Automatic Transmission - 4F50N: Assembly: Transaxle

Fig 1: Identifying Special Tool s (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 4)

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Fig 3: Identifying Special Tools (3 Of 4)

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Fig 4: Identifying Special Tools (4 Of 4)

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1. Install the parking pawl assembly.
   1. Install the parking pawl and return spring.
   2. Install the parking pawl shaft.
      Fig 5: Installing Parking Pawl Shaft

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2. Install the park pawl roll pin.
   Fig 6: Installing Park Pawl Roll Pin

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3. Using the special tool, install the cup plug.
   Fig 7: Identifying Cup Plug

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4. Using the special tools, install the new drive sprocket bearing, if it was removed.
   Fig 8: Installing Drive Sprocket Bearing

   Courtesy of FORD MOTOR CO.
NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.
Fig 9: Installing Driven Sprocket Support
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5. Install the driven sprocket support.
6. Install the bolts.
   Fig 10: Installing Converter Impeller Bolts

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7. Using the special tool, install the converter impeller hub seal.
   Fig 11: Installing Converter Impeller Hub Seal

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8. Install the differential carrier thrust bearing.
   1. Install the differential carrier thrust washer.
   2. Install the differential carrier thrust bearing and race (tabs down).
      Fig 12: Installing Differential Carrier Thrust Bearing

      Courtesy of FORD MOTOR CO.
9. Install the final drive ring gear.
   Fig 13: Installing Final Drive Ring Gear

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10. Install the rear planet support spacer.
    Fig 14: Installing Rear Planet Support Spacer

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11. Install the final drive differential assembly.
    Fig 15: Installing Final Drive Differential Assembly

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12. Align the rear lube tube holes in the case window.
    Fig 16: Aligning Rear Lube Tube Holes In Case Window

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NOTE: The retaining ring must be correctly installed.
Fig 17: Installing Beveled Retaining Ring (1 Of 2)
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Fig 18: Installing Beveled Retaining Ring (2 Of 2)
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13. Using the special tool install the beveled retaining ring.
CAUTION: If support is not visible on inside diameter of the retaining ring the low/intermediate piston could be damaged.
Fig 19: Identifying Beveled Retaining Ring Seats Correctly In Case Groove
Courtesy of FORD MOTOR CO.
14. Make sure that the beveled retaining ring seats correctly in case groove with the bevel down and final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall.
15. Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove.
    Fig 20: Identifying Retaining Ring Is Fully Seated In Top Of Case Groove

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16. Install the special tools.
    Fig 21: Installing Special Tools (307-187)

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17. Remove the No. 15 needle bearing.
    Fig 22: Removing Needle Bearing

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NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.
Fig 23: Installing Special Tools (307-300)
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18. Install the special tools.
19. Install the special tools and zero the dial indicator.
    Fig 24: Installing Special Tools (100-002) And Zero Dial Indicator

    Courtesy of FORD MOTOR CO.
20. Tighten the bolt.
    Fig 25: Tightening Bolt

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21. Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification the next larger beveled ring retainer will need to be used.
    Fig 26: Reading Dial Indicator Reading

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22. Select the correct beveled retaining ring.
    Fig 27: Beveled Retaining Ring Specification (1 Of 2)

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    Fig 28: Identifying Beveled Retaining Ring

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer.
Fig 29: Installing Thrust Bearing
Courtesy of FORD MOTOR CO.
23. Install the No. 15 thrust bearing.
24. Check the clearance for the No. 16 thrust washer. Mount the Dial Indicator with the stylus on the end of the output shaft. Zero the dial indicator.
    Fig 30: Setting Zero Dial Indicator

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25. Tighten the bolt. Read and record the dial indicator reading.
    Fig 31: Tightening Bolt

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NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.
Fig 32: Thrust Race (Washer) Specification
Courtesy of FORD MOTOR CO.
Fig 33: Reading Thrust Race (Washer)
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26. If the clearance is not within specification a thicker or thinner washer will need to be added.
27. Install the low-intermediate one-way clutch assembly.
    Fig 34: Installing Low-Intermediate One-Way Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The friction plate internal splines will center the one-way clutch.
28. Install the low-intermediate clutch pressure plate.
    1. Install the low-intermediate clutch wave spring.
    2. Install the low-intermediate clutch pack.
    3. Install the low-intermediate clutch pressure plate.
       Fig 35: Installing Low-Intermediate Clutch Pressure Plate

       Courtesy of FORD MOTOR CO.
CAUTION: Make sure that the retaining ring is seated in the case groove.
Fig 36: Installing Low-Intermediate Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
29. Install the low-intermediate clutch retaining ring.
WARNING: To prevent injury, wear eye protection when using pressurized air.
NOTE: Be sure the pressurized air is dry and regulated at 276 kPa (40 psi).
Fig 37: Applying Regulated Air Pressure To Low-Intermediate Apply Port
Courtesy of FORD MOTOR CO.
30. Apply regulated air pressure to the low-intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal.
31. Measure the clearance between the clutch pressure plate and the low- intermediate clutch retainer. If the clearance is not within specification a thicker or thinner retainer may be needed.
    Fig 38: Selective Retaining Rings Specification

    Courtesy of FORD MOTOR CO.
    Fig 39: Measuring Clearance Between Clutch Pressure Plate And Low- Intermediate Clutch Retainer

    Courtesy of FORD MOTOR CO.
32. Install the coast band.
    1. Install the coast band.
    2. Align the anchor pin pocket with the anchor pin in the case.
       Fig 40: Installing Coast Band

       Courtesy of FORD MOTOR CO.
33. Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.
    Fig 41: Installing Low-Intermediate Drum

    Courtesy of FORD MOTOR CO.
34. Install the park rod abutment and make sure that the park pawl moves freely.
    Fig 42: Installing Park Rod Abutment

    Courtesy of FORD MOTOR CO.
35. Install the coast band piston cover.
    1. Install the coast band servo piston spring.
    2. Install the coast band servo piston.
    3. Install the coast band servo piston cover.
       Fig 43: Installing Coast Band Piston Cover

       Courtesy of FORD MOTOR CO.
36. Using the special tool, install the coast servo cover retaining ring.
    Fig 44: Installing Coast Servo Cover Retaining Ring

    Courtesy of FORD MOTOR CO.
37. Using the special tools, install the front planetary/reverse clutch assembly.
    Fig 45: Installing Front Planetary/Reverse Clutch Assembly

    Courtesy of FORD MOTOR CO.
38. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.
    Fig 46: Aligning Reverse Clutch Cylinder Apply Tube Hole With Case Hole

    Courtesy of FORD MOTOR CO.
39. Loosely install the reverse clutch anchor pin.
    Fig 47: Installing Reverse Clutch Anchor Pin

    Courtesy of FORD MOTOR CO.
40. Using the special tool install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.
    Fig 48: Installing Forward/Intermediate Clutch Assembly

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41. Install the overdrive band.
    Fig 49: Installing Overdrive Band

    Courtesy of FORD MOTOR CO.
NOTE: The foot of the overdrive retainer goes down against the band.
Fig 50: Installing Overdrive Band Anchor Strut With Cross Hairs Facing Up
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42. Install the overdrive band anchor strut with the cross hairs facing up.
43. 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 51: Removing Sprocket Thrust Washer And Bearing And Race From Driven Sprocket Support

       Courtesy of FORD MOTOR CO.
44. Install only the No. 9 needle bearing with the outer lip up.
    Fig 52: Installing Needle Bearing With Outer Lip Up

    Courtesy of FORD MOTOR CO.
45. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.
    Fig 53: Installing Special Tool Over Output Shaft

    Courtesy of FORD MOTOR CO.
46. Install the special tool to make the measurements.
    Fig 54: Installing Special Tool (307-300) To Make Measurements

    Courtesy of FORD MOTOR CO.
47. When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by two to obtain reading A.
    Fig 55: Recording Readings On Both Sides Of Output Shaft

    Courtesy of FORD MOTOR CO.
NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.
Fig 56: No. 8 Thrust Washer Selection Chart
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48. Use the reading A to select the correct No. 8 thrust washer from the chart.
49. Remove the special tools.
    Fig 57: Removing Special Tools (307-320)

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50. Install the special tools to make the measurements.
    Fig 58: Installing Special Tools (307-300) To Make Measurements

    Courtesy of FORD MOTOR CO.
51. Measure down to the No. 5 thrust washer mating surface of the overdrive drum. Take another reading on the other side of the drum 180 degrees from the first one. Add both readings and divide by two to obtain reading B.
    Fig 59: Measuring Thrust Washer Mating Surface Of Overdrive Drum

    Courtesy of FORD MOTOR CO.
52. Remove the special tools.
    Fig 60: Removing Special Tools (307-300)

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NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
Fig 61: Thrust Washer Selection Chart
Courtesy of FORD MOTOR CO.
53. Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D.
54. Use Reading D to select the correct No. 5 thrust washer.
    Fig 62: 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 63: Installing Front Support Thrust Washer
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55. 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.
56. Install the correct bearing.
    1. Install the correct No. 8 driven sprocket support thrust washer.
    2. Install the No. 9 direct clutch needle bearing.
       Fig 64: Installing Driven Sprocket Support Thrust Washer And Direct Clutch Needle Bearing

       Courtesy of FORD MOTOR CO.
57. Install the driven sprocket support assembly.
    Fig 65: Installing Driven Sprocket Support Assembly

    Courtesy of FORD MOTOR CO.
58. Install the neutral/drive accumulator cover.
    1. Install the neutral/drive accumulator piston.
    2. Install the neutral/drive accumulator spring.
       • The outer spring is yellow in color.
       • The inner spring is grey in color.
    3. Install the neutral/drive accumulator cover.
       Fig 66: Installing Neutral/Drive Accumulator Cover

       Courtesy of FORD MOTOR CO.
59. Install the bolt.
    Fig 67: Installing Neutral/Drive Accumulator Cover Bolt

    Courtesy of FORD MOTOR CO.
NOTE: All the fluid supply tubes must have new O-rings installed.
Fig 68: Installing Fluid Supply Tubes
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60. Install the fluid supply tubes.
61. Install the brackets.
    Fig 69: Installing Brackets

    Courtesy of FORD MOTOR CO.
62. Using the special tool, install the manual control lever shaft seal.
    Fig 70: Installing Manual Control Lever Shaft Seal

    Courtesy of FORD MOTOR CO.
63. Install the parking lever actuating rod.
    • Push in on the park pawl.
    • Slide down the parking lever actuating rod to fit in the park pawl.
      Fig 71: Installing Parking Lever Actuating Rod

      Courtesy of FORD MOTOR CO.
NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.
Fig 72: Installing Manual Control Lever Shaft
Courtesy of FORD MOTOR CO.
64. Install the manual control lever shaft.
NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.
Fig 73: Installing Roll Pins
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65. Install the roll pins.
NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
66. Install the thrust washers.
    1. Install the No. 2 drive sprocket thrust washer.
    2. Install the No. 4 driven sprocket thrust washer.
       Fig 74: 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 75: Installing Drive Chain And Sprockets
Courtesy of FORD MOTOR CO.
67. Install the drive chain and sprockets.
68. Install the shift accumulator springs.
    1. Install the 1-2 accumulator outer spring (no color or pink).
    2. Install the 2-3 accumulator piston spring (orange).
    3. Install the reverse shift accumulator spring.
    4. Install the 3-4 accumulator spring (blue).
       Fig 76: Installing Shift Accumulator Springs

       Courtesy of FORD MOTOR CO.
NOTE: Make sure that the alignment pins are installed in case.
Fig 77: Installing Chain Cover Gasket
Courtesy of FORD MOTOR CO.
69. Install the new chain cover gasket.
CAUTION: Be extremely careful not to damage the cast iron sealing ring.
70. Use petroleum jelly to hold thrust washers in place during assembly.
    1. Install the No. 1 thrust washer.
    2. Install the No. 2 thrust washer.
    3. Install the chain cover.
       Fig 78: Installing Chain Cover

       Courtesy of FORD MOTOR CO.
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 79: Installing Chain Cover Bolt
Courtesy of FORD MOTOR CO.
71. Start two bolts.
72. Install the remaining bolts.
    Fig 80: Installing Chain Cover Remaining Bolts

    Courtesy of FORD MOTOR CO.
73. Install the bolts.
    Fig 81: Installing Bolts

    Courtesy of FORD MOTOR CO.
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.
74. Inspect the spring height.
    1. Test spring.
    2. Original spring.
       Fig 82: Inspecting Spring Height

       Courtesy of FORD MOTOR CO.
75. Overdrive servo travel check. Install the overdrive servo piston.
    1. Install the test spring.
    2. Install the overdrive servo piston.
       Fig 83: Installing Overdrive Servo Piston

       Courtesy of FORD MOTOR CO.
76. Install the special tools.
    Fig 84: Installing Special Tools (307-162)

    Courtesy of FORD MOTOR CO.
77. Using the special tools, tighten the center screw and zero out the dial indicator.
    Fig 85: Tightening Center Screw And Zero Out Dial Indicator

    Courtesy of FORD MOTOR CO.
78. Using the special tools, 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, see the overdrive specification chart and determine which overdrive servo rod to use.
    Fig 86: Reading Dial Indicator

    Courtesy of FORD MOTOR CO.
79. If the overdrive servo travel was incorrect, install a new overdrive 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 87: Overdrive Piston Rod Selection Chart

    Courtesy of FORD MOTOR CO.
CAUTION: Do not assemble the transaxle using the test spring.
80. Install the overdrive servo.
    1. Install the overdrive servo spring.
    2. Install the overdrive servo.
    3. Install the overdrive servo cover and bolts.
       Fig 88: Installing Overdrive Servo

       Courtesy of FORD MOTOR CO.
81. Install the transmission test plate.
    Fig 89: Installing Transmission Test Plate

    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.
NOTE: Plugging the vent hole during the test will provide an inaccurate result.
Fig 90: Transmission Test Plate Part Description
Courtesy of FORD MOTOR CO.
Fig 91: Identifying Transmission Test Plate Parts
Courtesy of FORD MOTOR CO.
82. Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate clutch ports.
CAUTION: The seals must be lapped correctly or internal leakage will occur.
Fig 92: Installing Teflon® Seals On Pump Shaft
Courtesy of FORD MOTOR CO.
83. Install the new Teflon® seals on the pump shaft.
84. Install the pump shaft.
    Fig 93: Installing Pump Shaft

    Courtesy of FORD MOTOR CO.
85. Install the manual valve detent lever.
    Fig 94: Installing Manual Valve Detent Lever

    Courtesy of FORD MOTOR CO.
86. 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 95: Installing Main Control Valve Body Over Pump Shaft

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.
Fig 96: Identifying Tightening Sequence Of Pump Assembly Bolt
Courtesy of FORD MOTOR CO.
87. Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolt and tighten in sequence.
88. Connect the connectors.
    Fig 97: Connecting Pump Assembly Connectors

    Courtesy of FORD MOTOR CO.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 98: Inspecting Gasket
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89. Clean and inspect the gasket.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 99: Installing Main Control Cover Gasket Onto Pan
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90. Install the main control cover gasket onto the pan.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 100: Installing Main Control Cover
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91. Install the main control cover.
NOTE: The transaxle side cover gasket is reusable if not torn or ripped.
Fig 101: Inspecting Gasket
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92. For vehicles equipped with a structural side pan, remove the gasket. Clean and inspect the gasket, reinstall into the pan.
93. For vehicles equipped with a structural side pan, install the pan.
    Fig 102: Installing Pan Bolts

    Courtesy of FORD MOTOR CO.
94. For vehicles equipped with a structural side pan, install the mount.
    Fig 103: Fastener Tightening Torque Specifications Table Of Mount Bolt

    Courtesy of FORD MOTOR CO.
95. Tighten the reverse clutch anchor bolt.
    1. Tighten the anchor bolt.
    2. Tighten the locknut.
       Fig 104: Fastener Tightening Torque Specifications Table Of Reverse Clutch Anchor Bolt

       Courtesy of FORD MOTOR CO.
96. Install the new seal and gasket kit and seal assembly.
    Fig 105: Installing Seal And Gasket Kit And Seal Assembly

    Courtesy of FORD MOTOR CO.
97. Install the fluid pan magnet.
    Fig 106: Installing Fluid Pan Magnet

    Courtesy of FORD MOTOR CO.
NOTE: The gasket is reusable if not damaged or torn.
Fig 107: Installing Transmission Fluid Pan And Gasket
Courtesy of FORD MOTOR CO.
98. Install the transmission fluid pan and gasket.
99. Install the turbine shaft speed (TSS) sensor.
    1. Install the sensor.
    2. Install the bolt.
       Fig 108: Installing Turbine Shaft Speed Sensor

       Courtesy of FORD MOTOR CO.
NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.
100. Verify that the shift selector lever is in NEUTRAL.
101. Install the digital TR sensor and loosely install the bolts.
     Fig 109: Installing Digital TR Sensor

     Courtesy of FORD MOTOR CO.
102. Using the special tool, align the digital TR sensor and tighten the bolts.
     Fig 110: Aligning Digital TR Sensor

     Courtesy of FORD MOTOR CO.
103. Install the fluid filler tube with a new grommet.
     1. Install the grommet.
     2. Install the fluid filler tube.
     3. Tighten the bolt.
        Fig 111: Installing Fluid Filler Tube

        Courtesy of FORD MOTOR CO.
104. Using the special tool install the LH output shaft seal.
     Fig 112: Installing LH Output Shaft Seal

     Courtesy of FORD MOTOR CO.
105. Using the special tool install the RH output shaft seal.
     Fig 113: Installing RH Output Shaft Seal

     Courtesy of FORD MOTOR CO.
106. Install the output shaft speed (OSS) sensor and reconnect the harness.
     Fig 114: Installing Output Shaft Speed Sensor

     Courtesy of FORD MOTOR CO.
107. Install the output shaft speed (OSS) sensor cover.
     1. Install the OSS cover.
     2. Install the bolt.
     3. Connect the connector to the bracket.
        Fig 115: Installing Output Shaft Speed Sensor Cover

        Courtesy of FORD MOTOR CO.
108. Install the identification tag, if removed.
     Fig 116: Installing Identification Tag

     Courtesy of FORD MOTOR CO.
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 117: Locating Orange Dot
Courtesy of FORD MOTOR CO.
109. Using the special tools, install the torque converter.