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Section 474 (Automatic Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2004 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G02783864Courtesy of FORD MOTOR CO.
NOTE: Refer to DISASSEMBLED VIEWS  for component location and orientation.
  1. Using the special tools, remove the torque converter from the transmission.
    Fig 2: Removing Torque Converter
    G02783865Courtesy of FORD MOTOR CO.
    2. CAUTION: The turbine shaft speed sensor (TSS) must be removed or damage to the sensors will occur.
    Fig 3: Removing Turbine Shaft Sensor (TSS)
    G02783866Courtesy of FORD MOTOR CO.
  2. Remove the turbine shaft sensor (TSS).
    1. Remove the bolt.
    2. Remove the turbine shaft sensor (TSS).
    3. CAUTION: The output shaft speed sensor (OSS) will need to be removed or damage to the sensors will occur.
    Fig 4: Removing Output Speed Sensor (OSS)
    G02783867Courtesy of FORD MOTOR CO.
  3. Remove the output shaft speed sensor (OSS).
    1. Remove the bolt.
    2. Remove the output shaft speed sensor (OSS).
  4. Mount the transmission to a suitable stand.
    5. CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.
    Fig 5: Removing Input Shaft
    G02783868Courtesy of FORD MOTOR CO.
  5. Remove the input shaft.
    6. CAUTION: The sealing washers may fall off the cooler line case fittings.
    NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
    Fig 6: Removing Cooler Bypass Valve
    G02783869Courtesy of FORD MOTOR CO.
  6. Remove the cooler bypass valve.
    1. Remove the cooler line case fittings.
    2. Remove the cooler bypass valve.
  7. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the transmission range (TR) sensor.
    Fig 7: Removing Transmission Range (TR) Sensor
    G02783870Courtesy of FORD MOTOR CO.
    8. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 8: Removing Fluid Pan & Gasket
    G02783871Courtesy of FORD MOTOR CO.
  8. Remove the transmission fluid pan and the gasket.
    9. CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
    NOTE: After removal, discard the filter and seal assembly.
    Fig 9: Removing Filter & Seal Assembly
    G02783872Courtesy of FORD MOTOR CO.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
  10. Remove the bolts, nuts and the accumulator body.
    Fig 10: Removing Accumulator Body
    G02783873Courtesy of FORD MOTOR CO.
    11. NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
    Fig 11: Removing Main Control Valve Body
    G02783874Courtesy of FORD MOTOR CO.
  11. Remove the main control valve body.
    1. Do not remove the two lower-to-upper main control valve body assembly bolts.
  12. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 12: Removing Solenoid Body Assembly
    G02783875Courtesy of FORD MOTOR CO.
  13. Remove the solenoid screen assembly by rotating and pulling.
    Fig 13: Removing Solenoid Screen Assembly
    G02783876Courtesy of FORD MOTOR CO.
    14. CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
    Fig 14: Removing Separator Plate Reinforcing Plate & Valve Body Separator Plate
    G02783877Courtesy of FORD MOTOR CO.
  14. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
    15. NOTE: The steel EPC check ball has a 0.5 mm (0.02 in) diameter and is smaller than the other check balls.
    Fig 15: Removing Steel EPC Check Ball & Spring
    G02783878Courtesy of FORD MOTOR CO.
  15. Remove the steel EPC check ball and spring.
    16. CAUTION: Use care not to damage the rubber check balls. Transmission shift problems can occur.
    Fig 16: Removing Rubber Check Balls
    G02783879Courtesy of FORD MOTOR CO.
  16. Using a small screwdriver, carefully remove the eight rubber check balls.
  17. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 17: Locating Intermediate Band Servo Assembly Piston
    G02783880Courtesy of FORD MOTOR CO.
    18. CAUTION: After removal, discard the feedbolts. The bolts will not retain torque specification if reused.
    Fig 18: Removing Feedbolts
    G02783881Courtesy of FORD MOTOR CO.
  18. Remove and discard the feedbolts.
  19. Remove the pump bolts and discard the washers.
    Fig 19: Removing Pump Bolts
    G02783882Courtesy of FORD MOTOR CO.
    20. NOTE: The special tools should be installed into the pump threaded holes as shown.
    Fig 20: Removing Pump
    G02783883Courtesy of FORD MOTOR CO.
  20. Using the special tools, remove the pump.
    21. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
    Fig 21: Removing No. 1 Pump Thrust Washer
    G02783884Courtesy of FORD MOTOR CO.
  21. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
    22. CAUTION: The coast clutch, overdrive ring gear, centershaft assembly must be removed as an assembly, using special service tool or damage to the overdrive one-way clutch can occur.
    Fig 22: Removing Coast Clutch, Overdrive Ring Gear & Centershaft Assembly
    G02783885Courtesy of FORD MOTOR CO.
  22. Using the special tool remove the coast clutch, overdrive ring gear, centershaft assembly.
    23. NOTE: The No. 5 thrust bearing may remaining on the center shaft or the center support.
    Fig 23: Removing No. 5 Overdrive Center Shaft Thrust Bearing Assembly
    G02783886Courtesy of FORD MOTOR CO.
  23. Remove the No. 5 overdrive center shaft thrust bearing assembly.
  24. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 24: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring
    G02783887Courtesy of FORD MOTOR CO.
    25. NOTE: Tag the parts for identification during installation.
    Fig 25: Removing Overdrive Clutch Pressure Plate
    G02783888Courtesy of FORD MOTOR CO.
  25. Remove the overdrive clutch pressure plate and the clutch pack.
  26. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 26: Removing Intermediate/Overdrive Cylinder Retaining Ring
    G02783889Courtesy of FORD MOTOR CO.
    27. CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
    Fig 27: Removing Intermediate/Overdrive Cylinder Assembly
    G02783890Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/overdrive cylinder assembly.
  28. Remove the intermediate clutch piston return spring.
    Fig 28: Removing Intermediate Clutch Piston Return Spring
    G02783891Courtesy of FORD MOTOR CO.
    29. CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.
    Fig 29: Removing Center Support Assembly
    G02783892Courtesy of FORD MOTOR CO.
  29. Carefully remove the center support assembly.
  30. Remove the No. 6 center support thrust washer.
    Fig 30: Removing No. 6 Center Support Thrust Washer
    G02783893Courtesy of FORD MOTOR CO.
    31. NOTE: Tag the parts for identification during installation.
    Fig 31: Removing Intermediate Clutch Rear Pressure Plate
    G02783894Courtesy of FORD MOTOR CO.
  31. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate.
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
  32. Remove the intermediate band.
    Fig 32: Removing Intermediate Band
    G02783895Courtesy of FORD MOTOR CO.
    33. NOTE: When installing the special tool, each leg of the tool must be rotated separately to engage notches on the input shell prior to tightening the top cross bar.
    Fig 33: Removing Direct Clutch, Forward Clutch & Input Shell
    G02783896Courtesy of FORD MOTOR CO.
  33. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
  34. Remove the reverse planet retaining ring.
    Fig 34: Removing Reverse Planet Retaining Ring
    G02783897Courtesy of FORD MOTOR CO.
  35. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 35: Removing Reverse Planet Assembly, No. 10B, & No. 11 Reverse Planet Carrier Thrust Washers
    G02783898Courtesy of FORD MOTOR CO.
    36. WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
    Fig 36: Removing Output Shaft Retaining Ring
    G02783899Courtesy of FORD MOTOR CO.
  36. Remove the output shaft retaining ring.
  37. Remove the output shaft ring gear and hub assembly.
    Fig 37: Removing Output Shaft Ring Gear & Hub Assembly
    G02783900Courtesy of FORD MOTOR CO.
    38. WARNING: Use care not to drop the output shaft while rotating the transmission.
    Fig 38: Removing Reverse Clutch Pack, Reverse Clutch Hub, & Low/Reverse One Way Clutch Assembly
    G02783901Courtesy of FORD MOTOR CO.
  38. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
  39. Using the special tools, remove the extension housing seal.
    Fig 39: Removing Extension Housing Seal
    G02783902Courtesy of FORD MOTOR CO.
  40. Using the special tool, remove the extension housing bushing.
    Fig 40: Removing Extension Housing Bushing
    G02783903Courtesy of FORD MOTOR CO.
  41. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 41: Removing Extension Housing Bolts
    G02783904Courtesy of FORD MOTOR CO.
    42. NOTE: Be sure not to damage the output shaft drive sprocket speed sensor wheel or the park gear.
    NOTE: The parking gear and output shaft drive sprocket speed sensor wheel are a press fit to the output shaft.
    Fig 42: Removing Output Shaft
    G02783905Courtesy of FORD MOTOR CO.
  42. Remove the output shaft.
  43. Remove the No. 13 thrust bearing.
    Fig 43: Removing No. 13 Thrust Bearing
    G02783906Courtesy of FORD MOTOR CO.
  44. Remove the plastic orifice lube plug form the rear of the case and discard.
    Fig 44: Removing Plastic Orifice Lube Plug
    G02783907Courtesy of FORD MOTOR CO.
  45. Remove the five bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 45: Removing Bolts
    G02783908Courtesy of FORD MOTOR CO.
  46. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 46: Removing Low/Reverse One-Way Clutch Inner Race & Reverse Clutch Return Spring Assembly
    G02783909Courtesy of FORD MOTOR CO.
  47. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to retain the reverse clutch piston.
    Fig 47: Reinstalling Reverse Clutch Pressure Plate & Reverse Clutch Pressure Plate Retainer Snap Ring
    G02783910Courtesy of FORD MOTOR CO.
  48. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 48: Blowing Out Reverse Clutch Piston Against Reverse Clutch Pressure Plate
    G02783911Courtesy of FORD MOTOR CO.
  49. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 49: Removing Reverse Clutch Pressure Plate Retainer Snap Ring, Reverse Clutch Pressure Plate & Reverse Clutch Piston
    G02783912Courtesy of FORD MOTOR CO.
  50. If required, remove the parking rod guide plate.
    Fig 50: Removing Parking Rod Guide Plate
    G02783913Courtesy of FORD MOTOR CO.
  51. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
    Fig 51: Removing Parking Pawl
    G02783914Courtesy of FORD MOTOR CO.
    52. CAUTION: The Torx® -head screw has a threadlocking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.
    Fig 52: Removing Parking Pawl Abutment
    G02783915Courtesy of FORD MOTOR CO.
  52. If required, remove the parking pawl abutment.
    53. NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
    Fig 53: Removing Manual Lever Shaft Retaining Pin
    G02783916Courtesy of FORD MOTOR CO.
  53. Using the special tool, remove the manual lever shaft retaining pin.
    54. CAUTION: Use care not to damage the manual control lever bore.
    NOTE: The manual control lever and manual control lever shaft are one piece.
    Fig 54: Removing Manual Control Lever Shaft Assembly
    G02783917Courtesy of FORD MOTOR CO.
  54. Remove the manual control lever shaft assembly.
      NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
  55. Using the special tool, remove the manual control lever seal.
    Fig 55: Removing Manual Control Lever Seal
    G02783918Courtesy of FORD MOTOR CO.
    56. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 56: Removing Short Fluid Inlet Tube
    G02783919Courtesy of FORD MOTOR CO.
  56. If required, remove the short fluid inlet tube.
  57. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
  58. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
  59. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the helicoil kit.
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