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Section 343 (Automatic Transaxle/Transmission): Disassembly: Transaxle: Disassembly

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the torque converter from the transaxle.
    Fig 1: Removing Torque Converter From Transaxle
    G03412319Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transaxle.
    Fig 2: Mounting Transaxle
    G03412320Courtesy of FORD MOTOR CO.
  3. Remove the transaxle oil cooler tubes.
    1. Remove the bracket bolt.
    2. Remove the tube bolts.
    3. Remove the tubes.
      Fig 3: Removing Transaxle Oil Cooler Tubes
      G03412321Courtesy of FORD MOTOR CO.
    4. NOTE: The shifter lever must be perpendicular to the transaxle pan gasket surface.
  4. Position the shifter lever into the PARK (P) position.
    • Move the shifter to the "up" position.
      Fig 4: Positioning Shifter Lever Into PARK (P) Position
      G03412322Courtesy of FORD MOTOR CO.
  5. Remove the transmission range (TR) sensor.
    1. Remove the screws.
    2. Remove the sensor.
      Fig 5: Removing Screws
      G03412323Courtesy of FORD MOTOR CO.
  6. Remove the transaxle oil pan.
    1. Remove the bolts.
    2. Remove the pan.
      Fig 6: Removing Bolts
      G03412324Courtesy of FORD MOTOR CO.
  7. Remove the transaxle oil pan magnets.
    Fig 7: Removing Transaxle Oil Pan Magnets
    G03412325Courtesy of FORD MOTOR CO.
  8. Inspect the particles in the transaxle oil pan. Refer to the symptom chart to determine the cause of the particles.
  9. Remove the spring clip from the transaxle harness.
    Fig 8: Removing Spring Clip From Transaxle Harness
    G03412326Courtesy of FORD MOTOR CO.
  10. Remove the main control valve body.
    1. Pull the harness through the case.
    2. Remove the bolts.
    3. Remove the main control valve body and harness.
      Fig 9: Removing Bolts
      G03412327Courtesy of FORD MOTOR CO.
  11. Remove the D-R accumulator piston return spring.
    Fig 10: Removing D-R Accumulator Piston Return Spring
    G03412328Courtesy of FORD MOTOR CO.
  12. Remove the D-R accumulator piston.
    • Apply compressed air to remove the piston.
      Fig 11: Removing D-R Accumulator Piston
      G03412329Courtesy of FORD MOTOR CO.
  13. Remove and discard the seals from the DRIVE/reverse accumulator piston.
    Fig 12: Removing And Discarding Seals From The Drive/Reverse Accumulator Piston
    G03412330Courtesy of FORD MOTOR CO.
  14. Remove the N-D accumulator piston and spring assembly.
    • Apply compressed air to remove the piston.
      Fig 13: Removing N-D Accumulator Piston And Spring Assembly
      G03412331Courtesy of FORD MOTOR CO.
  15. Remove and discard the seals from the N-D accumulator piston.
    Fig 14: Removing And Discarding Seals From N-D Accumulator Piston
    G03412332Courtesy of FORD MOTOR CO.
  16. Remove the seals from the transaxle case.
    Fig 15: Removing Seals From Transaxle Case
    G03412333Courtesy of FORD MOTOR CO.
  17. Remove the low/reverse clutch apply oil transfer tube.
    1. Remove the bolts.
    2. Remove the transfer tube.
      Fig 16: Removing Bolts
      G03412334Courtesy of FORD MOTOR CO.
  18. Remove and discard the seal from the low/reverse clutch apply oil transfer tube.
    Fig 17: Removing And Discarding Seal From Low/Reverse Clutch Apply Oil Transfer Tube
    G03412335Courtesy of FORD MOTOR CO.
  19. Remove the special tool from the transaxle.
    Fig 18: Removing Special Tool From Transaxle
    G03412336Courtesy of FORD MOTOR CO.
  20. Remove the torque converter housing.
    1. Remove the bolts.
    2. Remove the housing.
      Fig 19: Removing Bolts
      G03412337Courtesy of FORD MOTOR CO.
  21. Using the special tool, mount the transaxle.
    Fig 20: Mounting Transaxle
    G03412338Courtesy of FORD MOTOR CO.
  22. Remove the differential oil port O-ring from the differential oil port.
    Fig 21: Removing Differential Oil Port O-Ring From Differential Oil Port
    G03412339Courtesy of FORD MOTOR CO.
  23. Remove the differential.
    Fig 22: Removing Differential
    G03412340Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the differential bearing outer race from the transaxle case.
    Fig 23: Removing Differential Bearing Outer Race From Transaxle Case
    G03412341Courtesy of FORD MOTOR CO.
  25. Remove the differential bearing shim from the transaxle case.
    Fig 24: Removing Differential Bearing Shim From Transaxle Case
    G03412342Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the differential side bearing outer race from the torque converter housing.
    Fig 25: Removing Differential Side Bearing Outer Race From Torque Converter Housing
    G03412343Courtesy of FORD MOTOR CO.
  27. Remove the differential oil seal from the torque converter housing.
    Fig 26: Removing Differential Oil Seal From Torque Converter Housing
    G03412344Courtesy of FORD MOTOR CO.
  28. Remove the differential lubrication tube.
    1. Remove the bolts.
    2. Remove the lubrication tube.
      Fig 27: Removing Bolts
      G03412345Courtesy of FORD MOTOR CO.
  29. Remove the input shaft O-ring.
    Fig 28: Removing Input Shaft O-Ring
    G03412346Courtesy of FORD MOTOR CO.
  30. Remove the oil pump bolts.
    • Remove the oil pump baffle.
      Fig 29: Removing Oil Pump Bolts
      G03412347Courtesy of FORD MOTOR CO.
  31. Remove the oil pump.
    1. Remove the oil pump.
    2. Remove the reverse clutch drum thrust washer.
    3. Remove the 3-4 clutch drum bearing race.
    4. Remove the 3-4 clutch drum bearing.
      Fig 30: Removing Oil Pump
      G03412348Courtesy of FORD MOTOR CO.
  32. Remove the band adjusting stop.
    Fig 31: Removing Band Adjusting Stop
    G03412349Courtesy of FORD MOTOR CO.
    33. CAUTION: To prevent damage to the 2-4 band, do not allow the band to stretch or open after removal from the transaxle.
  33. Remove the 2-4 band.
    1. Remove the band.
    2. Remove the strut.
      Fig 32: Removing Band
      G03412350Courtesy of FORD MOTOR CO.
  34. Secure the 2-4 band with wire to prevent it from spreading open.
    Fig 33: Securing 2-4 Band With Wire
    G03412351Courtesy of FORD MOTOR CO.
  35. Remove the 2-4 servo assembly retainer.
    1. Remove the bolts.
    2. Remove the retainer.
      Fig 34: Removing Bolts
      G03412352Courtesy of FORD MOTOR CO.
  36. Remove the 2-4 servo assembly.
    • Apply compressed air to remove the servo assembly.
      Fig 35: Removing 2-4 Servo Assembly
      G03412353Courtesy of FORD MOTOR CO.
  37. Remove the input shaft with the 3-4 clutch assembly and the reverse clutch assembly.
    Fig 36: Removing Input Shaft With 3-4 Clutch Assembly And Reverse Clutch Assembly
    G03412354Courtesy of FORD MOTOR CO.
  38. Separate the reverse clutch assembly from the input shaft and the 3-4 clutch assembly.
    Fig 37: Separating Reverse Clutch Assembly From Input Shaft And 3-4 Clutch Assembly
    G03412355Courtesy of FORD MOTOR CO.
  39. Remove the 3-4 clutch hub assembly.
    1. Remove the 3-4 clutch hub bearing.
    2. Remove the 3-4 clutch hub.
      Fig 38: Removing 3-4 Clutch Hub Assembly
      G03412356Courtesy of FORD MOTOR CO.
  40. Remove the primary sun gear.
    1. Remove the primary sun gear bearing.
    2. Remove the primary sun gear.
    3. Remove the primary sun gear bearing race.
      Fig 39: Removing Primary Sun Gear
      G03412357Courtesy of FORD MOTOR CO.
  41. Remove the primary sun gear bearing from the front planetary gear set.
    Fig 40: Removing Primary Sun Gear Bearing From Front Planetary Gear Set
    G03412358Courtesy of FORD MOTOR CO.
  42. Remove the low one-way clutch snap ring.
    Fig 41: Removing Low One-Way Clutch Snap Ring
    G03412359Courtesy of FORD MOTOR CO.
  43. Remove the low one-way clutch.
    Fig 42: Removing Low One-Way Clutch
    G03412360Courtesy of FORD MOTOR CO.
  44. Remove the low/reverse clutch piston assembly snap ring.
    Fig 43: Removing Low/Reverse Clutch Piston Assembly Snap Ring
    G03412361Courtesy of FORD MOTOR CO.
  45. Remove the low/reverse clutch piston assembly.
    1. Remove the low/reverse clutch piston.
    2. Remove the front planetary gearset.
      Fig 44: Removing Low/Reverse Clutch Piston Assembly
      G03412362Courtesy of FORD MOTOR CO.
  46. Remove the rear sun gear thrust bearing.
    Fig 45: Removing Rear Sun Gear Thrust Bearing
    G03412363Courtesy of FORD MOTOR CO.
  47. Remove the low/reverse clutch piston spring retainer and springs.
    Fig 46: Removing Low/Reverse Clutch Piston Spring Retainer And Springs
    G03412364Courtesy of FORD MOTOR CO.
  48. Remove the rear planetary gearset assembly.
    1. Remove the rear planetary gearset.
    2. Remove the rear planetary gearset bearing.
      Fig 47: Removing Rear Planetary Gearset Assembly
      G03412365Courtesy of FORD MOTOR CO.
  49. Remove the rear sun gear assembly from the rear planetary gearset.
    1. Remove the rear sun gear.
    2. Remove the rear sun gear thrust bearing.
      Fig 48: Removing Rear Sun Gear Assembly From Rear Planetary Gearset
      G03412366Courtesy of FORD MOTOR CO.
  50. Remove the forward clutch ring gear assembly.
    1. Remove the forward clutch hub and ring gear assembly.
    2. Remove the forward clutch ring gear thrust washer.
      Fig 49: Removing Forward Clutch Ring Gear Assembly
      G03412367Courtesy of FORD MOTOR CO.
  51. Remove the ring gear from the forward clutch hub.
    1. Remove the ring gear.
    2. Remove the ring gear thrust washer.
      Fig 50: Removing Ring Gear From Forward Clutch Hub
      G03412368Courtesy of FORD MOTOR CO.
  52. Remove the forward one way clutch (sprag) from the forward clutch hub.
    1. Remove the one way clutch bearing.
    2. Remove the one way clutch (sprag).
    3. Remove the one way clutch bearing.
      Fig 51: Removing Forward One Way Clutch (Sprag) From Forward Clutch Hub
      G03412369Courtesy of FORD MOTOR CO.
  53. Inspect the one way clutch (sprag) for wear and damage.
  54. Remove the coasting clutch hub assembly.
    1. Remove the coasting clutch hub thrust washer.
    2. Remove the coasting clutch hub.
    3. Remove the forward clutch hub upper bearing.
      Fig 52: Removing Coasting Clutch Hub Thrust Washer
      G03412370Courtesy of FORD MOTOR CO.
  55. Remove the forward clutch assembly.
    1. Remove the forward clutch hub.
    2. Remove the lower forward clutch hub bearing.
      Fig 53: Removing Forward Clutch Assembly
      G03412371Courtesy of FORD MOTOR CO.
  56. Remove the low/reverse clutch pressure plate snap ring.
    Fig 54: Removing Low/Reverse Clutch Pressure Plate Snap Ring
    G03412372Courtesy of FORD MOTOR CO.
    57. NOTE: Identify the clutch components and their order to ease installation.
  57. Remove the low/reverse clutch assembly.
    1. Remove the pressure plate.
    2. Remove the dish plates.
    3. Remove the clutch assembly.
      Fig 55: Removing Low/Reverse Clutch Assembly
      G03412373Courtesy of FORD MOTOR CO.
    58. NOTE: Only four of the side cover bolts are not reused.
    Fig 56: Removing And Discarding Side Cover Bolts
    G03412374Courtesy of FORD MOTOR CO.
  58. Remove and discard the side cover bolts.
  59. Remove the transaxle side cover.
    1. Remove the bolts.
    2. Remove the side cover.
      Fig 57: Removing Bolts
      G03412375Courtesy of FORD MOTOR CO.
  60. Remove the output shaft bearing selective shim.
    Fig 58: Removing Output Shaft Bearing Selective Shim
    G03412376Courtesy of FORD MOTOR CO.
  61. Remove the output shaft assembly.
    Fig 59: Removing Output Shaft Assembly
    G03412377Courtesy of FORD MOTOR CO.
  62. Remove the output shaft hub thrust washer.
    Fig 60: Removing Output Shaft Hub Thrust Washer
    G03412378Courtesy of FORD MOTOR CO.
    63. CAUTION: Do not drop the output shaft bearing retainer. It is removed from the opposite side of the transaxle.
  63. Remove output shaft bearing retainer.
    1. Remove the bolts.
    2. Remove the bearing retainer from inside the transaxle.
      Fig 61: Removing Output Shaft Bearing Retainer Bolts
      G03412379Courtesy of FORD MOTOR CO.
  64. Remove the seals from the output shaft assembly.
    1. Remove the seals from the bearing retainer.
    2. Remove the seals from the output shaft.
      Fig 62: Removing Seals From Output Shaft Assembly
      G03412380Courtesy of FORD MOTOR CO.
  65. Place the shifter lever into the PARK (P)
    Fig 63: Locating Place Shifter Lever Into PARK (P)
    G03412381Courtesy of FORD MOTOR CO.
  66. Using the special tool, unstake the idler gear locknut.
    Fig 64: Unstaking Idler Gear Locknut
    G03412382Courtesy of FORD MOTOR CO.
  67. Remove and discard the idler gear locknut.
    Fig 65: Removing And Discarding Idler Gear Locknut
    G03412383Courtesy of FORD MOTOR CO.
    68. CAUTION: Do not allow the reduction gear to fall when the idler gear is removed.
    Fig 66: Removing Idler Gear
    G03412384Courtesy of FORD MOTOR CO.
  68. Using the special tools, remove the idler gear.
  69. Remove the reduction gear from the transaxle.
    Fig 67: Removing Reduction Gear From Transaxle
    G03412385Courtesy of FORD MOTOR CO.
  70. Remove the reduction gear bearing adjusting shim.
    Fig 68: Removing Reduction Gear Bearing Adjusting Shim
    G03412386Courtesy of FORD MOTOR CO.
  71. Using the special tools, remove the idler gear bearing outer race from the transaxle case.
    Fig 69: Removing Idler Gear Bearing Outer Race From Transaxle Case
    G03412387Courtesy of FORD MOTOR CO.
  72. Remove the reduction gear bearing outer race.
    1. Remove the bolts.
    2. Remove the outer race.
      Fig 70: Removing Bolts
      G03412388Courtesy of FORD MOTOR CO.
  73. Remove the parking brake assembly.
    1. Remove the parking pawl spring.
    2. Remove the parking pawl.
    3. Remove the parking actuator support bolts.
    4. Remove the parking actuator support.
      Fig 71: Removing Parking Actuator Support Bolts
      G03412389Courtesy of FORD MOTOR CO.
  74. Remove the manual detent spring.
    1. Remove the bolt.
    2. Remove the spring.
      Fig 72: Removing Bolt
      G03412390Courtesy of FORD MOTOR CO.
  75. Remove and discard the PARK actuator support roll pin.
    Fig 73: Removing And Discarding PARK Actuator Support Roll Pin
    G03412391Courtesy of FORD MOTOR CO.
  76. Remove and discard the manual detent lever roll pin.
    Fig 74: Removing And Discarding Manual Detent Lever Roll Pin
    G03412392Courtesy of FORD MOTOR CO.
  77. Remove the manual shift linkage rod.
    1. Remove the roll pin.
    2. Remove the linkage rod.
      Fig 75: Removing Roll Pin
      G03412393Courtesy of FORD MOTOR CO.
  78. Using the special tool, remove the manual control lever oil seal.
    Fig 76: Removing Manual Control Lever Oil Seal
    G03412394Courtesy of FORD MOTOR CO.
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