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Section 433 (Automatic Transaxle/Transmission): Assembly: Transaxle: Assembly

WARNING: This page is about a different car, the 2002 Mercury Cougar. However, it is still accessible from the selected car via links, so may be relevant.
  1. Prepare the transaxle for assembly by proceeding with the following steps:
    • Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
    • Dry all parts with moisture-free regulated compressed air (do not use shop towels).
    • Lubricate all internal parts (including friction plates) with clean automatic transmission fluid.
    • Order the required repair parts.
    • Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
      • Drive sprocket thrust washers
      • Driven sprocket thrust bearing shims
      • Differential case thrust bearing shims
      • Low/reverse clutch pressure plates
    • During assembly, use petroleum jelly to hold the parts in place (do not use grease).
    • When tightening fasteners, use an accurate torque wrench.
    • Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
  2. Install the intermediate and overdrive band assembly into the transaxle case.
    Fig 1: Installing Intermediate And Overdrive Band Assembly
    G02198721Courtesy of FORD MOTOR CO.
  3. Install the No. 1 pump support thrust bearing.
    • Lubricate the seal rings with automatic transmission fluid.
      Fig 2: Installing No. 1 Pump Support Thrust Bearing
      G02198722Courtesy of FORD MOTOR CO.
    4. NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.
    Fig 3: Installing Pump Assembly Into The Case
    G02198723Courtesy of FORD MOTOR CO.
  4. Install pump assembly into the case.
    5. NOTE: Tighten the bolts in the indicated sequence.
    Fig 4: Installing Pump Assembly Bolts
    G02198724Courtesy of FORD MOTOR CO.
  5. Install the pump assembly bolts.
    6. CAUTION: Make sure that the special tools are correctly aligned in the piston bore. Failure to follow this instruction may result in damage to the special tools.
  6. Using the special tools, install the low/reverse clutch piston.
    • Lubricate seals and piston bore with clean automatic transmission fluid.
      Fig 5: Installing Low/Reverse Clutch Piston
      G02198725Courtesy of FORD MOTOR CO.
  7. Install the low/reverse clutch return spring assembly.
    Fig 6: Installing Low/Reverse Clutch Return Spring Assembly
    G02198726Courtesy of FORD MOTOR CO.
  8. Install the low/reverse clutch return spring retaining ring.
    Fig 7: Installing Low/Reverse Clutch Return Spring Retaining Ring
    G02198727Courtesy of FORD MOTOR CO.
    9. CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
    Fig 8: Installing Thick, (Ten-Wave) Low/Reverse Clutch Wave Spring
    G02198728Courtesy of FORD MOTOR CO.
  9. Install the thick, (ten-wave) low/reverse clutch wave spring.
    10. NOTE: The number of clutch plates will vary per application.
  10. Install the low/reverse clutch plates.
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the thinner, eight-wave low, reverse clutch cushion spring.
    4. Install the low/reverse clutch pressure plate.
      Fig 9: Installing Low/Reverse Clutch Plates
      G02198729Courtesy of FORD MOTOR CO.
    11. CAUTION: The low one-way clutch thrust plate is fitted in the position for measurement purposes only.
    Fig 10: Installing Low One-Way Clutch Thrust Plate
    G02198730Courtesy of FORD MOTOR CO.
  11. Install the low one-way clutch thrust plate.
  12. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate (three plate clutch).
    • Take a second measurement on the opposite side.
    • Average the two measurements to obtain the clearance.
    • If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
    • Pressure plate sizes:
      • 2.57-2.46 mm (0.101-0.097 in)
      • 2.36-2.26 mm (0.092-0.089 in)
      • 2.16-2.06 mm (0.085-0.081 in)
        Fig 11: Measuring Clearance Between Low/Reverse Clutch Pressure Plate And Low One-Way Clutch Thrust Plate (Three Plate Clutch)
        G02198731Courtesy of FORD MOTOR CO.
  13. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate (two plate clutch).
    • Take a second measurement on the opposite side.
    • Average the two measurements to obtain the clearance.
    • If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
    • Pressure plate sizes:
      • 2.57-2.46 mm (0.101-0.097 in)
      • 2.36-2.26 mm (0.092-0.089 in)
      • 2.16-2.06 mm (0.085-0.081 in)
        Fig 12: Measuring Clearance Between Low/Reverse Clutch Pressure Plate And Low One-Way Clutch Thrust Plate (Two Plate Clutch)
        G02198732Courtesy of FORD MOTOR CO.
    14. NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.
  14. Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring and the low/reverse clutch internal spline clutch plates (friction).
    1. Low one-way clutch thrust plate.
    2. Low/reverse clutch pressure plate.
    3. Low/reverse clutch cushion spring (eight-wave).
    4. Low/reverse clutch external spline clutch plates (steel).
    5. Low/reverse clutch wave spring (ten-wave).
    6. Low/reverse clutch internal spline clutch plates (friction).
      Fig 13: Removing Low One-Way Clutch Thrust Plate, Low/Reverse Clutch Pressure Plate
      G02198733Courtesy of FORD MOTOR CO.
  15. Install the No. 1 pump support thrust bearing assembly.
    Fig 14: Installing No. 1 Pump Support Thrust Bearing Assembly
    G02198734Courtesy of FORD MOTOR CO.
    16. NOTE: Remove seal sizer from forward/coast/direct clutch cylinder.
    Fig 15: Installing Forward/Coast/Direct Clutch Cylinder Assembly
    G02198735Courtesy of FORD MOTOR CO.
  16. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
  17. Install the turbine shaft.
    Fig 16: Installing Turbine Shaft
    G02198736Courtesy of FORD MOTOR CO.
  18. Install the No. 4 turbine shaft thrust bearing.
    Fig 17: Installing No. 4 Turbine Shaft Thrust Bearing
    G02198737Courtesy of FORD MOTOR CO.
  19. Install the forward one-way clutch and low-intermediate sun gear assembly.
    Fig 18: Installing Forward One-Way Clutch And Low-Intermediate Sun Gear Assembly
    G02198738Courtesy of FORD MOTOR CO.
  20. Install the No. 5 low-intermediate sun gear thrust bearing.
    Fig 19: Installing No. 5 Low-Intermediate Sun Gear Thrust Bearing
    G02198739Courtesy of FORD MOTOR CO.
  21. Install the low-intermediate carrier assembly.
    Fig 20: Installing Low-Intermediate Carrier Assembly
    G02198740Courtesy of FORD MOTOR CO.
  22. Install the No. 6 low-intermediate carrier thrust bearing.
    Fig 21: Installing No. 6 Low-Intermediate Carrier Thrust Bearing
    G02198741Courtesy of FORD MOTOR CO.
  23. Install the low-intermediate ring gear assembly.
    Fig 22: Installing Low-Intermediate Ring Gear Assembly
    G02198742Courtesy of FORD MOTOR CO.
  24. Install the No. 7 reverse/overdrive sun gear thrust bearing.
    Fig 23: Installing No. 7 Reverse/Overdrive Sun Gear Thrust Bearing
    G02198743Courtesy of FORD MOTOR CO.
  25. Install the reverse/overdrive sun gear and shell assembly.
    Fig 24: Installing Reverse/Overdrive Sun Gear And Shell Assembly
    G02198744Courtesy of FORD MOTOR CO.
  26. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
    Fig 25: Installing Reverse/Overdrive Carrier Assembly With Captured No. 8 Thrust Bearing
    G02198745Courtesy of FORD MOTOR CO.
  27. Install the thick, ten-wave low/reverse clutch wave spring.
    Fig 26: Installing Thick, Ten-Wave Low/Reverse Clutch Wave Spring
    G02198746Courtesy of FORD MOTOR CO.
  28. Install the low/reverse clutch plate (model dependent).
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the low/reverse clutch pressure plate previously selected.
      Fig 27: Installing Low/Reverse Clutch Plate
      G02198747Courtesy of FORD MOTOR CO.
  29. Install the thin, eight-wave low/reverse clutch wave spring.
    Fig 28: Installing Thin, Eight-Wave Low/Reverse Clutch Wave Spring
    G02198748Courtesy of FORD MOTOR CO.
  30. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
    Fig 29: Installing Low One-Way Clutch Assembly With Identification Ring
    G02198749Courtesy of FORD MOTOR CO.
  31. Install the low one-way clutch thrust plate.
    Fig 30: Installing Low One-Way Clutch Thrust Plate
    G02198750Courtesy of FORD MOTOR CO.
    32. NOTE: Position the low one-way clutch retaining ring as shown.
    Fig 31: Installing Low One-Way Clutch Retaining Ring
    G02198751Courtesy of FORD MOTOR CO.
  32. Install the low one-way clutch retaining ring.
  33. Install the manual valve detent lever actuating rod assembly.
    • Install the parking cam actuator lever.
      Fig 32: Installing Manual Valve Detent Lever Actuating Rod Assembly
      G02198752Courtesy of FORD MOTOR CO.
  34. Install the manual valve detent lever.
    Fig 33: Installing Manual Valve Detent Lever
    G02198753Courtesy of FORD MOTOR CO.
  35. Install the special tools.
    Fig 34: Installing Special Tools
    G02198754Courtesy of FORD MOTOR CO.
  36. Install the special tool with short spacers.
    Fig 35: Installing Special Tool With Short Spacers
    G02198755Courtesy of FORD MOTOR CO.
  37. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
    • Record this dimension.
    • This dimension is designated with A.
      Fig 36: Measuring Distance From Top Of Special Tool To No. 12 Driven Sprocket Bearing Surface Area
      G02198756Courtesy of FORD MOTOR CO.
  38. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
    • Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
    • The average of these two dimensions is dimension B.
    • Remove the special tools.
      Fig 37: Measuring Distance From Top Of Special Tool To Bearing Surface On Reverse/Overdrive Carrier Assembly
      G02198757Courtesy of FORD MOTOR CO.
  39. Subtract dimension B from dimension A to obtain dimension C.
    • A-B = C
  40. Use the third dimension to select the correct No. 11 driven sprocket shim.
    • Select a shim from the driven sprocket shim chart.
  41. Install and lubricate the following:
    1. Lubricate the needles and seals in the No. 18 driven sprocket bearing.
    2. Install the selected No. 11 driven sprocket shim.
    3. Install the No. 12 driven sprocket bearing.
      Fig 38: Lubricating No. 18 Driven Sprocket Bearing, Installing Selected No. 11 Driven Sprocket Shim And No. 12 Driven Sprocket Bearing
      G02198758Courtesy of FORD MOTOR CO.
  42. Install the No. 9 reverse/overdrive ring gear thrust bearing.
    Fig 39: Installing No. 9 Reverse/Overdrive Ring Gear Thrust Bearing
    G02198759Courtesy of FORD MOTOR CO.
    43. NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
    Fig 40: Installing Reverse/Overdrive Ring Gear Assembly
    G02198760Courtesy of FORD MOTOR CO.
  43. Install the reverse/overdrive ring gear assembly.
  44. Install the special tools.
    Fig 41: Installing Special Tools
    G02198761Courtesy of FORD MOTOR CO.
  45. Install the special tool with short spacers.
    Fig 42: Installing Special Tool With Short Spacers
    G02198762Courtesy of FORD MOTOR CO.
  46. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area.
    • Repeat this measurement on the other side of the face of the reverse/overdrive ring gear assembly area 180 degrees from the first measurement.
    • The average of these two dimensions is the first dimension.
    • Remove the special tools.
      Fig 43: Measuring Distance From Top Of Special Tool To Face Of Reverse/Overdrive Ring Gear Assembly Surface Area
      G02198763Courtesy of FORD MOTOR CO.
  47. Add 25.4 mm (thickness of special tool 307-300) and short spacers' thickness.
    • This is the second dimension.
  48. Subtract the first dimension from the second dimension.
    • This is the third dimension.
  49. Select No. 10 thrust washer from the drive sprocket thrust washer chart in specifications. Refer to SPECIFICATIONS .
    • Use the third dimension to select the No. 10 drive sprocket thrust washer.
  50. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
    Fig 44: Installing Selected No. 10 Drive Sprocket Thrust Washer On Torque Converter Housing
    G02198764Courtesy of FORD MOTOR CO.
  51. Remove the reverse/overdrive ring gear assembly.
    Fig 45: Removing Reverse/Overdrive Ring Gear Assembly
    G02198765Courtesy of FORD MOTOR CO.
  52. Install the filter and seal assembly.
    Fig 46: Installing Filter And Seal Assembly
    G02198766Courtesy of FORD MOTOR CO.
  53. Install the special tool in the filter eyelet and transaxle hole.
    Fig 47: Installing Special Tool In Filter Eyelet And Transaxle Hole
    G02198767Courtesy of FORD MOTOR CO.
    54. NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
    Fig 48: Installing Filter Recirculating Regulator Exhaust Seal
    G02198768Courtesy of FORD MOTOR CO.
  54. Using the special tool, install the filter recirculating regulator exhaust seal.
  55. Install the chain pan in the transaxle case.
    Fig 49: Installing Chain Pan In Transaxle Case
    G02198769Courtesy of FORD MOTOR CO.
    56. WARNING: wear gloves as protection from sharp chain and sprocket teeth. Failure to follow these instructions may result in personal injury.
  56. Assemble and install the drive chain assembly.
    1. Drive chain (copper colored link facing upward).
    2. Driven sprocket assembly.
    3. Reverse/overdrive ring gear assembly.
      • Make sure that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
        Fig 50: Assembling And Installing Drive Chain Assembly
        G02198770Courtesy of FORD MOTOR CO.
  57. Install the chain pan cover by snapping it into place.
    Fig 51: Installing Chain Pan Cover By Snapping
    G02198771Courtesy of FORD MOTOR CO.
  58. Install the No. 13 driven sprocket thrust bearing.
    Fig 52: Installing No. 13 Driven Sprocket Thrust Bearing
    G02198772Courtesy of FORD MOTOR CO.
  59. Install the final drive carrier and differential assembly.
    Fig 53: Installing Final Drive Carrier And Differential Assembly
    G02198773Courtesy of FORD MOTOR CO.
    60. NOTE: Plastic washers should be placed between the bolts heads and the special tool.
  60. Install the special tools.
    1. Install the special tool.
    2. Install the special tool and bolts.
      Fig 54: Installing Special Tools
      G02198774Courtesy of FORD MOTOR CO.
  61. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
    • Repeat this measurement on the other side of the hub 180 degrees from the first measurement.
    • The average of these two dimensions is dimension B.
      Fig 55: Measuring Distance From Top Of Special Tool To Shim Surface Area
      G02198775Courtesy of FORD MOTOR CO.
  62. Use combined thickness of special tool 307-300 with long spacers 177.8 mm as dimension A.
  63. Subtract dimension B from dimension A.
    • This is dimension C.
  64. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
  65. Install the differential bearing assembly.
    1. Install the No. 14 differential bearing shim (selective fit).
    2. Install the No. 15 differential bearing.
      Fig 56: Installing Differential Bearing Assembly
      G02198776Courtesy of FORD MOTOR CO.
    66. NOTE: Check for correct alignment of the lube tube on the converter housing.
  66. Install the torque converter housing onto the transaxle case.
    • Position and install the split flange gasket.
      Fig 57: Installing Torque Converter Housing Onto Transaxle Case
      G02198777Courtesy of FORD MOTOR CO.
    67. NOTE: Tighten the bolts in the indicated sequence.
    Fig 58: Installing Torque Converter Housing To Transaxle Case Bolts
    G02198778Courtesy of FORD MOTOR CO.
  67. Install the torque converter housing to transaxle case bolts.
    68. NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.
  68. Lubricate the assembly with clean automatic transmission fluid.
    • Assemble the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
      1. Servo cover with bonded seal.
      2. Cushion spring.
      3. Servo apply rod.
      4. Servo return spring.
        Fig 59: Lubricating Assembly With Clean Automatic Transmission Fluid
        G02198779Courtesy of FORD MOTOR CO.
  69. Install the special tool.
    Fig 60: Installing Special Tool
    G02198780Courtesy of FORD MOTOR CO.
    70. NOTE: Struts on the special tool fit into the servo cover retaining ring groove.
  70. Assemble the special tool.
    1. Install struts.
    2. Install bar.
    3. Install bolts.
    4. Install the center bolt.
      Fig 61: Installing Center Bolt
      G02198781Courtesy of FORD MOTOR CO.
  71. Using the special tool 303-D026 measure the distance to the bar of special tool 307-S296.
    • Record the first dimension.
      Fig 62: Measuring Distance To Bar Of Special Tool
      G02198782Courtesy of FORD MOTOR CO.
  72. Back off the center bolt of special tool 307-S296 until the piston movement stops.
    Fig 63: Identifying Center Bolt Of Special Tool
    G02198783Courtesy of FORD MOTOR CO.
  73. Using the special tool 303-D026, measure the dimension to the bar of special tool 307-S296 (second dimension).
    • Subtract the first dimension from the second dimension to find the travel.
    • If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly from the servo apply rod chart in specifications. Refer to SPECIFICATIONS .
      Fig 64: Measuring Dimension To Bar Of Special Tool
      G02198784Courtesy of FORD MOTOR CO.
  74. Using a lint free cloth wipe the servo piston and the servo cover cap.
    75. CAUTION: Do not use cleaning solvent to clean the rubber sealing surfaces of the servo piston or servo cover cap. Failure to follow this instruction may result in damage to the sealing surfaces.
    NOTE: Check for damage in the area where the servo piston connects to the servo rod.
  75. Inspect the servo piston for cracks to the pressure and sealing surfaces.
    76. NOTE: If the lip of the servo piston is brittle install a new servo piston.
  76. Check the servo piston lip.
  77. Inspect the servo retainer spring for cracks, breaks or deformation.
    78. WARNING: Servo return spring force is very high. Failure to follow these instructions may result in personal injury.
    Fig 65: Assembling Special Tool
    G02198785Courtesy of FORD MOTOR CO.
  78. Assembly the special tool.
  79. Install the special tool.
    Fig 66: Installing special tool
    G02198786Courtesy of FORD MOTOR CO.
    80. CAUTION: Use only snap ring pliers to install the retaining ring. Failure to follow this instruction may result in damage to the case.
    CAUTION: If the case is stamped with a WG, install a wide groove snap ring. Failure to follow this instruction may result in damage to the servo.
    NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
  80. Tighten the special tool bolt.
    • Install the servo cover retaining ring.
      Fig 67: Tightening Special Tool Bolt
      G02198787Courtesy of FORD MOTOR CO.
  81. Loosen the special tool bolt.
    • When spring tension is released remove the special tool.
      Fig 68: Loosening Special Tool Bolt
      G02198788Courtesy of FORD MOTOR CO.
    82. CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.
    NOTE: If any leaks occur make sure that the special tool is correctly seated.
  82. Using the special tool, inspect the hydraulic circuits.
    • Use a rubber tipped blow gun and 2.76 bar of moisture free regulated compressed air.
      1. Reverse clutch test port
      2. Forward clutch test port
      3. Direct clutch test port
      4. Low/reverse clutch test port
      5. Servo release test port
      6. Servo apply test port
      7. Air test plate.
    • If air leakage is detected, disassemble the transaxle and locate source of leakage.
      Fig 69: Inspecting Hydraulic Circuits
      G02198789Courtesy of FORD MOTOR CO.
  83. Install the thermostatic fluid level control valve.
    1. Position the thermostatic fluid level control valve.
    2. Install the bracket.
    3. Install the thermostatic fluid level control valve bracket bolt.
      Fig 70: Installing Thermostatic Fluid Level Control Valve
      G02198790Courtesy of FORD MOTOR CO.
    84. CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals may result.
    Fig 71: Installing Solenoid Body Electrical Connector O-Ring Seal
    G02198791Courtesy of FORD MOTOR CO.
  84. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
    85. CAUTION: Handle main control valve body with care to prevent manual valve damage.
  85. Connect the manual valve.
    1. Lift the main control away from the case.
    2. Connect the Z-link to the manual valve.
      Fig 72: Connecting Manual Valve
      G02198792Courtesy of FORD MOTOR CO.
    86. NOTE: Tighten the bolts in the sequence shown. Bolts 1, 7 and 9 are longer than the others.
    Fig 73: Installing Main Control Valve Body Mounting Bolts
    G02198793Courtesy of FORD MOTOR CO.
  86. Install the main control valve body mounting bolts.
  87. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
    Fig 74: Loosening Nut On Ball Stud For Manual Valve Detent Lever Actuating Rod Assembly
    G02198794Courtesy of FORD MOTOR CO.
  88. Move the manual control lever shaft to the "D" position.
    • Install pin to hold special tool in place.
      Fig 75: Moving Manual Control Lever Shaft To "D" Position
      G02198795Courtesy of FORD MOTOR CO.
  89. Move the manual valve detent lever assembly to the "D" position.
    Fig 76: Moving Manual Valve Detent Lever Assembly To "D" Position
    G02198796Courtesy of FORD MOTOR CO.
  90. Tighten the nut on the ball.
    • Remove the shifter pin from the special tool.
      Fig 77: Tightening Nut On Ball
      G02198797Courtesy of FORD MOTOR CO.
  91. Rotate special tool 307-S290 (T94P-77000-H) until socket can be fitted.
    • Tighten the detent nut.
    • Rotate back to "D" position to recheck the adjustment.
      Fig 78: Tightening Detent Nut
      G02198798Courtesy of FORD MOTOR CO.
  92. Using the special tool, recheck the manual control lever assembly setting.
    Fig 79: Rechecking Manual Control Lever Assembly Setting
    G02198799Courtesy of FORD MOTOR CO.
  93. Install the manual control lever.
    1. Position the manual control lever.
    2. Tighten the manual control lever retaining bolt.
      Fig 80: Tightening Manual Control Lever Retaining Bolt
      G02198800Courtesy of FORD MOTOR CO.
  94. Rotate the manual valve detent lever assembly to the NEUTRAL position.
    1. Low 1
    2. Low 2
    3. Drive
    4. Neutral
    5. Reverse
    6. Park
      Fig 81: Rotating Manual Valve Detent Lever Assembly To Neutral Position
      G02198801Courtesy of FORD MOTOR CO.
  95. Position the transmission range (TR) sensor.
    Fig 82: Positioning Transmission Range (TR) Sensor
    G02198802Courtesy of FORD MOTOR CO.
  96. Align the TR sensor.
    • Using the special tool, align the TR sensor.
    • Tighten the TR sensor retaining bolts.
      Fig 83: Aligning TR Sensor
      G02198803Courtesy of FORD MOTOR CO.
  97. Install the main control cover gasket.
    98. NOTE: Tighten the bolts in the indicated sequence.
  98. Install the main control cover.
    • Install the vent tube.
    • Install the main control cover bolts.
      Fig 84: Main Control Cover Bolt Tightening Sequence
      G02198804Courtesy of FORD MOTOR CO.
  99. Install the new transmission filler tube grommet.
    Fig 85: Installing New Transmission Filler Tube Grommet
    G02198805Courtesy of FORD MOTOR CO.
  100. Install the transmission filler tube assembly.
    1. Install the tube.
    2. Install the transmission filler tube bolt.
      • Install the fluid level indicator.
        Fig 86: Installing Transmission Filler Tube Assembly
        G02198806Courtesy of FORD MOTOR CO.
  101. Install the turbine shaft speed (TSS) sensor.
    1. Use petroleum jelly on the O-ring seal and position the TSS sensor.
      • Install a new O-ring seal.
    2. Install the TSS sensor bolt.
      Fig 87: Installing TSS Sensor Bolt
      G02198807Courtesy of FORD MOTOR CO.
  102. Using the special tool install the differential seals.
    Fig 88: Installing Differential Seals
    G02198808Courtesy of FORD MOTOR CO.
    103. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
  103. Using the special tool, install the torque converter fluid seal.
    • Coat the torque converter seal garter spring with petroleum jelly.
      Fig 89: Installing Torque Converter Fluid Seal
      G02198809Courtesy of FORD MOTOR CO.
  104. Install the drain plug.
    Fig 90: Installing Drain Plug
    G02198810Courtesy of FORD MOTOR CO.
  105. Install the output shaft speed (OSS) sensor.
    Fig 91: Installing Output Shaft Speed (OSS) Sensor
    G02198811Courtesy of FORD MOTOR CO.
    106. NOTE: Check for correct rotation of the pump drive shaft.
    Fig 92: Installing Pump Drive Shaft
    G02198812Courtesy of FORD MOTOR CO.
  106. Install the pump drive shaft.
  107. Using the special tool, install the torque converter.
    Fig 93: Installing Torque Converter
    G02198813Courtesy of FORD MOTOR CO.
  108. Remove the special tools.
    Fig 94: Removing Special Tools
    G02198814Courtesy of FORD MOTOR CO.
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