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Home › Ford › 1990 › Tempo Base › Repair and Diagnosis › Transmission › Automatic Trans › Overhaul - ATX/FLC › Transaxle Reassembly

Transaxle Reassembly

NOTE: Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean ATF. Use petroleum jelly on gaskets, thrust washers and needle bearings to retain them in place. Use all new gaskets and seals, and tighten bolts evenly.
  1. Clean idler gear shaft threads and install a new "O" ring. Place idler gear and shaft in case. Insert a 12-mm Allen wrench in idler gear shaft and position it to catch on band anchor strut.
  2. Apply Loctite to idler shaft attaching nut. Install and tighten nut to specification using a 32-mm 12-point socket. Refer to the TORQUE SPECIFICATIONS  . Install No. 1 thrust bearing and input gear No. 2 caged needle bearing. See Fig 1 .
    Fig 1: Installing Thrust Bearing & Caged Needle Bearing
    G92F14055Courtesy of FORD MOTOR CO.
    NOTE: Before installing final drive housing, ensure band strut is rotated into its operating position. Transmission case and housing are matched parts. If one is damaged, both must be replaced.
  3. Install input gear over reactor support. Install No. 3 thrust bearing (needle) on input gear. See Fig 6 . Position final drive housing in case. Ensure it is firmly seated on alignment dowels. Install NEW final drive housing attaching bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Install No. 4 thrust washer. Install sun gear and drum. Install intermediate band. Ensure band lug engages stud. Place servo piston in case and install Remover/Installer (T81P-70027-A).
  5. Compress piston spring far enough to allow installation of retaining ring. Install servo retaining ring and before removing tool, ensure piston rod has engaged band lug.
  6. Place reverse clutch cylinder in case and tap cylinder in using a hammer handle. Using Seal Protector (T81P-70402-A), apply even pressure and install reverse clutch piston in clutch cylinder. Remove seal protector. Install No. 5 thrust washer on planetary gear set. Install assembly on sun gear.
    NOTE: Before installing reverse clutch piston return spring and holder assembly, reverse clutch clearance must be checked in the following manner:
  7. Install clutch pack wave spring, clutch pack and pressure plate then install clutch pack retaining ring. Clutch pack contains 3 friction and 3 steel plates. Using a feeler gauge, measure clearance between retaining ring and pressure plate at 2 places 180 degrees apart. See Fig 2 .
  8. If average clearance is .030-.055" (.76-1.40 mm). clutch clearance is correct. If clearance is less than .030" (.76 mm). install a thinner retaining ring. If clearance is greater than .055" (1.40 mm), install a thicker retaining ring.
    Fig 2: Measuring Reverse Clutch Clearance
    G92G14056Courtesy of FORD MOTOR CO.
    NOTE: Whenever new retaining ring is installed, repeat clearance check. See REVERSE CLUTCH RETAINING RING THICKNESSES  for available reverse clutch retaining rings.
    REVERSE CLUTCH RETAINING RING THICKNESSES

    Part No. (1) Thickness
    E6FZ7D483-A .051" (1.30mm)
    E6FZ7D483-B .072" (1.83mm)
    E6FZ7D483-C .085" (2.16mm)
    E6FZ7D483-D .102" (2.59mm)
    (1) Retaining ring thickness has .002" (.05 mm) tolerance.
  9. Remove reverse clutch pack retaining ring, pressure plate, clutch pack and wave spring. Install reverse clutch return spring and holder assembly. Reinstall wave spring, clutch pack, pressure plate and retaining ring.
  10. Install No. 7 thrust washer on planetary assembly. Install intermediate clutch hub and ring gear assembly into case. Install direct clutch assembly into case. Position No. 10 thrust bearing (needle type) on direct clutch.
  11. Install intermediate clutch assembly into case and check for proper clutch engagement as follows: position No. 11 thrust bearing on one of the machined tabs and push bearing up against case. If bearing is flush or slightly below machined pump housing surface in case, clutch is fully engaged. If clutch is not fully engaged, reposition clutch assembly. See Fig 3 . Position No. 11 thrust bearing on clutch drum.
  12. Install pump Alignment Pins (T81P-77100-A) and pump housing gasket. Position transaxle End Play Checking Tools (T81P-77389-A and T80L-77003-A) in intermediate clutch. See Fig 4 .
    Fig 3: Checking Intermediate Clutch for Engagement
    G92H14057Courtesy of FORD MOTOR CO.
    Fig 4: Installing Transaxle End Play Measuring Tools
    G92I14058Courtesy of FORD MOTOR CO.
  13. Using a micrometer, measure distance from top of gauge bar to top of No. 11 thrust bearing installed on intermediate clutch. Perform measurement at 2 places, 180 degrees apart, and use average of 2 measurements. Subtract .700" (17.78 mm) thickness of gauge bar from average of 2 measurements to determine end play. Choose proper end play thrust washer. See END PLAY THRUST WASHERS  .
  14. Install No. 12 thrust washer (selective), chosen from END PLAY THRUST WASHERS  , on oil pump. Position pump in case and tap into place using a hammer handle. Remove pump alignment pins. Install pump attaching bolts and washers to specification.
    CAUTION: Oil pump attaching bolt washers provide bolt seal and must not be substituted. Failure to use sealing washers may result in fluid leak.
    END PLAY THRUST WASHERS

    End Play: In. (mm) (1) Nylon Washer Color Metallic Washer ID
    .057-.070 (1.46-1.77) Green EA
    .070-.079 (1.77-2.00) Black AA
    .079- 087 (2.00-2.20) Natural BA
    .087-.095 (2.20-2.41) Blue CA
    (1) If thrust washer thickness is not known, see END PLAY THRUST WASHER THICKNESS  .
    END PLAY THRUST WASHER THICKNESS

    Thrust Washer ID/Color Thickness: In. (mm)
    AA/Black .055-.057 (1.40-1.45)
    BA/Natural .063-.065 (1.60-1.65)
    CA/Blue .071-.073 (1.80-1.85)
    EA/Green .045-.047 (1.15-1.20)
  15. Position differential assembly in transaxle case. Install differential bearing spacer shim. Install new "O" ring on differential retainer and position retainer in case (tap into place if necessary). Loctite bolt threads and install retainer attaching bolt. Tighten bolts to specification.
  16. Position new seal on oil filter and install filter in case. Install oil pan using a new gasket. Install new seal on speedometer driven gear retainer and position retainer in case. Tap retainer into position using a plastic hammer. Ensure retaining pin hole is aligned. With retainer properly positioned, tap retaining pin into case.
  17. Install governor into case. Install new seal on governor cover and position cover on case. Tap cover into place using plastic hammer and install cover retaining wire.
  18. Position governor screen into case bore. Position valve body gasket on case and install alignment pins to hold gasket in place. Place valve body in position in case and at the same time connect "Z" link to manual valve.
  19. Connect throttle valve control spring to inner lever cam and to separator plate. With valve body correctly positioned, ensure roller on end of throttle valve plunger has engaged cam on end of throttle lever shaft.
  20. Install the detent roller assembly, baffle plates and all remaining valve body attaching bolts. Tighten the valve body attaching bolts in sequence and to specification. See Fig 5 . For tightening specifications, see TORQUE SPECIFICATIONS  . Connect throttle return spring to spring anchor on throttle lever.
  21. Position a new valve body cover gasket on case. Install cover and tighten attaching bolts to specification. Install oil pump shaft. Install new seal on dipstick tube and install tube in case. Install torque converter into transaxle case.
Fig 5: Tightening Sequence for Valve Body Bolts
G92J14059Courtesy of FORD MOTOR CO.
Fig 6: Cross-Sectional View Of ATX Bearing Locations
G92C14060Courtesy of FORD MOTOR CO.
Fig 7: Exploded View Of ATX Automatic Transaxle Assembly
G92D14061Courtesy of FORD MOTOR CO.
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