LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2009 >> Sable Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1319 (Automatic Transmission) >> Assembly >> Transmission

Section 1319 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000964Courtesy of FORD MOTOR CO.
 Adjustment Set, Transmission Band 307-S022 (T71P-77370-A)
GF0000940Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0000965Courtesy of FORD MOTOR CO.
 Depth Micrometer 303-D026 (D80P-4201-A) or equivalent
GF0000909Courtesy of FORD MOTOR CO.
 Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)
GF0000966Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Oil Seal 307-038 (T74P-77052-A)
GF0000949Courtesy of FORD MOTOR CO.
 Sizer, Piston Seal 307-338 (T95L-70010-G)
GF0000946Courtesy of FORD MOTOR CO.
 Alignment Set, Fluid Pump 307-S039 (T74P-77103-X)
GF0000947Courtesy of FORD MOTOR CO.
 Aligner, Fluid Pump Handle 307-431
GF0000948Courtesy of FORD MOTOR CO.
 Aligner, Fluid Pump Pilot 307-432
GF0000967Courtesy of FORD MOTOR CO.
 Gauge Bar 307-400
GF0000941Courtesy of FORD MOTOR CO.
 Compressor, Servo Cover 307-402
GF0000968Courtesy of FORD MOTOR CO.
 Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)
GF0000942Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0000969Courtesy of FORD MOTOR CO.
 Compressor, Cushion Spring 307-401
GF0000925Courtesy of FORD MOTOR CO.
 Aligner, Valve Body 307-334 (T95L-70010-C)
GF0000970Courtesy of FORD MOTOR CO.
 Alignment Pins, Transmission Pump 307-399
GF0000971Courtesy of FORD MOTOR CO.
 Aligner, Flex Plate 307-403
GF0000910Courtesy of FORD MOTOR CO.
 Air Test Plate and Gaskets, Transmission 307-433-01, 307-433-2, 307-433-3
GF0000929Courtesy of FORD MOTOR CO.
 Installer, Drive Pinion flange 205-479
GF0000930Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Flange 307-404
Material

Item Specification
MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)		 MERCON® V
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
Fig 1: Exploded View Of Transmission Assembly (1 Of 3)
GF0000972Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transmission Assembly (2 Of 3)
GF0000973Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transmission Assembly (3 Of 3)
GF0000974Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7045 Converter-to-flexplate nut (attaches the converter assembly to the flexplate) (4.0L only)
2 7902 Converter assembly
3 N800750 Converter-to-adapter plate nut (attaches the converter assembly to the adapter plate) (8 required) (4.6L only)
4 N800750 Adapter plate-to-flexplate nut (attaches adapter plate to the flexplate) (4 required) (4.6L only)
5 6K374 Adapter plate assembly (4.6L only)
6 7902 Converter assembly
7 7017 Input shaft
8 7A248 Front fluid pump seal assembly
9 7A248 Front fluid pump seal
10 W704892 Screw and washer assembly - M8 x 35 internal lobe (attaches pump to case) (8 required)
11 7G178 Fluid pump cover assembly
12 7B472 Fluid pump adapter plate
13 7A136 Front fluid pump gasket
14 W701431 Fluid pump shaft-to-inner gear O-ring seal (also in pump assembly)
15 7L323 Stator support seal
16 7A108 Front pump support assembly
17 7H416 O-ring
18 7H411 Fluid pump control valve
19 7A103 Fluid pump assembly
20 W701429 M8 x 1 x 35 internal lobe screw (attaches pump support to pump assembly) (6 required)
21 7D025 Overdrive brake drum seals
22 7D014 Fluid pump input thrust washer No. 1
23 7D029 Intermediate and overdrive brake band anchor struts (2 required)
24 7D034 Intermediate and overdrive brake bands (2 required)
25 7D029 Intermediate and overdrive brake band apply struts (2 required)
26 7C492 Overdrive/intermediate band adjusting screws
27 71000 Overdrive/intermediate locking nuts
28 7L669 Overdrive brake band drum assembly
29 7A548 Direct and overdrive piston outer seals
30 7D404 Direct and overdrive piston inner seals
31 7A262 Direct and overdrive clutch pistons
32 7A480 Direct and overdrive clutch piston springs
33 7A527 Clutch piston spring retainers (2 required)
34 E860125 Retaining rings (retains 7D041 to drum) (2 required)
35 7B442 Coast clutch external splined plates (steel) (2 required)
36 7B164 Coast clutch internal splined friction plates (2 required)
37 7B066 Coast and direct clutch pressure plate (2 required)
38 E860126 - E860129 Coast and direct clutch plates retaining ring (select fit) (2 required)
39 7660 Coast clutch to overdrive carrier adapter
40 7D063 Overdrive sun gear
41 7B446 Overdrive planetary gear carrier (with trigger wheel)
42 7L495 Overdrive planet thrust bearing No. 2
43 7A153 Overdrive ring gear
44 7A089 Center shaft one-way clutch assembly
45 7A658 Overdrive center shaft
46 W702037 Retaining ring (retains 7686 to 7653)
47 7L678 Hub and ring gear assembly (includes 7C109, 7A153, 7A658, W702037)
48 7M153 Center shaft and forward clutch cylinder bearing assembly No. 3, No. 5, No. 8 and No. 9 (4 required)
49 W702465 Retaining ring
50 7A130 Center support assembly
51 E826160 Nut and cage assembly (attaches center support to case)
52 W705407 Bolt
53 7D014 Intermediate clutch drum bearing No. 4
54 7D044 Intermediate brake drum assembly
55 7B442 Direct clutch external splined steel plates (5 required)
56 7B164 Direct clutch internal splined friction plates (5 required)
57 7A360 Forward clutch cylinder
58 7A262 Forward clutch piston assembly
59 7G299 Forward clutch support and spring assembly
60 E860109 Forward clutch piston and spring retaining ring in forward clutch cylinder
61 7B442 Forward clutch external spline steel plates (5 required)
62 7B164 Forward clutch internally spline friction plates (5 required)
63 7B066 Forward clutch pressure plate
64 7D483 Retaining ring 141.45 x 1.37 internal (select fit)
65 7D234 Forward ring gear hub thrust bearing No. 6A
66 7D090 Forward clutch thrust washer No. 6B
67 7G375 Forward clutch hub retainer ring
68 7B067 Forward ring gear hub
69 7D392 Forward ring gear
70 7F374 Forward planet thrust bearing No. 7
71 7A398 Forward planetary
72 7A019 Shell and sun gear assembly
73 7C167 Low and reverse spacer gear
74 W702775 Reverse carrier drum snap ring
75 7D006 Reverse planet assembly
76 7B176 Output shaft sleeve
77 E860527 External retainer ring
78 7A153 Output shaft ring gear
79 7D164 Output shaft hub
80 7C122 Output shaft ring gear retaining ring
81 7D019 Output shaft hub seal
82 7H027 Low/intermediate sun gear bearing assembly
83 7C498 Reverse brake drum and clutch assembly (includes OWC)
84 7D095 Low/reverse band assembly
85 7R205 Output shaft bearing
86 7B368 Output shaft thrust washer No.11
87 7A233 Transmission parking gear assembly
88 7060 Output shaft
89 7A441 Parking pawl
90 7D070 Parking pawl return spring
91 7D071 Parking pawl shaft
92 7086 Extension housing gasket
93 7A039 Extension housing
94 W500311 M8 x 1.25 extension housing-to-case screw (5 required)
95 7052 Extension housing seal
96 7089 Output shaft flange
97 W701357 Output shaft flange nut
98 7D273 Fluid tube connector assembly (2 required)
99 7H074 Ring overdrive servo retainer
100 W703119 Overdrive servo cover seals (2 required)
101 7D027 Overdrive servo cover
102 7D021 Overdrive servo piston and rod
103 7D028 Intermediate/overdrive servo piston springs (2 required)
104 W702777 Ring intermediate servo retainer
105 W702969 Intermediate servo cover seal
106 7D027 Intermediate servo cover
107 7D021 Intermediate servo piston and rod
108 7005 Case assembly
109 7034 Case vent assembly
110 W708389 Speed sensor-to-case screws (M6 x 19)
111 7H103 Output shaft speed, turbine shaft speed and intermediate shaft speed sensors
112 W702981 Speed sensor-to-case O-ring seals
113 7A179 Reverse brake drum lever
114 7D433 Reverse band actuating lever shaft
115 7A232 Parking pawl actuating rod
116 390318 Pipe plug
117 W703001 Manual lever shaft outer and inner nut
118 7A115 Manual valve inner lever
119 7B498 Manual control lever seal
120 7A256 Manual control lever
121 7F293 Digital transmission range (TR) sensor
122 W500015 Digital TR sensor screw and washer (2 required)
123 6026 Fluid fill plug
124 7B210 Manual lever shaft pin retainer
125 7B193 Reverse servo assembly
126 7D372 Reverse servo plate
127 7D466 Reverse servo accumulator spring
128 7D189 Reverse servo piston and seal
129 7423 Reverse servo piston O-ring seal
130 7D036 Reverse servo cover
131 W702359 Reverse servo piston-to-case screw (4 required)
132 7D321 Control valve spring retainer
133 7A270 Main fluid pressure spring regulator valve
134 7D488 Reverse servo check valve
135 W701099 Main control valve body separating plate screws
136 7Z490 Main control valve body separating plate (bonded)
137 7A101 Lower main control valve body
138 W500102 Main control valve body screws (18 required)
139 W702791 Main control valve body screw
140 7E332 Manual valve detent spring
141 W500100 Screw detent spring
142 W706672 Main control valve body screw
143 7A100 Main control valve body
144 W705928 Solenoid body connector O-ring seals
145 7G391 Transmission control solenoid body
146 W702921 Transmission control solenoid body screw
147 W703189 Transmission control solenoid body screws (7 required)
148 7A098 Transmission fluid pan filter
149 W705559 Transmission fluid pan filter screws
150 7L027 Transmission fluid pan magnet
151 7A191 Transmission fluid pan gasket
152 7A194 Transmission fluid pan
153 6734 Transmission fluid pan drain plug gasket
154 7A010 Transmission fluid pan drain plug
155 W500213 Transmission fluid pan screw
156 W707919 Transmission fluid pan drain tube plug (short hex)
157 - Overdrive/coast clutch assembly
158 - Direct clutch assembly
159 - Forward clutch assembly
160 - Overdrive servo
161 - Intermediate servo
  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    • Stripped bolt hole threads.
    • Gasket and mating surfaces for burrs or nicks.
    • Obstructions to vent and fluid passages.
    • Cracks or warpage.
    3. Fig 4: Locating Transmission Case
    GF0015653Courtesy of FORD MOTOR CO.
  3. Inspect the extension housing for cracks, burrs or warpage.
    4. Fig 5: Locating Extension Housing
    GF0015654Courtesy of FORD MOTOR CO.
  4. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.
    5. Fig 6: Identifying Case Bearing
    GF0015655Courtesy of FORD MOTOR CO.
    WARNING: Always verify that the lock pin on the bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.
  5. Using the special tool, install the transmission into the bench with the converter housing facing up.
    6. Fig 7: Identifying Special Tool (307-003)
    GF0015513Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
    7. Fig 8: Installing Manual Control Lever Shaft Seal Using Special Tool (307-050)
    GF0010052Courtesy of FORD MOTOR CO.
  7. Install the parking lever rod.
    8. Fig 9: Identifying Parking Lever Actuating Rod
    GF0015575Courtesy of FORD MOTOR CO.
  8. Install the manual control lever.
    9. Fig 10: Identifying Manual Control Valve Inner Lever
    GF0015574Courtesy of FORD MOTOR CO.
  9. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    10. Fig 11: Locating Manual Valve Inner Lever At Parking Lever Actuating Rod
    GF0015573Courtesy of FORD MOTOR CO.
    NOTE: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
  10. Install the manual control lever shaft.
    11. Fig 12: Identifying Manual Control Lever Shaft
    GF0015656Courtesy of FORD MOTOR CO.
  11. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
    12. Fig 13: Locating Manual Valve Inner Lever And Mounting Nut
    GF0015657Courtesy of FORD MOTOR CO.
    CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
  12. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
    13. Fig 14: Locating Manual Control Lever Shaft Spring Pin
    GF0015658Courtesy of FORD MOTOR CO.
    CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
  13. Tighten the nut.
    • Tighten to 48 Nm (35 lb-ft).
    14. Fig 15: Tightening Nut
    GF0015659Courtesy of FORD MOTOR CO.
    CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated or damage may occur.
  14. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
    15. Fig 16: Locating Output Shaft Thrust Washer
    GF0015570Courtesy of FORD MOTOR CO.
  15. Install the park gear on the output shaft.
    16. Fig 17: Locating Park Gear On Output Shaft
    GF0015660Courtesy of FORD MOTOR CO.
  16. Install the output shaft and park gear.
    17. Fig 18: Locating Output Shaft And Park Gear
    GF0015569Courtesy of FORD MOTOR CO.
  17. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    18. Fig 19: Locating Low/Reverse Brake Drum
    GF0015566Courtesy of FORD MOTOR CO.
    NOTE: Make sure band is resting on the 2 anchor pins in the case.
  18. Install the low/reverse band over the reverse drum.
    19. Fig 20: Locating Reverse Band
    GF0015568Courtesy of FORD MOTOR CO.
    NOTE: The reverse band actuating lever must fit into the notches in the band.
  19. Install the reverse band actuating lever into the reverse band.
    20. Fig 21: Identifying Reverse Band Actuating Lever
    GF0015565Courtesy of FORD MOTOR CO.
  20. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.
    21. Fig 22: Identifying Reverse Band Actuating Lever Shaft
    GF0015564Courtesy of FORD MOTOR CO.
  21. Install the No. 10 needle bearing into the case.
    22. Fig 23: Identifying No. 10 Low Intermediate Sun Gear Bearing
    GF0015563Courtesy of FORD MOTOR CO.
    CAUTION: Do not damage the seal against the case during assembly.
  22. Install the output shaft ring gear, hub and seal.
    23. Fig 24: Locating Output Shaft Ring Gear
    GF0015562Courtesy of FORD MOTOR CO.
    CAUTION: Always install a new output shaft retaining ring, otherwise transmission damage can occur.
  23. Install a new output shaft retaining ring.
    24. Fig 25: Locating Output Shaft Retaining Ring
    GF0015561Courtesy of FORD MOTOR CO.
    NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
  24. Install the output shaft sleeve.
    25. Fig 26: Locating Output Shaft Sleeve
    GF0015560Courtesy of FORD MOTOR CO.
  25. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.
    26. Fig 27: Locating Thrust Bearing
    GF0015559Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the needle bearings stay in place or damage may occur.
  26. Install the low/reverse planetary assembly.
    27. Fig 28: Locating Low/Reverse Planetary Assembly
    GF0015558Courtesy of FORD MOTOR CO.
    NOTE: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
  27. Install the retaining ring.
    28. Fig 29: Identifying Retaining Ring
    GF0015557Courtesy of FORD MOTOR CO.
  28. Install the No. 8 thrust bearing.
    29. Fig 30: Identifying Thrust Bearing
    GF0015556Courtesy of FORD MOTOR CO.
  29. Install the spacer on the input shell, using petroleum jelly to hold it in place.
    30. Fig 31: Locating Spacer On Input Shell
    GF0015661Courtesy of FORD MOTOR CO.
  30. Install the input shell and sun gear assembly.
    31. Fig 32: Locating Input Shell And Sun Gear Assembly
    GF0015554Courtesy of FORD MOTOR CO.
    NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
  31. Install the forward planetary assembly.
    32. Fig 33: Locating Forward Planetary Assembly
    GF0015553Courtesy of FORD MOTOR CO.
  32. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.
    33. Fig 34: Identifying No. 7 Forward Planet Thrust Bearing
    GF0015552Courtesy of FORD MOTOR CO.
  33. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.
    34. Fig 35: Identifying No. 6B Forward Clutch Thrust Washer
    GF0015551Courtesy of FORD MOTOR CO.
  34. Install the forward ring gear and hub as an assembly.
    35. Fig 36: Locating Forward Ring Gear And Hub
    GF0015550Courtesy of FORD MOTOR CO.
  35. Install the No. 6A forward ring gear hub thrust bearing into the forward ring gear and hub.
    36. Fig 37: Locating No. 6A Forward Ring Gear Hub Thrust Bearing
    GF0015662Courtesy of FORD MOTOR CO.
  36. Install the forward clutch cylinder.
    37. Fig 38: Locating Forward Clutch Cylinder
    GF0015548Courtesy of FORD MOTOR CO.
  37. Install the No. 5 thrust bearing.
    38. Fig 39: Locating No. 5 Forward Clutch Cylinder Thrust Bearing
    GF0015547Courtesy of FORD MOTOR CO.
  38. Install the intermediate servo piston and spring.
    • Lubricate the servo bore with clean automatic transmission fluid.
    39. Fig 40: Locating Intermediate Servo Piston And Spring
    GF0015663Courtesy of FORD MOTOR CO.
  39. Using the special tool, install the retaining ring.
    40. Fig 41: Identifying Special Tool (307-402)
    GF0015522Courtesy of FORD MOTOR CO.
  40. Install the direct clutch drum.
    41. Fig 42: Locating Direct Clutch Drum
    GF0015546Courtesy of FORD MOTOR CO.
  41. Using a depth micrometer with an 8-inch extension, measure from the top of the gauge bar to center support ledge in the case at 4 places 90 degrees apart.
    • Add the 4 measurements, divide by 4, and record as dimension A.
    42. Fig 43: Identifying Special Tool (307-400)
    GF0015664Courtesy of FORD MOTOR CO.
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  42. Install the special tool.
    1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
      • Tighten to 15 Nm (11 lb-ft).
    2. Tighten the center screw.
      • Tighten to 1.13 Nm (10 lb-in).
    43. Fig 44: Identifying Special Tool (307-401)
    GF0015665Courtesy of FORD MOTOR CO.
    NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  43. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension C.
    44. Fig 45: Identifying Special Tools (307-400), (303-D026) & (307-401)
    GF0015666Courtesy of FORD MOTOR CO.
  44. Add dimension B to C, divide by 2, and record as dimension D.
  45. Subtract A from D and record as dimension E.
  46. Select bearing from the following chart, using dimension E.
    Dimension E Service Part Number (7D014) Bearing Thickness Identification (Notches)
    1.69-1.87 mm
    (0.066-0.074 in)    		 XW4Z-CA 2.65-2.80 mm
    (0.104-0.110 in)    		 None
    1.88-2.04 mm
    (0.073-0.080 in)    		 XW4X-DA 2.83-2.98 mm
    (0.111-0.116 in)    		 One
    2.05-2.22 mm
    (0.081- 0.088 in)    		 XW4Z-EA 3.01-3.16 mm
    (0.118-0.124 in)    		 Two
    2.23-2.43 mm
    (0.088-0.096 in)    		 XW4Z-FA 3.21-3.36 mm
    (0.126-0.132 in)    		 Three
    47. NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
    NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
    NOTE: The new intermediate band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  47. Install the intermediate band.
    48. Fig 46: Identifying Intermediate Band
    GF0015544Courtesy of FORD MOTOR CO.
    CAUTION: To avoid a "fall-out" condition of the strut from the screw during assembly and function, the small "U" shaped notch should be toward the band/case side and the large "U" shaped notch toward the main control side.
  48. Install the intermediate band anchor strut.
    1. Band/case side of the anchor (small U notch).
    2. Main control side of the anchor (large U notch).
    49. Fig 47: Locating Intermediate Band Anchor Strut
    GF0000975Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  49. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
    50. Fig 48: Checking Intermediate Band Anchor Strut Installation
    GF0015667Courtesy of FORD MOTOR CO.
  50. Loosely install the screw.
    51. Fig 49: Locating Screw
    GF0000943Courtesy of FORD MOTOR CO.
  51. Install the intermediate band apply strut.
    52. Fig 50: Locating Intermediate Band Apply Strut
    GF0015545Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  52. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
    53. Fig 51: Identifying Band Apply Strut Installed In Correct Orientation To Case And Piston Rod
    GF0015668Courtesy of FORD MOTOR CO.
  53. Install the selected No. 4 thrust washer on the direct clutch drum.
    • Coat the thrust washer with petroleum jelly.
    54. Fig 52: Locating Intermediate Brake Drum Thrust Bearing
    GF0015542Courtesy of FORD MOTOR CO.
    NOTE: Align the center support screw hole with correct case hole.
  54. Install the center support.
    55. Fig 53: Identifying Center Support
    GF0015537Courtesy of FORD MOTOR CO.
  55. Install the center support lock nut and cage.
    56. Fig 54: Locating Locknut And Cage
    GF0015535Courtesy of FORD MOTOR CO.
  56. Loosely install the screw.
    57. Fig 55: Locating Center Support Screw
    GF0015669Courtesy of FORD MOTOR CO.
    CAUTION: Install the center support retaining ring with the tapered side facing up or damage may occur.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring or damage may occur.
  57. Install the center support retaining ring.
    1. Make sure the center support retaining ring is installed with the tapered side facing up.
    2. Make sure the opening of the center support retaining ring is positioned correctly.
    58. Fig 56: Identifying Center Support Retaining Ring With Tapered Side Facing Up
    GF0010317Courtesy of FORD MOTOR CO.
  58. Install the center shaft thrust bearing (No. 3).
    59. Fig 57: Locating Center Shaft Thrust Bearing
    GF0015533Courtesy of FORD MOTOR CO.
  59. Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.
    60. Fig 58: Locating Overdrive Ring Gear
    GF0015532Courtesy of FORD MOTOR CO.
    CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
  60. Install the planetary gear overdrive carrier.
    61. Fig 59: Locating Planetary Gear Overdrive Carrier
    GF0015530Courtesy of FORD MOTOR CO.
  61. Install the overdrive brake drum and coast clutch drum assembly.
    62. Fig 60: Locating Overdrive Brake And Coast Clutch Drum
    GF0015529Courtesy of FORD MOTOR CO.
  62. Install the overdrive band servo piston and spring.
    • Lubricate the servo bore with clean automatic transmission fluid.
    63. Fig 61: Locating Overdrive Band Servo Piston
    GF0015670Courtesy of FORD MOTOR CO.
  63. Using the special tools, install the retaining ring.
    64. Fig 62: Installing Retaining Ring Using Special Tool (307-402)
    GF0015671Courtesy of FORD MOTOR CO.
    NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
    NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
    NOTE: The new overdrive band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  64. Install the overdrive band.
    65. Fig 63: Locating Overdrive Band
    GF0015528Courtesy of FORD MOTOR CO.
    CAUTION: To avoid a fall-out condition of the strut from the screw during assembly and function, the small U shaped notch should be toward the band/case side and the large U shaped notch toward the main control side.
  65. Install the overdrive band anchor strut.
    1. Band/case side of the anchor (small U notch).
    2. Main control side of the anchor (large U notch).
    66. Fig 64: Identifying Band/Case Side Of Anchor And Main Control Side Of Anchor
    GF0015672Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  66. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
    67. Fig 65: Checking Intermediate Band Anchor Strut Installation
    GF0015667Courtesy of FORD MOTOR CO.
  67. Loosely install the screw.
    68. Fig 66: Locating Screw
    GF0015526Courtesy of FORD MOTOR CO.
  68. Install the overdrive apply strut.
    69. Fig 67: Identifying Overdrive Apply Strut
    GF0015673Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  69. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.
    70. Fig 68: Identifying Overdrive Band Applying Strut Position
    GF0015674Courtesy of FORD MOTOR CO.
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  70. Install the special tool.
    1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
      • Tighten to 15 Nm (11 lb-ft).
    2. Tighten the center screw.
      • Tighten to 1 Nm (9 lb-in).
    71. Fig 69: Identifying Special Tool (307-401)
    GF0015675Courtesy of FORD MOTOR CO.
    NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  71. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension B.
    72. Fig 70: Identifying Special Tool (307-400) And (307-401)
    GF0015676Courtesy of FORD MOTOR CO.
  72. Add dimension A to B, divide by 2, and record as dimension C.
  73. Subtract the thickness of the gauge bar 17.78 mm (0.70 in) from dimension C and record as dimension D.
  74. Select the No. 1 thrust bearing from the following chart using dimension D.
    Dimension D Service Part Number (7D014) Bearing Thickness Identification (Color/ID)
    38.05-38.13 mm
    (1.498-1.501 in)    		 F7TZ-TA 1.55-1.60 mm (0.061-0.063 in) White
    38.14-38.28 mm
    (1.50-1.51 in)    		 F7TZ-MA 1.75-1.80 mm (0.069-0.071 in) Green
    38.29-38.42 mm
    (1.507-1.513 in)    		 F7TZ-NA 1.85-1.90 mm (0.073-0.075 in) Red
    38.43-38.61 mm
    (1.51-1.52 in)    		 F7TZ-RA 2.05-2.10 mm (0.081-0.083 in) Black
    38.62-38.74 mm (1.52-1.53 in) F7TZ-SA 2.15-2.20 mm (0.095-0.097 in) Yellow
  75. Install the selected No. 1 fluid pump input thrust washer.
    • Coat the fluid pump input thrust washer with petroleum jelly.
    76. Fig 71: Locating No. 1 Fluid Pump Input Thrust Washer
    GF0015677Courtesy of FORD MOTOR CO.
  76. Install the special tools into the transmission case.
    77. Fig 72: Identifying Special Tool (307-339)
    GF0015678Courtesy of FORD MOTOR CO.
  77. Install the pump gasket.
    78. Fig 73: Locating Pump Gasket
    GF0015679Courtesy of FORD MOTOR CO.
    CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step or damage may occur.
  78. Install the fluid pump.
    79. Fig 74: Installing Fluid Pump Using Special Tool (307-399)
    GF0015680Courtesy of FORD MOTOR CO.
    CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage.
  79. Using the special tool, align the fluid pump to the adapter plate.
    80. Fig 75: Aligning Fluid Pump To Adapter Plate Using Special Tools
    GF0000976Courtesy of FORD MOTOR CO.
  80. Install screws. Tighten the screws in a star pattern.
    • Tighten to 25 Nm (18 lb-ft).
    81. Fig 76: Tightening Screws In Star Pattern
    GF0015681Courtesy of FORD MOTOR CO.
  81. Remove the special tools and install the 2 remaining screws.
    • Tighten to 25 Nm (18 lb-ft).
    82. Fig 77: Locating Remaining Screws
    GF0015682Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut may fall out of position.
    NOTE: Install, but do not tighten, a new lock nut on the band adjustment screw. Apply petroleum jelly to the lock nut seal.
  82. Install a new lock nut on the band adjustment screw.
    83. Fig 78: Locating Lock nut On Band Adjustment Screw
    GF0015683Courtesy of FORD MOTOR CO.
    CAUTION: The overdrive servo must be installed prior to band adjustment or damage may occur.
  83. Using the special tool, tighten the overdrive band adjustment screw.
    • Tighten to 14 Nm (10 lb-ft).
    • Then back off the screw exactly 1.5 turns and hold that position.
    84. Fig 79: Identifying Special Tool (307-S022)
    GF0015684Courtesy of FORD MOTOR CO.
  84. Tighten the overdrive band lock nut.
    1. Hold the overdrive band adjustment screw stationary.
    2. Tighten the overdrive band lock nut.
      • Tighten to 54 Nm (40 lb-ft).
    85. Fig 80: Identifying Overdrive Band Adjustment Screw And Overdrive Band Lock nut
    GF0015685Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position.
    NOTE: Install, but do not tighten, a new lock nut on the band adjustment screw. Apply petroleum jelly to the lock nut seal.
  85. Install new nut on the band adjustment screw.
    86. Fig 81: Locating Lock nut On Band Adjustment Screw
    GF0000977Courtesy of FORD MOTOR CO.
    CAUTION: The intermediate servo must be installed prior to band adjustment or damage may occur.
  86. Using the special tool, tighten the intermediate band adjustment screw.
    • Tighten to 14 Nm (10 lb-ft).
    • Then back off the screw exactly 1.5 turns and hold that position.
    87. Fig 82: Identifying Special Tool (307-S022)
    GF0015686Courtesy of FORD MOTOR CO.
  87. Tighten the intermediate band lock nut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band lock nut.
      • Tighten to 54 Nm (40 lb-ft).
    88. Fig 83: Locating Intermediate Band Adjustment Screw And Intermediate Band Lock nut
    GF0015687Courtesy of FORD MOTOR CO.
  88. Tighten the center support screw.
    • Tighten to 11 Nm (8 lb-ft).
    89. Fig 84: Locating Center Support Screw
    GF0000978Courtesy of FORD MOTOR CO.
  89. Using the special tools, carry out the Air Pressure Tests . For additional information, refer to Special Testing Procedures .
    90. Fig 85: Carrying Out Air Pressure Test
    GF0015688Courtesy of FORD MOTOR CO.
  90. Install the special tools into the transmission case.
    91. Fig 86: Installing Special Tools (307-334) Into Transmission Case
    GF0015689Courtesy of FORD MOTOR CO.
  91. Using the special tools, install the main control valve body and loosely install the screws.
    1. Install the short screw.
    2. Install the screw with the larger head.
    3. Install the remaining screws.
    92. Fig 87: Locating Main Control Valve Body & Special Tool (307-334)
    GF0015472Courtesy of FORD MOTOR CO.
  92. Remove the special tools, and loosely install the screw.
    93. Fig 88: Locating Screw
    GF0015473Courtesy of FORD MOTOR CO.
  93. Tighten the screws in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    94. Fig 89: Identifying Tightening Sequence Of Main Control Valve Body Screws
    GF0015474Courtesy of FORD MOTOR CO.
  94. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
    • Tighten to 10 Nm (89 lb-in).
    95. Fig 90: Locating Manual Control Valve Detent Spring
    GF0015475Courtesy of FORD MOTOR CO.
  95. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.
    96. Fig 91: Locating O-Ring Seals On Solenoid Body Connector
    GF0015477Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.
  96. Install the solenoid body. Tighten the screws in the sequence shown.
    • Tighten to 8 Nm (71 lb-in).
    97. Fig 92: Identifying Solenoid Body Screw Tightening Sequence
    GF0015478Courtesy of FORD MOTOR CO.
  97. Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 11 N.m (8 lb-ft).
    98. Fig 93: Identifying Tightening Sequence For Reverse Servo Bolts
    GF0015690Courtesy of FORD MOTOR CO.
    CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
    NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
  98. Lubricate the seals and install the transmission fluid filter.
    • Tighten to 10 Nm (89 lb-in).
    99. Fig 94: Locating Transmission Fluid Filter Bolts
    GF0015479Courtesy of FORD MOTOR CO.
    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
  99. Install the transmission fluid pan and gasket and loosely install the screws.
    100. Fig 95: Locating Transmission Fluid Pan Gasket
    GF0000924Courtesy of FORD MOTOR CO.
  100. Tighten the 16 screws in a crisscross sequence.
    • Tighten to 11 Nm (8 lb-ft).
    101. Fig 96: Locating Transmission Fluid Pan Gasket
    GF0000924Courtesy of FORD MOTOR CO.
  101. Install the drain plug.
    • Install a new gasket onto the drain plug assembly.
    • Tighten to 26 Nm (19 lb-ft).
    102. Fig 97: Locating Drain Plug
    GF0015455Courtesy of FORD MOTOR CO.
  102. Install the parking pawl assembly and gasket.
    1. Install the parking pawl shaft.
    2. Install the parking pawl return spring.
    3. Install the parking pawl.
    4. Install a new gasket.
    103. Fig 98: Identifying Parking Pawl Shaft, Parking Pawl Return Spring, Parking Pawl And New Gasket
    GF0015691Courtesy of FORD MOTOR CO.
  103. Install the extension housing.
    • Tighten to 30 Nm (22 lb-ft).
    104. Fig 99: Locating Extension Housing And Mounting Screws
    GF0015488Courtesy of FORD MOTOR CO.
  104. Using the special tool, install the extension housing seal.
    105. Fig 100: Identifying Special Tool (307-038)
    GF0015692Courtesy of FORD MOTOR CO.
  105. Using the special tools, install the output shaft flange.
    106. Fig 101: Installing Output Shaft Flange Using Special Tools (307-404) & (205-479)
    GF0015486Courtesy of FORD MOTOR CO.
  106. Install a new nut.
    • Tighten to 130 Nm (96 lb-ft).
    107. Fig 102: Removing Driveshaft Nut
    GF0015482Courtesy of FORD MOTOR CO.
    CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor.
  107. Install the digital TR sensor and loosely install the screws.
    108. Fig 103: Locating Transmission Range (TR) Sensor
    GF0015494Courtesy of FORD MOTOR CO.
    CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
  108. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
    • Tighten 8 Nm (71 lb-in).
    109. Fig 104: Identifying Special Tool (307-351)
    GF0015453Courtesy of FORD MOTOR CO.
    CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump or damage may occur.
  109. Install the input shaft.
    110. Fig 105: Locating Input Shaft
    GF0015512Courtesy of FORD MOTOR CO.
  110. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
    111. Fig 106: Identifying Special Tool (307-338)
    GF0015693Courtesy of FORD MOTOR CO.
  111. Remove the special tool.
    112. Fig 107: Identifying Special Tool (307-338)
    GF0015693Courtesy of FORD MOTOR CO.
    CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the 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.
  112. Lubricate the converter hub with clean automatic transmission fluid.
    113. Fig 108: Lubricating Converter Hub
    GF0015694Courtesy of FORD MOTOR CO.
    WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.
  113. Using the special tools, install the torque converter by pushing and rotating.
    114. Fig 109: Using Special Tool (307-091) To Install Torque Converter
    GF0010372Courtesy of FORD MOTOR CO.
  114. Lubricate the torque converter pilot hub with multi-purpose grease.
    115. Fig 110: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    GF0015695Courtesy of FORD MOTOR CO.
    CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage may occur. In order to correctly install the special service tool, it must be installed using 1 round and 1 oblong hole. Using 2 oblong holes will cause damage to the transmission.
    NOTE: Position the adapter plate on the torque converter and identify the position of the orange or green paint daub on the converter face.
  115. If the vehicle is equipped, use the special tool to install the torque converter flexplate adapter assembly and 8 nuts.
    • Tighten to 44 Nm (32 lb-ft).
    116. Fig 111: Identifying Special Tool (307-403)
    GF0015696Courtesy of FORD MOTOR CO.
  116. Remove the special tool and install the remaining torque converter flexplate adapter nuts.
    • Tighten to 44 Nm (32 lb-ft).
    117. Fig 112: Locating Torque Converter Adapter Plate
    GF0015510Courtesy of FORD MOTOR CO.
  117. Using one of the speed sensor holes, fill the transmission with 8.5L (9 qt) of automatic transmission fluid.
    118. Fig 113: Locating Speed Sensor Holes
    GF0015697Courtesy of FORD MOTOR CO.
    NOTE: Inspect O-ring seals for damage. Install new O-ring seals if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
  118. Install the sensors.
    • Tighten to 14 Nm (10 lb-ft).
    119. Fig 114: Locating Speed Sensor
    GF0015698Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals