Disassembled Views

Fig 1: Exploded View Of Automatic Transmission (1 Of 5)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Automatic Transmission (2 Of 5)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Automatic Transmission (3 Of 5)

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Automatic Transmission (4 Of 5)

Courtesy of FORD MOTOR CO.

Fig 5: Exploded View Of Automatic Transmission (5 Of 5)

Courtesy of FORD MOTOR CO.

All vehicles 

1. Using the Holding Fixture 307-580, install the transaxle onto the bench.
   Fig 6: Installing Transaxle Onto Bench Using Holding Fixture 307-580

   Courtesy of FORD MOTOR CO.
2. Remove the Torque Converter Retainer 307-346.
   Fig 7: Identifying Torque Converter Retainer 307-346

   Courtesy of FORD MOTOR CO.
NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
Fig 8: Location of Torque Converter Bolts
Courtesy of FORD MOTOR CO.
3. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 9: Removing Torque Converter
Courtesy of FORD MOTOR CO.
4. Remove the torque converter from the transaxle.
NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur. Use only clean transmission fluid designated for the transaxle and torque converter being serviced.
5. Clean and inspect the torque converter for damage.
   1. Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
   2. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
      • A torque converter malfunction has been determined based on complete diagnostic procedures.
      • The torque converter stud or studs, impeller hub or bushing are damaged.
      • The torque converter exhibits external discoloration (due to overheating).
      • There is evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes.
        1. Major metallic failure
        2. Multiple clutch plates or band failures
        3. Sufficient component wear which results in metallic contamination
        4. Water or antifreeze contamination
   3. If none of the above conditions are present, continue with the following fluid inspection.
   4. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
   5. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
   NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur.
   6. If the fluid passed inspection:
      • drain the remaining fluid from the torque converter.
      • using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand.
      • thoroughly drain the fluid.
NOTE: Note the location of the of the studbolts for assembly.
Fig 10: Location of Main Control Cover Bolts
Courtesy of FORD MOTOR CO.
6. Remove the 14 bolts and the main control cover.
7. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.
   Fig 11: Sliding Transmission Range Sensor Electrical Connector Lock Tab

   Courtesy of FORD MOTOR CO.
8. Disconnect the TR sensor electrical connector.
   Fig 12: Location of TR Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Disconnect the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensor electrical connectors.
   1. TSS sensor
   2. OSS sensor
   Fig 13: Identifying Turbine Shaft Speed And Output Shaft Speed Sensor Electrical Connectors

   Courtesy of FORD MOTOR CO.
10. Remove the OSS sensor wire from the retainer.
    Fig 14: Location of OSS Sensor Wire

    Courtesy of FORD MOTOR CO.
NOTE: Handle the solenoid body with care or damage to the solenoid body may occur.
NOTE: Note the location of the different length bolts for assembly.
Fig 15: Location of Solenoid Body Bolts
Courtesy of FORD MOTOR CO.
11. Remove the 11 bolts and the solenoid body.
12. Remove the 10 main control valve body bolts and the valve body.
    Fig 16: Location of Main Control Valve Body Bolts

    Courtesy of FORD MOTOR CO.
13. Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. For additional information, refer to Main Control - Overhaul  .
14. Remove the forward clutch feed seal.
    Fig 17: Removing Forward Clutch Feed Seal

    Courtesy of FORD MOTOR CO.
15. Remove the bolt and the OSS sensor.
    Fig 18: Location of OSS Sensor Bolt

    Courtesy of FORD MOTOR CO.
16. Remove the 10 cover assembly bolts.
    Fig 19: Location of Cover Assembly Bolts

    Courtesy of FORD MOTOR CO.
17. Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transaxle case.
    Fig 20: Removing Cover Assembly

    Courtesy of FORD MOTOR CO.
18. Remove the cover assembly gasket.
    Fig 21: Location of Cover Assembly Gasket

    Courtesy of FORD MOTOR CO.
19. Remove the No. 1 cover assembly thrust bearing.
    Fig 22: Removing No. 1 Cover Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
20. Remove the overdrive/direct clutch hub and turbine shaft assembly.
    Fig 23: Removing Overdrive/Direct Clutch Hub And Turbine Shaft Assembly

    Courtesy of FORD MOTOR CO.
21. Remove No. 3 rear sun gear thrust bearing.
    Fig 24: Removing No. 3 Rear Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
22. Remove the intermediate clutch shell and sun gear assembly.
    Fig 25: Removing Intermediate Clutch Shell And Sun Gear Assembly

    Courtesy of FORD MOTOR CO.
23. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, as necessary.
    • Gear teeth
    • Shell-to-clutch pack surfaces
    • Thrust bearing surfaces
    Fig 26: Location of Damage Rear Planetary Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
24. Remove the intermediate clutch assembly.
    Fig 27: Location of Intermediate Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low One-Way Clutch (OWC) snap ring.
Fig 28: Location of Low/Reverse Clutch Assembly
Courtesy of FORD MOTOR CO.
25. Remove the low/reverse clutch assembly.
26. Remove the rear planetary carrier and center ring gear assembly.
    Fig 29: Removing Rear Planetary Carrier Assembly

    Courtesy of FORD MOTOR CO.
27. Clean and inspect the rear planetary gear carrier assembly for damage or wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing
    • Thrust bearing surfaces
    • Ring gear teeth
    Fig 30: Location of Rear Planetary Gear Carrier Assembly

    Courtesy of FORD MOTOR CO.
28. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
    Fig 31: Removing No. 6 Center Sun Gear And No. 5 Center/Rear Planetary Thrust Bearings

    Courtesy of FORD MOTOR CO.
29. Remove the center planetary sun gear.
    Fig 32: Removing Center Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
30. Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
    Fig 33: Location of Center Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
31. Remove the center planetary carrier and front ring gear assembly.
    Fig 34: Removing Center Planetary Carrier

    Courtesy of FORD MOTOR CO.
32. Clean and inspect the center planetary gear carrier assembly for damage or wear and install new, as necessary
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing surfaces
    • Ring gear teeth
    Fig 35: Location of Center Planetary Gear Carrier Assembly

    Courtesy of FORD MOTOR CO.
33. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
    Fig 36: Removing No. 7 Center Sun Gear And No. 8 Front/Center Planetary Gear Assembly Thrust Bearings

    Courtesy of FORD MOTOR CO.
34. Remove the front planetary carrier and rear ring gear assembly.
    Fig 37: Removing Front Planetary Carrier And Rear Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
35. Clean and inspect the front planetary gear carrier assembly for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Ring gear teeth
    • Shell-to-clutch pack surfaces
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing
    Fig 38: Location of Front Planetary Gear Carrier Assembly

    Courtesy of FORD MOTOR CO.
36. Remove the front planetary sun gear and shell assembly.
    Fig 39: Removing Front Planetary Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
37. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, if necessary.
    • Sun gear teeth
    • Shell-to-clutch pack surfaces
    • Bearing surfaces
    Fig 40: Location of Front Planetary Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
38. Remove the No. 10 front sun gear thrust bearing.
    Fig 41: Removing No. 10 Front Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
39. Remove the front planetary carrier hub assembly.
    Fig 42: Location of Front Planetary Carrier Hub Assembly

    Courtesy of FORD MOTOR CO.
40. Clean and inspect the front planetary carrier hub for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Hub-to-stator support surfaces
    Fig 43: Location of Front Planetary Carrier Hub

    Courtesy of FORD MOTOR CO.
41. Remove the No. 11 support assembly thrust bearing.
    Fig 44: Removing No. 11 Support Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.
Fig 45: Location of Low OWC Snap Ring
Courtesy of FORD MOTOR CO.
42. Remove the low OWC snap ring.
43. Remove the low OWC.
    Fig 46: Removing Low OWC

    Courtesy of FORD MOTOR CO.
NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.
NOTE: The low OWC cannot be disassembled.
Fig 47: Location of Low OWC
Courtesy of FORD MOTOR CO.
44. Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should rotate counterclockwise and lock when rotated clockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC.
45. Inspect the forward clutch surface for damage. If the surface is burned or worn excessively, install a new OWC.
    Fig 48: Location of Forward Clutch Surface

    Courtesy of FORD MOTOR CO.
46. Remove the forward clutch assembly.
    Fig 49: Location of Forward Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
Fig 50: Compressing Forward Clutch Piston Return Spring Using Forward Clutch Spring Compressor 307-574 (307-574/1 And 307-574/2)
Courtesy of FORD MOTOR CO.
47. Using the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) compress the forward clutch piston return spring.
NOTE: The Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) are not shown in illustration for clarity.
Fig 51: Location of Forward Clutch Piston Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
48. Remove the forward clutch piston return spring snap ring.
49. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).
    Fig 52: Compressing Forward Clutch Piston Return Spring And Forward/Intermediate Spring Compressor

    Courtesy of FORD MOTOR CO.
50. Remove the forward clutch piston return spring.
    Fig 53: Location of Forward Clutch Piston Return Spring

    Courtesy of FORD MOTOR CO.
51. Remove and discard the forward clutch piston.
    Fig 54: Removing Forward Clutch Piston

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the studbolts for assembly.
Fig 55: Location of Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
52. Remove the 19 torque converter housing bolts.
NOTE: Carefully pry on the transaxle torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.
Fig 56: Removing Torque Converter Housing Using Suitable Tool
Courtesy of FORD MOTOR CO.
53. Carefully pry the torque converter housing off the transaxle case just enough to break the seal of the silicone and remove the torque converter housing from the transaxle case.
54. Remove the transaxle lube tube.
    Fig 57: Location of Transaxle Lube Tube

    Courtesy of FORD MOTOR CO.
55. Remove the differential and ring gear assembly.
    Fig 58: Location of Differential And Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
56. Remove the transfer shaft and gear assembly.
    Fig 59: Location of Transfer Shaft And Gear Assembly

    Courtesy of FORD MOTOR CO.
NOTE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.
Fig 60: Location of Differential Bearing Cup And Ring Gear
Courtesy of FORD MOTOR CO.
57. Inspect the differential for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the ring gear for damage. Install new bearings or a ring gear on the differential if damage or excessive wear is found. For additional information, refer to Differential Gear Assembly  . If the differential bearings are replaced the bearing races in the transaxle case and the torque converter housing must also be replaced. For additional information, refer to Transaxle Case  and Torque Converter Housing  . If the differential ring gear is replaced, the transfer shaft must also be replaced. For additional information, refer to Transfer Shaft and Gear  .
NOTE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.
Fig 61: Identifying Bearings, Transfer Shaft, Transfer Shaft Input Gear And Park Pawl Wheel
Courtesy of FORD MOTOR CO.
58. Inspect the transfer shaft for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the park pawl wheel, transfer shaft and transfer shaft input gear for damage. Install new bearings, park pawl wheel, transfer shaft or transfer shaft input gear if damage or excessive wear is found. For additional information, refer to Transfer Shaft and Gear  . If the transfer shaft bearings are replaced the bearing races in the transaxle case and the torque converter housing case must also be replaced. For additional information, refer to Transaxle Case  and Torque Converter Housing  . If the transfer shaft is replaced, the differential ring gear must also be replaced. For additional information, refer to Differential Gear Assembly  .
    1. Bearings
    2. Transfer shaft input gear
    3. Transfer shaft
    4. Park pawl wheel
59. Remove the pump-to-case seal.
    Fig 62: Location of Pump-To-Case Seal

    Courtesy of FORD MOTOR CO.
60. Remove the 2 bolts and the oil reservoir.
    Fig 63: Location of Oil Reservoir Bolts

    Courtesy of FORD MOTOR CO.
61. Remove the reservoir O-ring seal.
    Fig 64: Removing Reservoir O-Ring Seal Using Suitable Tool

    Courtesy of FORD MOTOR CO.
NOTE: Gently pry the pin out of the hole from under the head on each side or the pin may be broken off in the hole.
Fig 65: Location of TR Sensor Locking Pin
Courtesy of FORD MOTOR CO.
62. Remove and discard the TR sensor locking pin.
63. Remove the TR sensor.
    1. Slide the TR sensor out of the transaxle case.
    2. Rotate the TR sensor detent plate until it rests against the transaxle case.
    3. Remove the park pawl actuator rod from the detent lever and remove the TR sensor.
    Fig 66: Removing TR Sensor

    Courtesy of FORD MOTOR CO.
64. Remove the park pawl actuator rod.
    Fig 67: Removing Park Pawl Actuator Rod

    Courtesy of FORD MOTOR CO.
65. Remove the manual lever shaft seal.
    Fig 68: Removing Manual Lever Shaft Seal Using Suitable Tool

    Courtesy of FORD MOTOR CO.
NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.
Fig 69: Location of Transaxle Case Side Transfer Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
66. Inspect the transaxle case side transfer shaft bearing cup for damage. If the transaxle case side transfer shaft bearing cup is damaged, install a new bearing cup. For additional information, refer to Transaxle Case  . If a new bearing cup is installed in the transaxle case, install a new transfer shaft bearing cup in the torque converter housing. For additional information, refer to Torque Converter Housing  . Install new bearings on the transfer shaft. For additional information, refer to Transfer Shaft and Gear  .
67. Remove the halfshaft seal from the transaxle case.
    Fig 70: Removing Halfshaft Seal From Transaxle Case

    Courtesy of FORD MOTOR CO.
NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transaxle failure can occur.
Fig 71: Location of Transaxle Case Side Differential Bearing Cup
Courtesy of FORD MOTOR CO.
68. Inspect the transaxle case side differential bearing cup for damage. If the transaxle case side differential bearing cup is damaged, install a new bearing cup. For additional information, refer to Transaxle Case  . If a new bearing cup is installed in the transaxle case, install a new differential bearing cup in the torque converter housing. For additional information, refer to Torque Converter Housing  . If a new bearing cup was installed, the differential bearings must also be replaced. For additional information, refer to Differential Gear Assembly  .
69. Remove the bolt and the fluid baffle from the torque converter housing.
    Fig 72: Location of Differential Carrier Baffle And Bolt

    Courtesy of FORD MOTOR CO.
70. Remove the 9 stator support assembly bolts.
    Fig 73: Location of Stator Support Assembly Bolts

    Courtesy of FORD MOTOR CO.
71. Remove the stator support assembly.
    Fig 74: Removing Stator Support Assembly

    Courtesy of FORD MOTOR CO.
72. Remove the 3 bolts and the fluid pump and filter assembly.
    Fig 75: Location of Fluid Pump And Filter Assembly Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Note the orientation of the fluid filter to the fluid pump.
Fig 76: Pulling Filter Out Of Bore Of Fluid Pump
Courtesy of FORD MOTOR CO.
73. Remove and discard the fluid filter.
    1. Pull the filter out of the bore of the fluid pump. Discard the fluid filter.
    2. If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.
74. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.
75. Remove the fluid pump sprocket and chain assembly.
    Fig 77: Location of Fluid Pump Sprocket And Chain Assembly

    Courtesy of FORD MOTOR CO.
76. Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
    • Check the drive chain for wear, damage, stretching or tightness of the chain links.
    • Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.
    Fig 78: Location of Pump Chain And Sprocket Damage Areas

    Courtesy of FORD MOTOR CO.
77. Remove the fluid pump drive sprocket and driven sprocket thrust washers.
    Fig 79: Location of Pump Drive Sprocket And Driven Sprocket Thrust Washers

    Courtesy of FORD MOTOR CO.
NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.
Fig 80: Location of Transaxle Case Side Transfer Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
78. Inspect the torque converter housing side transfer shaft bearing cup for damage. If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. For additional information, refer to Torque Converter Housing  . If a new bearing cup is installed in the torque converter housing, install a new transfer shaft bearing cup in the transaxle case. For additional information, refer to Transaxle Case  . Install new bearings on the transfer shaft. For additional information, refer to Transfer Shaft and Gear  .

    Front Wheel Drive (FWD) vehicles 

79. Remove the halfshaft seal from the torque converter housing.
    Fig 81: Removing Halfshaft Seal From Torque Converter Housing Using Suitable Tool

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transaxle failure can occur.
Fig 82: Location of Transaxle Case Side Differential Bearing Cup
Courtesy of FORD MOTOR CO.
80. Inspect the torque converter housing side differential bearing cup for damage. If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. For additional information, refer to Torque Converter Housing  . If a new bearing cup is installed in the torque converter housing, install a new differential bearing cup in the transaxle case. For additional information, refer to Transaxle Case  . If a new bearing cup was installed, the differential bearings must also be replaced. For additional information, refer to Differential Gear Assembly  .
81. Remove the torque converter hub seal from the torque converter housing.
    Fig 83: Removing Torque Converter Hub Seal From Torque Converter Housing

    Courtesy of FORD MOTOR CO.
82. Clean and inspect the transaxle case and torque converter housing for damage and install a new transaxle case or torque converter housing if necessary. If a new transaxle case or torque converter housing is installed, refer to Transaxle Case  for bearing cup installation and Differential Shim Selection for differential/transfer gear bearing shim measurement.
83. Clean and inspect the thrust bearings and washers for damage and install new bearings or washers as necessary.
84. Remove the overdrive clutch snap ring.
    Fig 84: Removing Overdrive Clutch Snap Ring

    Courtesy of FORD MOTOR CO.
85. Remove the overdrive clutch hub and clutch assembly.
    Fig 85: Removing Overdrive Clutch Hub And Clutch Assembly

    Courtesy of FORD MOTOR CO.
86. Remove the bottom overdrive clutch steel plate.
    Fig 86: Removing Bottom Overdrive Clutch Steel Plate

    Courtesy of FORD MOTOR CO.
87. Remove the No. 2 rear sun gear thrust bearing.
    Fig 87: Removing No. 2 Rear Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
88. Install the Overdrive Clutch, Balance Piston and the Direct Clutch Compressor 307-589/1 and the Forward/Intermediate Spring Compressor 307-584/2 on the balance piston. Using a press, compress the overdrive piston return spring.
    Fig 88: Compressing Overdrive Piston Return Spring Using A Press

    Courtesy of FORD MOTOR CO.
89. With the overdrive piston return spring compressed, remove the balance piston snap ring.
    Fig 89: Location of Balance Piston Snap Ring

    Courtesy of FORD MOTOR CO.
90. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor Set 307-589/1 and the Forward/Intermediate Spring Compressor 307-584/2.
    Fig 90: Removing Overdrive Clutch, Balance Piston And Direct Clutch Using Compressor Set 307-589/1 And Compressor 307-584/2

    Courtesy of FORD MOTOR CO.
91. Remove and discard the balance piston.
    Fig 91: Removing Balance Piston

    Courtesy of FORD MOTOR CO.
92. Remove the overdrive piston return spring.
    Fig 92: Location of Overdrive Piston Return Spring

    Courtesy of FORD MOTOR CO.
93. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
    Fig 93: Identifying No. 1 Thrust Bearing On Overdrive/Direct Clutch Assembly

    Courtesy of FORD MOTOR CO.
94. Position the overdrive/direct clutch assembly in the rear cover.
    Fig 94: Identifying Overdrive/Direct Clutch Assembly Position

    Courtesy of FORD MOTOR CO.
95. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
    Fig 95: Removing Overdrive Piston

    Courtesy of FORD MOTOR CO.
96. Remove the overdrive/direct clutch assembly from the rear cover.
    Fig 96: Location of Overdrive/Direct Clutch Assembly

    Courtesy of FORD MOTOR CO.
97. Remove and discard the overdrive clutch piston inner seal.
    Fig 97: Removing Overdrive Clutch Piston Inner Seal

    Courtesy of FORD MOTOR CO.
98. Remove and discard the overdrive clutch piston outer seals from the piston.
    Fig 98: Removing Overdrive Clutch Piston Outer Seals From Piston

    Courtesy of FORD MOTOR CO.
NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Fig 99: Compressing Direct Clutch Piston Return Spring And Removing Snap Ring Using Press
Courtesy of FORD MOTOR CO.
99. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
    2. Remove the snap ring.
100. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2.
     Fig 100: Removing Overdrive Clutch, Balance Piston Using Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2

     Courtesy of FORD MOTOR CO.
101. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
     Fig 101: Identifying No. 1 Thrust Bearing On Overdrive/Direct Clutch Assembly

     Courtesy of FORD MOTOR CO.
102. Remove the direct clutch cylinder. Position the overdrive/direct clutch assembly in the cover assembly. Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port to remove the direct clutch cylinder from the overdrive/direct clutch assembly. Remove the overdrive/direct clutch assembly from the rear cover and remove the direct clutch cylinder.
     Fig 102: Removing Direct Clutch Cylinder

     Courtesy of FORD MOTOR CO.
103. Remove the rear direct clutch piston seal.
     Fig 103: Removing Rear Direct Clutch Piston Seal

     Courtesy of FORD MOTOR CO.
104. Remove and discard the direct clutch piston.
     Fig 104: Removing Direct Clutch Piston

     Courtesy of FORD MOTOR CO.
105. Remove the direct clutch piston return spring.
     Fig 105: Removing Direct Clutch Piston Return Spring

     Courtesy of FORD MOTOR CO.
106. Remove and discard the direct clutch piston seals.
     Fig 106: Removing Direct Clutch Piston Seals

     Courtesy of FORD MOTOR CO.
107. Remove the direct clutch snap ring.
     Fig 107: Removing Direct Clutch Snap Ring

     Courtesy of FORD MOTOR CO.
108. Remove the direct clutch pressure plate, clutch assembly and wave spring.
     Fig 108: Removing Direct Clutch Pressure Plate, Clutch Assembly And Wave Spring

     Courtesy of FORD MOTOR CO.
109. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.
110. Install the direct clutch wave spring.
     Fig 109: Location of Direct Clutch Wave Spring

     Courtesy of FORD MOTOR CO.
111. Lubricate the direct clutch pack in clean transmission fluid.
     Fig 110: Identifying Direct Clutch Pack

     Courtesy of FORD MOTOR CO.
112. Install the direct clutch assembly and pressure plate.
     Fig 111: Installing Direct Clutch Assembly And Pressure Plate

     Courtesy of FORD MOTOR CO.
113. Install the direct clutch snap ring.
     Fig 112: Installing Direct Clutch Snap Ring

     Courtesy of FORD MOTOR CO.
114. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
     Fig 113: Installing Direct Clutch Piston Seals

     Courtesy of FORD MOTOR CO.
115. Install the direct clutch piston return spring.
     Fig 114: Installing Direct Clutch Piston Return Spring

     Courtesy of FORD MOTOR CO.
116. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
     Fig 115: Installing Direct Clutch Piston

     Courtesy of FORD MOTOR CO.
117. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
     Fig 116: Installing Rear Direct Clutch Piston Seal

     Courtesy of FORD MOTOR CO.
118. Install the direct clutch cylinder.
     Fig 117: Installing Direct Clutch Cylinder

     Courtesy of FORD MOTOR CO.
NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
Fig 118: Compressing Direct Clutch Piston Return Spring And Installing Snap Ring Using Press
Courtesy of FORD MOTOR CO.
119. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.
     1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
     2. Install the snap ring.
120. Remove the Overdrive Clutch, Balance Piston Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2.
     Fig 119: Identifying Overdrive Clutch, Balance Piston Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2

     Courtesy of FORD MOTOR CO.
121. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
     Fig 120: Installing Seals On Overdrive Clutch Piston

     Courtesy of FORD MOTOR CO.
122. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
     Fig 121: Location of Overdrive Clutch Piston Inner Seal

     Courtesy of FORD MOTOR CO.
123. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1.
     Fig 122: Pushing Overdrive Clutch Piston In Cylinder Using Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1

     Courtesy of FORD MOTOR CO.
NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
Fig 123: Location of Clutch Overdrive Piston Return Spring
Courtesy of FORD MOTOR CO.
124. Install the overdrive clutch piston return spring.
125. Lubricate the seals on a new balance piston with petroleum jelly.
     Fig 124: Location of Seals On Balance Piston

     Courtesy of FORD MOTOR CO.
126. Install the new balance piston and install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
     Fig 125: Identifying Direct Clutch Compressor Set 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2

     Courtesy of FORD MOTOR CO.
127. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
     Fig 126: Compressing Overdrive Clutch Piston Return Spring And Installing Snap Ring Using Press

     Courtesy of FORD MOTOR CO.
128. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and the Forward/Intermediate Spring Compressor 307-584/2 from the balance piston.
     Fig 127: Removing Overdrive Clutch, Balance Piston Using Direct Clutch Compressor 307-589/1 And Spring Compressor 307-584/2

     Courtesy of FORD MOTOR CO.
129. Install the No. 2 rear sun gear thrust bearing.
     Fig 128: Installing No. 2 Rear Sun Gear Thrust Bearing

     Courtesy of FORD MOTOR CO.
130. Install the overdrive clutch hub.
     Fig 129: Installing Overdrive Clutch Hub

     Courtesy of FORD MOTOR CO.
131. Lubricate the overdrive clutch pack in clean transmission fluid.
     Fig 130: Identifying Overdrive Clutch Pack

     Courtesy of FORD MOTOR CO.
132. Install the overdrive clutch pack assembly and the pressure plate.
     Fig 131: Location of Overdrive Clutch Pack Assembly

     Courtesy of FORD MOTOR CO.
133. Install the overdrive clutch pack snap ring.
     Fig 132: Location of Overdrive Clutch Pack Snap Ring

     Courtesy of FORD MOTOR CO.
134. Remove the bolt and the TSS sensor.
     Fig 133: Location of Turbine Shaft Speed (TSS) Sensor Bolt

     Courtesy of FORD MOTOR CO.
135. Using the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2, compress the intermediate clutch return spring, using a press and remove the snap ring.
     Fig 134: Removing Snap Ring Using Press

     Courtesy of FORD MOTOR CO.
136. Remove the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2.
     Fig 135: Removing Forward/Intermediate Spring Compressor 307-584/1 And 307-584/2

     Courtesy of FORD MOTOR CO.
137. Remove the intermediate clutch return spring.
     Fig 136: Removing Intermediate Clutch Return Spring

     Courtesy of FORD MOTOR CO.
138. Remove and discard the intermediate clutch piston.
     Fig 137: Removing Intermediate Clutch Piston

     Courtesy of FORD MOTOR CO.
139. Install the Forward/Intermediate Spring Compressor 307-584/2 and the Reverse Clutch Piston and Retaining Ring Set 307-588/3, using a press, compress the low/reverse clutch return spring and remove the snap ring.
     Fig 138: Compressing Low/Reverse Clutch Return Spring And Removing Snap Ring Using Press

     Courtesy of FORD MOTOR CO.
140. Remove the Forward/Intermediate Spring Compressor 307-584/2 and the Reverse Clutch Piston and Retaining Ring Set 307-588/3.
     Fig 139: Removing Forward/Intermediate Spring Compressor 307-584/2 And Reverse Clutch Piston And Retaining Ring Set 307-588/3

     Courtesy of FORD MOTOR CO.
141. Remove the low/reverse clutch return spring.
     Fig 140: Removing Low/Reverse Clutch Return Spring

     Courtesy of FORD MOTOR CO.
142. Remove and discard the low/reverse clutch piston.
     Fig 141: Removing Low/Reverse Clutch Piston

     Courtesy of FORD MOTOR CO.
143. Remove and discard the 4 Teflon® seals.
     Fig 142: Removing Teflon Seals Using Suitable Tool

     Courtesy of FORD MOTOR CO.
144. Clean and inspect the cover for damage. Install a new cover, if damaged.
145. Install the Input Shaft Support Seal Installer 307-578/3 on the cover and adjust the Input Shaft Support Seal Installer to align the bottom edge of the Input Shaft Support Seal Installer with the top edge of the bottom Teflon® seal groove.
     Fig 143: Identifying Input Shaft Support Seal Installer 307-578/3

     Courtesy of FORD MOTOR CO.
146. Install a new Teflon® seal on the Input Shaft Support Seal Installer 307-578/3.
     Fig 144: Location of Teflon® Seal On Input Shaft

     Courtesy of FORD MOTOR CO.
147. Install the Input Shaft Support Seal Installer 307-578/2 over 307-578/3. Using the Input Shaft Support Seal Installer 307-578/2, slide the Teflon® seal over the cover and into the groove.
     Fig 145: Sliding Teflon Seal Over Cover And Into Groove

     Courtesy of FORD MOTOR CO.
148. Remove the Input Shaft Support Seal Installer 307-578.
     • Repeat Steps  145 through 148 for the other 3 Teflon® seals.
     Fig 146: Removing Input Shaft Support Seal Installer 307-578

     Courtesy of FORD MOTOR CO.
149. Install the Input Shaft Support Seal Installer 307-578/1 on the cover to size the 4 Teflon® seals.
     Fig 147: Installing Input Shaft Support Seal Installer 307-578/1 On Cover

     Courtesy of FORD MOTOR CO.
150. Install the Reverse Clutch Piston and Retaining Ring Set 307-588/1 and 307-588/2.
     Fig 148: Installing Reverse Clutch Piston And Retaining Ring Set 307-588/1 And 307-588/2

     Courtesy of FORD MOTOR CO.
151. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly and position the low/reverse piston in the cover.
     1. Lubricate the seals.
     2. Position the low/reverse piston in the cover so that the semicircles in the piston are aligned with the indentation in the cover.
     Fig 149: Location of Low/Reverse Piston Position And Seals

     Courtesy of FORD MOTOR CO.
152. Make sure the low/reverse piston bleed hole and semicircle area are aligned with the indentation in the cover and the intermediate cylinder fill hole.
     1. Low/reverse piston bleed hole
     2. Low/reverse piston semicircle area
     3. Cover indentation
     4. Intermediate cylinder fill hole
     Fig 150: Identifying Low/Reverse Piston Bleed Hole, Semicircle Area, Cover Indentation And Intermediate Cylinder Fill Hole

     Courtesy of FORD MOTOR CO.
153. Position the low/reverse piston in the cover, make sure that the piston bleed hole stays aligned with the indentation in the cover and push the piston in the cylinder using the Reverse Clutch Piston and Retaining Ring Set 307-588/3.
     Fig 151: Positioning Low/Reverse Piston In Cover Making Sure Piston Bleed Hole Stays Aligned

     Courtesy of FORD MOTOR CO.
154. Remove the Reverse Clutch Piston and Retaining Ring Set 307-588/1 and 307-588/2.
     Fig 152: Removing Reverse Clutch Piston And Retaining Ring Set 307-588/1 And 307-588/2

     Courtesy of FORD MOTOR CO.
155. Install the low/reverse piston return spring with the tabs facing down.
     Fig 153: Location of Low/Reverse Piston Return Spring

     Courtesy of FORD MOTOR CO.
156. Install the Forward/Intermediate Spring Compressor 307-584/2 and the Reverse Clutch Piston and Retaining Ring Set 307-588/3.
     Fig 154: Installing Forward/Intermediate Spring Compressor 307-584/2, Reverse Clutch Piston And Retaining Ring Set 307-588/3

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Fig 155: Compressing Low/Reverse Piston Return Spring
Courtesy of FORD MOTOR CO.
157. Compress the low/reverse piston return spring, install the snap ring and remove the Forward/Intermediate Spring Compressor 307-584/2 and the Reverse Clutch Piston and Retaining Ring Set 307-588/3.
158. Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.
     Fig 156: Location of Sealing Surfaces On Intermediate Clutch Piston

     Courtesy of FORD MOTOR CO.
159. Install the intermediate clutch piston.
     Fig 157: Installing Intermediate Clutch Piston

     Courtesy of FORD MOTOR CO.
160. Install the intermediate clutch piston return spring.
     Fig 158: Installing Intermediate Clutch Piston Return Spring

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Fig 159: Installing Snap Ring Using Press
Courtesy of FORD MOTOR CO.
161. Install the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2. Using a press, compress the intermediate clutch piston return spring, install the snap ring and remove the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2.
162. Remove the Input Shaft Support Seal Installer 307-578/1.
     Fig 160: Removing Input Shaft Support Seal Installer 307-578/1

     Courtesy of FORD MOTOR CO.
163. Lubricate the O-ring seal on the TSS sensor with clean transmission fluid and install the TSS sensor in the cover and install the bolt.
     • Tighten to 12 Nm (106 lb-in).
     Fig 161: Location of TSS Sensor And Bolt

     Courtesy of FORD MOTOR CO.
164. Remove and discard the stator support assembly seal.
     Fig 162: Location of Stator Support Assembly Seal

     Courtesy of FORD MOTOR CO.
165. Install 7/8 Inch to 1 Inch Collet 303-D020 on the input shaft seal.
     Fig 163: Installing Collet 303-D020 On Input Shaft Seal

     Courtesy of FORD MOTOR CO.
166. Assemble Slide Hammer 100-001 and 7/8 Inch to 1 Inch Collet 303-D020 and remove and discard the input shaft seal.
     Fig 164: Removing Input Shaft Seal

     Courtesy of FORD MOTOR CO.
167. Remove the drive sprocket thrust washer.
     Fig 165: Removing Drive Sprocket Thrust Washer

     Courtesy of FORD MOTOR CO.
168. Remove the stator support-to-torque converter seal.
     Fig 166: Removing Stator Support-To-Torque Converter Seal

     Courtesy of FORD MOTOR CO.
NOTE: Note the location of the Torx® head and the hex head bolts for assembly.
Fig 167: Location of Stator Support Feed Tube Bolts
Courtesy of FORD MOTOR CO.
169. Remove the 4 bolts and the stator support feed tube.
170. Remove and discard the gasket for the feed tube assembly.
     Fig 168: Location of Feed Tube Assembly Hole

     Courtesy of FORD MOTOR CO.
171. Clean and inspect the stator support assembly for damage and install new, if necessary.
172. Install the Support Solid Seal Installer 307-579/3 on the stator support assembly.
     Fig 169: Installing Support Solid Seal Installer 307-579/3 On Stator Support Assembly

     Courtesy of FORD MOTOR CO.
173. Install a new seal on the Support Solid Seal Installer 307-579/3.
     Fig 170: Installing Seal On Support Solid Seal Installer 307-579/3

     Courtesy of FORD MOTOR CO.
174. Install the Support Solid Seal Installer 307-579/2 on the Support Solid Seal Installer 307-579/3 and slide the seal in to the groove on the stator support assembly.
     Fig 171: Sliding Seal In To Stator Support Assembly Groove

     Courtesy of FORD MOTOR CO.
175. Remove the Support Solid Seal Installer 307-579 (includes 307-579/2 and 307-579/3) from the stator support assembly.
     Fig 172: Removing Support Solid Seal Installer 307-579 From Stator Support Assembly

     Courtesy of FORD MOTOR CO.
176. Install the Support Solid Seal Installer 307-579/1 on the stator support assembly to size the seal.
     Fig 173: Installing Support Solid Seal Installer 307-579/1 On Stator Support Assembly

     Courtesy of FORD MOTOR CO.
177. Install a new gasket on the stator support assembly.
     Fig 174: Location of Gasket On Stator Support Assembly

     Courtesy of FORD MOTOR CO.
178. Position the stator support feed tube assembly in place and install the bolts hand-tight  .
     Fig 175: Location of Feed Tube Assembly Bolts

     Courtesy of FORD MOTOR CO.
179. Tighten the 2 stator support feed tube Torx® head bolts.
     • Tighten to 7 Nm (62 lb-in).
     Fig 176: Tightening Stator Support Feed Tube Torx Head Bolts

     Courtesy of FORD MOTOR CO.
180. Tighten the 2 stator support feed tube hex-head bolts.
     • Tighten to 12 Nm (106 lb-in).
     Fig 177: Tightening Stator Support Feed Tube Hex-Head Bolts

     Courtesy of FORD MOTOR CO.
181. Install a new input shaft seal on the Support Seal Installer 307-585.
     Fig 178: Location of Support Seal Installer 307-585

     Courtesy of FORD MOTOR CO.
182. Using the Support Seal Installer 307-585, install the input shaft seal.
     Fig 179: Installing Input Shaft Seal Using Support Seal Installer 307-585

     Courtesy of FORD MOTOR CO.
183. Remove the Support Seal Installer 307-579/1 from the stator support assembly.
     Fig 180: Removing Support Seal Installer 307-579/1 From Stator Support Assembly

     Courtesy of FORD MOTOR CO.
184. Install the drive sprocket thrust washer.
     Fig 181: Installing Drive Sprocket Thrust Washer

     Courtesy of FORD MOTOR CO.
185. Install a new stator support assembly seal.
     Fig 182: Location of Stator Support Assembly Seal

     Courtesy of FORD MOTOR CO.
NOTE: The solenoid body should be handled with care or damage to the solenoid body may occur.
NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transaxle will occur if the solenoid body is not correctly aligned.
Fig 183: Location of Solenoid Body Filter Assembly
Courtesy of FORD MOTOR CO.
186. Remove the solenoid body filter assembly by pulling it straight up from the alignment tabs. Discard the filter.
187. Remove and discard the solenoid body assembly electrical connector seal.
     Fig 184: Removing Solenoid Body Assembly Electrical Connector Seal

     Courtesy of FORD MOTOR CO.
188. Clean and inspect the solenoid body assembly for damage and install new if necessary.
     Fig 185: Identifying Solenoid Body Assembly

     Courtesy of FORD MOTOR CO.
189. If replacing the solenoid body, install the replacement service tag on the transaxle case over the current solenoid body strategy tag.
     Fig 186: Location of Replacement Service Tag On Transaxle Case

     Courtesy of FORD MOTOR CO.
190. Install a new solenoid body assembly electrical connector seal.
     Fig 187: Installing Solenoid Body Assembly Electrical Connector Seal

     Courtesy of FORD MOTOR CO.
NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transaxle will occur if the solenoid body is not correctly aligned.
NOTE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transaxle will occur if the filter passages are not clean.
Fig 188: Installing Solenoid Body Filter Assembly
Courtesy of FORD MOTOR CO.
191. Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.
192. Slide the park pawl over and install the park pawl actuator rod.
     Fig 189: Installing Park Pawl Actuator Rod

     Courtesy of FORD MOTOR CO.
193. Lubricate a new manual shaft seal and the Manual Lever Seal Installer 307-581 with petroleum jelly and install the seal on the Manual Lever Seal Installer 307-581.
     Fig 190: Identifying Seal And Manual Lever Seal Installer 307-581

     Courtesy of FORD MOTOR CO.
194. Using the Manual Lever Seal Installer 307-581, install the manual lever shaft seal in the transaxle case.
     Fig 191: Installing Manual Lever Shaft Seal In Transaxle Case Using Manual Lever Seal Installer 307-581

     Courtesy of FORD MOTOR CO.
195. Install the TR sensor.
     1. Position the park pawl actuating rod in the TR sensor detent plate.
     2. Install the TR sensor in the transaxle case.
     Fig 192: Identifying Park Pawl Actuating Rod And TR Sensor

     Courtesy of FORD MOTOR CO.
196. Install a new TR sensor locking pin in the transaxle case.
     Fig 193: Location of TR Sensor Locking Pin

     Courtesy of FORD MOTOR CO.
197. Using the Manual Lever Retaining Pin Installer 307-592, drive the TR sensor locking pin into the transaxle case.
     Fig 194: Installing TR Sensor Locking Pin Into Transaxle Case Using Manual Lever Retaining Pin Installer 307-592

     Courtesy of FORD MOTOR CO.
198. Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.
     Fig 195: Location of O-Ring Seal

     Courtesy of FORD MOTOR CO.
199. Install the transmission fluid reservoir and the 2 bolts.
     • Tighten to 12 Nm (106 lb-in).
     Fig 196: Location of Transmission Fluid Reservoir Bolts

     Courtesy of FORD MOTOR CO.
200. Install a new pump-to-case seal.
     Fig 197: Location of Pump-To-Case Seal

     Courtesy of FORD MOTOR CO.
201. Install the transfer shaft and gear assembly.
     Fig 198: Location of Gear Assembly

     Courtesy of FORD MOTOR CO.
202. Tilt the transfer shaft and gear assembly over and install the differential assembly.
     Fig 199: Installing Differential Assembly

     Courtesy of FORD MOTOR CO.
203. Install a new torque converter hub seal on the Converter Seal Installer 307-575.
     Fig 200: Installing Torque Converter Hub Seal On Converter Seal Installer 307-575

     Courtesy of FORD MOTOR CO.
NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Fig 201: Installing Torque Converter Hub Seal In Torque Converter Housing Using Converter Seal Installer 307-575 And Dead Blow Hammer
Courtesy of FORD MOTOR CO.
204. Using the Converter Seal Installer 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.

     Front Wheel Drive (FWD) vehicles 

205. Assemble the Handle 205-153 on the Cover Axle Seal Installer 307-582A and install a new RH halfshaft seal on Cover Axle Seal Installer 307-582A.
     Fig 202: Assembling Handle 205-153 On Cover Axle Seal Installer 307-582A

     Courtesy of FORD MOTOR CO.
NOTE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.
Fig 203: Installing RH Halfshaft Seal In Torque Converter Housing Using Handle 205-153 And Cover Axle Seal Installer 307-582A
Courtesy of FORD MOTOR CO.
206. Use the Handle 205-153 and the Cover Axle Seal Installer 307-582A. Install the RH halfshaft seal in the torque converter housing.

     All vehicles 

207. Install the pump drive sprocket and driven sprocket thrust washers.
     Fig 204: Location of Pump Drive Sprocket And Driven Sprocket Thrust Washers

     Courtesy of FORD MOTOR CO.
NOTE: The dot on the pump sprocket is installed facing upward.
Fig 205: Location of Pump Sprocket And Chain Assembly
Courtesy of FORD MOTOR CO.
208. Install the pump sprocket and chain assembly.
209. Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
NOTE: Lubricate the seal with clean transmission fluid.
Fig 206: Location of Fluid Filter Seal
Courtesy of FORD MOTOR CO.
210. Install the fluid filter seal in the fluid pump.
NOTE: Install the filter in the correct orientation as noted in removal.
Fig 207: Installing Fluid Filter In Fluid Pump
Courtesy of FORD MOTOR CO.
211. Install the fluid filter in the fluid pump.
212. Position the pump and filter assembly in place and install the 3 bolts.
     • Tighten to 12 Nm (106 lb-in).
     Fig 208: Location of Pump And Filter Assembly Mounting Bolts

     Courtesy of FORD MOTOR CO.
NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Fig 209: Positioning Stator Support Assembly On Torque Converter Housing
Courtesy of FORD MOTOR CO.
213. Position the stator support assembly in place on the torque converter housing.
214. Install the stator support bolts. Tighten in the sequence shown in illustration.
     • Tighten to 41 Nm (30 lb-ft).
     Fig 210: Identifying Stator Support Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
215. Position the differential carrier baffle in place and install the bolt.
     • Tighten to 12 Nm (106 lb-in).
     Fig 211: Location of Differential Carrier Baffle And Bolts

     Courtesy of FORD MOTOR CO.
216. Lubricate the ends of the transaxle fluid tube with petroleum jelly and install it in the transaxle.
     Fig 212: Location of Transaxle Fluid Tube

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the sealing surface of both the transaxle case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transaxle case.
Fig 213: Applying Sealant To Machined Surface Of Transaxle Case
Courtesy of FORD MOTOR CO.
217. Apply a bead of silicone sealant to the machined surface of the transaxle case.
NOTE: Install the 2 studbolts in the correct location as noted during disassembly.
Fig 214: Location of Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
218. Install the torque converter housing on top of the transaxle case and install the bolts.
NOTE: The studbolts are 1 and 16 in the tightening sequence.
Fig 215: Identifying Torque Converter Housing Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
219. Tighten the bolts in the sequence shown in illustration.
     • Tighten to 24 Nm (18 lb-ft).
220. Assemble the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install a new halfshaft seal on Cover Axle Seal Installer 307-582A.
     Fig 216: Installing Halfshaft Seal On Cover Axle Seal Installer 307-582A

     Courtesy of FORD MOTOR CO.
221. Using the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install the halfshaft seal in the transaxle case.
     Fig 217: Installing Halfshaft Seal In Transaxle Case Using Handle 205-153 And Cover Axle Seal Installer 307-582A

     Courtesy of FORD MOTOR CO.
222. Lubricate the forward clutch piston seals with petroleum jelly.
     Fig 218: Location of Forward Clutch Piston Seals

     Courtesy of FORD MOTOR CO.
223. Position the forward clutch piston in place in the transaxle case.
     Fig 219: Location of Forward Clutch Piston Position

     Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Intermediate Spring Compressor 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.
Fig 220: Pushing Forward Clutch Piston Down Into Bore Using Forward/Intermediate Spring Compressor 307-584/1
Courtesy of FORD MOTOR CO.
224. Using the Forward/Intermediate Spring Compressor 307-584/1, push the forward clutch piston down into the bore.
225. Install the forward clutch piston return spring with the tabs facing downward.
     Fig 221: Location of Forward Clutch Piston Return Spring

     Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
Fig 222: Compressing Forward Clutch Piston Return Spring Using Forward Clutch Spring Compressor 307-574 (307-574/1 And 307-574/2)
Courtesy of FORD MOTOR CO.
226. Install the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and compress the forward clutch piston return spring.
NOTE: Forward Clutch Spring Compressor and the Forward/Overdrive Spring Compressor not shown for clarity.
Fig 223: Location of Forward Clutch Piston Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
227. Install the forward clutch piston return spring snap ring.
     • Install the snap ring.
     • The snap ring gap should be at the top of the transaxle case.
228. Remove the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).
     Fig 224: Compressing Forward Clutch Piston Return Spring Using Forward Clutch Spring Compressor 307-574 (307-574/1 And 307-574/2)

     Courtesy of FORD MOTOR CO.
229. Install the forward clutch wave spring.
     Fig 225: Location of Forward Clutch Wave Spring

     Courtesy of FORD MOTOR CO.
230. Lubricate the forward clutch pack in clean transmission fluid.
     Fig 226: Identifying Forward Clutch Pack

     Courtesy of FORD MOTOR CO.
231. Install the forward clutch pack assembly.
     1. Position the forward clutch pack assembly in the case.
     2. Make sure the alignment tab on the clutch pack is positioned in the correct location.
     Fig 227: Identifying Forward Clutch Pack Assembly And Alignment Tab

     Courtesy of FORD MOTOR CO.
232. Install the low OWC.
     Fig 228: Installing Low OWC

     Courtesy of FORD MOTOR CO.
NOTE: The low OWC snap ring gap must be positioned as shown in illustration so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.
Fig 229: Location of Low OWC Snap Ring
Courtesy of FORD MOTOR CO.
233. Install the low OWC snap ring.
234. Compare the position of the low OWC snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
     Fig 230: Location of Low/Reverse Clutch Pressure Plate Tab

     Courtesy of FORD MOTOR CO.
235. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transaxle case and position the plunger on a top friction disc tab.
     Fig 231: Installing Dial Indicator Gauge With Holding Fixture 100-002 On Transaxle Case

     Courtesy of FORD MOTOR CO.
236. Install a new forward clutch feed seal.
     Fig 232: Installing Forward Clutch Feed Seal

     Courtesy of FORD MOTOR CO.
237. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low OWC for correct installation. If the forward clutch pack and low OWC is correctly installed, install a new forward clutch pack.
     Fig 233: Measuring Clutch Pack Clearance

     Courtesy of FORD MOTOR CO.
238. Remove the Dial Indicator Gauge with Holding Fixture 100-002 from the transaxle case.
239. Install the No. 11 stator support thrust bearing.
     Fig 234: Installing No. 11 Support Assembly Thrust Bearing

     Courtesy of FORD MOTOR CO.
240. Install the front planetary carrier hub.
     Fig 235: Location of Front Planetary Carrier Hub Assembly

     Courtesy of FORD MOTOR CO.
241. Install the No. 10 front sun gear thrust bearing.
     Fig 236: Installing No. 10 Front Sun Gear Thrust Bearing

     Courtesy of FORD MOTOR CO.
242. Install the front sun gear and shell assembly.
     Fig 237: Installing Front Planetary Sun Gear And Shell Assembly

     Courtesy of FORD MOTOR CO.
243. Install the front carrier and rear ring gear assembly.
     Fig 238: Installing Front Carrier And Rear Ring Gear Assembly

     Courtesy of FORD MOTOR CO.
244. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
     Fig 239: Installing No. 8 Front/Center Planetary Gear Assembly And No. 7 Center Sun Gear Thrust Bearings

     Courtesy of FORD MOTOR CO.
245. Install the center planetary carrier and front ring gear assembly.
     Fig 240: Installing Center Planetary Carrier And Front Ring Gear Assembly

     Courtesy of FORD MOTOR CO.
NOTE: The groove on the center sun gear is installed facing up.
Fig 241: Installing Center Planetary Sun Gear
Courtesy of FORD MOTOR CO.
246. Install the center planetary sun gear.
247. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
     Fig 242: Installing No. 6 Center Sun Gear And No. 5 Center/Rear Planetary Thrust Bearings

     Courtesy of FORD MOTOR CO.
248. Install the rear planetary gear carrier assembly.
     Fig 243: Installing Rear Planetary Carrier Assembly

     Courtesy of FORD MOTOR CO.
NOTE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low OWC snap ring may result in damage to the transaxle.
Fig 244: Installing Low/Reverse Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
249. Install the low/reverse clutch pressure plate.
     1. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC snap ring.
     2. Install the low/reverse clutch pressure plate.
250. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
     Fig 245: Measuring Depth Of Low/Reverse Clutch Pressure Plate

     Courtesy of FORD MOTOR CO.
251. Lubricate the low/reverse clutch pack with clean transmission fluid.
     Fig 246: Identifying Low/Reverse Clutch Pack

     Courtesy of FORD MOTOR CO.
252. Install the low/reverse clutch pack.
     Fig 247: Location of Low/Reverse Clutch Pack

     Courtesy of FORD MOTOR CO.
253. Install the low/reverse pressure plate.
     Fig 248: Installing Low/Reverse Pressure Plate

     Courtesy of FORD MOTOR CO.
254. Using a straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to the low/reverse pressure plate.
     Fig 249: Measuring Distance From Transaxle Case Deck Surface To Low/Reverse Pressure Plate Using Straightedge And Depth Micrometer 303-D075

     Courtesy of FORD MOTOR CO.
255. Using the same straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.
     Fig 250: Measuring Distance From Low/Reverse Clutch Piston To Cover Assembly Deck Surface Using Straightedge

     Courtesy of FORD MOTOR CO.
256. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 1.01 mm (0.039 in) and 2.47 mm (0.097 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack.

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the low/reverse clutch clearance.

257. Install the intermediate clutch pressure plate.
     Fig 251: Installing Intermediate Clutch Pressure Plate

     Courtesy of FORD MOTOR CO.
258. Lubricate the intermediate clutch pack assembly in clean transmission fluid.
     Fig 252: Identifying Intermediate Clutch Pack Assembly

     Courtesy of FORD MOTOR CO.
259. Install the intermediate clutch pack assembly.
     Fig 253: Location of Intermediate Clutch Pack Assembly

     Courtesy of FORD MOTOR CO.
260. Install the intermediate clutch pack wave spring.
     Fig 254: Installing Intermediate Clutch Pack Wave Spring

     Courtesy of FORD MOTOR CO.
261. Using a straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to a low point on the intermediate clutch wave spring.
     Fig 255: Measuring Distance From Transaxle Case Deck Surface To Intermediate Clutch Wave Spring Using Straightedge

     Courtesy of FORD MOTOR CO.
262. Using the straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.
     Fig 256: Measuring Distance From Intermediate Clutch Piston To Cover Assembly Deck Surface Using Straightedge

     Courtesy of FORD MOTOR CO.
263. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.038 in) and 2.56 mm (0.1 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the intermediate clutch clearance.

264. Install the rear sun gear and shell assembly.
     Fig 257: Installing Rear Sun Gear And Shell Assembly

     Courtesy of FORD MOTOR CO.
265. Install the No. 3 rear sun gear thrust bearing.
     Fig 258: Installing No. 3 Rear Sun Gear Thrust Bearing

     Courtesy of FORD MOTOR CO.
266. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
     Fig 259: Installing No. 1 Thrust Bearing On Overdrive/Direct Clutch Assembly

     Courtesy of FORD MOTOR CO.
267. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 or a dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
     Fig 260: Checking Clutch Pack Clearance Using Dial Indicator

     Courtesy of FORD MOTOR CO.
268. Position the Dial Indicator Gauge with Holding Fixture 100-002 on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
     Fig 261: Measuring Clutch Pack Clearance Using Dial Indicator

     Courtesy of FORD MOTOR CO.
269. Install the overdrive/direct clutch hub and turbine shaft assembly.
     Fig 262: Installing Overdrive/Direct Clutch Hub And Turbine Shaft Assembly

     Courtesy of FORD MOTOR CO.
270. Install the No. 1 cover assembly thrust bearing.
     Fig 263: Installing No. 1 Cover Assembly Thrust Bearing

     Courtesy of FORD MOTOR CO.
271. Install the cover assembly gasket.
     Fig 264: Location of Cover Assembly Gasket

     Courtesy of FORD MOTOR CO.
272. Route the TSS sensor harness through the transaxle case to the valve body area and install the cover assembly.
     Fig 265: Installing Cover Assembly

     Courtesy of FORD MOTOR CO.
273. Install the cover assembly bolts and tighten the bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
     Fig 266: Identifying Cover Assembly Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
274. Install the OSS sensor and the bolt.
     • Tighten to 12 Nm (106 lb-in).
     Fig 267: Tightening Output Shaft Speed (OSS) Sensor Bolt

     Courtesy of FORD MOTOR CO.
NOTE: Be careful not to pinch the TSS, OSS or TR sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.
NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Fig 268: Identifying Manual Pin And Valve
Courtesy of FORD MOTOR CO.
275. Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.
     1. Manual pin
     2. Manual valve
276. Install the main control valve body bolts. Tighten the bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
     Fig 269: Identifying Main Control Valve Body Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
NOTE: Make sure not to pinch the TSS, OSS or TR sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
NOTE: Install the different length bolts in the locations noted during disassembly.
Fig 270: Identifying Solenoid Body Bolts with Tightening Sequence
Courtesy of FORD MOTOR CO.
277. Install the solenoid body bolts hand-tight.
     1. 42 mm (1.653 in) bolt
     2. 63 mm (2.48 in) bolts
     3. 80 mm (3.149 in) bolts
     4. 95 mm (3.74 in) bolts
278. Tighten the solenoid body bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
     Fig 271: Identifying Solenoid Body Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
279. Route the OSS sensor wiring harness into the retainer.
     Fig 272: Location of OSS Sensor Wire

     Courtesy of FORD MOTOR CO.
280. Connect the TSS and OSS sensor electrical connectors.
     Fig 273: Location of TSS And OSS Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
281. Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
     Fig 274: Location of TR Sensor Electrical Connector Lock Tab

     Courtesy of FORD MOTOR CO.
282. Inspect the transaxle main control cover seal for damage and install new if necessary.
     Fig 275: Location of Transaxle Main Control Cover Seal

     Courtesy of FORD MOTOR CO.
NOTE: Install the studbolts in the locations noted during disassembly.
Fig 276: Identifying Transaxle Main Control Cover Bolts And Studbolts
Courtesy of FORD MOTOR CO.
283. Install the transaxle main control cover and install the bolts.
     1. Bolt location
     2. Studbolt location
284. Tighten the main control cover bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
     Fig 277: Identifying Main Control Cover Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
Fig 278: Installing Torque Converter In Transaxle
Courtesy of FORD MOTOR CO.
285. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transaxle.
286. Remove the bolts from the torque converter.
     Fig 279: Location of Torque Converter Bolts

     Courtesy of FORD MOTOR CO.
287. Install the Torque Converter Retainer 307-346.

Fig 280: Identifying Torque Converter Retainer 307-346

Courtesy of FORD MOTOR CO.