Removing Intermediate (2, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
53. Remove the intermediate (2, 6) clutch piston.
54. Remove and discard the 5 clutch feed seals.
    Fig 54: Locating Clutch Feed Seals

    Courtesy of FORD MOTOR CO.
55. Remove the nut and the manual control lever from the manual shaft.
    Fig 55: Locating Manual Control Lever And Nut

    Courtesy of FORD MOTOR CO.
NOTE: Do not drive the roll pin through the manual shaft. The roll pin will contact the transaxle case causing damage to the transaxle case.
Fig 56: Identifying Roll Pin Remover 211-061
Courtesy of FORD MOTOR CO.
56. Using Roll Pin Remover 211-061, pull the roll pin out of the manual shaft.
57. Remove the manual shaft.
    Fig 57: Removing Manual Shaft

    Courtesy of FORD MOTOR CO.
58. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.
    Fig 58: Removing TR Sensor And Park Pawl Actuator Rod

    Courtesy of FORD MOTOR CO.
59. Using a suitable tool, remove and discard the manual shaft seal.
    Fig 59: Removing Manual Shaft Seal

    Courtesy of FORD MOTOR CO.
60. Using a suitable tool, remove and discard the LH halfshaft seal.
    Fig 60: Removing LH Halfshaft Seal

    Courtesy of FORD MOTOR CO.
NOTE: Press the bushing out of the transaxle case from the outside to the inside so that the transaxle case rests on a flat surface.
Fig 61: Removing LH Transaxle Case Bushing From Transaxle Case
Courtesy of FORD MOTOR CO.
61. Using the Wheel Speed Sensor Ring Installer 206-084/2 and a suitable press, remove and discard the LH transaxle case bushing from the transaxle case.
62. Remove the 2 bolts and the oil baffle from the torque converter housing.
    Fig 62: Locating Bolts And Oil Baffle

    Courtesy of FORD MOTOR CO.
63. Remove the 8 bolts and the pump and filter assembly.
    Fig 63: Locating Bolts, Pump And Filter Assembly

    Courtesy of FORD MOTOR CO.
64. Remove the differential ring gear snap ring.
    Fig 64: Locating Differential Ring Gear Snap Ring

    Courtesy of FORD MOTOR CO.
65. Remove the differential ring gear.
    Fig 65: Locating Differential Ring Gear

    Courtesy of FORD MOTOR CO.
66. Using a suitable tool, remove and discard the RH halfshaft seal.
    Fig 66: Removing RH Halfshaft Seal

    Courtesy of FORD MOTOR CO.