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Automatic Transmission: Disassembly: Transaxle: Disassembly

    CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 1: Removing Torque Converter
    G02145808Courtesy of FORD MOTOR CO.
  1. Using the special tools, remove the torque converter.
  2. Using the special tool, install the transaxle into the bench.
    Fig 2: Installing Transaxle Into Bench
    G02145809Courtesy of FORD MOTOR CO.
    3. NOTE: During a case replacement, a new identification tag will need to be installed. Use caution not to damage the tag.
    Fig 3: Removing Identification Tag
    G02145810Courtesy of FORD MOTOR CO.
  3. Remove the identification tag.
  4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
    Fig 4: Placing Drain Pan Under Transaxle
    G02145811Courtesy of FORD MOTOR CO.
  5. Remove the filler tube.
    Fig 5: Removing Filler Tube
    G02145812Courtesy of FORD MOTOR CO.
    6. CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.
    Fig 6: Removing Overdrive Servo Piston And Rod
    G02145813Courtesy of FORD MOTOR CO.
  6. Remove the overdrive servo piston and rod.
    • Remove the bolts.
    • Remove the cover.
    • Remove the piston and rod.
  7. Remove the output shaft speed (OSS) sensor cover.
    Fig 7: Removing Output Shaft Speed Sensor Cover
    G02145814Courtesy of FORD MOTOR CO.
  8. Remove the output shaft speed (OSS) sensor.
    • Unclip the harness.
    • Remove the output shaft speed (OSS) sensor.
    Fig 8: Removing Output Shaft Speed Sensor
    G02145815Courtesy of FORD MOTOR CO.
  9. Remove the digital TR sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 9: Removing Digital TR Sensor
    G02145816Courtesy of FORD MOTOR CO.
  10. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
    Fig 10: Removing TSS Sensor
    G02145817Courtesy of FORD MOTOR CO.
    11. NOTE: The differential seal is a two-piece constructed seal.
    Fig 11: Installing Special Tools Into LH Differential Seal
    G02145818Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the LH differential seal.
  12. Using the special tools, 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 LH differential seal and remove the protector from the tool.
    Fig 12: Removing LH Differential Seal - Metal Protector
    G02145819Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the rubber portion of LH differential seal.
    1. Install the special tool into the LH differential seal.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 13: Removing LH Differential Seal - Rubber Portion
    G02145820Courtesy of FORD MOTOR CO.
  14. Install the special tool into the RH differential seal.
    Fig 14: Installing Special Tool Into RH Differential Seal
    G02145821Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
    Fig 15: Removing RH Differential Seal - Metal Protector
    G02145822Courtesy of FORD MOTOR CO.
  16. Using the special tool, 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 16: Removing RH Differential Seal - Rubber Portion
    G02145823Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the converter hub seal.
    Fig 17: Removing Converter Hub Seal
    G02145824Courtesy of FORD MOTOR CO.
  18. Remove the bolts.
    Fig 18: Removing Bolts
    G02145825Courtesy of FORD MOTOR CO.
  19. Rotate the transaxle to a horizontal position.
  20. If not previously removed, remove the mount.
    Fig 19: Removing Mount
    G02145826Courtesy of FORD MOTOR CO.
  21. Remove the bolts, and remove the pan.
    Fig 20: Removing Pan
    G02145827Courtesy of FORD MOTOR CO.
    22. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
    Fig 21: Disconnecting Electrical Connectors
    G02145828Courtesy of FORD MOTOR CO.
  22. Lift the locking tab and disconnect the electrical connectors.
    23. NOTE: The manual valve should be inserted completely.
    Fig 22: Positioning Manual Valve To Low Detent Position
    G02145829Courtesy of FORD MOTOR CO.
  23. Using a 9 mm (0.36 in) wrench rotate the manual control lever to the low detent.
    24. 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.
    CAUTION: Only four of the six pump cover bolts need to be removed.
    Fig 23: Removing Pump Assembly And Main Control Valve Body Bolts
    G02145830Courtesy of FORD MOTOR CO.
  24. Remove the bolts.
  25. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
    Fig 24: Removing Pump Assembly And Main Control Valve Body
    G02145831Courtesy of FORD MOTOR CO.
  26. Disconnect the manual control valve actuating rod.
    Fig 25: Disconnecting Manual Control Valve Actuating Rod
    G02145832Courtesy of FORD MOTOR CO.
  27. Remove the pump shaft.
    Fig 26: Removing Pump Shaft
    G02145833Courtesy of FORD MOTOR CO.
    28. NOTE: The transaxle pan gasket is reusable if not torn or damaged.
    Fig 27: Removing Bolts, Transmission Fluid Pan And Gasket
    G02145834Courtesy of FORD MOTOR CO.
  28. Remove the bolts, transmission fluid pan and gasket.
  29. Remove, clean and inspect the magnet.
    Fig 28: Locating Magnet
    G02145835Courtesy of FORD MOTOR CO.
  30. Remove the filter.
    Fig 29: Removing Filter
    G02145836Courtesy of FORD MOTOR CO.
    31. NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
    Fig 30: Removing Fluid Filter Seal
    G02145837Courtesy of FORD MOTOR CO.
  31. Remove the fluid filter seal.
  32. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 31: Removing Reverse Clutch Anchor Pin
    G02145838Courtesy of FORD MOTOR CO.
    33. 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 32: Removing Chain Cover Bolts
    G02145839Courtesy of FORD MOTOR CO.
  33. Remove the bolts.
    34. NOTE: The plastic thrust washers No.1 and 3 may stick to the cover or to the sprockets.
    Fig 33: Removing Chain Cover And Gasket
    G02145840Courtesy of FORD MOTOR CO.
  34. Remove the chain cover and gasket.
    35. NOTE: Tag and mark the location of the accumulator springs.
    Fig 34: Removing Accumulator Springs
    G02145841Courtesy of FORD MOTOR CO.
    1. Remove the intermediate 1-2 accumulator outer spring.
    2. Remove the direct 2-3 accumulator piston spring.
    3. Remove the neutral reverse shift accumulator spring.
    4. Remove the overdrive 3-4 accumulator spring.
    36. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
    Fig 35: Removing Drive Sprocket, Driven Sprocket, And Drive Chain
    G02145842Courtesy of FORD MOTOR CO.
  36. Remove the drive sprocket, driven sprocket, and drive chain as an assembly.
    37. NOTE: The thrust washers may remain on the sprockets.
    Fig 36: Removing Thrust Washers
    G02145843Courtesy of FORD MOTOR CO.
  37. Remove the thrust washers.
    1. Remove the No.2 thrust washer.
    2. Remove the No.4 thrust washer.
    38. CAUTION: Use care not to 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 37: Removing Roll Pins
    G02145844Courtesy of FORD MOTOR CO.
  38. Remove the roll pins.
    39. 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 38: Removing Manual Control Lever Shaft
    G02145845Courtesy of FORD MOTOR CO.
  39. Remove the manual control lever shaft.
  40. Remove the parking lever actuating rod.
    Fig 39: Removing Parking Lever Actuating Rod
    G02145846Courtesy of FORD MOTOR CO.
  41. Remove the manual control lever shaft seal.
    Fig 40: Removing Manual Control Lever Shaft Seal
    G02145847Courtesy of FORD MOTOR CO.
    42. NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
    Fig 41: Removing Bolts And Brackets
    G02145848Courtesy of FORD MOTOR CO.
  42. Remove the bolts and brackets.
  43. Using the special tools, remove the fluid lube tubes.
    Fig 42: Removing Fluid Lube Tubes
    G02145849Courtesy of FORD MOTOR CO.
  44. Remove the bolts and the park pawl abutment.
    Fig 43: Removing Bolts And Park Pawl Abutment
    G02145850Courtesy of FORD MOTOR CO.
  45. Remove the neutral/drive accumulator bolt.
    Fig 44: Removing Neutral/Drive Accumulator Bolt
    G02145851Courtesy of FORD MOTOR CO.
  46. Remove the neutral/drive accumulator.
    1. Remove the neutral/drive accumulator cover.
    2. Remove the neutral/drive accumulator springs.
    3. Remove the neutral/drive accumulator piston and shaft.
    Fig 45: Removing Neutral/Drive Accumulator
    G02145852Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston, and rod as an assembly.
    Fig 46: Removing Coast Band Servo
    G02145853Courtesy of FORD MOTOR CO.
    48. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
    Fig 47: Removing Drive Sprocket Support And No.5 Thrust Washer
    G02145854Courtesy of FORD MOTOR CO.
  48. Remove the drive sprocket support and the No.5 thrust washer.
    49. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
    Fig 48: Removing No.8 Driven Sprocket Support Thrust Washer
    G02145855Courtesy of FORD MOTOR CO.
  49. Using the special tool, remove the No.8 driven sprocket support selective fit rear thrust washer and the No.9 needle bearing.
  50. Remove the plastic overdrive band retainer.
    Fig 49: Removing Plastic Overdrive Band Retainer
    G02145856Courtesy of FORD MOTOR CO.
  51. Remove the overdrive band.
    Fig 50: Removing Overdrive Band
    G02145857Courtesy of FORD MOTOR CO.
    52. NOTE: Do not over tighten the handle of the tool Place two 3/8 inch washers between the handle and the notched block.
    Fig 51: Positioning Special Tool Into Case
    G02145858Courtesy of FORD MOTOR CO.
  52. Position the special tool into the case and install the hook end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
  53. Using the special tool, remove the front clutch assembly.
    Fig 52: Removing Front Clutch Assembly
    G02145859Courtesy of FORD MOTOR CO.
  54. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 53: Removing Reverse Clutch And Planet Assembly
    G02145860Courtesy of FORD MOTOR CO.
  55. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 54: Removing Low/Intermediate Drum, Sun Gear And One-Way Clutch Assembly
    G02145861Courtesy of FORD MOTOR CO.
  56. Remove the coast band.
    Fig 55: Removing Coast Band
    G02145862Courtesy of FORD MOTOR CO.
    57. CAUTION: Use care not to damage any machined surfaces.
    Fig 56: Removing Low/Intermediate Clutch Retaining Ring
    G02145863Courtesy of FORD MOTOR CO.
  57. Remove the low/intermediate clutch retaining ring.
  58. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
    Fig 57: Removing Low/Intermediate Clutch Pack
    G02145864Courtesy of FORD MOTOR CO.
    59. WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
    CAUTION: Use care not to damage final drive support assembly, transaxle case, or retaining ring during removal.
    Fig 58: Removing Beveled Retaining Ring
    G02145865Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
  60. Remove the final drive differential and rear planet support assembly.
    Fig 59: Removing Final Drive Differential And Rear Planet Support Assembly
    G02145866Courtesy of FORD MOTOR CO.
    61. NOTE: The differential carrier thrust washer may remain on the differential assembly.
    Fig 60: Removing Differential Carrier Thrust Washer
    G02145867Courtesy of FORD MOTOR CO.
  61. Remove the differential carrier thrust washer
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
  62. Remove the rear planet support spacer.
    Fig 61: Removing Rear Planet Support Spacer
    G02145868Courtesy of FORD MOTOR CO.
  63. Remove the final drive ring gear.
    Fig 62: Removing Final Drive Ring Gear
    G02145869Courtesy of FORD MOTOR CO.
    64. NOTE: If the drive sprocket bearing is worn or damaged install a new bearing.
    Fig 63: Removing Drive Sprocket Bearing
    G02145870Courtesy of FORD MOTOR CO.
  64. Using the special tools, remove the drive sprocket bearing.
    65. NOTE: The following procedures are done only if a case replacement is necessary.
    Fig 64: Removing Stator Support Assembly Bolts
    G02145871Courtesy of FORD MOTOR CO.
  65. Remove the bolts.
  66. Remove the stator support assembly.
    Fig 65: Removing Stator Support Assembly
    G02145872Courtesy of FORD MOTOR CO.
  67. Remove the park pawl shaft retaining pin.
    Fig 66: Removing Park Pawl Shaft Retaining Pin
    G02145873Courtesy of FORD MOTOR CO.
  68. Using the special tools remove the cup plug.
    Fig 67: Removing Cup Plug
    G02145874Courtesy of FORD MOTOR CO.
  69. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
    Fig 68: Removing Parking Pawl And Return Spring
    G02145875Courtesy of FORD MOTOR CO.
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