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Automatic Transaxle/Transmission - 4F27E: Assembly: Transaxle: Assembly

  1. 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
    G07496504Courtesy of FORD MOTOR CO.
  2. 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: Seating Final Drive Input Gear Bearing
    G07496505Courtesy of FORD MOTOR CO.
  3. Install a new collapsible spacer.
    Fig 3: Locating Collapsible Spacer
    G07496506Courtesy of FORD MOTOR CO.
  4. Using the Drive Pinion Bearing Cup Installer, position the final drive input gear.
    Fig 4: Positioning Final Drive Input Gear
    G07496507Courtesy of FORD MOTOR CO.
    5. 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.
  5. Rotate the transaxle 180 degrees.
  6. 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
    G07496508Courtesy of FORD MOTOR CO.
  7. Rotate the transaxle 180 degrees.
  8. Using the Final Drive Input Gear Holding Tool, lock the final drive input gear.
    Fig 6: Identifying Final Drive Input Gear Holding Tool
    G07496509Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
    10. NOTE: A high tightening torque of approximately 200 Nm (148 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.
    Fig 7: Identifying Final Drive Input Nut Socket And Wrench Guide Plate
    G07496510Courtesy of FORD MOTOR CO.
  10. Using the Wrench Guide Plate and Final Drive Input Nut Socket, tighten the nut in small increments to achieve a turning torque of 0.55-0.85 Nm (4.9-7.5 lb-in).
  11. Rotate the transaxle 180 degrees.
    12. NOTE: Make sure that the final drive rotates.
    Fig 8: Locating Final Drive Input Gear Holding Tool
    G07496511Courtesy of FORD MOTOR CO.
  12. Unlock the Final Drive Input Gear Holding Tool.
  13. Rotate the transaxle 180 degrees.
    14. NOTE: Make sure the bearing preload is between 0.55-0.85 Nm (4.9-7.5 lb-in) or bearing failure can occur.
    NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.
    Fig 9: Identifying Final Drive Input Nut Socket And Wrench Guide Plate
    G07496512Courtesy of FORD MOTOR CO.
  14. Using the Wrench Guide Plate and Final Drive Input Nut Socket, measure the rotating torque.
    • Rotational torque is 0.55-0.85 Nm (4.9-7.5 lb-in).
  15. 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: Locating Wrench Guide Plate And Final Drive Input Nut Socket
    G07496513Courtesy of FORD MOTOR CO.
  16. Rotate the transaxle 180 degrees.
  17. Position the transfer shaft gears in the transaxle case.
    Fig 11: Locating Transfer Shaft Gears
    G07496514Courtesy of FORD MOTOR CO.
  18. Install the parking pawl return spring.
    Fig 12: Locating Parking Pawl Return Spring
    G07496515Courtesy of FORD MOTOR CO.
  19. 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, Pin And Spring
    G07496516Courtesy of FORD MOTOR CO.
  20. Install the parking pawl assembly cover and bolts.
    • Tighten to 13 Nm (115 lb-in).
    Fig 14: Locating Parking Pawl Assembly Cover Bolts
    G07496517Courtesy of FORD MOTOR CO.
  21. Install the differential case assembly.
    Fig 15: Locating Differential Assembly
    G07496518Courtesy of FORD MOTOR CO.
  22. Position the bearing cups.
    Fig 16: Locating Bearing Cups
    G07496519Courtesy of FORD MOTOR CO.
  23. Install the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.
    Fig 17: Remove/Install Differential/Transfer Gear Bearing Shim Gauge And Shim Selection Set
    G07496520Courtesy of FORD MOTOR CO.
    24. 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.
    Fig 18: Identifying Assembling Transaxle Using Shim Selection Set
    G07496521Courtesy of FORD MOTOR CO.
  24. 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).
  25. Remove the converter housing.
    1. Remove bolts.
    2. Remove the converter housing.
    Fig 19: Identifying Converter Housing With Bolts
    G07496522Courtesy of FORD MOTOR CO.
  26. Remove the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.
    Fig 20: Remove/Install Differential/Transfer Gear Bearing Shim Gauge And Shim Selection Set
    G07496523Courtesy of FORD MOTOR CO.
  27. Remove the bearing cups.
    Fig 21: Locating Bearing Cups
    G07496524Courtesy of FORD MOTOR CO.
    28. NOTE: If the plunger is above the contact surface, the reading will be incorrect.
    Fig 22: Measuring Depth Of Plunger On Differential/Transfer Gear Bearing Shim Gauge
    G07496525Courtesy of FORD MOTOR CO.
  28. 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  in this service information.
  29. Using the Transfer Gear Bearing Cup Installer and Handle, install the correct transfer shaft shim and bearing cup into the converter housing.
    Fig 23: Installing Correct Transfer Shaft Shim And Bearing Cup Into Converter Housing
    G07496527Courtesy of FORD MOTOR CO.
  30. Using the Differential Bearing Cup Installer and Handle, install the correct differential shaft shim and differential case bearing cup into the converter housing.
    Fig 24: Installing Correct Differential Shaft Shim And Differential Case Bearing Cup Into Converter Housing
    G07496528Courtesy of FORD MOTOR CO.
  31. Apply a 1 mm (0.04 in) thick bead of silicone sealer to the case half.
    Fig 25: Locating Thick Bead Of Silicone Sealer Applying Area On Case Half
    G07496529Courtesy of FORD MOTOR CO.
  32. Position the converter housing on the transaxle case and install the converter housing-to-transaxle case bolts and stud.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 26: Remove/Install Converter Housing Bolts
    G07496530Courtesy of FORD MOTOR CO.
  33. Install the intermediate/overdrive band servo piston return spring.
    Fig 27: Locating Intermediate And O/D Servo Piston Return Spring
    G07496531Courtesy of FORD MOTOR CO.
  34. Install the intermediate/overdrive servo piston.
    Fig 28: Locating Intermediate And O/D Servo Piston
    G07496532Courtesy of FORD MOTOR CO.
  35. Install the O-ring seal.
    Fig 29: Locating O-Ring Seal
    G07496533Courtesy of FORD MOTOR CO.
    36. NOTE: The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.
    Fig 30: Remove/Install Intermediate And O/D Piston Servo Cover Bolts
    G07496534Courtesy of FORD MOTOR CO.
  36. Install the intermediate/overdrive band servo cover and bolts.
    • Tighten to 13 Nm (115 lb-in).
  37. Install the park pawl assembly and bolt.
    • Tighten to 13 Nm (115 lb-in).
    Fig 31: Locating Park Pawl Assembly And Bolt
    G07496535Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the O-ring with clean transmission fluid prior to assembly.
    Fig 32: Identifying Manual Control Lever Shaft O-Ring Seals
    G07496536Courtesy of FORD MOTOR CO.
  38. Install the new O-rings on the manual control lever shaft.
  39. Install the manual control lever shaft.
    Fig 33: Locating Manual Control Lever Shaft
    G07496537Courtesy of FORD MOTOR CO.
    40. NOTE: The roll pin does not need to sit flush with the park pawl assembly.
    Fig 34: Locating Manual Control Lever Shaft Roll Pin
    G07496538Courtesy of FORD MOTOR CO.
  40. Install a new manual control lever shaft roll pin.
  41. Loosely install the Transmission Range (TR) sensor.
    Fig 35: Locating Transmission Range Sensor
    G07496539Courtesy of FORD MOTOR CO.
    42. NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.
    Fig 36: Locating Thinner And Longer Neutral Drive Accumulator Springs
    G07496540Courtesy of FORD MOTOR CO.
  42. Install the thinner and longer neutral drive accumulator springs.
  43. Install the neutral drive accumulator piston.
    Fig 37: Locating Neutral Drive Accumulator Piston
    G07496541Courtesy of FORD MOTOR CO.
  44. Install the 1-2 accumulator springs.
    Fig 38: Locating 1-2 Accumulator Springs
    G07496542Courtesy of FORD MOTOR CO.
  45. Install the 1-2 accumulator piston.
    Fig 39: Locating 1-2 Accumulator Piston
    G07496543Courtesy of FORD MOTOR CO.
  46. Inspect the seals. Lubricate the seals in clean transmission fluid. Install the transaxle internal harness electrical connector.
    Fig 40: Locating Transaxle Internal Harness Electrical Connector
    G07496544Courtesy of FORD MOTOR CO.
    47. 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.
    Fig 41: Locating Main Control Valve Body Bolt
    G07496545Courtesy of FORD MOTOR CO.
  47. Install the main control valve body.
  48. Tighten the main control valve body bolts.
    • Tighten the bolts in the sequence shown in illustration.
      • Tighten to 9 Nm (80 lb-in).
    Fig 42: Identifying Main Control Valve Body Bolts Tightening Sequence
    G07496546Courtesy of FORD MOTOR CO.
    49. 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.
    Fig 43: Locating Main Control Wiring Harness Connectors
    G07496547Courtesy of FORD MOTOR CO.
  49. 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 (neutral).
    6. Shift Solenoid B (SSB), color B (black).
      • Tighten the main control ground wire bolt to 10 Nm (89 lb-in).
  50. Install the transmission fluid filter.
    Fig 44: Locating Transmission Fluid Filter
    G07496548Courtesy of FORD MOTOR CO.
  51. Connect the Transmission Fluid Temperature (TFT) sensor.
    Fig 45: Locating TFT Sensor Electrical Connector
    G07496549Courtesy of FORD MOTOR CO.
    52. NOTE: Do not use more than the specified amount of sealer on the transmission fluid pan or internal transaxle damage could occur.
    Fig 46: Identifying Bead Thick Of Sealer Applying Area On Transmission Fluid Pan
    G07496550Courtesy of FORD MOTOR CO.
  52. Apply a bead 1.5 mm (0.06 in) diameter of silicone sealer to the transmission fluid pan.
  53. Install the transmission fluid pan.
    • Tighten to 10 Nm (89 lb-in).
    Fig 47: Identifying Transmission Fluid Pan Bolts
    G07496551Courtesy of FORD MOTOR CO.
  54. Rotate the transaxle 180 degrees.
  55. Install the low/reverse clutch piston.
    Fig 48: Locating Low/Reverse Clutch Piston
    G07496552Courtesy of FORD MOTOR CO.
    56. NOTE: Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.
    Fig 49: Identifying Low/Reverse Clutch Return Spring
    G07496553Courtesy of FORD MOTOR CO.
  56. Install the low/reverse clutch return spring.
  57. Install the wave spring.
    Fig 50: Locating Wave Spring
    G07496554Courtesy of FORD MOTOR CO.
  58. Install the low One-Way Clutch (OWC) inner race.
    Fig 51: Locating Low OWC Inner Race
    G07496555Courtesy of FORD MOTOR CO.
    59. NOTE: The opening of the retaining ring must be at the 10 o'clock position.
    Fig 52: Locating Low OWC Retaining Ring
    G07496556Courtesy of FORD MOTOR CO.
  59. Install the low OWC  retaining ring.
  60. Install the low/reverse plates and pressure plate.
    Fig 53: Locating Low/Reverse Clutch Plates
    G07496557Courtesy of FORD MOTOR CO.
  61. 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 (1.0-1.3 mm [0.0393-0.0511 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 54: Locating Low/Reverse Clutch Plate Retaining Ring
    G07496558Courtesy of FORD MOTOR CO.
    62. NOTE: Make sure that the snap ring is installed before installing the planet assembly.
    Fig 55: Locating Planet Assembly
    G07496559Courtesy of FORD MOTOR CO.
  62. Install the planet assembly.
    63. 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.
    Fig 56: View Of Installed Planet Assembly
    G07496560Courtesy of FORD MOTOR CO.
  63. Inspect the planet assembly installation.
    64. NOTE: The planet assembly must only rotate counterclockwise.
    Fig 57: Rotating Planet Assembly
    G07496561Courtesy of FORD MOTOR CO.
  64. Check to make sure that the OWC  is correctly installed.
    • Rotate the planet assembly clockwise and counterclockwise.
  65. Install the intermediate/Overdrive (O/D) drum assembly.
    Fig 58: Identifying Intermediate/Overdrive (O/D) Drum Assembly
    G07496562Courtesy of FORD MOTOR CO.
  66. Install the intermediate/O/D  band.
    Fig 59: Locating Intermediate And O/D Band
    G07496563Courtesy of FORD MOTOR CO.
  67. Install the direct clutch cylinder thrust bearing with the rollers facing up.
    Fig 60: Locating Direct Clutch Cylinder Thrust Bearing
    G07496564Courtesy of FORD MOTOR CO.
  68. Install new end cover-to-case seals.
    Fig 61: Locating End Cover-To-Case Seals
    G07496565Courtesy of FORD MOTOR CO.
  69. Install new end cover seals.
    Fig 62: Locating End Cover Seals
    G07496566Courtesy of FORD MOTOR CO.
  70. 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 63: Identifying Direct Clutch Hub Bearing Shim And Additional Shim Thickness With Specifications
    G07496567Courtesy of FORD MOTOR CO.
    71. NOTE: Failure to support the transaxle end cover in the center can result in inaccurate measurements causing damage to the transaxle.
    Fig 64: Identifying Gap Between Transaxle End Cover And Transaxle Assembly
    G07496568Courtesy of FORD MOTOR CO.
  71. 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.
  72. Remove the transaxle end cover.
    Fig 65: Locating Transaxle End Cover
    G07496569Courtesy of FORD MOTOR CO.
    73. NOTE: The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.001-0.020 in).
    NOTE: The correct shim thickness is between minimum and maximum.
    Fig 66: Locating Direct Clutch Hub Bearing Shim
    G07496570Courtesy of FORD MOTOR CO.
  73. 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 (0.001 in) from Line 3 for maximum shim thickness.
    • Subtract 0.50 mm (0.020 in) from Line 3 for the minimum thickness shim.
    74. 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.
    Fig 67: Locating Bead Of Silicone Sealer Applying Area On Transaxle End Cover
    G07496571Courtesy of FORD MOTOR CO.
  74. Apply a 1 mm (0.04 in) bead of silicone sealer to the transaxle end cover.
  75. Install the transaxle end cover.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 68: Remove/Install Transaxle End Cover Bolts
    G07496572Courtesy of FORD MOTOR CO.
  76. 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 69: Tightening Intermediate/O/D Band Fasteners
    G07496573Courtesy of FORD MOTOR CO.
  77. 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 70: Locating Intermediate/O/D Band Fasteners
    G07496574Courtesy of FORD MOTOR CO.
  78. 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 71: Measuring End Of Bolt To Face Of Nut
    G07496575Courtesy of FORD MOTOR CO.
    79. NOTE: Apply thread sealer to the bolt.
    Fig 72: Locating Intermediate/Overdrive (O/D) Band Anchor Bolt
    G07496576Courtesy of FORD MOTOR CO.
  79. Install the intermediate/O/D  band anchor bolt.
    • Tighten to 45 Nm (33 lb-ft).
  80. Rotate the transaxle 180 degrees.
  81. Install the forward clutch hub.
    Fig 73: Identifying Forward Clutch Hub
    G07496577Courtesy of FORD MOTOR CO.
  82. Install the forward clutch assembly.
    Fig 74: Locating Forward Clutch Assembly
    G07496578Courtesy of FORD MOTOR CO.
  83. Install the forward clutch thrust washer.
    Fig 75: Locating Forward Clutch Thrust Washer
    G07496579Courtesy of FORD MOTOR CO.
  84. Install new pump seals and lubricate with clean transmission fluid.
    Fig 76: Locating Transmission Pump Seals
    G07496580Courtesy of FORD MOTOR CO.
  85. Install the pump (do not force the pump down at this time).
    Fig 77: Locating Pump
    G07496581Courtesy of FORD MOTOR CO.
  86. 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 78: Remove/Install Pump-To-Case Bolts
    G07496582Courtesy of FORD MOTOR CO.
  87. Install the Output Shaft Speed (OSS) sensor.
    • Tighten to 10 Nm (89 lb-in).
    Fig 79: Remove/Install Output Shaft Speed Sensor Bolt
    G07496583Courtesy of FORD MOTOR CO.
    88. NOTE: Apply thread sealer to the bolt.
    Fig 80: Remove/Install Turbine Shaft Speed Sensor Bolt
    G07496584Courtesy of FORD MOTOR CO.
  88. Install the Turbine Shaft Speed (TSS) sensor.
    • Tighten to 10 Nm (89 lb-in).
  89. Using the Transmission Range Sensor Alignment Tool, align the TR  sensor and tighten the bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 81: Aligning TR Sensor Using Transmission Range Sensor Alignment Tool
    G07496585Courtesy of FORD MOTOR CO.
    90. 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.
    Fig 82: Remove/Install Manual Control Lever Bolt
    G07496586Courtesy of FORD MOTOR CO.
  90. Install the manual control lever bolt.
    • Tighten to 30 Nm (22 lb-ft).
  91. Install the vent cap past the second detent notch. Be sure the vent moves up and down freely.
    Fig 83: Identifying Rubber Vent Cap
    G07496587Courtesy of FORD MOTOR CO.
  92. Using the Axle Oil Seal Installer and Handle, install the LH halfshaft seal.
    Fig 84: Installing Halfshaft Seal Using Axle Oil Seal Installer And Handle
    G07496588Courtesy of FORD MOTOR CO.
  93. Using the Output Shaft Seal Installer and Handle, install the RH halfshaft seal.
    Fig 85: Installing Halfshaft Seal Using Output Shaft Seal Installer And Handle
    G07496589Courtesy of FORD MOTOR CO.
  94. Install the differential opening cover.
    Fig 86: Locating Transaxle Opening Cover
    G07496590Courtesy of FORD MOTOR CO.
  95. Using the Torque Converter Handles, install the torque converter.
    Fig 87: View Of Torque Converter Using Torque Converter Handles
    G07496591Courtesy of FORD MOTOR CO.
  96. Using the Torque Converter Retainer, secure the torque converter.
    Fig 88: Identifying Torque Converter Retainer
    G07496592Courtesy of FORD MOTOR CO.
  97. Remove the Transmission Mounting Bracket from the transaxle.
    Fig 89: Identifying Transaxle To Bench Using Transmission Mounting Bracket
    G07496593Courtesy of FORD MOTOR CO.
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