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Section 343 (Automatic Transaxle/Transmission): Assembly: Transaxle: Assembly

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Soak all friction clutch plates in clean Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON®.
  1. Prior to installation, lightly lubricate all O-ring seals with clean Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON®.

    Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

    Clean all mating surfaces before assembly.

  2. Using the special tool, install the differential bearing outer race into the converter housing.
    Fig 1: Installing Differential Bearing Outer Race Into Converter Housing
    G03412585Courtesy of FORD MOTOR CO.
  3. Place the differential into the converter housing.
    1. Install the differential.
    2. Install the differential bearing race.
      Fig 2: Placing Differential Into Converter Housing
      G03412586Courtesy of FORD MOTOR CO.
  4. Using the special tools, assemble the transaxle cases for thrust washer measurement.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the transaxle case.
    4. Install the special tools.
      Fig 3: Positioning Transaxle Case
      G03412587Courtesy of FORD MOTOR CO.
  5. Adjust the special tool.
    1. Install the special tool.
    2. Rotate the special tool until all clearance between the tool and the transaxle case is removed.
      Fig 4: Adjusting Special Tool
      G03412588Courtesy of FORD MOTOR CO.
  6. Adjust the differential turning torque.
    1. Install the special tool.
    2. Use a torque wrench to measure the turning torque of the differential.
    3. Adjust the special tools until the proper turning torque is achieved.
      Fig 5: Adjusting Differential Turning Torque
      G03412589Courtesy of FORD MOTOR CO.
  7. Measure the special tool clearance at four points around the tool, each 90° apart. Use the largest of these measurements to select the proper differential bearing shim from the chart below.
    DIFFERENTIAL BEARING SHIM THICKNESS SPECIFICATION

    Thickness Part Number
    0.48 mm (0.0189 in) F3XY-4067-A
    0.52 mm (0.0205 in) F3XY-4067-B
    0.56 mm (0.0220 in) F3XY-4067-C
    0.60 mm (0.0236 in) F3XY-4067-D
    0.64 mm (0.0252 in) F3XY-4067-E
    0.68 mm (0.0268 in) F3XY-4067-F
    0.72 mm (0.0283 in) F3XY-4067-G
    0.76 mm (0.0299 in) F3XY-4067-H
    0.80 mm (0.0315 in) F3XY-4067-J
    0.84 mm (0.0331 in) F3XY-4067-K
    0.88 mm (0.0346 in) F3XY-4067-M
    0.92 mm (0.0362 in) F3XY-4A053-B
    Fig 6: Locating Differential Bearing Shim Thickness
    G03412590Courtesy of FORD MOTOR CO.
  8. Remove the special tools.
    Fig 7: Removing Special Tools (1 Of 2)
    G03412591Courtesy of FORD MOTOR CO.
  9. Remove the special tools.
    1. Remove the special tools.
    2. Remove the transaxle case.
    3. Remove the special tools.
    4. Remove the special tools.
      Fig 8: Removing Special Tools (2 Of 2)
      G03412592Courtesy of FORD MOTOR CO.
  10. Mount the transaxle case using the special tool.
    Fig 9: Mounting Transaxle Case
    G03412593Courtesy of FORD MOTOR CO.
  11. Install the correct differential bearing shim into the transaxle case.
    Fig 10: Installing Correct Differential Bearing Shim Into Transaxle Case
    G03412594Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the differential bearing outer race into the transaxle case.
    Fig 11: Installing Differential Bearing Outer Race Into Transaxle Case
    G03412595Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the manual control lever seal.
    Fig 12: Installing Manual Control Lever Seal
    G03412596Courtesy of FORD MOTOR CO.
  14. Position the park actuator support/parking lever actuating rod assembly.
    Fig 13: Positioning Park Actuator Support/Parking Lever Actuating Rod Assembly
    G03412597Courtesy of FORD MOTOR CO.
  15. Position the manual detent lever.
    Fig 14: Positioning Manual Detent Lever
    G03412598Courtesy of FORD MOTOR CO.
    16. NOTE: The linkage rod must pass through the manual detent lever and the park actuator support/parking lever.
  16. Install the manual shift linkage rod.
    1. Install the rod.
    2. Install the roll pin.
      Fig 15: Installing Roll Pin
      G03412599Courtesy of FORD MOTOR CO.
  17. Install the manual detent lever roll pin.
    Fig 16: Installing Manual Detent Lever Roll Pin
    G03412600Courtesy of FORD MOTOR CO.
  18. Install the park actuator support/parking lever actuating rod pin.
    Fig 17: Installing Park Actuator Support/Parking Lever Actuating Rod Pin
    G03412601Courtesy of FORD MOTOR CO.
  19. Install the manual detent spring.
    1. Position the spring.
    2. Install the bolt.
      Fig 18: Installing Bolt
      G03412602Courtesy of FORD MOTOR CO.
    20. NOTE: The differential seal in the torque converter housing is the smaller of the two differential seals.
    Fig 19: Installing Differential Oil Seal In Torque Converter Housing
    G03412603Courtesy of FORD MOTOR CO.
  20. Using the special tool, install the differential oil seal in the torque converter housing.
  21. Using the special tool, install the differential seal in the transaxle case.
    Fig 20: Installing Differential Seal In Transaxle Case
    G03412604Courtesy of FORD MOTOR CO.
  22. Install the reduction gear bearing outer race.
    1. Install the race.
    2. Install the bolts.
      Fig 21: Installing Bolts
      G03412605Courtesy of FORD MOTOR CO.
  23. Install the parking actuator support.
    1. Install the support.
    2. Install the bolts.
      Fig 22: Installing Parking Actuator Support
      G03412606Courtesy of FORD MOTOR CO.
  24. Install the parking pawl.
    1. Install the parking pawl shaft.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
      Fig 23: Installing Parking Pawl
      G03412607Courtesy of FORD MOTOR CO.
  25. Using the special tool, install the idler gear bearing outer race.
    Fig 24: Installing Idler Gear Bearing Outer Race
    G03412608Courtesy of FORD MOTOR CO.
    26. NOTE: The reduction gear is installed through the reduction gear bearing outer race.
  26. Install the reduction gear/shaft into the transaxle.
    • Support the reduction gear to hold it in the transaxle.
  27. Install the idler bearing.
    Fig 25: Installing Idler Bearing
    G03412609Courtesy of FORD MOTOR CO.
    28. NOTE: To verify a correct reading, take the measurement in at least two places.
  28. Using the special tool, measure the distance between the end of the reduction gear shaft and the transaxle case. Record this as measurement "B".
    • The thickness of the special tool must be added to the measurement.
      Fig 26: Measuring Distance Between End Of Reduction Gear Shaft And Transaxle Case
      G03412610Courtesy of FORD MOTOR CO.
    29. NOTE: To verify a correct reading, take the measurement in at least two places.
  29. Using the special tool, measure the distance from the transaxle case to the idler gear bearing inner race. Record this as measurement "C".
    • The thickness of the special tool must be subtracted from the measurement.
      Fig 27: Measuring Distance From Transaxle Case To Idler Gear Bearing Inner Race
      G03412611Courtesy of FORD MOTOR CO.
  30. Remove the reduction gear/shaft from the transaxle case.
    31. NOTE: To verify a correct reading, take the measurement in at least two places.
    Fig 28: Measuring Distance Between Reduction Gear End And Reduction Gear Adjusting Shim Mating Surface
    G03412612Courtesy of FORD MOTOR CO.
  31. Measure the distance between the reduction gear end and the reduction gear adjusting shim mating surface. Record this as measurement "D".
  32. Calculate dimension A. Use the equation D - (B+C) = A.
    33. NOTE: To verify a correct reading, take the measurement in at least two places.
    Fig 29: Measuring Distance Between End Of Idler Gear And Idler Gear Bearing Inner Race Mating Surface
    G03412613Courtesy of FORD MOTOR CO.
  33. Measure the distance between the end of the idler gear and the idler gear bearing inner race mating surface. Record this as measurement "E".
  34. Calculate the thickness of the reduction gear bearing adjusting shim. Use the equation A - E - 0.5 mm (0.02 in). Select the appropriate adjusting shim from the chart below.
    REDUCTION GEAR BEARING ADJUSTING SHIMS SPECIFICATION

    Thickness Part Number
    5.0 mm (0.1969 in) - 5.52 mm (0.2173 in) F3XY-7N112-A
    5.54 mm (0.2181 in) - 6.06 mm (0.2386 in) F3XY-7N112-B
    6.08 mm (0.2394 in) - 6.72 mm (0.2646 in) F3XY-7N112 -C
  35. Install the correct reduction gear bearing adjusting shim on the reduction gear shaft.
    Fig 30: Installing Correct Reduction Gear Bearing Adjusting Shim On Reduction Gear Shaft
    G03412614Courtesy of FORD MOTOR CO.
  36. Using the special tools, press the idler gear bearing onto the idler gear.
    Fig 31: Using Special Tools, Press Idler Gear Bearing Onto Idler Gear
    G03412615Courtesy of FORD MOTOR CO.
    37. NOTE: The reduction gear is installed through the reduction gear bearing outer race.
  37. Install the reduction gear/shaft into the transaxle.
    • Support the reduction gear/shaft to hold it in the transaxle.
    38. NOTE: Engage the parking pawl to hold the idler gear during nut installation.
  38. Install the idler gear.
    1. Install the idler gear.
    2. Install the locknut.
      Fig 32: Installing Locknut (1 Of 2)
      G03412616Courtesy of FORD MOTOR CO.
  39. Rotate the idler gear clockwise and counter clockwise several rotations in order to seat the bearing rollers.
  40. Measure the turning torque of the reduction gear. If the torque is too low, increase the thickness of the reduction bearing adjusting shim. If the turning torque is too high, reduce the thickness of the reduction bearing adjusting shim.
    Fig 33: Installing Locknut (2 Of 2)
    G03412617Courtesy of FORD MOTOR CO.
  41. Using the special tool, stake the idler gear locknut.
    Fig 34: Staking Idler Gear Locknut
    G03412618Courtesy of FORD MOTOR CO.
    42. NOTE: The output shaft is installed from the side of the transaxle opposite the idler gear.
  42. Install the output shaft bearing retainer.
    1. Install the bearing retainer.
    2. Install the bolts.
      Fig 35: Installing Bolts
      G03412619Courtesy of FORD MOTOR CO.
  43. Install the output shaft hub thrust washer.
    Fig 36: Installing Output Shaft Hub Thrust Washer
    G03412620Courtesy of FORD MOTOR CO.
  44. Install the output shaft assembly into the transaxle case.
    Fig 37: Installing Output Shaft Assembly Into Transaxle Case
    G03412621Courtesy of FORD MOTOR CO.
    45. NOTE: To verify a correct reading, take the measurement in at least two places.
  45. Using the special tool, measure the distance from the side cover mating surface to the output shaft hub thrust washer surface. Record this as measurement "A".
    • The thickness of the special tool must be subtracted from the measurement.
      Fig 38: Measuring Distance From Side Cover Mating Surface To Output Shaft Hub Thrust Washer Surface
      G03412622Courtesy of FORD MOTOR CO.
    46. NOTE: To verify a correct reading, take the measurement in at least two places.
  46. Using the special tool, measure the distance from output shaft hub thrust washer to the transaxle case. Record this as measurement "B".
    • The thickness of the special tool must be subtracted from the measurement.
      Fig 39: Measuring Distance From Output Shaft Hub Thrust Washer To Transaxle Case
      G03412623Courtesy of FORD MOTOR CO.
  47. Calculate the thickness of the output shaft bearing shim. Use the equation A - B. Select the appropriate adjusting shim from the chart below.
    OUTPUT SHAFT BEARING SELECTIVE SHIMS SPECIFICATION

    Thickness Part Number
    0.8 mm (0.0315 in) F3XY-7F405-A
    0.84 mm (0.0331 in) F3XY-7F405-B
    0.88 mm (0.0346 in) F3XY-7F405-C
    0.92 mm (0.0362 in) F3XY-7F405-D
    0.96 mm (0.0378 in) F3XY-7F405-E
    1.00 mm (0.0394 in) F3XY-7F405-F
    1.04 mm (0.0409 in) F3XY-7F405-G
    1.08 mm (0.0425 in) F3XY-7F405-H
    1.12 mm (0.0441 in) F3XY-7F405-J
    1.16 mm (0.0457 in) F3XY-7F405-K
    1.20 mm (0.0472 in) F3XY-7F405-L
  48. Install the output shaft bearing shim.
    Fig 40: Installing Output Shaft Bearing Shim
    G03412624Courtesy of FORD MOTOR CO.
  49. Apply a 1.5 mm (0.06 in) bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5 to the transaxle case mating surface.
    Fig 41: Locating Gasket
    G03412625Courtesy of FORD MOTOR CO.
    50. NOTE: The self sealing bolts must not be reused.
  50. Install the transaxle side cover.
    1. Install the side cover.
    2. Install new self sealing bolts
    3. Install the remaining bolts.
      Fig 42: Installing Transaxle Side Cover
      G03412626Courtesy of FORD MOTOR CO.
    51. NOTE: Do not align the engagement teeth on the clutch dish plates.
    NOTE: Install the clutch dish plates with the outer edges touching.
  51. Install the low/reverse clutch pack.
    1. Install the clutch assembly.
    2. Install the dish plates with the two plates engagement teeth not aligned.
    3. Install the clutch pressure plate.
      Fig 43: Installing Low/Reverse Clutch Pack
      G03412627Courtesy of FORD MOTOR CO.
  52. Install the low/reverse clutch snap ring.
    Fig 44: Installing Low/Reverse Clutch Snap Ring
    G03412628Courtesy of FORD MOTOR CO.
  53. Measure the clearance between the low/reverse clutch pressure plate retainer snap ring and the pressure plate. The standard clearance is 1.7 mm (0.067 in) to 2.1 mm (0.083 in). If the clearance is greater than 3.3 mm (0.130 in), select and insert the proper low/reverse clutch pressure plate from the chart below.
    LOW/REVERSE CLUTCH PRESSURE PLATES SPECIFICATION

    Thickness Part Number
    2.0 mm (0.079 in) F3XY-7B066-ABA
    2.2 mm (0.087 in) F3XY-7B066-ACA
    2.4 mm (0.094 in) F3XY-7B066-ADA
    2.6 mm (0.102 in) F3XY-7B066-AEA
    2.8 mm (0.110 in) F3XY-7B066-AFA
    3.0 mm (0.118 in) F3XY-7B066-AGA
    3.2 mm (0.126 in) F3XY-7B066-AHA
    3.4 mm (0.134 in) F3XY-7B066-AJA
    Fig 45: Measuring Clearance Between Low/Reverse Clutch Pressure Plate Retainer Snap Ring And Pressure Plate
    G03412629Courtesy of FORD MOTOR CO.
    54. NOTE: The bearing is installed with the black side facing up.
  54. Install the forward clutch assembly.
    1. Install the lower forward clutch hub bearing.
    2. Install the forward clutch hub.
      Fig 46: Installing Forward Clutch Assembly
      G03412630Courtesy of FORD MOTOR CO.
    55. NOTE: The forward clutch hub upper bearing is installed with the black side facing up.
    NOTE: Verify that the teeth on the coasting clutch hub thrust washer engage the slots in the coasting clutch hub.
  55. Install the coasting clutch hub assembly.
    1. Install the coasting clutch hub thrust washer.
    2. Install the coasting clutch hub.
    3. Install the forward clutch hub upper bearing.
      Fig 47: Installing Forward Clutch Hub Upper Bearing
      G03412631Courtesy of FORD MOTOR CO.
  56. Install the forward clutch hub and ring gear assembly.
    1. Install the forward clutch ring gear thrust washer.
    2. Install the forward clutch hub and ring gear assembly.
      Fig 48: Installing Forward Clutch Hub And Ring Gear Assembly
      G03412632Courtesy of FORD MOTOR CO.
  57. Install the rear sun gear into the rear planetary gear set.
    1. Install the rear sun gear rear thrust bearing.
    2. Install the rear sun gear.
      Fig 49: Installing Rear Sun Gear Into Rear Planetary Gear Set
      G03412633Courtesy of FORD MOTOR CO.
  58. Install the rear planetary gearset.
    1. Install the rear planetary thrust bearing.
    2. Install the rear planetary gearset.
      Fig 50: Installing Rear Planetary Thrust Bearing
      G03412634Courtesy of FORD MOTOR CO.
    59. NOTE: The rear sun gear front thrust bearing is installed with the black side facing up (towards the front planetary gearset).
  59. Install the front planetary gearset assembly.
    1. Install the rear sun gear front thrust bearing.
    2. Install the front planetary gearset.
    3. Install the primary sun gear lower thrust washer.
      Fig 51: Installing Front Planetary Gearset Assembly
      G03412635Courtesy of FORD MOTOR CO.
  60. Install the low/reverse clutch piston spring retainer and springs.
    Fig 52: Installing Low/Reverse Clutch Piston Spring Retainer And Springs
    G03412636Courtesy of FORD MOTOR CO.
  61. Align the low reverse clutch piston return spring assembly with the transaxle case.
    Fig 53: Aligning Low Reverse Clutch Piston Return Spring Assembly With Transaxle Case
    G03412637Courtesy of FORD MOTOR CO.
  62. Coat the low/reverse clutch piston with Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON®.
    63. NOTE: The low/reverse clutch piston must align with the return spring.
  63. Install the low/reverse clutch piston assembly.
    • Align the low/reverse clutch piston retainer tab with the 2-4 servo band piston rod opening.
      Fig 54: Installing Low/Reverse Clutch Piston Assembly
      G03412638Courtesy of FORD MOTOR CO.
  64. Position the low/reverse clutch piston snap ring on top of the low/reverse clutch piston.
    Fig 55: Positioning Low/Reverse Clutch Piston Snap Ring On Top Of Low/Reverse Clutch Piston
    G03412639Courtesy of FORD MOTOR CO.
    65. NOTE: The snap ring must be positioned before using the special tools to compress the clutch pack.
    Fig 56: Installing Low/Reverse Clutch Snap Ring
    G03412640Courtesy of FORD MOTOR CO.
  65. Using the special tools, install the low/reverse clutch snap ring.
  66. Install the low one-way clutch.
    Fig 57: Installing Low One-Way Clutch
    G03412641Courtesy of FORD MOTOR CO.
  67. Verify that the low one-way clutch rotates only in the clockwise direction.
  68. Install the low one-way clutch snap ring.
    Fig 58: Installing Low One-Way Clutch Snap Ring
    G03412642Courtesy of FORD MOTOR CO.
  69. Install the primary sun gear assembly.
    1. Install the primary sun gear bearing race.
    2. Install the primary sun gear.
    3. Install the primary sun gear bearing.
      Fig 59: Installing Primary Sun Gear Assembly
      G03412643Courtesy of FORD MOTOR CO.
  70. Install the 3-4 clutch hub assembly.
    1. Install the 3-4 clutch hub.
    2. Install the 3-4 clutch hub bearing.
      Fig 60: Installing 3-4 Clutch Hub Assembly
      G03412644Courtesy of FORD MOTOR CO.
  71. Install the 3-4 clutch assembly/reverse clutch assembly.
    1. Install the 3-4 clutch assembly.
    2. Install the reverse clutch assembly.
      Fig 61: Installing 3-4 Clutch Assembly/Reverse Clutch Assembly
      G03412645Courtesy of FORD MOTOR CO.
  72. Install the 3-4 clutch drum and input shaft upper thrust bearing.
    Fig 62: Installing 3-4 Clutch Drum And Input Shaft Upper Thrust Bearing
    G03412646Courtesy of FORD MOTOR CO.
    73. NOTE: To verify a correct reading, take the measurement in at least two places.
  73. Using the special tool, measure the distance from the oil pump end surface to the oil pump bearing surface. Record this as measurement "A".
    • The thickness of the special tool must be subtracted from the measurement.
      Fig 63: Measuring Distance From Oil Pump End Surface To Oil Pump Bearing Surface
      G03412647Courtesy of FORD MOTOR CO.
    74. NOTE: To verify a correct reading, take the measurement in at least two places.
  74. Using the special tool, measure the distance from the oil pump end to the oil pump mating surface. Record this as measurement "B".
    • Subtract the special tool thickness from measurement "B".
      Fig 64: Measuring Distance From Oil Pump End To Oil Pump Mating Surface
      G03412648Courtesy of FORD MOTOR CO.
  75. Using the equation B - A, calculate measurement "C".
  76. Position a new gasket on the transaxle oil pump mating surface.
    77. NOTE: The oil pump gasket must be in position to obtain a correct reading.
    NOTE: To verify a correct reading, take the measurement in at least two places.
  77. Using the special tool, measure the distance from the oil pump mating surface (on the transaxle) to the 3-4 clutch drum and input shaft upper thrust bearing. Record this as measurement "D".
    • The thickness of the special tool must be subtracted from the measurement.
      Fig 65: Measuring Distance From Oil Pump Mating Surface To 3-4 Clutch Drum And Input Shaft Upper Thrust Bearing
      G03412649Courtesy of FORD MOTOR CO.
  78. Using the equation D - C, calculate the total reverse clutch drum end play.
    79. NOTE: The reverse clutch drum end thrust washer is not yet installed.
  79. Select a shim that will bring the reverse clutch drum end play within 0.55 mm (0.0217 in) to 0.90 mm (0.0354 in) from the chart below.
    REVERSE CLUTCH DRUM END THRUST WASHER SIZE SPECIFICATION

    Thickness Part Number
    0.80 mm (0.0315 in) F3XY-7D061-A
    0.95 mm (0.0374 in) F3XY-7D061-C
    1.10 mm (0.0433 in) F3XY-7D061-D
    1.25 mm (0.0492 in) F3XY-7D061-E
    1.40 mm (0.0551 in) F3XY-7D061-B
    1.55 mm (0.0610 in) F3XY-7D061-F
    1.70 mm (0.0669 in) F3XY-7D061-G
    1.85 mm (0.0728 in) F3XY-7D061-H
  80. Install the 2-4 band adjusting stop and band.
    Fig 66: Installing 2-4 Band Adjusting Stop And Band
    G03412650Courtesy of FORD MOTOR CO.
  81. Install the 2-4 band.
    1. Install the band.
    2. Position the strut.
      Fig 67: Installing 2-4 Band
      G03412651Courtesy of FORD MOTOR CO.
  82. Install the 2-4 servo piston assembly.
    Fig 68: Installing 2-4 Servo Piston Assembly
    G03412652Courtesy of FORD MOTOR CO.
  83. Install the 2-4 servo piston retainer bolts.
    Fig 69: Installing 2-4 Servo Piston Retainer Bolts
    G03412653Courtesy of FORD MOTOR CO.
  84. Tighten the band adjusting stop until the band fits evenly around the reverse clutch drum.
    Fig 70: Tightening Bolt
    G03412654Courtesy of FORD MOTOR CO.
  85. Position the reverse clutch drum thrust washer.
    • Apply petroleum jelly to hold the washer in position.
      Fig 71: Positioning Reverse Clutch Drum Thrust Washer
      G03412655Courtesy of FORD MOTOR CO.
  86. Install the oil pump.
    1. Position a new oil pump gasket.
    2. Install the pump.
      Fig 72: Installing Oil Pump
      G03412656Courtesy of FORD MOTOR CO.
  87. Install the oil pump bolts.
    1. Install the baffle plate.
    2. Install the bolts.
      Fig 73: Installing Oil Pump Bolts
      G03412657Courtesy of FORD MOTOR CO.
  88. Install the input shaft O-ring.
    • Coat the O-ring with clean transmission fluid.
      Fig 74: Installing Input Shaft O-Ring
      G03412658Courtesy of FORD MOTOR CO.
  89. Tighten the 2-4 band.
    • Tighten the band in three stages.
    • Stage 1: Tighten the adjustable band stop to 5 N.m(45 lb/in).
    • Stage 2: Loosen the adjustable band stop 2.5 turns.
    • Stage 3: Tighten the adjustable stop locknut to 34 N.m(25 lb/ft).
      Fig 75: Tightening 2-4 Band
      G03412659Courtesy of FORD MOTOR CO.
  90. Check the operation of the 2-4 band.
    • Apply compressed air to the fluid passages and verify band operation.
      Fig 76: Checking Operation Of 2-4 Band
      G03412660Courtesy of FORD MOTOR CO.
  91. Install the differential.
    Fig 77: Installing Differential
    G03412661Courtesy of FORD MOTOR CO.
  92. Install the differential lubrication tube.
    1. Install the tube.
    2. Install the bolts.
      Fig 78: Installing Bolts
      G03412662Courtesy of FORD MOTOR CO.
  93. Install the differential port O-ring.
    Fig 79: Installing Differential Port O-Ring
    G03412663Courtesy of FORD MOTOR CO.
  94. Remove the special tool from the transaxle.
    Fig 80: Removing Special Tool From Transaxle
    G03412664Courtesy of FORD MOTOR CO.
    95. NOTE: The mating surfaces must be clean prior to sealant application.
    Fig 81: Identifying Gasket
    G03412665Courtesy of FORD MOTOR CO.
  95. Apply a 1.5 mm (0.06 in) bead of Gasket Maker E2AZ-19562-B meeting Ford specification WSKM2G348-A5 to the transaxle case.
  96. Install the torque converter housing.
    1. Install the housing.
    2. Install the bolts.
      Fig 82: Installing Bolts
      G03412666Courtesy of FORD MOTOR CO.
  97. Install the low/reverse clutch apply oil transfer tube seal.
    Fig 83: Installing Low/Reverse Clutch Apply Oil Transfer Tube Seal
    G03412667Courtesy of FORD MOTOR CO.
  98. Install the low/reverse clutch apply oil transfer tube.
    1. Install the tube.
    2. Install the bolts.
      Fig 84: Installing Bolts
      G03412668Courtesy of FORD MOTOR CO.
  99. Inspect the D -R and N-D accumulator pistons for damage.
  100. Install the D-R accumulator piston O-rings.
    Fig 85: Installing D-R Accumulator Piston O-Rings
    G03412669Courtesy of FORD MOTOR CO.
  101. Install the N-D accumulator piston O-rings.
    Fig 86: Installing N-D Accumulator Piston O-Rings
    G03412670Courtesy of FORD MOTOR CO.
  102. Install the D-R accumulator piston.
    1. Install the piston.
    2. Install the return spring.
      Fig 87: Installing D-R Accumulator Piston
      G03412671Courtesy of FORD MOTOR CO.
  103. Install the N-D accumulator piston.
    1. Install the return spring.
    2. Install the piston.
      Fig 88: Installing N-D Accumulator Piston
      G03412672Courtesy of FORD MOTOR CO.
    104. CAUTION: Do not apply more than 392 kPa (57 psi) of air pressure).
  104. Check operation of the 3-4 clutch and the 2-4 band.
    1. Apply compressed air to check the 3-4 clutch application.
    2. Apply compressed air to check fourth gear band application.
    3. Apply compressed air to check second gear band application.
      Fig 89: Checking Operation Of 3-4 Clutch And 2-4 Band
      G03412673Courtesy of FORD MOTOR CO.
    105. NOTE: Coat the seals with petroleum jelly.
    Fig 90: Installing Seals
    G03412674Courtesy of FORD MOTOR CO.
  105. Install the seals.
  106. Position the manual shift linkage rod to the NEUTRAL position.
  107. Position the valve body.
    • Align the manual valve with the manual detent lever.
      Fig 91: Positioning Valve Body
      G03412675Courtesy of FORD MOTOR CO.
    108. CAUTION: Use the 43.5 mm (1.74 in) long bolts for this step or damage to the transaxle case or valve body may occur.
  108. Install the main control valve body.
    1. Feed the wiring harness through the transaxle case.
    2. Install the control valve body bolts.
      Fig 92: Installing Control Valve Body Bolts (1 Of 3)
      G03412676Courtesy of FORD MOTOR CO.
    109. CAUTION: Use the 33 mm (1.32 in) long bolts for this step or damage to the transaxle case or valve body may occur.
    Fig 93: Installing Control Valve Body Bolts (2 Of 3)
    G03412677Courtesy of FORD MOTOR CO.
  109. Install control valve body bolts.
    110. CAUTION: Use the 40 mm (1.6 in) long bolts for this step or damage to the transaxle case or valve body may occur.
    Fig 94: Installing Control Valve Body Bolts (3 Of 3)
    G03412678Courtesy of FORD MOTOR CO.
  110. Install the control valve body bolts.
  111. Install the transaxle harness spring clip.
    Fig 95: Installing Transaxle Harness Spring Clip
    G03412679Courtesy of FORD MOTOR CO.
  112. Install the magnets in the transaxle fluid pan.
    Fig 96: Installing Magnets In Transaxle Fluid Pan
    G03412680Courtesy of FORD MOTOR CO.
  113. Install the transaxle fluid pan.
    1. Position a new pan gasket.
    2. Position the pan.
    3. Install the bolts in a crisscross pattern.
      Fig 97: Installing Bolts In Crisscross Pattern
      G03412681Courtesy of FORD MOTOR CO.
  114. Install a new gasket on the drain pan plug.
  115. Install the transaxle fluid pan drain plug.
    Fig 98: Installing Transaxle Fluid Pan Drain Plug
    G03412682Courtesy of FORD MOTOR CO.
  116. Position the manual shift linkage rod in the PARK (P) position.
    117. NOTE: The manual shift linkage rod pin must locate in the transaxle range sensor arm.
  117. Install the transaxle range sensor.
    1. Install the sensor.
    2. Loosely install the bolts.
      Fig 99: Installing Bolts
      G03412683Courtesy of FORD MOTOR CO.
    118. NOTE: The special tool must pass through both the sensor arm and the manual shift linkage rod.
  118. Using the special tool, adjust the transaxle range sensor.
    1. Install the special tool.
    2. Tighten the bolts.
      Fig 100: Tightening Bolts
      G03412684Courtesy of FORD MOTOR CO.
  119. Remove the special tool from the transaxle range sensor.
    Fig 101: Removing Special Tool From Transaxle Range Sensor
    G03412685Courtesy of FORD MOTOR CO.
  120. Install the transaxle oil cooler tubes.
    1. Install the tubes.
    2. Install the tube bolts.
    3. Install the tube bracket bolt.
      Fig 102: Installing Tube Bracket Bolt
      G03412686Courtesy of FORD MOTOR CO.
  121. If installing a new torque converter, add one liter (one quart) of Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON® to the torque converter. If using the original torque converter, add the amount that was removed from the converter.
  122. Remove the transaxle from the special tool.
    Fig 103: Removing Transaxle From Special Tool
    G03412687Courtesy of FORD MOTOR CO.
    123. CAUTION: The torque converter notches must align with the transaxle oil pump to ensure proper installation.
    Fig 104: Installing Torque Converter
    G03412688Courtesy of FORD MOTOR CO.
  123. Install torque converter.
  124. Measure the distance from the transaxle mounting surface to the torque converter. The distance should measure a minimum of 19 mm (0.76 in). If the distance is less than 19 mm (0.76 in), the torque converter is not properly installed.
    Fig 105: Measuring Distance From Transaxle Mounting Surface To Torque Converter
    G03412689Courtesy of FORD MOTOR CO.
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