Disassembled Views

Fig 1: Disassembled Views Of Transaxle - Overhaul (1 Of 5)

Courtesy of FORD MOTOR CO.

Fig 2: Disassembled Views Of Transaxle - Overhaul (2 Of 5)

Courtesy of FORD MOTOR CO.

Fig 3: Disassembled Views Of Transaxle - Overhaul (3 Of 5)

Courtesy of FORD MOTOR CO.

Fig 4: Disassembled Views Of Transaxle - Overhaul (4 Of 5)

Courtesy of FORD MOTOR CO.

Fig 5: Disassembled Views Of Transaxle - Overhaul (5 Of 5)

Courtesy of FORD MOTOR CO.

All vehicles 

1. Using the special tool, mount the transmission onto the bench.

   Special Tool(s): Holding Fixture 307-580

2. Remove the special tool.

   Special Tool(s): Retainer, Torque Converter 307-346

3. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
   NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.

   Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and remove the torque converter from the transmission.

4. 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.

   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 transmission assembly or fluid contamination due to the following transmission or converter failure modes.
        • Major metallic failure
        • Multiple clutch plates or band failures
        • Sufficient component wear which results in metallic contamination
        • 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 transmission damage will occur.

      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.
5. NOTE: Note the location of the studbolts for assembly.

   Remove the bolts and the main control cover.

6. Slide the TR  sensor electrical connector lock tab over to unlock the connector and disconnect the TR  sensor electrical connector.
7. Disconnect the TSS  sensor and the OSS  sensor electrical connectors.
8. Remove the OSS  sensor wire from the retainer.
9. NOTE: Handle the solenoid body with care or damage to the solenoid body may occur.
   NOTE: Note the location of the different length bolts for assembly.

   Remove the bolts and the solenoid body.

10. Remove the main control valve body bolts and the valve body.
11. Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. Refer to MAIN CONTROL - OVERHAUL .
12. Remove and discard the forward clutch feed seal.
13. Remove the bolt and the OSS  sensor.
14. Remove the cover assembly bolts.
15. Remove the cover assembly and carefully route the TSS  sensor wiring harness and electrical connector out of the transmission case.
16. Remove the cover assembly gasket.
17. Remove the No. 1 cover assembly thrust bearing
18. Remove the overdrive/direct clutch hub and turbine shaft assembly.
19. Remove the No. 3 rear sun gear thrust bearing.
20. Remove the intermediate clutch shell and sun gear assembly.
21. Clean and inspect the rear 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
22. Remove the intermediate clutch assembly.
23. NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low OWC  snap ring.

    Remove the low/reverse clutch assembly.

24. Remove the rear planetary carrier and center ring gear assembly.
25. Clean and inspect the rear planetary gear carrier assembly for damage or 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
26. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
27. Remove the center planetary sun gear.
28. Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
29. Remove the center planetary carrier and front ring gear assembly.
30. Clean and inspect the center planetary gear carrier assembly for damage or wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing surfaces
    • Ring gear teeth
31. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
32. Remove the front planetary carrier and rear ring gear assembly.
33. Clean and inspect the front planetary gear carrier assembly for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Ring gear teeth
    • Shell-to-clutch pack surfaces
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing
34. Remove the front planetary sun gear and shell assembly.
35. Clean and inspect the front 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
36. Remove the No. 10 front sun gear thrust bearing.
37. Remove the front planetary carrier hub assembly.
38. Clean and inspect the front planetary carrier hub for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Hub-to-stator support surfaces
39. Remove the No. 11 support assembly thrust bearing.
40. NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.

    Remove the low OWC  snap ring.

41. Remove the low OWC  .
42. NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.
    NOTE: The low OWC  cannot be disassembled.

    Clean and inspect the low OWC  for cracks and damaged splines. The internal splined section should rotate counterclockwise and lock when rotated clockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC  .

43. Inspect the forward clutch surface for damage. If the surface is burned or worn excessively, install a new OWC  .
44. Remove the forward clutch assembly.
45. NOTE: Install the Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

    Using the special tools, compress the forward clutch piston return spring.

    Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (includes 307-584/1 and 307-584/2), Compressor, Forward Clutch Spring 307-574 (includes 307-574/1 and 307-574/2)

46. NOTE: The special tools are not shown in illustration below for clarity.

    Remove the forward clutch piston return spring snap ring.

47. Remove the forward clutch piston return spring.
48. Remove and discard the forward clutch piston.
49. NOTE: Note the location of the studbolts for assembly.

    Remove the torque converter housing bolts.

50. NOTE: Carefully pry on the transmission torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.

    Carefully pry the torque converter housing off the transmission case just enough to break the seal of the silicone and remove the torque converter housing from the transmission case.

51. Remove the transmission lube tube.
52. Remove the differential and ring gear assembly.
53. Remove the transfer shaft and gear assembly.
54. NOTE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

    Inspect the differential for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the ring gear for damage. Install new bearings or a ring gear on the differential if damage or excessive wear is found. Refer to DIFFERENTIAL GEAR ASSEMBLY . If the differential bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to TRANSAXLE CASE  and TORQUE CONVERTER HOUSING . If the differential ring gear is replaced, the transfer shaft must also be replaced. Refer to TRANSFER SHAFT AND GEAR .

55. NOTE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

    Inspect the transfer shaft for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the park pawl wheel, transfer shaft and transfer shaft input gear for damage. Install new bearings, park pawl wheel, transfer shaft or transfer shaft input gear if damage or excessive wear is found. Refer to TRANSFER SHAFT AND GEAR . If the transfer shaft bearings are replaced the bearing races in the transmission case and the torque converter housing case must also be replaced. Refer to TRANSAXLE CASE  and TORQUE CONVERTER HOUSING . If the transfer shaft is replaced, the differential ring gear must also be replaced. Refer to DIFFERENTIAL GEAR ASSEMBLY .

    1. Bearings
    2. Transfer shaft input gear
    3. Transfer shaft
    4. Park pawl wheel
56. Remove and discard the pump-to-case seal.
57. Remove the bolts and the oil reservoir.
58. Remove and discard the reservoir O-ring seal.
59. NOTE: Gently pry the pin out of the hole from under the head on each side with the special tool or the pin may be broken off in the hole.

    Using the special tool, remove and discard the TR  sensor locking pin.

    Special tool(s): Remover, TRS Retaining Pin 307-696

60. Remove the TR  sensor.
    1. Slide the TR  sensor out of the transmission case.
    2. Rotate the TR  sensor detent plate until it rests against the transmission case.
    3. Remove the park pawl actuator rod from the detent lever and remove the TR  sensor.
61. Remove the park pawl actuator rod.
62. Remove and discard the manual lever shaft seal.
63. NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

    Check the transmission case side transfer shaft bearing cup for damage. If the transmission case side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to TRANSAXLE CASE . If a new bearing cup is installed in the transmission case, install a new transfer shaft bearing cup in the torque converter housing. Refer to TORQUE CONVERTER HOUSING . Install new bearings on the transfer shaft. Refer to TRANSFER SHAFT AND GEAR .

64. Remove and discard the halfshaft seal.
65. NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.

    Inspect the transmission case side differential bearing cup for damage. If the transmission case side differential bearing cup is damaged, install a new bearing cup. Refer to TRANSAXLE CASE . If a new bearing cup is installed in the transmission case, install a new differential bearing cup in the torque converter housing. Refer to TORQUE CONVERTER HOUSING . If a new bearing cup was installed, the differential bearings must also be replaced. Refer to DIFFERENTIAL GEAR ASSEMBLY .

66. Remove the bolt and the fluid baffle from the torque converter housing.
67. Remove the stator support assembly bolts and remove the stator support assembly.
68. Remove the bolts and the fluid pump and filter assembly.
69. NOTE: Note the orientation of the fluid filter to the fluid pump.

    Remove and discard the fluid filter.

    1. Pull the filter out of the bore of the fluid pump.
    2. If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.
70. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.
71. Remove the fluid pump sprocket and chain assembly.
72. Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
    • Check the drive chain for wear, damage, stretching or tightness of the chain links.
    • Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.
73. Remove the fluid pump drive sprocket and driven sprocket thrust washers.
74. NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

    Inspect the torque converter housing side transfer shaft bearing cup for damage. If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to TORQUE CONVERTER HOUSING . If a new bearing cup is installed in the torque converter housing, install a new transfer shaft bearing cup in the transmission case. Refer to TRANSAXLE CASE . Install new bearings on the transfer shaft. Refer to TRANSFER SHAFT AND GEAR .

    FWD vehicles 

75. Remove and discard the halfshaft seal.

    All vehicles 

76. NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.

    Inspect the torque converter housing side differential bearing cup for damage. If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. Refer to TORQUE CONVERTER HOUSING . If a new bearing cup is installed in the torque converter housing, install a new differential bearing cup in the transmission case. Refer to TRANSAXLE CASE . If a new bearing cup was installed, the differential bearings must also be replaced. Refer to DIFFERENTIAL GEAR ASSEMBLY .

77. Using a dent puller, remove and discard the torque converter hub seal from the torque converter housing.
78. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
    • Clean and inspect the transmission case and torque converter housing for damage and install a new transmission case or torque converter housing if necessary. If a new transmission case or torque converter housing is installed, refer to TRANSAXLE CASE  for bearing cup installation and Torque Converter Housing  for torque converter housing bearing cup installation and differential/transfer gear bearing shim measurement.
    • Make sure that the mating faces are clean and free of foreign material. Refer to RTV Sealing Surface Cleaning and Preparation in ENGINE SYSTEM - GENERAL INFORMATION .
    • Clean and inspect the thrust bearings and washers for damage and install new bearings or washers as necessary.
79. Remove the overdrive clutch snap ring.
80. Remove the overdrive clutch hub and clutch assembly.
81. Remove the bottom overdrive clutch steel plate.
82. Remove the No. 2 rear sun gear thrust bearing.
83. Install the special tools on the balance piston. Using a press, compress the overdrive piston return spring. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/1), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
84. With the overdrive piston return spring compressed, remove the balance piston snap ring.
85. Remove and discard the balance piston.
86. Remove the overdrive piston return spring.
87. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
88. Position the overdrive/direct clutch assembly in the rear cover.
89. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
90. Remove and discard the overdrive clutch piston inner seal.
91. Remove and discard the overdrive clutch piston outer seals from the piston.
92. 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.

    Install the special tools on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder to remove the snap ring.

    1. Piston alignment tab
    2. Snap ring
       • Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/2), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
93. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
94. Position the overdrive/direct clutch assembly in the rear cover.
95. Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port and remove the direct clutch cylinder from the overdrive/direct clutch assembly.
96. Remove and discard the rear direct clutch cylinder seal.
97. Remove and discard the direct clutch piston.
98. Remove the direct clutch piston return spring.
99. Remove and discard the direct clutch piston seals.
100. Remove the direct clutch snap ring.
101. Remove the direct clutch pressure plate, clutch assembly and wave spring.
102. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.
103. Install the direct clutch wave spring.
104. Soak the direct clutch pack in clean transmission fluid.
105. Install the direct clutch assembly and pressure plate.
106. Install the direct clutch snap ring.
107. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
108. Install the direct clutch piston return spring.
109. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
110. Install a new rear direct clutch cylinder seal and lubricate it with petroleum jelly.
111. Install the direct clutch cylinder.
112. NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
     NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.

     Install the special tools on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.

     1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
     2. Install the snap ring.
        • Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/2), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
113. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
114. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
115. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the special tool.

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

116. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.

     Install the overdrive clutch piston return spring.

117. Lubricate the seals on a new balance piston with petroleum jelly.
118. Install the new balance piston and install the special tools.

     Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/1), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)

119. Using a press and the special tools, compress the overdrive clutch piston return spring and install the snap ring.
120. Install the No. 2 rear sun gear thrust bearing
121. Install the overdrive clutch hub.
122. Soak the overdrive clutch pack in clean transmission fluid.
123. Install the overdrive clutch pack assembly and the pressure plate.
124. Install the overdrive clutch pack snap ring.
125. Remove the bolt and the TSS  sensor.
126. Using a press and the special tools, compress the intermediate clutch return spring and remove the snap ring.

     Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2)

127. Remove the intermediate clutch return spring.
128. Remove and discard the intermediate clutch piston.
129. Install the special tools, using a press, compress the low/reverse clutch return spring and remove the snap ring.

     Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/2), Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)

130. Remove the low/reverse clutch return spring.
131. Remove and discard the low/reverse clutch piston.
132. Remove and discard the 4 Teflon® seals.
133. Clean and inspect the cover for damage. Install a new cover, if damaged.
134. Install the new Teflon® seals.
     1. Install 307-578/3 on the cover and adjust 307-578/3 to align the bottom edge of 307-578/3 with the top edge of the bottom Teflon® seal groove.
     2. Install a new Teflon® seal on 307-578/3.
     3. Install 307-578/2 over 307-578/3. Using 307-578/2, slide the Teflon® seal over the cover and into the groove.
     4. Repeat Steps  1 through  3 for the other 3 Teflon® seals.
        • Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578 (307-578/2, 307-578/3)
135. Install the special tool on the cover to size the 4 Teflon® seals.

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

136. Install the special tools.

     Special Tool(s): Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)

137. NOTE: Make sure the low/reverse piston bleed hole and semicircle area are aligned with the indentation in the cover and the intermediate cylinder fill hole.

     Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly, align the piston bleed hole with the indentation in the cover and push the piston in the cylinder using the special tools.

     Special Tool(s): Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)

138. Install the low/reverse piston return spring with the tabs facing down.
139. NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

     Using the special tools and a press, compress the low/reverse piston return spring and install the snap ring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/2) and the Reverse Clutch Piston and Retaining Ring Set (307-588) 307-588/3

140. Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.
141. Install the intermediate clutch piston.
142. Install the intermediate clutch piston return spring.
143. NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

     Install the special tools. Using a press, compress the intermediate clutch piston return spring and install the snap ring.

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

144. Remove the special tool.

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

145. Lubricate the O-ring seal on TSS  sensor with clean transmission fluid and install the TSS  sensor in the cover and install the bolt.
     • Tighten to 12 Nm (106 lb-in).
146. Remove and discard the stator support assembly seal.
147. Assemble the special tools, using the tools remove and discard the input shaft seal.

     Special Tool(s): Slide Hammer 100-001, Collet 7/8" to 1" 303-D020, Actuating Pin (Dia 3/16") 303-D011

148. Remove the drive sprocket thrust washer.
149. Remove and discard the stator support-to-torque converter seal.
150. NOTE: Note the location of the Torx® head and the hex head bolts for assembly.

     Remove the bolts and the stator support feed tube.

151. Remove and discard the gasket for the feed tube assembly.
152. Clean and inspect the stator support assembly for damage and install new, if necessary.
153. Install a new stator support-to-torque converter seal.
     1. Install 307-579/3 on the stator support assembly.
     2. Install a new seal on 307-579/3.
     3. Install 307-579/2 on 307-579/3 and slide the seal in to the groove on the stator support assembly.
        • Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/2 and 307-579/3)
154. Install the special tool.

     Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/1)

155. Install a new gasket on the stator support assembly.
156. NOTE: Install the Torx® and the hex bolts in the correct locations as noted during disassembly.

     Position the stator support feed tube assembly in place and install the bolts hand-tight.

157. Tighten the stator support feed tube Torx® head bolts.
     • Tighten to 7 Nm (62 lb-in).
158. Tighten the stator support feed tube hex-head bolts.
     • Tighten to 12 Nm (106 lb-in).
159. Install a new input shaft seal on the special tool.

     Special Tool(s): Support Seal Installer 307-585

160. Using the special tool, install the input shaft seal.

     Special Tool(s): Support Seal Installer 307-585

161. Remove the special tool from the stator support assembly.

     Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/1)

162. Install the drive sprocket thrust washer.
163. Install a new stator support assembly seal.
164. NOTE: The solenoid body should be handled with care or damage to the solenoid body may occur.
     NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
     NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.

     Remove the solenoid body filter assembly by pulling it straight up from the alignment tabs. Discard the filter.

165. Remove and discard the solenoid body assembly electrical connector seal.
166. Clean and inspect the solenoid body assembly for damage and install new if necessary.
167. If replacing the solenoid body, install the replacement service tag on the transmission case over the current solenoid body strategy tag.
168. Install a new solenoid body assembly electrical connector seal.
169. NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
     NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.
     NOTE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transmission will occur if the filter passages are not clean.

     Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.

170. Slide the park pawl over and install the park pawl actuator rod.
171. Using the special tool, install the manual lever shaft seal in the transmission case.
     1. Lubricate a new manual shaft seal and the special tool with petroleum jelly.
     2. Install the seal on the special tool and install the seal in the transmission case.
        • Special Tool(s): Manual Lever Seal Installer 307-581
172. Install the TR  sensor.
     1. Position the park pawl actuating rod in the TR  sensor detent plate.
     2. Install the TR  sensor in the transmission case.
173. Install a new TR  sensor locking pin in the transmission case.
     • Use the special tool to drive the TR  sensor locking pin into the transmission case.
     • Special Tool(s): Manual Lever Seal Installer 307-581
174. Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.
175. Install the transmission fluid reservoir and the bolts.
     • Tighten to 12 Nm (106 lb-in).
176. Install a new pump-to-case seal.
177. Install the transfer shaft and gear assembly.
178. Tilt the transfer shaft and gear assembly over and install the differential assembly.
179. Install a new torque converter hub seal on the special tool.

     Special Tool(s): Converter Seal Installer 307-575

180. NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

     Using the special tool and a dead blow hammer, install the torque converter hub seal in the torque converter housing.

     Special Tool(s): Converter Seal Installer 307-575

     FWD vehicles 

181. Assemble the special tools and install a new RH halfshaft seal on the special tool.

     Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A

182. NOTE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.

     Using the special tools, install the new RH halfshaft seal in the torque converter housing.

     Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A

     All vehicles 

183. Install the pump drive sprocket and driven sprocket thrust washers.
184. NOTE: The dot on the pump sprocket is installed facing upward.

     Install the pump sprocket and chain assembly.

185. Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
186. NOTE: Lubricate the seal with clean transmission fluid.

     Install the fluid filter seal in the fluid pump.

187. NOTE: Install the filter in the correct orientation as noted in removal.

     Install the fluid filter in the fluid pump.

188. Position the pump and filter assembly in place and install the bolts.
     • Tighten to 12 Nm (106 lb-in).
189. NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.

     Position the stator support assembly in place on the torque converter housing. Install the stator support bolts. Tighten in the sequence shown in illustration below.

     • Tighten to 41 Nm (30 lb-ft).
190. Position the differential carrier baffle in place and install the bolt.
     • Tighten to 12 Nm (106 lb-in).
191. Lubricate the ends of the transmission fluid tube with petroleum jelly and install it in the transmission.
192. NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.

     Apply a bead of the Ultra Silicone Sealant.

193. NOTE: Install the 2 studbolts in the correct location as noted during disassembly.

     Install the torque converter housing on top of the transmission case and install the bolts hand tight.

194. NOTE: The studbolts are 1 and 16 in the tightening sequence.

     Tighten the bolts in the sequence shown in illustration below.

     • Tighten to 24 Nm (18 lb-ft).
195. Assemble the special tools, install a new halfshaft seal on the special tool.

     Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A

196. Using the special tools, install the new halfshaft seal in the transmission case.

     Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A

197. Lubricate the forward clutch piston seals with petroleum jelly.
198. NOTE: Install the Compressor, Forward/Intermediate Spring 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.

     Position the forward clutch piston in place in the transmission case.

     Using the special tool, push the forward clutch piston down into the bore.

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

199. NOTE: Install the Compressor, Forward/Intermediate Spring with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

     Install the forward clutch piston return spring with the tabs facing downward.

200. NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
     NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.

     Install the special tools and compress the forward clutch piston return spring.

     Special Tool(s): Compressor, Forward Clutch Spring 307-574 (307-574/1 and 307-574/2), Compressor, Forward/Intermediate Spring 307-584 (includes 307-584/1 and 307-584/2)

201. NOTE: The special tools not shown in illustration below for clarity.

     Install the forward clutch piston return spring snap ring.

     • Install the snap ring.
     • The snap ring gap should be at the top of the transmission case.
202. Install the forward clutch wave spring.
203. Soak the forward clutch pack in clean transmission fluid.
204. Install the forward clutch pack assembly.
     1. Position the forward clutch pack assembly in the case.
     2. Make sure the alignment tab on the clutch pack is positioned in the correct location.
205. Install the low OWC  .
206. NOTE: The low OWC  snap ring gap must be positioned as shown in illustration below so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.

     Install the low OWC  snap ring.

207. Compare the position of the low OWC  snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
208. Install the special tool on the transmission case and position the plunger on a top friction disc tab. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
209. Install a new forward clutch feed seal.
210. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low OWC  for correct installation. If the forward clutch pack and low OWC  is correctly installed, install a new forward clutch pack.

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

211. Install the No. 11 stator support thrust bearing.
212. Install the front planetary carrier hub.
213. Install the No. 10 front sun gear thrust bearing.
214. Install the front sun gear and shell assembly.
215. Install the front carrier and rear ring gear assembly.
216. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
217. Install the center planetary carrier and front ring gear assembly.
218. NOTE: The groove on the center sun gear is installed facing up.

     Install the center planetary sun gear.

219. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
220. Install the rear planetary gear carrier assembly.
221. NOTE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low OWC  snap ring may result in damage to the transmission.

     Install the low/reverse clutch pressure plate.

     1. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC  snap ring.
     2. Install the low/reverse clutch pressure plate.
222. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC  snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
223. Soak the low/reverse clutch pack with clean transmission fluid.
224. Install the low/reverse clutch pack.
225. NOTE: The low/reverse clutch wave spring and pressure plate are temporarily reversely installed to measure the low/reverse clutch clearance.

     Temporarily install the low/reverse clutch wave spring and pressure plate with the pressure plate on top of the wave spring.

     1. Pressure plate
     2. Wave spring
226. Using a straightedge and the Depth Micrometer, measure and record as measurement A, the distance from the transmission case deck surface to the low/reverse pressure plate.

     Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A

227. Using the same straightedge and the Depth Micrometer, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.

     Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A

228. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 0.83 mm (0.032 in) and 2.43 mm (0.095 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 low/reverse clutch pack.

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the low/reverse clutch clearance.

229. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.

     Correctly install the low/reverse clutch wave spring and pressure plate.

     1. Wave spring
     2. Pressure plate
230. Install the intermediate clutch pressure plate.
231. Soak the intermediate clutch pack assembly in clean transmission fluid.
232. Install the intermediate clutch pack assembly.
233. Install the intermediate clutch pack wave spring.
234. Using a straightedge and the Depth Micrometer, measure and record as measurement A, the distance from the transmission case deck surface to a low point on the intermediate clutch wave spring.

     Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A

235. Using the straightedge and the Depth Micrometer, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.

     Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A

236. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.038 in) and 2.56 mm (0.1 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the intermediate clutch clearance.

237. Install the rear sun gear and shell assembly.
238. Install the No. 3 rear sun gear thrust bearing.
239. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
240. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.

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

241. Position the Dial Indicator plunger on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.

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

242. Install the overdrive/direct clutch hub and turbine shaft assembly.
243. Install the No. 1 cover assembly thrust bearing.
244. Install the cover assembly gasket.
245. Route the TSS  sensor harness through the transmission case to the valve body area and install the cover assembly.
246. Install the cover assembly bolts and tighten the bolts in the sequence shown in illustration below.
     • Tighten to 12 Nm (106 lb-in).
247. Install the OSS  sensor and the bolt.
     • Tighten to 12 Nm (106 lb-in).
248. NOTE: Be careful not to pinch the TSS  , OSS  or TR  sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.
     NOTE: Make sure that the manual pin (part of the TR  sensor) is correctly installed in the manual valve.

     Position the TSS  , OSS  and TR  sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.

     1. Manual valve
     2. Manual pin
249. Install the main control valve body bolts. Tighten the bolts in the sequence shown in illustration below.
     • Tighten to 12 Nm (106 lb-in).
250. NOTE: Make sure not to pinch the TSS  , OSS  or TR  sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
     NOTE: Install the different length bolts in the locations noted during disassembly.

     Install the solenoid body bolts hand-tight.

     1. 42 mm (1.653 in) bolt
     2. 63 mm (2.48 in) bolts
     3. 80 mm (3.149 in) bolts
     4. 95 mm (3.74 in) bolts
251. Tighten the solenoid body bolts in the sequence shown in illustration below.
     • Tighten to 12 Nm (106 lb-in).
252. Route the OSS  sensor wiring harness into the retainer.
253. Connect the TSS  and OSS  sensor electrical connectors.
254. Connect the TR  sensor electrical connector and slide the lock tab to the LOCK position.
255. Inspect the transmission main control cover seal for damage and install new if necessary.
256. NOTE: Install the studbolts in the correct locations as noted during disassembly.

     Install the transmission main control cover and loosely install the bolts.

257. Tighten the main control cover bolts in the sequence shown in illustration below.
     • Tighten to 12 Nm (106 lb-in).
258. NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.

     Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transmission.

259. Install the special tool.

     Special Tool(s): Retainer, Torque Converter 307-346