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Disassembly & Assembly

WARNING: This page is about a different car, the 2005 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Using the special tools, remove the torque converter.
    Fig 1: Removing Torque Converter
    G03929273Courtesy of FORD MOTOR CO.
    2. NOTE: The transmission fluid pan, gasket, filter and magnets are serviced as a complete unit.
    Fig 2: Removing Transmission Fluid Pan Assembly
    G03929134Courtesy of FORD MOTOR CO.
  2. Remove and discard the transmission fluid pan assembly.
  3. Press the release tab and lift up on the bulkhead connector retainer.
    Fig 3: Pressing Release Tab
    G03929275Courtesy of FORD MOTOR CO.
  4. With the release tab up, pull the outer shell of the bulkhead electrical connector.
    Fig 4: Pulling Outer Shell Of Bulkhead Electrical Connector
    G03929276Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 5: Pulling Outer Shell Of Bulkhead Electrical Connector
    G03929277Courtesy of FORD MOTOR CO.
  5. Pull the outer shell of the bulkhead electrical connector out of the transmission.
  6. Remove the 10 bolts from the mechatronic assembly.
    Fig 6: Removing Bolts From Mechatronic Assembly
    G03929278Courtesy of FORD MOTOR CO.
  7. Remove the mechatronic assembly.
    Fig 7: Removing Mechatronic Assembly
    G03929279Courtesy of FORD MOTOR CO.
  8. Remove the rubber adapter and the fluid filter seal.
    Fig 8: Removing Rubber Adapter And Fluid Filter Seal
    G03929280Courtesy of FORD MOTOR CO.
  9. Remove and discard the 4 rubber feed tubes for the center support. Note the size and location while removing for correct installation.
    Fig 9: Removing Rubber Feed Tubes
    G03929281Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove and discard the front pump seal.
    Fig 10: Removing Front Pump Seal
    G03929282Courtesy of FORD MOTOR CO.
  11. Remove and discard the front pump bolts.
    Fig 11: Removing Front Pump Bolts
    G03929283Courtesy of FORD MOTOR CO.
  12. Using the special tools, remove the front pump support. Make sure that the selective shim is on the back side of the pump.
    Fig 12: Removing Front Pump Support
    G03929284Courtesy of FORD MOTOR CO.
  13. Remove the forward (clutch A)/overdrive (clutch E) clutch assembly.
    Fig 13: Removing Forward (Clutch A)/Overdrive Clutch Assembly
    G03929285Courtesy of FORD MOTOR CO.
  14. Remove the roller bearing.
    Fig 14: Removing Roller Bearing
    G03929286Courtesy of FORD MOTOR CO.
  15. Remove the direct clutch assembly.
    Fig 15: Removing Direct Clutch Assembly
    G03929287Courtesy of FORD MOTOR CO.
  16. Using the special tool, remove the center support snap ring.
    Fig 16: Removing Center Support Snap Ring
    G03929288Courtesy of FORD MOTOR CO.
  17. Remove the center support.
    Fig 17: Removing Center Support
    G03929289Courtesy of FORD MOTOR CO.
    18. NOTE: When removing the planet carrier and the low/reverse clutch pack, some of the clutch plates may stay in the case. Try to keep all the clutches together.
    Fig 18: Removing Planet Carrier
    G03929290Courtesy of FORD MOTOR CO.
  18. Remove the planet carrier and the low/reverse clutch pack as an assembly.
  19. Remove the low/reverse bearing race.
    Fig 19: Removing Low/Reverse Bearing Race
    G03929291Courtesy of FORD MOTOR CO.
  20. Remove the low/reverse sun gear.
    Fig 20: Removing Low/Reverse Sun Gear
    G03929292Courtesy of FORD MOTOR CO.
    21. NOTE: When removing the sun gear, take note that the taper edge is facing up toward the torque converter housing.
    Fig 21: Removing Sun Gear Into Planet Assembly
    G03929293Courtesy of FORD MOTOR CO.
  21. Remove the sun gear into the planet assembly.
  22. Remove the top and the bottom roller bearings from the sun gear.
    Fig 22: Removing Top And Bottom Roller Bearings From Sun Gear
    G03929294Courtesy of FORD MOTOR CO.
  23. Remove the roller bearing race in the bottom of the carrier.
    Fig 23: Removing Roller Bearing Race In Bottom Of Carrier
    G03929295Courtesy of FORD MOTOR CO.
  24. Remove the washer.
    Fig 24: Removing Washer
    G03929296Courtesy of FORD MOTOR CO.

    25. 4x2 vehicles 

  25. Remove and discard the output shaft flange nut.
    Fig 25: Removing Output Shaft Flange Nut
    G03929297Courtesy of FORD MOTOR CO.
  26. Remove the output shaft flange.
    Fig 26: Removing Output Shaft Flange
    G03929298Courtesy of FORD MOTOR CO.
  27. Remove the planet carrier hub and output shaft assembly.
    Fig 27: Removing Planet Carrier Hub & Output Shaft Assembly
    G03929299Courtesy of FORD MOTOR CO.
  28. Remove the 4 bolts and remove the transmission support bracket.
    Fig 28: Removing Transmission Support Bracket
    G03929300Courtesy of FORD MOTOR CO.
  29. Remove the output shaft seal.
    Fig 29: Removing Output Shaft Seal
    G03929301Courtesy of FORD MOTOR CO.
  30. Remove the anti-click washer.
    Fig 30: Removing Anti-Click Washer
    G03929302Courtesy of FORD MOTOR CO.
    31. NOTE: 4x4 case shown, 4x2 case similar.
    Fig 31: Removing Snap Ring From Case
    G03929303Courtesy of FORD MOTOR CO.
  31. Remove the snap ring from the case.
    32. NOTE: 4x4 case shown, 4x2 case similar.
    Fig 32: Removing Roller Bearing
    G03929304Courtesy of FORD MOTOR CO.
  32. Using the special tools, remove the roller bearing.
  33. Using a small pick, remove the snap ring.
    Fig 33: Removing Snap Ring
    G03929305Courtesy of FORD MOTOR CO.
    34. CAUTION: Use care when installing the special tool. Look inside the transmission case to make sure that the tool contacts the bearing only and not the lip of the case, or damage to the case will result.
    Fig 34: Removing Bearing Assembly
    G03929306Courtesy of FORD MOTOR CO.
  34. Using the special tool, remove the bearing assembly.

    35. 4x4 vehicles 

  35. Remove the planet carrier hub and output shaft assembly.
    Fig 35: Removing Planet Carrier Hub & Output Shaft Assembly
    G03929299Courtesy of FORD MOTOR CO.
  36. Remove the 11 bolts and the extension housing.
    Fig 36: Removing Bolts & Extension Housing
    G03929157Courtesy of FORD MOTOR CO.
  37. Remove and discard the output shaft seal.
    Fig 37: Discarding Output Shaft Seal
    G03929309Courtesy of FORD MOTOR CO.
  38. Remove the anti-click washer.
    Fig 38: Removing Anti-Click Washer
    G03929302Courtesy of FORD MOTOR CO.
  39. Remove the snap ring from the case.
    Fig 39: Removing Snap Ring From Case
    G03929311Courtesy of FORD MOTOR CO.
  40. Using the special tools, remove the bearing spacer.
    Fig 40: Removing Bearing Spacer
    G03929312Courtesy of FORD MOTOR CO.
  41. Using a small pick, remove the snap ring.
    Fig 41: Removing Snap Ring
    G03929305Courtesy of FORD MOTOR CO.
    42. CAUTION: Use care when installing the special tool. Look inside the transmission case to make sure that the tool contacts the bearing only and not the lip of the case, or damage to the case will result.
    Fig 42: Removing Bearing Assembly
    G03929306Courtesy of FORD MOTOR CO.
  42. Using the special tool, remove the bearing assembly.

    43. All vehicles 

  43. Remove the park rod actuating plate.
    Fig 43: Removing Park Rod Actuating Plate
    G03929180Courtesy of FORD MOTOR CO.
  44. Remove the manual control lever.
    1. Remove the roll pin.
    2. Slide the manual control lever shaft out of the case.
    3. Hold the spacer to keep it from falling into the case.
    4. Remove the manual valve inner lever and the park rod as an assembly.
    Fig 44: Removing Manual Control Lever
    G03929316Courtesy of FORD MOTOR CO.
  45. Remove and discard the manual control lever seal.
    Fig 45: Removing Manual Control Lever Seal
    G03929182Courtesy of FORD MOTOR CO.
  46. Remove the bolt from the back of the case to gain access to the park pawl pin.
    Fig 46: Removing Bolt From Back Of Case
    G03929318Courtesy of FORD MOTOR CO.
  47. From inside the case, push the park pawl pin out toward the back side of the case, while holding the spring and the park pawl. Remove the park pawl pin, then remove the park pawl and spring.
    Fig 47: Removing Park Pawl Pin, Park Pawl & Spring
    G03929319Courtesy of FORD MOTOR CO.
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