Automatic Transmission: Assembly: Transmission

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	204-029 Drawbar
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	307-541 Installer, Transfer Gear Bearing TKIT-2005D1-F
Courtesy of FORD MOTOR COMPANY	307-576 Bearing Cup Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	307-591 Shim Gauge, Differential/Transfer Gear Bearing TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	307-626 Installer, Differential Seal TKIT-2008ET-FLM TKIT-2008ET-ROW
Courtesy of FORD MOTOR COMPANY	307-672 Installer, Input Guide and Seal TKIT-2010D-FLM TKIT-2010D-ROW
Courtesy of FORD MOTOR COMPANY	307-689 Installer, Bearing Cup TKIT-2012B-FL TKIT-2012B-ROW
Courtesy of FORD MOTOR COMPANY	307-692 Tool, Transfer Gear Preload TKIT-2012C-FL TKIT-2012C-ROW TKIT-2012C-ROW2
Courtesy of FORD MOTOR COMPANY	307-693 Installer, Transfer Gear Bearing Cup TKIT-2012C-FL TKIT-2012C-ROW TKIT-2012C-ROW2
Feeler Gauge
Hydraulic Press

Materials

Name	Specification
Motorcraft ® Ultra Silicone Sealant TA-29	-
Motorcraft ® MERCON ® LV Automatic Transmission Fluid XT-10-QLVC	MERCON ® LVWSS-M2C938-A

1.

NOTE: When installing the bearing make sure to only press on the inner bearing race or damage may occur to the bearing.

Press the traction motor drive gear front bearing on the traction motor drive gear. Use the General Equipment: Hydraulic Press

GFD153260

Courtesy of FORD MOTOR COMPANY

2.

Press the traction motor drive gear rear bearing on the traction motor drive gear. Use the General Equipment: Hydraulic Press

GFD153261

Courtesy of FORD MOTOR COMPANY

3.

Install the traction motor drive gear oil seal and lubricate with transmission fluid.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)

GFD153262

Courtesy of FORD MOTOR COMPANY

4.

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.

Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

GFD153263

Courtesy of FORD MOTOR COMPANY

5.

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.

Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

GFD153264

Courtesy of FORD MOTOR COMPANY

6.

Using the special tool, install the transmission case side differential bearing cup. Use Special Service Tool: 204-029 Drawbar., 307-541 Installer, Transfer Gear Bearing., 307-689 Installer, Bearing Cup.

GFD153265

Courtesy of FORD MOTOR COMPANY

7.

Using the special tool, install the transmission case side transfer shaft bearing cup. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-693 Installer, Transfer Gear Bearing Cup.

GFD153266

Courtesy of FORD MOTOR COMPANY

8.

Install the transfer shaft gear assembly and the differential carrier gear assembly.

GFD153267

Courtesy of FORD MOTOR COMPANY

9.

Place the differential bearing cup and the transfer shaft bearing cup on the bearings.

GFD153268

Courtesy of FORD MOTOR COMPANY

10.

Install the special tools on top of the bearing cups. Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing., 307-692 Tool, Transfer Gear Preload.

GFD153269

Courtesy of FORD MOTOR COMPANY

11.

Install the special tools, placing the spacers on the studs. Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.

GFD153270

Courtesy of FORD MOTOR COMPANY

12.

NOTE: Make sure that the silicone has been cleaned off the machined surface of the transmission case and the damper housing before installing the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) or the preload measurement may be inaccurate.

Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.

GFD153271

Courtesy of FORD MOTOR COMPANY

13.

Install the damper housing on the special tools.

GFD153272

Courtesy of FORD MOTOR COMPANY

14.

Install the special tools by installing the nuts on the studs. Use Special Service Tool: 307-591 Shim Gauge, Differential/Transfer Gear Bearing.
Torque: 18 lb.ft (24 Nm)

GFD153273

Courtesy of FORD MOTOR COMPANY

15.

Rotate the transfer shaft and the differential several times to seat the bearing cups.

GFD153274

Courtesy of FORD MOTOR COMPANY

16.

Measure and record the smallest and largest preload gap on the Shim Gauge, Differential/Transfer Gear Bearing 307-591/1. Average the 2 measurements to get the thickness of the differential bearing preload shim. For the differential bearing preload shim part number. Refer to: Specifications . Use the General Equipment: Feeler Gauge

GFD153275

Courtesy of FORD MOTOR COMPANY

17.

Measure and record the smallest and largest preload gap on the Transfer Gear Preload Tool 307-692. Average the 2 measurements to get the thickness of the transfer gear bearing preload shim. For the transfer bearing preload shim part number. Refer to: Specifications . Use the General Equipment: Feeler Gauge

GFD153276

Courtesy of FORD MOTOR COMPANY

18.

Install the transfer shaft preload shim.

GFD153228

Courtesy of FORD MOTOR COMPANY

19.

Using the special tools, install the damper housing side transfer gear bearing cup. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-693 Installer, Transfer Gear Bearing Cup.

GFD153277

Courtesy of FORD MOTOR COMPANY

20.

Install the differential preload shim.

GFD153231

Courtesy of FORD MOTOR COMPANY

21.

Using the special tools, install the damper housing side differential bearing cup. Use Special Service Tool: 204-029 Drawbar., 307-541 Installer, Transfer Gear Bearing., 307-576 Bearing Cup Installer.

GFD153278

Courtesy of FORD MOTOR COMPANY

22.

Using the special tool, install the input shaft oil seal. Use Special Service Tool: 307-672 Installer, Input Guide and Seal.

GFD153279

Courtesy of FORD MOTOR COMPANY

23.

Using the special tool, install the RH halfshaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.

GFD153280

Courtesy of FORD MOTOR COMPANY

24.

Install the oil collector plate and the retainers.
Torque: 97 lb.in (11 Nm)

GFD153224

Courtesy of FORD MOTOR COMPANY

25.

Install the transmission fluid oil sump baffle and the retainers.
Torque: 97 lb.in (11 Nm)

GFD153223

Courtesy of FORD MOTOR COMPANY

26.

Using the special tool, install the LH halfshaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.

GFD153281

Courtesy of FORD MOTOR COMPANY

27.

Install the differential carrier gear assembly.

GFD153218

Courtesy of FORD MOTOR COMPANY

28.

Install the final drive input gear assembly.

GFD153216

Courtesy of FORD MOTOR COMPANY

29.

Install the transfer shaft gear assembly and the traction motor drive gear assembly.

GFD153214

Courtesy of FORD MOTOR COMPANY

30.

Connect the TFT sensor.

GFD153213

Courtesy of FORD MOTOR COMPANY

31.

Prepare the case sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

32.

NOTE: Make sure silicone is applied to the shoulder on the inner bolt hole.

Apply silicone to the transmission case assembly.

Material: Motorcraft ® Ultra Silicone Sealant / TA-29

GFD153282

Courtesy of FORD MOTOR COMPANY

33.

NOTE: Tighten in a crisscross pattern.

Install the damper housing and the bolts.

Torque: 18 lb.ft (25 Nm)

GFD153212

Courtesy of FORD MOTOR COMPANY

34.

Install the vent assembly.

GFD153211

Courtesy of FORD MOTOR COMPANY

35.

Install the transmission fluid auxiliary pump, transmission fluid tubes and the bolts.
- 1.
  
  Torque: 80 lb.in (9 Nm)
- 2.
  
  Torque: 18 lb.ft (25 Nm)
- 3.
  
  Torque: 80 lb.in (9 Nm)

GFD153283

Courtesy of FORD MOTOR COMPANY