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Home >> Mazda >> 1998 >> B2500 SX, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - 4R44E >> Transmission Reassembly

Transmission Reassembly

NOTE: Lubricate all parts with ATF during reassembly. Thrust washers, bearings and gaskets should be held in place with petroleum jelly. See Fig 6 for location of thrust washers and bearings.
  1. Install manual control lever shaft seal. See Fig 4 and Fig 6 . Install control lever shaft and retaining pin. Assemble manual valve inner lever and parking pawl actuating rod. Install manual valve inner lever and nut. Tighten nut to specification. See TORQUE SPECIFICATIONS  .
  2. Lubricate and install No. 11 thrust washer with tabs facing into case. Install park gear. Install low-reverse brake drum. Lubricate and install No. 10 bearing onto the output shaft ring gear.
  3. Install output shaft through park gear. Install output shaft ring gear and hub. Install NEW output shaft retaining ring. Install output shaft sleeve with cone facing upward. Lubricate and install No. 8 and No. 9 bearings onto low-reverse planetary gear assembly.
  4. Install low-reverse planetary gear assembly into output shaft ring gear. Pull brake drum forward and install low-reverse planetary gear assembly retaining ring into brake drum groove. Install low-reverse brake band over brake drum ensuring band rests on anchor pins.
  5. Temporarily install low-reverse band servo piston and rod to hold band in position. Install forward gear train assembly. Turn transmission so output shaft points downward. Place Gauge Bar (T93L-77003-AH) on case shoulder. See Fig 1 .
    Fig 1: Measuring No. 4 Thrust Washer Clearance
    G94J38835Courtesy of FORD MOTOR CO.
  6. Using depth micrometer, measure between gauge bar and intermediate brake drum No. 4 thrust bearing mating surface at 2 locations, 180 degrees apart. Use the following formula to select correct thrust bearing thickness: "T" = (("A" + "B") /2) - "C".
    1. "A" = Depth measurement to one side thrust bearing mating surface.
    2. "B" = Depth measurement of opposite thrust bearing mating surface.
    3. "C" = Gauge bar thickness.
    4. "T" = Thrust bearing thickness required.
  7. Select and install No. 4 thrust bearing onto center support. See NO. 4 SELECTIVE THRUST BEARING  table. The No. 4 selective thrust bearing is used to obtain end play of .008-.020" (.21-.51 mm). Install intermediate servo actuating lever. Install intermediate band lever shaft through servo actuating lever. Install intermediate band apply strut onto servo actuating lever.
    NO. 4 SELECTIVE THRUST BEARING

    Average Reading In. (mm) Bearing Thickness In. (mm) ID Notches (1)
    .066-.073 (1.67-1.90) .104-.110 (2.65-2.80) None
    .073-.080 (1.86-2.04) .110-.116 (2.80-2.95) 1
    .081-.088 (2.05-2.23) .118-.124 (3.00-3.15) 2
    .089-.096 (2.25-2.43) .126-.132 (3.20-3.35) 3
    (1) Number of notches located on thrust bearing.
  8. Install intermediate band and ensure apply strut is aligned correctly. Temporarily install intermediate band adjusting screw and anchor strut. Install center support into intermediate brake and direct clutch drum. Ensure center support screw hole aligns correctly with case hole.
  9. Temporarily install input shaft and wiggle it until center support is seated properly. Remove input shaft. Install center support retaining ring with tapered side facing up. Ensure retaining ring does not block center support notch. See Fig 2 . Install center support lock nut and cage. Install center support-to-case screw and tighten to specifications. See TORQUE SPECIFICATIONS  .
    Fig 2: Installing Center Support Retaining Ring
    G96C04221Courtesy of FORD MOTOR CO.
  10. Route Turbine Shaft Speed (TSS) sensor wiring through case and install into center support. Install TSS sensor screw and tighten to specifications. See TORQUE SPECIFICATIONS  . Install No. 3 thrust bearing onto center support. Install front planetary carrier, ring gear, one-way clutch and center shaft assembly.
  11. Using Turbine Shaft Speed Sensor Gauge (49 UN01 145 ), place thick end over TSS sensor. Rotate trigger wheel ensuring all windows clear gauge. If trigger wheel is bent, replace front planetary gear and trigger wheel. Install overdrive brake drum and coast clutch drum assembly.
  12. Install overdrive servo band lever and overdrive band lever-to-case bracket. Install overdrive band lever shaft through band lever. Install overdrive band apply strut onto band lever. Install overdrive band over overdrive brake and coast clutch drum. If band is reused, ensure band is installed in same position as when removed. Temporarily install overdrive band adjusting screw as an alignment guide for overdrive band anchor strut.
  13. Lubricate and install No. 1 thrust washer onto pump. Install pump body into case and ensure pump is seated properly. Place gauge bar across case. See Fig 3 . Using depth micrometer, measure depth to pump face in 2 places, 180 degrees apart. Use the following formula to calculate correct No. 1 thrust washer thickness: "T" = (("A" + "B") /2) - "C".
    1. "A" = Depth measurement of one side pump surface.
    2. "B" = Depth measurement of opposite side pump surface.
    3. "C" = Gauge bar thickness.
    4. "T" = Measured front end clearance.
    Fig 3: Checking End Play
    G96E04222Courtesy of FORD MOTOR CO.
  14. Remove depth gauge and gauge bar. Remove pump and thrust washer. Front end clearance should be .007-.028" (.18-.70 mm). If measured front end clearance is less than specification, replace thrust washer with thinner washer necessary to obtain specification. See NO. 1 SELECTIVE THRUST WASHER  table. If measured front end clearance is more than specification, replace thrust washer with thicker washer necessary to obtain specification.
    NO. 1 SELECTIVE THRUST WASHER

    Identification Thickness In. (mm)
    Blue .053-.055 (1.35-1.40)
    White .061-.063 (1.55-1.60)
    Green .069-.071 (1.75-1.80)
    Red .073-.075 (1.85-1.90)
    Tan .077-.079 (1.95-2.00)
    Black .081-.083 (2.05-2.10)
    Yellow .085-.087 (2.15-2.20)
  15. If new thrust washer is selected, repeat steps  13 and  14 . Install new "O" ring on pump drive gear. Lubricate Front Pump Seal Sizing Tool (49 UM01 142 ) and place into drive gear to seat "O" ring.
  16. Remove front pump seal sizing tool. Place pump gears into pump housing. The inside edge of small gear has a chamfer on one side. This chamfer must face toward front of transmission. The larger gear has a dimple on one side which must face toward rear of transmission.
  17. Install pump adapter plate. Position pump housing and adapter plate onto converter housing. Notch on outside of adapter plate will be at 9 o'clock position relative to convertor housing. Install bolts finger tight.
  18. To prevent seal leakage, pump gear breakage or bushing failure, align pump in converter housing with Pump Alignment Set (49 UN01 015 ). Select smallest I.D. sleeve which will fit completely over pump shaft. Outside diameter of sleeve will center pump in converter housing.
  19. Install 6 new Allen bolts. Tighten to specification. See TORQUE SPECIFICATIONS  . Remove alignment tool. Install overdrive brake drum seal rings. Ensure seal ring ends are properly overlapped and ring gaps are placed 180 degrees apart. Coat converter housing gasket with petroleum jelly and position on converter housing.
  20. Install seal ring on converter housing. Position No. 1 selected thrust washer on rear of pump. Turn convertor housing over and install front pump support seal ring. Install input shaft and convertor guide pins. Install and align converter housing and pump to transmission case. Remove alignment pins. Install 8 new bolts with "O" rings and tighten to specification. See TORQUE SPECIFICATIONS  .
  21. Remove input shaft. Replace piston "O" ring and install intermediate servo piston assembly. Install piston cover and snap ring. Replace piston "O" ring and install overdrive servo piston assembly. Install piston cover and snap ring. Do not press servo cover and "O" ring past relief hole in case. "O" ring damage may occur.
  22. Install new lock nut on overdrive band adjusting screw. Apply petroleum jelly to lock nut seal. Tighten adjusting screw to 120 INCH lbs. (14 N.m) and back off exactly 2 turns. Hold adjusting screw and tighten lock nut to 35-45 ft. lbs. (47-61 N.m). Repeat procedure for intermediate band adjusting screw, except back off intermediate band adjusting screw exactly 2 1/2 turns.
  23. Lubricate and install new 16-pin connector "O" rings. Install 16-pin connector through case hole and ensure tab locks in place. Install case connector retaining ring. Install TSS connector into 16-pin case connector.
  24. Align valve body to separator plate and gasket using tapered punches. Use a small amount of petroleum jelly to hold gasket in place. Install Valve Body Alignment Pins (49 UN01 139 and 49 UN01 140 ) into case. Install valve body onto case while aligning manual valve with manual valve inner lever pin.
    NOTE: Valve body bolts are of different lengths. Ensure each bolt is installed in its correct location. See Figure .
  25. Install and finger tighten bolts "A", "B", and "C". See Figure . Remove valve body alignment pins. Install and finger tighten remaining bolts. DO NOT install filter screen bolt at this time. Tighten all bolts to specification in sequence. See Figure . Install manual lever detent spring.
    NOTE: If low-reverse servo piston rod is to be checked, perform installation procedures in LOW-REVERSE SERVO  under ON-VEHICLE SERVICE. Ensure A4LD Servo Check Spring (D4ZZ-7D031-A) is removed after checking piston rod travel.
  26. Install solenoid connectors. Install wiring protector and guide. Install new "O" rings on filter screen and lube with petroleum jelly. Install filter screen and bolt. Install transmission tester and perform static tests. See appropriate ELECTRONIC CONTROLS article. Install oil pan with new gasket. Tighten pan bolts to specification. See TORQUE SPECIFICATIONS  .
  27. Install parking pawl and return spring in extension housing. Using new gasket, install extension housing. Ensure operating parking rod is correctly seated in extension guide cup. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  28. Install extension housing bushing (if removed). Ensure lube hole in bushing is aligned with slot in extension housing at 3 o'clock position. Install rear seal with drain hole at 6 o'clock position.
  29. Install transmission range sensor on manual lever. Install sensor bolts finger tight. Rotate manual lever to neutral position (2 detents rearward). Install TR Sensor Alignment Tool (49 UN01 086 ) into 3 slots on sensor. Tighten TR sensor bolts to specification and remove alignment tool. Install manual control outer lever. Tighten nut to specification. See TORQUE SPECIFICATIONS  .
  30. Install heat shield (if equipped). Install VSS with new "O" ring (if necessary). Install input shaft and torque converter. Ensure torque converter is properly installed. When installation is correct, measurement between torque converter pilot nose and front face of housing will be .403-.568" (10.23-14.43 mm).
Fig 4: Exploded View Of 4R44E Transmission (1 Of 2)
G98I01937Courtesy of FORD MOTOR CO.
Fig 5: Exploded View Of 4R44E Transmission (2 Of 2)
G98A01938Courtesy of FORD MOTOR CO.
Fig 6: Exploded View Of Thrust Bearing & Washer Locations
G98H01932Courtesy of FORD MOTOR CO.
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