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Automatic Transmission - Cd4E: Assembly: Transaxle: Assembly

  1. Prepare the transaxle for assembly by proceeding with the following steps:
    • Clean all parts (except the friction plates, seals and intermediate/overdrive band) in solvent.
    • Dry all parts with moisture-free regulated compressed air (do not use shop towels).
    • Lubricate all internal parts (including friction plates) with clean automatic transmission fluid.
    • Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
      • Drive sprocket thrust washers
      • Driven sprocket thrust bearing shims
      • Differential case thrust bearing shims
      • Low/reverse clutch pressure plates
    • During assembly, use petroleum jelly to hold the parts in place (do not use grease).
    • Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
  2. Install intermediate and overdrive band assembly into the transaxle case.
    Fig 1: Locating Intermediate & Overdrive Band Assembly Into Transaxle Case
    G04620428Courtesy of FORD MOTOR CO.
    3. NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle. Lubricate the seal rings with clean automatic transmission fluid.
    Fig 2: Locating Pump Assembly Into Case
    G04620429Courtesy of FORD MOTOR CO.
  3. Install pump assembly into the case.
    4. NOTE: Tighten the bolts in the indicated sequence.
  4. Install the pump assembly bolts.
    • Tighten to 11 N.m (8 lb-ft)
      Fig 3: Identifying Tightening Sequence Of Pump Assembly Bolts
      G04620430Courtesy of FORD MOTOR CO.
  5. Using the special tools, install the low/reverse clutch piston.
    • Lubricate seals and piston bore with clean automatic transmission fluid.
      Fig 4: Installing Low/Reverse Clutch Piston Using Special Tools
      G04620431Courtesy of FORD MOTOR CO.
  6. Install the low/reverse clutch return spring assembly.
    Fig 5: Locating Low/Reverse Clutch Return Spring Assembly
    G04620432Courtesy of FORD MOTOR CO.
  7. Install the low/reverse clutch return spring retaining ring.
    Fig 6: Locating Low/Reverse Clutch Return Spring Retaining Ring
    G04620433Courtesy of FORD MOTOR CO.
    8. CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
    Fig 7: Identifying Low/Reverse Clutch Wave Spring
    G04620434Courtesy of FORD MOTOR CO.
  8. Install the low/reverse clutch wave spring.
  9. Install the low/reverse clutch plates.
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the thin 8-wave low/reverse clutch cushion spring.
    4. Install the low/reverse clutch pressure plate.
      Fig 8: Identifying Low/Reverse Clutch Plates
      G04620435Courtesy of FORD MOTOR CO.
  10. Install the special tool.
    Fig 9: Installing Special Tool
    G04620436Courtesy of FORD MOTOR CO.
  11. Measure the clearance between the low/reverse clutch pressure plate and the transmission end play gauge.
    • Take a second measurement on the opposite side.
    • Average the 2 measurements to get the clearance.
    • If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
    • Pressure plate sizes:
      • 2.57-2.46 mm (0.101-0.097 in).
      • 2.36-2.26 mm (0.092-0.089 in).
      • 2.16-2.06 mm (0.085-0.081 in).
        Fig 10: Locating Pressure Plate Sizes
        G04620437Courtesy of FORD MOTOR CO.
    12. NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.
  12. Remove the special tool, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring and the low/reverse clutch internal spline clutch plates (friction).
    1. Low/reverse clutch pressure plate
    2. Low/reverse clutch external spline clutch plates (steel)
    3. Low/reverse clutch wave spring
    4. Low/reverse clutch internal spline clutch plates (friction)
      Fig 11: Identifying Low/Reverse Clutch Pressure Plate, Low/Reverse Clutch External Spline Clutch Plates (Steel)
      G04620438Courtesy of FORD MOTOR CO.
  13. Install the No. 1 pump support thrust bearing assembly.
    Fig 12: Locating No. 1 Pump Support Thrust Bearing Assembly
    G04620439Courtesy of FORD MOTOR CO.
    14. NOTE: Remove the seal sizer from forward/coast/direct clutch cylinder.
    Fig 13: Locating Seal Sizer From Forward/Coast/Direct Clutch Cylinder
    G04620440Courtesy of FORD MOTOR CO.
  14. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
  15. Install the turbine shaft.
    Fig 14: Locating Turbine Shaft
    G04620441Courtesy of FORD MOTOR CO.
  16. Install the No. 4 turbine shaft thrust bearing.
    Fig 15: Locating No. 4 Turbine Shaft Thrust Bearing
    G04620442Courtesy of FORD MOTOR CO.
  17. Install the forward one-way clutch and low/intermediate sun gear assembly.
    Fig 16: Locating Forward One-Way Clutch & Low/Intermediate Sun Gear Assembly
    G04620443Courtesy of FORD MOTOR CO.
  18. Install the No. 5 low/intermediate sun gear thrust bearing.
    Fig 17: Locating No. 5 Low/Intermediate Sun Gear Thrust Bearing
    G04620444Courtesy of FORD MOTOR CO.
  19. Install the low/intermediate carrier assembly.
    Fig 18: Locating Low/Intermediate Carrier Assembly
    G04620445Courtesy of FORD MOTOR CO.
  20. Install the No. 6 low/intermediate carrier thrust bearing.
    Fig 19: Locating No. 6 Low/Intermediate Carrier Thrust Bearing
    G04620446Courtesy of FORD MOTOR CO.
  21. Install the low/intermediate ring gear assembly.
    Fig 20: Locating Low/Intermediate Ring Gear Assembly
    G04620447Courtesy of FORD MOTOR CO.
  22. Install the No. 7 reverse/overdrive sun gear thrust bearing.
    Fig 21: Locating No. 7 Reverse/Overdrive Sun Gear Thrust Bearing
    G04620448Courtesy of FORD MOTOR CO.
  23. Install the reverse/overdrive sun gear and shell assembly.
    Fig 22: Locating Reverse/Overdrive Sun Gear & Shell Assembly
    G04620449Courtesy of FORD MOTOR CO.
  24. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
    Fig 23: Locating Reverse/Overdrive Carrier Assembly With Captured No. 8 Thrust Bearing
    G04620450Courtesy of FORD MOTOR CO.
  25. Install the thick, 10-wave low/reverse clutch wave spring.
    Fig 24: Identifying Thick, 10-Wave Low/Reverse Clutch Wave Spring
    G04620451Courtesy of FORD MOTOR CO.
  26. Install the low/reverse clutch plates (model dependent).
    1. Install the low/reverse clutch external spline (steel) clutch plates.
    2. Install the low/reverse clutch internal spline (friction) clutch plates.
    3. Install the low/reverse clutch pressure plate previously selected.
      Fig 25: Identifying Low/Reverse Clutch Plates (Model Dependent)
      G04620452Courtesy of FORD MOTOR CO.
  27. Install the thin, 8-wave low/reverse clutch wave spring.
    Fig 26: Locating Thin, 8-Wave Low/Reverse Clutch Wave Spring
    G04620453Courtesy of FORD MOTOR CO.
  28. If equipped, install the low one-way clutch sprag-type assembly with the identification ring on the inner ring facing upward.
    Fig 27: Locating Identification Ring On Inner Ring Facing Upward
    G04620454Courtesy of FORD MOTOR CO.
  29. Install the low one-way clutch thrust plate.
    Fig 28: Locating Low One-Way Clutch Thrust Plate
    G04620455Courtesy of FORD MOTOR CO.
    30. NOTE: Do not use a thrust plate with the mechanical diode one-way clutch.
    Fig 29: Locating Mechanical Diode One-Way Clutch With Rubber Isolators
    G04620456Courtesy of FORD MOTOR CO.
  30. If equipped, install the mechanical diode one-way clutch with the rubber isolators in the positions indicated.
    31. NOTE: Make sure to position the low one-way clutch retaining ring as shown.
    Fig 30: Locating Low One-Way Clutch Retaining Ring
    G04620457Courtesy of FORD MOTOR CO.
  31. Install the low one-way clutch retaining ring.
  32. Install the manual valve detent lever actuating rod assembly.
    • Install the parking cam actuator lever.
      Fig 31: Locating Manual Valve Detent Lever Actuating Rod Assembly
      G04620458Courtesy of FORD MOTOR CO.
  33. Install the manual valve detent lever.
    Fig 32: Locating Manual Valve Detent Lever
    G04620459Courtesy of FORD MOTOR CO.
  34. Install the special tools.
    • Tighten to 13 N.m (10 lb-ft).
      Fig 33: Installing Special Tools
      G04620460Courtesy of FORD MOTOR CO.
  35. Install the special tool with short spacers.
    Fig 34: Installing Special Tool With Short Spacers
    G04620461Courtesy of FORD MOTOR CO.
  36. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
    • Record this as dimension A.
      Fig 35: Measuring Distance From Top Of Special Tool To No. 12 Driven Sprocket Bearing Surface Area
      G04620462Courtesy of FORD MOTOR CO.
  37. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
    • Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension B.
    • Remove the special tools.
      Fig 36: Measuring Distance From Top Of Special Tool To Bearing Surface On Reverse/Overdrive Carrier Assembly
      G04620463Courtesy of FORD MOTOR CO.
  38. Subtract dimension B from dimension A to get dimension C.
  39. Use dimension C to select the correct No. 11 driven sprocket shim.
    • Select a shim from the driven sprocket shim table.
    DRIVEN SPROCKET ALIGNMENT SHIM NO. 11

    Shim Size mm Inch
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim AB: 2.20-2.10 0.086-0.082
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim BB: 2.02-1.92 0.079-0.075
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim CB: 1.85-1.75 0.072-0.068
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim DB: 1.67-1.57 0.065-0.061
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim EB: 1.50-1.40 0.059-0.052
    Transaxle case to driven sprocket/final drive sun gear thrust bearing shim FB: 1.32-1.22 0.051-0.048
    Distance measured during gauging procedure and appropriate thrust bearing shim AB: 14.34-14.1 0.564-0.557
    Distance measured during gauging procedure and appropriate thrust bearing shim BB: 14.16-14.00 0.557-0.551
    Distance measured during gauging procedure and appropriate thrust bearing shim CB: 13.99-13.83 0.551-0.544
    Distance measured during gauging procedure and appropriate thrust bearing shim DB: 13.82-13.66 0.544-0.537
    Distance measured during gauging procedure and appropriate thrust bearing shim EB: 13.65-13.49 0.537-0.531
    Distance measured during gauging procedure and appropriate thrust bearing shim FB: 13.48-13.32 0.531-0.524
  40. Install and lubricate the following:
    1. Lubricate the needles and seals in the No. 18 driven sprocket bearing.
    2. Install the selected No. 11 driven sprocket shim.
    3. Install the No. 12 driven sprocket bearing.
      Fig 37: Identifying Needles & Seals In No. 18 Driven Sprocket Bearing
      G04620464Courtesy of FORD MOTOR CO.
  41. Install the No. 9 reverse/overdrive ring gear thrust bearing.
    Fig 38: Locating No. 9 Reverse/Overdrive Ring Gear Thrust Bearing
    G04620465Courtesy of FORD MOTOR CO.
    42. NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
    Fig 39: Locating Reverse/Overdrive Ring Gear Assembly
    G04620466Courtesy of FORD MOTOR CO.
  42. Install the reverse/overdrive ring gear assembly.
  43. Install the special tools.
    • Tighten to 13 N.m (10 lb-ft).
      Fig 40: Installing Special Tools
      G04620467Courtesy of FORD MOTOR CO.
  44. Install the special tool with short spacers.
    Fig 41: Installing Special Tool With Short Spacers
    G04620468Courtesy of FORD MOTOR CO.
  45. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension A.
    • Remove the special tools.
      Fig 42: Measuring Distance From Top Of Special Tool To Face Of Reverse/Overdrive Ring Gear Assembly Surface Area
      G04620469Courtesy of FORD MOTOR CO.
  46. Subtract 25.4 mm (1.00 in) thickness of special tool and the thickness of short spacers.
    • This is the dimension B.
  47. Subtract dimension A from dimension B.
    • This is dimension C.
  48. Select No. 10 thrust washer from the drive sprocket thrust washer table.
    • Use dimension C to select the No. 10 drive sprocket thrust washer.
    DRIVE SPROCKET THRUST WASHER SPECIFICATION

    No.10 Thrust Washer mm Inch
    Drive sprocket to converter housing thrust washer AA: 1.51-1.41 0.059-0.052
    Drive sprocket to converter housing thrust washer BA: 1.77-1.67 0.069-0.065
    Drive sprocket to converter housing thrust washer CA: 2.03-1.93 0.079-0.075
    Drive sprocket to converter housing thrust washer DA: 2.29-2.19 0.090-0.086
    Distance measured during gauging procedure and appropriate thrust washer AA: 1.12-0.86 0.044-0.033
    Distance measured during gauging procedure and appropriate thrust washer BA: 0.85-0.60 0.033-0.023
    Distance measured during gauging procedure and appropriate thrust washer CA: 0.59-0.34 0.023-0.013
    Distance measured during gauging procedure and appropriate thrust washer DA: 0.33-0.08 0.012-0.003
  49. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
    Fig 43: Locating No. 10 Drive Sprocket Thrust Washer On Torque Converter Housing
    G04620470Courtesy of FORD MOTOR CO.
  50. Remove the reverse/overdrive ring gear assembly.
    Fig 44: Locating Reverse/Overdrive Ring Gear Assembly
    G04620471Courtesy of FORD MOTOR CO.
  51. Install the filter and seal assembly.
    Fig 45: Locating Filter & Seal Assembly
    G04620472Courtesy of FORD MOTOR CO.
    52. NOTE: Refer to Fig 46 and Fig 47 for correct tool usage.
    Fig 46: Installing Special Tool In Filter Eyelet & Transaxle Hole (1 Of 2)
    G04620473Courtesy of FORD MOTOR CO.
  52. Install the special tool in the filter eyelet and transaxle hole.
    53. Fig 47: Installing Special Tool In Filter Eyelet & Transaxle Hole (2 Of 2)
    G04620474Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
    Fig 48: Installing Filter Recirculating Regulator Exhaust Seal
    G04620475Courtesy of FORD MOTOR CO.
  53. Using the special tool, install the filter recirculating regulator exhaust seal.
  54. Install the chain pan in the transaxle case.
    Fig 49: Installing Chain Pan In Transaxle Case
    G04620476Courtesy of FORD MOTOR CO.
  55. Assemble and install the drive chain assembly.
    1. Drive chain (copper colored link facing upward)
    2. Driven sprocket assembly
    3. Reverse/overdrive ring gear assembly
    • Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
      Fig 50: Identifying Drive Chain Assembly Components
      G04620477Courtesy of FORD MOTOR CO.
  56. Install the chain pan cover by snapping it into place.
    Fig 51: Locating Chain Pan Cover By Snapping
    G04620478Courtesy of FORD MOTOR CO.
  57. Install the No. 13 driven sprocket thrust bearing.
    Fig 52: Locating No. 13 Driven Sprocket Thrust Bearing
    G04620479Courtesy of FORD MOTOR CO.
    58. NOTE: The all wheel drive differential is shown. The front wheel drive differential may or may not have splines.
    Fig 53: Locating Final Drive Carrier And Differential Assembly
    G04620480Courtesy of FORD MOTOR CO.
  58. Install the final drive carrier and differential assembly.
    59. NOTE: Plastic washers should be placed between bolt heads and special tool.
  59. Install the special tools.
    1. Install the special tool.
    2. Install the special tool and bolts.
      • Tighten to 13 N.m (10 lb-ft).
        Fig 54: Installing Special Tools & Bolts
        G04620481Courtesy of FORD MOTOR CO.
  60. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
    • The special tools must be relocated to carry out the second measurement.
    • Repeat this measurement 180 degrees from the first measurement.
    • The average of these 2 dimensions is dimension B.
      Fig 55: Measuring Distance From Top Of Special Tool To Shim Surface Area Of Final Drive Carrier
      G04620482Courtesy of FORD MOTOR CO.
  61. Use combined thickness of the special tool with long spacers 177.8 mm (7.0 in) as dimension A.
  62. Subtract dimension B from dimension A. This is dimension C.
  63. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim table.
    No. 14 DIFFERENTIAL SHIM SPECIFICATION

    If dimension C is: Use No. 14 Differential Shim:
    130.76 to 130.46 mm (5.148 to 5.136 in.) 1.08 to 0.98 mm (0.042 to 0.038 in.)
    130.45 to 130.16 mm (5.136 to 5.124 in.) 1.38 to 1.28 mm (0.054 to 0.050 in.)
    130.15 to 129.87 mm (5.124 to 5.113 in.) 1.67 to 1.57 mm (0.065 to 0.061 in.)
    129.86 to 129.57 mm (5.113 to 5.101 in.) 1.97 to 1.87 mm (0.077 to 0.073 in.)
    129.56 to 129.27 mm (5.101 to 5.089 in.) 2.27 to 2.17 mm (0.089 to 0.085 in.)
  64. Install the differential bearing assembly
    1. Install the No. 14 differential bearing shim (selective fit).
    2. Install the No. 15 differential bearing.
      Fig 56: Identifying Differential Bearing Assembly
      G04620483Courtesy of FORD MOTOR CO.
    65. NOTE: Check for correct alignment of the lube tube on the converter housing.
  65. Install the torque converter housing onto the transaxle case.
    • Position and install the split flange gasket.
      Fig 57: Locating Split Flange Gasket
      G04620484Courtesy of FORD MOTOR CO.
    66. NOTE: Tighten the bolts in the indicated sequence.
  66. Install the torque converter housing-to-transaxle case bolts.
    • Tighten to 22 N.m (16 lb-ft).
      Fig 58: Identifying Tightening Sequence Of Torque Converter Housing-To-Transaxle Case Bolts
      G04620485Courtesy of FORD MOTOR CO.
    67. NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.
  67. Lubricate the assembly with clean transmission fluid.
    1. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
    2. Install the intermediate and overdrive servo apply rod and piston assembly.
    3. Install the overdrive servo apply rod spring.
      Fig 59: Identifying Intermediate & Overdrive Servo Return Spring Assembly Components
      G04620486Courtesy of FORD MOTOR CO.
  68. Install the special tool.
    Fig 60: Installing Special Tool
    G04620487Courtesy of FORD MOTOR CO.
    69. NOTE: Struts on the special tool fit into the servo cover retaining ring groove.
  69. Assemble the special tool.
    1. Install struts.
    2. Install bar.
    3. Install bolts.
    4. Install the center bolt.
      • Tighten to 4 N.m (35 lb-in).
        Fig 61: Assembling Special Tool Into Servo Cover Retaining Ring Groove
        G04620488Courtesy of FORD MOTOR CO.
  70. Using the special tool, measure the distance to the bar of special tool.
    • Record this as dimension A.
      Fig 62: Measuring Distance To Bar Of Special Tool
      G04620489Courtesy of FORD MOTOR CO.
  71. Back off the center bolt of special tool until the piston movement stops.
    Fig 63: Locating Center Bolt Of Special Tool
    G04620490Courtesy of FORD MOTOR CO.
  72. Using the special tool, measure the dimension to the bar of special tool record as dimension B.
    • Subtract dimension A from B to find the travel.
    • If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
    INTERMEDIATE/OVERDRIVE SERVO APPLY ROD

    Part Number Number of Rings Rod Length
    F3RP-7H188-CB 0 108.1 mm (4.25 in)
    F3RP-7H188-BB 1 107.1 mm (4.21 in)
    F3RP-7H188-AB 2 105.7 mm (4.16 in)
    Fig 64: Measuring Dimension To Bar Of Special Tool Record
    G04620491Courtesy of FORD MOTOR CO.
  73. Wipe the servo piston and the servo cover cap with a lint-free cloth.
    74. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.
  74. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attaches to the servo rod.
  75. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
  76. Inspect the servo retainer spring for cracks, breaks or deformation.
  77. Install the special tool.
    Fig 65: Installing Special Tool
    G04620492Courtesy of FORD MOTOR CO.
    78. CAUTION:
    1. If the case is stamped WG, install a wide-groove snap ring, or damage to the servo will result.
    2. Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.
    NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
  78. Tighten the special tool bolt.
    • Install the servo cover retaining ring, using retaining ring pliers.
      Fig 66: Tightening Special Tool Bolt
      G04620493Courtesy of FORD MOTOR CO.
  79. Loosen the special tool bolt.
    • When spring tension is released, remove the special tool.
      Fig 67: Locating Special Tool Bolt
      G04620494Courtesy of FORD MOTOR CO.
    80. CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.
    NOTE: If any leaks occur, make sure the special tool is correctly seated.
  80. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 276 kPa (40 psi) of moisture-free regulated compressed air.
    1. Reverse clutch test port
    2. Forward clutch test port
    3. Direct clutch test port
    4. Low/reverse clutch test port
    5. Servo release test port
    6. Servo apply test port
    7. Transmission air test plate
    • If air leakage is detected, disassemble the transaxle and locate source of leakage.
      Fig 68: Inspecting Hydraulic Circuits Using Special Tools
      G04620495Courtesy of FORD MOTOR CO.
  81. Install the thermostatic fluid level control valve.
    1. Position the thermostatic fluid level control valve.
    2. Install the bracket.
    3. Install the thermostatic fluid level control valve bracket bolt.
      • Tighten to 12 N.m (9 lb-ft).
        Fig 69: Identifying Thermostatic Fluid Level Control Valve Components
        G04620496Courtesy of FORD MOTOR CO.
    82. CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
    Fig 70: Locating Solenoid Body Electrical Connector O-Ring Seal
    G04620497Courtesy of FORD MOTOR CO.
  82. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
    83. CAUTION: Handle main control valve body with care to prevent manual valve damage.
  83. Connect the manual valve.
    1. Lift the main control away from the case.
    2. Connect the Z-link to the manual valve.
      Fig 71: Locating Z-Link To Manual Valve
      G04620498Courtesy of FORD MOTOR CO.
    84. NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.
  84. Install the main control valve body mounting bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 72: Identifying Tightening Sequence Of Main Control Valve Body Bolts
      G04620499Courtesy of FORD MOTOR CO.
  85. Install the manual control lever.
    • Tighten to 27 N.m (20 lb-ft).
      Fig 73: Locating Manual Control Lever
      G04620500Courtesy of FORD MOTOR CO.
  86. Rotate the manual valve detent lever assembly to the NEUTRAL position.
    1. Low 1
    2. Low 2
    3. Drive
    4. Neutral
    5. Reverse
    6. Park
      Fig 74: Identifying Manual Valve Detent Lever Assembly
      G04620501Courtesy of FORD MOTOR CO.
  87. Position the transmission range (TR) sensor.
    Fig 75: Locating Transmission Range (TR) Sensor
    G04620502Courtesy of FORD MOTOR CO.
  88. Using the special tool, align the TR sensor and tighten the bolts.
    • Tighten to 11 N.m (8 lb-ft).
      Fig 76: Aligning TR Sensor Using Special Tools
      G04620503Courtesy of FORD MOTOR CO.
    89. NOTE: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary.
  89. Install the main control cover gasket.
    90. NOTE:
    1. Tighten the bolts and studs in the indicated sequence.
    2. The cooler bypass valve studs are in locations 3 and 11.
  90. Install the main control valve body cover and bolts.
    • Tighten to 13 N.m (10 lb-ft).
      Fig 77: Identifying Tightening Sequence Of Main Control Valve Body Cover & Bolts
      G04620504Courtesy of FORD MOTOR CO.
  91. Install the vent tube.
    Fig 78: Locating Vent Tube
    G04620505Courtesy of FORD MOTOR CO.
  92. Install a new transmission filler tube grommet.
    Fig 79: Locating Transmission Filler Tube Grommet
    G04620506Courtesy of FORD MOTOR CO.
  93. Install the transmission filler tube assembly.
    1. Install the tube.
    2. Install the transmission filler tube bolt.
      • Tighten to 8 N.m (71 lb-in).
      • Install the fluid level indicator.
        Fig 80: Identifying Transmission Filler Tube Assembly
        G04620507Courtesy of FORD MOTOR CO.
  94. Install a new O-ring seal on the turbine shaft speed (TSS) sensor and install the sensor.
    1. Using petroleum jelly on the O-ring seal, position the TSS sensor into the case.
    2. Install the TSS sensor bolt.
      • Tighten to 12 N.m (9 lb-ft).
        Fig 81: Installing TSS Sensor Bolt
        G04620508Courtesy of FORD MOTOR CO.
  95. Using the special tool, install the LH differential seal.
    Fig 82: Installing LH Differential Seal Using Special Tools
    G04620509Courtesy of FORD MOTOR CO.
  96. If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal.
    Fig 83: Installing RH Differential Seal Using Special Tools
    G04620510Courtesy of FORD MOTOR CO.
  97. If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal.
    Fig 84: Installing RH Differential Seal Using Special Tools
    G04620511Courtesy of FORD MOTOR CO.
    98. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
  98. Using the special tool, install the torque converter fluid seal.
    • Coat the torque converter seal garter spring with petroleum jelly.
      Fig 85: Installing Torque Converter Fluid Seal Using Special Tools
      G04620512Courtesy of FORD MOTOR CO.
  99. Using a small amount of pipe sealant on the threads, install the transaxle drain plug.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 86: Identifying Transaxle Drain Plug
      G03900626Courtesy of FORD MOTOR CO.
    100. NOTE: Check for correct rotation of the pump driveshaft.
    Fig 87: Locating Pump Assembly Driveshaft
    G04620514Courtesy of FORD MOTOR CO.
  100. Install the pump driveshaft.
  101. Using the special tool, install the torque converter.
    Fig 88: Installing Torque Converter Using Special Tools
    G04620515Courtesy of FORD MOTOR CO.
    102. NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.
  102. Check the installation depth of the torque converter.
    1. Lay a straightedge on the transaxle converter housing.
    2. Check the clearance between the straightedge and the pilot hub.
      • Clearance is 17 mm (0.66 in).
        Fig 89: Locating Installation Depth Of Torque Converter
        G04620516Courtesy of FORD MOTOR CO.
  103. Remove the transaxle from the special tool.
    Fig 90: Removing Transaxle From Special Tool
    G04620517Courtesy of FORD MOTOR CO.
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