FixVault
Home › Lincoln › 2003 › Aviator AWD › Repair and Diagnosis › External Pages › Different car › Section 1366 (Automatic Transmission) › Disassembly › Transmission

Section 1366 (Automatic Transmission): Disassembly: Transmission

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.
SPECIAL TOOL(S)

G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03912866
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G03990108
 Slide Hammer 307-005 (T59L-100-B)
G03888701
 Remover, Transmission Fluid Seal 307-048 (T74P-77248-A)
G03914889
 Handle, Torque Converter 307-091 (T81P-7902-C)
G03964078
 Remover, Transmission Fluid Pump 307-221 (T89T-70010-A)
G03929773
 Remover/Installer, Servo Piston 307-251 (T92P-70023-A)
G03888701
 Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH)
G03889235
 Retainer, Torque Converter 307-346 (T97T-7902-A)
G03960920
 Remover, Bearing Cup 308-047 (T77F-1102-A)
  1. Using the special tool, remove the torque converter.
    Fig 1: Removing/Installing Torque Converter Using Special Tools
    G03882883Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transmission to the bench.
    Fig 2: Mounting Transmission To Bench
    G04016831Courtesy of FORD MOTOR CO.
    3. NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
    Fig 3: Removing Transmission Fluid Pan And Transmission Fluid Pan Gasket
    G03888706Courtesy of FORD MOTOR CO.
  3. Remove the transmission fluid pan and transmission fluid pan gasket.
    1. Remove the bolts.
    2. Remove the transmission fluid pan and transmission fluid pan-to-case gasket.
  4. Clean the transmission fluid pan and pan magnet.
    Fig 4: Locating Pan Magnet In Transmission Fluid Pan
    G03888537Courtesy of FORD MOTOR CO.
    5. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
    Fig 5: Removing Fluid Filter And Grommet
    G04016834Courtesy of FORD MOTOR CO.
  5. Remove the fluid filter and grommet.
    6. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
    Fig 6: Identifying Molded Lead Frame For Solenoids
    G03888595Courtesy of FORD MOTOR CO.
  6. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead interconnector.
  7. Remove the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor plug.
    1. Remove the OSS speed sensor bolt.
    2. Remove the OSS speed sensor.
    3. Remove the TSS speed sensor bolt.
    4. Remove the TSS speed sensor.
    Fig 7: Removing Output Shaft Speed (OSS) Sensor And Turbine Shaft Speed (TSS) Sensor Plug
    G03882630Courtesy of FORD MOTOR CO.
  8. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 8: Removing Digital TR Sensor
    G03888711Courtesy of FORD MOTOR CO.
  9. Remove the manual control valve detent lever spring.
    1. Remove the bolt.
    2. Remove the manual control valve detent lever spring.
    Fig 9: Removing Manual Control Valve Detent Lever Spring
    G03888712Courtesy of FORD MOTOR CO.
  10. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 10: Removing 24 Main Control Valve Body Bolts
    G03882633Courtesy of FORD MOTOR CO.
  11. Remove and discard the pump outlet screen.
    Fig 11: Identifying Pump Outlet Screen
    G03888559Courtesy of FORD MOTOR CO.
    12. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 12: Removing Manual Lever Shaft Retaining Pin
    G03882495Courtesy of FORD MOTOR CO.
  12. Remove the manual lever shaft retaining pin.
  13. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    Fig 13: Removing Manual Lever Shaft Inner Nut
    G03888716Courtesy of FORD MOTOR CO.
  14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    Fig 14: Removing Parking Lever Actuating Rod
    G03888717Courtesy of FORD MOTOR CO.
    15. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged, the new seal may leak.
    Fig 15: Removing Manual Control Lever Shaft Seal
    G03929870Courtesy of FORD MOTOR CO.
  15. Remove the manual control lever shaft seal.
  16. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
    Fig 16: Removing EPC Solenoid
    G03888596Courtesy of FORD MOTOR CO.
  17. Remove the 2-3 accumulator spring retainer.
    Fig 17: Removing 2-3 Accumulator Spring Retainer
    G03888720Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    Fig 18: Removing 2-3 Accumulator Piston
    G04016847Courtesy of FORD MOTOR CO.
  19. Using the special tool, remove the reverse band servo retaining ring.
    Fig 19: Removing Reverse Band Servo Retaining Ring
    G03882642Courtesy of FORD MOTOR CO.
  20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
    Fig 20: Removing Reverse Band Servo Spring
    G03888723Courtesy of FORD MOTOR CO.
    21. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
    Fig 21: Removing/Installing Overdrive Servo Piston Retainer Using Special Tool
    G03882644Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    Fig 22: Removing Overdrive Servo Piston Return Spring
    G04016851Courtesy of FORD MOTOR CO.
  23. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 23: Locating Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
  24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the 1-2 accumulator lower spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    Fig 24: Removing 1-2 Accumulator Upper Spring
    G04016853Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the extension housing seal.
    Fig 25: Removing Extension Housing Seal
    G03882648Courtesy of FORD MOTOR CO.
    26. NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
    Fig 26: Removing Extension Housing
    G04016855Courtesy of FORD MOTOR CO.
  26. Remove the extension housing.
    1. Remove the 4 bolts and 2 nuts.
    2. Remove the extension housing and the extension housing gasket.
  27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    Fig 27: Removing Parking Pawl
    G04016856Courtesy of FORD MOTOR CO.
  28. Rotate the transmission to the vertical position with the output shaft toward the floor.
    29. CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
    Fig 28: Pushing Connector Out Through Bottom Of Case
    G03888731Courtesy of FORD MOTOR CO.
  29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  30. Using the special tools, remove the front pump seal.
    Fig 29: Removing Front Pump Seal
    G03888732Courtesy of FORD MOTOR CO.
    31. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 30: Removing Bolts
    G03888733Courtesy of FORD MOTOR CO.
  31. Remove the bolts.
  32. Using the special tools, remove the front pump support.
    Fig 31: Removing Front Pump Support
    G03882654Courtesy of FORD MOTOR CO.
  33. Remove and discard the pump gasket.
    • Remove the intermediate clutch piston return spring.
    • Remove the intermediate clutch piston return spring support.
  34. Remove the intermediate anti-rattle clip, if equipped.
    Fig 32: Identifying Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
    35. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
    Fig 33: Removing Forward Clutch Assembly
    G03888736Courtesy of FORD MOTOR CO.
  35. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
  36. Disengage and remove the overdrive band.
    Fig 34: Removing Overdrive Band
    G03888737Courtesy of FORD MOTOR CO.
  37. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 35: Removing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G03888738Courtesy of FORD MOTOR CO.
  38. Remove the intermediate stub shaft.
    Fig 36: Removing Intermediate Stub Shaft
    G03888739Courtesy of FORD MOTOR CO.
  39. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 37: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin
    G04016866Courtesy of FORD MOTOR CO.
  40. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
    Fig 38: Removing Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear Bearing, Reverse Clutch Sun Gear, & No. 4 Forward Clutch Hub Bearing
    G03888741Courtesy of FORD MOTOR CO.
  41. Remove the center support retaining ring and note location for assembly.
    Fig 39: Removing Center Support Retaining Ring
    G03888742Courtesy of FORD MOTOR CO.
  42. Remove the case-to-planet support spring.
    Fig 40: Removing Case-To-Planet Support Spring
    G03888743Courtesy of FORD MOTOR CO.
  43. Remove the planetary gear support and planetary as an assembly.
    Fig 41: Removing Planetary Gear Support And Planetary
    G03888744Courtesy of FORD MOTOR CO.
  44. Remove the reverse clutch band.
    Fig 42: Removing Reverse Clutch Band
    G03888745Courtesy of FORD MOTOR CO.
  45. Remove the retaining ring.
    Fig 43: Removing Retaining Ring
    G03888746Courtesy of FORD MOTOR CO.
  46. Remove the direct clutch pack.
    Fig 44: Identifying Direct Clutch
    G03888747Courtesy of FORD MOTOR CO.
  47. Remove the No. 8 bearing.
    Fig 45: Identifying No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  48. Remove the output shaft and output shaft ring gear assembly.
    Fig 46: Removing Output Shaft And Output Shaft Ring Gear Assembly
    G03888749Courtesy of FORD MOTOR CO.
  49. Remove the No. 9 case rear bearing.
    Fig 47: Locating Case Rear Bearing No. 9
    G03888750Courtesy of FORD MOTOR CO.
  50. Inspect and, if necessary, use the special tools to remove the rear case bushing.
    Fig 48: Removing Rear Case Bushing
    G03888751Courtesy of FORD MOTOR CO.
About FixVault