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Home › Ford › 2013 › Escape Titanium, AWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - 6F35 › Disassembly And Assembly › Transmission - Overhaul › Disassembled Views

Disassembled Views

Fig 1: Exploded View Of Automatic Transaxle 6F35 Service Components (1 Of 3)
G08031100Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Automatic Transaxle 6F35 Service Components (2 Of 3)
G08031101Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Automatic Transaxle 6F35 Service Components (3 Of 3)
G08031102Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7005 Transmission 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 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-transmission 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 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-transmission case seal (2 required)
121 W713644 OSS sensor bolt
122 7H103 OSS sensor
123 7Z490 Main control-to-transmission 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-transmission case bolt (long) (10 required)
130 W302862 Main control-to-transmission 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 TSS sensor
144 W500214 TSS bolt
145 7A246 Vent tube
146 W500214 Fluid reservoir bolts
147 7G342 Solenoid body strategy tag
148 7B148 Transmission 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. Special Tool(s): Holding Fixture 307-625.
    G08411922
  2. Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B), Holding Fixture 307-625.

    General Equipment: Work Bench.

    G08411923
  3. Special Tool(s): Retainer, Torque Converter 307-566.
    G08411924
  4. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.

    Special Tool(s): Handle, Torque Converter 307-091 (T81P-7902-C).

    G08411925
  5. NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.
    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 transmission assembly or fluid contamination due to the following transmission 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.
      G08411926
  6. NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur.

    Drain the remaining fluid from the torque converter. Apply the specified amount of fluid.

    • Agitate by hand.
    • Thoroughly drain the fluid.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08411927
  7. NOTE: Note the location of the stud bolts for assembly.
    G08614322
  8. G08411929
  9. G08411930
  10. G08411931
  11. NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.
    G08411692
  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. Refer to MAIN CONTROL - OVERHAUL .
    G08411933
  13. G08411682
  14. G08411935
  15. G08411936
  16. G08411937
  17. G08411938
  18. NOTE: Note the location of the stud bolts for assembly.
    G08411939
  19. General Equipment: Pry Bar.
    G08411940
  20. G08411941
  21. G08411942
  22. G08411943
  23. Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear. Install new components, if necessary. Refer to DIFFERENTIAL GEAR ASSEMBLY .
    G08411944
  24. G08411945
  25. Check for damage or excessive wear.
    G08411946
  26. G08411947
  27. G08411948
  28. NOTE: Simultaneously lift the drive, driven sprockets and chain.
    G08411949
  29. G08411950
  30. Check for damage or excessive wear.
    • Check for stretching or tightness of the chain links.
    • Check that the chain moves freely.
      G08411951
  31. Check that bearing spins freely. Check for damage or excessive wear.
    G08411952
  32. G08411953
  33. Check for damage or excessive wear.
    G08411954
  34. Check for damage or excessive wear.
    G08411955
  35. G08411953
  36. G08411950
  37. G08411958
  38. G08411959
  39. G08411960
  40. G08411961
  41. G08411962
  42. G08411963
  43. NOTE: Note the location of the snap ring gap for assembly.
    G08411964
  44. Clutch pressure plate, clutch plates and wave spring.
    G08411965
  45. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
    G08411966
  46. G08411967
  47. Check for damage or excessive wear.
    G08411968
  48. G08411969
  49. Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
    G08411970
  50. G08411971
  51. G08411972
  52. Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
    G08411973
  53. G08411974
  54. Check for damage or excessive wear.
    G08411975
  55. G08411976
  56. G08411977
  57. G08411978
  58. Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
    G08411979
  59. Wave spring, clutch plates and pressure plate.
    G08411980
  60. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
    G08411981
  61. G08411982
  62. 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.

    Check for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise.

    G08411983
  63. Check for burned or excessively worn surface.
    G08411984
  64. G08411985
  65. Inspect the clutch plate surfaces for damage or excessive wear.
    G08411986
  66. Check for damage or excessive wear.
    G08411987
  67. Pressure plate and the wave spring.
    G08411988
  68. Inspect the pressure plate surface for damage or excessive wear.
    G08411989
  69. G08411990
  70. G08411991
  71. 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.
    G08411992
  72. G08411993
  73. G08411994
  74. NOTE: Note the location of the snap ring gap for assembly.
    G08411995
  75. NOTE: Note the position of the return spring for assembly.
    G08411996
  76. NOTE: Note the position of the intermediate clutch piston for assembly.
    G08411997
  77. G08411998
  78. G08411999
  79. NOTE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transmission case causing damage to the transmission case.

    Special Tool(s): Remover, Roll Pin 211-061 (T78P-3504-N1).

    G08412000
  80. G08412001
  81. G08412002
  82. G08412003
  83. General Equipment: Pry Bar.
    G08412004
  84. NOTE: If the LH transmission case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transmission case bushing and a new LH halfshaft must be installed, or excessive noise or transmission failure can occur.

    If the LH transmission case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components. Refer to TRANSMISSION CASE .

    G08412005
  85. G08412006
  86. G08412007
  87. General Equipment: Pry bar.
    G08412008
  88. If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear. Refer to TRANSMISSION CASE .
    G08412009
  89. G08412010
  90. G08412011
  91. Special Tool(s): Slide Hammer 100-001 (T50T-100-A), Actuator Pin 303-D011 (D80L-100-G), Collet, 3/4 Inch to 7/8 Inch 303-D019 (D810L-100-Q).
    G08412012
  92. G08412013
  93. G08412014
  94. General Equipment: Dent puller.
    G08412015
  95. Bolts hand-tight.
    G08412016
  96. G08412017
  97. G08412018
  98. G08412019
  99. G08412020
  100. Compress the valve spring with a screwdriver and remove the retainer with a magnet.

    General Equipment: Screwdriver, Magnet.

    G08412021
  101. General Equipment: M4 bolt.
    G08412022
  102. Compress the valve spring with a screwdriver and remove the retainer with a magnet.

    General Equipment: Screwdriver, Magnet.

    G08412023
  103. G08412024
  104. 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.
  105. NOTE: TCC control valve retainer shown in illustration assembled in the pump body, main pressure regulator valve retainer similar.
    G08412025
  106. NOTE: The dot on the inner pump gear faces up.
    G08412026
  107. Bolts hand-tight.
    G08412027
  108. Bolts hand-tight.
    G08412016
    • Tighten to 10 Nm (89 lb-in).
      G08412029
  110. G08412016
  111. Special Tool(s): Installer, Converter Seal 307-627.
    G08412031
  112. Special Tool(s): Installer, Converter Seal 307-627.
    G08412032
  113. G08412014
  114. G08412013
  115. Special Tool(s): Seal Installer, Turbine Shaft 307-634.
    G08412035
  116. Special Tool(s): Seal Installer, Turbine Shaft 307-634.
    G08412036
  117. New O-ring.

    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412037
  118. G08412011
  119. G08412039
  120. 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.

    Position the center support on a press with the long legs facing up.

    Special Tool(s): Compressor, Center Support Piston Spring 307-630.

    General Equipment: Shop Press.

    G08412040
  121. G08412041
  122. Apply 483 kPa (70 psi) of air pressure.
    G08412042
  123. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.

    Position the center support on a press with the short legs facing up.

    Special Tool(s): Compressor, Center Support Piston Spring 307-630.

    General Equipment: Shop Press.

    G08412043
  124. G08412044
  125. Apply 483 kPa (70 psi) of air pressure.
    G08412045
  126. Check for damage or excessive wear.
    G08412046
  127. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.

    Short leg side of the center support facing up.

    Special Tool(s): Seal Protector, Low Reverse Piston 307-628/2, Seal Protector, Low Reverse/1-2-3-4 Piston 307-629.

    G08412047
  128. Shop Supplies: Petroleum Jelly.
    G08412048
  129. Special Tool(s): Seal Protector, Low Reverse Piston 307-628/2, Seal Protector, Low Reverse/1-2-3-4 Piston 307-629.
    G08412049
  130. 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.
    G08412044
  131. Position the center support on a press with the short legs facing up.

    Special Tool(s): Compressor, Center Support Piston Spring 307-630.

    General Equipment: Shop Press.

    G08412043
  132. Check the snap ring to be sure it is seated in the groove.
    G08412052
  133. Position the center support with the long legs facing up.

    Special Tool(s): Seal Protector, Low Reverse Piston 307-628 (includes 307-628/1 and 307-628/2).

    G08412053
  134. Shop Supplies: Petroleum Jelly.
    G08412054
  135. Special Tool(s): Seal Protector, Low Reverse Piston 307-628 (includes 307-628/1 and 307-628/2).
    G08412055
  136. G08412041
  137. Position the center support on a press with the long legs facing up.

    Special Tool(s): Compressor, Center Support Piston Spring 307-630.

    General Equipment: Shop Press.

    G08412040
  138. Check the snap ring to be sure it is seated in the groove.
    G08412058
  139. G08412059
  140. Check for damage or excessive wear.
    G08412060
  141. Align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove.

    Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.

    G08412061
  142. Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
    G08412062
  143. Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/2, Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
    G08412063
  144. Remove tools and repeat steps for the other 3 Teflon® seals.

    Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/2, Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.

    G08412064
  145. Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/1.
    G08412065
  146. G08412066
  147. G08412067
  148. G08412068
  149. G08412069
  150. G08412070
  151. G08412071
  152. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
    G08412072
  153. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring 307-584/2.
    G08412073
  154. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring 307-584/2. General Equipment: Shop Press.
    G08412074
  155. G08412075
  156. G08412076
    • Tighten to 12 Nm (106 lb-in).
      G08412077
  158. Remove the special tool.

    Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/1.

    G08412078
  159. G08412079
  160. G08412080
  161. Apply compressed air to the piston port.
    G08412081
  162. G08412082
  163. G08412083
  164. G08412084
  165. 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.

    Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/2, Compressor, Forward/Intermediate Spring 307-584/2. General Equipment: Shop Press.

    G08412085
  166. G08412086
  167. G08412087
  168. G08412088
    1. Slightly lift up on the clutch so that the snap ring floats freely.
    2. Compress the snap ring.
    3. Allow the clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    4. Remove the snap ring.

    General Equipment: Screwdrivers.

    G08412089
  170. G08412090
  171. Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
    G08412091
  172. G08412092
  173. Check for damage or excessive wear.
    G08412093
  174. Shop Supplies: Petroleum Jelly.
    G08412094
  175. G08412095
  176. Soak the clutch plates.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412096
  177. G08412090
    1. Compress the snap ring.
    2. Lift the clutch so that the snap ring is in the groove of the pressure plate.
    3. Release the tension on the snap ring.

      General Equipment: Snap-ring Pliers.

      G08412098
  179. NOTE: Install the return spring with the flat side facing down.
    G08412099
  180. Shop Supplies: Petroleum Jelly.
    G08412100
  181. G08412086
  182. 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.

    Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/2, Compressor, Forward/Intermediate Spring 307-584/2.

    General Equipment: Shop Press.

    G08412085
  183. Shop Supplies: Petroleum Jelly.
    G08412103
  184. Shop Supplies: Petroleum Jelly.
    G08412104
  185. G08412105
  186. Install by hand.

    Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1.

    G08412106
  187. NOTE: Holes face up on the clutch piston return spring.
    G08412107
  188. Shop Supplies: Petroleum Jelly.
    G08412108
  189. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring Compressor 307-584/2.
    G08412109
  190. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring Compressor 307-584/2.

    General Equipment: Shop Press.

    G08412074
  191. G08412111
  192. G08412112
  193. Soak the clutch plates.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412113
  194. G08412114
  195. G08412115
  196. G08412116
  197. G08412067
  198. G08412066
  199. Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
    G08412119
  200. 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.

    Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).

    G08412120
  201. 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. 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.

    Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).

    G08412121
  202. Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
    G08412122
  203. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
    G08412123
  204. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
    G08412124
  205. Special Tool(s): Manual Lever Seal Installer 307-581.
    G08412125
  206. Special Tool(s): Manual Lever Seal Installer 307-581.
    G08412126
  207. Special Tool(s): Seal Protector, 2-6 Piston 307-632.
    G08412127
  208. Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.
    G08412128
  209. NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.
    G08412129
  210. Position the 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 transmission case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Inner double tabs
    2. Bleed hole
    3. Outer tabs
      G08412130
  211. G08412131
  212. Push the clutch piston into the clutch cylinder by hand.

    Special Tool(s): Compressor, Forward/Intermediate Spring 307-584/1.

    G08412132
  213. 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 transmission can occur.

    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. Inner double tabs
    2. Bleed hole
    3. Outer tabs
      G08412133
  214. NOTE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.

    Align the gap of the snap ring to face the front of the transmission.

    1. Snap ring
    2. Snap ring gap
    3. Clutch hydraulic ports (located at the front of the transmission case)
      G08412134
  215. Special Tool(s): Spring Compressor, 2-6 Piston Return 307-633/2.
    G08412135
  216. Special Tool(s): Spring Compressor, 2-6 Piston Return 307-633/1.
    G08412136
  217. Special Tool(s): Compressor, Forward Clutch Spring 307-574/1.
    G08412137
  218. NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.

    Special Tool(s): Compressor, Forward Clutch Spring 307-574/1, Spring Compressor, 2-6 Piston Return 307-633 (Includes 307-633/1 and 307-633/2).

    General Equipment: Wrench.

    G08412138
  219. Tap the ring in place.
    G08412139
  220. NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.
    G08412140
  221. G08411991
  222. NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.
    G08411990
  223. G08412143
  224. Clutch wave spring.
    G08412144
  225. Soak the clutch plates.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412145
  226. Position the clutch plates, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    1. Steel plate
    2. Friction plate
      G08614923
  227. Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
    G08412147
  228. Record as measurement A, the distance from the Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the clutch plate at 3 different points and average the 3 distances.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412148
  229. Record as measurement B, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the transmission case step above the intermediate (2, 6) clutch.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412149
  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.
    1. Friction plate
    2. Steel plate
      G08412150
  232. G08411982
  233. G08412152
  234. NOTE: Note the position of the pressure plate. When installing the center support, the long support legs must fit through the pressure plate and rest on the OWC.
    G08412153
  235. Soak the clutch plates.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412154
  236. Position the wave spring and clutch plate, temporarily reversing the wave spring and steel plate for the clutch stack-up measurement.
    1. Steel plate.
    2. Wave spring.
      G08412155
  237. Position the center support with the long legs facing up.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    G08412156
  238. Record as measurement A, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the contact surface of the low/reverse clutch piston.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412157
  239. Record as measurement B, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the leg surface of the center support.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412158
  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. Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
    G08412159
  242. Record as measurement D, the distance from the Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the OWC.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412160
  243. Record as measurement E, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the low/reverse clutch at 3 different points and average the 3 distances.

    Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).

    General Equipment: Depth Gauge.

    G08412161
  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.
    1. Wave spring
    2. Steel plate
      G08412162
  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 transmission.
    1. Long legs face down.
    2. Feed holes face the front of the transmission case.
      G08412163
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
      G08412164
  249. G08411974
  250. G08411972
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
      G08412167
  252. G08411969
  253. Wave spring.
    G08412169
  254. Soak the clutch plates.

    Material: Clean Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

    G08412170
  255. Clutch plates.
    G08412171
  256. Pressure plate.
    G08412172
  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 transmission.

    Clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.

    G08412173
  258. Seat the snap ring in the snap ring groove.
    G08412174
  259. Position the plunger on the top clutch friction plate.

    Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).

    G08412175
  260. G08412176
  261. Apply 483 kPa (70 psi) of air pressure to the 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 transmission 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.

    Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).

    G08412177
  262. G08412178
  263. G08412179
  264. G08412180
  265. G08412181
  266. G08412182
  267. Align the manual control shaft pin holes.
    G08412183
  268. G08412184
  269. 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.
    • Tighten to 24 Nm (18 lb-ft).
      G08411999
  270. G08412186
    • Tighten to 12 Nm (106 lb-in).
      G08411961
    • Tighten to 12 Nm (106 lb-in).
      G08411960
  273. G08411958
  274. NOTE: Simultaneously lower the drive, driven sprockets and chain.

    Lightly tap on the driven sprocket to be sure it is fully seated in the case.

    G08412190
  275. G08411948
  276. G08411947
  277. G08411945
  278. G08411943
  279. G08411942
  280. Special Tool(s): Seal Protector, Turbine Shaft 307-635.
    G08412196
  281. FWD Vehicles.

    Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.

    G08412197
  282. FWD Vehicles.

    Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.

    G08412198
  283. AWD Vehicles.

    Special Tool(s): Installer, RH Halfshaft Fluid Seal 307-428.

    G08412199
  284. AWD Vehicles.

    Special Tool(s): Installer, RH Halfshaft Fluid Seal 307-428.

    G08412200
    • Tighten to 35 Nm (26 lb-ft).
      G08412007
    • Tighten to 12 Nm (106 lb-in).
      G08412006
  287. NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.

    Material: Ultra Silicone Sealant TA-29.

    G08412203
  288. G08411941
  289. NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
    • Tighten to 24 Nm (18 lb-ft).
      G08411939
  290. Remove the special tool.

    Special Tool(s): Seal Protector, Turbine Shaft 307-635.

    G08412206
    • Tighten to 10 Nm (89 lb-in).
      G08411936
    • Tighten to 10 Nm (89 lb-in).
      G08411938
  293. Align the new separator plate on the stud and the guide pin.
    G08411687
  294. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
    G08411688
  295. Nut hand-tight.
    G08411689
  296. Short bolts hand-tight.
    G08411690
  297. Long bolts hand-tight.
    G08411691
  298. Tighten in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      G08411692
  299. Alignment tab in the alignment hole.
    • Tighten to 13 Nm (115 lb-in).
      G08412215
  300. NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
    G08411693
  301. G08411930
  302. G08411929
  303. G08614323
  304. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
    • Tighten to 12 Nm (106 lb-in).
      G08614322
  305. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.

    Special Tool(s): Handle, Torque Converter 307-091 (T81P-7902-C).

    G08412222
  306. Special Tool(s): Retainer, Torque Converter 307-566.
    G08412223
  307. Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B), Holding Fixture 307-625.
    G08411923
  308. Special Tool(s): Holding Fixture 307-625.
    G08411922
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