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Disassembled Views

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transaxle Components (1 Of 3)
G07783410Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transaxle Components (2 Of 3)
G07783411Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle Components (3 Of 3)
G07783412Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION

Item Part Number Description
1 7005 Transaxle case
2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal
15 7C099 Direct (3, 5, R) clutch piston inner (front) seal
16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/Overdrive (O/D) (4, 5, 6) clutch cylinder and hub assembly
19 7A548 O/D (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
21 7D234 No. 2 thrust bearing
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 O/D (4, 5, 6) clutch piston outer (rear) seal
28 7A548 O/D (4, 5, 6) clutch piston outer (front) seal
29 7A262 O/D (4, 5, 6) clutch piston
30 7F222 O/D (4, 5, 6) clutch piston return spring
31 7H360 O/D (4, 5, 6) clutch balance piston
32 7C122 O/D (4, 5, 6) clutch piston snap ring
33 7B164 O/D (4, 5, 6) clutch friction plates (5 required)
34 7B442 O/D (4, 5, 6) clutch steel plates (5 required)
35 7B066 O/D (4, 5, 6) clutch pressure plate
36 7D483 O/D (4, 5, 6) clutch snap ring
37 7H351 O/D (4, 5, 6) clutch hub
38 7D234 No. 3 thrust bearing
39 7A019 Rear planetary sun gear and shell assembly
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2 required)
42 7B442 Intermediate (2, 6) clutch steel plates (2 required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
45 7C096 No. 6 thrust bearing
46 7G177 No. 5 thrust bearing
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7B070 Low/reverse clutch piston return spring
53 7D402 Low/reverse clutch piston
54 7L328 Center support
55 7A262 Forward (1, 2, 3, 4) clutch piston
56 7B070 Forward (1, 2, 3, 4) clutch piston return spring
57 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
58 7D491 Center planetary carrier/front ring gear
59 7D063 Center planetary sun gear
60 7C096 No. 7 thrust bearing
61 7C096 No. 8 thrust bearing
62 7D491 Front planetary carrier/rear ring gear
63 7A019 Front planetary sun gear and shell assembly
64 7D234 No. 10 thrust bearing
65 7B070 Forward (1, 2, 3, 4) clutch wave spring
66 7B164 Forward (1, 2, 3, 4) clutch friction plates (2 required)
67 7B442 Forward (1, 2, 3, 4) clutch steel plates (2 required)
68 7B066 Forward (1, 2, 3, 4) clutch pressure plate
69 7D483 Forward (1, 2, 3, 4) clutch snap ring
70 7978 Transmission fluid baffle
71 W500214 Transmission fluid baffle bolt (2 required)
72 7060 Park gear
73 7G132 Drive chain drive sprocket
74 7C122 Drive sprocket snap ring
75 7G099 No. 13 thrust washer
76 7G249 Drive chain
77 7D234 No. 11 thrust washer
78 7048 Input shaft seal
79 7A098 Transmission fluid filter
80 W302860 Pump-to-torque converter housing bolt (8 required)
81 7A103 Pump assembly
82 7A248 Pump assembly-to-torque converter housing O-ring seal
83 7A248 Torque converter hub seal
84 7F343 Different ring gear
85 7C122 Differential ring gear snap ring
86 7H245 Differential transmission fluid baffle
87 W500214 Differential transmission fluid baffle bolt (2 required)
88 7975 Torque converter housing
89 W701606 Torque converter housing stud bolt
90 7A443 Torque converter housing bolt (16 required)
91 7902 Torque converter
92 1177 RH halfshaft seal
93 391308-S Transaxle filler tube O-ring
94 7A228 Transaxle filler tube
95 W520101 Transaxle filler tube nut
96 7A020 Transmission fluid level indicator
97 7G355 No. 12 thrust bearing
98 7G132 Drive chain driven sprocket
99 7F342 Differential sun gear
100 7F465 Differential assembly
101 7G112 No. 15 thrust bearing
102 7B362 Torque converter housing-to-transaxle case guide pins
103 7D070 Park pawl spring
104 7A441 Park pawl
105 7D071 Park pawl pin
106 7F337 Manual control shaft seal
107 7A232 Park pawl actuator rod
108 7H557 Transmission Range (TR) sensor
109 7C493 Manual control shaft
110 7G100 Manual control shaft pin
111 7A256 Manual control lever
112 W708455 Manual control lever nut
113 7E332 Manual valve detent spring
114 W711235 Manual valve detent spring bolt
115 7J387 Lubrication funnel
116 7A248 Torque converter housing-to-transaxle case seal (large)
117 7A248 Torque converter housing-to-transaxle case seal (small) (4 required)
118 7B431 Main control alignment pin
119 7C207 Main control stud
120 7G199 Main control-to-center support seal (2 required)
121 7H322 Thermal bypass valve and sleeve
122 - Thermal bypass valve spring (part of 7H322)
123 W713644 Output Shaft Speed (OSS) sensor bolt
124 7H103 OSS sensor
125 7Z490 Main control-to-transaxle case separator plate
126 7A100 Main control valve body
127 N605770 Separator plate-to-soledoid body bolt (2 required)
128 7Z490 Main control valve body-to-solenoid body
129 7G391 Solenoid body
130 W500303 Solenoid body-to-valve body bolt (2 required)
131 W302863 Main control-to-transaxle case bolt (long) (10 required)
132 W302862 Main control-to-transaxle case bolt (short) (12 required)
133 W520412 Main control nut
134 7G276 Main control leadframe
135 W505513 Main control leadframe screw (5 required)
136 7B329 Main control-to-cover seal
137 7G004 Main control cover
138 W714629 Main control cover stud bolt (5 required)
139 W500214 Main control cover bolt (8 required)
140 7010 Drain plug
141 7H398 Line pressure tap
142 7D273 Transmission fluid cooler tube fittings (2 required)
143 1177 LH halfshaft seal
144 7025 LH halfshaft bushing
145 7M101 Turbine Shaft Speed (TSS) sensor
146 W500214 TSS bolt
147 7A246 Vent tube
148 7L027 Magnet
149 7A033 Lubrication funnel bracket
150 7G342 Solenoid body strategy tag
151 7B148 Transaxle service identification tag
152 - Direct clutch (3, 5, R)
153 - Intermediate clutch (2, 6)
154 - O/D clutch (4, 5, 6)
155 - Forward clutch (1, 2, 3, 4)
156 - Low/reverse clutch

All vehicles 

  1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.
    Fig 4: Locating Transaxle Case-To-Torque Converter Housing And Main Control Cover Sealing Surfaces
    G07783413Courtesy of FORD MOTOR CO.
  2. Assemble the Handle 205-153 and the Bushing Installer 307-664 and install a new bushing on the Bushing Installer.
    Fig 5: Locating Bushing On Bushing Installer
    G07783414Courtesy of FORD MOTOR CO.
  3. Using the Handle 205-153 and the Bushing Installer 307-664, install the new bushing in the transaxle case.
    Fig 6: Installing Bushing On Transaxle Case Using Handle 205-153 And Bushing Installer 307-664
    G07783415Courtesy of FORD MOTOR CO.
  4. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the Differential Seal Installer 307-626.
    Fig 7: Locating LH Halfshaft Seal On Differential Seal Installer 307-626
    G07783416Courtesy of FORD MOTOR CO.
  5. Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in the transaxle case.
    Fig 8: Installing LH Halfshaft Seal In Transaxle Case
    G07783417Courtesy of FORD MOTOR CO.
  6. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.
    Fig 9: Identifying Manual Control Shaft Seal On Manual Lever Seal Installer 307-581
    G07783418Courtesy of FORD MOTOR CO.
  7. Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the transaxle case.
    Fig 10: Installing Manual Control Shaft Seal
    G07783419Courtesy of FORD MOTOR CO.
  8. If not previously installed, install the clutch support tower and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 11: Locating Clutch Support Tower
      G07783420Courtesy of FORD MOTOR CO.
  9. Remove Input Shaft Support Seal Installer 307-578/1.
    Fig 12: Identifying Input Shaft Support Seal Installer 307-578/1
    G07783421Courtesy of FORD MOTOR CO.
  10. Install 2-6 Piston Seal Protector 307-632.
    Fig 13: Identifying 2-6 Piston Seal Protector 307-632
    G07783422Courtesy of FORD MOTOR CO.
  11. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.
    Fig 14: Identifying Intermediate (2, 6) Clutch Piston
    G07783423Courtesy of FORD MOTOR CO.
    12. NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.
    Fig 15: Locating Intermediate (2, 6) Clutch Piston
    G07783424Courtesy of FORD MOTOR CO.
  12. Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.
  13. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Open area at the bottom of the transaxle case
    3. Bleed hole
    4. Inner double tabs
      Fig 16: Identifying Intermediate (2, 6) Clutch Piston Return Spring Outer Tabs, Bleed Hole And Double Tabs
      G07783425Courtesy of FORD MOTOR CO.
  14. Remove the intermediate (2, 6) clutch piston return spring.
    Fig 17: Locating Intermediate (2, 6) Clutch Piston Return Spring
    G07783426Courtesy of FORD MOTOR CO.
  15. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.
    Fig 18: Identifying 2-6 Spring Compressor 307-584/1
    G07783427Courtesy of FORD MOTOR CO.
  16. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
    Fig 19: Pushing Intermediate (2, 6) Clutch Piston Into Clutch Cylinder
    G07783428Courtesy of FORD MOTOR CO.
  17. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector 307-632.
    Fig 20: Identifying Forward/Intermediate Spring Compressor 307-584/1 And Clutch Piston Seal Protector 307-632
    G07783429Courtesy of FORD MOTOR CO.
    18. NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.
  18. Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Bleed hole
    3. Inner double tabs
      Fig 21: Identifying Intermediate (2, 6) Clutch Piston Return Spring Outer Tabs, Bleed Hole And Inner Double Tabs
      G07783430Courtesy of FORD MOTOR CO.
    19. NOTE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
  19. Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
    1. Snap ring
    2. Snap ring gap
    3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)
      Fig 22: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Hydraulic Ports And Snap Ring
      G07783431Courtesy of FORD MOTOR CO.
  20. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the intermediate (2, 6) clutch return spring.
    Fig 23: Identifying 2-6 Piston Return Spring Compressor 307-633/2
    G07783432Courtesy of FORD MOTOR CO.
  21. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.
    Fig 24: Identifying 2-6 Piston Return Spring Compressor 307-633/1
    G07783433Courtesy of FORD MOTOR CO.
  22. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.
    Fig 25: Identifying Forward Clutch Spring Compressor 307-574/1 On Transaxle Case
    G07783434Courtesy of FORD MOTOR CO.
    23. NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.
    Fig 26: Installing Intermediate (2, 6) Clutch Snap Ring
    G07783435Courtesy of FORD MOTOR CO.
  23. Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.
  24. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633.
    Fig 27: Identifying Forward Clutch Spring Compressor 307-574/1 And 2-6 Piston Return Spring Compressor 307-633
    G07783436Courtesy of FORD MOTOR CO.
  25. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.
    Fig 28: Tapping Intermediate (2, 6) Clutch Apply Ring
    G07783437Courtesy of FORD MOTOR CO.
    26. NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.
    Fig 29: Locating No. 1 Thrust Bearing
    G07783438Courtesy of FORD MOTOR CO.
  26. Install the No. 1 thrust bearing with the flat side facing up.
  27. Install the overdrive/direct clutch assembly.
    Fig 30: Locating Overdrive/Direct Clutch Assembly
    G07783439Courtesy of FORD MOTOR CO.
    28. NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.
    Fig 31: Locating No. 3 Thrust Bearing
    G07783440Courtesy of FORD MOTOR CO.
  28. Install the No. 3 thrust bearing with the flat side facing down.
  29. Install the direct/intermediate clutch hub and rear sun gear assembly.
    Fig 32: Locating Direct/Intermediate Clutch Hub And Rear Sun Gear Assembly
    G07783441Courtesy of FORD MOTOR CO.
  30. Install the intermediate (2, 6) wave spring assembly.
    Fig 33: Locating Intermediate (2, 6) Wave Spring Assembly
    G07783442Courtesy of FORD MOTOR CO.
  31. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.
    Fig 34: Identifying Intermediate (2, 6) Clutch Assembly
    G07783443Courtesy of FORD MOTOR CO.
  32. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    Fig 35: Locating Intermediate (2, 6) Clutch Assembly
    G07783444Courtesy of FORD MOTOR CO.
  33. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 36: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G07783445Courtesy of FORD MOTOR CO.
  34. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
    Fig 37: Measuring Distance From Shim Selection Gauge 307-300 To Top Of Intermediate (2, 6) Clutch Pack (Measurement A)
    G07783446Courtesy of FORD MOTOR CO.
  35. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
    Fig 38: Measuring Distance From Shim Selection Gauge 307-300 To Top Of Intermediate (2, 6) Clutch (Measurement B)
    G07783447Courtesy of FORD MOTOR CO.
  36. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in)  
    37. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
    Fig 39: Installing Intermediate (2, 6) Clutch Friction And Steel Plate
    G07783448Courtesy of FORD MOTOR CO.
  37. Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.
  38. Install the One-Way Clutch (OWC) assembly.
    Fig 40: Locating Low One-Way Clutch (OWC)
    G07783449Courtesy of FORD MOTOR CO.
  39. Install the rear planetary carrier/center ring gear assembly.
    Fig 41: Locating Rear Planetary Carrier/Center Ring Gear Assembly
    G07783450Courtesy of FORD MOTOR CO.
    40. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.
    Fig 42: Locating Low/Reverse Pressure Plate
    G07783451Courtesy of FORD MOTOR CO.
  40. Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.
  41. Soak the low/reverse clutch in clean automatic transmission fluid.
    Fig 43: Identifying Low/Reverse Clutch
    G07783452Courtesy of FORD MOTOR CO.
  42. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.
    Fig 44: Locating Low/Reverse Clutch Pack
    G07783453Courtesy of FORD MOTOR CO.
  43. Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs.
    Fig 45: Identifying Shim Selection Gauge 307-300
    G07783454Courtesy of FORD MOTOR CO.
  44. Using a suitable depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
    Fig 46: Measuring Contact Surface Of Low/Reverse Clutch Piston Using Depth Gauge
    G07783455Courtesy of FORD MOTOR CO.
  45. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.
    Fig 47: Measuring Leg Surface Of Center Support Using Depth Gauge
    G07783456Courtesy of FORD MOTOR CO.
  46. Subtract measurement B from measurement A and record as measurement C.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and record as measurement C.  
  47. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 48: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G07783457Courtesy of FORD MOTOR CO.
  48. Using a suitable depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge 307-300 to the top of the OWC.
    Fig 49: Measuring Distance From Shim Selection Gauge 307-300 To Top Of OWC Using Depth Micrometer
    G07783458Courtesy of FORD MOTOR CO.
  49. Using a suitable depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average the 3 distances.
    Fig 50: Measuring Distance From Top Of Shim Selection Gauge 307-300 To Top Of Low/Reverse Clutch
    G07783459Courtesy of FORD MOTOR CO.
  50. Subtract measurement E from measurement D and record as measurement F.
    Description Reading
    Measurement D  
    Measurement E  
    Subtract measurement E from measurement D and record as measurement F  
  51. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement C  
    Measurement F  
    Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in)  
    52. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
    Fig 51: Installing Low/Reverse Clutch Steel Plate
    G07783460Courtesy of FORD MOTOR CO.
  52. Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.
    53. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.
  53. Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
    1. Long center support legs face down
    2. Feed holes face the front of the transaxle case
      Fig 52: Installing Center Support With Long Legs Facing Down
      G07783461Courtesy of FORD MOTOR CO.
  54. Install the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
      Fig 53: Identifying No. 5 And No. 6 Thrust Bearings
      G07783462Courtesy of FORD MOTOR CO.
  55. Install the center sun gear.
    Fig 54: Locating Center Sun Gear
    G07783463Courtesy of FORD MOTOR CO.
  56. Install the center carrier/front ring gear assembly.
    Fig 55: Locating Center Carrier/Front Ring Gear Assembly
    G07783464Courtesy of FORD MOTOR CO.
  57. Install the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
      Fig 56: Identifying No. 7 And No. 8 Thrust Bearings
      G07783465Courtesy of FORD MOTOR CO.
  58. Install the front planetary/rear ring gear assembly.
    Fig 57: Locating Front Planetary Carrier/Rear Ring Gear Assembly
    G07783466Courtesy of FORD MOTOR CO.
  59. Install the forward (1, 2, 3, 4) clutch wave spring.
    Fig 58: Locating Forward (1, 2, 3, 4) Clutch Wave Spring
    G07783467Courtesy of FORD MOTOR CO.
  60. Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid.
    Fig 59: Identifying Forward (1, 2, 3, 4) Clutch Pack
    G07783468Courtesy of FORD MOTOR CO.
  61. Install the forward (1, 2, 3, 4) clutch pack.
    Fig 60: Locating Forward (1, 2, 3, 4) Clutch Pack
    G07783469Courtesy of FORD MOTOR CO.
  62. Install the forward (1, 2, 3, 4) clutch pressure plate.
    Fig 61: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate
    G07783470Courtesy of FORD MOTOR CO.
    63. NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
  63. Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
    1. Forward (1, 2, 3, 4) clutch snap ring
    2. Forward (1, 2, 3, 4) clutch snap ring gap
      Fig 62: Identifying Forward (1, 2, 3, 4) Clutch Snap Ring
      G07783471Courtesy of FORD MOTOR CO.
  64. Using a suitable tool, seat the snap ring in the snap ring groove.
    Fig 63: Seating Snap Ring On Snap Ring Grooves
    G07783472Courtesy of FORD MOTOR CO.
  65. Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
    Fig 64: Positioning Plunger On Top Forward (1, 2, 3, 4) Clutch Friction Plate
    G07783473Courtesy of FORD MOTOR CO.
  66. Install the new low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.
    Fig 65: Locating Low/Reverse And Forward (1, 2, 3, 4) Clutch Feed Seals
    G07783474Courtesy of FORD MOTOR CO.
  67. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
    Fig 66: Applying Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
    G07783475Courtesy of FORD MOTOR CO.
  68. Install the front planetary sun gear and shell assembly.
    Fig 67: Locating Front Planetary Sun Gear And Shell Assembly
    G07783476Courtesy of FORD MOTOR CO.
  69. Install the No. 10 thrust bearing.
    Fig 68: Locating No. 10 Thrust Bearing
    G07783477Courtesy of FORD MOTOR CO.
  70. Install the park pawl.
    Fig 69: Locating Park Pawl
    G07783478Courtesy of FORD MOTOR CO.
  71. Install the park pawl pin and spring.
    Fig 70: Locating Park Pawl Pin And Spring
    G07783479Courtesy of FORD MOTOR CO.
  72. Install the park pawl actuator rod in the Transmission Range (TR) sensor.
    Fig 71: Locating Park Pawl Actuator Rod
    G07783480Courtesy of FORD MOTOR CO.
  73. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transaxle case.
    Fig 72: Positioning Park Pawl Actuator Rod And TR Sensor In Transaxle Case
    G07783481Courtesy of FORD MOTOR CO.
  74. Install the manual control shaft and align the roll pin holes.
    Fig 73: Installing Manual Control Shaft
    G07783482Courtesy of FORD MOTOR CO.
  75. Install the manual control shaft roll pin.
    Fig 74: Installing Manual Control Shaft Roll Pin
    G07783483Courtesy of FORD MOTOR CO.
    76. NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
  76. Install the manual control lever and the nut.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 75: Locating Manual Lever And Nut
      G07783484Courtesy of FORD MOTOR CO.
  77. Install the 5 new clutch feed seals.
    Fig 76: Locating Clutch Feed Seals
    G07783485Courtesy of FORD MOTOR CO.
  78. Position the transmission fluid baffle in place.
    Fig 77: Locating Transmission Fluid Baffle
    G07783486Courtesy of FORD MOTOR CO.
  79. Install the lube funnel and position the alignment pin in the alignment hole.
    Fig 78: Locating Lube Funnel
    G07783487Courtesy of FORD MOTOR CO.
  80. Position the lube funnel hold-down bracket in place and install the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 79: Locating Hold-Down Bracket And Bolts
      G07783488Courtesy of FORD MOTOR CO.
  81. Install the No. 12 thrust bearing.
    Fig 80: Locating No. 12 Driven Sprocket Thrust Bearing
    G07783489Courtesy of FORD MOTOR CO.
  82. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
    Fig 81: Installing Drive/Driven Sprocket And Chain Assembly
    G07783490Courtesy of FORD MOTOR CO.
  83. Install the No. 11 thrust bearing.
    Fig 82: Remove/Install No. 11 Drive Sprocket Thrust Bearing
    G07783491Courtesy of FORD MOTOR CO.
  84. Install the No. 13 thrust washer.
    Fig 83: Identifying No. 13 Thrust Washer
    G07783492Courtesy of FORD MOTOR CO.
  85. Install the final drive sun gear.
    Fig 84: Locating Final Drive Sun Gear
    G07783493Courtesy of FORD MOTOR CO.
  86. Install the differential assembly.
    Fig 85: Locating Differential Assembly
    G07783494Courtesy of FORD MOTOR CO.
  87. Install the No. 15 thrust bearing.
    Fig 86: Locating No. 15 Thrust Bearing
    G07783495Courtesy of FORD MOTOR CO.
  88. Install the Turbine Shaft Seal Protector 307-635 on the input shaft.
    Fig 87: Identifying Turbine Shaft Seal Protector 307-635 On Input Shaft
    G07783496Courtesy of FORD MOTOR CO.
  89. Clean the torque converter housing sealing surface.
    Fig 88: Locating Torque Converter Housing Sealing Surface
    G07783497Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  90. Assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the Seal Installer 307-626.
    Fig 89: Locating RH Seal On Seal Installer 307-626
    G07783498Courtesy of FORD MOTOR CO.
  91. Using the Handle 205-153 and Differential Seal Installer 307-626, install the new RH halfshaft seal.
    Fig 90: Installing RH Halfshaft Seal
    G07783499Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  92. Install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428.
    Fig 91: Locating RH Seal On RH Halfshaft Fluid Seal Installer 307-428
    G07783500Courtesy of FORD MOTOR CO.
  93. Using the RH Halfshaft Fluid Seal Installer 307-428, install the new RH halfshaft seal.
    Fig 92: Installing RH Halfshaft Fluid Seal
    G07783501Courtesy of FORD MOTOR CO.

    All vehicles 

  94. Install the differential ring gear in the torque converter housing.
    Fig 93: Remove/Install Differential Ring Gear
    G07783502Courtesy of FORD MOTOR CO.
    95. NOTE: Be sure the flat side of the beveled snap ring is facing down or the ring can come loose, causing damage to the transaxle.
    Fig 94: Locating Differential Ring Gear Snap Ring
    G07783503Courtesy of FORD MOTOR CO.
  95. Install the beveled differential ring gear snap ring with the flat side facing down.
  96. Seat the snap ring using a suitable tool.
    Fig 95: Seating Snap Ring Using Tool
    G07783504Courtesy of FORD MOTOR CO.
  97. Install the pump and filter assembly in the torque converter housing and install the 8 pump bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 96: Locating Pump And Filter Assembly Bolts
      G07783505Courtesy of FORD MOTOR CO.
  98. Install the transmission fluid baffle and the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 97: Locating Torque Fluid Baffle And Bolts
      G07783506Courtesy of FORD MOTOR CO.
    99. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
    Fig 98: Locating Silicone Applying Sealing Surface Of Transaxle Case
    G07783507Courtesy of FORD MOTOR CO.
  99. Apply silicone to the sealing surface of the transaxle case.
    100. NOTE: Be sure the stud bolt is in the correct location as noted during disassembly.
  100. Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque converter housing bolts.
    1. Tighten to 24 Nm (18 lb-ft).
    2. Stud bolt location.
      Fig 99: Locating Transaxle Case-To-Torque Converter Housing Bolts
      G07783508Courtesy of FORD MOTOR CO.
  101. Remove the Turbine Shaft Seal Protector 307-635.
    Fig 100: Identifying Turbine Shaft Seal Protector 307-635
    G07783509Courtesy of FORD MOTOR CO.
  102. Install the Turbine Shaft Speed (TSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 101: Locating Turbine Shaft Speed (TSS) Sensor Bolt
      G07783510Courtesy of FORD MOTOR CO.
  103. Install the Output Shaft Speed (OSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 102: Locating OSS Sensor Bolt
      G07783511Courtesy of FORD MOTOR CO.
  104. Assemble the bypass valve in the sleeve and install the assembly in the case.
    1. Bypass valve
    2. Bypass valve sleeve
      Fig 103: Assembling Bypass Valve In Sleeve
      G07783512Courtesy of FORD MOTOR CO.
  105. Install the bypass valve spring.
    Fig 104: Installing Bypass Valve Spring
    G07783513Courtesy of FORD MOTOR CO.
  106. Install the new main control-to-transaxle case separator plate and align it on the stud and the guide pin.
    Fig 105: Locating Main Control-To-Transaxle Case Separator Plate
    G07783514Courtesy of FORD MOTOR CO.
    107. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
    Fig 106: Locating Main Control Assembly Position
    G07783515Courtesy of FORD MOTOR CO.
  107. Position the main control assembly in place and align the manual valve on the TR sensor.
  108. Install the nut hand-tight.
    Fig 107: Locating Main Control Assembly Nut
    G07783516Courtesy of FORD MOTOR CO.
  109. Install the short bolts hand-tight.
    Fig 108: Locating Main Control Assembly Short Bolts
    G07783517Courtesy of FORD MOTOR CO.
  110. Install the long bolts hand-tight.
    Fig 109: Locating Main Control Assembly Long Bolts
    G07783518Courtesy of FORD MOTOR CO.
  111. Tighten the main control bolts and the nut in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      Fig 110: Locating Main Control Bolts And Nut
      G07783519Courtesy of FORD MOTOR CO.
  112. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 111: Locating TR Sensor Detent Spring And Bolt
      G07783520Courtesy of FORD MOTOR CO.
    113. NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
    Fig 112: Locating Solenoid Body-To-Main Control Cover Seal
    G07783521Courtesy of FORD MOTOR CO.
  113. Install the solenoid body-to-main control cover seal.
  114. Connect the TR sensor electrical connector.
    Fig 113: Locating TR Sensor Electrical Connector
    G07783522Courtesy of FORD MOTOR CO.
  115. Connect the OSS sensor electrical connector.
    Fig 114: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G07783523Courtesy of FORD MOTOR CO.
  116. Clean the main control cover sealing surface.
    Fig 115: Locating Main Control Cover Sealing Surface
    G07783524Courtesy of FORD MOTOR CO.
  117. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 116: Locating Main Control Sealing Surface Of Transaxle Case
    G07783525Courtesy of FORD MOTOR CO.
  118. Position the main control cover in place.
    Fig 117: Locating Main Control Cover
    G07783526Courtesy of FORD MOTOR CO.
    119. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
  119. Install the main control cover bolts.
    1. Bolt location
    2. Stud bolt location
      • Tighten to 12 Nm (106 lb-in).
        Fig 118: Identifying Main Control Cover Bolts
        G07783527Courtesy of FORD MOTOR CO.
    120. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 119: Remove/Install Torque Converter Using Torque Converter Handle (307-091)
    G07783528Courtesy of FORD MOTOR CO.
  120. Using the Torque Converter Handle 307-091, install the torque converter.
  121. Remove the Torque Converter Handle 307-091.
    Fig 120: Identifying Torque Converter Handle (307-091)
    G07783529Courtesy of FORD MOTOR CO.
  122. Install the Torque Converter Retainer 307-566.
    Fig 121: Identifying Torque Converter Retainer (307-566)
    G07783530Courtesy of FORD MOTOR CO.
  123. Remove the transaxle from the bench-mounted holding fixture.
    Fig 122: Identifying Transaxle
    G07783531Courtesy of FORD MOTOR CO.
  124. Remove the Holding Fixture 307-625.
    Fig 123: Identifying Holding Fixture 307-625
    G07783532Courtesy of FORD MOTOR CO.
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