Automatic Transmission: Disassembly: Transmission

Special Tools

Illustration	Tool Name	Tool Number
	Slide Hammer	100-001 (T50T-100-A)
	Holding Fixture, Transmission	307-003 (T57L-500-B)
	Slide Hammer	307-005 (T59L-100-B)
	Remover, Transmission Fluid Seal	307-048 (T74P-77248-A)
	Handle, Torque Converter	307-091 (T81P-7902-C)
	Remover, Transmission Fluid Pump	307-221 (T89T-70010-A)
	Remover/Installer, Servo Piston	307-251 (T92P-70023-A)
	Remover, Torque Converter Fluid Seal	307-309 (T94P-77001-BH)
	Remover, Bearing Cup	308-047 (T77F-1102-A)

1. Using the special tools, remove the torque converter.
2. Using the special tool, mount the transmission to the bench.
Fig 1: Mounting Transmission To Bench
Courtesy of FORD MOTOR CO.
NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
3. Remove the bolts, transmission fluid pan and transmission fluid pan-to-case gasket.
Fig 2: Locating Transmission Fluid Pan Bolts
Courtesy of FORD MOTOR CO.
4. Clean the transmission fluid pan and pan magnet.
Fig 3: Locating Pan Magnet In Transmission Fluid Pan
Courtesy of FORD MOTOR CO.
CAUTION: If installing a new filter and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
5. Remove the fluid filter and grommet.
Fig 4: Removing Transmission Fluid Filter And Grommet
Courtesy of FORD MOTOR CO.
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
6. Disconnect the molded lead frame from the solenoids.
   1. Disconnect the shift solenoid SSA and SSB.
   2. Disconnect the torque converter clutch (TCC).
   3. Disconnect the electronic pressure control (EPC) solenoid.
   4. Disconnect the bulkhead interconnector.
Fig 5: Identifying Molded Lead Frame And Solenoids
Courtesy of FORD MOTOR CO.
7. Remove the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
   1. Remove the OSS sensor bolt.
   2. Remove the OSS sensor.
   3. Remove the TSS sensor bolt.
   4. Remove the TSS sensor.
Fig 6: Identifying OSS And TSS Sensor & Bolts
Courtesy of FORD MOTOR CO.
8. Remove the digital transmission range (TR) sensor.
   1. Remove the bolts.
   2. Remove the digital TR sensor.
Fig 7: Identifying Digital TR Sensor Bolts
Courtesy of FORD MOTOR CO.
9. Remove the manual control valve detent lever spring.
   • Remove the bolt.
Fig 8: Removing Manual Control Valve Detent Lever Spring Bolts
Courtesy of FORD MOTOR CO.
10. Remove the 24 main control valve body bolts and the main control valve body.
Fig 9: Locating 24 Valve Body-To-Case Bolts And EPC Bracket Bolt
Courtesy of FORD MOTOR CO.
11. Remove and discard the pump outlet screen.
Fig 10: Identifying Pump Outlet Screen
Courtesy of FORD MOTOR CO.
NOTE: Use a shop cloth to protect the transmission case surface.
12. Remove the manual lever shaft retaining pin.
Fig 11: Removing Manual Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
13. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
Fig 12: Removing Manual Control Lever Shaft
Courtesy of FORD MOTOR CO.
14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
Fig 13: Identifying Parking Lever Actuating Rod
Courtesy of FORD MOTOR CO.
CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged, the new seal may leak.
15. Remove the manual control lever shaft seal.
Fig 14: Locating Manual Control Lever Shaft Seal
Courtesy of FORD MOTOR CO.
16. Remove the EPC solenoid.
Fig 15: Locating EPC Solenoid
Courtesy of FORD MOTOR CO.
17. Remove the 2-3 accumulator spring retainer.
Fig 16: Locating 2-3 Accumulator Spring Retainer
Courtesy of FORD MOTOR CO.
18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
Fig 17: Identifying 2-3 Accumulator Piston & Spring
Courtesy of FORD MOTOR CO.
19. Using the special tool, remove the reverse band servo retaining ring.
Fig 18: Removing Reverse Band Servo Retaining Ring Using Special Tool
Courtesy of FORD MOTOR CO.
20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
Fig 19: Identifying Reverse Band Servo Piston And Rod
Courtesy of FORD MOTOR CO.
NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
Fig 20: Removing Overdrive Servo Piston Retainer
Courtesy of FORD MOTOR CO.
22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
Fig 21: Removing Overdrive Servo Piston Return Spring
Courtesy of FORD MOTOR CO.
23. Compress the 1-2 accumulator cover and remove the retaining ring.
Fig 22: Locating Accumulator Piston Retaining Ring
Courtesy of FORD MOTOR CO.
24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the inner and outer lower 1-2 accumulator spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
Fig 23: Identifying 1-2 Accumulator Upper Spring
Courtesy of FORD MOTOR CO.
25. Using the special tools, remove the extension housing seal.
Fig 24: Removing Extension Housing Seal
Courtesy of FORD MOTOR CO.
NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
26. Remove the extension housing.
    1. Remove the 4 bolts and 2 nuts.
    2. Remove the extension housing and the extension housing gasket.
Fig 25: Removing Extension Housing And Extension Housing Gasket
Courtesy of FORD MOTOR CO.
27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
Fig 26: Identifying Parking Pawl Return Spring
Courtesy of FORD MOTOR CO.
28. Rotate the transmission to the vertical position with the output shaft toward the floor.
CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
Fig 27: Locating Connector
Courtesy of FORD MOTOR CO.
30. Using the special tools, remove the front pump seal.
Fig 28: Removing Front Pump Seal Using Special Tools
Courtesy of FORD MOTOR CO.
NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
31. Remove the bolts.
Fig 29: Locating Front Pump Bolts
Courtesy of FORD MOTOR CO.
32. Using the special tools, remove the front pump support.
Fig 30: Removing Front Pump Support
Courtesy of FORD MOTOR CO.
33. Remove and discard the pump gasket.

NOTE: For assembly, note the location of the check ball and the intermediate clutch piston return spring pack indent during disassembly.
34. Remove the intermediate clutch piston return spring pack.
Fig 31: Locating Intermediate Clutch Piston Return Spring Pack
Courtesy of FORD MOTOR CO.
35. Remove the intermediate anti-rattle clip, if equipped.
Fig 32: Identifying Intermediate Clutch Anti-Rattle Clip
Courtesy of FORD MOTOR CO.
CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
36. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
Fig 33: Removing Clutch Assembly
Courtesy of FORD MOTOR CO.
37. Disengage and remove the overdrive band.
Fig 34: Locating Overdrive Band
Courtesy of FORD MOTOR CO.
38. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
Fig 35: Locating Forward Clutch Hub & No. 3 Forward Clutch Hub Front Bearing
Courtesy of FORD MOTOR CO.
39. Remove the intermediate stub shaft.
Fig 36: Locating Intermediate Stub Shaft
Courtesy of FORD MOTOR CO.
40. Align the reverse sun shell with the overdrive band anchor pin for removal.
Fig 37: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin
Courtesy of FORD MOTOR CO.
41. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
Fig 38: Removing Clutch Assembly Components
Courtesy of FORD MOTOR CO.
42. Remove the center support retaining ring and note location for assembly.
Fig 39: Locating Center Support Retaining Ring
Courtesy of FORD MOTOR CO.
43. Remove the case-to-planet support spring.
Fig 40: Identifying Case-To-Planet Support Spring
Courtesy of FORD MOTOR CO.
44. Remove the planetary gear support and planetary as an assembly.
Fig 41: Locating Planetary Gear Support
Courtesy of FORD MOTOR CO.
45. Remove the reverse clutch band.
Fig 42: Locating Reverse Clutch Band
Courtesy of FORD MOTOR CO.
46. Remove the retaining ring.
Fig 43: Locating Retaining Ring
Courtesy of FORD MOTOR CO.
47. Remove the direct clutch pack.
Fig 44: Identifying Direct Clutch Pack
Courtesy of FORD MOTOR CO.
48. Remove the No. 8 bearing.
Fig 45: Locating No. 8 Bearing
Courtesy of FORD MOTOR CO.
49. Remove the output shaft and output shaft ring gear assembly.
Fig 46: Locating Output Shaft And Output Shaft Ring Gear Assembly
Courtesy of FORD MOTOR CO.
50. Remove the No. 9 case rear bearing.
Fig 47: Locating No. 9 Case Rear Bearing
Courtesy of FORD MOTOR CO.
51. Inspect and, if necessary, use the special tools to remove the rear case bushing.
Fig 48: Removing Rear Case Bushing Using Special Tool
Courtesy of FORD MOTOR CO.