Section 39 (Automatic Transaxle - 6F35 - Disassembly, Disassembly And Assembly Of Subassemblies, Assembly, Installation): Disassembly: Transaxle

SPECIAL TOOL(S)

	Handle, Torque Converter 307-091 (T81P-7902-C)
	Holding Fixture 307-625
	Installer, Wheel Speed Sensor Ring 206-084/2
	Remover, Roll Pin 211-061 (T78P-3504-N1)
	Retainer, Torque Converter 307-566

1. Install the Holding Fixture 307-625.
   Fig 1: Identifying Holding Fixture 307-625

   Courtesy of FORD MOTOR CO.
2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.
   Fig 2: Identifying Transaxle On Bench-Mounted Holding Fixture

   Courtesy of FORD MOTOR CO.
3. Remove the Torque Converter Retainer 307-566.
   Fig 3: Identifying Torque Converter Retainer (307-566)

   Courtesy of FORD MOTOR CO.
4. Install the Torque Converter Handle 307-091.
   Fig 4: Identifying Torque Converter Handle (307-091)

   Courtesy of FORD MOTOR CO.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 5: Remove/Install Torque Converter Using Torque Converter Handle (307-091)
Courtesy of FORD MOTOR CO.
5. Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
NOTE: Note the location of the stud bolts for assembly.
Fig 6: Locating Main Control Cover Bolts
Courtesy of FORD MOTOR CO.
6. Remove the 13 bolts and the main control cover.
7. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
   Fig 7: Locating Output Shaft Speed (OSS) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Disconnect the Transmission Range (TR) sensor electrical connector.
   Fig 8: Locating TR Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Remove the solenoid body-to-main control cover grommet.
   Fig 9: Locating Solenoid Body-To-Main Control Cover Grommet

   Courtesy of FORD MOTOR CO.
NOTE: Note the location of the short and long main control bolts for reassembly.
Fig 10: Locating Main Control Assembly Torx Bolts
Courtesy of FORD MOTOR CO.
10. Remove the nut and the 22 Torx bolts and remove the main control assembly.
11. Remove and discard the main control-to-transaxle case separator plate.
    Fig 11: Locating Main Control-To-Transaxle Case Separator Plate

    Courtesy of FORD MOTOR CO.
12. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center support seals.
    1. Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal.
    2. Low/reverse clutch transaxle case-to-center support seal.
       Fig 12: Identifying Low/Reverse Clutch Transaxle Case-To-Center Support Seal

       Courtesy of FORD MOTOR CO.
13. Remove the internal cooler bypass spring, sleeve and valve.
    Fig 13: Identifying Internal Cooler Bypass Spring, Sleeve And Valve

    Courtesy of FORD MOTOR CO.
14. Remove the bolt and the Turbine Shaft Speed (TSS) sensor.
    Fig 14: Locating Turbine Shaft Speed (TSS) Sensor

    Courtesy of FORD MOTOR CO.
15. Remove the bolt and the TR sensor detent spring.
    Fig 15: Locating TR Sensor Detent Spring With Bolts

    Courtesy of FORD MOTOR CO.
16. Remove the bolt and the OSS sensor.
    Fig 16: Locating OSS Sensor Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the stud bolts for assembly.
Fig 17: Locating Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
17. Remove the 17 torque converter housing bolts.
18. Using a suitable tool, pry the torque converter housing loose from the transaxle case.
    Fig 18: Removing Torque Converter Housing From Transaxle Case

    Courtesy of FORD MOTOR CO.
19. Remove the torque converter housing loose from the transaxle case.
    Fig 19: Locating Torque Converter Housing

    Courtesy of FORD MOTOR CO.
20. Remove the No. 15 differential thrust bearing.
    Fig 20: Removing No. 15 Differential Thrust Bearing

    Courtesy of FORD MOTOR CO.
21. Remove the differential.
    Fig 21: Removing Differential

    Courtesy of FORD MOTOR CO.
22. Remove the differential planetary sun gear.
    Fig 22: Removing Differential Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
23. Remove the No. 13 thrust washer.
    Fig 23: Identifying No. 13 Thrust Washer

    Courtesy of FORD MOTOR CO.
24. Remove the No. 11 drive sprocket thrust bearing.
    Fig 24: Remove/Install No. 11 Drive Sprocket Thrust Bearing

    Courtesy of FORD MOTOR CO.
25. Simultaneously remove the drive and driven sprockets and the chain.
    Fig 25: Removing Drive And Driven Sprockets

    Courtesy of FORD MOTOR CO.
26. Remove the No. 12 driven sprocket thrust bearing.
    Fig 26: Locating No. 12 Driven Sprocket Thrust Bearing

    Courtesy of FORD MOTOR CO.
27. Remove the No. 10 front sun gear and shell assembly thrust bearing.
    Fig 27: Locating No. 10 Front Sun Gear And Shell Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
28. Remove the 2 bolts and the transmission fluid reservoir hold-down bracket.
    Fig 28: Locating Hold-Down Bracket And Bolts

    Courtesy of FORD MOTOR CO.
29. Remove the transmission fluid reservoir.
    Fig 29: Locating Transmission Fluid Reservoir

    Courtesy of FORD MOTOR CO.
30. Remove the transmission fluid baffle.
    Fig 30: Locating Transmission Fluid Baffle

    Courtesy of FORD MOTOR CO.
31. Remove the park pawl pin and spring.
    Fig 31: Removing Park Pawl Pin And Spring

    Courtesy of FORD MOTOR CO.
32. Remove the park pawl.
    Fig 32: Locating Park Pawl

    Courtesy of FORD MOTOR CO.
NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).
NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
Fig 33: Locating Forward (1, 2, 3, 4) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
33. Remove the forward (1, 2, 3, 4) clutch snap ring.
34. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
    Fig 34: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate

    Courtesy of FORD MOTOR CO.
35. Remove the front sun gear and shell assembly.
    Fig 35: Locating Front Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
36. Remove the front planetary carrier/rear ring gear assembly.
    Fig 36: Locating Front Planetary Carrier/Rear Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
37. Remove the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
       Fig 37: Identifying No. 7 And No. 8 Thrust Bearings

       Courtesy of FORD MOTOR CO.
38. Remove the center planetary carrier/front ring gear assembly.
    Fig 38: Locating Center Carrier/Front Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
39. Remove the center planetary sun gear.
    Fig 39: Locating Center Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
40. Remove the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
       Fig 40: Identifying No. 5 And No. 6 Thrust Bearings

       Courtesy of FORD MOTOR CO.
41. Remove the center support assembly.
    Fig 41: Locating Center Support Assembly

    Courtesy of FORD MOTOR CO.
42. Remove the rear planetary carrier/center ring gear assembly.
    Fig 42: Locating Rear Planetary Carrier/Center Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
43. Remove the low/reverse wave spring, clutch pack and pressure plate.
    Fig 43: Locating Low/Reverse Wave Spring, Clutch Pack And Pressure Plate

    Courtesy of FORD MOTOR CO.
44. Remove the low One-Way Clutch (OWC).
    Fig 44: Locating Low One-Way Clutch (OWC)

    Courtesy of FORD MOTOR CO.
NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Fig 45: Removing Rear Planetary Sun Gear And Shell Assembly
Courtesy of FORD MOTOR CO.
45. Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
46. Remove the pressure plate and the wave spring.
    Fig 46: Locating Pressure Plate And Wave Spring

    Courtesy of FORD MOTOR CO.
47. Remove the No. 3 thrust bearing.
    Fig 47: Locating No. 3 Thrust Bearing

    Courtesy of FORD MOTOR CO.
48. Remove the overdrive/direct clutch assembly.
    Fig 48: Locating Overdrive/Direct Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: If the No. 1 thrust bearing stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
Fig 49: Locating No. 1 Thrust Bearing
Courtesy of FORD MOTOR CO.
49. Remove the No. 1 thrust bearing.
50. Remove the intermediate (2, 6) clutch apply ring.
    Fig 50: Locating Intermediate (2, 6) Clutch Apply Ring

    Courtesy of FORD MOTOR CO.
51. Remove the 3 bolts and the clutch support tower.
    Fig 51: Locating Clutch Support Tower Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the snap ring gap for assembly.
Fig 52: Locating Intermediate (2, 6) Clutch Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
52. Remove the intermediate (2, 6) clutch return spring snap ring.
NOTE: Note the position of the return spring for assembly.
Fig 53: Locating Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
53. Remove the intermediate (2, 6) clutch return spring.
NOTE: Note the position of the intermediate clutch piston for assembly.
Fig 54: Removing Intermediate (2, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
54. Remove the intermediate (2, 6) clutch piston.
55. Remove and discard the 5 clutch feed seals.
    Fig 55: Locating Clutch Feed Seals

    Courtesy of FORD MOTOR CO.
56. Remove the nut and the manual lever from the manual shaft.
    Fig 56: Locating Manual Lever And Nut

    Courtesy of FORD MOTOR CO.
NOTE: Do not drive the roll pin through the manual shaft. The roll pin will contact the transaxle case causing damage to the transaxle case.
Fig 57: Pulling Roll Pin Out Of Manual Shaft
Courtesy of FORD MOTOR CO.
57. Using Roll Pin Remover 211-061, pull the roll pin out of the manual shaft.
58. Remove the manual shaft.
    Fig 58: Removing Manual Shaft

    Courtesy of FORD MOTOR CO.
59. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.
    Fig 59: Removing TR Sensor And Park Pawl Actuator Rod

    Courtesy of FORD MOTOR CO.
60. Using a suitable tool, remove and discard the manual shaft seal.
    Fig 60: Removing Manual Shaft Seal

    Courtesy of FORD MOTOR CO.
61. Using a suitable tool, remove and discard the LH halfshaft seal.
    Fig 61: Removing LH Halfshaft Seal

    Courtesy of FORD MOTOR CO.
NOTE: Press the bushing out of the transaxle case from the outside to the inside so that the transaxle case rests on a flat surface.
Fig 62: Removing LH Transaxle Case Bushing From Transaxle Case Using Special Tools
Courtesy of FORD MOTOR CO.
62. Using the Wheel Speed Sensor Ring Installer 206-084/2 and a suitable press, remove and discard the LH transaxle case bushing from the transaxle case.
63. Remove the 2 bolts and the oil baffle from the torque converter housing.
    Fig 63: Locating Torque Fluid Baffle And Bolts

    Courtesy of FORD MOTOR CO.
64. Remove the 8 bolts and the pump and filter assembly.
    Fig 64: Locating Pump And Filter Assembly Bolts

    Courtesy of FORD MOTOR CO.
65. Remove the differential ring gear snap ring.
    Fig 65: Locating Differential Ring Gear Snap Ring

    Courtesy of FORD MOTOR CO.
66. Remove the differential ring gear.
    Fig 66: Remove/Install Differential Ring Gear

    Courtesy of FORD MOTOR CO.
67. Using a suitable tool, remove and discard the RH halfshaft seal.
    Fig 67: Removing RH Halfshaft Seal

    Courtesy of FORD MOTOR CO.