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Section 484 (Automatic Transmission): Assembly: Transmission: Assembly

WARNING: This page is about a different car, the 2004 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Before beginning assembly, carry out and inspect the following:

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. The necessary torques can be found in the GENERAL SPECIFICATIONS .

When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.


Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.
  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
      Fig 1: Installing Rear Case Bushing
      G03249150Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    Fig 2: Installing No. 9 Case Rear Bearing
    G03249151Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown. Internal damage and shift problems may occur.
    Fig 3: Installing Output Shaft And Output Shaft Ring Gear
    G03249152Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 4: Installing No. 8 Bearing
    G03249153Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 5: Installing Direct Clutch
    G03249154Courtesy of FORD MOTOR CO.
    7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
    Fig 6: Installing Reverse Band Support Retaining Ring
    G03249155Courtesy of FORD MOTOR CO.
  7. Install the reverse band support retaining ring.
    8. NOTE: Make sure the band is seated on the anchor pins.
    Fig 7: Installing Reverse Band
    G03249156Courtesy of FORD MOTOR CO.
  8. Install the reverse band.
    9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
      Fig 8: Installing Planetary Assembly And Planetary Gear Support
      G03249157Courtesy of FORD MOTOR CO.
    10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
    Fig 9: Installing Case To Planet Support Spring
    G03249158Courtesy of FORD MOTOR CO.
  10. Install the case to the planet support spring located at the 1 o'clock position.
    11. NOTE: When installing the center support retaining ring, the opening should be toward the hole in the case where the turbine shaft speed (TSS) sensor would go.
    Fig 10: Installing Center Support Retaining Ring
    G03249159Courtesy of FORD MOTOR CO.
  11. Install the center support retaining ring.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear two piece bearing and the reverse sun gear.
    Fig 11: Installing Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear & Reverse Sun Gear
    G03249160Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 12: Installing No. 4 Forward Clutch Hub Bearing
    G03249161Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 13: Installing Intermediate Stub Shaft
    G03249162Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 14: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G03249163Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 15: Installing Forward Clutch Assembly
    G03249164Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
      Fig 16: Installing Reverse Clutch Cylinder Assembly
      G03249165Courtesy of FORD MOTOR CO.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
      Fig 17: Installing Overdrive Band
      G03249166Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
      Fig 18: Installing Overdrive Servo Spring
      G03249167Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 19: Verifying Tip Of Piston Assembly Engages Pocket Of Overdrive Band
    G03249168Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 20: Installing Overdrive Servo Retaining Ring
    G03249169Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 21: Installing Intermediate Clutch Pressure Plate
    G03249170Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid.
    Fig 22: Installing Intermediate Clutch Pack And Selective Steel Plate
    G03249171Courtesy of FORD MOTOR CO.
  23. Install the intermediate clutch pack and selective steel plate.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

    SELECTIVE STEEL PLATES SPECIFICATION CHART

    Specification
    1.80-1.70 mm (0.071-0.067 inch)
    2.05-1.95 mm (0.081-0.077 inch)
    2.31-2.20 mm (0.091-0.087 inch)
    2.56-2.46 mm (0.101-0.097 inch)
    Fig 23: Checking Intermediate Clutch Clearance
    G03249172Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure end clearance for the No.1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

      Use the No.1 thrust washer chart to select the correct washer.

    NO.1 THRUST WASHER CHART

    Depth Thickness Color Code
    37.706 -38.184 mm (1.485-1.503 inch) 1.270-1.372 mm (0.050-0.054 inch) Green
    38.185 -38.641 mm (1.504-1.521 inch) 1.727-1.829 mm (0.068-0.072 inch) Yellow
    38.642 -39.073 mm (1.522-1.538 inch) 2.159-2.261 mm (0.085-0.089 inch) Natural
    39.074 -39.505 mm (1.539-1.555 inch) 2.591-2.692 mm (0.102-0.106 inch) Red
    39.506 -40.165 mm (1.556-1.581 inch) 3.023-3.124 mm (0.119-0.123 inch) Blue
    Fig 24: Measuring End Clearance For Front Pump Thrust Washer
    G03249173Courtesy of FORD MOTOR CO.
  26. Install the intermediate anti-rattle clip, if equipped.
    Fig 25: Installing Intermediate Anti-Rattle Clip
    G03249174Courtesy of FORD MOTOR CO.
  27. Install the intermediate clutch return spring support with the lip facing upward and place the wave spring on the retainer.
  28. Install the No.1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
      Fig 26: Installing No. 1 Front Pump Support Thrust Washer
      G03249175Courtesy of FORD MOTOR CO.
    29. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 27: Installing Alignment Pin To Top Of Case
    G03249176Courtesy of FORD MOTOR CO.
  29. Install an alignment pin at the top of the case.
    30. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  30. Install the pump gasket.
    31. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 28: Installing Pump Assembly
    G03249177Courtesy of FORD MOTOR CO.
  31. Install the pump assembly.
  32. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
    Fig 29: Installing Front Pump Bolts
    G03249178Courtesy of FORD MOTOR CO.
  33. Rotate the transmission to the horizontal position.
  34. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
      Fig 30: Installing Parking Pawl
      G03249179Courtesy of FORD MOTOR CO.
  35. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
      Fig 31: Installing Extension Housing
      G03249180Courtesy of FORD MOTOR CO.
    36. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the six o'clock position.
    Fig 32: Installing Extension Housing Seal
    G03249181Courtesy of FORD MOTOR CO.
  36. Using the special tool, install a new extension housing seal.
  37. Install the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor plug.
    1. Install the OSS speed sensor.
    2. Install the OSS speed sensor bolt.
    3. Install the TSS speed sensor plug.
    4. Install the TSS speed sensor plug bolt.
      Fig 33: Installing Output Shaft Speed (OSS) Sensor And Turbine Shaft Speed (TSS) Sensor Plug
      G03249182Courtesy of FORD MOTOR CO.
  38. Using the special tool, install the manual control lever seal.
    Fig 34: Installing Manual Control Lever Seal
    G03249183Courtesy of FORD MOTOR CO.
    39. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
    Fig 35: Installing EPC Solenoid Into Case
    G03249184Courtesy of FORD MOTOR CO.
  39. Lubricate the EPC solenoid and install it into the case.
  40. Install the manual valve detent lever and parking lever actuating rod.
    Fig 36: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod
    G03249185Courtesy of FORD MOTOR CO.
  41. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
      Fig 37: Installing Manual Control Lever Shaft
      G03249186Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the inner and outer lower 1-2 accumulator spring.
    4. Install the 1-2 accumulator cover and seal.
      Fig 38: Installing 1-2 Accumulator Piston Assembly
      G03249187Courtesy of FORD MOTOR CO.
  43. Install the 1-2 accumulator retaining ring.
    Fig 39: Installing 1-2 Accumulator Retaining Ring
    G03249188Courtesy of FORD MOTOR CO.
    44. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
    NOTE: Do not install the reverse servo piston cover and seal at this time.
    Fig 40: Installing Reverse Servo Piston And Rod Assembly
    G03249189Courtesy of FORD MOTOR CO.
  44. Install the reverse servo piston and rod assembly.
  45. Install the special tool.
    • Tighten the bolt.
      Fig 41: Installing Special Tool
      G03249190Courtesy of FORD MOTOR CO.
  46. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
      Fig 42: Installing Special Tool
      G03249191Courtesy of FORD MOTOR CO.
  47. Loosen the bolt until the piston stops against the tool.
    Fig 43: Loosening Special Tool Bolt
    G03249192Courtesy of FORD MOTOR CO.
  48. Verify that the amount of piston travel on the dial indicator is within specification.
    Fig 44: Checking Amount Of Piston Travel On Dial Indicator
    G03249193Courtesy of FORD MOTOR CO.
  49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
      Fig 45: Identifying Servo Assembly Specifications
      G03249194Courtesy of FORD MOTOR CO.
  50. Remove the special tools.
    Fig 46: Removing Special Tools
    G03249195Courtesy of FORD MOTOR CO.
  51. Install the reverse servo assembly.
    1. Install the rod.
    2. Install the piston assembly.
    3. Install the reverse servo piston cover and seal.
      Fig 47: Installing Reverse Servo Assembly
      G03249196Courtesy of FORD MOTOR CO.
  52. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
      Fig 48: Installing Reverse Band Servo Retaining Ring
      G03249197Courtesy of FORD MOTOR CO.
  53. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
      Fig 49: Installing 2-3 Accumulator Assembly
      G03249198Courtesy of FORD MOTOR CO.
  54. Using the special tools, apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 50: Applying Regulated Air Pressure To Test Ports
    G03249199Courtesy of FORD MOTOR CO.
    55. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 51: Installing Electrical Connector Into Case
    G03249200Courtesy of FORD MOTOR CO.
  55. Install the electrical connector into the case.
    56. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 52: Positioning Main Control Valve Body
    G03249201Courtesy of FORD MOTOR CO.
  56. Align the main control valve body alignment bolts and position the main control valve body.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 53: Installing Main Control Valve Body Bolts
    G03249202Courtesy of FORD MOTOR CO.
  57. Loosely install the 11 long main control valve body bolts.
    58. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 54: Installing Short Main Control Valve Body Bolts
    G03249203Courtesy of FORD MOTOR CO.
  58. Loosely install the 12 short main control valve body bolts.
  59. Install the EPC solenoid bracket and loosely install the bolt.
    Fig 55: Installing EPC Solenoid Bracket
    G03249204Courtesy of FORD MOTOR CO.
  60. Install the manual control valve detent lever spring and loosely install the bolt.
    Fig 56: Installing Manual Control Valve Detent Lever Bolts
    G03249205Courtesy of FORD MOTOR CO.
  61. Tighten the bolts in the sequence shown.
    Fig 57: Identifying Main Control Valve Body Bolts Tightening Sequence
    G03249206Courtesy of FORD MOTOR CO.
  62. Inspect the lead frame for damage.
    • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
      Fig 58: Inspecting Lead Frame For Damage
      G03249207Courtesy of FORD MOTOR CO.
  63. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
      Fig 59: Connecting Molded Lead Frame To Solenoids
      G03249208Courtesy of FORD MOTOR CO.
  64. Install the fluid filter and seal assembly.
    Fig 60: Installing Fluid Filter And Seal Assembly
    G03249209Courtesy of FORD MOTOR CO.
  65. Position the pan magnet into the transmission fluid pan.
    Fig 61: Positioning Pan Magnet Into Transmission Fluid Pan
    G03249210Courtesy of FORD MOTOR CO.
    66. NOTE: The pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
    Fig 62: Installing Fluid Pan
    G03249211Courtesy of FORD MOTOR CO.
  66. Install the fluid pan.
    1. Position the transmission fluid pan and gasket.
    2. Install the transmission fluid pan bolts.
  67. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
      Fig 63: Installing Digital Transmission Range (TR) Sensor
      G03249212Courtesy of FORD MOTOR CO.
    68. NOTE: The tool is designed to fit snugly.
    NOTE: Manual shift lever must be in the NEUTRAL position.
    Fig 64: Aligning Digital TR Sensor Slots
    G03249213Courtesy of FORD MOTOR CO.
  68. Using the special tool, align the digital TR sensor slots.
    69. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    Fig 65: Tightening Digital TR Sensor Screws
    G03249214Courtesy of FORD MOTOR CO.
  69. Tighten the screws in an alternating sequence.
  70. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 66: Identifying Converter Hub
    G03249215Courtesy of FORD MOTOR CO.
    71. WARNING: The torque converter can fall out if the transmission is tipped.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
    Fig 67: Installing Torque Converter
    G03249216Courtesy of FORD MOTOR CO.
  71. Using the special tools, install the torque converter.
  72. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 68: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G03249217Courtesy of FORD MOTOR CO.
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