LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2004 >> Grand Marquis GS >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Assembly >> Transmission

Automatic Transmission: Assembly: Transmission

Fig 1: Identifying Special Tool(s) (1 Of 2)
G02757940Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool(s) (2 Of 2)
G02757941Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATIONS

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V
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. In addition to appearing in this article, 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 3: Installing Rear Case Bushing
    G02757942Courtesy 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 4: Installing Bearing
    G02757943Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES . Internal damage and shift problems may occur.
    Fig 5: Installing Output Shaft And Output Shaft Ring Gear
    G02757944Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 6: Installing No. 8 Bearing
    G02757945Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 7: Installing Direct Clutch
    G02757946Courtesy 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 8: Installing Reverse Band Support Retaining Ring
    G02757947Courtesy 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 9: Installing Reverse Band
    G02757948Courtesy 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.
    Fig 10: Installing Planetary Assembly
    G02757949Courtesy of FORD MOTOR CO.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
    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 11: Installing Case To Planet Support Spring
    G02757950Courtesy of FORD MOTOR CO.
  10. Install the case to the planet support spring located at the 1 o'clock position.
  11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
    Fig 12: Installing Center Support Retaining Ring
    G02757951Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear two piece bearing and the reverse sun gear.
    Fig 13: Installing Forward Clutch Sun Gear
    G02757952Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 14: Installing No. 4 Forward Clutch Hub Bearing
    G02757953Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 15: Installing Intermediate Stub Shaft
    G02757954Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 16: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G02757955Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 17: Installing Forward Clutch Assembly
    G02757956Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
    Fig 18: Installing Reverse Clutch Cylinder Assembly
    G02757957Courtesy of FORD MOTOR CO.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
    Fig 19: Installing Overdrive Band
    G02757958Courtesy 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 20: Installing Overdrive Servo Spring
    G02757959Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 21: Checking Tip Of Piston Assembly Engages Pocket Of Overdrive Band
    G02757960Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 22: Installing Overdrive Servo Retaining Ring
    G02757961Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 23: Installing Intermediate Clutch Pressure Plate
    G02757962Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid.
    Fig 24: Installing Intermediate Clutch Pack And Selective Steel Plate
    G02757963Courtesy 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
      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 25: Checking Intermediate Clutch Clearance
    G02757964Courtesy 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 THICKNESS

      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 26: Measuring End Play Clearance
    G02757965Courtesy of FORD MOTOR CO.
  26. Install the intermediate anti-rattle clip, if equipped.
    Fig 27: Installing Intermediate Anti-Rattle Clip
    G02757966Courtesy 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 28: Installing No.1 Front Pump Support Thrust Washer
    G02757967Courtesy 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 29: Installing Alignment Pin At Top Of Case
    G02757968Courtesy 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 30: Installing Pump Assembly
    G02757969Courtesy 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 31: Installing Front Pump Bolts
    G02757970Courtesy 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 32: Installing Parking Pawl
    G02757971Courtesy 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 33: Installing Extension Housing Gasket
    G02757972Courtesy 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 34: Installing Extension Housing Seal
    G02757973Courtesy 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 35: Installing Output Shaft Speed (OSS) Sensor
    G02757974Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
    Fig 36: Installing EPC Solenoid
    G02757975Courtesy of FORD MOTOR CO.
  38. Install the EPC solenoid and loosely install the EPC solenoid bracket and bolt.
  39. Using the special tool, install the manual control lever seal.
    Fig 37: Installing Manual Control Lever Seal
    G02757976Courtesy of FORD MOTOR CO.
  40. Install the manual valve detent lever and parking lever actuating rod.
    Fig 38: Installing Manual Valve Detent Lever
    G02757977Courtesy 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 39: Installing Manual Control Lever Shaft
    G02757978Courtesy 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 1-2 accumulator lower spring.
    4. Install the 1-2 accumulator cover and seal.
    Fig 40: Installing 1-2 Accumulator Piston Assembly
    G02757979Courtesy of FORD MOTOR CO.
  43. Install the 1 -2 accumulator retaining ring.
    Fig 41: Installing 1 -2 Accumulator Retaining Ring
    G02757980Courtesy 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 42: Installing Reverse Servo Piston And Rod Assembly
    G02757981Courtesy of FORD MOTOR CO.
  44. Install the reverse servo piston and rod assembly.
  45. Install the special tool.
    • Tighten the bolt.
    Fig 43: Installing Special Tool
    G02757982Courtesy 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 44: Positioning Dial Indicator In Zero Position
    G02757983Courtesy of FORD MOTOR CO.
  47. Loosen the bolt until the piston stops against the tool.
    Fig 45: Loosening Bolt
    G02757984Courtesy of FORD MOTOR CO.
  48. Verify that the amount of piston travel on the dial indicator is within specification
    Fig 46: Checking Dial Indicator Readings
    G02757985Courtesy 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 47: Identifying Servo Piston
    G02757986Courtesy of FORD MOTOR CO.
  50. Remove the special tools.
    Fig 48: Removing Special Tools
    G02757987Courtesy 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 49: Installing Reverse Servo Assembly
    G02757988Courtesy 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 50: Installing Reverse Servo Retaining Ring
    G02757989Courtesy 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 51: Installing 2-3 Accumulator Assembly
    G02757990Courtesy 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 52: Applying Regulated Air Pressure To Test Ports
    G02757991Courtesy of FORD MOTOR CO.
    55. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 53: Installing Electrical Connector Into Case
    G02757992Courtesy 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 54: Positioning Main Control Valve Body
    G02757993Courtesy 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 55: Installing Bolts (Loosely)
    G02757994Courtesy 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 56: Installing Short Main Control Valve Body Bolts (Loosely)
    G02757995Courtesy of FORD MOTOR CO.
  58. Loosely install the 12 short main control valve body bolts.
  59. Install the manual control valve detent lever spring and loosely install the bolt.
    Fig 57: Installing Manual Control Valve Detent Lever Spring
    G02757996Courtesy of FORD MOTOR CO.
  60. Tighten the bolts in the sequence shown.
    Fig 58: Tightening Bolts
    G02757997Courtesy of FORD MOTOR CO.
  61. 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 59: Inspecting Lead Frame For Damage
    G02757998Courtesy of FORD MOTOR CO.
  62. 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 60: Connecting Molded Lead Frame To Solenoids
    G02757999Courtesy of FORD MOTOR CO.
  63. Install the fluid filter and seal assembly.
    Fig 61: Installing Fluid Filter And Seal Assembly
    G02758000Courtesy of FORD MOTOR CO.
  64. Position the pan magnet into the transmission fluid pan.
    Fig 62: Positioning Pan Magnet Into Transmission Fluid Pan
    G02758001Courtesy of FORD MOTOR CO.
    65. NOTE: The pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
    Fig 63: Installing Fluid Pan
    G02758002Courtesy of FORD MOTOR CO.
  65. Install the fluid pan.
    1. Position the transmission fluid pan and gasket.
    2. Install the transmission fluid pan bolts.
  66. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
    Fig 64: Installing Digital Transmission Range (TR) Sensor
    G02758003Courtesy of FORD MOTOR CO.
    67. NOTE: The tool is designed to fit snugly.
    NOTE: Manual shift lever must be in the NEUTRAL position.
    Fig 65: Aligning Digital TR Sensor Slots
    G02758004Courtesy of FORD MOTOR CO.
  67. Using the special tool, align the digital TR sensor slots.
    68. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    Fig 66: Tightening Screws
    G02758005Courtesy of FORD MOTOR CO.
  68. Tighten the screws in an alternating sequence.
  69. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 67: Identifying Converter Hub
    G02758006Courtesy of FORD MOTOR CO.
    70. 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 68: Installing Torque Converter
    G02758007Courtesy of FORD MOTOR CO.
  70. Using the special tools, install the torque converter.
  71. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 69: Identifying Torque Converter Pilot Hub
    G02758008Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals