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Automatic Transaxle - 4F27E: Disassembly: Transaxle: Disassembly

    NOTE: If, during repair work, abrasive particles are found in the transmission fluid (particles from the clutch or metal chips or foreign material), the transaxle must be disassembled completely and thoroughly cleaned. Also, clean the fluid tubes, fluid cooler and torque converter carefully. In the case of extreme soiling of the fluid pipes, install a new fluid cooler and torque converter.
    NOTE: In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid.
  1. Inspect the transaxle during disassembly.
  2. Remove the Output Shaft Speed (OSS) sensor in the following sequence.
    1. Remove the bolt.
    2. Remove the OSS sensor.
      Fig 1: Locating Output Shaft Speed (OSS) Sensor With Bolt
      G06292909Courtesy of FORD MOTOR CO.
  3. Remove the Turbine Shaft Speed (TSS) sensor.
    Fig 2: Locating Turbine Shaft Speed (TSS) Sensor With Bolt
    G06292910Courtesy of FORD MOTOR CO.
    4. NOTE: Do not use air tools or damage to the transaxle manual control valve internal linkage can occur.
    Fig 3: Locating Manual Control Lever Bolt
    G06292911Courtesy of FORD MOTOR CO.
  4. While holding the manual control lever, remove the manual control lever bolt.
  5. Remove the Transmission Range (TR) sensor.
    Fig 4: Locating Transmission Range (TR) Sensor
    G06439800Courtesy of FORD MOTOR CO.
  6. Remove the Torque Converter Retainer.
    Fig 5: Removing Torque Converter Retainer
    G06292896Courtesy of FORD MOTOR CO.
  7. Remove the rubber vent cap.
    Fig 6: Locating Rubber Vent Cap
    G06292914Courtesy of FORD MOTOR CO.
    8. NOTE: Do not tilt the torque converter when removing it to prevent damaging the torque converter hub.
    NOTE: The torque converter is filled with transmission fluid. Drain the torque converter .
    Fig 7: Removing Torque Converter Using Torque Converter Handles
    G06292915Courtesy of FORD MOTOR CO.
  8. Using the Torque Converter Handles, remove the torque converter.
  9. Remove the differential opening cover.
    Fig 8: Locating Differential Opening Cover
    G06292897Courtesy of FORD MOTOR CO.
  10. Remove the LH and RH axle seals.
  11. Using the Transmission Mounting Bracket, mount the transaxle to a bench.
    Fig 9: Mounting Transaxle To Bench Using Transmission Mounting Bracket
    G06292917Courtesy of FORD MOTOR CO.
  12. Remove the bolts.
    Fig 10: Locating Pump-To-Case Bolts
    G06292918Courtesy of FORD MOTOR CO.
  13. Using the two 10-mm (50 mm [2 in] long) bolts, remove the pump.
    Fig 11: Locating Fluid Pump With Bolts
    G06439807Courtesy of FORD MOTOR CO.
  14. Remove the transmission pump seals.
    Fig 12: Locating Transmission Pump Seals
    G06292920Courtesy of FORD MOTOR CO.
  15. Remove the forward clutch thrust washer.
    Fig 13: Locating Forward Clutch Thrust Washer
    G06292921Courtesy of FORD MOTOR CO.
  16. Remove the forward clutch assembly.
    Fig 14: Locating Forward Clutch Assembly
    G06292922Courtesy of FORD MOTOR CO.
    17. NOTE: Small levers will aid in the removal of the forward clutch hub.
    Fig 15: Locating Forward Clutch Hub
    G06292923Courtesy of FORD MOTOR CO.
  17. Remove the forward clutch hub.
  18. Rotate the transaxle 180 degrees.
  19. Remove the end cover.
    Fig 16: Locating Transaxle End Cover Bolts
    G06292924Courtesy of FORD MOTOR CO.
  20. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface prep.
  21. Remove the direct clutch hub bearing shim.
    Fig 17: Locating Direct Clutch Hub Bearing Shim
    G06292925Courtesy of FORD MOTOR CO.
  22. Remove the end cover seals.
    Fig 18: Locating End Cover Seals
    G06292926Courtesy of FORD MOTOR CO.
  23. Remove the end cover-to-case seals.
    Fig 19: Locating End Cover-To-Case Seals
    G06292927Courtesy of FORD MOTOR CO.
  24. Remove the direct clutch cylinder thrust bearing.
    Fig 20: Locating Direct Clutch Cylinder Thrust Bearing
    G06292928Courtesy of FORD MOTOR CO.
  25. Remove the intermediate/O/D band anchor bolt.
    Fig 21: Locating Intermediate/Overdrive Band Anchor Bolt
    G06292929Courtesy of FORD MOTOR CO.
  26. Remove the intermediate/O/D band.
    Fig 22: Locating Intermediate/Overdrive Band
    G06292930Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/O/D drum assembly.
    Fig 23: Locating Intermediate/Overdrive Drum Assembly
    G06292931Courtesy of FORD MOTOR CO.
  28. Remove the planet gear assembly.
    Fig 24: Locating Planet Gear Assembly
    G06292932Courtesy of FORD MOTOR CO.
  29. Remove the low/reverse clutch plate retaining ring.
    Fig 25: Locating Low/Reverse Clutch Plate Retaining Ring
    G06292933Courtesy of FORD MOTOR CO.
  30. Remove the low/reverse clutch plates, pressure plate and wave spring.
    Fig 26: Locating Low/Reverse Clutch Plates, Pressure Plate And Wave Ring
    G06292934Courtesy of FORD MOTOR CO.
  31. Remove the low One-Way Clutch (OWC) retaining ring.
    Fig 27: Locating Low One-Way Clutch Retaining Ring
    G06292935Courtesy of FORD MOTOR CO.
  32. Remove the low OWC inner race.
    Fig 28: Locating Low One-Way Clutch Inner Race
    G06292936Courtesy of FORD MOTOR CO.
  33. Remove the low/reverse clutch return spring.
    Fig 29: Locating Low/Reverse Clutch Return Spring
    G06292937Courtesy of FORD MOTOR CO.
  34. Remove the low/reverse clutch piston.
    Fig 30: Locating Low/Reverse Clutch Piston
    G06292938Courtesy of FORD MOTOR CO.
  35. Remove the transmission fluid pan.
    • Remove the bolts.
    • Remove the transmission fluid pan.
      Fig 31: Locating Transmission Fluid Pan Bolts
      G06292799Courtesy of FORD MOTOR CO.
  36. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface prep.
  37. Disconnect the Transmission Fluid Temperature (TFT) sensor.
    Fig 32: Locating Transmission Fluid Temperature (TFT) Sensor Electrical Connector
    G06292739Courtesy of FORD MOTOR CO.
  38. Remove the transmission fluid filter.
    Fig 33: Locating Transmission Fluid Filter
    G06292803Courtesy of FORD MOTOR CO.
    39. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.
  39. Remove the main control ground wire bolt, disconnect the electrical connectors and remove the wire harness.
    1. Shift Solenoid C (SSC), color N (white).
    2. Shift Solenoid E (SSE), color G (green).
    3. Shift Solenoid D (SSD), color L (blue).
    4. Line Pressure Control (LPC), color B (black).
    5. Shift Solenoid A (SSA), color N (neutral).
    6. Shift Solenoid B (SSB), color B (black).
      Fig 34: Identifying Electrical Connectors, Main Control Wiring Harness And Ground Wire Bolt
      G06292804Courtesy of FORD MOTOR CO.
    40. NOTE: Note the locations of the longer bolts.
    Fig 35: Locating Main Control Valve Body Bolts
    G06292943Courtesy of FORD MOTOR CO.
  40. Remove the 13 main control valve body bolts.
    41. NOTE: Squeeze the tabs on the side of the electrical connector.
    Fig 36: Locating Transaxle Internal Harness Electrical Connector
    G06292944Courtesy of FORD MOTOR CO.
  41. Remove the transaxle internal harness electrical connector.
    42. NOTE: Each accumulator piston has 2 springs inside of them, totaling 4 springs. All 4 springs are different sizes. The accumulator piston bore and accumulator pistons are a match as to depth. Some of the accumulator piston may have steps. Take note of the size, depth and location of the accumulator pistons and the spring sizes to aid assembly.
    Fig 37: Locating Accumulator Pistons And Springs
    G06292945Courtesy of FORD MOTOR CO.
  42. Remove the accumulator pistons and springs.
  43. Remove the manual control lever shaft roll pin.
    Fig 38: Locating Manual Control Lever Shaft Roll Pin
    G06292946Courtesy of FORD MOTOR CO.
  44. Remove the manual control lever shaft.
    Fig 39: Locating Manual Control Lever Shaft
    G06292947Courtesy of FORD MOTOR CO.
  45. Remove the O-ring seals from the manual control lever shaft.
    Fig 40: Locating O-Ring Seals On Manual Lever Shaft
    G06292948Courtesy of FORD MOTOR CO.
  46. Remove the manual control lever detent assembly.
    Fig 41: Locating Manual Control Lever Bolt
    G06292949Courtesy of FORD MOTOR CO.
    47. NOTE: The intermediate/O/D band servo cover plate is spring loaded. The bolts should be removed evenly until plate is unloaded, then remove the bolts. Failure to do so can result in bolt thread damage.
    Fig 42: Locating Intermediate/O/D Piston Servo Cover Bolts
    G06292950Courtesy of FORD MOTOR CO.
  47. Remove the 3 intermediate/O/D piston servo cover bolts and the servo cover.
  48. Remove the O-ring seal.
    Fig 43: Locating O-Ring Seal
    G06292951Courtesy of FORD MOTOR CO.
  49. Remove the intermediate/O/D servo piston.
    Fig 44: Locating Intermediate/Overdrive Servo Piston
    G06292952Courtesy of FORD MOTOR CO.
  50. Remove the intermediate/O/D servo piston return spring.
    Fig 45: Locating Intermediate/Overdrive Servo Piston Return Spring
    G06292953Courtesy of FORD MOTOR CO.
  51. NOTE: If the intermediate/O/D servo bore has excessive wear, a lack of apply pressure will occur and damage to the direct clutch and or intermediate/O/D band may occur.

    Inspect the intermediate/O/D servo bore and servo pin. If the intermediate/O/D servo bore or servo pin shows signs of excessive wear or damage, install a servo bore bushing. Refer to Servo Bore Repair.

    Fig 46: Inspecting Intermediate/O/D Servo Bore And Servo Pin
    G00530991Courtesy of FORD MOTOR CO.
  52. Rotate the transaxle 180 degrees.
  53. Remove the bolts and separate the converter housing from the transaxle case.
    Fig 47: Locating Converter Housing Bolts
    G06292954Courtesy of FORD MOTOR CO.
  54. Remove the differential assembly.
    Fig 48: Locating Differential Assembly
    G06292955Courtesy of FORD MOTOR CO.
  55. Remove the parking pawl assembly cover.
    • Remove the bolts and the parking pawl assembly cover.
      Fig 49: Locating Parking Pawl Assembly Cover Bolts
      G06292956Courtesy of FORD MOTOR CO.
  56. Remove the parking pawl abutment.
    1. Unclip the spring.
    2. Remove the pin.
    3. Remove the lever.
    4. Remove the parking pawl abutment.
      Fig 50: Identifying Parking Pawl Abutment Spring, Pin And Lever
      G06292957Courtesy of FORD MOTOR CO.
  57. Remove the spring.
    Fig 51: Locating Parking Pawl Return Spring
    G06292958Courtesy of FORD MOTOR CO.
  58. Remove the transfer shaft gears.
    Fig 52: Locating Transfer Shaft Gear
    G06292959Courtesy of FORD MOTOR CO.
  59. Using the Final Drive Input Gear Holding Tool, lock the final drive input gear.
    Fig 53: Locking Final Drive Input Gear Using Final Drive Input Gear Holding Tool
    G06292960Courtesy of FORD MOTOR CO.
  60. Rotate the transaxle 180 degrees.
    61. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
    Fig 54: Removing Final Drive Input Gear Bearing Retainer Nut
    G06292961Courtesy of FORD MOTOR CO.
  61. Using the Final Drive Input Nut Socket and Wrench Guide Plate, remove the final drive input gear bearing retainer nut.
  62. Remove the Final Drive Input Nut Socket and Wrench Guide Plate.
  63. Rotate the transaxle 180 degrees.
  64. Remove the Final Drive Input Gear Holding Tool.
    Fig 55: Removing Final Drive Input Gear Holding Tool
    G06292960Courtesy of FORD MOTOR CO.
    65. NOTE: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case or damage to the input gear can occur.
  65. Rotate the transaxle 180 degrees.
  66. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
    Fig 56: Locating Final Drive Input Gear Bearing
    G06292963Courtesy of FORD MOTOR CO.
  67. Remove and discard the collapsible spacer.
    Fig 57: Locating Collapsible Spacer
    G06292964Courtesy of FORD MOTOR CO.
    68. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
    Fig 58: Locating Final Drive Input Gear Bearing
    G06292965Courtesy of FORD MOTOR CO.
  68. Using a suitable chisel, remove the final drive input gear bearing.
  69. Using the Front Wheel Hub Remover/Installer, Bearing Puller and Step Plate remove the final drive input gear bearing inner race.
    Fig 59: Removing Differential Case Bearings
    G06292966Courtesy of FORD MOTOR CO.
  70. Clean the converter housing and transaxle case surfaces thoroughly with metal surface prep.
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