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Automatic Transaxle/Transmission: Assembly: Transmission: Notes

Special Tool(s) 

Fig 1: Identifying Special Tool(s) (1 Of 5)
G01300014Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool(s) (2 Of 5)
G01300015Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tool(s) (3 Of 5)
G01300016Courtesy of FORD MOTOR CO.
Fig 4: Identifying Special Tool(s) (4 Of 5)
G01300017Courtesy of FORD MOTOR CO.
Fig 5: Identifying Special Tool(s) (5 Of 5)
G01300018Courtesy of FORD MOTOR CO.

Material 

Fig 6: Material Specification
G01300019Courtesy of FORD MOTOR CO.
NOTE: The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.
  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    1. Stripped bolt hole threads.
    2. Gasket and mating surfaces for burrs or nicks.
    3. Obstructions to vent and fluid passages.
      • Cracks or warpage.
      Fig 7: Inspecting Transmission Case
      G01300020Courtesy of FORD MOTOR CO.
  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 8: Inspecting Extension Housing For Cracks
    G01300021Courtesy of FORD MOTOR CO.
  4. Inspect case bearing for damage. Install new components as needed. Follow steps 6-8 if replacing the case bearing. If not replacing the case bearing, proceed to Step 8.
    Fig 9: Inspecting Case Bearing For Damage
    G01300022Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the case bearing.
    • Use an oil stone to remove any nicks or burrs in the bearing case bore.
    Fig 10: Removing Case Bearing
    G01300023Courtesy of FORD MOTOR CO.
  6. Inspect the rear case inner race for burrs, nicks and scoring. If any damage has been found, a new case must be installed.
    Fig 11: Inspecting Rear Case Inner Race For Burrs
    G01300024Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure the bearing seal ring is facing the drive handle.
    Fig 12: Installing A New Case Bearing
    G01300025Courtesy of FORD MOTOR CO.
  7. Install a new case bearing.
    1. Assemble the special tool.
    2. Position new case bearing onto special tool.
  8. Using the special tool, tap case bearing into case bearing bore.
    Fig 13: Using Special Tool, Tap Case Bearing
    G01300026Courtesy of FORD MOTOR CO.
  9. Install the special tool on the rear of the transmission case.
    Fig 14: Installing Special Tool On Rear Of Transmission Case
    G01300027Courtesy of FORD MOTOR CO.
  10. Attach the fixture arm of the special tool as shown.
    Fig 15: Attaching Fixture Arm Of Special Tool
    G01300028Courtesy of FORD MOTOR CO.
  11. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury. 

    Install transmission into the special tool.

    • Rotate the transmission so that the fluid pan rail is facing up.
    Fig 16: Installing Transmission Into Special Tool
    G01300029Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the manual control lever shaft seal.
    • Lubricate the manual control lever shaft seal with petroleum jelly.
    Fig 17: Installing Manual Control Lever Shaft Seal
    G01300030Courtesy of FORD MOTOR CO.
  13. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 18: Assembling Manual Valve Inner Lever And Parking Lever Actuating Rod
    G01300031Courtesy of FORD MOTOR CO.
  14. Install the manual control lever shaft.
    Fig 19: Installing Manual Control Lever Shaft
    G01300032Courtesy of FORD MOTOR CO.
    15. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
    Fig 20: Installing Manual Control Lever Shaft Spring Pin
    G01300033Courtesy of FORD MOTOR CO.
  15. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
    16. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 21: Installing Manual Valve Inner Lever And Parking Lever Actuating Rod
    G01300034Courtesy of FORD MOTOR CO.
  16. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.
    17. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 22: Installing Manual Valve Inner Lever Nut
    G01300035Courtesy of FORD MOTOR CO.
  17. Install the manual valve inner lever nut on the manual control lever shaft and tighten.
    18. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
    Fig 23: Installing Output Shaft Thrust Washer (No. 11)
    G01300036Courtesy of FORD MOTOR CO.
  18. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
  19. Install the park gear.
    Fig 24: Installing Park Gear
    G01300037Courtesy of FORD MOTOR CO.
  20. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    Fig 25: Installing Low/Reverse Brake Drum
    G01300038Courtesy of FORD MOTOR CO.
  21. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly.
    • Coat the needle bearing with petroleum jelly.
    Fig 26: Installing No. 10B Needle Bearing
    G01300039Courtesy of FORD MOTOR CO.
  22. Install the output shaft through the output shaft park gear.
    Fig 27: Installing Output Shaft Through Output Shaft Park Gear
    G01300040Courtesy of FORD MOTOR CO.
  23. Install the output shaft ring gear and output shaft hub.
    Fig 28: Installing Output Shaft Ring Gear And Output Shaft Hub
    G01300041Courtesy of FORD MOTOR CO.
    24. CAUTION: Always install a new output shaft retaining ring.
    Fig 29: Installing A New Output Shaft Retaining Ring
    G01300042Courtesy of FORD MOTOR CO.
  24. Install a new output shaft retaining ring.
    25. NOTE: Install the output shaft sleeve with the cone facing up.
    Fig 30: Installing Output Shaft Sleeve
    G01300043Courtesy of FORD MOTOR CO.
  25. Install the output shaft sleeve.
  26. Install low/reverse planetary carrier needle bearings.
    1. Install low/reverse planetary carrier needle bearing (No. 8) on the front face of the low/reverse planetary.
    2. Install low/reverse planetary carrier needle bearing (No. 9) on the rear face of the low/reverse planetary.
      • Coat the low/reverse planet carrier needle bearing (No. 8) and low/reverse planetary carrier needle bearing (No. 9) with petroleum jelly.
      Fig 31: Installing Low/Reverse Planetary Carrier Needle Bearings
      G01300044Courtesy of FORD MOTOR CO.
    27. CAUTION: Make sure needle bearings stay in place.
    Fig 32: Installing Low/Reverse Planetary Assembly With No. 8 And No. 9 Low/Reverse Planetary Carrier Needle Bearings
    G01300045Courtesy of FORD MOTOR CO.
  27. Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier needle bearings into the output shaft ring gear.
    28. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 33: Installing Low/Reverse Retaining Ring Into Low/Reverse Brake Drum Groove
    G01300046Courtesy of FORD MOTOR CO.
  28. Install the low/reverse retaining ring into the low/reverse brake drum groove.
    29. CAUTION: Make sure band is resting on the two anchor pins in the case.
    Fig 34: Installing Low/Reverse Band Over Low/Reverse Brake Drum
    G01300047Courtesy of FORD MOTOR CO.
  29. Install the low/reverse band over the low/reverse brake drum.
  30. Temporarily install the low/reverse band servo piston and rod to hold the low/reverse band in position.
    Fig 35: Installing Low/Reverse Band Servo Piston And Rod To Hold Low/Reverse Band In Position
    G01300048Courtesy of FORD MOTOR CO.
  31. Install the previously assembled forward geartrain assembly.
    Fig 36: Installing Previously Assembled Forward Geartrain Assembly
    G01300049Courtesy of FORD MOTOR CO.
  32. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury. 

    Rotate transmission assembly so that the converter housing surface is facing up.

  33. Select the intermediate brake drum thrust bearing (No. 4) as follows:
    1. Install the special tool on case assembly shoulder.
    2. Set the special tool on top as shown.
    Fig 37: Selecting Intermediate Brake Drum Thrust Bearing (No. 4)
    G01300050Courtesy of FORD MOTOR CO.
  34. Calculate the thrust bearing thickness.
    • Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.
    Fig 38: Calculating Thrust Bearing Thickness
    G01300051Courtesy of FORD MOTOR CO.
  35. Place the micrometer on the opposite side of the special tool and repeat measurement. This is dimension B.
    Fig 39: Placing Micrometer On Opposite Side
    G01300052Courtesy of FORD MOTOR CO.
  36. Add dimension A and B, divide the total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 in). Record this reading as dimension C.
  37. Place the special tool across the center support. Place the micrometer on the top of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.
    Fig 40: Placing Micrometer On Top Of Special Tool
    G01300053Courtesy of FORD MOTOR CO.
  38. Place the special tool on the opposite side of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.
    Fig 41: Placing Special Tool On Opposite Side Of Special Tool
    G01300054Courtesy of FORD MOTOR CO.
  39. Add dimensions D and F. Divide the total of D and F by two. Subtract the special tool thickness 17.78 mm (0.700 in) dimension E. The result is dimension G.
    Fig 42: Subtracting Special Tool Thickness
    G01300055Courtesy of FORD MOTOR CO.
  40. Add dimensions C and G. This total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.008-0.021 in).
    Fig 43: Dimension H Table
    G01300056Courtesy of FORD MOTOR CO.
  41. Install the intermediate servo actuating lever.
    Fig 44: Installing Intermediate Servo Actuating Lever
    G01300057Courtesy of FORD MOTOR CO.
    42. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 45: Installing Intermediate Band Actuating Lever Shaft
    G01300058Courtesy of FORD MOTOR CO.
  42. Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.
  43. Install the intermediate band apply strut on the intermediate servo actuating lever.
    Fig 46: Installing Intermediate Band
    G01300059Courtesy of FORD MOTOR CO.
    44. NOTE: Make sure that the intermediate apply strut is aligned with the band notch.
    Fig 47: Installing Intermediate Band
    G01300060Courtesy of FORD MOTOR CO.
  44. Install the intermediate band.
    45. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.
    NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.
    Fig 48: Installing Intermediate Band Adjustment Screw
    G01300061Courtesy of FORD MOTOR CO.
  45. Install the intermediate band anchor strut and the intermediate band adjustment screw.
  46. Install the selected intermediate brake drum thrust washer (No. 4) on the center support.
    • Coat the intermediate brake drum thrust washer with petroleum jelly.
    Fig 49: Installing Selected Intermediate Brake Drum Thrust Washer (No. 4) On Center Support
    G01300062Courtesy of FORD MOTOR CO.
    47. CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings can result. Make sure the rear planetary support is seated.
    NOTE: Align the center support screw hole with correct case hole.
    Fig 50: Installing Center Support
    G01300063Courtesy of FORD MOTOR CO.
  47. Install the center support.
    1. Position the center support into the intermediate brake and direct clutch drum.
    2. Temporarily insert input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
    48. CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
    Fig 51: Installing Center Support Retaining Ring
    G01300064Courtesy of FORD MOTOR CO.
  48. Install the center support retaining ring.
    1. Position center support retaining ring with the tapered side facing up.
    2. Install the center support retaining ring so that the notch opening is not obstructed.
  49. Install the center support locknut and cage.
    Fig 52: Installing Center Support Locknut
    G01300065Courtesy of FORD MOTOR CO.
  50. Install the center support-to-case capscrew.
    Fig 53: Installing Center Support-To-Case Capscrew
    G01300066Courtesy of FORD MOTOR CO.
    51. CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
    NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.
    Fig 54: Installing Turbine Shaft Speed (TSS) Sensor
    G01300067Courtesy of FORD MOTOR CO.
  51. Install the Turbine Shaft Speed (TSS) sensor.
    1. Install the TSS sensor.
    2. Install TSS sensor screw.
    52. CAUTION: Use only the center shaft thrust bearing (No. 3).
    NOTE: The center shaft thrust bearing (No. 3) has no notches on the outer race.
    Fig 55: Installing Center Shaft Thrust Bearing (No. 3)
    G01300068Courtesy of FORD MOTOR CO.
  52. Install the center shaft thrust bearing (No. 3).
    53. CAUTION: Do not bend the trigger wheel.
    Fig 56: Installing Overdrive Planetary And One-Way Clutch Assembly
    G01300069Courtesy of FORD MOTOR CO.
  53. Install the overdrive planetary and one-way clutch assembly.
    54. CAUTION: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
    Fig 57: Placing Thin Blade Of Special Tool Over TSS Sensor
    G01300070Courtesy of FORD MOTOR CO.
  54. Using the special tool, check TSS sensor air gap.
    1. Place the thin blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    55. CAUTION: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
    Fig 58: Placing Thick Blade Of Special Tool Over TSS Sensor
    G01300071Courtesy of FORD MOTOR CO.
  55. Using the special tool, check TSS sensor air gap.
    1. Place the thick blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    56. NOTE: Align the clutch plates and front adapter gear.
    Fig 59: Installing Front Brake Drum And Coast Clutch Drum Assembly
    G01300072Courtesy of FORD MOTOR CO.
  56. Install the front brake drum and coast clutch drum assembly.
  57. Install the front servo band lever and front band lever-to-case bracket into the transmission case.
    Fig 60: Installing Front Servo Band Lever And Front Band Lever-To-Case Bracket
    G01300073Courtesy of FORD MOTOR CO.
    58. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.
    Fig 61: Installing Front Band Actuating Lever Shaft
    G01300074Courtesy of FORD MOTOR CO.
  58. Install the front band actuating lever shaft through the front servo band lever.
  59. Install the front band apply strut.
    Fig 62: Installing Front Band Apply Strut
    G01300075Courtesy of FORD MOTOR CO.
    60. NOTE: If the front band is reused, it must be installed in the same position as when removed.
    Fig 63: Installing Front Band Over Front Brake And Coast Clutch Drum
    G01300076Courtesy of FORD MOTOR CO.
  60. Install the front band over the front brake and coast clutch drum.
    61. NOTE: Use the band adjustment screw as a temporary alignment guide.
    Fig 64: Installing Front Band Anchor Strut
    G01300077Courtesy of FORD MOTOR CO.
  61. Install the front band anchor strut.
  62. Install the front band adjusting screw.
    Fig 65: Installing Front Band Adjusting Screw
    G01300078Courtesy of FORD MOTOR CO.
    63. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 66: Installing Fluid Pump Inlet Thrust Washer (No. 1)
    G01300079Courtesy of FORD MOTOR CO.
  63. Perform front end play check procedure as follows:
    • Coat the fluid pump inlet thrust washer (No. 1) with petroleum jelly.
    • Install the fluid pump inlet thrust washer (No. 1) on the rear of the fluid pump and place pump into position in case.
    64. CAUTION: The special tool must rest on the gasket surface.
  64. Measure the front end play clearance.
    1. Place special tool across the case.
    2. Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
      • Read the measurement and subtract special tool thickness 17.78 mm (0.700 in). This is dimension A.
      • Repeat the measurement at the opposite side of the transmission case. This is dimension B.
      • Add dimensions A and B together and divide by two. This is front end clearance dimension C.
      Fig 67: Inserting Special Tool And Extend Micrometer Probe
      G01300080Courtesy of FORD MOTOR CO.
    65. CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
    NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 in).
  65. Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).
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