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Home › Ford › 1996 › Taurus SHO › Repair and Diagnosis › Transmission › Automatic Trans › Overhaul - Ax4N Automatic Transmission › 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.
NOTE: For identification and position of thrust bearings and washers, see Fig 1 .
  1. Place case in horizontal position. Install parking pawl system; shaft, pawl and return spring. Install NEW roll pin in parking pawl. Install drive sprocket support bearing in stator support, if necessary. Install stator support. Stator support bolt holes are offset. Stator support can only be aligned one way. Install and tighten 6 Torx (T-30) bolts to specification. See TORQUE SPECIFICATIONS.
  2. Install converter oil seal using appropriate seal driver. Position transaxle case in vertical position. Install No. 19 thrust bearing and race over case boss with flat side facing up and outer lip facing down. See Fig 1 . Install final drive ring with external splines up.
    Fig 1: Identifying Thrust Washers & Needle Bearings
    G96J04074Courtesy of FORD MOTOR CO.
  3. Lower final drive assembly by output shaft into case, including rear planetary support assembly. Ensure both oil transfer tube holes in rear planetary support align in case window. See Fig 2 . Install original selective snap ring with bevel down.
    Fig 2: Aligning Oil Transfer Tube Holes In Rear Planetary Support Assembly
    G96C04075Courtesy of FORD MOTOR CO.
    CAUTION: Ensure beveled selective snap ring is properly seated. Snap ring must be seated with rear planetary support assembly visible on inside diameter of snap ring and must not seat against case wall.
  4. Place screwdriver into differential through case slot and pry up to verify snap ring is seated. See Fig 2 . Rear planetary support clearance check needs to be performed if case, rear planetary support or final drive ring gear has been replaced. If any of these parts have not been replaced, go to step 7. If any of these parts have been replaced, go to next step.
  5. Check end play by installing Step Plate Adapter (D80L-630-3) and End Play Tool (T87P-70012-AH) over right output shaft opening. See Fig 3 . Remove No. 15 needle bearing. Place gauge bar across chain cover gasket surface. Mount dial indicator with extension rod to case. Extension rod should pass through gauge bar and rest on No. 15 needle bearing surface. Zero dial indicator. Tighten end play tool to 10-15 INCH lbs. (1.1-1.7 N.m).
  6. If end play is more than .0005" (.0127 mm), install next largest selective snap ring and recheck end play. See Figure . Remove gauge bar and dial indicator. Install No. 15 thrust bearing.
  7. Check end clearance at output shaft to select No. 16 selective thrust washer. Mount dial indicator to end of output shaft. Zero dial indicator. Tighten end play tool screw to 35-44 INCH lbs. (4-5 N.m). Observe dial indicator. End clearance should be .004-.016" (.10-.40 mm).
  8. If not within specification, replace No. 16 selective thrust washer. See NO. 16 SELECTIVE THRUST WASHER (7F451)  .
    NO. 16 SELECTIVE THRUST WASHER (7F451)

    Thickness/In. (mm) Color Code
    .085-.089 (2.15-2.25) Green
    .089-.093 (2.27-2.37) Blue
    .094-.098 (2.39-2.49) Black
    .099-.103 (2.51-2.61) White
    .104-.107 (2.63-2.73) Brown
    .108-.112 (2.75-2.85) Gold
  9. Removal of beveled selective snap ring and rear planetary support assembly is necessary to replace No. 16 selective thrust washer. After installing correct thrust washer, recheck clearance. If end clearance is within specifications, remove end play tool and dial indicator.
    Fig 3: Checking End Play
    G96E04076Courtesy of FORD MOTOR CO.
  10. Ensure No. 15 needle bearing is on top of rear planetary support hub and No. 15 thrust washer is on top of low-intermediate support and spring assembly. Install low-intermediate one-way clutch assembly. Install low-intermediate clutch wave spring, clutch pack and pressure plate over low-intermediate one-way clutch. Friction plate internal splines will center low-intermediate one-way clutch.
  11. Install low-intermediate clutch selective snap ring. Using air pressure, apply about 40 psi to low-intermediate apply port to ensure piston movement and no seal leakage. See Fig 2 .
  12. Check clutch pack clearance using a feeler gauge. Measure between selective snap ring and pressure plate. Clearance should be .050-.075" (1.27-1.90 mm). If clearance is not within specification, replace selective snap ring. Recheck clearance with NEW selective snap ring installed and adjust as necessary. Selective snap rings (7D483) are available in the following thicknesses:
    • .061-.065" (1.54-1.64 mm)
    • .082-.086" (2.08-2.18 mm)
    • .103-.107" (2.62-2.72 mm)
    • .124-.128" (3.16-3.26 mm)
    • .145-.149" (3.68-3.78 mm)
  13. Install coast band aligning band anchor pin pocket with anchor pin in case. Install low-intermediate drum and sun gear assembly. Rotate drum counterclockwise to seat into one-way clutch. Install parking pawl actuator bracket. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Ensure parking pawl works smoothly.
  14. Install coast servo assembly. Ensure NEW seals have been installed on coast servo piston and cover. See Figure and Fig 4 . Install front planetary/reverse clutch assembly with installation handle, (handle was added to assembly during COMPONENT DISASSEMBLY & REASSEMBLY procedure). Align anchor bolt pocket on assembly with anchor bolt case hole.
  15. Ensure supply oil transfer tube hole is aligned. See Fig 5 . Remove installation handle and collet from front planetary/reverse clutch assembly. Install reverse clutch cylinder anchor bolt and lock nut finger tight. See Fig 5 .
    Fig 4: Exploded View Of Coast Servo
    G96H04068Courtesy of FORD MOTOR CO.
    Fig 5: Reverse Clutch Anchor Bolt & Oil Transfer Tube Holes
    G96G04077Courtesy of FORD MOTOR CO.
  16. Install Front Clutch Loading Tool (T86P-70389-A) with Extended Front Clutch Loading Tool Screw (T94P-77001-HH) to sun gear and shell assembly. Install hook portion of Extended Front Clutch Loading Tool Screw into one of lube holes of sun gear and shell assembly. Position notched block over edge of assembly and tighten handle.
  17. Using Front Clutch Loading Tool, lower assembly into case. Align shell and sun gear splines into forward planetary. Ensure assembly is fully seated before removing tool.
  18. Install overdrive band into case. Install plastic retainer with crosshairs facing up. Install No. 9 direct clutch hub needle bearing over output shaft with outer lip facing up. Install Gauge Tube (T94P-77001-MH) over output shaft and seat against No. 9 direct clutch hub needle bearing.
  19. Place Gauge Bar (T94P-77000-Q) with round legs across chain cover gasket surface. Using depth micrometer, measure distance between gauge bar and gauge tube. Take 2 readings 180 degrees apart and note average as specification "A". Use specification "A" to select No. 8 thrust washer. See NO. 8 THRUST WASHER SELECTION (7G273)  .
    NO. 8 THRUST WASHER SELECTION (7G273)

    Specification "A" Inch (mm) Washer Thickness Inch (mm) Washer Color
    1.688-1.696 (42.88-43.10) .056-.060 (1.43-1.53) Natural
    1.697-1.706 (43.11-43.34) .066-.070 (1.68-1.78) Dk. Green
    1.707-1.716 (43.35-43.59) .075-.079 (1.92-2.02) Lt. Blue
    1.717-1.723 (43.60-43.77) .085-.089 (2.17-2.27) Red
    1.724-1.731 (43.78-43.98) .093-.096 (2.35-2.45) Black
  20. Remove Gauge Tube and take a measurement from gauge bar to No. 5 thrust washer mating surface. Take 2 readings 180 degrees apart and note average as specification "B". Remove gauge bar and depth micrometer.
  21. To find appropriate No. 5 thrust washer, subtract specification "A" from specification "B" and to that subtotal add the mid range thickness of Lt. Blue thrust washer No. 8 (example: .077"/1.97 mm for Lt. Blue washer), this new total is specification "C". See formula below. From specification "C" selection of No. 5 thrust washer can be made. See NO. 5 THRUST WASHER SELECTION (7D014)  .
    NO. 5 THRUST WASHER SELECTION (7D014)

    Specification "A" Inch (mm) Washer Thickness Inch (mm) Washer Color
    1.027-1.038 (26.08-26.37) .086-.090 (2.18-2.28) Green
    1.039-1.047 (26.38-26.61) .095-.099 (2.43-2.53) Black
    1.048-1.057 (26.62-26.86) .105-.109 (2.67-2.77) Natural
    1.058-1.068 (26.87-27.15) .115-.118 (2.92-3.02) Red
    1.069-1.083 (27.16-27.50) .128-.132 (3.26-3.36) Blue
  22. Apply petroleum jelly to newly selected No. 5 thrust washer and install on driven sprocket support. Install newly selected No. 8 thrust washer on end of driven sprocket support. Remove No. 9 direct clutch hub needle bearing from transaxle and install on top of No. 8 thrust washer. Use petroleum jelly to hold needle bearing and thrust washer in place on driven sprocket support. Apply petroleum jelly to seals and install driven sprocket support.
  23. Install N-D accumulator assembly. See Figure . Tighten cover bolt to specification. See TORQUE SPECIFICATIONS  . Install NEW "O" rings on all oil transfer tubes. Install oil transfer tubes in order; reverse clutch, coast servo, low intermediate clutch and rear fluid. See Figure . Install tube support brackets and tighten to specification.
  24. If manual shaft components have not been installed, tap manual shaft seal into case. Install parking lever actuating rod in case. Push in parking pawl and adjust parking lever actuating rod between parking pawl and parking pawl bracket.
  25. Start manual shaft through seal, and slide manual control lever onto shaft. Slide shaft through park rod actuating lever and tap into case hole. Install NEW roll pins through manual linkage holes and case, aligning with groove in shaft. Ensure parking pawl engages park gear and returns freely.
  26. Align tabs of No. 2 and No. 4 thrust washers and install on drive and driven sprocket supports. Apply petroleum jelly to thrust washers to hold in place. Install chain on drive and driven sprockets. Lower assembly into sprocket supports, rotating to ensure components are fully seated.
  27. Install accumulator springs in same positions as removed from case. Ensure alignment pins are in case for chain cover installation. Install NEW chain cover gasket. Using petroleum jelly to hold thrust washers in place, install No. 1 and No. 3 (plastic) thrust washers to bottom side of chain cover. Ensure thrust washer tabs are aligned with slots in chain cover.
  28. Carefully align chain cover input shaft bore with input shaft. Ensure cast iron sealing ring is not damaged. Gently apply downward pressure, to overcome accumulator spring pressure, and start 2 chain cover bolts 180 degrees apart. Install remaining chain cover bolts and tighten to specification from center out. Input shaft should have end play and rotate freely. If it does not rotate freely, remove chain cover and check for damaged cast iron seal.
    NOTE: Ensure overdrive servo test spring is not interchanged with operational spring. Test spring is weaker and shorter. Spring color may be identical.
  29. Install spring from Overdrive Servo Rod Kit (T86P-70023-B) in case. Install servo piston and rod in case. Install servo rod tool from kit and secure in case using servo cover bolts. Tighten bolts to 80-106 INCH lbs. (9-12 N.m). Tighten gauge center screw to 10 INCH lbs (1.13 N.m). See Fig 6 .
  30. Attach a dial indicator and position stylus through hole in gauge. Ensure stylus contacts piston on a flat surface. DO NOT contact step on piston. Zero dial indicator. Back off gauge center screw until piston movement stops and read piston travel on dial indicator. Piston travel is determined by servo rod length. Piston travel should be .070-.149" (1.8-3.8 mm).
  31. If piston travel is not within specification, change piston rod and recheck. Piston rod is identified by number of grooves located on tip of rod. See OVERDRIVE SERVO ROD SELECTION  . Install overdrive servo assembly with operational spring. Install NEW seals, cover and bolts. Tighten bolts to 80-106 INCH lbs. (9-12 N.m).
    OVERDRIVE SERVO ROD SELECTION (7F203)

    Number Of Grooves In Rod Tip Rod Length Inch (mm)
    0 (No Grooves) 3.911 (99.33)
    1 3.860 (98.05)
    2 3.810 (96.78)
    Fig 6: Overdrive Servo Check
    G96I04078Courtesy of FORD MOTOR CO.
  32. Perform air pressure test. See AIR PRESSURE TEST  under TESTING. Install NEW Teflon seals on oil pump driveshaft. Install shaft and connect manual control valve actuating rod link to manual valve detent lever.
  33. Start oil pump and valve body assembly over pump shaft and connect manual control valve actuating rod to manual control valve. Push valve body down until seated. Install valve body bolts in proper locations and tighten from center out.
  34. Install bulkhead connector and electrical connectors. Ensure connectors "click" to lock position as they are installed. See Figure . Install valve body cover with NEW self-adhesive gasket. Tighten bolts to specification.
  35. Tighten reverse clutch anchor bolt to 80-106 INCH lbs. (9-12 N.m) and lock nut to 25-36 ft. lbs. (27-35 N.m). Install seal and oil filter into case. Install oil pan with NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  36. Install remaining chain cover bolts in bellhousing and tighten to specification. Install Turbine Shaft Speed (TSS) sensor. Install Transmission Range (TR) sensor but DO NOT tighten bolts fully at this time. Using a 9 mm wrench on flats of manual shaft, rotate shaft counterclockwise to Park detent and clockwise 2 detents to Neutral detent.
  37. Using MLPS Alignment Tool (T92P-70010-AH), adjust TR sensor and tighten bolts to specification. Install dipstick tube grommet and dipstick tube in case. Install VSS. Install left and right output shaft seal and circlips. Install torque converter.
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