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Automatic Transaxle/Transmission: Assembly: Transmission

Fig 1: Identifying Special Tools (1 Of 3)
G01565069Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 3)
G01565070Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tools (3 Of 3)
G01565071Courtesy of FORD MOTOR CO.
Fig 4: Identifying Material Specifications
G01565072Courtesy 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 the necessary torques can be found in the 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 5: Installing Rear Case Bushing
      G01565073Courtesy 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 6: Installing No. 9 Case Rear Bearing On The Case Boss
    G01565074Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur.
    Fig 7: Installing Output Shaft And Output Shaft Ring Gear
    G01565075Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 8: Installing No. 8 Bearing
    G01565076Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 9: Installing Direct Clutch
    G01565077Courtesy 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, it will not affect the operation of the transmission.
    Fig 10: Installing Reverse Band Support Retaining Ring
    G01565078Courtesy 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 11: Installing Reverse Band
    G01565079Courtesy 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.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
      Fig 12: Rotating Output Shaft
      G01565080Courtesy of FORD MOTOR CO.
    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 13: Installing Case To Planet Support Spring
    G01565081Courtesy of FORD MOTOR CO.
  10. Install the case to planet support spring located at the 1 o'clock position.
  11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
      Fig 14: Installing Center Support Retaining Ring
      G01565082Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, No. 5 forward clutch sun gear bearing and the reverse sun gear.
    Fig 15: Installing Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear Bearing And The Reverse Sun Gear
    G01565083Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 16: Installing No. 4 Forward Clutch Hub Bearing
    G01565084Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 17: Installing Intermediate Stub Shaft
    G01565085Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 18: Installing Forward Clutch Hub And The No. 3 Forward Clutch Hub Front Bearing
    G01565086Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 19: Installing Forward Clutch Assembly
    G01565087Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder assembly.
    2. Install the No. 2 forward clutch bearing.
      Fig 20: Installing Reverse Clutch Cylinder Assembly
      G01565088Courtesy of FORD MOTOR CO.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
      Fig 21: Installing Overdrive Band
      G01565089Courtesy 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 22: Installing Overdrive Servo Spring
      G01565090Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 23: Identifying Piston Assembly Tip Engagement With Overdrive Band Pocket
    G01565091Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 24: Compressing The Overdrive Servo Assembly
    G01565092Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 25: Installing Intermediate Clutch Pressure Plate
    G01565093Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.
    Fig 26: Installing Intermediate Clutch Pack And Steel Plate
    G01565094Courtesy 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.

      Fig 27: Selective Steel Plates Specifications (1 Of 2)
      G01565095Courtesy of FORD MOTOR CO.
    Fig 28: Selective Steel Plates Specifications (2 Of 2)
    G01565096Courtesy of FORD MOTOR CO.
    Fig 29: Measuring Intermediate Clutch Clearance
    G01565097Courtesy 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.

      Fig 30: No.1 Thrust Washer Chart
      G01565098Courtesy of FORD MOTOR CO.
      Fig 31: Measuring No. 1 Front Pump Thrust Washer End Clearance
      G01565099Courtesy of FORD MOTOR CO.
  26. If equipped, install the intermediate clutch anti-rattle clip.
    Fig 32: Installing Intermediate Clutch Anti-Rattle Clip
    G01565100Courtesy of FORD MOTOR CO.
  27. Install the No. 1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
      Fig 33: Installing No. 1 Front Pump Support Thrust Washer
      G01565101Courtesy of FORD MOTOR CO.
    28. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 34: Installing Alignment Pin At The Top Of The Case
    G01565102Courtesy of FORD MOTOR CO.
  28. Install an alignment pin at the top of the case.
    29. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  29. Install the pump gasket.
    30. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 35: Installing Pump Assembly
    G01565103Courtesy of FORD MOTOR CO.
  30. Install the pump assembly.
  31. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
      Fig 36: Removing Alignment Pin And Installing The Front Pump Bolts
      G01565104Courtesy of FORD MOTOR CO.
  32. Rotate the transmission to the horizontal position.
  33. Install the parking pawl.
    • Position the parking pawl return spring.
    • Position the parking pawl.
    • Install the parking pawl shaft.
      Fig 37: Installing Parking Pawl
      G01565105Courtesy of FORD MOTOR CO.
  34. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
      Fig 38: Installing Extension Housing Gasket And The Extension Housing
      G01565106Courtesy of FORD MOTOR CO.
  35. Using the special tool, install a new extension housing seal.
    Fig 39: Installing Extension Housing Seal
    G01565107Courtesy of FORD MOTOR CO.
  36. Install the output shaft speed (OSS) sensor.
    1. Position the OSS sensor.
    2. Install the bolt.
      Fig 40: Installing Output Shaft Speed Sensor
      G01565108Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the manual control lever seal.
    Fig 41: Installing Manual Control Lever Seal
    G01565109Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
  38. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the EPC solenoid bracket and bolt.
      Fig 42: Installing EPC Solenoid
      G01565110Courtesy of FORD MOTOR CO.
  39. Install the manual valve detent lever and parking lever actuating rod.
    Fig 43: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod
    G01565111Courtesy of FORD MOTOR CO.
  40. 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 44: Installing Manual Control Lever Shaft
      G01565112Courtesy of FORD MOTOR CO.
  41. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator spring.
    2. Install the 1-2 accumulator.
    3. Install the inner and outer 1-2 accumulator springs.
    4. Install the 1-2 accumulator cover and seal.
      Fig 45: Installing 1-2 Accumulator Piston Assembly
      G01565113Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator springs and install the accumulator piston retaining ring.
    Fig 46: Installing Accumulator Piston Retaining Ring
    G01565114Courtesy of FORD MOTOR CO.
    43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When a new piston and rod assembly 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.
    Fig 47: Installing Reverse Servo Piston And Return Spring
    G01565115Courtesy of FORD MOTOR CO.
  43. Install the reverse servo piston and return spring.
  44. Install the special tool.
    • Tighten the bolt.
      Fig 48: Tightening Bolts
      G01565116Courtesy of FORD MOTOR CO.
  45. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
      Fig 49: Installing Special Tool
      G01565117Courtesy of FORD MOTOR CO.
  46. Loosen the bolt until the piston stops against the tool.
    Fig 50: Loosening The Bolt
    G01565118Courtesy of FORD MOTOR CO.
  47. Verify the amount of piston travel on the dial indicator is within specification.
    Fig 51: Measuring Piston Travel Distance On The Dial Indicator
    G01565119Courtesy of FORD MOTOR CO.
  48. 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 52: Identifying Correct Servo Assembly
      G01565120Courtesy of FORD MOTOR CO.
  49. Remove the special tools.
    Fig 53: Removing Special Tools
    G01565121Courtesy of FORD MOTOR CO.
  50. Install the reverse servo assembly.
    1. Install the rod.
    2. Install the piston assembly.
    3. Install the reverse servo piston cover and seal.
      Fig 54: Installing Reverse Servo Assembly
      G01565122Courtesy of FORD MOTOR CO.
  51. 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 55: Installing Reverse Servo Retaining Ring
      G01565123Courtesy of FORD MOTOR CO.
  52. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
      Fig 56: Installing 2-3 Accumulator Assembly
      G01565124Courtesy of FORD MOTOR CO.
  53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 57: Applying Regulated Air Pressure To The Test Ports
    G01565125Courtesy of FORD MOTOR CO.
    54. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 58: Installing Electrical Connector Into Case
    G01565126Courtesy of FORD MOTOR CO.
  54. Install the electrical connector into case.
    55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 59: Aligning Main Control Valve Body Alignment Bolts And Position The Main Control Valve Body
    G01565127Courtesy of FORD MOTOR CO.
  55. Align the main control valve body alignment bolts and position the main control valve body.
    56. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 60: Installing Long Main Control Valve Body Bolts
    G01565128Courtesy of FORD MOTOR CO.
  56. Loosely install the 11 long main control valve body bolts.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 61: Installing Short Main Control Valve Body Bolts
    G01565129Courtesy of FORD MOTOR CO.
  57. Loosely install the 12 short main control valve body bolts.
  58. Install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring.
    2. Install the bolt.
      Fig 62: Installing Manual Control Valve Detent Lever Spring
      G01565130Courtesy of FORD MOTOR CO.
  59. Tighten the bolts in the sequence shown.
    Fig 63: Tightening Main Control Valve Body Bolts In Sequence
    G01565131Courtesy of FORD MOTOR CO.
  60. Inspect the lead frame for damage.
    • Using the special tool, check all 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: Identifying Lead Frame
      G01565132Courtesy of FORD MOTOR CO.
  61. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead inter-connector 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: Connecting Molded Lead Frame To The Solenoids
      G01565133Courtesy of FORD MOTOR CO.
  62. Install the fluid filter and seal assembly.
    Fig 66: Installing Fluid Filter And Seal Assembly
    G01565134Courtesy of FORD MOTOR CO.
  63. Position the pan magnet onto the fluid pan.
    Fig 67: Positioning Pan Magnet Onto The Fluid Pan
    G01565135Courtesy of FORD MOTOR CO.
    64. NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.
  64. Install the fluid pan and gasket.
    1. Position the transmission fluid pan with the gasket in place.
    2. Install the bolts.
      Fig 68: Installing Fluid Pan And Gasket And Tightening Bolts
      G01565136Courtesy of FORD MOTOR CO.
  65. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
      Fig 69: Installing Digital Transmission Range Sensor
      G01565137Courtesy of FORD MOTOR CO.
    66. NOTE: The tool is designed to fit snug.
    NOTE: Manual shift lever must be in the neutral position.
    Fig 70: Aligning Digital TR Sensor Slots
    G01565138Courtesy of FORD MOTOR CO.
  66. Using the special tool, align the digital TR sensor slots.
  67. Tighten the bolts.
    Fig 71: Tightening Digital TR Sensor Bolts
    G01565139Courtesy of FORD MOTOR CO.
  68. Install the manual control lever.
    1. Install the manual control lever.
    2. Install the nut.
      Fig 72: Installing Manual Control Lever
      G01565140Courtesy of FORD MOTOR CO.
  69. Install the transmission vent tube, if equipped.
    1. Install the transmission vent tube.
    2. Install the bolt.
      Fig 73: Installing Transmission Vent Tube
      G01565141Courtesy of FORD MOTOR CO.
  70. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 74: Lubricating The Converter Hub
    G01565142Courtesy 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 75: Installing Torque Converter
    G01565143Courtesy of FORD MOTOR CO.
  71. Using special tools, install the torque converter.
  72. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 76: Lubricating The Torque Converter Pilot
    G01565144Courtesy of FORD MOTOR CO.
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