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Automatic Transaxle/Transmission: Disassembly: Transmission

Special Tool(s) 

Fig 1: Identifying Special Tool(s) (1 Of 3)
G01299141Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool(s) (2 Of 3)
G01299142Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tool(s) (3 Of 3)
G01299143Courtesy 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. WARNING: Do not remove the torque converter from the transmission while still on the jack. Doing so could cause the transmission to fall. Failure to follow these instructions may result in personal injury. 

    Place the transmission on a workbench.

    Fig 4: Placing Transmission On A Workbench
    G01299144Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 5: Removing Special Tool
    G01299145Courtesy of FORD MOTOR CO.
  3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury. 

    Using the special tool, remove the torque converter.

    Fig 6: Removing Torque Converter
    G01299146Courtesy of FORD MOTOR CO.
    4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
    Fig 7: Removing Input Shaft
    G01299147Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
  5. Remove output shaft speed (OSS) sensor.
    1. Remove the OSS screw.
    2. Remove OSS sensor.
    Fig 8: Removing Output Shaft Speed (OSS) Sensor
    G01299148Courtesy of FORD MOTOR CO.
  6. If equipped, remove the intermediate shaft speed (ISS) sensor.
    1. Remove the ISS screw.
    2. Remove ISS sensor.
    Fig 9: Removing ISS Screw
    G01299149Courtesy of FORD MOTOR CO.
  7. If equipped, remove the heat shield.
    1. Remove the nut.
    2. Remove the heat shield.
    Fig 10: Removing Nut
    G01299150Courtesy of FORD MOTOR CO.
  8. Remove manual control outer lever nut and manual control outer lever.
    Fig 11: Removing Manual Control Outer Lever Nut
    G01299151Courtesy of FORD MOTOR CO.
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the screws.
    2. Remove the digital TR sensor.
    Fig 12: Removing Screws
    G01299152Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the extension housing seal.
    Fig 13: Removing Extension Housing Seal
    G01299153Courtesy of FORD MOTOR CO.
    11. NOTE: Remove the extension housing bushing only if service is required.
    Fig 14: Removing Extension Housing Bushing
    G01299154Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the extension housing bushing.
    • Inspect the extension housing bushing and driveshaft slip yoke for nicks, gouges, scoring and wear.
    12. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 15: Removing Screws
    G01299155Courtesy of FORD MOTOR CO.
  12. Remove the screws, studs, and the extension housing.
    • Discard the extension housing gasket.
  13. Remove the parking pawl assembly.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    Fig 16: Removing Parking Pawl
    G01299156Courtesy of FORD MOTOR CO.
    14. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
    Fig 17: Installing Special Tool
    G01299157Courtesy of FORD MOTOR CO.
  14. Install the special tool.
  15. Assemble the special tools.
    Fig 18: Assembling Special Tools
    G01299158Courtesy of FORD MOTOR CO.
  16. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury. 

    Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.

    Fig 19: Installing Transmission Into Special Tool
    G01299159Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not reuse the fluid pan gasket.
    Fig 20: Removing Transmission Fluid Pan Screws
    G01299160Courtesy of FORD MOTOR CO.
  17. Remove the transmission fluid pan screws, pan and transmission pan gasket and then discard gasket.
  18. Remove the transmission fluid filter and discard.
    1. Remove the screw.
    2. Remove the transmission fluid filter.
    Fig 21: Removing Transmission Fluid Filter
    G01299161Courtesy of FORD MOTOR CO.
  19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
    Fig 22: identifying wire loom guide
    G01299162Courtesy of FORD MOTOR CO.
  20. Disconnect the solenoid electrical connectors.
    1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors.
    2. Disconnect the torque converter clutch (TCC) solenoid electrical connector.
    3. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
      Fig 23: Disconnecting Solenoid Electrical Connectors
      G01299744Courtesy of FORD MOTOR CO.
  21. Remove the manual control valve detent lever spring.
    1. Remove the screw.
    2. Remove the manual control valve detent lever spring.
    Fig 24: Removing Screw
    G01299745Courtesy of FORD MOTOR CO.
  22. Remove the low/reverse band servo cover.
    1. Remove the screws.
    2. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
    • Discard the low/reverse servo separator plate cover gasket.
    Fig 25: Removing Screws
    G01299746Courtesy of FORD MOTOR CO.
  23. Remove the low/reverse band servo piston and rod assembly.
    Fig 26: Removing Low/Reverse Band Servo Piston And Rod Assembly
    G01299747Courtesy of FORD MOTOR CO.
    24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.
    Fig 27: Removing Two Screws
    G01299748Courtesy of FORD MOTOR CO.
  24. Do not remove the two (gold colored) screws specified.
  25. Remove the twenty-three valve body screws.
    Fig 28: Removing Twenty-Three Valve Body Screws
    G01299749Courtesy of FORD MOTOR CO.
  26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket.
    • Discard gaskets.
    Fig 29: Discarding Gaskets
    G01299750Courtesy of FORD MOTOR CO.
    27. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 30: Removing Locknuts
    G01299751Courtesy of FORD MOTOR CO.
  27. Remove the locknuts. Back off the screws.
    28. CAUTION: The servo cover is under spring tension.
    Fig 31: Removing Intermediate Servo Cover Retaining Ring
    G01299752Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the intermediate servo cover retaining ring.
    • Remove the special tool.
    29. NOTE: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo, cover and bore.
    Fig 32: Releasing Intermediate Band Servo
    G01299753Courtesy of FORD MOTOR CO.
  29. Using the special tool, release the intermediate band servo piston.
  30. Remove the intermediate band servo cover, piston and spring.
    Fig 33: Removing Intermediate Band Servo Cover, Piston And Spring
    G01299754Courtesy of FORD MOTOR CO.
    31. CAUTION: Servo cover is under spring tension.
    Fig 34: Removing Overdrive Servo Retaining Ring
    G01299755Courtesy of FORD MOTOR CO.
  31. Using the special tool, remove the overdrive servo retaining ring and cover.
    32. NOTE: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo piston and bore.
    Fig 35: Releasing Overdrive Band Servo
    G01299756Courtesy of FORD MOTOR CO.
  32. Using the special tool, release the overdrive band servo piston.
  33. Remove the overdrive band servo cover, piston and spring.
    Fig 36: Removing Overdrive Band Servo Cover, Piston And Spring
    G01299757Courtesy of FORD MOTOR CO.
  34. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury. 

    Rotate the transmission so the converter housing faces up.

    35. CAUTION: Discard the screws. The screws are not reusable for assembly.
    Fig 37: Removing And Discarding Screws
    G01299758Courtesy of FORD MOTOR CO.
  35. Remove and discard the screws.
  36. Remove the converter housing and fluid pump support.
    • Turn and lift the converter housing and fluid pump support from the case.
    Fig 38: Removing Converter Housing And Fluid Pump Support
    G01299759Courtesy of FORD MOTOR CO.
  37. Remove the fluid pump input thrust washer (No. 1).
    • Tag and identify the thrust washer.
    Fig 39: Removing Fluid Pump Input Thrust Washer (No. 1)
    G01299760Courtesy of FORD MOTOR CO.
  38. Remove the front band adjusting screw.
    Fig 40: Removing Front Band Adjusting Screw
    G01299761Courtesy of FORD MOTOR CO.
  39. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
    Fig 41: Removing Front Band Anchor Strut
    G01299762Courtesy of FORD MOTOR CO.
    40. CAUTION: Identify the anchor and apply ends of the front band.
    Fig 42: Removing Front Band
    G01299763Courtesy of FORD MOTOR CO.
  40. Remove the front band.
  41. Remove the front brake and coast clutch drum.
    Fig 43: Removing Front Brake And Coast Clutch Drum
    G01299764Courtesy of FORD MOTOR CO.
  42. Remove the front band apply strut.
    Fig 44: Removing Front Band Apply Strut
    G01299765Courtesy of FORD MOTOR CO.
    43. NOTE: The front band lever shaft is longer than the intermediate band lever shaft.
    Fig 45: Removing Front Band Actuating Lever Shaft
    G01299766Courtesy of FORD MOTOR CO.
  43. Remove the front band actuating lever shaft.
    44. CAUTION: Do not bend trigger wheel.
    NOTE: The No. 2 thrust bearing is in this assembly.
    Fig 46: Removing Planetary Gear Overdrive Carrier
    G01299767Courtesy of FORD MOTOR CO.
  44. Remove the planetary gear overdrive carrier.
    45. NOTE: Tag and identify the front band servo lever. The front band servo lever has a letter stamped on the side.
    Fig 47: Removing Front Band Servo Lever And Front Band Lever To Case Bracket
    G01299768Courtesy of FORD MOTOR CO.
  45. Remove the front band servo lever and front band lever to case bracket.
  46. Remove the front planet thrust bearing (No. 2).
    Fig 48: Removing Front Planet Thrust Bearing (No. 2)
    G01299769Courtesy of FORD MOTOR CO.
  47. Remove the front ring gear, front one-way clutch assembly, and center shaft as an assembly.
    Fig 49: Removing Front Ring Gear, Front One-Way Clutch Assembly, And Center Shaft
    G01299770Courtesy of FORD MOTOR CO.
    48. NOTE: Tag and identify the center shaft thrust bearing (No. 3) for assembly.
    Fig 50: Removing No. 3 Center Shaft Thrust Bearing
    G01299771Courtesy of FORD MOTOR CO.
  48. Remove the No. 3 center shaft thrust bearing.
    49. CAUTION: The center support locknut can fall into the remaining assembly if not removed.
    Fig 51: Removing Center Support Cap Screw
    G01299772Courtesy of FORD MOTOR CO.
  49. Remove the center support cap screw.
  50. Remove the locknut and cage.
    Fig 52: Removing Locknut And Cage
    G01299773Courtesy of FORD MOTOR CO.
    51. CAUTION: Do not pry on other wires or damage the connector or case surface.
    Fig 53: Removing TSS Sensor Connector Wires
    G01299774Courtesy of FORD MOTOR CO.
  51. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    1. Remove the TSS sensor electrical connector from the transmission case (16-pin) electrical connector.
    2. Remove the TSS sensor connector wires from wire locator.
    52. CAUTION: Carefully route the TSS connector and wiring into the transmission through the opening in the case.
    Fig 54: Removing Screw
    G01299775Courtesy of FORD MOTOR CO.
  52. Remove the TSS sensor.
    1. Remove the screw.
    2. Remove the TSS sensor.
    53. CAUTION: Do not overstretch the retaining spring.
    Fig 55: Removing Transmission Case (16-Pin) Electrical Connector
    G01299776Courtesy of FORD MOTOR CO.
  53. Remove the transmission case (16-pin) electrical connector retaining spring.
    54. CAUTION: Do not damage the connector or harness.
    Fig 56: Pushing Transmission Case (16-Pin) Electrical Connector
    G01299777Courtesy of FORD MOTOR CO.
  54. Compress the tabs on the transmission case (16-pin) electrical connector.

    Push the transmission case (16-pin) electrical connector out of transmission case.

  55. Remove the center support retaining ring.
    Fig 57: Removing Center Support Retaining Ring
    G01299778Courtesy of FORD MOTOR CO.
    56. NOTE: When removing the center support, pull evenly around the center support web.
    Fig 58: Removing Center Support
    G01299779Courtesy of FORD MOTOR CO.
  56. Remove the center support.
    57. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 59: Removing Intermediate Brake Drum Thrust Bearing (No. 4)
    G01299780Courtesy of FORD MOTOR CO.
  57. Remove the intermediate brake drum thrust bearing (No. 4).
  58. Remove the intermediate band anchor strut and adjusting screw.
    Fig 60: Removing Intermediate Band Anchor Strut And Adjusting Screw
    G01299781Courtesy of FORD MOTOR CO.
    59. CAUTION: Identify the anchor and apply ends of the intermediate band.
    Fig 61: Removing Intermediate Band
    G01299782Courtesy of FORD MOTOR CO.
  59. Remove the intermediate band.
  60. Remove the intermediate band apply strut.
    Fig 62: Removing Intermediate Band Apply Strut
    G01299783Courtesy of FORD MOTOR CO.
    61. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 63: Removing Intermediate Band Actuating Lever Shaft
    G01299784Courtesy of FORD MOTOR CO.
  61. Remove the intermediate band actuating lever shaft.
    62. NOTE: Tag and identify the intermediate servo band lever. The intermediate servo band lever has a letter stamped into its side.
    Fig 64: Removing Intermediate Servo Actuating Lever
    G01299785Courtesy of FORD MOTOR CO.
  62. Remove the intermediate servo actuating lever.
  63. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury. 

    Rotate the transmission so the transmission fluid pan surface is facing up.

    Fig 65: Rotating Transmission Fluid Pan Surface
    G01299786Courtesy of FORD MOTOR CO.
    64. NOTE: The forward clutch cylinder thrust bearing (No. 5) may come out with the intermediate brake and direct clutch drum.
    Fig 66: Removing Intermediate Brake And Directing Clutch Drum
    G01299787Courtesy of FORD MOTOR CO.
  64. Remove the intermediate brake and direct clutch drum.
  65. Remove the forward clutch cylinder thrust bearing (No. 5) tag and identify.
    Fig 67: Removing Forward Clutch Cylinder Thrust Bearing (No. 5) Tag
    G01299788Courtesy of FORD MOTOR CO.
  66. Remove the forward clutch cylinder.
    Fig 68: Removing Forward Clutch Cylinder
    G01299789Courtesy of FORD MOTOR CO.
  67. Remove the forward ring gear hub thrust bearing (No. 6A).
    Fig 69: Removing Forward Ring Gear Hub Thrust Bearing (No. 6A)
    G01299790Courtesy of FORD MOTOR CO.
  68. Remove the forward ring gear and forward ring gear hub as an assembly.
    Fig 70: Removing Forward Ring Gear And Forward Ring Gear Hub
    G01299791Courtesy of FORD MOTOR CO.
  69. Remove forward clutch thrust washer (No. 6B) from the forward ring gear hub.
    Fig 71: Removing Forward Clutch Thrust Washer (No. 6B)
    G01299792Courtesy of FORD MOTOR CO.
    70. NOTE: Check black oxidized side during removal to make sure of correct placement during reassembly. Black oxidized side must be toward planetary assembly. The uncoated side must face up.
    Fig 72: Removing Forward Planet Thrust Bearing (No. 7)
    G01299793Courtesy of FORD MOTOR CO.
  70. Remove the forward planet thrust bearing (No. 7).
  71. Remove the forward planetary assembly.
    Fig 73: Removing Forward Planetary Assembly
    G01299794Courtesy of FORD MOTOR CO.
  72. Remove input shell with the forward sun gear.
    Fig 74: Removing Input Shell With The Forward Sun Gear
    G01299795Courtesy of FORD MOTOR CO.
    73. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 8).
    Fig 75: Removing Low/Reverse Planetary Carrier Thrust Bearing (No. 8)
    G01299796Courtesy of FORD MOTOR CO.
  73. Remove the low/reverse planetary carrier thrust bearing (No. 8).
  74. Remove the low/reverse planetary retaining ring.
    Fig 76: Removing Low/Reverse Planetary Retaining Ring
    G01299797Courtesy of FORD MOTOR CO.
  75. Remove low/reverse planetary assembly.
    Fig 77: Removing Low/Reverse Planetary Assembly
    G01299798Courtesy of FORD MOTOR CO.
    76. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 9).
    Fig 78: Removing Low/Reverse Planetary Carrier Thrust Bearing (No. 9)
    G01299799Courtesy of FORD MOTOR CO.
  76. Remove the low/reverse planetary carrier thrust bearing (No. 9).
  77. Remove the output shaft sleeve.
    Fig 79: Removing Output Shaft Sleeve
    G01299800Courtesy of FORD MOTOR CO.
    78. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 80: Removing And Discarding Output Shaft Retaining Ring
    G01299801Courtesy of FORD MOTOR CO.
  78. Remove and discard the output shaft retaining ring.
  79. Remove the output shaft ring gear and the output shaft hub.
    Fig 81: Removing Output Shaft Ring Gear And Output Shaft Hub
    G01299802Courtesy of FORD MOTOR CO.
    80. NOTE: Tag and identify the output shaft hub thrust bearing (No. 10).
    Fig 82: Removing Output Shaft Thrust Bearing (No. 10)
    G01299803Courtesy of FORD MOTOR CO.
  80. Remove the output shaft thrust bearing (No. 10).
    81. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
    Fig 83: Removing Low/Reverse Brake Drum And One-Way Clutch Assembly
    G01299804Courtesy of FORD MOTOR CO.
  81. Remove the low/reverse brake drum and one-way clutch assembly.
  82. Remove the reverse band.
    Fig 84: Removing Reverse Band
    G01299805Courtesy of FORD MOTOR CO.
  83. Remove the output shaft.
    Fig 85: Removing Output Shaft
    G01299806Courtesy of FORD MOTOR CO.
  84. Remove the park gear.
    Fig 86: Removing Park Gear
    G01299807Courtesy of FORD MOTOR CO.
    85. NOTE: Tag and identify the output shaft thrust washer (No. 11).
    Fig 87: Removing Output Shaft Thrust Washer (No. 11)
    G01299808Courtesy of FORD MOTOR CO.
  85. Remove the output shaft thrust washer (No. 11).
    86. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.
    Fig 88: Removing Manual Control Valve Inner Lever Nut
    G01299809Courtesy of FORD MOTOR CO.
  86. Remove the manual control valve inner lever nut.
  87. Remove the manual control valve inner lever and the parking lever actuating rod.
    Fig 89: Removing Manual Control Valve Inner Lever And Parking Lever Actuating Rod
    G01299810Courtesy of FORD MOTOR CO.
    88. CAUTION: Do not damage the case fluid pan rail.
    Fig 90: Removing Manual Control Lever Shaft Spring Pin
    G01299811Courtesy of FORD MOTOR CO.
  88. Remove the manual control lever shaft spring pin.
    • Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
    • Pry the spring pin out of its bore.
  89. Remove the manual control lever shaft.
    Fig 91: Removing Manual Control Lever Shaft
    G01299812Courtesy of FORD MOTOR CO.
    90. CAUTION: Do not damage the bore.
    Fig 92: Removing Manual Control Lever Seal
    G01299813Courtesy of FORD MOTOR CO.
  90. Remove the manual control lever seal.
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