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Section 2010 (Automatic Transmission - Cd4E): Disassembly: Transaxle: Disassembly

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Clean the transaxle assembly to prevent the entry of dirt when reassembling.
  1. Inspect transaxle during disassembly.
  2. Remove the special tool.
    3. Fig 1: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
    CAUTION: Do not tilt the torque converter when removing it. This can damage the torque converter hub.
    NOTE: The torque converter is filled with fluid. Position it on a table so that fluid will drain out of the torque converter into a drain pan.
  3. Using the special tool, remove the torque converter.
    4. Fig 2: Removing Torque Converter
    GF0024881Courtesy of FORD MOTOR CO.
  4. Remove the turbine shaft speed (TSS) sensor.
    1. Remove the bolt.
    2. Remove the TSS sensor.
    5. Fig 3: Identifying Turbine Shaft Speed Sensor
    GF0024882Courtesy of FORD MOTOR CO.
  5. Remove and discard the TSS and OSS sensor O-ring seals.
    6. Fig 4: O-Ring Seal
    GF0024883Courtesy of FORD MOTOR CO.
  6. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the TR sensor from the manual valve detent lever shaft.
    7. Fig 5: Identifying Transmission Range (TR) Sensor
    GF0024884Courtesy of FORD MOTOR CO.
  7. Using the special tool, secure the transaxle to the bench.
    8. Fig 6: Securing Transaxle To Bench
    GF0024885Courtesy of FORD MOTOR CO.
  8. Position the drain pan under the transaxle, remove the drain plug, and drain the transmission fluid.
    9. Fig 7: Transaxle Drain Plug
    GF0024762Courtesy of FORD MOTOR CO.
  9. Remove the pump assembly driveshaft.
    10. Fig 8: Pump Assembly Driveshaft
    GF0024886Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove and discard the torque converter impeller hub seal.
    11. Fig 9: Removing Torque Converter Impeller Hub Seal
    GF0024887Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the LH differential seal.
    12. Fig 10: Removing LH Differential Seal Using Special Tools
    GF0024888Courtesy of FORD MOTOR CO.
  12. If the vehicle is equipped with a power transfer unit (PTU), use the special tools to remove the RH differential seal.
    13. Fig 11: Removing RH Differential Seal Using Special Tools (1 Of 2)
    GF0024789Courtesy of FORD MOTOR CO.
  13. If the vehicle is not equipped with a PTU, use the special tools to remove the RH differential seal.
    14. Fig 12: Removing RH Differential Seal Using Special Tools (2 Of 2)
    GF0024790Courtesy of FORD MOTOR CO.
  14. Remove the transaxle fluid filler tube bolt.
    15. Fig 13: Transaxle Fluid Filler Tube Bolt
    GF0024889Courtesy of FORD MOTOR CO.
  15. Remove the transaxle fluid filler tube.
    16. Fig 14: Transaxle Fluid Filler Tube
    GF0024890Courtesy of FORD MOTOR CO.
  16. Remove and discard the transaxle filler tube grommet.
    17. Fig 15: Transaxle Fluid Filler Tube Grommet
    GF0024891Courtesy of FORD MOTOR CO.
  17. Remove the main control cover bolts, studs and cover.
    18. Fig 16: Locating Main Control Cover Bolts, Studs & Cover
    GF0024772Courtesy of FORD MOTOR CO.
  18. Remove the gasket.
    19. Fig 17: Locating Main Control Cover Gasket
    GF0024773Courtesy of FORD MOTOR CO.
  19. Inspect the fitting of the main control cover vent tube for blockage.
  20. Remove the main control valve body bolts.
    21. Fig 18: Main Control Valve Body Mounting Bolt Tightening Sequence
    GF0024776Courtesy of FORD MOTOR CO.
  21. Disconnect the manual valve link from the manual valve when lifting the main control valve body from the case.
    22. Fig 19: Manual Valve Link At Main Control Valve Body
    GF0024777Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull on solenoid body electrical connector wires, or use a hammer on the electrical connector.
  22. Remove the solenoid body electrical connector.
    • Release the retaining tabs and push the connector through the transaxle case.
    23. Fig 20: Solenoid Body Electrical Connector Retaining Tabs
    GF0024892Courtesy of FORD MOTOR CO.
  23. Support the manual valve and remove the main control.
    24. Fig 21: Manual Valve Body & Main Control
    GF0024893Courtesy of FORD MOTOR CO.
  24. Remove the thermostatic fluid level control valve bracket.
    1. Remove the bolt.
    2. Remove the bracket.
    25. Fig 22: Thermostatic Fluid Level Control Valve Bracket & Bolt
    GF0024894Courtesy of FORD MOTOR CO.
  25. Remove the thermostatic fluid level control valve.
    26. Fig 23: Thermostatic Fluid Level Control Valve
    GF0024895Courtesy of FORD MOTOR CO.
    WARNING: Follow the specified procedure when using the tool to remove the servo cover. The servo and servo cover are under high spring force and can separate forcefully, which may result in serious personal injury.
    CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case can occur. Use only snap ring pliers to remove the retaining ring.
  26. Using the special tool, remove the servo assembly.
    1. Install the special tool.
    2. Compress the servo assembly by tightening the bolt.
    3. Remove the retaining ring.
    27. Fig 24: Removing Servo Retaining Ring Using Special Tools
    GF0024798Courtesy of FORD MOTOR CO.
  27. Remove the servo cover assembly.
  28. Remove the intermediate and overdrive servo piston and return spring.
    29. NOTE: If the bonded seal is damaged, install a new servo assembly.
  29. Inspect the intermediate and overdrive servo assembly and bore for damage or wear.
    1. Servo cover with bonded seal.
    2. Cushion spring
    3. Servo apply rod
    4. Servo return spring
    5. Case servo bore
    30. Fig 25: Identifying Intermediate & Overdrive Servo Assembly Components
    GF0024896Courtesy of FORD MOTOR CO.
    NOTE: Position the transaxle with the torque converter housing facing upward.
  30. Remove the 20 bolts.
    31. Fig 26: Torque Converter Housing Bolts
    GF0024897Courtesy of FORD MOTOR CO.
    NOTE: Place the torque converter housing on the engine flange side after removal to prevent damage to the lube tube.
  31. Separate the torque converter housing from the transaxle case.
    • Remove and discard the transaxle split flange gasket.
    32. Fig 27: Torque Converter Housing
    GF0024898Courtesy of FORD MOTOR CO.
  32. Remove the differential bearing and shim.
    1. Remove the No. 15 differential bearing.
    2. Remove the No. 14 differential bearing shim.
    33. Fig 28: No. 15 Differential Bearing & No. 14 Differential Bearing Shim
    GF0024899Courtesy of FORD MOTOR CO.
    NOTE: The all wheel drive differential is shown. The front wheel drive differential may or may not have splines.
  33. Remove the final drive carrier and differential assembly.
    34. Fig 29: Final Drive Carrier & Differential Assembly
    GF0024900Courtesy of FORD MOTOR CO.
  34. Remove the No. 13 driven sprocket thrust bearing.
    35. Fig 30: No. 13 Driven Sprocket Thrust Bearing
    GF0024901Courtesy of FORD MOTOR CO.
  35. Unclip and remove the chain pan cover.
    36. Fig 31: Chain Pan Cover
    GF0024902Courtesy of FORD MOTOR CO.
    NOTE: The driven sprocket thrust washer may adhere to the converter housing.
  36. Remove the No. 10 driven sprocket thrust washer from the reverse/overdrive ring gear assembly.
    37. Fig 32: No. 10 Driven Sprocket Thrust Washer
    GF0024903Courtesy of FORD MOTOR CO.
  37. Remove the chain drive, reverse/overdrive ring gear and driven sprocket assembly.
    38. Fig 33: Chain Drive, Reverse/Overdrive Ring Gear & Driven Sprocket Assembly
    GF0024904Courtesy of FORD MOTOR CO.
  38. Separate the drive chain assembly from the driven sprocket assembly and reverse/overdrive ring gear assembly.
    39. Fig 34: Drive Chain Assembly
    GF0024905Courtesy of FORD MOTOR CO.
    NOTE: Inspect the magnet located on the chain pan for excessive metal particles.
  39. Remove the chain pan (with the magnet retained) from the transaxle case.
    40. Fig 35: Chain Pan
    GF0024906Courtesy of FORD MOTOR CO.
  40. Assemble the special tools.
    41. Fig 36: Assembling Special Tools
    GF0024907Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove and discard fluid filter recirculating regulator exhaust seal.
    42. Fig 37: Removing Fluid Filter Recirculating Regulator Exhaust Seal Using Special Tools
    GF0024908Courtesy of FORD MOTOR CO.
  42. Remove the fluid filter and seal assembly.
    1. Discard the fluid filter.
    2. Discard the fluid filter seal.
    43. Fig 38: Identifying Fluid Filter & Seal Assembly
    GF0024909Courtesy of FORD MOTOR CO.
  43. Remove the No. 12 driven sprocket bearing.
    44. Fig 39: No. 12 Driven Sprocket Bearing
    GF0024910Courtesy of FORD MOTOR CO.
  44. Remove the No. 11 driven sprocket shim (selective fit).
    45. Fig 40: No. 11 Driven Sprocket Shim
    GF0024911Courtesy of FORD MOTOR CO.
  45. Disconnect the parking lever actuating rod from the parking cam actuator lever assembly.
    46. Fig 41: Parking Lever Actuating Rod & Parking Cam Actuator Lever Assembly
    GF0024912Courtesy of FORD MOTOR CO.
  46. Disconnect the parking lever actuation rod from the manual valve detent lever, and remove the parking lever actuation rod.
    47. Fig 42: Parking Lever Actuation Rod At Manual Valve Detent Lever
    GF0024913Courtesy of FORD MOTOR CO.
    NOTE: The thrust bearing may adhere to the reverse/overdrive sprocket.
  47. Remove the No. 9 reverse/overdrive ring gear thrust bearing.
    48. Fig 43: No. 9 Reverse/Overdrive Ring Gear Thrust Bearing
    GF0024914Courtesy of FORD MOTOR CO.
    NOTE: The thrust bearing is part of the reverse/overdrive carrier assembly.
  48. Remove the reverse/overdrive carrier assembly with captured No. 8 thrust bearing.
    49. Fig 44: Reverse/Overdrive Carrier Assembly
    GF0024915Courtesy of FORD MOTOR CO.
  49. Remove the reverse/overdrive sun gear and shell assembly.
    50. Fig 45: Reverse/Overdrive Sun Gear & Shell Assembly
    GF0024916Courtesy of FORD MOTOR CO.
    NOTE: The thrust bearing may adhere to the reverse/overdrive sun gear and shell.
  50. Remove the reverse/overdrive sun gear and No. 7 shell thrust bearing.
    51. Fig 46: Reverse/Overdrive Sun Gear & No. 7 Shell Thrust Bearing
    GF0024917Courtesy of FORD MOTOR CO.
  51. Remove the low/intermediate ring gear assembly.
    52. Fig 47: Low/Intermediate Ring Gear Assembly
    GF0024918Courtesy of FORD MOTOR CO.
    NOTE: The low/intermediate carrier thrust bearing may adhere to the low/intermediate ring gear.
  52. Remove the No. 6 low/intermediate carrier thrust bearing.
    53. Fig 48: No. 6 Low/Intermediate Carrier Thrust Bearing
    GF0024919Courtesy of FORD MOTOR CO.
  53. Remove the low/intermediate carrier assembly.
    54. Fig 49: Low/Intermediate Carrier Assembly
    GF0024920Courtesy of FORD MOTOR CO.
  54. Remove the No. 5 low/intermediate sun gear thrust bearing and tag for installation.
    55. Fig 50: No. 5 Low/Intermediate Sun Gear Thrust Bearing
    GF0024921Courtesy of FORD MOTOR CO.
  55. Remove the forward one-way clutch and low/intermediate sun gear.
    56. Fig 51: Forward One-Way Clutch & Low/Intermediate Sun Gear
    GF0024922Courtesy of FORD MOTOR CO.
    NOTE: The turbine shaft thrust bearing may adhere to the forward one-way clutch and low/intermediate sun gear.
  56. Remove the No. 4 turbine shaft thrust bearing.
    57. Fig 52: No. 4 Turbine Shaft Thrust Bearing
    GF0024923Courtesy of FORD MOTOR CO.
  57. Remove the turbine shaft assembly.
    58. Fig 53: Turbine Shaft Assembly
    GF0024924Courtesy of FORD MOTOR CO.
  58. Remove the forward/coast/direct cylinder assembly and reverse clutch drum assembly from the transaxle.
    59. Fig 54: Forward/Coast/Direct Cylinder Assembly & Reverse Clutch Drum Assembly
    GF0024925Courtesy of FORD MOTOR CO.
    NOTE: The pump support thrust bearing assembly may adhere to the reverse clutch drum assembly.
  59. Remove the No. 1 pump support thrust bearing and tag for installation.
    60. Fig 55: No. 1 Pump Support Thrust Bearing
    GF0024926Courtesy of FORD MOTOR CO.
  60. Remove the low one-way clutch retaining ring.
    61. Fig 56: Low One-Way Clutch Retaining Ring
    GF0024927Courtesy of FORD MOTOR CO.
  61. Remove the mechanical diode assembly.
    62. Fig 57: Mechanical Diode Assembly
    GF0024928Courtesy of FORD MOTOR CO.
  62. Remove the thin, 8-wave low/reverse clutch wave spring.
    63. Fig 58: Thin Low/Reverse Clutch Wave Spring
    GF0024929Courtesy of FORD MOTOR CO.
  63. Remove the low/reverse clutch plates.
    • Inspect the friction plates for partially stripped, broken or bent spline teeth, burnt, worn or flaked-off friction material and warped or bent friction discs.
    • Inspect the steel plates for heat discoloration or warpage.
    64. Fig 59: Low/Reverse Clutch Plates
    GF0024930Courtesy of FORD MOTOR CO.
  64. Remove the thick, 10-wave low/reverse clutch wave spring.
    65. Fig 60: Thick Low/Reverse Clutch Wave Spring
    GF0024931Courtesy of FORD MOTOR CO.
  65. Remove and discard the low/reverse clutch return spring retaining ring.
    66. Fig 61: Low/Reverse Clutch Return Spring Retaining Ring
    GF0024932Courtesy of FORD MOTOR CO.
  66. Remove the low/reverse clutch return spring assembly.
    67. Fig 62: Low/Reverse Clutch Return Spring Assembly
    GF0024933Courtesy of FORD MOTOR CO.
    NOTE: Rotate the low/reverse clutch piston while pulling upward.
  67. Remove the low/reverse clutch piston.
    68. Fig 63: Low/Reverse Clutch Piston
    GF0024934Courtesy of FORD MOTOR CO.
    NOTE: Position the transaxle so the pump assembly is facing upward.
  68. Remove the pump assembly bolts.
    69. Fig 64: Pump Assembly Bolts
    GF0024935Courtesy of FORD MOTOR CO.
  69. Using the special tools, remove the pump assembly.
    1. Install the special tool.
    2. Assemble the special tools.
    3. Using the special tools, remove the pump assembly.
    70. Fig 65: Removing Pump Assembly Using Special Tools
    GF0024936Courtesy of FORD MOTOR CO.
  70. Remove the intermediate and overdrive band assembly from the case.
    • Inspect the intermediate and overdrive band assembly for damage and wear.
    71. Fig 66: Intermediate & Overdrive Band Assembly
    GF0024937Courtesy of FORD MOTOR CO.
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