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Forward Geartrain: Assembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Forward Clutch Cylinder Thrust Bearing (No. 5) On Forward Clutch Cylinder Assembly
GF0010238Courtesy of FORD MOTOR CO.
  1. Install the forward clutch cylinder thrust bearing (No. 5) on the forward clutch cylinder assembly.
    • Use petroleum jelly to hold the forward clutch cylinder thrust bearing (No. 5) in place.
    2. Fig 2: Identifying Forward Clutch Cylinder Assembly Into Intermediate Brake & Direct Clutch Drum Assembly
    GF0010239Courtesy of FORD MOTOR CO.
  2. Install the forward clutch cylinder assembly into the intermediate brake and direct clutch drum assembly.
    3. Fig 3: Installing Forward Ring Gear Hub Thrust Bearing (No. 6A) With Tabs Facing Up
    GF0010240Courtesy of FORD MOTOR CO.
  3. Install the forward ring gear hub thrust bearing (No. 6A) with the tabs facing up.
    4. Fig 4: Installing Forward Clutch Thrust Washer (No. 6B) Into Forward Ring Gear Hub
    GF0010241Courtesy of FORD MOTOR CO.
  4. Install the forward clutch thrust washer (No. 6B) into the forward ring gear hub.
    • Use petroleum jelly to hold the forward clutch thrust washer (No. 6B) in place.
    5. Fig 5: Identifying Forward Ring Gear Into Forward Clutch Cylinder
    GF0010242Courtesy of FORD MOTOR CO.
    NOTE: Make sure the forward ring gear hub thrust bearing (No. 6A) and forward clutch thrust washer (No. 6B) are inside the forward ring gear.
  5. Install the forward ring gear into the forward clutch cylinder.
    6. Fig 6: Locating Forward Planetary Thrust Bearing (No. 7)
    GF0010243Courtesy of FORD MOTOR CO.
    CAUTION: Black oxidized color of thrust bearing must face up towards the planetary assembly.
  6. Install the forward planetary thrust bearing (No. 7) into the forward ring gear.
    7. Fig 7: Locating Forward Planetary Assembly
    GF0010244Courtesy of FORD MOTOR CO.
    NOTE: The forward planetary assembly is serviced with a 6-pinion assembly in all applications.
  7. Install the forward planetary assembly into the forward ring gear.
    8. Fig 8: Locating Sun Gear & Input Shell
    GF0010245Courtesy of FORD MOTOR CO.
    NOTE: There is not a bushing inside the forward sun gear or washer on the back of the input shell.
    NOTE: If the sun gear or input shell is damaged, carry out the following steps. If not, install the input shell and forward sun gear assembly into planetary gearset.
    NOTE: Make sure the forward sun gear aligns with the forward planetary assembly. Make sure the input shell aligns with the intermediate brake and direct clutch.
  8. Inspect sun gear and input shell for damage or wear. If sun gear or input shell are damaged, install new as necessary. Install the input shell and forward sun gear assembly into planetary gearset.
    9. Fig 9: Locating Rear Retaining Ring, Sun Gear & Retaining Ring
    GF0010246Courtesy of FORD MOTOR CO.
  9. Remove the rear retaining ring, sun gear and the retaining ring from the sun gear.
    1. Remove the rear retaining ring.
    2. Remove the sun gear.
    10. Fig 10: Locating Front Retaining Ring
    GF0010247Courtesy of FORD MOTOR CO.
  10. Remove the front retaining ring from the sun gear.
    11. Fig 11: Locating Retaining Ring
    GF0010247Courtesy of FORD MOTOR CO.
  11. Install a new retaining ring onto the sun gear.
    12. Fig 12: Locating Sun Gear On Input Shell
    GF0010248Courtesy of FORD MOTOR CO.
  12. Install the sun gear into the input shell.
    13. Fig 13: Locating Rear Retaining Ring
    GF0010249Courtesy of FORD MOTOR CO.
  13. Install a new rear retaining ring.
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