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 thrust 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.

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 .
Install converter oil seal using appropriate seal driver. Position transaxle case in vertical position. Install thrust bearing and race No. 19 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
Courtesy of FORD MOTOR CO.
Install rear support spacer on top of final drive ring gear and case splines. 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
Courtesy 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.

Place screwdriver into differential through case slot and pry up to verify snap ring is seated. See Fig 2. Rear planetary support end play 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.
Check end play by installing Step Plate Adapter (D80L-630-3) and End Play Tool (T87P-70014-AH) over right output shaft opening. See Fig 3. Remove thrust bearing No. 15. 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 thrust bearing No. 15 surface. Zero dial indicator. Tighten end play tool to 10-15 INCH lbs. (1.1-1.7 N.m).
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 thrust bearing No. 15.
Check end play at output shaft to install selective race No. 16. 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 play should be .004-.016" (.10-.40 mm).

If end play is not within specification, replace selective race No. 16. See SELECTIVE RACE NO. 16 table.

SELECTIVE RACE NO. 16

Thickness In. (mm)		Color Code
Continental
.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
.103-.107 (2.63-2.73)		Brown
.108-.112 (2.75-2.85		-
Sable & Taurus
.082-.086 (2.09-2.19)		Green
.087-.091 (2.22-2.32)		Blue
.092-.096 (2.35-2.45)		Black
.098-.102 (2.48-2.58)		White
.103-.107 (2.61-2.71)		Brown
.108-.112 (2.74-2.84)		Gold

Removal of beveled selective snap ring and rear planetary support assembly is necessary to replace selective race No. 16. After installing correct selective race, recheck end play. If end play is within specifications, remove end play tool and dial indicator.

Fig 3: Checking End Play
Courtesy of FORD MOTOR CO.
Ensure thrust bearing No. 15 is on top of rear planetary support hub and race No. 15 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.
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.
Using a feeler gauge, measure low-intermediate clutch pack clearance. Measure between selective snap ring and pressure plate. See Fig 4. 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).

Fig 4: Measuring Low-Intermediate Clutch Pack Clearance
Courtesy of FORD MOTOR CO.
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 (park rod abutment) bracket. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure parking pawl works smoothly.
Install coast servo assembly. Ensure NEW seals have been installed on coast servo piston and cover. See Figure and Fig 5 . Install front planetary/reverse clutch assembly with installation handle, (handle was added to assembly during COMPONENT DISASSEMBLY & REASSEMBLY ). Align anchor bolt pocket on assembly with anchor bolt case hole.
Ensure supply oil transfer tube hole is aligned. See Fig 6. Remove installation handle and collet from front planetary/reverse clutch assembly. Install reverse clutch cylinder anchor bolt and lock nut finger tight. See Fig 6.

Fig 5: Exploded View Of Coast Servo
Courtesy of FORD MOTOR CO.

Fig 6: Locating Reverse Clutch Anchor Bolt & Oil Transfer Tube Holes
Courtesy of FORD MOTOR CO.
Install Front Clutch Loading Tool (T86P-70389-A) with Front Clutch Loading Tool Screw (T94P-77001-HH) to sun gear and shell assembly. Install hook portion of loading tool screw into one of lube holes of sun gear and shell assembly. Position notched block over edge of assembly and tighten handle.
Using front clutch loading tool, lower assembly into case. See Figure. Align shell and sun gear splines into forward planetary. Ensure assembly is fully seated before removing tool.
Install overdrive band into case. Install plastic retainer with crosshairs facing up. Install thrust bearing No. 9 over output shaft with outer lip facing up. Install Gauge Tube (T94P-77001-MH) over output shaft and seat against thrust bearing No. 9.

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. See Fig 7. Take 2 readings 180 degrees apart and note average as dimension "A". Use dimension "A" to select thrust washer No. 8. See THRUST WASHER NO. 8 SELECTION table.

THRUST WASHER NO. 8 SELECTION

Dimension "A" - In. (mm)	Washer Thickness - In. (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

Fig 7: Measuring Dimension "A"

Courtesy of FORD MOTOR CO.

Remove Gauge Tube and take a measurement from gauge bar to thrust washer No. 5 mating surface. See Fig 8. Take 2 readings 180 degrees apart and note average as dimension "B". Remove gauge bar and depth micrometer.

Fig 8: Measuring Dimension "B"
Courtesy of FORD MOTOR CO.

To find appropriate No. 5 thrust washer, use the following formula: ("B" - "A") + Washer Thickness No. 8 = "C" . From dimension "C", selection of No. 5 thrust washer can be calculated. See THRUST WASHER NO. 5 SELECTION table.

THRUST WASHER NO. 5 SELECTION

Dimension "C" In. (mm)	Washer Thickness In. (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

Apply petroleum jelly to newly selected thrust washer No. 5 and install on driven sprocket support. Install newly selected thrust washer No. 8 on end of driven sprocket support. Remove thrust bearing No. 9 from transaxle and install on top of thrust washer No. 8. Use petroleum jelly to hold thrust bearing No. 9 and thrust washer No. 8 in place on driven sprocket support. Apply petroleum jelly to seals and install driven sprocket support.
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 the following order; reverse clutch, coast band servo, low-intermediate clutch and rear lube fluid. See Figure. Install tube support brackets and tighten to specification.
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.
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 parking gear and returns freely.
Align tabs of thrust washers No. 2 and 4 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.
Install accumulator springs in same positions as removed from case. See Figure. 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 thrust washers No. 1 and 3 (plastic) to bottom side of chain cover. See Figure. Ensure thrust washer tabs are aligned with slots in chain cover.
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.

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. (1.1 N.m). See Fig 9.
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 .071-.150" (1.80-3.80 mm).

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 table. 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

Number Of Grooves In Rod Tip	Rod Length - In. (mm)
0 (No Grooves)	3.911 (99.33)
1	3.860 (98.05)
2	3.810 (96.78)

Fig 9: Overdrive Servo Check

Courtesy of FORD MOTOR CO.

Perform air pressure test. See AIR PRESSURE TESTS under PERFORMANCE TESTS. Install NEW Teflon seals on oil pump driveshaft. Install shaft and connect manual control valve actuating rod link to manual valve detent lever.
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.
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.
Tighten reverse clutch anchor bolt to 80-106 INCH lbs. (9-12 N.m) and lock nut to 25-35 ft. lbs. (34-47 N.m). Install seal and oil filter into case. Install oil pan with NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
Install remaining chain cover bolts in bellhousing and tighten to specification. Install TSS sensor. Install 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.
Using MLPS Alignment Tool (T92P-70010-A), 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.