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Disassembled Views

Fig 1: Disassembled View Of Transaxle Components (1 Of 3)
G07932203Courtesy of FORD MOTOR CO.
Fig 2: Disassembled View Of Transaxle Components (2 Of 3)
G07932204Courtesy of FORD MOTOR CO.
Fig 3: Disassembled View Of Transaxle Components (3 Of 3)
G07932205Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7005 Transaxle case
2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal
15 7C099 Direct (3, 5, R) clutch piston inner (front) seal
16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/overdrive (4, 5, 6) clutch cylinder and hub assembly
19 7A548 Overdrive (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
21 7D234 No. 2 thrust bearing
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 Overdrive (4, 5, 6) clutch piston outer (rear) seal
28 7A548 Overdrive (4, 5, 6) clutch piston outer (front) seal
29 7A262 Overdrive (4, 5, 6) clutch piston
30 7F222 Overdrive (4, 5, 6) clutch piston return spring
31 7H360 Overdrive (4, 5, 6) clutch balance piston
32 7C122 Overdrive (4, 5, 6) clutch piston snap ring
33 7B164 Overdrive (4, 5, 6) clutch friction plates (5 required)
34 7B442 Overdrive (4, 5, 6) clutch steel plates (5 required)
35 7B066 Overdrive (4, 5, 6) clutch pressure plate
36 7D483 Overdrive (4, 5, 6) clutch snap ring
37 7H351 Overdrive (4, 5, 6) clutch hub
38 7D234 No. 3 thrust bearing
39 7A019 Rear planetary sun gear and shell assembly
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2 required)
42 7B442 Intermediate (2, 6) clutch steel plates (2 required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
45 7C096 No. 6 thrust bearing
46 7G177 No. 5 thrust bearing
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7H318 Low/reverse clutch piston snap ring retainer
53 7B070 Low/reverse clutch piston return spring
54 7D402 Low/reverse clutch piston
55 7L328 Center support
56 7A262 Forward (1, 2, 3, 4) clutch piston
57 7B070 Forward (1, 2, 3, 4) clutch piston return spring
58 7D041 Forward (1, 2, 3, 4) clutch piston snap ring retainer
59 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
60 7D491 Center planetary carrier/front ring gear
61 7D063 Center planetary sun gear
62 7C096 No. 7 thrust bearing
63 7C096 No. 8 thrust bearing
64 7D491 Front planetary carrier/rear ring gear
65 7A019 Front planetary sun gear and shell assembly
66 7D234 No. 10 thrust bearing
67 7B070 Forward (1, 2, 3, 4) clutch wave spring
68 7B164 Forward (1, 2, 3, 4) clutch friction plates (2 required)
69 7B442 Forward (1, 2, 3, 4) clutch steel plates (2 required)
70 7B066 Forward (1, 2, 3, 4) clutch pressure plate
71 7D483 Forward (1, 2, 3, 4) clutch snap ring
72 7978 Transmission fluid baffle
73 W500214 Transmission fluid baffle bolt (2 required)
74 7060 Park gear
75 7G132 Drive chain drive sprocket
76 7C122 Drive sprocket snap ring
77 7G099 No. 13 thrust washer
78 7G249 Drive chain
79 7D234 No. 11 thrust washer
80 7048 Input shaft seal
81 7A098 Transmission fluid filter
82 7L027 Magnet
83 W302860 Pump-to-torque converter housing bolt (8 required)
84 7A103 Pump assembly
85 7A248 Pump assembly-to-torque converter housing O-ring seal
86 7A248 Torque converter hub seal
87 7P113 Torque converter hub seal retainer
88 7F343 Different ring gear
89 7C122 Differential ring gear snap ring
90 7H245 Differential transmission fluid baffle
91 W500214 Differential transmission fluid baffle bolt (2 required)
92 7975 Torque converter housing
93 W701606 Torque converter housing stud bolt
94 7A443 Torque converter housing bolt (16 required)
95 7902 Torque converter
96 1177 RH halfshaft seal
97 7G355 No. 12 thrust bearing
98 7G132 Drive chain driven sprocket
99 7F342 Differential sun gear
100 7F465 Differential assembly
101 7G112 No. 15 thrust bearing
102 7B362 Torque converter housing-to-transaxle case guide pins
103 7D070 Park pawl spring
104 7A441 Park pawl
105 7D071 Park pawl pin
106 7F337 Manual control shaft seal
107 7A232 Park pawl actuator rod
108 7H557 Transmission Range (TR) sensor
109 7C493 Manual control shaft
110 7G100 Manual control shaft pin
111 7A256 Manual control lever
112 W708455 Manual control lever nut
113 7E332 Manual valve detent spring
114 W711235 TR sensor detent spring bolt
115 7J387 Fluid reservoir
116 7A248 Clutch feed seal (large)
117 7A248 Clutch feed seal (small) (4 required)
118 7B431 Main control alignment pin
119 7C207 Main control stud
120 7G199 Main control-to-transaxle case seal (2 required)
121 W713644 Output Shaft Speed (OSS) sensor bolt
122 7H103 OSS sensor
123 7Z490 Main control-to-transaxle case separator plate
124 7A100 Main control valve body
125 N605770 Separator plate-to-solenoid body bolt (2 required)
126 7Z490 Main control valve body-to-solenoid body separator plate
127 7G391 Solenoid body
128 W500303 Solenoid body-to-valve body bolt (2 required)
129 W302863 Main control-to-transaxle case bolt (long) (10 required)
130 W302862 Main control-to-transaxle case bolt (short) (12 required)
131 W520412 Main control nut
132 7G276 Main control leadframe
133 W505513 Main control leadframe screw (5 required)
134 7B329 Main control-to-cover seal
135 7G004 Main control cover
136 W714629 Main control cover stud bolt (5 required)
137 W500214 Main control cover bolt (8 required)
138 7010 Drain plug
139 7H398 Line pressure tap
140 - Oil leveling plug
141 1177 LH halfshaft seal
142 7025 LH halfshaft bushing
143 7M101 Turbine Shaft Speed (TSS) sensor
144 W500214 TSS bolt
145 7A246 Vent tube
146 W500214 Fluid reservoir bolts
147 7G342 Solenoid body strategy tag
148 7B148 Transaxle service identification tag
149 - Direct clutch (3, 5, R)
150 - Intermediate clutch (2, 6)
151 - Overdrive clutch (4, 5, 6)
152 - Forward clutch (1, 2, 3, 4)
153 - Low/reverse clutch
  1. Install the Holding Fixture 307-625.
    Fig 4: Identifying Holding Fixture 307-625
    G06097347Courtesy of FORD MOTOR CO.
  2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.
    Fig 5: Identifying Transaxle On Bench-Mounted Holding Fixture
    G06097348Courtesy of FORD MOTOR CO.
  3. Remove the Torque Converter Retainer 307-566.
    Fig 6: Identifying Torque Converter Retainer 307-566
    G06097349Courtesy of FORD MOTOR CO.
  4. Install the Torque Converter Handle 307-091.
    Fig 7: Identifying Torque Converter Handle 307-091
    G06097350Courtesy of FORD MOTOR CO.
    5. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 8: Removing/Installing Torque Converter
    G06097351Courtesy of FORD MOTOR CO.
  5. Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
    6. NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur. Use only clean transmission fluid designated for the transaxle and torque converter being serviced.
  6. Clean and inspect the torque converter for damage.
    1. Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
    2. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
      • A torque converter malfunction has been determined based on complete diagnostic procedures.
      • The torque converter stud or studs, impeller hub or bushing are damaged.
      • The torque converter exhibits external discoloration (due to overheating).
      • There is evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes.
        1. Major metallic failure
        2. Multiple clutch plates or band failures
        3. Sufficient component wear which results in metallic contamination
        4. Water or antifreeze contamination
    3. If none of the above conditions are present, continue with the following fluid inspection.
    4. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
    5. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
      6. NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur.
    6. If the fluid passed inspection:
      • drain the remaining fluid from the torque converter.
      • using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand.
      • thoroughly drain the fluid.
    7. NOTE: Note the location of the stud bolts for assembly.
    Fig 9: Locating Main Control Cover Bolts
    G06097352Courtesy of FORD MOTOR CO.
  7. Remove the 13 main control cover bolts and the main control cover.
  8. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
    Fig 10: Locating Output Shaft Speed Sensor Electrical Connector
    G06097353Courtesy of FORD MOTOR CO.
  9. Disconnect the Transmission Range (TR) sensor electrical connector.
    Fig 11: Locating TR Sensor Electrical Connector
    G06097354Courtesy of FORD MOTOR CO.
  10. Remove the main control-to-cover seal.
    Fig 12: Locating Main Control-To-Cover Seal
    G06097355Courtesy of FORD MOTOR CO.
    11. NOTE: Note the location of the short and long main control-to-transaxle case bolts for reassembly.
    Fig 13: Locating Main Control Nut And Main Control-To-Transaxle Case Bolts
    G06097356Courtesy of FORD MOTOR CO.
  11. Remove the main control nut and the main control-to-transaxle case bolts and remove the main control assembly.
  12. Clean and inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it. For additional information, refer to MAIN CONTROL - OVERHAUL .
  13. Remove and discard the main control-to-transaxle case separator plate.
    Fig 14: Locating Main Control-To-Transaxle Case Separator Plate
    G06097357Courtesy of FORD MOTOR CO.
  14. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transaxle case seals.
    1. Forward (1, 2, 3, 4) clutch main control-to-transaxle case seal.
    2. Low/reverse clutch main control-to-transaxle case seal.
      Fig 15: Identifying Forward (1, 2, 3, 4) Clutch Main Control-To-Transaxle Case Seal And Low/Reverse Clutch Main Control-To-Transaxle Case Seal
      G07932217Courtesy of FORD MOTOR CO.
  15. Remove the Turbine Shaft Speed (TSS) sensor bolt and the TSS sensor.
    Fig 16: Locating Turbine Shaft Speed Sensor With Bolt
    G06097360Courtesy of FORD MOTOR CO.
  16. Remove the TR sensor detent spring bolt and the TR sensor detent spring.
    Fig 17: Locating TR Sensor Detent Spring And Bolt
    G06097361Courtesy of FORD MOTOR CO.
  17. Remove the OSS sensor bolt and the OSS sensor.
    Fig 18: Locating OSS Sensor Bolt
    G06097362Courtesy of FORD MOTOR CO.
    18. NOTE: Note the location of the stud bolts for assembly.
    Fig 19: Locating Torque Converter Housing Bolts
    G06097363Courtesy of FORD MOTOR CO.
  18. Remove the 17 torque converter housing bolts.
  19. Pry the torque converter housing loose from the transaxle case.
    Fig 20: Loosening Torque Converter Housing From Transaxle Case
    G06097364Courtesy of FORD MOTOR CO.
  20. Remove the torque converter housing from the transaxle case.
    Fig 21: Identifying Torque Converter Housing
    G06097365Courtesy of FORD MOTOR CO.
  21. Remove the No. 15 differential thrust bearing.
    Fig 22: Removing No. 15 Differential Thrust Bearing
    G06097366Courtesy of FORD MOTOR CO.
  22. Remove the differential assembly.
    Fig 23: Removing Differential Assembly
    G06097367Courtesy of FORD MOTOR CO.
  23. Clean and inspect the differential assembly for damage or excessive wear and install new components, if necessary. For additional information, refer to DIFFERENTIAL GEAR ASSEMBLY .
    • Thrust bearing surfaces
    • Spider gear and side gear teeth
    • Differential planetary gear teeth
    • Differential planetary gear teeth to be sure they spin freely and do not move back and forth or side to side excessively
  24. Remove the differential sun gear.
    Fig 24: Locating Differential Sun Gear
    G07932226Courtesy of FORD MOTOR CO.
  25. Clean and inspect the differential sun gear for damage or wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
      Fig 25: Identifying Differential Sun Gear
      G06097420Courtesy of FORD MOTOR CO.
  26. Remove the No. 13 thrust washer.
    Fig 26: Locating No. 13 Thrust Washer
    G07932228Courtesy of FORD MOTOR CO.
  27. Remove the No. 11 drive sprocket thrust bearing.
    Fig 27: Locating No. 11 Drive Sprocket Thrust Bearing
    G07932229Courtesy of FORD MOTOR CO.
  28. Simultaneously remove the drive and driven sprockets and the chain.
    Fig 28: Locating Chain, Drive And Driven Sprockets
    G07932230Courtesy of FORD MOTOR CO.
  29. Remove the drive chain from the drive and driven sprockets.
    Fig 29: Locating Drive Chain With Drive And Driven Sprockets
    G06097506Courtesy of FORD MOTOR CO.
  30. Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
    • Check the drive chain for wear, stretching or tightness of the chain links.
    • Check that the chain moves freely.
      Fig 30: Locating Drive Chain
      G06097507Courtesy of FORD MOTOR CO.
  31. Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
    • Chain teeth
    • Spline teeth
    • Thrust bearing surfaces
    • Bearing
      Fig 31: Inspecting Driven Sprocket
      G06097508Courtesy of FORD MOTOR CO.
  32. Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
    Fig 32: Locating Drive Sprocket On Front Planetary Hub/Park Gear Assembly
    G06097509Courtesy of FORD MOTOR CO.
  33. Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
    • Chain teeth
    • Spline teeth
      Fig 33: Inspecting Drive Sprocket For Damage Or Excessive Wear
      G06097510Courtesy of FORD MOTOR CO.
    • Thrust washer surface
  34. Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if necessary.
    • Park gear teeth
    • Spline teeth
    • Thrust washer surface
    • Thrust bearing surface
    • Bearing surfaces
    • Needle bearing
      Fig 34: Locating Front Planetary Hub/Park Gear Assembly
      G06097511Courtesy of FORD MOTOR CO.
  35. Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
    Fig 35: Locating Drive Sprocket On Front Planetary Hub/Park Gear Assembly
    G06097509Courtesy of FORD MOTOR CO.
  36. Install the drive chain on the drive and driven sprockets.
    Fig 36: Locating Drive Chain With Drive And Driven Sprockets
    G06097506Courtesy of FORD MOTOR CO.
  37. Remove the No. 12 driven sprocket thrust bearing.
    Fig 37: Locating No. 12 Driven Sprocket Thrust Bearing
    G07932239Courtesy of FORD MOTOR CO.
  38. Remove the No. 10 front sun gear and shell assembly thrust bearing.
    Fig 38: Locating No. 10 Front Sun Gear And Shell Assembly Thrust Bearing
    G07932240Courtesy of FORD MOTOR CO.
  39. Remove the 2 fluid reservoir bolts and the fluid reservoir.
    Fig 39: Locating Fluid Reservoir Bolt
    G07932241Courtesy of FORD MOTOR CO.
  40. Remove the 2 transmission fluid baffle bolts and the transmission fluid baffle.
    Fig 40: Locating Transmission Fluid Baffle Bolts
    G07932242Courtesy of FORD MOTOR CO.
  41. Remove the park pawl pin and spring.
    Fig 41: Removing Park Pawl Pin And Spring
    G06097377Courtesy of FORD MOTOR CO.
  42. Remove the park pawl.
    Fig 42: Locating Park Pawl
    G06097378Courtesy of FORD MOTOR CO.
    43. NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).
    NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transaxle.
    Fig 43: Locating Forward (1, 2, 3, 4) Clutch Snap Ring
    G06097379Courtesy of FORD MOTOR CO.
  43. Remove the forward (1, 2, 3, 4) clutch snap ring.
  44. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
    Fig 44: Identifying Forward (1, 2, 3, 4) Clutch Pressure Plate, Clutch Assembly And Wave Spring
    G06097380Courtesy of FORD MOTOR CO.
  45. Remove the front planetary sun gear and shell assembly.
    Fig 45: Locating Front Planetary Sun Gear And Shell Assembly
    G06097381Courtesy of FORD MOTOR CO.
  46. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, as necessary.
    • Gear teeth
    • Shell-to-clutch pack surfaces
    • Thrust bearing surfaces
      Fig 46: Locating Front Planetary Sun Gear And Shell Assembly
      G06097500Courtesy of FORD MOTOR CO.
  47. Remove the front planetary carrier/rear ring gear assembly.
    Fig 47: Locating Front Planetary Carrier/Rear Ring Gear Assembly
    G06097382Courtesy of FORD MOTOR CO.
  48. Clean and inspect the front planetary carrier/rear ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing
    • Thrust bearing surfaces
    • Ring gear teeth
      Fig 48: Locating Front Planetary Gear Carrier/Rear Ring Gear Assembly
      G06097501Courtesy of FORD MOTOR CO.
  49. Remove the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
      Fig 49: Identifying No. 7 And No. 8 Thrust Bearings
      G06097383Courtesy of FORD MOTOR CO.
  50. Remove the center planetary carrier/front ring gear assembly.
    Fig 50: Locating Center Carrier/Front Ring Gear Assembly
    G06097384Courtesy of FORD MOTOR CO.
  51. Clean and inspect the center planetary carrier/front ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing surfaces
    • Ring gear teeth
      Fig 51: Locating Center Planetary Gear Carrier/Front Ring Gear Assembly
      G06097502Courtesy of FORD MOTOR CO.
  52. Remove the center planetary sun gear.
    Fig 52: Locating Center Planetary Sun Gear
    G06097385Courtesy of FORD MOTOR CO.
  53. Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
      Fig 53: Identifying Center Planetary Sun Gear
      G06097503Courtesy of FORD MOTOR CO.
  54. Remove the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
      Fig 54: Identifying No. 5 And No. 6 Thrust Bearings
      G06097386Courtesy of FORD MOTOR CO.
  55. Remove the center support assembly.
    Fig 55: Locating Center Support Assembly
    G06097387Courtesy of FORD MOTOR CO.
  56. Remove the rear planetary carrier/center ring gear assembly.
    Fig 56: Locating Rear Planetary Carrier/Center Ring Gear Assembly
    G06097388Courtesy of FORD MOTOR CO.
  57. Clean and inspect the rear planetary carrier/center ring gear assembly for damage or excessive wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing surfaces
    • Thrust bearing
      Fig 57: Locating Rear Planetary Carrier/Center Ring Gear Assembly
      G06097504Courtesy of FORD MOTOR CO.
  58. Remove the low/reverse wave spring, clutch pack and pressure plate.
    • Inspect the low/reverse clutch pack and pressure plate surface for damage or excessive wear and install new, if necessary.
      Fig 58: Locating Low/Reverse Wave Spring, Clutch Pack And Pressure Plate
      G06097389Courtesy of FORD MOTOR CO.
  59. Remove the low One-Way Clutch (OWC).
    Fig 59: Locating Low One-Way Clutch (OWC)
    G06097390Courtesy of FORD MOTOR CO.
    60. NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.
    NOTE: The low OWC should not be disassembled.
    Fig 60: Inspecting Low OWC Cracks And Damaged Splines
    G06097514Courtesy of FORD MOTOR CO.
  60. Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC.
  61. Inspect the intermediate (2, 6) clutch surface for damage. If the surface is burned or worn excessively, install a new low OWC.
    Fig 61: Locating Intermediate (2, 6) Clutch Surface
    G06097515Courtesy of FORD MOTOR CO.
    62. NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
  62. Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
    • Inspect the intermediate (2, 6) clutch surface for damage or excessive wear and install new, if necessary.
      Fig 62: Removing Rear Planetary Sun Gear And Shell Assembly
      G06097391Courtesy of FORD MOTOR CO.
  63. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, if necessary.
    • Sun gear teeth
    • Shell-to-clutch pack surfaces
    • Bearing surfaces
      Fig 63: Locating Rear Planetary Sun Gear And Shell Assembly
      G06097505Courtesy of FORD MOTOR CO.
  64. Remove the pressure plate and the wave spring.
    • Inspect the pressure plate surface for damage or excessive wear and install new, if necessary.
      Fig 64: Locating Pressure Plate And Wave Spring
      G06097392Courtesy of FORD MOTOR CO.
  65. Remove the No. 3 thrust bearing.
    Fig 65: Locating No. 3 Thrust Bearing
    G06097393Courtesy of FORD MOTOR CO.
  66. Remove the overdrive/direct clutch assembly.
    Fig 66: Locating Overdrive/Direct Clutch Assembly
    G06097394Courtesy of FORD MOTOR CO.
    67. NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
    Fig 67: Locating No. 1 Thrust Bearing
    G06097395Courtesy of FORD MOTOR CO.
  67. Remove the No. 1 thrust bearing.
  68. Remove the intermediate (2, 6) clutch apply ring.
    Fig 68: Locating Intermediate (2, 6) Clutch Apply Ring
    G06097396Courtesy of FORD MOTOR CO.
  69. Remove the 3 clutch support tower bolts and the clutch support tower.
    Fig 69: Locating Clutch Support Tower
    G06097397Courtesy of FORD MOTOR CO.
    70. NOTE: Note the location of the snap ring gap for assembly.
    Fig 70: Locating Intermediate (2, 6) Clutch Return Spring Snap Ring
    G06097398Courtesy of FORD MOTOR CO.
  70. Remove the intermediate (2, 6) clutch return spring snap ring.
    71. NOTE: Note the position of the return spring for assembly.
    Fig 71: Locating Intermediate (2, 6) Clutch Return Spring
    G06097399Courtesy of FORD MOTOR CO.
  71. Remove the intermediate (2, 6) clutch return spring.
    72. NOTE: Note the position of the intermediate clutch piston for assembly.
    Fig 72: Removing Intermediate (2, 6) Clutch Piston
    G06097400Courtesy of FORD MOTOR CO.
  72. Remove the intermediate (2, 6) clutch piston.
  73. Remove and discard the 5 clutch feed seals.
    Fig 73: Locating Clutch Feed Seals
    G06097401Courtesy of FORD MOTOR CO.
  74. Remove the manual control lever nut and the manual control lever from the manual control shaft.
    Fig 74: Locating Manual Control Lever And Nut
    G06097402Courtesy of FORD MOTOR CO.
    75. NOTE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transaxle case causing damage to the transaxle case.
    Fig 75: Pulling Manual Control Shaft Pin Out Of Manual Control Shaft Using Roll Pin Remover 211-061
    G06097403Courtesy of FORD MOTOR CO.
  75. Using the Roll Pin Remover 211-061, pull the manual control shaft pin out of the manual control shaft.
  76. Remove the manual control shaft.
    Fig 76: Removing Manual Control Shaft
    G06097404Courtesy of FORD MOTOR CO.
  77. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.
    Fig 77: Removing TR Sensor And Park Pawl Actuator Rod
    G06097405Courtesy of FORD MOTOR CO.
  78. Remove and discard the manual control shaft seal.
    Fig 78: Removing Manual Control Shaft Seal
    G06097406Courtesy of FORD MOTOR CO.
  79. Remove and discard the LH halfshaft seal.
    Fig 79: Removing LH Half Shaft Seal
    G06097407Courtesy of FORD MOTOR CO.
    80. NOTE: If the LH transaxle case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transaxle case bushing and a new LH halfshaft must be installed, or excessive noise or transaxle failure can occur.
    Fig 80: Locating LH Transaxle Case Bushing And Case Surface
    G07932282Courtesy of FORD MOTOR CO.
  80. Clean and inspect the LH transaxle case bushing and the bushing surface on the LH halfshaft for damage or excessive wear. If the LH transaxle case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components. For additional information, refer to TRANSAXLE CASE . Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.
  81. Remove the 2 differential transmission fluid baffle bolts and the differential transmission fluid baffle from the torque converter housing.
    Fig 81: Locating Differential Transmission Fluid Baffle Bolts
    G06097408Courtesy of FORD MOTOR CO.
  82. Remove the 8 pump-to-torque converter housing bolts and the pump and filter assembly.
    Fig 82: Locating Pump-To-Torque Converter Housing Bolts
    G07444260Courtesy of FORD MOTOR CO.
  83. Remove and discard the RH halfshaft seal.
    Fig 83: Removing RH Halfshaft Seal
    G06097412Courtesy of FORD MOTOR CO.
  84. Clean and inspect the torque converter housing and the differential ring gear for damage or excessive wear. If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear. For additional information, refer to TRANSAXLE CASE . Clean the silicone from the torque converter housing-to-transmission case sealing surface.
    • Differential ring gear teeth
      Fig 84: Locating Torque Converter Housing And Differential Ring Gear
      G07932286Courtesy of FORD MOTOR CO.
    85. NOTE: Note the orientation of the transmission fluid filter to the fluid pump assembly.
  85. Remove the transmission fluid filter from the pump assembly.
    1. Rotate the transmission fluid filter 90 degrees clockwise.
    2. Pull the transmission fluid filter out of the pump assembly.
      Fig 85: Rotating Transmission Fluid Filter 90 Degrees Clockwise
      G06097431Courtesy of FORD MOTOR CO.
  86. Remove the magnet from the transmission fluid filter.
    Fig 86: Locating Magnet On Transmission Fluid Filter
    G06097432Courtesy of FORD MOTOR CO.
  87. Assemble the Slide Hammer 100-001 and 3/4 Inch to 7/8 Inch Collet 303-D019 and remove and discard the input shaft seal.
    Fig 87: Removing Input Shaft Seal
    G06097433Courtesy of FORD MOTOR CO.
  88. Remove the pump assembly-to-torque converter housing O-ring seal.
    Fig 88: Removing/Installing Pump-To-Torque Converter Housing Seal
    G06097434Courtesy of FORD MOTOR CO.
  89. If equipped, remove the torque converter hub seal snap ring.
    Fig 89: Locating Torque Converter Hub Seal Snap Ring
    G07932291Courtesy of FORD MOTOR CO.
  90. Using a dent puller, remove the torque converter hub seal.
    Fig 90: Removing Torque Converter Hub Seal Using Dent Puller
    G06097435Courtesy of FORD MOTOR CO.
  91. Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
    Fig 91: Locating Pump-To-Torque Converter Housing Bolts
    G06097436Courtesy of FORD MOTOR CO.
  92. Loosen the 23 pump bolts.
    Fig 92: Locating Pump Bolts
    G06097437Courtesy of FORD MOTOR CO.
  93. Remove the 2 pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
    Fig 93: Locating Pump-To-Torque Converter Housing Bolts
    G06097438Courtesy of FORD MOTOR CO.
  94. Remove the 23 pump bolts and separate the pump assembly halves.
    Fig 94: Locating Pump Bolts
    G06097439Courtesy of FORD MOTOR CO.
    95. NOTE: The dot on the inner pump gear faces up.
    Fig 95: Locating Pump Gears
    G06097440Courtesy of FORD MOTOR CO.
  95. Remove the pump gears.
  96. Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a magnet.
    Fig 96: Compressing Main Pressure Regulator Valve Spring Using Screwdriver
    G06097441Courtesy of FORD MOTOR CO.
  97. Install an M4 bolt in the valve and remove the main pressure regulator valve assembly.
    Fig 97: Identifying M4 Bolt And Main Pressure Regulator Valve Assembly
    G06097442Courtesy of FORD MOTOR CO.
  98. Compress the Torque Converter Clutch (TCC) control valve spring with a screwdriver and remove the retainer with a magnet.
    Fig 98: Compressing Torque Converter Clutch Control Valve Spring Using Screwdriver
    G06097443Courtesy of FORD MOTOR CO.
  99. Remove the TCC control valve assembly.
    Fig 99: Identifying TCC Control Valve Assembly
    G06097444Courtesy of FORD MOTOR CO.
  100. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump assembly for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the pump assembly as an assembly.
    101. NOTE: TCC control valve retainer shown in illustration assembled in the pump body, main pressure regulator valve retainer similar.
    Fig 100: Identifying TCC Control Valve And Main Pressure Regulator Valve
    G06097445Courtesy of FORD MOTOR CO.
  101. Assemble the TCC control valve and main pressure regulator valve and install the valves in the pump. Compress the valve springs with a screwdriver and install the retainers.
    102. NOTE: The dot on the inner pump gear faces up.
    Fig 101: Locating Pump Gears
    G06097446Courtesy of FORD MOTOR CO.
  102. Install the pump gears.
  103. Position the stator support on the pump housing and install the 23 pump bolts hand-tight.
    Fig 102: Locating Pump Bolts
    G06097439Courtesy of FORD MOTOR CO.
  104. Install the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
    Fig 103: Locating Pump-To-Torque Converter Housing Bolts
    G06097436Courtesy of FORD MOTOR CO.
  105. Tighten the 23 pump bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 104: Locating Pump Bolts
      G06097449Courtesy of FORD MOTOR CO.
  106. Remove the 2 pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
    Fig 105: Locating Pump-To-Torque Converter Housing Bolts
    G06097436Courtesy of FORD MOTOR CO.
  107. Install a new torque converter hub seal on Converter Seal Installer 307-627.
    Fig 106: Identifying Torque Converter Hub Seal On Converter Seal Installer 307-627
    G06097451Courtesy of FORD MOTOR CO.
  108. Using the Converter Seal Installer 307-627, install a new torque converter hub seal.
    Fig 107: Installing Torque Converter Hub Seal Using Converter Seal Installer 307-627
    G06097452Courtesy of FORD MOTOR CO.
  109. If equipped, install the torque converter hub seal snap ring.
    Fig 108: Locating Torque Converter Hub Seal Snap Ring
    G07932291Courtesy of FORD MOTOR CO.
  110. Install a new pump assembly-to-torque converter housing O-ring seal.
    Fig 109: Removing/Installing Pump-To-Torque Converter Housing Seal
    G06097434Courtesy of FORD MOTOR CO.
  111. Install a new input shaft seal on Turbine Shaft Seal Installer 307-634.
    Fig 110: Locating Input Shaft Seal On Turbine Shaft Seal Installer 307-634
    G06097454Courtesy of FORD MOTOR CO.
  112. Using Turbine Shaft Seal Installer 307-634, install the input shaft seal.
    Fig 111: Installing Turbine Shaft Seal Using Turbine Shaft Seal Installer 307-634
    G06097455Courtesy of FORD MOTOR CO.
  113. Install a new O-ring on a new transmission fluid filter and lubricate it with clean transmission fluid.
    Fig 112: Locating O-Ring
    G06097456Courtesy of FORD MOTOR CO.
  114. Install the magnet on the transmission fluid filter.
    Fig 113: Locating Magnet On Transmission Fluid Filter
    G06097432Courtesy of FORD MOTOR CO.
  115. Install the transmission fluid filter.
    1. Position the transmission fluid filter in the pump assembly.
    2. Rotate the transmission fluid filter counterclockwise 90 degrees.
      Fig 114: Rotating Filter Counterclockwise 90 Degrees
      G06097458Courtesy of FORD MOTOR CO.
    116. NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/ reverse or forward clutch.
    NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.
    Fig 115: Compressing Low/Reverse Clutch Return Spring
    G07932317Courtesy of FORD MOTOR CO.
  116. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer.
  117. Remove the low/reverse clutch return spring.
    Fig 116: Locating Low/Reverse Clutch Return Spring
    G07932318Courtesy of FORD MOTOR CO.
  118. Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the low/reverse clutch piston.
    Fig 117: Applying Air Pressure To Low/Reverse Clutch Piston Port
    G06097589Courtesy of FORD MOTOR CO.
    119. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
    Fig 118: Compressing Forward (1, 2, 3, 4) Clutch Return Spring
    G07932320Courtesy of FORD MOTOR CO.
  119. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer.
  120. Remove the return spring from the forward (1, 2, 3, 4) clutch piston.
    Fig 119: Identifying Return Spring From Forward (1, 2, 3, 4) Clutch Piston
    G07932321Courtesy of FORD MOTOR CO.
  121. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the forward (1, 2, 3, 4) clutch piston.
    Fig 120: Applying Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
    G06097584Courtesy of FORD MOTOR CO.
  122. Clean and inspect the center support for damage. Install a new center support if necessary.
    123. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
    Fig 121: Identifying Low Reverse Piston Seal Protector 307-628/2 And Low Reverse / 1-2-3-4 Piston Seal Protector 307-629
    G06097599Courtesy of FORD MOTOR CO.
  123. Install the Low Reverse Piston Seal Protector 307-628/2 and the Low Reverse / 1-2-3-4 Piston Seal Protector 307-629 on the forward clutch piston side of the center support.
  124. Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly.
    Fig 122: Locating Forward (1, 2, 3, 4) Clutch Piston Sealing Surface
    G06097600Courtesy of FORD MOTOR CO.
  125. Position the forward (1, 2, 3, 4) clutch piston on Low Reverse Piston Seal Protector 307-628/2 and the Low Reverse / 1-2-3-4 Piston Seal Protector 307-629 and push it down into the center support.
    Fig 123: Positioning Forward (1, 2, 3, 4) Clutch Piston On Protector 307-628/2
    G06097601Courtesy of FORD MOTOR CO.
    126. NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
    Fig 124: Identifying Return Spring From Forward (1, 2, 3, 4) Clutch Piston
    G07932321Courtesy of FORD MOTOR CO.
  126. Install the forward (1, 2, 3, 4) clutch piston return spring.
  127. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2, 3, 4) clutch return spring and install the snap ring retainer and the snap ring.
    Fig 125: Compressing Forward (1, 2, 3, 4) Clutch Return Spring
    G07932320Courtesy of FORD MOTOR CO.
  128. Inspect the snap ring to be sure it is seated in the groove on the center support.
    Fig 126: Inspecting Snap Ring Seated In Groove On Center Support
    G06097607Courtesy of FORD MOTOR CO.
  129. Turn the center support over and install the Low Reverse Piston Seal Protector 307-628/1 and 307-628/2 on the low/reverse piston side of the center support.
    Fig 127: Identifying Seal Protector 307-628/1 And 307-628/2 On Low/Reverse Piston Side Of Center Support
    G06097590Courtesy of FORD MOTOR CO.
  130. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly.
    Fig 128: Locating Sealing Surfaces Of Low/Reverse Piston
    G06097591Courtesy of FORD MOTOR CO.
  131. Position the low/reverse clutch piston on the Low Reverse Piston Seal Protector 307-628/1 and 307-628/2 and push it down into the center support.
    Fig 129: Positioning Low/Reverse Clutch Piston On Seal Protector 307-628
    G06097592Courtesy of FORD MOTOR CO.
  132. Install the low/reverse piston return spring.
    Fig 130: Locating Low/Reverse Piston Return Spring
    G07932318Courtesy of FORD MOTOR CO.
  133. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse clutch return spring and install the snap ring retainer and the snap ring.
    Fig 131: Compressing Low/Reverse Clutch Return Spring
    G07932317Courtesy of FORD MOTOR CO.
  134. Inspect the snap ring to be sure it is seated in the groove on the center support.
    Fig 132: Inspecting Snap Ring Seated In Groove On Center Support
    G06097598Courtesy of FORD MOTOR CO.
  135. Remove and discard the 4 Teflon® seals.
    Fig 133: Removing Teflon® Seal
    G06097460Courtesy of FORD MOTOR CO.
  136. Clean and inspect the clutch support tower for damage. Install a new clutch support tower if damaged.
    Fig 134: Identifying Clutch Support Tower
    G06097461Courtesy of FORD MOTOR CO.
  137. Install the Input Shaft Support Seal Installer 307-578/3 on the clutch support tower and adjust the Input Shaft Support Seal Installer to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove.
    Fig 135: Installing Input Shaft Support Seal Installer 307-578/3 On Clutch Support Tower
    G06097462Courtesy of FORD MOTOR CO.
  138. Install a new Teflon® seal on the Input Shaft Support Seal Installer 307-578/3.
    Fig 136: Locating Teflon® Seal On Input Shaft Support Seal Installer 307-578/3
    G06097463Courtesy of FORD MOTOR CO.
  139. Install the Input Shaft Support Seal Installer 307-578/2 over 307-578/3. Using the Input Shaft Support Seal Installer 307-578/2, slide the Teflon® seal over the clutch support tower and into the groove.
    Fig 137: Sliding Teflon® Seal Over Clutch Support Tower
    G06097464Courtesy of FORD MOTOR CO.
  140. Remove the Input Shaft Support Seal Installer 307-578/2 and 307-578/3.
    • Repeat Steps  137 through  140 for the other 3 Teflon® seals.
      Fig 138: Identifying Input Shaft Support Seal Installer 307-578/2 And 307-578/3
      G06097465Courtesy of FORD MOTOR CO.
  141. Install the Input Shaft Support Seal Installer 307-578/1 on the clutch support tower to size the 4 Teflon® seals.
    Fig 139: Identifying Input Shaft Support Seal Installer 307-578/1 On Clutch Support Tower
    G06097466Courtesy of FORD MOTOR CO.
  142. Remove the input shaft snap ring.
    Fig 140: Locating Input Shaft Snap Ring
    G07932342Courtesy of FORD MOTOR CO.
  143. Remove the input shaft.
    Fig 141: Locating Input Shaft
    G06097521Courtesy of FORD MOTOR CO.
  144. Remove the overdrive (4, 5, 6) clutch hub.
    Fig 142: Locating Overdrive (O/D) (4, 5, 6) Clutch Hub
    G06097522Courtesy of FORD MOTOR CO.
  145. Remove the overdrive (4, 5, 6) clutch hub, No. 2 thrust bearing.
    Fig 143: Locating O/D (4, 5, 6) Clutch Hub, No. 2 Thrust Bearing
    G06097523Courtesy of FORD MOTOR CO.
  146. Remove the overdrive (4, 5, 6) clutch snap ring.
    Fig 144: Locating Overdrive (4, 5, 6) Clutch Snap Ring
    G06097524Courtesy of FORD MOTOR CO.
  147. Remove the overdrive (4, 5, 6) clutch pressure plate and clutch assembly.
    Fig 145: Locating O/D (4, 5, 6) Clutch Pressure Plate And Clutch Assembly
    G06097525Courtesy of FORD MOTOR CO.
  148. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 146: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1
    G06097526Courtesy of FORD MOTOR CO.
  149. Using a press, compress the overdrive (4, 5, 6) clutch return spring and remove the snap ring.
    Fig 147: Compressing O/D (4, 5, 6) Clutch Return Spring
    G06097527Courtesy of FORD MOTOR CO.
  150. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 148: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06097528Courtesy of FORD MOTOR CO.
  151. Remove and discard the balance piston.
    Fig 149: Locating Balance Piston
    G06097529Courtesy of FORD MOTOR CO.
  152. Remove the overdrive (4, 5, 6) piston return spring.
    Fig 150: Locating O/D (4, 5, 6) Clutch Piston Return Spring
    G06097530Courtesy of FORD MOTOR CO.
  153. Install the clutch support tower in the transaxle case and install the 3 clutch support tower bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 151: Locating Clutch Support Tower
      G06097531Courtesy of FORD MOTOR CO.
  154. Remove the Input Shaft Support Seal Installer 307-578/1 (sizer).
    Fig 152: Identifying Input Shaft Support Seal Installer 307-578/1
    G06097532Courtesy of FORD MOTOR CO.
  155. Install the No. 1 overdrive/direct clutch assembly thrust bearing.
    Fig 153: Locating No. 1 O/D/Direct Clutch Assembly Thrust Bearing
    G06097533Courtesy of FORD MOTOR CO.
  156. Position the overdrive/direct clutch assembly in the transaxle case.
    Fig 154: Locating O/D/Direct Clutch Assembly
    G06097534Courtesy of FORD MOTOR CO.
  157. Apply compressed air to the overdrive (4, 5, 6) clutch piston port and remove the overdrive (4, 5, 6) clutch piston.
    Fig 155: Applying Compressed Air To O/D (4, 5, 6) Clutch Piston Port
    G06097535Courtesy of FORD MOTOR CO.
  158. Remove the overdrive/direct clutch assembly from the transaxle case.
    Fig 156: Locating O/D/Direct Clutch Assembly
    G06097536Courtesy of FORD MOTOR CO.
  159. Remove the overdrive (4, 5, 6) clutch piston seal from the overdrive/direct clutch assembly.
    Fig 157: Removing O/D (4, 5, 6) Clutch Piston Seal
    G06097537Courtesy of FORD MOTOR CO.
  160. Remove the 2 seals from the overdrive (4, 5, 6) clutch piston.
    Fig 158: Removing Seal From O/D (4, 5, 6) Clutch Piston
    G06097538Courtesy of FORD MOTOR CO.
    161. NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
  161. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    2. Remove the snap ring.
      Fig 159: Removing/Installing Snap Ring
      G06097539Courtesy of FORD MOTOR CO.
  162. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 160: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06097540Courtesy of FORD MOTOR CO.
  163. Remove the direct (3, 5, R) clutch cylinder.
    Fig 161: Removing Direct (3, 5, R) Clutch Cylinder
    G06097541Courtesy of FORD MOTOR CO.
  164. Remove and discard the direct (3, 5, R) clutch piston.
    Fig 162: Removing Direct (3, 5, R) Clutch Piston
    G06097542Courtesy of FORD MOTOR CO.
    165. NOTE: Note the position of the return spring for assembly. The flat side faces down.
    Fig 163: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G06097543Courtesy of FORD MOTOR CO.
  165. Remove the direct (3, 5, R) clutch piston return spring.
  166. Remove the direct (3, 5, R) clutch snap ring.
    1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
    2. Using a suitable tool, compress the snap ring.
    3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    4. Remove the snap ring.
      Fig 164: Removing Snap Ring
      G06097544Courtesy of FORD MOTOR CO.
  167. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
    Fig 165: Locating Direct (3, 5, R) Clutch Pressure Plate, Clutch Pack And Wave Spring
    G06097545Courtesy of FORD MOTOR CO.
  168. Remove and discard the 3 direct (3, 5, R) clutch piston seals.
    Fig 166: Removing Direct (3, 5, R) Clutch Piston Seals
    G06097546Courtesy of FORD MOTOR CO.
  169. Clean and inspect the overdrive/direct clutch assembly for damage or excessive wear and install new components as necessary.
  170. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 167: Locating Direct (3, 5, R) Clutch Piston Seals
    G06097547Courtesy of FORD MOTOR CO.
  171. Install the direct (3, 5, R) clutch wave spring.
    Fig 168: Locating Direct (3, 5, R) Clutch Wave Spring
    G06097548Courtesy of FORD MOTOR CO.
  172. Soak the direct (3, 5, R) clutch pack in clean transmission fluid.
    Fig 169: Identifying Direct (3, 5, R) Clutch Pack
    G06097549Courtesy of FORD MOTOR CO.
  173. Install the direct (3, 5, R) clutch assembly and pressure plate.
    Fig 170: Locating Direct (3, 5, R) Clutch Pressure Plate, Clutch Pack And Wave Spring
    G06097545Courtesy of FORD MOTOR CO.
  174. Install the direct (3, 5, R) clutch snap ring.
    1. Compress the snap ring.
    2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
    3. Release the tension on the snap ring.
      Fig 171: Releasing Tension On Snap Ring
      G06097551Courtesy of FORD MOTOR CO.
    175. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
    Fig 172: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G06097543Courtesy of FORD MOTOR CO.
  175. Install the direct (3, 5, R) clutch piston return spring.
  176. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
    Fig 173: Locating Direct (3, 5, R) Clutch Piston
    G06097553Courtesy of FORD MOTOR CO.
  177. Install the direct (3, 5, R) clutch cylinder.
    Fig 174: Locating Direct (3, 5, R) Clutch Cylinder
    G06097554Courtesy of FORD MOTOR CO.
    178. NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
  178. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    2. Install the snap ring.
      Fig 175: Removing/Installing Snap Ring
      G06097539Courtesy of FORD MOTOR CO.
  179. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 176: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06097540Courtesy of FORD MOTOR CO.
  180. Install 2 new seals on the overdrive (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
    Fig 177: Locating Seals On O/D (4, 5, 6) Clutch Piston
    G06097557Courtesy of FORD MOTOR CO.
  181. Install a new overdrive (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 178: Locating O/D (4, 5, 6) Clutch Piston Inner Seal
    G06097558Courtesy of FORD MOTOR CO.
  182. Position the overdrive (4, 5, 6) clutch piston in place.
    Fig 179: Locating O/D (4, 5, 6) Clutch Piston
    G06097559Courtesy of FORD MOTOR CO.
  183. Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor 307-589/1, install the overdrive (4, 5, 6) clutch piston into the overdrive/direct clutch assembly by hand.
    Fig 180: Installing Overdrive (4, 5, 6) Clutch Piston Into Overdrive/Direct Clutch Assembly
    G06097560Courtesy of FORD MOTOR CO.
    184. NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.
    Fig 181: Locating O/D (4, 5, 6) Clutch Piston Return Spring
    G06097530Courtesy of FORD MOTOR CO.
  184. Install the overdrive (4, 5, 6) clutch piston return spring.
  185. Lubricate the seals on a new balance piston and position the piston in place.
    Fig 182: Locating Seals On Balance Piston
    G06097562Courtesy of FORD MOTOR CO.
  186. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 183: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1
    G06097526Courtesy of FORD MOTOR CO.
  187. Using a press, compress the overdrive (4, 5, 6) clutch return spring and install the snap ring.
    Fig 184: Compressing O/D (4, 5, 6) Clutch Return Spring
    G06097527Courtesy of FORD MOTOR CO.
  188. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 185: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06097528Courtesy of FORD MOTOR CO.
  189. Install the No. 2 thrust bearing.
    Fig 186: Locating No. 2 Thrust Bearing
    G06097566Courtesy of FORD MOTOR CO.
  190. Install the overdrive (4, 5, 6) clutch hub.
    Fig 187: Locating O/D (4, 5, 6) Clutch Hub
    G06097567Courtesy of FORD MOTOR CO.
  191. Soak the overdrive (4, 5, 6) clutch pack in clean transmission fluid.
    Fig 188: Identifying O/D (4, 5, 6) Clutch Pack
    G06097568Courtesy of FORD MOTOR CO.
  192. Install the overdrive (4, 5, 6) clutch pack.
    Fig 189: Locating O/D (4, 5, 6) Clutch Pack
    G06097569Courtesy of FORD MOTOR CO.
  193. Install the overdrive (4, 5, 6) clutch pressure plate.
    Fig 190: Locating O/D (4, 5, 6) Clutch Pressure Plate
    G06097570Courtesy of FORD MOTOR CO.
  194. Install the overdrive (4, 5, 6) clutch snap ring.
    Fig 191: Locating O/D (4, 5, 6) Clutch Snap Ring
    G06097571Courtesy of FORD MOTOR CO.
  195. Install the input shaft.
    Fig 192: Locating Input Shaft
    G06097521Courtesy of FORD MOTOR CO.
  196. While holding the input shaft in place, install the snap ring.
    Fig 193: Locating Input Shaft Snap Ring
    G06097520Courtesy of FORD MOTOR CO.
  197. Position the overdrive/direct clutch assembly in the transaxle case, install Dial Indicator Gauge With Holding Fixture 100-002 or a dial indicator and position the plunger on the overdrive (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.
    Fig 194: Applying Air Pressure To O/D (4, 5, 6) Clutch Piston Port
    G06097574Courtesy of FORD MOTOR CO.
  198. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator Gauge With Holding Fixture 100-002. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
    Fig 195: Applying Air Pressure To Direct (3, 5, R) Clutch Piston Port
    G06097575Courtesy of FORD MOTOR CO.
  199. Remove Dial Indicator Gauge With Holding Fixture 100-002, overdrive/direct clutch assembly and the No. 1 overdrive/direct clutch assembly thrust bearing.
    Fig 196: Identifying Dial Indicator Gauge With Holding Fixture 100-002,
    G06097576Courtesy of FORD MOTOR CO.
  200. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the Differential Seal Installer 307-626.
    Fig 197: Identifying Handle 205-153 And Seal Installer 307-626
    G06097627Courtesy of FORD MOTOR CO.
  201. Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in the transaxle case.
    Fig 198: Installing LH Halfshaft Seal In Transaxle Case
    G06097628Courtesy of FORD MOTOR CO.
  202. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.
    Fig 199: Locating Manual Control Shaft Seal On Manual Lever Seal Installer 307-581
    G06097629Courtesy of FORD MOTOR CO.
  203. Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the transaxle case.
    Fig 200: Installing Manual Control Shaft Seal
    G06097630Courtesy of FORD MOTOR CO.
  204. Install 2-6 Piston Seal Protector 307-632.
    Fig 201: Identifying 2-6 Piston Seal Protector 307-632
    G06097633Courtesy of FORD MOTOR CO.
  205. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.
    Fig 202: Locating Intermediate (2, 6) Clutch Piston
    G06097634Courtesy of FORD MOTOR CO.
    206. NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.
    Fig 203: Locating Intermediate (2, 6) Clutch Piston On Seal Protector
    G06097635Courtesy of FORD MOTOR CO.
  206. Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.
  207. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Open area at the bottom of the transaxle case
    3. Bleed hole
    4. Inner double tabs
      Fig 204: Identifying Intermediate (2, 6) Clutch Piston Return Spring Outer And Inner Double Tabs
      G06097636Courtesy of FORD MOTOR CO.
  208. Remove the intermediate (2, 6) clutch piston return spring.
    Fig 205: Locating Intermediate (2, 6) Clutch Piston Return Spring
    G06097637Courtesy of FORD MOTOR CO.
  209. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.
    Fig 206: Identifying Forward/Intermediate Spring Compressor 307-584/1 On Intermediate (2, 6) Clutch Piston
    G06097638Courtesy of FORD MOTOR CO.
  210. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
    Fig 207: Pushing Intermediate (2, 6) Clutch Piston Into Clutch Cylinder
    G06097639Courtesy of FORD MOTOR CO.
  211. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector 307-632.
    Fig 208: Identifying Forward/Intermediate Spring Compressor 307-584/1 And Clutch Piston Seal Protector 307-632
    G06097640Courtesy of FORD MOTOR CO.
    212. NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.
  212. Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Bleed hole
    3. Inner double tabs
      Fig 209: Identifying Intermediate (2, 6) Clutch Piston Return Spring Outer And Inner Double Tabs
      G06097641Courtesy of FORD MOTOR CO.
    213. NOTE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
  213. Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
    1. Snap ring
    2. Snap ring gap
    3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)
      Fig 210: Identifying Snap Ring, Snap Ring Gap And Low/Reverse And Forward (1, 2, 3, 4) Clutch Hydraulic Ports
      G06097642Courtesy of FORD MOTOR CO.
  214. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the intermediate (2, 6) clutch return spring.
    Fig 211: Identifying 2-6 Piston Return Spring Compressor 307-633/2 On Transaxle Case
    G06097643Courtesy of FORD MOTOR CO.
  215. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.
    Fig 212: Identifying 2-6 Piston Return Spring Compressor 307-633/1 On Snap Ring
    G06097644Courtesy of FORD MOTOR CO.
  216. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.
    Fig 213: Identifying Forward Clutch Spring Compressor 307-574/1 On Transaxle Case
    G06097645Courtesy of FORD MOTOR CO.
    217. NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.
    Fig 214: Installing Intermediate (2, 6) Clutch Snap Ring In Groove
    G06097646Courtesy of FORD MOTOR CO.
  217. Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.
  218. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633.
    Fig 215: Identifying Forward Clutch Spring Compressor 307-574/1 And 2-6 Piston Return Spring Compressor 307-633
    G06097647Courtesy of FORD MOTOR CO.
  219. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place.
    Fig 216: Installing Intermediate (2, 6) Clutch Apply Ring
    G06097648Courtesy of FORD MOTOR CO.
    220. NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.
    Fig 217: Locating No. 1 Thrust Bearing
    G06097649Courtesy of FORD MOTOR CO.
  220. Install the No. 1 thrust bearing with the flat side facing up.
  221. Install the overdrive/direct clutch assembly.
    Fig 218: Locating Overdrive/Direct Clutch Assembly
    G06097394Courtesy of FORD MOTOR CO.
    222. NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.
    Fig 219: Locating No. 3 Thrust Bearing
    G06097393Courtesy of FORD MOTOR CO.
  222. Install the No. 3 thrust bearing with the flat side facing down.
  223. Install the direct/intermediate clutch hub and rear sun gear assembly.
    Fig 220: Locating Direct/Intermediate Clutch Hub And Rear Sun Gear Assembly
    G06097652Courtesy of FORD MOTOR CO.
  224. Install the intermediate (2, 6) wave spring assembly.
    Fig 221: Locating Intermediate (2, 6) Wave Spring Assembly
    G06097653Courtesy of FORD MOTOR CO.
  225. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.
    Fig 222: Identifying Intermediate (2, 6) Clutch Assembly
    G06097654Courtesy of FORD MOTOR CO.
  226. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    Fig 223: Locating Intermediate (2, 6) Clutch Assembly
    G06097655Courtesy of FORD MOTOR CO.
  227. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 224: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G06097656Courtesy of FORD MOTOR CO.
  228. Using a depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
    Fig 225: Measuring Measurement A Using Shim Selection Gauge 307-300
    G06097657Courtesy of FORD MOTOR CO.
  229. Using a depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
    Fig 226: Measuring Measurement B Using Shim Selection Gauge 307-300
    G06097658Courtesy of FORD MOTOR CO.
  230. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in)  
    231. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
    Fig 227: Removing Top Intermediate (2, 6) Clutch Friction And Steel Plate
    G06097659Courtesy of FORD MOTOR CO.
  231. Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.
  232. Install the OWC assembly.
    Fig 228: Locating Low One-Way Clutch (OWC)
    G06097390Courtesy of FORD MOTOR CO.
  233. Install the rear planetary carrier/center ring gear assembly.
    Fig 229: Locating Rear Planetary Carrier/Center Ring Gear Assembly
    G06097661Courtesy of FORD MOTOR CO.
    234. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.
    Fig 230: Locating Low/Reverse Pressure Plate
    G06097662Courtesy of FORD MOTOR CO.
  234. Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.
  235. Soak the low/reverse clutch in clean transmission fluid.
    Fig 231: Identifying Low/Reverse Clutch
    G06097663Courtesy of FORD MOTOR CO.
  236. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.
    Fig 232: Locating Low/Reverse Clutch Pack
    G06097664Courtesy of FORD MOTOR CO.
  237. Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs.
    Fig 233: Identifying Shim Selection Gauge 307-300
    G06097665Courtesy of FORD MOTOR CO.
  238. Using a depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
    Fig 234: Measuring Measurement A Using Shim Selection Gauge 307-300
    G06097666Courtesy of FORD MOTOR CO.
  239. Using a depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.
    Fig 235: Measuring Measurement B Using Shim Selection Gauge 307-300
    G06097667Courtesy of FORD MOTOR CO.
  240. Subtract measurement B from measurement A and record as measurement C.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and record as measurement C.  
  241. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 236: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G06097668Courtesy of FORD MOTOR CO.
  242. Using a depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge 307-300 to the top of the OWC.
    Fig 237: Measuring Measurement D Using Shim Selection Gauge 307-300
    G06097669Courtesy of FORD MOTOR CO.
  243. Using a depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average the 3 distances.
    Fig 238: Measuring Measurement E Using Shim Selection Gauge 307-300
    G06097670Courtesy of FORD MOTOR CO.
  244. Subtract measurement E from measurement D and record as measurement F.
    Description Reading
    Measurement D  
    Measurement E  
    Subtract measurement E from measurement D and record as measurement F  
  245. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement C  
    Measurement F  
    Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in)  
    246. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
    Fig 239: Removing Top Low/Reverse Clutch Steel Plate And Wave Spring
    G06097671Courtesy of FORD MOTOR CO.
  246. Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.
    247. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.
  247. Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
    1. Long center support legs face down
    2. Feed holes face the front of the transaxle case
      Fig 240: Installing Center Support With Long Legs Facing Down
      G06097672Courtesy of FORD MOTOR CO.
  248. Install the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
      Fig 241: Identifying No. 5 And No. 6 Thrust Bearings
      G06097386Courtesy of FORD MOTOR CO.
  249. Install the center planetary sun gear.
    Fig 242: Locating Center Planetary Sun Gear
    G06097674Courtesy of FORD MOTOR CO.
  250. Install the center carrier/front ring gear assembly.
    Fig 243: Locating Center Carrier/Front Ring Gear Assembly
    G06097384Courtesy of FORD MOTOR CO.
  251. Install the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
      Fig 244: Identifying No. 7 And No. 8 Thrust Bearings
      G06097383Courtesy of FORD MOTOR CO.
  252. Install the front planetary/rear ring gear assembly.
    Fig 245: Locating Front Planetary Carrier/Rear Ring Gear Assembly
    G06097382Courtesy of FORD MOTOR CO.
  253. Install the forward (1, 2, 3, 4) clutch wave spring.
    Fig 246: Locating Forward (1, 2, 3, 4) Clutch Wave Spring
    G06097678Courtesy of FORD MOTOR CO.
  254. Soak the forward (1, 2, 3, 4) clutch pack in clean transmission fluid.
    Fig 247: Identifying Forward (1, 2, 3, 4) Clutch Pack
    G06097679Courtesy of FORD MOTOR CO.
  255. Install the forward (1, 2, 3, 4) clutch pack.
    Fig 248: Locating Forward (1, 2, 3, 4) Clutch Pack
    G06097680Courtesy of FORD MOTOR CO.
  256. Install the forward (1, 2, 3, 4) clutch pressure plate.
    Fig 249: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate
    G06097681Courtesy of FORD MOTOR CO.
    257. NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
  257. Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
    1. Forward (1, 2, 3, 4) clutch snap ring
    2. Forward (1, 2, 3, 4) clutch snap ring gap
      Fig 250: Identifying Forward (1, 2, 3, 4) Clutch Snap Ring And Snap Ring Gap
      G06097682Courtesy of FORD MOTOR CO.
  258. Seat the snap ring in the snap ring groove.
    Fig 251: Seating Snap Ring In Snap Ring Groove
    G06097683Courtesy of FORD MOTOR CO.
  259. Install Dial Indicator Gauge With Holding Fixture 100-002 or a dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
    Fig 252: Identifying Dial Indicator Gauge With Holding Fixture 100-002
    G06097684Courtesy of FORD MOTOR CO.
  260. Install the new low/reverse and forward (1, 2, 3, 4) clutch main control-to-transaxle case seals.
    Fig 253: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Main Control-To-Transaxle Case Seals
    G06097685Courtesy of FORD MOTOR CO.
  261. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
    Fig 254: Applying Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
    G06097686Courtesy of FORD MOTOR CO.
  262. Install the front planetary sun gear and shell assembly.
    Fig 255: Locating Front Planetary Sun Gear And Shell Assembly
    G06097687Courtesy of FORD MOTOR CO.
  263. Install the No. 10 thrust bearing.
    Fig 256: Locating No. 10 Thrust Bearing
    G06097688Courtesy of FORD MOTOR CO.
  264. Install the park pawl.
    Fig 257: Locating Park Pawl
    G06097689Courtesy of FORD MOTOR CO.
  265. Install the park pawl pin and spring.
    Fig 258: Locating Park Pawl Pin And Spring
    G06097690Courtesy of FORD MOTOR CO.
  266. Install the park pawl actuator rod in the TR sensor.
    Fig 259: Locating Park Pawl Actuator Rod
    G06097691Courtesy of FORD MOTOR CO.
  267. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transaxle case.
    Fig 260: Positioning Park Pawl Actuator Rod And TR Sensor In Transaxle Case
    G06097692Courtesy of FORD MOTOR CO.
  268. Install the manual control shaft and align the manual control shaft pin holes.
    Fig 261: Installing Manual Control Shaft
    G06097693Courtesy of FORD MOTOR CO.
  269. Install the manual control shaft pin.
    Fig 262: Installing Manual Control Shaft Roll Pin
    G06097694Courtesy of FORD MOTOR CO.
    270. NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
  270. Install the manual control lever and the manual control lever nut.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 263: Locating Manual Control Lever And Nut
      G06097402Courtesy of FORD MOTOR CO.
  271. Install the 5 new clutch feed seals.
    Fig 264: Locating Clutch Feed Seals
    G06097696Courtesy of FORD MOTOR CO.
  272. Position the transmission fluid baffle in place and install the 2 transmission fluid baffle bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 265: Locating Transmission Fluid Baffle Bolts
      G07932242Courtesy of FORD MOTOR CO.
  273. Position the fluid reservoir in place and install the 2 fluid reservoir bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 266: Locating Fluid Reservoir Bolt
      G07932241Courtesy of FORD MOTOR CO.
  274. Install the No. 12 thrust bearing.
    Fig 267: Locating No. 12 Driven Sprocket Thrust Bearing
    G07932239Courtesy of FORD MOTOR CO.
  275. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
    Fig 268: Installing Drive/Driven Sprocket And Chain Assembly
    G07932470Courtesy of FORD MOTOR CO.
  276. Install the No. 11 thrust bearing.
    Fig 269: Locating No. 11 Drive Sprocket Thrust Bearing
    G07932229Courtesy of FORD MOTOR CO.
  277. Install the No. 13 thrust washer.
    Fig 270: Locating No. 13 Thrust Washer
    G07932228Courtesy of FORD MOTOR CO.
  278. Install the differential sun gear.
    Fig 271: Locating Differential Sun Gear
    G07932226Courtesy of FORD MOTOR CO.
  279. Install the differential assembly.
    Fig 272: Locating Differential Assembly
    G06097705Courtesy of FORD MOTOR CO.
  280. Install the No. 15 thrust bearing.
    Fig 273: Locating No. 15 Thrust Bearing
    G06097706Courtesy of FORD MOTOR CO.
  281. Install the Turbine Shaft Seal Protector 307-635 on the input shaft.
    Fig 274: Locating Turbine Shaft Seal Protector 307-635 On Input Shaft
    G07932476Courtesy of FORD MOTOR CO.
  282. For vehicles equipped with Front Wheel Drive (FWD), assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the Seal Installer 307-626.
    Fig 275: Identifying Handle 205-153 And Differential Seal Installer 307-626
    G06097709Courtesy of FORD MOTOR CO.
  283. Using the Handle 205-153 and Differential Seal Installer 307-626, install the new RH halfshaft seal.
    Fig 276: Installing RH Halfshaft Seal
    G06097710Courtesy of FORD MOTOR CO.
  284. For vehicles equipped with All-Wheel Drive (AWD), install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428.
    Fig 277: Locating RH Seal On RH Halfshaft Fluid Seal Installer 307-428
    G06097711Courtesy of FORD MOTOR CO.
  285. Using the RH Halfshaft Fluid Seal Installer 307-428, install the new RH halfshaft seal.
    Fig 278: Installing RH Halfshaft Seal Using RH Halfshaft Fluid Seal Installer 307-428
    G06097712Courtesy of FORD MOTOR CO.
  286. Install the pump and filter assembly in the torque converter housing and install the 8 pump-to-torque converter housing bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 279: Locating Pump-To-Torque Converter Housing Bolts
      G07444260Courtesy of FORD MOTOR CO.
  287. Install the differential transmission fluid baffle and the 2 differential transmission fluid baffle bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 280: Locating Differential Transmission Fluid Baffle Bolts
      G06097408Courtesy of FORD MOTOR CO.
    288. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
    Fig 281: Applying Silicone To Sealing Surface Of Transaxle Case
    G07932483Courtesy of FORD MOTOR CO.
  288. Apply silicone to the sealing surface of the transaxle case.
    289. NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
  289. Install the torque converter housing on the transaxle case and install the 16 torque converter housing bolts and the torque converter housing stud bolt.
    1. Torque converter housing bolt location.
    2. Torque converter housing stud bolt location.
      • Tighten to 24 Nm (18 lb-ft).
        Fig 282: Locating Transaxle Converter Housing Bolts
        G06097719Courtesy of FORD MOTOR CO.
  290. Remove the Turbine Shaft Seal Protector 307-635.
    Fig 283: Identifying Turbine Shaft Seal Protector 307-635
    G06097720Courtesy of FORD MOTOR CO.
  291. Install the TSS sensor and the TSS sensor bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 284: Locating TSS Sensor Bolt
      G06097721Courtesy of FORD MOTOR CO.
  292. Install the OSS sensor and the OSS sensor bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 285: Locating OSS Sensor Bolt
      G06097362Courtesy of FORD MOTOR CO.
  293. Install the new main control-to-transaxle case separator plate and align it on the stud and the guide pin.
    Fig 286: Locating Main Control-To-Transaxle Case Separator Plate
    G06097725Courtesy of FORD MOTOR CO.
    294. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
    Fig 287: Identifying Main Control Assembly Position
    G06097726Courtesy of FORD MOTOR CO.
  294. Position the main control assembly in place and align the manual valve on the TR sensor.
  295. Install the main control nut hand-tight.
    Fig 288: Locating Main Control Nut
    G06097727Courtesy of FORD MOTOR CO.
  296. Install the short main control-to-transaxle case bolts hand-tight.
    Fig 289: Locating Short Main Control-To-Transaxle Case Bolts
    G06097728Courtesy of FORD MOTOR CO.
  297. Install the long main control-to-transaxle case bolts hand-tight.
    Fig 290: Locating Long Main Control-To-Transaxle Case Bolts
    G06097729Courtesy of FORD MOTOR CO.
  298. Tighten the main control-to-transaxle case bolts and the main control nut in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      Fig 291: Locating Main Control-To-Transaxle Case Bolts
      G06097730Courtesy of FORD MOTOR CO.
  299. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the TR sensor detent spring bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 292: Locating TR Sensor Detent Spring And Bolt
      G06097731Courtesy of FORD MOTOR CO.
    300. NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
    Fig 293: Locating Main Control-To-Cover Seal
    G06097355Courtesy of FORD MOTOR CO.
  300. Install the main control-to-cover seal.
  301. Connect the TR sensor electrical connector.
    Fig 294: Locating TR Sensor Electrical Connector
    G06097354Courtesy of FORD MOTOR CO.
  302. Connect the OSS sensor electrical connector.
    Fig 295: Locating Output Shaft Speed Sensor Electrical Connector
    G06097353Courtesy of FORD MOTOR CO.
  303. Clean the main control cover sealing surface.
    Fig 296: Locating Main Control Cover Sealing Surface
    G06097735Courtesy of FORD MOTOR CO.
  304. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 297: Locating Main Control Sealing Surface Of Transaxle Case
    G06097736Courtesy of FORD MOTOR CO.
  305. Position the main control cover in place.
    Fig 298: Locating Main Control Cover
    G06097737Courtesy of FORD MOTOR CO.
    306. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
  306. Install the main control cover bolts.
    1. Bolt location
    2. Stud bolt location
      • Tighten to 12 Nm (106 lb-in).
        Fig 299: Identifying Main Control Cover Bolts
        G06097738Courtesy of FORD MOTOR CO.
    307. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 300: Removing/Installing Torque Converter
    G06097351Courtesy of FORD MOTOR CO.
  307. Using the Torque Converter Handle 307-091, install the torque converter.
  308. Remove the Torque Converter Handle 307-091.
    Fig 301: Identifying Torque Converter Handle 307-091
    G06097350Courtesy of FORD MOTOR CO.
  309. Install the Torque Converter Retainer 307-566.
    Fig 302: Identifying Torque Converter Retainer 307-566
    G06097349Courtesy of FORD MOTOR CO.
  310. Remove the transaxle from the bench-mounted holding fixture.
    Fig 303: Identifying Transaxle On Bench-Mounted Holding Fixture
    G06097742Courtesy of FORD MOTOR CO.
  311. Remove the Holding Fixture 307-625.
    Fig 304: Identifying Holding Fixture 307-625
    G06097347Courtesy of FORD MOTOR CO.
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