All applications

Prepare the transaxle for assembly by proceeding with the following steps:
- Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
- Dry all parts with moisture-free regulated compressed air (do not use shop towels).
- Lubricate all internal parts (including friction plates) with clean automatic transmission fluid.
- Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
  - Drive sprocket thrust washers.
  - Driven sprocket thrust bearing shims.
  - Differential case thrust bearing shims.
  - Low/reverse clutch pressure plates.
- During assembly, use petroleum jelly to hold the parts in place (do not use grease).
- Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
Install intermediate and overdrive band assembly into the transaxle case.

Fig 1: Installing Intermediate And Overdrive Band Assembly
Courtesy of FORD MOTOR CO.
Install the No.1 pump support thrust bearing.
- Lubricate the seal rings with clean automatic transmission fluid.
  
  Fig 2: Installing Pump Support Thrust Bearing
  Courtesy of FORD MOTOR CO.

NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.

Fig 3: Installing Pump Assembly

Courtesy of FORD MOTOR CO.

Install pump assembly into the case.

NOTE: Tighten the bolts in the indicated sequence.

Fig 4: Installing Pump Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the pump assembly bolts.
Using the special tools, install the low/reverse clutch piston.
- Lubricate seals and piston bore with clean automatic transmission fluid.
  
  Fig 5: Installing Low/Reverse Clutch Piston
  Courtesy of FORD MOTOR CO.
Install the low/reverse clutch return spring assembly.

Fig 6: Installing Low/Reverse Clutch Return Spring Assembly
Courtesy of FORD MOTOR CO.
Install the low/reverse clutch return spring retaining ring.

Fig 7: Installing Low/Reverse Clutch Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.

CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.

Fig 8: Installing Low/Reverse Clutch Wave Spring

Courtesy of FORD MOTOR CO.

Install the low/reverse clutch wave spring.
Install the low/reverse clutch plates.
1. Install the low/reverse clutch external spline (steel) clutch plates.
2. Install the low/reverse clutch internal spline (friction) clutch plates.
3. Install the thin eight wave low/reverse clutch cushion spring.
4. Install the low/reverse clutch pressure plate.
  
  Fig 9: Installing Low/Reverse Clutch Plates
  Courtesy of FORD MOTOR CO.

CAUTION: The low one-way clutch thrust plate is fitted in the position for measurement purposes only.

Fig 10: Installing Low One-Way Clutch Thrust Plate

Courtesy of FORD MOTOR CO.

Install the low one-way clutch thrust plate.
Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate.
- Take a second measurement on the opposite side.
- Average the two measurements to get the clearance.
- If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
- Pressure plate sizes:
  - 2.57-2.46 mm (0.101-0.097 in)
  - 2.36-2.26 mm (0.092-0.089 in)
  - 2.16-2.06 mm (0.085-0.081 in)
    
    Fig 11: Measuring Clearance Between Low/Reverse Clutch Pressure Plate And Low One-Way Clutch Thrust Plate
    Courtesy of FORD MOTOR CO.

NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.

Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction).
1. Low one-way clutch thrust plate.
2. Low/reverse clutch pressure plate.
3. Low/reverse clutch external spline clutch plates (steel).
4. Low/reverse clutch wave spring.
5. Low/reverse clutch internal spline clutch plates (friction).
  
  Fig 12: Removing Low One-Way Clutch Thrust Plate
  Courtesy of FORD MOTOR CO.
Install the No. 1 pump support thrust bearing assembly.

Fig 13: Installing Pump Support Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.

NOTE: Remove the seal sizer from forward/coast/direct clutch cylinder.

Fig 14: Installing Forward/Coast/Direct Clutch Cylinder Assembly

Courtesy of FORD MOTOR CO.

Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
Install the turbine shaft.

Fig 15: Installing Turbine Shaft
Courtesy of FORD MOTOR CO.
Install the No. 4 turbine shaft thrust bearing.

Fig 16: Installing Turbine Shaft Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the forward one-way clutch and low/intermediate sun gear assembly.

Fig 17: Installing Forward One-Way Clutch
Courtesy of FORD MOTOR CO.
Install the No. 5 low/intermediate sun gear thrust bearing.

Fig 18: Installing Low/Intermediate Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the low/intermediate carrier assembly.

Fig 19: Installing Low/Intermediate Carrier Assembly
Courtesy of FORD MOTOR CO.
Install the No. 6 low/intermediate carrier thrust bearing.

Fig 20: Installing Low/Intermediate Carrier Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the low/intermediate ring gear assembly.

Fig 21: Installing Low/Intermediate Ring Gear Assembly
Courtesy of FORD MOTOR CO.
Install the No. 7 reverse/overdrive sun gear thrust bearing.

Fig 22: Installing Reverse/Overdrive Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the reverse/overdrive sun gear and shell assembly.

Fig 23: Installing Reverse/Overdrive Sun Gear And Shell Assembly
Courtesy of FORD MOTOR CO.
Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.

Fig 24: Installing Reverse/Overdrive Carrier Assembly
Courtesy of FORD MOTOR CO.
Install the thick, ten-wave low/reverse clutch wave spring.

Fig 25: Installing Low/Reverse Clutch Wave Spring
Courtesy of FORD MOTOR CO.
1. Install the low/reverse clutch plates (model dependent).
2. Install the low/reverse clutch external spline (steel) clutch plates.
3. Install the low/reverse clutch internal spline (friction) clutch plates.
4. Install the low/reverse clutch pressure plate previously selected.
  
  Fig 26: Installing Low/Reverse Clutch Plates
  Courtesy of FORD MOTOR CO.

NOTE: Early production vehicles may not have a wave spring.

Fig 27: Installing Low/Reverse Clutch Wave Spring

Courtesy of FORD MOTOR CO.

If equipped, install the thin, eight-wave low/reverse clutch wave spring.
Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.

Fig 28: Installing Low One-Way Clutch Assembly
Courtesy of FORD MOTOR CO.
Install the low one-way clutch thrust plate.

Fig 29: Installing Low One-Way Clutch Thrust Plate
Courtesy of FORD MOTOR CO.

NOTE: Make sure to position the low one-way clutch retaining ring as shown.

Fig 30: Installing Low One-Way Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

Install the low one-way clutch retaining ring.
Install the manual valve detent lever actuating rod assembly.
- Install the parking cam actuator lever.
  
  Fig 31: Installing Parking Cam Actuator Lever
  Courtesy of FORD MOTOR CO.
Install the manual valve detent lever.

Fig 32: Installing Manual Valve Detent Lever
Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 33: Installing Special Tools
Courtesy of FORD MOTOR CO.
Install the special tool with short spacers.

Fig 34: Installing Special Tool With Short Spacers
Courtesy of FORD MOTOR CO.
Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
- Record this dimension.
- This dimension is designated with A.
  
  Fig 35: Measuring Distance From Top Of Special Tool To Driven Sprocket Bearing Surface Area
  Courtesy of FORD MOTOR CO.
Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
- Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
- The average of these two dimensions is dimension B.
- Remove the special tools.
  
  Fig 36: Removing Special Tools
  Courtesy of FORD MOTOR CO.
Subtract dimension B from dimension A to get dimension C.
Use the third dimension to select the correct No. 11 driven sprocket shim.
- Select a shim from the driven sprocket shim chart.
DRIVEN SPROCKET ALIGNMENT SHIM NO. 11

Fig 37: Driven Sprocket Alignment Shim No. 11 Chart (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 38: Driven Sprocket Alignment Shim No. 11 Chart (2 Of 2)
Courtesy of FORD MOTOR CO.
Install and lubricate the following:
1. Lubricate the needles and seals in the No. 18 driven sprocket bearing.
2. Install the selected No. 11 driven sprocket shim.
3. Install the No. 12 driven sprocket bearing.
  
  Fig 39: Installing Driven Sprocket Shim
  Courtesy of FORD MOTOR CO.
Install the No. 9 reverse/overdrive ring gear thrust bearing.

Fig 40: Installing Reverse/Overdrive Ring Gear Thrust Bearing
Courtesy of FORD MOTOR CO.

NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.

Fig 41: Installing Reverse/Overdrive Ring Gear Assembly

Courtesy of FORD MOTOR CO.

Install the reverse/overdrive ring gear assembly.
Install the special tools.

Fig 42: Installing Special Tools
Courtesy of FORD MOTOR CO.
Install the special tool with short spacers.

Fig 43: Installing Special Tool
Courtesy of FORD MOTOR CO.
Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area.
- Repeat this measurement 180 degrees from the first measurement.
- The average of these two dimensions is dimension A.
- Remove the special tools.
  
  Fig 44: Removing Special Tools
  Courtesy of FORD MOTOR CO.
Add 25.4 mm (1.01 in) (thickness of special tool) and thickness of short spacers.
- This is the dimension B.
Subtract dimension A from dimension B.
- This is dimension C.
Select No. 10 thrust washer from the drive sprocket thrust washer chart.
- Use the third dimension to select the No. 10 drive sprocket thrust washer.
DRIVE SPROCKET ALIGNMENT NO. 10 THRUST WASHER

Fig 45: Drive Sprocket Alignment No. 10 Thrust Washer Chart
Courtesy of FORD MOTOR CO.
Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.

Fig 46: Installing Drive Sprocket Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the reverse/overdrive ring gear assembly.

Fig 47: Removing Reverse/Overdrive Ring Gear Assembly
Courtesy of FORD MOTOR CO.
Install the filter and seal assembly.

Fig 48: Installing Filter And Seal Assembly
Courtesy of FORD MOTOR CO.

NOTE: Refer to the following illustration for correct tool usage.

Fig 49: Installing Special Tool

Courtesy of FORD MOTOR CO.

Fig 50: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool in the filter eyelet and transaxle hole.

NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.

Fig 51: Installing Filter Recirculating Regulator Exhaust Seal

Courtesy of FORD MOTOR CO.

Using the special tool, install the filter recirculating regulator exhaust seal.
Install the chain pan in the transaxle case.

Fig 52: Installing Chain Pan In Transaxle Case
Courtesy of FORD MOTOR CO.
Assemble and install the drive chain assembly.
1. Drive chain (copper colored link facing upward).
2. Driven sprocket assembly.
3. Reverse/overdrive ring gear assembly.
- Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
  
  Fig 53: Installing Drive Chain Assembly
  Courtesy of FORD MOTOR CO.
Install the chain pan cover by snapping it into place.

Fig 54: Installing Chain Pan Cover
Courtesy of FORD MOTOR CO.
Install the No. 13 driven sprocket thrust bearing.

Fig 55: Installing Driven Sprocket Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the final drive carrier and differential assembly.

Fig 56: Installing Final Drive Carrier And Differential Assembly
Courtesy of FORD MOTOR CO.

NOTE: Plastic washers should be placed between bolt heads and special tool.

Install the special tools.
1. Install the special tool.
2. Install the special tool and bolts.
  
  Fig 57: Installing Special Tools
  Courtesy of FORD MOTOR CO.
Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
- The special tools will need to be relocated to carry out the second measurement.
- Repeat this measurement 180 degrees from the first measurement.
- The average of these two dimensions is dimension B.
  
  Fig 58: Measuring Distance From Top Of Special Tool To Shim Surface Area Of Final Drive Carrier
  Courtesy of FORD MOTOR CO.
Use combined thickness of the special tool with long spacers 177.8 mm (6.99 in) as dimension A.
Subtract dimension B from dimension A. This is dimension C.
Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
DIFFERENTIAL END PLAY NO. 14 SHIM

Fig 59: Differential End Play No. 14 Shim Chart
Courtesy of FORD MOTOR CO.
Install the differential bearing assembly
1. Install the No. 14 differential bearing shim (selective fit).
2. Install the No. 15 differential bearing.
  
  Fig 60: Installing Differential Bearing Assembly
  Courtesy of FORD MOTOR CO.

NOTE: Check for correct alignment of the lube tube on the converter housing.

Install the torque converter housing onto the transaxle case.
- Position and install the split flange gasket.
  
  Fig 61: Installing Torque Converter Housing
  Courtesy of FORD MOTOR CO.

NOTE: Tighten the bolts in the indicated sequence.

Fig 62: Installing Torque Converter Housing-To-Transaxle Case Bolts

Courtesy of FORD MOTOR CO.

Install the torque converter housing-to-transaxle case bolts.

NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.

Lubricate the assembly with clean transmission fluid.
1. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
2. Install the intermediate and overdrive servo apply rod and piston assembly.
3. Install the overdrive servo apply rod spring.
  
  Fig 63: Installing Overdrive Servo Apply Rod Spring
  Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 64: Installing Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Struts on the special tool fit into the servo cover retaining ring groove.

Assemble the special tool.
1. Install struts.
2. Install bar.
3. Install bolts.
4. Install the center bolt.
  
  Fig 65: Installing Special Tool
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the distance to the bar of special tool.
- Record this as dimension A.
  
  Fig 66: Measuring Distance To Bar Of Special Tool
  Courtesy of FORD MOTOR CO.
Back off the center bolt of special tool until the piston movement stops.

Fig 67: Locating Special Tool Center Bolt
Courtesy of FORD MOTOR CO.

VEHICLES WITH NARROW GROOVE CASE
Using the special tool, measure the dimension to the bar of special tool record as dimension B.
- Subtract dimension A from B to find the travel.
- If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

Fig 68: Intermediate/Overdrive Servo Apply Rod Length Chart
Courtesy of FORD MOTOR CO.

Fig 69: Measuring Distance
Courtesy of FORD MOTOR CO.

VEHICLES WITH WIDE GROOVE CASE
Using the special tool, measure the dimension to the bar of special tool record as dimension B.
- Subtract dimension A from B to find the travel.
- If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

Fig 70: Intermediate/Overdrive Servo Apply Rod Length Chart
Courtesy of FORD MOTOR CO.

Fig 71: Measuring Distance
Courtesy of FORD MOTOR CO.

ALL APPLICATIONS
Wipe the servo piston and the servo cover cap with a lint-free cloth.

CAUTION: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.

Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attached to the servo rod.
Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
Inspect the servo retainer spring for cracks, breaks or deformation.

WARNING: Servo return spring force is very high. Failure to follow these instructions can result in personal injury.

Fig 72: Assembling Special Tool

Courtesy of FORD MOTOR CO.

Assemble the special tool.
Install the special tool.

Fig 73: Installing Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: If the case is stamped "WG", install a wide-groove snap ring, or damage to the servo will result.

CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.

NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.

Tighten the special tool bolt.
- Install the servo cover retaining ring, using retaining ring pliers.
  
  Fig 74: Installing Servo Cover Retaining Ring
  Courtesy of FORD MOTOR CO.
Loosen the special tool bolt.
- When spring tension is released, remove the special tool.
  
  Fig 75: Loosening Special Tool Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.

NOTE: If any leaks occur, make sure the special tool is correctly seated.

Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 19 kPa (2.76 psi) of moisture-free regulated compressed air.
1. Reverse clutch test port.
2. Forward clutch test port.
3. Direct clutch test port.
4. Low/reverse clutch test port.
5. Servo release test port.
6. Servo apply test port.
7. Transmission air test plate.
- If air leakage is detected, disassemble the transaxle and locate source of leakage.
  
  Fig 76: Identifying Hydraulic Circuits
  Courtesy of FORD MOTOR CO.
Install the thermostatic fluid level control valve.
1. Position the thermostatic fluid level control valve.
2. Install the bracket.
3. Install the thermostatic fluid level control valve bracket bolt.
  
  Fig 77: Installing Thermostatic Fluid Level Control Valve
  Courtesy of FORD MOTOR CO.

CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.

Fig 78: Installing Solenoid Body Electrical Connector O-Ring Seal

Courtesy of FORD MOTOR CO.

Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.

CAUTION: Handle main control valve body with care to prevent manual valve damage.

Connect the manual valve.
1. Lift the main control away from the case.
2. Connect the Z-link to the manual valve.
  
  Fig 79: Connecting Manual Valve
  Courtesy of FORD MOTOR CO.

NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.

Fig 80: Installing Main Control Valve Body Mounting Bolts

Courtesy of FORD MOTOR CO.

Install the main control valve body mounting bolts.
Install the manual control lever.

Fig 81: Installing Manual Control Lever
Courtesy of FORD MOTOR CO.
Rotate the manual valve detent lever assembly to the NEUTRAL position.
1. Low 1
2. Low 2
3. Drive
4. Neutral
5. Reverse
6. Park
  
  Fig 82: Identifying Manual Valve Detent Lever Assembly
  Courtesy of FORD MOTOR CO.
Position the transmission range (TR) sensor.

Fig 83: Positioning Transmission Range (TR) Sensor
Courtesy of FORD MOTOR CO.
Using the special tool, align the TR sensor and tighten the bolts.

Fig 84: Installing Special Tool
Courtesy of FORD MOTOR CO.
Install the main control cover gasket.

NOTE: Tighten the bolts in the indicated sequence.

Fig 85: Tightening Bolts In Proper Sequence

Courtesy of FORD MOTOR CO.

Install the main control cover.
Install the vent tube.

Fig 86: Installing Vent Tube
Courtesy of FORD MOTOR CO.
Install a new transmission filler tube grommet.

Fig 87: Installing New Transmission Filler Tube Grommet
Courtesy of FORD MOTOR CO.
Install the transmission filler tube assembly.
1. Install the tube.
2. Install the transmission filler tube bolt.
  - Install the fluid level indicator.
    
    Fig 88: Installing Transmission Filler Tube Assembly
    Courtesy of FORD MOTOR CO.
Install the turbine shaft speed (TSS) sensor.
1. Use petroleum jelly on the O-ring seal and position the TSS sensor.
  - Install a new O-ring seal.
2. Install the TSS sensor bolt.
  
  Fig 89: Installing Turbine Shaft Speed (TSS) Sensor
  Courtesy of FORD MOTOR CO.
Using the special tool, install the LH differential seal.

Fig 90: Installing LH Differential Seal
Courtesy of FORD MOTOR CO.
Using the special tool, install the RH differential seal.

Fig 91: Installing RH Differential Seal
Courtesy of FORD MOTOR CO.

NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.

Using the special tool, install the torque converter fluid seal.
- Coat the torque converter seal garter spring with petroleum jelly.
  
  Fig 92: Installing Torque Converter Fluid Seal
  Courtesy of FORD MOTOR CO.
Install the drain plug.

Fig 93: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.

Fig 94: Installing Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.

NOTE: Check for correct rotation of the pump drive shaft.

Fig 95: Installing Pump Drive Shaft

Courtesy of FORD MOTOR CO.

Install the pump drive shaft.
Using the special tool, install the torque converter.

Fig 96: Installing Torque Converter
Courtesy of FORD MOTOR CO.

NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.

Check the installation depth of the torque converter.
1. Lay a straightedge on the transaxle converter housing.
2. Check the clearance between the straight edge and the pilot hub.
  
  Fig 97: Inserting Straightedge On Transaxle Converter Housing
  Courtesy of FORD MOTOR CO.
Lubricate the torque converter pilot hub with grease.

Fig 98: Locating Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
Remove the transaxle from the special tool.

Fig 99: Removing Transaxle From Special Tool
Courtesy of FORD MOTOR CO.