Automatic Transmission Overhaul - Ax4S: Disassembly: Transaxle

Fig 1: Identifying Special Tools (1 Of 4)

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Fig 2: Identifying Special Tools (2 Of 4)

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Fig 3: Identifying Special Tools (3 Of 4)

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Fig 4: Identifying Special Tools (4 Of 4)

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CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
1. Using the special tools, remove the torque converter.
Fig 5: Removing Torque Converter
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2. Using the special tool, install the transaxle.
Fig 6: Identifying Holding Fixture
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NOTE: During installation of a new case, a new identification tag will need to be installed, use caution not to damage the tag.
3. Remove the identification tag.
Fig 7: Removing Identification Tag
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4. Place a drain pan under the transaxle, rotate the transaxle to a vertical position and allow the fluid to drain. Once the fluid has drained rotate the transaxle to the horizontal position.
Fig 8: Rotating Transmission To Vertical Position
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5. Remove the output shaft speed (OSS) sensor cover.
   1. Remove the connector.
   2. Remove the bolt.
   3. Remove the cover.
      Fig 9: Removing OSS Sensor Cover

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6. Remove the output shaft speed (OSS) sensor.
   Fig 10: Removing OSS Sensor

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7. Remove the cover.
   Fig 11: Removing Cover

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8. Remove the filler tube and grommet.
   Fig 12: Removing Filler Tube

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CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken during removal as components may be ejected from the case.
9. Remove the overdrive servo piston and rod.
   • Remove the bolts.
   • Remove the cover.
   • Remove the piston and rod.
     Fig 13: Removing Overdrive Servo Piston & Rod

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10. Remove the low/intermediate servo cover.
    Fig 14: Removing Low/Intermediate Servo Cover

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11. Remove the manual control lever.
    Fig 15: Removing Manual Control Lever

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12. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the sensor.
       Fig 16: Removing TR Sensor

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NOTE: The differential seal is of two-piece construction.
Fig 17: Installing Special Tool Into Left Differential Seal
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13. Install the special tool into the LH differential seal.
14. Using the special tool, remove the LH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector from the left differential seal and remove protector from tool.
       Fig 18: Removing Left Differential Seal Metal Protector

       Courtesy of FORD MOTOR CO.
15. Using the special tool, remove the rubber portion of the LH differential seal.
    1. Install the special tool into the left differential seal and rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
       Fig 19: Removing Left Differential Seal Rubber Portion

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16. Install the special tools into the right differential seal.
Fig 20: Installing Special Tool Into Right Differential Seal
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17. Using the special tool, remove the right differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector.
       Fig 21: Removing Right Differential Seal Metal Protector

       Courtesy of FORD MOTOR CO.
18. Using the special tools, remove the rubber portion of the seal.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
       Fig 22: Removing Right Differential Seal Rubber Portion

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19. Using the special tool, remove the converter hub seal.
    Fig 23: Removing Converter Hub Seal

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20. Remove the bolts.
    1. Remove the Torx(R) bolts.
    2. Remove the bolts.
       Fig 24: Removing Bolts

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21. Rotate the transaxle to a vertical position.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 25: Identifying Main Control Cover
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22. Remove the cover.
CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
Fig 26: Identifying Electrical Connectors
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23. Lift the locking tab and disconnect the electrical connectors.
NOTE: The manual valve should be inserted completely into the main control valve body.
Fig 27: Rotating Manual Control Lever
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24. Rotate the manual control lever to the low detent.
CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body and become damaged.
Fig 28: Identifying Main Control Valve Body Bolts
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25. Remove the bolts. Note the size and location of the bolts.
26. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting to remove.
      Fig 29: Removing Main Control Valve Body

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27. Disconnect the manual control valve actuating rod.
    Fig 30: Disconnecting Manual Control Valve Actuating Rod

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28. Remove the pump shaft.
    Fig 31: Removing Pump Shaft

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29. Remove the output shaft circlip.
    Fig 32: Removing Output Shaft Circlip

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30. Remove the turbine shaft speed (TSS) sensor.
    Fig 33: Removing TSS Sensor

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NOTE: The transaxle pan gasket is reusable if not torn or damaged.
Fig 34: Removing Fluid Pan
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31. Remove the fluid pan.
32. Remove the magnet.
    Fig 35: Removing Magnet

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33. Remove the filter and the seal.
    Fig 36: Removing Filter

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34. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 37: Removing Reverse Clutch Anchor Pin

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CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.
NOTE: Mark bolt size and location for assembly.
Fig 38: Identifying Chain Cover Bolts
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35. Remove the bolts starting from the inside and work out.
NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.
Fig 39: Removing Chain Cover
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36. Remove the chain cover and gasket.
NOTE: Tag and mark the location of the accumulator springs.
37. 1. Remove the drive shift accumulator spring.
    2. Remove the 3-4 accumulator spring.
    3. Remove the 1-2 accumulator spring.
       Fig 40: Removing Accumulator Spring

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CAUTION: Be careful not to damage or bend the tabs on the exciter ring. If bent, the TSS sensor will not operate.
Fig 41: Removing Drive Sprocket, Driven Sprocket, & Drive Chain
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38. Remove the drive sprocket, driven sprocket, and drive chain as an assembly.
NOTE: The thrust washers may remain on the sprockets.
39. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
       Fig 42: Removing Thrust Washers

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40. Inspect the bearing for damage. Install a new bearing if necessary.
    Fig 43: Inspecting Bearing

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41. Using the special tools, remove the bearing.
    Fig 44: Removing Bearing

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42. Using the special tool, remove the roll pin.
    Fig 45: Removing Roll Pin

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CAUTION: Do not damage the machined surface of the case.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 46: Removing Roll Pins
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43. Remove the remaining roll pins.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 47: Removing Manual Control Lever Shaft
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44. Remove the manual control lever shaft.
45. Remove the parking lever actuating rod.
    Fig 48: Removing Parking Lever Actuating Rod

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46. Using a screwdriver remove the manual control lever shaft seal.
    Fig 49: Removing Manual Control Lever Shaft Seal

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NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
Fig 50: Removing Drive Sprocket Support & No. 5 Thrust Washer
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47. Remove the drive sprocket support and the No. 5 thrust washer.
NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and the driven sprocket.
Fig 51: Removing No. 8 Driven Sprocket Support Selective Fit Rear Thrust Washer & No. 9 Needle Bearing
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48. Remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
49. Remove the plastic overdrive band retainer.
    Fig 52: Removing Plastic Overdrive Band Retainer

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50. Remove the overdrive band.
    Fig 53: Removing Overdrive Band

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51. Remove the bolts and the lube tube brackets.
    Fig 54: Removing Bolts & Lube Tube Brackets

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52. Using the special tool, remove the lube tubes.
    Fig 55: Removing Lube Tubes

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53. Remove the park pawl assembly.
    1. Remove the bolts.
    2. Remove the park pawl abutment.
    3. Remove the park pawl shaft.
    4. Remove the park pawl return spring.
       Fig 56: Removing Park Pawl Assembly

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NOTE: Do not overtighten the handle of the tool. Place two 3/8-inch washers between the handle and the notched block.
Fig 57: Removing Front Sun & Shell Assembly
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54. Using the special tools, remove the front sun and shell assembly.
55. Using the special tool, remove the reverse clutch and planet assembly.
    Fig 58: Removing Reverse Clutch & Planet Assembly

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56. Remove the front planet and rear ring gear.
    Fig 59: Removing Front Planet & Rear Ring Gear

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57. Remove the rear sun gear, drum, and the No. 15 rear sun gear thrust bearing and race.
    Fig 60: Removing Rear Sun Gear, Drum, & No. 15 Rear Sun Gear Thrust Bearing & Race

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58. Remove the low and intermediate band.
    Fig 61: Removing Low & Intermediate Band

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CAUTION: Do not damage any machined surfaces.
Fig 62: Removing Rear Support Snap Ring Through Side Of Case
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59. Using a screwdriver, remove the rear support snap ring through the side of the case.
60. Remove the final drive/differential assembly.
    Fig 63: Remove Final Drive/Differential Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The differential carrier thrust washer may remain on the differential assembly.
61. Remove the differential carrier thrust washers.
    • Remove the No. 18 differential carrier thrust washer.
    • Remove the No. 19 differential carrier thrust bearing and race.
      Fig 64: Removing Differential Carrier Thrust Washers

      Courtesy of FORD MOTOR CO.
62. Remove the final drive ring gear.
    Fig 65: Removing Final Drive Ring Gear

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NOTE: The following procedures are done only if installing a new case.
Fig 66: Removing Bolts
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63. Remove the bolts.
64. Remove the stator support assembly.
    Fig 67: Removing Stator Support Assembly

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