Automatic Transmission - Automatic Transaxle/Transmission: Assembly: Transaxle: Assembly

Using the Drive Pinion Bearing Cone Installer, install the final drive input gear bearing.
1. Install the final drive input gear bearing.
2. Install the Drive Pinion Bearing Cone Installer.
Fig 1: Installing Final Drive Input Gear Bearing
Courtesy of FORD MOTOR CO.
Using an arbor press, the Bearing/Oil Seal Plate and the Drive Pinion Bearing Cone Installer, seat the final drive input gear bearing.

Fig 2: Installing Final Drive Input Gear Bearing
Courtesy of FORD MOTOR CO.
Install a new collapsible spacer.

Fig 3: Locating Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Bearing Cup Installer, position the final drive input gear.

Fig 4: Positioning Final Drive Input Gear
Courtesy of FORD MOTOR CO.
NOTE: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case or damage to the input gear can occur.

Rotate the transaxle 180 degrees.
Using the Drive Pinion Bearing Cup Installer and Differential Fluid Seal Installer, install the final drive input gear bearing.

Fig 5: Installing Final Drive Input Gear Bearing
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Using the Final Drive Input Gear Holding Tool, lock the final drive input gear.

Fig 6: Locking Final Drive Input Gear
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
NOTE: A high tightening torque specification of 400 Nm (295 lb-ft) is necessary to crush the collapsible spacer for correct bearing preload.

NOTE: If the preload is too high, a new collapsible spacer must be installed.

Using the Wrench Guide Plate and Final Drive Input Nut Socket, tighten the nut to achieve the preload specification.
- Tighten to 400 Nm (295 lb-ft).
Fig 7: Locating Final Drive Input Gear Bearing Retainer Nut
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
NOTE: Make sure that the final drive rotates.

Unlock the Final Drive Input Gear Holding Tool.

Fig 8: Unlocking Special Tool
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
NOTE: Make sure the bearing preload is between 0.4-0.7 Nm (3.5-6.2 lb-in) or bearing failure can occur.

NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.

Using the Wrench Guide Plate and Final Drive Input Nut Socket, measure the rotating torque.
- Rotational torque is 0.4-0.7 Nm (3.5-6.2 lb-in).
Fig 9: Locating Final Drive Input Gear Bearing Retainer Nut
Courtesy of FORD MOTOR CO.
After achieving the correct rotating torque specification, remove the Wrench Guide Plate and Final Drive Input Nut Socket and stake the nut to prevent movement.

Fig 10: Staking Nut
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Position the transfer shaft gears in the transaxle case.

Fig 11: Positioning Transfer Shaft Gears In Transaxle Case
Courtesy of FORD MOTOR CO.
Install the parking pawl return spring.

Fig 12: Locating Parking Pawl Return Spring
Courtesy of FORD MOTOR CO.
Connect the spring.
1. Install the parking pawl abutment.
2. Install the lever.
3. Install the pin.
4. Connect the spring.
Fig 13: Identifying Parking Pawl Abutment, Lever And Pin
Courtesy of FORD MOTOR CO.
Install the parking pawl assembly cover and bolts.
- Tighten to 13 Nm (115 lb-in).
Fig 14: Locating Parking Pawl Assembly Cover Bolts
Courtesy of FORD MOTOR CO.
Install the differential case assembly.

Fig 15: Locating Differential Assembly
Courtesy of FORD MOTOR CO.
Position the bearing cups.

Fig 16: Locating Bearing Cups
Courtesy of FORD MOTOR CO.
Install the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.

Fig 17: Installing Differential/Transfer Gear Bearing Shim Gauge And Shim Selection Set
Courtesy of FORD MOTOR CO.
NOTE: Do not use the bolts from Shim Selection Set 308-164, they will not work. Use only the bolts from Shim Selection Set 308-161 or damage to the transaxle case threads can occur.

NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.

Using the Shim Selection Set, assemble the transaxle for end play measurement.
1. Position the converter housing.
2. Install the Shim Selection bolts and seat the case cover flat.
  - Tighten to 5 Nm (44 lb-in).
  Fig 18: Identifying Shim Selection Bolts And Seat Case Cover Flat
  Courtesy of FORD MOTOR CO.
Remove the converter housing.
1. Remove bolts.
2. Remove the converter housing.
Fig 19: Identifying Converter Housing Bolts
Courtesy of FORD MOTOR CO.
Remove the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.

Fig 20: Installing Differential/Transfer Gear Bearing Shim Gauge And Shim Selection Set
Courtesy of FORD MOTOR CO.
Remove the bearing cups.

Fig 21: Locating Bearing Cups
Courtesy of FORD MOTOR CO.
NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct transfer shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct transfer shaft shim. For additional information, refer to SPECIFICATIONS .

Fig 22: Identifying Plunger With Differential/Transfer Gear Bearing Shim Gauge
Courtesy of FORD MOTOR CO.
NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct differential shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct differential shaft shim. For additional information, refer to SPECIFICATIONS .

Fig 23: Identifying Plunger With Differential/Transfer Gear Bearing Shim Gauge
Courtesy of FORD MOTOR CO.
Using the Transfer Gear Bearing Cup Installer and Handle, install the correct transfer shaft shim and bearing cup into the converter housing.

Fig 24: Installing Correct Transfer Shaft Shim And Bearing Cup Into Converter Housing
Courtesy of FORD MOTOR CO.
Using the Differential Bearing Cup Installer and Handle, install the correct differential shaft shim and differential case bearing cup into the converter housing.

Fig 25: Installing Correct Differential Shaft Shim And Differential Case Bearing Cup Into Converter Housing
Courtesy of FORD MOTOR CO.
Apply a 1 mm (0.039 in) thick bead of silicone sealer to the case half.

Fig 26: Applying One Millimeter Thick Bead Of Loctite
Courtesy of FORD MOTOR CO.
NOTE: Failure to apply threadlock and sealer to the bolts can result in a transmission fluid leak.

Position the converter housing on the transaxle case. Apply threadlock and sealer to the 5 bolts.

Install and hand-tighten the bolts in the transaxle case.

Fig 27: Locating Transaxle Case Bolts
Courtesy of FORD MOTOR CO.
Install the rest of the converter housing-to-transaxle case bolts and tighten all of the bolts.
- Tighten to 22 Nm (16 lb-ft).
Fig 28: Locating Converter Housing Bolts
Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive band servo piston return spring.

Fig 29: Locating Intermediate/Overdrive Servo Piston Return Spring
Courtesy of FORD MOTOR CO.
Install the intermediate/overdrive servo piston.

Fig 30: Locating Intermediate/Overdrive Servo Piston
Courtesy of FORD MOTOR CO.
Install the O-ring seal.

Fig 31: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.
NOTE: The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.

Install the intermediate/overdrive band servo cover and bolts.
- Tighten to 13 Nm (115 lb-in).
Fig 32: Locating Intermediate/Overdrive Piston Servo Cover Bolts
Courtesy of FORD MOTOR CO.
Install the park pawl assembly and bolt.
- Tighten to 13 Nm (115 lb-in).
Fig 33: Locating Control Lever Assembly Bolt
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring with transmission fluid prior to assembly.

Install the new O-rings on the manual control lever shaft.

Fig 34: Locating O-Ring Seals On Manual Lever Shaft
Courtesy of FORD MOTOR CO.
Install the manual control lever shaft.

Fig 35: Locating Manual Lever Shaft
Courtesy of FORD MOTOR CO.
NOTE: The roll pin does not need to sit flush with the park pawl assembly.

Install a new manual control lever shaft roll pin.

Fig 36: Locating Manual Lever Shaft Roll Pin
Courtesy of FORD MOTOR CO.
Loosely install the Transmission Range (TR) sensor.

Fig 37: Locating Transmission Range (TR) Sensor
Courtesy of FORD MOTOR CO.
NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.

Install the thinner and longer neutral drive accumulator springs.

Fig 38: Locating Thinner And Longer Neutral Drive Accumulator Springs
Courtesy of FORD MOTOR CO.
Install the neutral drive accumulator piston.

Fig 39: Locating Neutral Drive Accumulator Piston
Courtesy of FORD MOTOR CO.
Install the 1-2 accumulator springs.

Fig 40: Locating 1-2 Accumulator Springs
Courtesy of FORD MOTOR CO.
Install the 1-2 accumulator piston.

Fig 41: Locating 1-2 Accumulator Piston
Courtesy of FORD MOTOR CO.
Inspect the seals. Lubricate the seals in transmission fluid. Install the transaxle internal harness electrical connector.

Fig 42: Locating Transaxle Internal Harness Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Make sure that the manual valve is in the manual control valve selector lever.

NOTE: Do not fully tighten the bolts at this stage.

Install the main control valve body.

Fig 43: Locating Main Control Valve Body
Courtesy of FORD MOTOR CO.
Tighten the main control valve body bolts.
- Tighten the bolts in the sequence shown in illustration.
  - Tighten to 9 Nm (80 lb-in).
  Fig 44: Tightening Main Control Valve Body Retaining Bolts
  Courtesy of FORD MOTOR CO.
NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly.

Connector color letters are cast in the solenoid body.

Install the main control wiring harness, connect the electrical connectors and install the main control ground wire bolt.
1. Shift Solenoid C (SSC), color N (White)
2. Shift Solenoid E (SSE), color G (Green)
3. Shift Solenoid D (SSD), color L (Blue)
4. Line Pressure Control (LPC), color B (Black)
5. Shift Solenoid A (SSA), color N (Natural)
6. Shift Solenoid B (SSB), color B (Black)
  - Tighten the main control ground wire bolt to 10 Nm (89 lb-in).
  Fig 45: Identifying Electrical Connectors, Main Control Wiring Harness And Ground Wire Bolt
  Courtesy of FORD MOTOR CO.
Install the transmission fluid filter.

Fig 46: Locating Transmission Fluid Filter
Courtesy of FORD MOTOR CO.
Connect the Transmission Fluid Temperature (TFT) sensor.

Fig 47: Locating Transmission Fluid Temperature (TFT) Sensor
Courtesy of FORD MOTOR CO.
NOTE: Do not use more than the specified amount of sealer on the transmission fluid pan or internal transaxle damage could occur.

Apply a bead 1.5 mm (0.059 in) diameter of silicone sealer to the transmission fluid pan.

Fig 48: Identifying Silicone Sealer Applying Area
Courtesy of FORD MOTOR CO.
Install the transmission fluid pan.
- Tighten to 10 Nm (89 lb-in).
Fig 49: Locating Transmission Fluid Pan Bolts
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Install the low/reverse clutch piston.

Fig 50: Locating Low/Reverse Clutch Piston
Courtesy of FORD MOTOR CO.
NOTE: Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.

Install the low/reverse clutch return spring.

Fig 51: Identifying Low/Reverse Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the wave spring.

Fig 52: Locating Bevel Ring
Courtesy of FORD MOTOR CO.
Install the low One-Way Clutch (OWC) inner race.

Fig 53: Locating Low One-Way Clutch Inner Race
Courtesy of FORD MOTOR CO.
NOTE: The opening of the retaining ring must be at the 10 o'clock position.

Install the low OWC retaining ring.

Fig 54: Installing Low One-Way Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
Install the low/reverse plates and pressure plate.

Fig 55: Locating Low/Reverse Clutch Plates And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the low reverse clutch plate selective retaining ring.
- Using a feeler gauge, measure the clutch clearance.
- Compare the low reverse clutch pack clearance to the specification (2.2-2.5 mm [0.0866-0.0984 in]). If the clutch pack clearance is not within specification, select and install the correct size selective retaining ring to obtain the specified clearance.
Fig 56: Locating Low/Reverse Clutch Plate Retaining Ring
Courtesy of FORD MOTOR CO.
NOTE: Make sure that the snap ring is installed before installing the planet assembly.

Install the planet assembly.

Fig 57: Locating Planet Assembly
Courtesy of FORD MOTOR CO.
NOTE: If the planet assembly is installed correctly, the edge of the planet assembly will fit flush with the transaxle case. If the planet assembly does not fit flush with the transaxle case, further assembly will cause damage to the transaxle.

Inspect the planet assembly installation.

Fig 58: Locating Planet Assembly
Courtesy of FORD MOTOR CO.
NOTE: The planet assembly must only rotate counterclockwise. If the planet assembly rotates clockwise, then the OWC was not installed correctly.

Check to make sure that the OWC is correctly installed.
- Rotate the planet assembly clockwise and counterclockwise.
Fig 59: Rotating Planet Assembly
Courtesy of FORD MOTOR CO.
Install the intermediate/Overdrive (O/D) drum assembly.

Fig 60: Locating Intermediate/Overdrive Drum Assembly
Courtesy of FORD MOTOR CO.
Install the intermediate/O/D band.

Fig 61: Locating Intermediate/Overdrive Band
Courtesy of FORD MOTOR CO.
Install the direct clutch cylinder thrust bearing with the rollers facing up.

Fig 62: Locating Direct Clutch Cylinder Thrust Bearing
Courtesy of FORD MOTOR CO.
Install new end cover-to-case seals.

Fig 63: Locating End Cover On Case Seals
Courtesy of FORD MOTOR CO.
Install new end cover seals.

Fig 64: Locating End Cover Seals
Courtesy of FORD MOTOR CO.
Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown in illustration or greater.

Fig 65: Locating Clutch Hub Bearing Shim
Courtesy of FORD MOTOR CO.
NOTE: Failure to support the transaxle end cover in the center can result in inaccurate measurements causing damage to the transaxle.

Measure the gap between the transaxle end cover and the transaxle assembly.
1. Position the transaxle end cover on the transaxle assembly.
2. Support the transaxle end cover in the center.
3. Measure the gap between the transaxle end cover and the transaxle assembly.
Fig 66: Measuring Gap Between Transaxle End Cover And Transaxle Assembly
Courtesy of FORD MOTOR CO.
Remove the transaxle end cover.

Fig 67: Locating Transaxle End Cover
Courtesy of FORD MOTOR CO.
NOTE: The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.009-0.019 in).

NOTE: The correct shim thickness is between minimum and maximum.

Choose and install the correct direct clutch hub bearing shim:
- Line 1: total amount of shim thickness used during transaxle end cover mock up.
- Line 2: measure the gap between transaxle end cover and transaxle case.
- Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.
- Line 4: subtract 0.25 mm (0.009 in) from Line 3 for maximum shim thickness.
- Subtract 0.50 mm (0.019 in) from Line 3 for the minimum thickness shim.
Fig 68: Locating Correct Direct Clutch Hub Bearing Shim
Courtesy of FORD MOTOR CO.
NOTE: Applying too much silicone sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.

Apply a 1 mm (0.039 in) bead of silicone sealer to the transaxle end cover.

Fig 69: Applying Bead Of Sealer To Transaxle End Cover
Courtesy of FORD MOTOR CO.
Install the transaxle end cover.
- Tighten to 22 Nm (16 lb-ft).
Fig 70: Locating Transaxle End Cover Bolts
Courtesy of FORD MOTOR CO.
Using the Transmission Band Select Gauge, collapse the intermediate/O/D band.
- Tighten to 5 Nm (44 lb-in), then back out three and a half turns.
Fig 71: Identifying Transmission Band Select Gauge
Courtesy of FORD MOTOR CO.
Holding the Transmission Band Select Gauge, lightly seat the nut against the transaxle case, then remove the Transmission Band Select Gauge without changing the relationship of the nut on the bolt.

Fig 72: Seating Nut Against Transaxle Case
Courtesy of FORD MOTOR CO.
Using the Transmission Band Select Gauge, select an intermediate/O/D band bolt that measures from the end of the bolt to the face of the nut as shown in illustration.

Fig 73: Measuring End Of Bolt To Face Of Nut
Courtesy of FORD MOTOR CO.
NOTE: Apply thread sealer to the bolt.

Install the intermediate/O/D band anchor bolt.
- Tighten to 45 Nm (33 lb-ft).
Fig 74: Locating Intermediate/Overdrive Band Anchor Bolt
Courtesy of FORD MOTOR CO.
Rotate the transaxle 180 degrees.
Install the forward clutch hub.

Fig 75: Locating Forward Clutch Hub
Courtesy of FORD MOTOR CO.
Install the forward clutch assembly.

Fig 76: Locating Forward Clutch Assembly
Courtesy of FORD MOTOR CO.
Install the forward clutch thrust washer.

Fig 77: Locating Forward Clutch Thrust Washer
Courtesy of FORD MOTOR CO.
Install new pump seals and lubricate with clean transmission fluid.

Fig 78: Locating Fluid Pump Seals
Courtesy of FORD MOTOR CO.
Install the pump (do not force the pump down at this time).

Fig 79: Locating Fluid Pump
Courtesy of FORD MOTOR CO.
NOTE: Failure to apply threadlock and sealer to the bolts can result in a transmission fluid leak.

Apply threadlock and sealer to the bolts and install the pump-to-case bolts.
- Use the bolts to seat the pump.
- Tighten the bolts in a crisscross pattern.
- Tighten to 30 Nm (22 lb-ft).
Fig 80: Locating Transaxle Bolts
Courtesy of FORD MOTOR CO.
Install the Output Shaft Speed (OSS) sensor.
- Tighten to 10 Nm (89 lb-in).
Fig 81: Locating Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.
NOTE: Apply thread sealer to the bolt.

Install the Turbine Shaft Speed (TSS) sensor.
- Tighten to 10 Nm (89 lb-in).
Fig 82: Locating Turbine Shaft Speed (TSS) Sensor
Courtesy of FORD MOTOR CO.
Using the Transmission Range Sensor Alignment Tool, align the TR sensor and tighten the bolts.
- Tighten to 10 Nm (89 lb-in).
Fig 83: Locating TR Sensor Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt. Damage to the manual control lever shaft will occur.

Install the manual control lever bolt.
- Tighten to 30 Nm (22 lb-ft).
Fig 84: Locating Manual Control Lever Bolt
Courtesy of FORD MOTOR CO.
Install the vent cap past the second detent notch. Be sure the vent moves up and down freely.

Fig 85: Locating Rubber Vent Cap
Courtesy of FORD MOTOR CO.
Using the Axle Oil Seal Installer and Handle, install the LH halfshaft seal.

Fig 86: Locating Halfshaft Seal
Courtesy of FORD MOTOR CO.
Using the Output Shaft Seal Installer and Handle, install the RH halfshaft seal.

Fig 87: Installing Halfshaft Seal
Courtesy of FORD MOTOR CO.
Install the differential opening cover.

Fig 88: Locating Differential Opening Cover
Courtesy of FORD MOTOR CO.
Using the Torque Converter Handles, install the torque converter.

Fig 89: Installing Torque Converter
Courtesy of FORD MOTOR CO.
Using the Torque Converter Retainer, secure the torque converter.

Fig 90: Identifying Torque Converter Retainer To Torque Converter
Courtesy of FORD MOTOR CO.
Remove the Transmission Mounting Bracket from the transaxle.

Fig 91: Mounting Transaxle To Bench
Courtesy of FORD MOTOR CO.