Automatic Transmission - Ax4S: Assembly: Transaxle

Fig 1: Identifying Special Tools (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 4)

Courtesy of FORD MOTOR CO.

Fig 3: Identifying Special Tools (3 Of 4)

Courtesy of FORD MOTOR CO.

Fig 4: Identifying Special Tools (4 Of 4)

Courtesy of FORD MOTOR CO.

NOTE: Place the transaxle in the horizontal position.

Fig 5: Installing Drive Sprocket Bearing

Courtesy of FORD MOTOR CO.

Using the special tools, install the drive sprocket bearing, if it was removed.

NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.

Fig 6: Installing Driven Sprocket Support

Courtesy of FORD MOTOR CO.

Install the driven sprocket support.
Install the bolts.

Fig 7: Identifying Tightening Torque Of Converter Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, install the converter impeller hub seal.

Fig 8: Installing Converter Impeller Hub Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install the right hand output shaft seal.

Fig 9: Installing Right Hand Output Shaft Seal
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 10: Installing Special Tool (307-187)
Courtesy of FORD MOTOR CO.
Rotate the transaxle to a vertical position.
Install the differential carrier thrust washers.
- Install the No. 18 differential carrier thrust washer.
- Install the No. 19 differential carrier thrust bearing and race.
  
  Fig 11: Installing Differential Carrier Thrust Washers
  Courtesy of FORD MOTOR CO.
Install the final drive ring gear.

Fig 12: Installing Final Drive Ring Gear
Courtesy of FORD MOTOR CO.
Install the final drive differential assembly and snap ring. Align the opening of the snap ring with the lube transfer tube passages.

Fig 13: Installing Final Drive Differential Assembly And Snap Ring
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 14: Installing Special Tool (100-002)
Courtesy of FORD MOTOR CO.
Using the special tools installed, carry out the end clearance check.
- Pry up on the bottom of the final drive assembly.
- Back out the screw on the End Plate Gauge until it no longer contacts the output shaft.
- Zero out the dial indicator.
- Tighten the screw on the bottom of the End Plate Gauge to 5 Nm (44 lb-in).
- Record the reading on the dial indicator.
- The clearance should be within specification; if it is not within specification a selective thrust washer is available. Refer to the No. 18 Selective Thrust Washer chart.
  
  Fig 15: Identifying No. 18 Selective Thrust Washers Specification Table (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 16: Identifying No. 18 Selective Thrust Washers Specification Table (2 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 17: Checking End Clearance
  Courtesy of FORD MOTOR CO.
Install the low and intermediate band. Align the anchor pin pocket with the anchor pin.

Fig 18: Installing Low And Intermediate Band
Courtesy of FORD MOTOR CO.
Install the No. 15 rear sun gear thrust bearing and race, and the rear sun gear and drum.

Fig 19: Installing Rear Sun Gear Thrust Bearing And Race, And Rear Sun Gear And Drum
Courtesy of FORD MOTOR CO.
Install the reverse clutch onto the planet assembly.

Fig 20: Installing Reverse Clutch Onto Planet Assembly
Courtesy of FORD MOTOR CO.
Assemble the special tools onto the planet assembly.

Fig 21: Assembling Special Tools Onto Planet Assembly
Courtesy of FORD MOTOR CO.
Using the special tools, install the planet and reverse clutch assembly.

Fig 22: Installing Planet And Reverse Clutch Assembly
Courtesy of FORD MOTOR CO.
Loosely install the reverse anchor pin and bolt.

Fig 23: Installing Reverse Anchor Pin And Bolt
Courtesy of FORD MOTOR CO.
Install the special tools onto the front sun and shell assembly.

Fig 24: Installing Special Tools Onto Front Sun And Shell Assembly
Courtesy of FORD MOTOR CO.
Install the front sun shell assembly.

Fig 25: Installing Front Sun Shell Assembly
Courtesy of FORD MOTOR CO.
Install the overdrive band.

Fig 26: Installing Overdrive Band
Courtesy of FORD MOTOR CO.
Install the plastic overdrive retainer.

Fig 27: Installing Plastic Overdrive Retainer
Courtesy of FORD MOTOR CO.
Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
1. Remove the No. 9 bearing and race.
2. Remove the No. 8 sprocket support.
  
  Fig 28: Removing Sprocket Thrust Washer And Bearing And Race From Driven Sprocket Support
  Courtesy of FORD MOTOR CO.
Install only the No. 9 needle bearing with the outer lip up.

Fig 29: Installing Needle Bearing With Outer Lip Up
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 30: Installing Special Tool (307-020)
Courtesy of FORD MOTOR CO.
Using the special tools, record the measurement. Take a measurement on both sides of the output shaft (180 degrees apart). Add both readings and divide by two to obtain reading A.

Fig 31: Measuring Output Shaft
Courtesy of FORD MOTOR CO.

NOTE: Reading A and dimension C from this chart will be used in the selection of the No. 5 thrust washer.

Fig 32: Selective Thrust Washer Chart

Courtesy of FORD MOTOR CO.

Use reading A to select the correct No. 8 thrust washer from the No. 8 selective thrust washer chart.
Remove the special tools.

Fig 33: Removing Special Tools (307-300)
Courtesy of FORD MOTOR CO.
Using the special tools, record the measurement. Take a measurement on both sides of the No. 5 thrust washer mating surface of the overdrive drum (180 degrees apart). Add both readings, and divide by two to obtain reading B.

Fig 34: Measuring Thrust Washer Mating Surface Of Overdrive Drum
Courtesy of FORD MOTOR CO.

NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.

Fig 35: Thrust Washer Selection Chart

Courtesy of FORD MOTOR CO.

Subtract reading A from reading B and add the difference between A and B to dimension C. Record this reading as D.
Use Reading D to select the correct No. 5 thrust washer.

Fig 36: Identifying No. 5 Support Thrust Washer Chart
Courtesy of FORD MOTOR CO.

NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.

Fig 37: Installing Front Support Thrust Washer

Courtesy of FORD MOTOR CO.

Install the No. 5 front support thrust washer.

CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure.

Use petroleum jelly to hold bearing and washer in place.
1. Install the correct No. 8 driven sprocket support thrust washer.
2. Install the No. 9 direct clutch needle bearing.
  
  Fig 38: Installing Direct Clutch Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 39: Removing Special Tools
Courtesy of FORD MOTOR CO.
Install the driven sprocket support assembly.

Fig 40: Installing Driven Sprocket Support Assembly
Courtesy of FORD MOTOR CO.
Install the park pawl abutment.
1. Install the parking pawl and the return spring.
2. Install the parking pawl shaft.
3. Install the park pawl abutment.
4. Install the bolts.
  
  Fig 41: Installing Park Pawl Abutment
  Courtesy of FORD MOTOR CO.
Install the parking lever actuating rod.

Fig 42: Installing Parking Lever Actuating Rod
Courtesy of FORD MOTOR CO.

NOTE: All the fluid supply tubes must have new O-rings installed.

Fig 43: Identifying Fluid Supply Tubes And Brackets

Courtesy of FORD MOTOR CO.

Install the fluid supply tubes and brackets.
Using the special tool, install the manual control lever shaft seal.

Fig 44: Installing Manual Control Lever Shaft Seal
Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever is pointing toward the driven sprocket support.

Install the manual control lever shaft.
1. Install the manual control lever shaft.
2. Install the manual valve detent lever.
3. Install the parking lever actuating rod.
4. Install the new roll pins.
  
  Fig 45: Identifying Manual Control Lever Shaft
  Courtesy of FORD MOTOR CO.

NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.

Install the thrust washers.
1. Install the No. 2 drive sprocket thrust washer.
2. Install the No. 4 driven sprocket thrust washer.
  
  Fig 46: Installing Thrust Washers
  Courtesy of FORD MOTOR CO.

CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent.

NOTE: Lower the assembly into the sprocket supports simultaneously.

Fig 47: Installing Drive Chain And Sprockets

Courtesy of FORD MOTOR CO.

Install the drive chain and sprockets as an assembly.
Install the shift accumulator springs.
1. Install the drive shift accumulator spring (green).
2. Install the 3-4 accumulator springs.
  - The outer spring is yellow.
  - The inner spring is white.
3. Install the 1-2 accumulator springs (no color).
  
  Fig 48: Installing Shift Accumulator Springs
  Courtesy of FORD MOTOR CO.
Install the new chain cover gasket.

Fig 49: Installing Chain Cover Gasket
Courtesy of FORD MOTOR CO.

CAUTION: Be extremely careful not to damage the cast iron sealing ring.

NOTE: Make sure that the alignment pins are installed in the case.

NOTE: Use petroleum jelly to hold thrust washers in place during assembly.

Fig 50: Installing Chain Cover With Thrust Washers

Courtesy of FORD MOTOR CO.

Install the chain cover with the No. 3 and No. 1 thrust washers installed.

NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.

Fig 51: Identifying Chain Cover Bolt

Courtesy of FORD MOTOR CO.

Start two bolts.
Tighten the bolts in the sequence shown.

Fig 52: Identifying Tightening Sequence Of Chain Cover Bolt
Courtesy of FORD MOTOR CO.
Using the special tool, install the seal.

Fig 53: Installing Seal
Courtesy of FORD MOTOR CO.
Install the bolts.

Fig 54: Identifying Tightening Torque Of Bolts
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Tighten the reverse clutch anchor bolt.
1. Tighten the anchor bolt.
2. Tighten the locknut.
  
  Fig 55: Identifying Tightening Torque Of Clutch Anchor Bolt
  Courtesy of FORD MOTOR CO.
Install the filter.

Fig 56: Installing Filter
Courtesy of FORD MOTOR CO.
Install the magnet.

Fig 57: Identifying Magnet
Courtesy of FORD MOTOR CO.

NOTE: The fluid pan gasket is reusable if not damaged.

Fig 58: Identifying Tightening Torque Of Fluid Pan Bolt

Courtesy of FORD MOTOR CO.

Install the fluid pan and gasket.

CAUTION: The test spring from the overdrive servo rod tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.

Inspect the spring height.
1. Test spring.
2. Original spring.
  
  Fig 59: Inspecting Spring Height
  Courtesy of FORD MOTOR CO.
Overdrive servo travel check. Install the overdrive servo piston.
- Using the special tool, install the overdrive servo piston.
  
  Fig 60: Installing Overdrive Servo Piston
  Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 61: Installing Special Tools (100-002)
Courtesy of FORD MOTOR CO.
Tighten the center screw and zero out the dial indicator.

Fig 62: Tightening Center Screw And Zero Out Dial Indicator
Courtesy of FORD MOTOR CO.
Back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, refer to the overdrive specification chart and determine which overdrive servo rod to use.

Fig 63: Reading Dial Indicator
Courtesy of FORD MOTOR CO.
If the overdrive servo travel was incorrect, install a new overdrive servo piston and rod assembly. Zero the dial indicator and repeat the above step to verify the amount of piston travel.
If within specification, remove the tool and test spring.

Fig 64: Overdrive Piston And Rod Assembly Selection Chart
Courtesy of FORD MOTOR CO.

a Grooves are at the tip.

CAUTION: The test spring from the low/intermediate servo is plain in color and has a thinner wire diameter than the original spring. Extreme care must be used not to assemble the transaxle using the test spring.

Install the low and intermediate servo spring retainer on the test spring. Install the test spring into the transaxle case.
1. Test spring.
2. Original spring.
  
  Fig 65: Identifying Test Spring And Transaxle Case
  Courtesy of FORD MOTOR CO.
Remove the servo piston small seal from the servo band piston and install the servo band piston and rod into the case.

Fig 66: Installing Servo Band Piston And Rod Into Case
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 67: Installing Special Tool (307-167)
Courtesy of FORD MOTOR CO.
Tighten the center screw.

Fig 68: Identifying Tightening Torque Of Center Screw
Courtesy of FORD MOTOR CO.
Install the special tool. Make sure that the indicator stylus has contacted the servo band piston on a flat surface not on the step of the band piston. Zero out the dial indicator.

Fig 69: Installing Special Tool (100-02)
Courtesy of FORD MOTOR CO.

NOTE: If a new low and intermediate band is installed, the reading should be within the specification.

Fig 70: Reading Dial Indicator Specifications

Courtesy of FORD MOTOR CO.

Back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, refer to the low/intermediate specification chart and determine which rod to use.
If the low/intermediate servo travel was incorrect install a new low/intermediate servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.

Fig 71: Overdrive Piston Rod Selection Chart
Courtesy of FORD MOTOR CO.

a Grooves are at the tip.

CAUTION: Do not assemble the overdrive servo using the test spring.

Install the overdrive servo.
1. Install the overdrive servo spring.
2. Install the overdrive servo.
3. Install the overdrive servo cover.
  
  Fig 72: Installing Overdrive Servo
  Courtesy of FORD MOTOR CO.
Install the bolts.

Fig 73: Identifying Tightening Torque Of Overdrive Servo Cover Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Do not assemble the low/intermediate servo using the test spring.

Install the low/intermediate servo.
1. Install the low/intermediate servo spring.
2. Install the low/intermediate servo.
3. Install the low/intermediate servo cover.
  
  Fig 74: Installing Low/Intermediate Servo
  Courtesy of FORD MOTOR CO.
Install the bolts.

Fig 75: Identifying Tightening Torque Of Low/Intermediate Servo Cover Bolts
Courtesy of FORD MOTOR CO.
Install the cover.

Fig 76: Installing Cover
Courtesy of FORD MOTOR CO.
Install the output shaft circlip.

Fig 77: Installing Output Shaft Circlip
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 78: Installing Special Tool (307-239)
Courtesy of FORD MOTOR CO.

WARNING: Wear safety glasses while carrying out this procedure to prevent personal injury.

NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies.

Fig 79: Item Test Port Table

Courtesy of FORD MOTOR CO.

Fig 80: Identifying Test Port

Courtesy of FORD MOTOR CO.

Apply air pressure to each of the appropriate ports. Remove the test plate after the test has been completed.

NOTE: Inspect the pump drive shaft in the area that the bearings ride. Install a new shaft and main control if worn.

Fig 81: Identifying Teflon® Seals And Inspect Shaft

Courtesy of FORD MOTOR CO.

Install new Teflon® seals and inspect the shaft.

NOTE: Make sure that the seals are installed correctly.

Fig 82: Identifying Pump Shaft Seals

Courtesy of FORD MOTOR CO.

Install four new seals on the pump shaft.
Install the pump shaft.

Fig 83: Identifying Pump Shaft
Courtesy of FORD MOTOR CO.
Install the manual valve detent lever.

Fig 84: Installing Manual Valve Detent Lever
Courtesy of FORD MOTOR CO.
Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.

Fig 85: Installing Main Control Valve Body
Courtesy of FORD MOTOR CO.
Install the bolts. Tighten in sequence from the center outward.

Fig 86: Identifying Tightening Sequence Of Main Control Valve Body Bolts
Courtesy of FORD MOTOR CO.
Connect the connectors.

Fig 87: Identifying Main Control Valve Body Connectors
Courtesy of FORD MOTOR CO.

NOTE: The main control cover gasket is reusable if not torn or damaged.

Fig 88: Identifying Tightening Torque Of Main Control Cover Bolt

Courtesy of FORD MOTOR CO.

Install the main control cover, gasket and bolts.
Install the lower fluid filler tube and grommet.

Fig 89: Identifying Lower Fluid Filler Tube And Grommet
Courtesy of FORD MOTOR CO.
Install the turbine shaft speed (TSS) sensor.

Fig 90: Identifying Turbine Shaft Speed Sensor
Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.

Fig 91: Installing Output Shaft Speed Sensor
Courtesy of FORD MOTOR CO.
Install the OSS cover and bolt and connect the connector to the filler tube.

Fig 92: Installing OSS Cover
Courtesy of FORD MOTOR CO.
Install the digital transmission range (TR) sensor. For additional information, refer to DIGITAL TRANSMISSION RANGE (TR) SENSOR .

NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.

Fig 93: Installing Torque Converter

Courtesy of FORD MOTOR CO.

Using the special tools, install the torque converter.