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Section 81 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different car, the 2008 Ford Expedition EL and 2008 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0022683Courtesy of FORD MOTOR CO.
 Aligner, Valve Body 307-334 (T95L-70010-C)
GF0000024Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0017679Courtesy of FORD MOTOR CO.
 End Play Gauge, Transmission 307-534
GF0001106Courtesy of FORD MOTOR CO.
 Handle, Driver 205-153 (T80T-4000-W)
GF0000942Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0022685Courtesy of FORD MOTOR CO.
 Installer, Ball Bearing 307-557
GF0022506Courtesy of FORD MOTOR CO.
 Installer, Fluid Pump Seal 307-556
GF0022684Courtesy of FORD MOTOR CO.
 Installer, Needle Bearing 307-558
GF0022516Courtesy of FORD MOTOR CO.
 Installer, Shifter Fluid Seal 307-559
GF0022505Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Fluid Seal 307-560
GF0022323Courtesy of FORD MOTOR CO.
 Remover, Transmission Fluid Pump 307-553
GF0006856Courtesy of FORD MOTOR CO.
 Retaining Ring Pliers 307-343 (T95P-77001-AHR)
Material

Item Specification
MERCON® SP Automatic Transmission Fluid
XT-6-QSP (US); CXT-6-LSP12 (Canada)		 MERCON® SP
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
Fig 1: Exploded View Of Transmission Components (1 Of 3)
GF0022801Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transmission Components (2 Of 3)
GF0022802Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transmission Components (3 Of 3)
GF0022803Courtesy of FORD MOTOR CO.
Item Part Number Description
1 N800750-S437 Flex plate-to-torque converter nut (4 required)
2 7902 Torque converter
3 7A103 Pump assembly
4 7A248 Front pump oil seal
5 7N877 Torque converter pump retaining ring
6 7B031 Front pump outer oil seal
7 7R166 Front oil pump bearing assembly
8 7N817 Bushing converter stator support
9 7N134 Front pump-to-case bolts (13 required)
10 7A103 Front pump assembly
11 7R078 Bolt - attaches stator support to pump adapter assembly (6 required)
12 W707871-S300 Bolt - attaches pump to pump adapter assembly (11 required)
13 7B261 Converter stator support bushing
14 7G427 Front bushing forward clutch drum
15 7Z463 Clutch support fluid seal
16 7L323 Front pump support seal
17 7G428 Forward clutch rear bushing
18 7D014 Front pump support thrust washer
19 7A511 Forward clutch assembly (clutch A)
20 7J011 Forward clutch cylinder and hub assembly
21 7G242 Forward clutch inner piston seal
22 7F227 Forward clutch outer piston seal
23 7L140 Forward clutch piston
24 7F230 Forward clutch piston retaining spring
25 7J032 Forward clutch balance piston assembly
26 7F227 Forward clutch balance piston outer seal
27 7H365 Forward clutch balance piston snap ring
28 7N572 Forward clutch cushion spring
29 7E314 Forward clutch steel plates (externally splined) (part number model dependent)
30 7B164 Forward clutch friction plates (internally splined) (part number model dependent)
31 7B066 Forward clutch pressure plate
32 7B421 Pressure plate retaining snap ring
33 7G231 Front planetary sun gear (No. 1)
34 7H375 Bearing (T1)
35 7D483 Front planetary carrier assembly snap ring
36 7G218 Front planetary carrier assembly
37 7H578 Plate transmission fluid collector
38 7L495 Bearing (T2)
39 7L668 Overdrive clutch assembly (clutch E)
40 7G091 Turbine shaft seals (2 required)
41 7J006 Input shaft
42 7C232 Fluid distributor sleeve
43 7B256 Output shaft bushing
44 7J008 Overdrive clutch piston outer seal
45 7G007 Overdrive clutch piston inner seal
46 7G418 Overdrive clutch piston
47 7N529 Overdrive clutch piston spring
48 7J009 Balance piston outer seal
49 7J029 Overdrive balance piston
50 7J010 Balance piston snap ring
51 7N572 Clutch cushion plate
52 7B442 Overdrive clutch steel plates (externally splined) (part number model dependent)
53 7B164 Overdrive clutch friction plates (internally splined) (part number model dependent)
54 7C576 Overdrive pressure plate
55 7M157 Overdrive clutch retaining ring
56 7A453 Bearing (T3)
57 7F351 Intermediate clutch shaft
58 7H375 Bearing (T4)
59 7D065 Sun gear bushings (2 required) (part of 7R193)
60 7R193 Sun gear hub and shaft assembly
61 7F236 Direct clutch hub
62 7H076 Direct clutch cylinder retaining ring
63 7C108 Direct clutch assembly (clutch B)
64 7B421 Direct clutch pressure plate retaining ring
65 7B477 Direct clutch pressure plate
66 7B164 Direct clutch friction plates (internally splined) (part number model dependent)
67 7E314 Direct clutch steel plates (externally splined) (part number model dependent)
68 7N572 Direct clutch cushion plate
69 7D283 Bearing (T5)
70 7H363 Direct clutch balance piston snap ring
71 7D427 Direct clutch piston spring retainer
72 7B488 Direct clutch piston return spring
73 7B492 Direct clutch piston retaining ring
74 7H359 Direct clutch balance piston
75 7C000 Direct clutch balance seal
76 7F254 Direct clutch piston
77 7C000 Direct clutch piston outer seal
78 7F234 Direct clutch piston inner seal
79 7H240 Direct clutch hub bushings (part of 7F281) (2 required)
80 7C486 Gear shaft tube sleeve
81 7F360 Direct clutch cylinder
82 7B399 Shell cylinder seals (2 required)
83 7L327 Center support retaining ring
84 7F388 Intermediate clutch assembly (clutch C)
85 7B421 Intermediate clutch pressure plate retaining ring
86 7E314 Intermediate clutch pressure plate
87 7E314 Intermediate clutch steel plates (externally splined) (part number model dependent)
88 7B164 Intermediate clutch friction plates (internally splined) (part number model dependent)
89 7H136 Intermediate clutch pressure plate spring
90 7N169 Intermediate clutch retaining ring
91 7B043 Intermediate clutch ring
92 7C151 Intermediate clutch piston spring
93 7J015 Intermediate clutch piston
94 7F225 Intermediate clutch piston inner seal
95 7F224 Intermediate clutch piston outer seal
96 7F373 Bearing (T6)
97 7B314 Center shaft sleeve (part of 7G033)
98 7J114 Center support keys (2 required)
99 7J135 Center support seals (4 required)
100 7G033 Support assembly
101 7G446 Low/reverse clutch piston center seal
102 7G444 Low/reverse clutch piston inner seal
103 7G445 Low/reverse clutch piston outer seal
104 7D343 Low/reverse clutch piston
105 7D405 Low/reverse clutch piston return spring
106 7G494 Low/reverse clutch piston retaining ring
107 7N572 Clutch disc cushion plate
108 7E314 Low/reverse clutch steel plates (externally splined) (part number model dependent)
109 7B164 Low/reverse clutch friction plates (internally splined) (part number model dependent)
110 7E314 Low/reverse clutch pressure plate (select fit)
111 7H286 Gear thrust shim (select fit)
112 7C041 Bearing (T7)
113 7H580 Sun gear No. 2
114 7D235 Thrust bearing outer race
115 7D234 Bearing (T8)
116 7A348 Sun gear No. 3
117 7D234 Bearing (T9)
118 7193 Bearing race (T9)
119 7G224 Rear planetary carrier assembly
120 7H583 Fluid collar rear planetary plate (part of 7G224)
121 7A153 Output shaft ring gear assembly
122 7M152 Bearing (T10)
123 7B256 Output shaft bushing (part of 7096)
124 7096 Output shaft parking gear assembly rear wheel drive (RWD)
125 7096 Output shaft parking gear assembly four wheel drive (4WD)
126 7N194 Output shaft retaining ring
127 7006 Transmission case assembly (model dependent)
128 7E389 Transmission case fluid fill plug assembly
129 7E380 Transmission case fluid fill plug
130 7E390 Transmission case fluid fill seal
131 7E049 Transmission oil level indicator
132 7034 Transmission case vent assembly (model dependent)
133 7A415 Output shaft bearing assembly
134 7030A Output shaft retaining ring
135 7E413 Bearing (T11) (4WD only)
136 7R205 Output shaft bearing (RWD only)
137 7A433 Output shaft spacer (4WD only)
138 7030B Output shaft bearing retainer shim
139 7N135 Anti-click washer
140 7052 Extension housing seal (RWD)
141 7052 Extension housing seal (4WD)
142 7A021 Output shaft flange (RWD)
143 7K440 Output shaft flange retaining nut (RWD)
144 7E332 Manual valve detent spring
145 W711235-S300 Manual valve detent spring retaining screw and washer
146 7D410 Parking pawl actuating rod
147 7A441 Parking pawl
148 7D070 Parking pawl return spring
149 7D071 Parking pawl shaft
150 7H398 Plug assembly transmission case housing
151 7G101 Parking pawl abutment
152 W711235-S300 Parking pawl abutment retaining screw and washer
153 W708455-S441 Manual control lever nut
154 7A256 Manual control lever
155 7B498 Manual control lever shaft seal
156 7C493 Manual control lever shaft
157 7C257 Manual control lever shaft spacer
158 7A115 Manual valve detent lever assembly
159 7G100 Manual valve detent lever retaining pin
160 7H322 Thermal bypass valve
161 7F401 Front pump adapter seal
162 7A100 Main control assembly
163 7A091 Main control valve body assembly
164 7Z490 Main control valve body separator plate
165 7G423 Lower main control valve body
166 14C247 Control module assembly
167 7H585 Bulkhead connector sleeve
168 - Transmission fluid filter seal (part of 7G186)
169 7G186 Transmission fluid filter
170 - Transmission fluid pan magnet
171 7A191 Transmission fluid pan gasket
172 7A194 Transmission fluid pan
173 W500214-S437 Transmission fluid pan bolts

All vehicles 

  1. If removed, position the rear case roller bearing in the case.
    2. Fig 4: Locating Rear Case Roller Bearing
    GF0022804Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the roller bearing.
    3. Fig 5: Installing Roller Bearing Using Special Tools (205-153, 307-558)
    GF0022805Courtesy of FORD MOTOR CO.
  3. Install the snap ring.
    4. Fig 6: Locating Inner Bearing Snap Ring
    GF0022758Courtesy of FORD MOTOR CO.

    Rear wheel drive (RWD) vehicles 

  4. Using the special tools, install the rear case roller bearing in the case.
    5. Fig 7: Installing Rear Case Roller Bearing Using Special Tools (205-153, 307-557)
    GF0022690Courtesy of FORD MOTOR CO.
  5. Install the roller bearing snap ring.
    6. Fig 8: Locating Rear Bearing Spacer Snap Ring
    GF0022580Courtesy of FORD MOTOR CO.

    Four wheel drive (4WD) vehicles 

  6. Using the special tools, install the rear bearing spacer.
    7. Fig 9: Installing Rear Bearing Spacer Using Special Tools (205-153, 307-558)
    GF0022806Courtesy of FORD MOTOR CO.
  7. Install the rear bearing spacer snap ring.
    8. Fig 10: Locating Rear Bearing Spacer Snap Ring
    GF0022585Courtesy of FORD MOTOR CO.

    All vehicles 

  8. Place the transmission in the vertical position.
  9. Install the planet carrier hub and output shaft assembly.
    10. Fig 11: Locating Planet Carrier Hub & Output Shaft Assembly
    GF0022577Courtesy of FORD MOTOR CO.
  10. Install the silver shim (caged bearing) on the planet carrier hub and output shaft assembly.
    11. Fig 12: Locating Silver Shim On Planet Carrier Hub
    GF0022692Courtesy of FORD MOTOR CO.
  11. Position the park pawl pin into the case.
    12. Fig 13: Positioning Park Pawl Pin Into Case
    GF0022693Courtesy of FORD MOTOR CO.
  12. Position the park pawl into the case and push the park pawl pin in to hold the park pawl and spring in position.
    13. Fig 14: Locating Park Pawl Pin, Park Pawl & Spring
    GF0022589Courtesy of FORD MOTOR CO.
  13. Install the park pawl pin bolt.
    • Tighten to 35 Nm (26 lb-ft).
    14. Fig 15: Locating Park Pawl Pin Bolt
    GF0022588Courtesy of FORD MOTOR CO.

    4WD vehicles 

  14. Position a new output shaft seal in place.
    15. Fig 16: Positioning Output Shaft Seal In Place
    GF0022807Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the output shaft seal.
    16. Fig 17: Installing Output Shaft Seal Using Special Tool (307-560)
    GF0022740Courtesy of FORD MOTOR CO.

    RWD vehicles 

  16. Install the anti-click washer.
    17. Fig 18: Locating Anti-Click Washer
    GF0022756Courtesy of FORD MOTOR CO.
  17. Position a new output shaft seal in place.
    18. Fig 19: Locating Output Shaft Seal
    GF0022578Courtesy of FORD MOTOR CO.
  18. Using the special tool, install the output shaft seal.
    19. Fig 20: Installing Output Shaft Seal Using Special Tool (307-556)
    GF0022808Courtesy of FORD MOTOR CO.
  19. Install the output shaft flange.
    20. Fig 21: Output Shaft Flange
    GF0022576Courtesy of FORD MOTOR CO.
  20. Install a new output shaft flange nut.
    • Tighten to 60 Nm (44 lb-ft).
    • After installing the new nut, it must be staked at the slots to prevent it from coming loose.
    21. Fig 22: Output Shaft Flange Nut
    GF0022575Courtesy of FORD MOTOR CO.

    All vehicles 

  21. Install the roller bearing race in the bottom of the carrier.
    22. Fig 23: Locating Roller Bearing Race
    GF0022573Courtesy of FORD MOTOR CO.
  22. Snap the top and the bottom roller bearings onto the sun gear.
    23. Fig 24: Sun Gear Top & Bottom Roller Bearings
    GF0022572Courtesy of FORD MOTOR CO.
    NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque converter housing.
  23. Install the sun gear into the planet assembly.
    24. Fig 25: Locating Sun Gear In Planet Assembly
    GF0022755Courtesy of FORD MOTOR CO.
  24. Install the low/reverse sun gear.
    25. Fig 26: Locating Low/Reverse Sun Gear
    GF0022754Courtesy of FORD MOTOR CO.
  25. Install the low/reverse thrust bearing (T7).
    26. Fig 27: Locating Low/Reverse Bearing Race
    GF0022569Courtesy of FORD MOTOR CO.
    NOTE: Inspect and install new thrust bearings as required.
  26. Install the select fit thrust gear shim.
  27. Install the planet carrier.
    28. Fig 28: Locating Low/Reverse Clutch Pack
    GF0022568Courtesy of FORD MOTOR CO.
  28. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates, and ending with the wave spring plate on the top.
    29. Fig 29: Locating Direct Clutch Assembly
    GF0022565Courtesy of FORD MOTOR CO.
  29. Install the roller bearing and shim onto the center support.
    30. Fig 30: Locating Bearing On Back Of Center Support
    GF0022753Courtesy of FORD MOTOR CO.
    NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.
  30. Install the center support into the case.
    31. Fig 31: Locating Center Support Into Case
    GF0022695Courtesy of FORD MOTOR CO.
    NOTE: Rotate case to the horizontal position.
  31. Using the special tool, install the center support snap ring. Tap the snap ring into the case to make sure that it is seated into the case.
    32. Fig 32: Identifying Center Support Snap Ring Using Special Tool (307-343)
    GF0022752Courtesy of FORD MOTOR CO.
  32. Using the special tool, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.006-0.013 in).
    • If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
    33. Fig 33: Lifting Up On Output Shaft & Record Reading Using Special Tool (100-002)
    GF0022809Courtesy of FORD MOTOR CO.
  33. Install the roller bearing if not previously installed on the direct clutch drum.
    34. Fig 34: Locating Roller Bearing
    GF0022810Courtesy of FORD MOTOR CO.
  34. Install the direct clutch drum.
    35. Fig 35: Locating Direct Clutch Drum
    GF0022567Courtesy of FORD MOTOR CO.
  35. Install the bearing on the direct clutch assembly.
    36. Fig 36: Locating Caged Roller Bearing
    GF0022750Courtesy of FORD MOTOR CO.
  36. Install the forward and overdrive clutch assembly.
    37. Fig 37: Locating Forward And Overdrive Clutch Assembly
    GF0022699Courtesy of FORD MOTOR CO.
  37. Install the pump washer.
    38. Fig 38: Locating Pump Washer
    GF0022700Courtesy of FORD MOTOR CO.
  38. Install the special tool into the case.
    39. Fig 39: Installing Special Tool (307-334) Into Case
    GF0022811Courtesy of FORD MOTOR CO.
  39. Using the special tools, install the front pump.
    40. Fig 40: Install Front Pump Using Special Tools (307-334, 307-553)
    GF0022812Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.
    NOTE: Add 0.118L (4 oz.) of clean transmission fluid to prime the pump.
  40. Make sure that the pump is correctly aligned with the case.
    41. Fig 41: Locating Seal
    GF0022703Courtesy of FORD MOTOR CO.
  41. Loosely install the new front pump bolts with the new washers.
    42. Fig 42: Identifying Special Tools (307-334, 307-553)
    GF0022813Courtesy of FORD MOTOR CO.
  42. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
    43. Fig 43: Locating Front Pump Bolts
    GF0022561Courtesy of FORD MOTOR CO.
  43. Install the special tool onto the input shaft to measure end play.
    • Tighten the wing nut.
    44. Fig 44: Installing Special Tool (307-534) Onto Input Shaft
    GF0017722Courtesy of FORD MOTOR CO.
  44. Install the remaining special tool.
    • Push down on the special tool and zero out the dial indicator.
    • Lift up on the special tool and record the measurement 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new pump washer.
    • Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.
    45. Fig 45: Identifying Special Tools (100-002, 307-534)
    GF0022814Courtesy of FORD MOTOR CO.
  45. Install the park rod actuating plate.
    • Tighten to 10 Nm (89 lb-in).
    46. Fig 46: Locating Park Rod Actuating Plate
    GF0022519Courtesy of FORD MOTOR CO.
  46. Position a new manual control lever seal in place.
    47. Fig 47: Manual Control Lever Seal
    GF0022521Courtesy of FORD MOTOR CO.
  47. Using the special tool, install a new manual control lever shaft seal.
    48. Fig 48: Installing Manual Control Lever Shaft Seal Using Special Tool (307-559)
    GF0022742Courtesy of FORD MOTOR CO.
  48. Position the manual lever and park rod in place.
    • Push down on the park pawl and slide the park rod in place.
    49. Fig 49: Park Pawl & Park Rod
    GF0022706Courtesy of FORD MOTOR CO.
  49. Install the manual lever in the case.
    1. Slide the manual lever in the case.
    2. Position the spacer in place while sliding the manual lever into the spacer.
    3. Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
    4. Install the roll pin.
    50. Fig 50: Manual Lever, Spacer, Manual Valve Inner Lever & Roll Pin Hole
    GF0022707Courtesy of FORD MOTOR CO.
  50. Install the 4 rubber feed tubes for the center support.
    1. Black feed tubes.
    2. Green feed tube.
    3. Blue feed tube.
    51. Fig 51: Locating Rubber Feed Tubes
    GF0022732Courtesy of FORD MOTOR CO.
  51. Install the rubber adapter.
    52. Fig 52: Locating Rubber Adapter
    GF0022733Courtesy of FORD MOTOR CO.
  52. Install the thermal bypass valve into the case.
    53. Fig 53: Locating Thermal Bypass Valve
    GF0022734Courtesy of FORD MOTOR CO.
    NOTE: The mechatronic assembly will not lay flush on the case, this is normal, the bolts will pull the mechatronic assembly down.
  53. Loosely install the 11 mechatronic bolts.
    1. Align the manual valve and control lever linkage.
    54. Fig 54: Locating Mechatronic Assembly Bolts
    GF0022735Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.
  54. Tighten the bolts in the sequence shown.
    • Tighten to 6 Nm (53 lb-in).
    55. Fig 55: Tightening Mechatronic Bolts In Sequence
    GF0022744Courtesy of FORD MOTOR CO.
    CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.
  55. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the transmission control module (TCM).
    56. Fig 56: Locating Outer Shell Of Bulkhead Electrical Connector And Release Tab
    GF0022554Courtesy of FORD MOTOR CO.
  56. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.
    57. Fig 57: Locating Outer Shell Of Bulkhead Electrical Connector And Tab
    GF0022524Courtesy of FORD MOTOR CO.
  57. Install a new transmission fluid filter.
    58. Fig 58: Locating Transmission Fluid Filter
    GF0022493Courtesy of FORD MOTOR CO.
    NOTE: The fluid pan gasket can be reused if not damaged.
  58. Install a new transmission fluid pan gasket if required.
    59. Fig 59: Locating Transmission Fluid Pan Gasket
    GF0022721Courtesy of FORD MOTOR CO.
  59. Install the fluid pan and tighten the bolts in a crisscross pattern.
    • Tighten to 14 Nm (10 lb-ft).
    60. Fig 60: Locating Transmission Fluid Pan Bolts
    G04640119Courtesy of FORD MOTOR CO.
  60. Using the special tools, install the torque converter.
    61. Fig 61: Identifying Torque Converter Using Special Tool (307-091)
    GF0022745Courtesy of FORD MOTOR CO.
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