LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2009 >> Sable Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1376 (Automatic Transmission) >> Disassembly >> Transmission

Section 1376 (Automatic Transmission): Disassembly: Transmission

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

Illustration Tool Name Tool Number
GF0000942Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0000940Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0003256Courtesy of FORD MOTOR CO.
 Remover, Bearing Cup 308-047 (T77F-1102-A)
GF0003517Courtesy of FORD MOTOR CO.
 Remover/Installer, Servo Piston 307-251 (T92P-70023-A)
GF0003503Courtesy of FORD MOTOR CO.
 Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH)
GF0003559Courtesy of FORD MOTOR CO.
 Remover, Transmission Fluid Pump 307-221 (T89T-70010-A)
GF0003503Courtesy of FORD MOTOR CO.
 Remover, Transmission Fluid Seal 307-048 (T74P-77248-A)
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0003558Courtesy of FORD MOTOR CO.
 Slide Hammer 307-005 (T59L-100-B)
  1. Using the special tools, remove the torque converter.
    2. Fig 1: Removing/Installing Torque Converter
    GF0003560Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transmission to the bench.
    3. Fig 2: Mounting Transmission To Bench
    GF0003561Courtesy of FORD MOTOR CO.
    NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
  3. Remove the bolts, transmission fluid pan and transmission fluid pan gasket.
    4. Fig 3: Locating Transmission Fluid Pan Bolts
    GF0003562Courtesy of FORD MOTOR CO.
  4. Clean the transmission fluid pan and pan magnet.
    5. Fig 4: Locating Pan Magnet In Transmission Fluid Pan
    G03888537Courtesy of FORD MOTOR CO.
    CAUTION: If installing a new transmission fluid filter and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new transmission fluid filter and seal. The transmission fluid filter may be reused if no excessive contamination is present.
  5. Remove the transmission fluid filter and grommet.
    6. Fig 5: Removing Transmission Fluid Filter And Grommet
    GF0003563Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
  6. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead interconnector.
    7. Fig 6: Identifying Molded Lead Frame And Solenoids
    G04584282Courtesy of FORD MOTOR CO.
  7. Remove the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
    1. Remove the OSS sensor bolt.
    2. Remove the OSS sensor.
    3. Remove the TSS sensor bolt.
    4. Remove the TSS sensor.
    8. Fig 7: Identifying OSS And TSS Sensor & Bolts
    GF0003564Courtesy of FORD MOTOR CO.
  8. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    9. Fig 8: Identifying Digital TR Sensor Bolts
    GF0003566Courtesy of FORD MOTOR CO.
  9. Remove the manual control valve detent lever spring.
    • Remove the bolt.
    10. Fig 9: Identifying Manual Control Valve Detent Lever Spring Bolts
    G04584504Courtesy of FORD MOTOR CO.
  10. Remove the 24 main control valve body bolts and the main control valve body.
    11. Fig 10: Locating 24 Main Control Valve Body Bolts
    GF0003493Courtesy of FORD MOTOR CO.
  11. Remove and discard the pump outlet screen.
    12. Fig 11: Identifying Pump Outlet Screen
    G03888559Courtesy of FORD MOTOR CO.
    NOTE: Use a shop cloth to protect the transmission case surface.
  12. Remove the manual control lever shaft retaining pin.
    13. Fig 12: Removing Manual Lever Shaft Retaining Pin
    GF0012381Courtesy of FORD MOTOR CO.
  13. Remove the manual control lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    14. Fig 13: Removing Manual Control Lever Shaft
    GF0012382Courtesy of FORD MOTOR CO.
  14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    15. Fig 14: Identifying Parking Lever Actuating Rod
    GF0003567Courtesy of FORD MOTOR CO.
    CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged, the new seal may leak.
  15. Remove the manual control lever shaft seal.
    16. Fig 15: Locating Manual Control Lever Shaft Seal
    GF0003568Courtesy of FORD MOTOR CO.
  16. Remove the EPC solenoid.
    17. Fig 16: Locating EPC Solenoid
    GF0003569Courtesy of FORD MOTOR CO.
  17. Remove the 2-3 accumulator spring retainer.
    18. Fig 17: Locating 2-3 Accumulator Spring Retainer
    GF0003570Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    19. Fig 18: Identifying 2-3 Accumulator Piston & Spring
    GF0003571Courtesy of FORD MOTOR CO.
  19. Using the special tool, remove the reverse band servo retaining ring.
    20. Fig 19: Removing Reverse Band Servo Retaining Ring Using Special Tool
    GF0003572Courtesy of FORD MOTOR CO.
  20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
    21. Fig 20: Identifying Reverse Band Servo Piston And Rod
    GF0003573Courtesy of FORD MOTOR CO.
    NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
  21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
    22. Fig 21: Removing Overdrive Servo Piston Retainer
    GF0003574Courtesy of FORD MOTOR CO.
  22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    23. Fig 22: Removing Overdrive Servo Piston Return Spring
    GF0003575Courtesy of FORD MOTOR CO.
  23. Compress the 1-2 accumulator cover and remove the retaining ring.
    24. Fig 23: Locating Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
  24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the inner and outer lower 1-2 accumulator spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    25. Fig 24: Identifying 1-2 Accumulator Upper Spring
    GF0003576Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the extension housing seal.
    26. Fig 25: Removing Extension Housing Seal
    GF0003505Courtesy of FORD MOTOR CO.
    NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
  26. Remove the extension housing.
    1. Remove the 4 bolts and 2 nuts.
    2. Remove the extension housing and the extension housing gasket.
    27. Fig 26: Extension Housing & Bolts
    GF0003577Courtesy of FORD MOTOR CO.
  27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    28. Fig 27: Identifying Parking Pawl Return Spring
    GF0003578Courtesy of FORD MOTOR CO.
  28. Rotate the transmission to the vertical position with the output shaft toward the floor.
    29. CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body or damage may occur to the connector.
  29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
    30. Fig 28: Locating Connector
    GF0003579Courtesy of FORD MOTOR CO.
  30. Using the special tools, remove the front pump seal.
    31. Fig 29: Removing Front Pump Seal Using Special Tools
    GF0003580Courtesy of FORD MOTOR CO.
    NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
  31. Remove the bolts.
    32. Fig 30: Locating Front Pump Bolts
    GF0003581Courtesy of FORD MOTOR CO.
  32. Using the special tools, remove the front pump support.
    33. Fig 31: Removing Front Pump Support
    GF0003582Courtesy of FORD MOTOR CO.
  33. Remove and discard the pump gasket.

    34. NOTE: For assembly, note the location of the check ball and the intermediate clutch piston return spring pack indent during disassembly.
  34. Remove the intermediate clutch piston return spring pack.
    35. Fig 32: Locating Intermediate Clutch Piston Return Spring Pack
    GF0003583Courtesy of FORD MOTOR CO.
  35. Remove the intermediate anti-rattle clip, if equipped.
    36. Fig 33: Identifying Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
    CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
  36. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch (OWC).
    • Reverse clutch.
    • Forward clutch assembly.
    37. Fig 34: Removing Clutch Assembly
    GF0003584Courtesy of FORD MOTOR CO.
  37. Disengage and remove the overdrive band.
    38. Fig 35: Locating Overdrive Band
    GF0003585Courtesy of FORD MOTOR CO.
  38. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    39. Fig 36: Locating Forward Clutch Hub & No. 3 Forward Clutch Hub Front Bearing
    GF0003586Courtesy of FORD MOTOR CO.
  39. Remove the intermediate stub shaft.
    40. Fig 37: Locating Intermediate Stub Shaft
    GF0003587Courtesy of FORD MOTOR CO.
  40. Align the reverse sun shell with the overdrive band anchor pin for removal.
    41. Fig 38: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin
    GF0003588Courtesy of FORD MOTOR CO.
  41. Remove the following components as an assembly:
    • Forward clutch sun gear
    • No. 5 forward clutch sun gear bearing
    • Reverse clutch sun gear
    • No. 4 forward clutch hub bearing
    42. Fig 39: Removing Clutch Assembly Components
    GF0003589Courtesy of FORD MOTOR CO.
  42. Remove the center support retaining ring and note location for assembly.
    43. Fig 40: Locating Center Support Retaining Ring
    GF0003590Courtesy of FORD MOTOR CO.
  43. Remove the case-to-planet support spring.
    44. Fig 41: Identifying Case-To-Planet Support Spring
    GF0003591Courtesy of FORD MOTOR CO.
  44. Remove the planetary gear support and planetary as an assembly.
    45. Fig 42: Locating Planetary Gear Support
    GF0003592Courtesy of FORD MOTOR CO.
  45. Remove the reverse clutch band.
    46. Fig 43: Locating Reverse Clutch Band
    GF0003593Courtesy of FORD MOTOR CO.
  46. Remove the retaining ring.
    47. Fig 44: Locating Retaining Ring
    GF0003594Courtesy of FORD MOTOR CO.
  47. Remove the direct clutch pack.
    48. Fig 45: Identifying Direct Clutch Pack
    G03888747Courtesy of FORD MOTOR CO.
  48. Remove the No. 8 bearing.
    49. Fig 46: Locating No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  49. Remove the output shaft and output shaft ring gear assembly.
    50. Fig 47: Locating Output Shaft And Output Shaft Ring Gear Assembly
    GF0003595Courtesy of FORD MOTOR CO.
  50. Remove the No. 9 case rear bearing.
    51. Fig 48: Coating No. 9 Case Rear Bearing With Petroleum Jelly
    GF0003596Courtesy of FORD MOTOR CO.
  51. Inspect and, if necessary, use the special tools to remove the rear case bushing.
    52. Fig 49: Removing Rear Case Bushing Using Special Tool
    GF0003597Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals