Automatic Transmission Overhaul - Ax4S: Assembly: Transaxle

Fig 1: Identifying Special Tool (1 Of 5)

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Fig 2: Identifying Special Tool (2 Of 5)

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Fig 3: Identifying Special Tool (3 Of 5)

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Fig 4: Identifying Special Tool (4 Of 5)

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Fig 5: Identifying Special Tool (5 Of 5)

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NOTE: Place the transaxle in the horizontal position.
1. Using the special tools, install the drive sprocket bearing, if it was removed.
Fig 6: Installing Drive Sprocket Bearing
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NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.
2. Install the driven sprocket support.
Fig 7: Installing Driven Sprocket Support
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3. Install the bolts.
Fig 8: Installing Bolts
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4. Using the special tool, install the converter impeller hub seal.
Fig 9: Installing Converter Impeller Hub Seal
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5. Using the special tools, install the right hand output shaft seal.
Fig 10: Installing Right Hand Output Shaft Seal
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6. Install the special tool.
Fig 11: Installing Special Tool
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7. Rotate the transaxle to a vertical position.
8. Install the differential carrier thrust washers.
   • Install the No. 18 differential carrier thrust washer.
   • Install the No. 19 differential carrier thrust bearing and race.
Fig 12: Installing No. 18 & No. 19 Thrust Washers
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9. Install the final drive ring gear.
Fig 13: Installing Final Drive Ring Gear
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10. Install the final drive differential assembly and snap ring. Align the opening of the snap ring with the lube transfer tube passages.
Fig 14: Installing Final Drive Differential Assembly
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11. Install the special tool.
Fig 15: Installing Special Tool
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12. Using the special tools installed, carry out the end clearance check.
    • Pry up on the bottom of the final drive assembly.
    • Back out the screw on the End Plate Gauge until it no longer contacts the output shaft.
    • Zero out the dial indicator.
    • Tighten the screw on the bottom of the End Plate Gauge to 5 Nm (44 lb-in).
    • Record the reading on the dial indicator.
    • The clearance should be within specification; if it is not within specification a selective thrust washer is available. Refer to Fig 17 .
Fig 16: Checking End Clearance
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Fig 17: No. 18 Selective Thrust Washers Table
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13. Install the low and intermediate band. Align the anchor pin pocket with the anchor pin.
Fig 18: Installing Low & Intermediate Band
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14. Install the No. 15 rear sun gear thrust bearing and race, and the rear sun gear and drum.
Fig 19: Installing No. 15 Rear Sun Gear Thrust Bearing, Race, Rear Sun Gear & Drum
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15. Install the reverse clutch onto the planet assembly.
Fig 20: Installing Reverse Clutch Onto The Planet Assembly
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16. Assemble the special tools onto the planet assembly.
Fig 21: Assembling Special Tools Onto The Planet Assembly
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17. Using the special tools, install the planet and reverse clutch assembly.
Fig 22: Installing Planet & Reverse Clutch Assembly
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18. Loosely install the reverse anchor pin and bolt.
Fig 23: Loosely Installing Reverse Anchor Pin & Bolt
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19. Install the special tools onto the front sun and shell assembly.
Fig 24: Installing Special Tools Onto Front Sun & Shell Assembly
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20. Install the front sun shell assembly.
Fig 25: Installing Front Sun Shell Assembly
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21. Install the overdrive band.
Fig 26: Installing Overdrive Band
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22. Install the plastic overdrive retainer.
Fig 27: Installing Plastic Overdrive Retainer
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23. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
    1. Remove the No. 9 bearing and race
    2. Remove the No. 8 sprocket support.
Fig 28: Removing No. 8 Sprocket Thrust Washer & No. 9 Bearing & Race From Driven Sprocket Support
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24. Install only the No. 9 needle bearing with the outer lip up.
Fig 29: Installing No. 9 Needle Bearing With Outer Lip Up
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25. Install the special tool.
Fig 30: Installing Special Tool
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26. Using the special tools, record the measurement. Take a measurement on both sides of the output shaft (180 degrees apart). Add both readings and divide by two to obtain reading A.
Fig 31: Taking Measurement On Both Sides Of Output Shaft
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NOTE: Reading A and dimension C from this chart will be used in the selection of the No. 5 thrust washer.
27. Use reading A to select the correct No. 8 thrust washer from the No. 8 selective thrust washer chart.
Fig 32: No. 8 Selective Thrust Washer Table
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28. Remove the special tools.
Fig 33: Removing Special Tools
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29. Using the special tools, record the measurement. Take a measurement on both sides of the No. 5 thrust washer mating surface of the overdrive drum (180 degrees apart). Add both readings, and divide by two to obtain reading B.
Fig 34: Measuring On Both Sides Of No. 5 Thrust Washer Mating Surface Of Overdrive Drum
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NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
30. Subtract reading A from reading B and add the difference between A and B to dimension C. Record this reading as D.
Fig 35: Selecting No. 5 Support Thrust Washer Formula
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31. Use Reading D to select the correct No. 5 thrust washer.
Fig 36: No. 5 Support Thrust Washer Table (1 Of 2)
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Fig 37: No. 5 Support Thrust Washer Table (2 Of 2)
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NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
32. Install the No. 5 front support thrust washer.
Fig 38: Installing No. 5 Front Support Thrust Washer
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CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure.
33. Use petroleum jelly to hold bearing and washer in place.
    1. Install the correct No. 8 driven sprocket support thrust washer
    2. Install the No. 9 direct clutch needle bearing.
Fig 39: Installing Correct No. 8 Driven Sprocket Support Thrust Washer & Install No. 9 Direct Clutch Needle Bearing
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34. Remove the special tools.
Fig 40: Removing Special Tool
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35. Install the driven sprocket support assembly.
Fig 41: Installing Driven Sprocket Support Assembly
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36. Install the park pawl abutment.
    1. Install the parking pawl and the return spring
    2. Install the parking pawl shaft
    3. Install the park pawl abutment
    4. Install the bolts.
Fig 42: Installing Park Pawl Abutment
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37. Install the parking lever actuating rod.
Fig 43: Installing Parking Lever Actuating Rod
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NOTE: All the fluid supply tubes must have new O-rings installed.
38. Install the fluid supply tubes and brackets.
Fig 44: Installing Fluid Supply Tubes & Brackets
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39. Using the special tool, install the manual control lever shaft seal.
Fig 45: Installing Manual Control Lever Shaft Seal
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NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever is pointing toward the driven sprocket support.
40. Install the manual control lever shaft.
    1. Install the manual control lever shaft
    2. Install the manual valve detent lever
    3. Install the parking lever actuating rod
    4. Install the new roll pins.
Fig 46: Installing Manual Control Lever Shaft
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NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
41. 1. Install the No. 2 drive sprocket thrust washer.
    2. Install the No. 4 driven sprocket thrust washer.
Fig 47: Installing No. 2 & No. 4 Drive Sprocket Thrust Washer
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CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent.
NOTE: Lower the assembly into the sprocket supports simultaneously.
42. Install the drive chain and sprockets as an assembly.
Fig 48: Installing Drive Chain & Sprockets As An Assembly
Courtesy of FORD MOTOR CO.
43. Install the shift accumulator springs.
    1. Install the drive shift accumulator spring (green)
    2. Install the 3-4 accumulator springs.
       1. The outer spring is yellow.
       2. The inner spring is white
    3. Install the 1-2 accumulator springs (no color).
Fig 49: Installing 1-2 Accumulator Springs
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44. Install the new chain cover gasket.
Fig 50: Installing Chain Cover Gasket
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CAUTION: Be extremely careful not to damage the cast iron sealing ring.
NOTE: Make sure that the alignment pins are installed in the case.
NOTE: Use petroleum jelly to hold thrust washers in place during assembly.
45. Install the chain cover with the No. 3 and No. 1 thrust washers installed.
Fig 51: Installing Chain Cover With No. 3 & No. 1 Thrust Washers
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NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.
46. Start two bolts.
Fig 52: Identifying Two Bolts
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47. Tighten the bolts in the sequence shown.
Fig 53: Bolt Tightening Sequence
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48. Using the special tool, install the seal.
Fig 54: Installing Seal
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49. Install the bolts.
Fig 55: Identifying Bolts
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50. Tighten the reverse clutch anchor bolt.
    1. Tighten the anchor bolt
    2. Tighten the locknut.
Fig 56: Tightening Reverse Clutch Anchor Bolt
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51. Install the filter.
Fig 57: Installing Filter
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52. Install the magnet.
Fig 58: Installing Magnet
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NOTE: The fluid pan gasket is reusable if not damaged.
53. Install the fluid pan and gasket.
Fig 59: Installing Fluid Pan
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CAUTION: The test spring from the overdrive servo rod tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
54. Inspect the spring height.
    1. Test spring
    2. Original spring.
Fig 60: Inspecting Spring Height
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55. Overdrive servo travel check. Install the overdrive servo piston.
    • Using the special tool, install the overdrive servo piston.
Fig 61: Installing Overdrive Servo Piston
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56. Install the special tools.
Fig 62: Installing Special Tools
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57. Tighten the center screw and zero out the dial indicator.
Fig 63: Identifying Center Screw
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58. Back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, refer to Fig 65 and determine which overdrive servo rod to use.
Fig 64: Reading Dial Indicator
Courtesy of FORD MOTOR CO.
59. If the overdrive servo travel was incorrect, install a new overdrive servo piston and rod assembly. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.
Fig 65: Overdrive Piston & Rod Assembly Selection Chart
Courtesy of FORD MOTOR CO.
CAUTION: The test spring from the low/intermediate servo is plain in color and has a thinner wire diameter than the original spring. Extreme care must be used not to assemble the transaxle using the test spring.
60. Install the low and intermediate servo spring retainer on the test spring. Install the test spring into the transaxle case.
    1. Test spring
    2. Original spring.
Fig 66: Identifying Test Spring & Original Spring
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61. Remove the servo piston small seal from the servo band piston and install the servo band piston and rod into the case.
Fig 67: Identifying servo band piston
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62. Install the special tool.
Fig 68: Installing Special Tool
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63. Tighten the center screw.
Fig 69: Tightening Center Screw
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64. Install the special tool. Make sure that the indicator stylus has contacted the servo band piston on a flat surface not on the step of the band piston. Zero out the dial indicator.
Fig 70: Installing Dial Indicator
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NOTE: If a new low and intermediate band is installed, the reading should be within the specification.
65. Back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, refer to Fig 72 and determine which rod to use.
Fig 71: Reading Dial Indicator
Courtesy of FORD MOTOR CO.
66. If the low/intermediate servo travel was incorrect install a new low/intermediate servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.
Fig 72: Low/Intermediate Servo Rod Selection Chart
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CAUTION: Do not assemble the overdrive servo using the test spring.
67. Install the overdrive servo.
    1. Install the overdrive servo spring
    2. Install the overdrive servo
    3. Install the overdrive servo cover.
Fig 73: Installing Overdrive Servo
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68. Install the bolts.
Fig 74: Tightening Overdrive Servo Bolts
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CAUTION: Do not assemble the low/intermediate servo using the test spring.
69. Install the low/intermediate servo.
    1. Install the low/intermediate servo spring
    2. Install the low/intermediate servo
    3. Install the low/intermediate servo cover.
Fig 75: Installing Low/Intermediate Servo
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70. Install the bolts.
Fig 76: Tightening Low/Intermediate Servo Bolts
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71. Install the cover.
Fig 77: Installing Cover
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72. Install the output shaft circlip.
Fig 78: Installing Output Shaft Circlip
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73. Install the special tool.
Fig 79: Installing Special Tool
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WARNING: Wear safety glasses while carrying out this procedure to prevent personal injury.
NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies.
74. Apply air pressure to each of the appropriate ports. Remove the test plate after the test has been completed.
Fig 80: Identifying Test Ports (1 Of 2)
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Fig 81: Identifying Test Ports (2 Of 2)
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NOTE: Inspect the pump drive shaft in the area that the bearings ride. Install a new shaft and main control if worn.
75. Install new Teflon(R) seals and inspect the shaft.
Fig 82: Identifying Teflon Seals
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NOTE: Make sure that the seals are installed correctly.
Fig 83: Identifying Correctly Installed Seals
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76. Install four new seals on the pump shaft.
77. Install the pump shaft.
    Fig 84: Installing Pump Shaft

    Courtesy of FORD MOTOR CO.
78. Install the manual valve detent lever.
    Fig 85: Installing Manual Valve Detent Lever

    Courtesy of FORD MOTOR CO.
79. Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.
    Fig 86: Installing Main Control Valve Body Over The Pump Shaft

    Courtesy of FORD MOTOR CO.
80. Install the bolts. Tighten in sequence from the center outward.
    Fig 87: Main Control Valve Body Torque Sequence

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81. Connect the connectors.
    Fig 88: Identifying Connectors

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NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 89: Identifying Main Control Valve Cover
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82. Install the main control cover, gasket and bolts.
83. Install the lower fluid filler tube and grommet.
    Fig 90: Installing Lower Fluid Filler Tube & Grommet

    Courtesy of FORD MOTOR CO.
84. Install the turbine shaft speed (TSS) sensor.
    Fig 91: Installing TSS Sensor

    Courtesy of FORD MOTOR CO.
85. Install the output shaft speed (OSS) sensor.
    Fig 92: Installing OSS Sensor

    Courtesy of FORD MOTOR CO.
86. Install the OSS cover and bolt and connect the connector to the filler tube.
    Fig 93: Installing OSS Cover & Bolt

    Courtesy of FORD MOTOR CO.
87. Install the digital transmission range (TR) sensor. For additional information, refer to TRANSMISSION RANGE SENSOR .
88. Using the special tools, install the torque converter.
    Fig 94: Installing Torque Converter

    Courtesy of FORD MOTOR CO.