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Section 1366 (Automatic Transmission): Assembly: Transmission: Material

WARNING: This page is about a different car, the 2005 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V
Fig 1: Automatic Transmission - Disassembled View (1 Of 6)
G03929539Courtesy of FORD MOTOR CO.
Fig 2: Automatic Transmission - Disassembled View (2 Of 6)
G03963773Courtesy of FORD MOTOR CO.
Fig 3: Automatic Transmission - Disassembled View (3 Of 6)
G04017019Courtesy of FORD MOTOR CO.
Fig 4: Automatic Transmission - Disassembled View (4 Of 6)
G04017020Courtesy of FORD MOTOR CO.
Fig 5: Automatic Transmission - Disassembled View (5 Of 6)
G04017021Courtesy of FORD MOTOR CO.
Fig 6: Automatic Transmission - Disassembled View (6 Of 6)
G04017022Courtesy of FORD MOTOR CO.
CAUTION: Before beginning assembly, carry out and inspect the following:

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. In addition to appearing in the article, the necessary torques can be found in GENERAL SPECIFICATIONS .

When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.

Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.

Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.

  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
    Fig 7: Installing Rear Case Bushing
    G03888897Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    Fig 8: Locating Case Rear Bearing No. 9
    G03888750Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES . Internal damage and shift problems may occur.
    Fig 9: Installing Output Shaft And Output Shaft Ring Gear
    G03888899Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 10: Identifying No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 11: Identifying Direct Clutch
    G03888747Courtesy of FORD MOTOR CO.
    7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
    Fig 12: Installing Reverse Band Support Retaining Ring
    G03888902Courtesy of FORD MOTOR CO.
  7. Install the reverse band support retaining ring.
    8. NOTE: Make sure the band is seated on the anchor pins.
    Fig 13: Installing Reverse Band
    G03888903Courtesy of FORD MOTOR CO.
  8. Install the reverse band.
    9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
    Fig 14: Rotating Output Shaft To Fully Seat Planetary Assembly
    G03888904Courtesy of FORD MOTOR CO.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
    10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
    Fig 15: Installing Case To Planet Support Spring Located At 1 O'Clock Position
    G03888905Courtesy of FORD MOTOR CO.
  10. Install the case to the planet support spring located at the 1 o'clock position.
    11. NOTE: When installing the center support retaining ring, the opening should be toward the hole in the case where the turbine shaft speed (TSS) sensor would go.
    Fig 16: Installing Center Support Retaining Ring
    G03888906Courtesy of FORD MOTOR CO.
  11. Install the center support retaining ring.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear two-piece bearing and the reverse sun gear.
    Fig 17: Installing Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear Two-Piece Bearing & Reverse Sun Gear
    G03888907Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 18: Installing No. 4 Forward Clutch Hub Bearing
    G03888908Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 19: Installing Intermediate Stub Shaft
    G03888909Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 20: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G03888910Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 21: Installing Forward Clutch Assembly
    G03888911Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
    Fig 22: Installing No. 2 Forward Clutch Bearing
    G03930055Courtesy of FORD MOTOR CO.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
    Fig 23: Positioning Overdrive Band Pocket Onto Anchor Pin
    G03930056Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
    Fig 24: Installing Overdrive Servo Spring
    G04017040Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 25: Verifying Tip Of Piston Assembly Engages Pocket Of Overdrive Band
    G03930058Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 26: Removing/Installing Overdrive Servo Piston Retainer Using Special Tool
    G03882644Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 27: Installing Intermediate Clutch Pressure Plate
    G03930060Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid.
    Fig 28: Installing Intermediate Clutch Pack And Selective Steel Plate
    G03888918Courtesy of FORD MOTOR CO.
  23. Install the intermediate clutch pack and selective steel plate.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

    SELECTIVE STEEL PLATES

    Specification
    1.80-1.70 mm (0.071-0.067 inch)
    2.05-1.95 mm (0.081-0.077 inch)
    2 .31-2 .20 mm (0.091-0.087 inch)
    2.56-2.46 mm (0.101-0.097 inch)
    Fig 29: Checking Intermediate Clutch Clearance Using Special Tool
    G03882839Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure end clearance for the No.1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

    Use the No.1 thrust washer chart to select the correct washer.

    NO.1 THRUST WASHER CHART

    Depth Thickness Color Code
    37.706-38.184 mm (1.485-1.503 inch) 1.270-1.372 mm (0.050-0.054 inch) Green
    38.185-38.641 mm (1.504-1.521 inch) 1.727-1.829 mm (0.068-0.072 inch) Yellow
    38.642-39.073 mm (1.522-1.538 inch) 2.159-2.261 mm (0.085-0.089 inch) Natural
    39.074-39.505 MM (1.539-1.555 inch) 2.591-2.692 mm (0.102-0.106 inch) Red
    39.506-40.165 mm (1.556-1.581 inch) 3.023-3.124 mm (0.119-0.123 inch) Blue
    Fig 30: Measuring End Clearance For No.1 Front Pump Thrust Washer
    G03882840Courtesy of FORD MOTOR CO.
  26. Install the intermediate anti-rattle clip, if equipped.
    Fig 31: Identifying Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
  27. Install the intermediate clutch return spring support and wave spring.
  28. Install the No.1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
    Fig 32: Locating Selective Pump Support Thrust Washer No. 1
    G03888769Courtesy of FORD MOTOR CO.
    29. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 33: Installing An Alignment Pin At Top Of Case
    G03888923Courtesy of FORD MOTOR CO.
  29. Install an alignment pin at the top of the case.
    30. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  30. Install the pump gasket.
    31. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 34: Installing Pump Assembly
    G03888924Courtesy of FORD MOTOR CO.
  31. Install the pump assembly.
  32. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
    Fig 35: Front Pump Bolts Torque Specification
    G03888925Courtesy of FORD MOTOR CO.
  33. Rotate the transmission to the horizontal position.
  34. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
    Fig 36: Installing Parking Pawl Shaft
    G04017052Courtesy of FORD MOTOR CO.
  35. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the 4 bolts and 2 nuts.
    Fig 37: Installing 4 Bolts And 2 Nuts - With Torque Specification
    G03888588Courtesy of FORD MOTOR CO.
    36. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the six o'clock position.
    Fig 38: Installing New Extension Housing Seal
    G03882848Courtesy of FORD MOTOR CO.
  36. Using the special tool, install a new extension housing seal.
  37. Install the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
    1. Install the OSS speed sensor.
    2. Install the OSS speed sensor bolt.
    3. Install the TSS speed sensor.
    4. Install the TSS speed sensor bolt.
    Fig 39: Installing OSS Sensor & TSS Sensor
    G03882576Courtesy of FORD MOTOR CO.
  38. Using the special tool, install the manual control lever seal.
    Fig 40: Installing Manual Control Lever Seal
    G03882850Courtesy of FORD MOTOR CO.
    39. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
    Fig 41: Lubricating EPC Solenoid And Installing Into Case
    G03888931Courtesy of FORD MOTOR CO.
  39. Lubricate the EPC solenoid and install it into the case.
  40. Install the manual valve detent lever and parking lever actuating rod.
    Fig 42: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod
    G03888932Courtesy of FORD MOTOR CO.
  41. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
    Fig 43: Installing Manual Control Lever Shaft
    G03964304Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the inner and outer lower 1-2 accumulator spring.
    4. Install the 1-2 accumulator cover and seal.
    Fig 44: Installing 1-2 Accumulator Piston Assembly
    G03888934Courtesy of FORD MOTOR CO.
  43. Install the 1-2 accumulator retaining ring.
    Fig 45: Locating Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
    44. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
    NOTE: Do not install the reverse servo piston cover and seal at this time.
    Fig 46: Installing Reverse Servo Piston And Rod Assembly
    G03888936Courtesy of FORD MOTOR CO.
  44. Install the reverse servo piston and rod assembly.
  45. Install the special tool.
    • Tighten the bolt.
    Fig 47: Tightening Bolt
    G04017063Courtesy of FORD MOTOR CO.
  46. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
    Fig 48: Positioning Indicator Stem On Flat Portion Of Reverse Servo Piston
    G03888938Courtesy of FORD MOTOR CO.
  47. Loosen the bolt until the piston stops against the tool.
    Fig 49: Loosening Bolt Until Piston Stops Against Tool
    G03888939Courtesy of FORD MOTOR CO.
  48. Verify that the amount of piston travel on the dial indicator is within specification.
    Fig 50: Verifying Amount Of Piston Travel On Dial Indicator Is Within Specification
    G03888940Courtesy of FORD MOTOR CO.
  49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove.
    2. Two grooves.
    3. Three grooves.
    Fig 51: Identifying Servo Piston Travel
    G03930084Courtesy of FORD MOTOR CO.
  50. Remove the special tools.
    Fig 52: Removing Special Tools
    G03930085Courtesy of FORD MOTOR CO.
  51. Install the reverse servo assembly.
    1. Install the rod.
    2. Install the piston assembly.
    3. Install the reverse servo piston cover and seal.
    Fig 53: Installing Reverse Servo Assembly
    G03888943Courtesy of FORD MOTOR CO.
  52. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
    Fig 54: Installing Reverse Band Servo Retaining Ring
    G03882864Courtesy of FORD MOTOR CO.
  53. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
    Fig 55: Installing Accumulator Spring Retainer
    G03888945Courtesy of FORD MOTOR CO.
  54. Using the special tools, apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 56: Applying Regulated Air Pressure To Test Ports
    G03882866Courtesy of FORD MOTOR CO.
    55. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 57: Installing Electrical Connector Into Case
    G04017073Courtesy of FORD MOTOR CO.
  55. Install the electrical connector into the case.
    56. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 58: Installing Control Valve Body
    G03888560Courtesy of FORD MOTOR CO.
  56. Align the main control valve body alignment bolts and position the main control valve body.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 59: Installing 11 Long Main Control Valve Body Bolts
    G04584287Courtesy of FORD MOTOR CO.
  57. Loosely install the 11 long main control valve body bolts.
    58. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 60: Identifying 12 Short Main Control Valve Body Bolts
    G03882434Courtesy of FORD MOTOR CO.
  58. Loosely install the 12 short main control valve body bolts.
  59. Install the EPC solenoid bracket and loosely install the bolt.
    Fig 61: Installing EPC Solenoid Bracket Bolt
    G03888951Courtesy of FORD MOTOR CO.
  60. Install the manual control valve detent lever spring and loosely install the bolt.
    Fig 62: Installing Manual Control Valve Detent Lever Spring Bolt
    G03888952Courtesy of FORD MOTOR CO.
  61. Tighten the bolts in the sequence shown.
    Fig 63: Tightening Main Control Valve Body Bolts In Sequence - With Torque Specifications
    G03882436Courtesy of FORD MOTOR CO.
  62. Inspect the lead frame for damage.
    • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
    Fig 64: Checking Molded Lead Frame Connector Pins
    G03882360Courtesy of FORD MOTOR CO.
  63. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    Fig 65: Identifying Molded Lead Frame Solenoids
    G03888599Courtesy of FORD MOTOR CO.
  64. Install the fluid filter and seal assembly.
    Fig 66: Installing Fluid Filter And Seal Assembly
    G04017082Courtesy of FORD MOTOR CO.
  65. Position the pan magnet into the transmission fluid pan.
    Fig 67: Locating Pan Magnet In Transmission Fluid Pan
    G03888537Courtesy of FORD MOTOR CO.
    66. NOTE: The pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
    Fig 68: Installing Transmission Fluid Pan Bolts - With Torque Specification
    G03882407Courtesy of FORD MOTOR CO.
  66. Install the fluid pan.
    1. Position the transmission fluid pan and gasket.
    2. Install the transmission fluid pan bolts.
  67. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
    Fig 69: Installing Digital TR Sensor
    G03888959Courtesy of FORD MOTOR CO.
    68. NOTE: The tool is designed to fit snugly.
    NOTE: Manual shift lever must be in the NEUTRAL position.
    Fig 70: Aligning Digital TR Sensor Slots
    G03882880Courtesy of FORD MOTOR CO.
  68. Using the special tool, align the digital TR sensor slots.
    69. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    Fig 71: Digital TR Sensor Bolts - With Torque Specifications
    G03929639Courtesy of FORD MOTOR CO.
  69. Tighten the screws in an alternating sequence.
  70. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 72: Identifying Converter Hub
    G03888962Courtesy of FORD MOTOR CO.
    71. WARNING: The torque converter can fall out if the transmission is tipped.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
    Fig 73: Removing/Installing Torque Converter Using Special Tools
    G03882883Courtesy of FORD MOTOR CO.
  71. Using the special tools, install the torque converter.
  72. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 74: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G03908769Courtesy of FORD MOTOR CO.
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