Section 189 (Automatic Transaxle/Transmission): Disassembly: Transmission

Illustration	Tool Name	Tool Number
	Slide Hammer	100-001 (T50T-100-A)
	Handle, Torque Converter	307-091 (T81P-7902-C)
	Remover, Input Shaft Oil Seal	308-375
	Retaining Ring Pliers	307-343 (T95P-77001-AHR)
	Collet, 1-1/4 to 1-1/24 Inch	303-D022 (D80L-100T) or equivalent
	Actuator Pin	303-D012 (D80L-100-H) or equivalent
	Remover, Transmission Fluid Pump	307-553
	Remover, Bearing	307-562 (includes 307-562/1 and 307-562/2)

All vehicles 

1. Using the special tools, remove the torque converter.
Fig 1: Locating Torque Converter
Courtesy of FORD MOTOR CO.
2. Remove the transmission fluid pan.
Fig 2: Transmission Fluid Pan Bolts
Courtesy of FORD MOTOR CO.
3. Remove and discard the fluid pan gasket.
Fig 3: Transmission Fluid Pan Gasket
Courtesy of FORD MOTOR CO.
4. Remove and discard the transmission fluid filter.
Fig 4: Locating Transmission Fluid Filter
Courtesy of FORD MOTOR CO.
5. Clean and inspect the transmission fluid pan and magnets.
Fig 5: Transmission Fluid Pan Magnets
Courtesy of FORD MOTOR CO.
6. Press the release tab and lift up on the bulkhead connector retainer.
Fig 6: Locating Release Tab
Courtesy of FORD MOTOR CO.
7. With the release tab up, pull the outer shell of the bulkhead electrical connector.
Fig 7: Locating Outer Shell Of Bulkhead Electrical Connector And Release Tab
Courtesy of FORD MOTOR CO.
CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
8. Pull the outer shell of the bulkhead electrical connector out of the transmission.
Fig 8: Locating Outer Shell Of Bulkhead Electrical Connector
Courtesy of FORD MOTOR CO.
9. Remove the 10 bolts from the mechatronic assembly.
Fig 9: Locating Mechatronic Assembly Bolts
Courtesy of FORD MOTOR CO.
10. Remove the mechatronic assembly.
Fig 10: Locating Mechatronic Assembly
Courtesy of FORD MOTOR CO.
11. Remove the rubber adapter and the fluid filter seal.
Fig 11: Rubber Adapter
Courtesy of FORD MOTOR CO.
12. Remove and discard the 4 rubber feed tubes for the center support. Note the size and location while removing for correct installation.
Fig 12: Locating Rubber Feed Tubes
Courtesy of FORD MOTOR CO.
13. Remove the thermal bypass valve.
Fig 13: Thermal Bypass Valve
Courtesy of FORD MOTOR CO.
14. Inspect the thermal bypass valve for damage, install a new valve if damage is indicated.
Fig 14: Inspecting Thermal Bypass Valve
Courtesy of FORD MOTOR CO.
15. Using the special tools, remove and discard the front pump seal.
Fig 15: Removing Front Pump Seal
Courtesy of FORD MOTOR CO.
16. Remove and discard the front pump bolts.
Fig 16: Locating Front Pump Bolts
Courtesy of FORD MOTOR CO.
17. Using the special tools, remove the front pump support. Make sure that the selective shim is on the back side of the pump.
Fig 17: Removing Front Pump Support
Courtesy of FORD MOTOR CO.
18. Remove the forward (clutch A)/overdrive (clutch E) clutch assembly.
Fig 18: Locating Forward (Clutch A)/Overdrive (Clutch E) Clutch Assembly
Courtesy of FORD MOTOR CO.
19. Remove the roller bearing.
Fig 19: Removing Roller Bearing
Courtesy of FORD MOTOR CO.
20. Remove the direct clutch assembly.
Fig 20: Locating Direct Clutch Assembly
Courtesy of FORD MOTOR CO.
21. Using the special tool, remove the center support snap ring.
Fig 21: Center Support Snap Ring
Courtesy of FORD MOTOR CO.
22. Remove the center support.
Fig 22: Locating Center Support
Courtesy of FORD MOTOR CO.
NOTE: When removing the planet carrier and the low/reverse clutch pack, some of the clutch plates may stay in the case. Try to keep all the clutches together.
23. Remove the planet carrier and the low/reverse clutch pack as an assembly.
Fig 23: Locating Low/Reverse Clutch Pack
Courtesy of FORD MOTOR CO.
24. Remove the low/reverse bearing race.
Fig 24: Locating Low/Reverse Bearing Race
Courtesy of FORD MOTOR CO.
25. Remove the low/reverse sun gear.
Fig 25: Locating Low/Reverse Sun Gear
Courtesy of FORD MOTOR CO.
NOTE: When removing the sun gear, take note that the taper edge is facing up toward the torque converter housing.
26. Remove the sun gear into the planet assembly.
Fig 26: Removing Sun Gear Into Planet Assembly
Courtesy of FORD MOTOR CO.
27. Remove the top and the bottom roller bearings from the sun gear.
Fig 27: Sun Gear Top & Bottom Roller Bearings
Courtesy of FORD MOTOR CO.
28. Remove the roller bearing race in the bottom of the carrier.
Fig 28: Locating Roller Bearing Race
Courtesy of FORD MOTOR CO.
29. Remove the washer.
Fig 29: Locating Washer
Courtesy of FORD MOTOR CO.

Rear wheel drive (RWD) vehicles 

NOTE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to removing the nut, remove the stake to prevent damage to the output shaft.
30. Remove and discard the output shaft flange nut.
Fig 30: Output Shaft Flange Nut
Courtesy of FORD MOTOR CO.
31. Remove the output shaft flange.
Fig 31: Output Shaft Flange
Courtesy of FORD MOTOR CO.
32. Remove the planet carrier hub and output shaft assembly.
Fig 32: Locating Planet Carrier Hub & Output Shaft Assembly
Courtesy of FORD MOTOR CO.
33. Remove the output shaft seal.
Fig 33: Locating Output Shaft Seal
Courtesy of FORD MOTOR CO.
34. Remove the anti-click washer.
Fig 34: Locating Anti-Click Washer
Courtesy of FORD MOTOR CO.
NOTE: Four wheel drive (4WD) case shown, rear wheel drive (RWD) case similar.
35. Remove the snap ring from the case.
Fig 35: Locating Rear Bearing Spacer Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: 4WD case shown, RWD case similar.
36. Using the special tools, remove the roller bearing.
Fig 36: Removing Roller Bearing
Courtesy of FORD MOTOR CO.
37. Using a small pick, remove the snap ring.
Fig 37: Locating Snap Ring
Courtesy of FORD MOTOR CO.
CAUTION: Use care when installing the special tool. Look inside the transmission case to make sure that the tool contacts the bearing only and not the lip of the case, or damage to the case will result.
38. Using the special tool, remove the bearing assembly.
Fig 38: Removing Bearing Assembly
Courtesy of FORD MOTOR CO.

Four wheel drive (4WD) vehicles 

39. Remove the planet carrier hub and output shaft assembly.
Fig 39: Locating Planet Carrier Hub & Output Shaft Assembly
Courtesy of FORD MOTOR CO.
40. Remove and discard the output shaft seal.
Fig 40: Locating Output Shaft Seal
Courtesy of FORD MOTOR CO.
41. Remove the anti-click washer.
Fig 41: Locating Anti-Click Washer
Courtesy of FORD MOTOR CO.
42. Remove the snap ring from the case.
Fig 42: Locating Rear Bearing Spacer Snap Ring
Courtesy of FORD MOTOR CO.
43. Using the special tools, remove the bearing spacer.
Fig 43: Locating Bearing Spacer
Courtesy of FORD MOTOR CO.
44. Using a small pick, remove the snap ring.
Fig 44: Locating Snap Ring
Courtesy of FORD MOTOR CO.
CAUTION: Use care when installing the special tool. Look inside the transmission case to make sure that the tool contacts the bearing only and not the lip of the case, or damage to the case will result.
45. Using the special tool, remove the bearing assembly.
Fig 45: Removing Bearing Assembly
Courtesy of FORD MOTOR CO.

All vehicles 

46. Remove the park rod actuating plate.
Fig 46: Locating Park Rod Actuating Plate
Courtesy of FORD MOTOR CO.
47. Remove the manual control lever.
    1. Remove the roll pin.
    2. Slide the manual control lever shaft out of the case.
    3. Hold the spacer to keep it from falling into the case.
    4. Remove the manual valve inner lever and the park rod as an assembly.
Fig 47: Manual Control Lever, Roll Pin, Park Rod & Spacer
Courtesy of FORD MOTOR CO.
48. Remove and discard the manual control lever seal.
Fig 48: Manual Control Lever Seal
Courtesy of FORD MOTOR CO.
49. Remove the bolt from the back of the case to gain access to the park pawl pin.
Fig 49: Locating Park Pawl Pin Bolt
Courtesy of FORD MOTOR CO.
50. From inside the case, push the park pawl pin out toward the back side of the case, while holding the spring and the park pawl. Remove the park pawl pin, then remove the park pawl and spring.
Fig 50: Locating Park Pawl Pin, Park Pawl & Spring
Courtesy of FORD MOTOR CO.