Automatic Transmission: Assembly: Transaxle

Special Tool(s) 

Fig 1: Identifying Special Tools (1 Of 6)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 6)

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Fig 3: Identifying Special Tools (3 Of 6)

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Fig 4: Identifying Special Tools (4 Of 6)

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Fig 5: Identifying Special Tools (5 Of 6)

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Fig 6: Identifying Special Tools (6 Of 6)

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1. Install the parking pawl assembly.
   1. Install the parking pawl and return spring.
   2. Install the parking pawl shaft.
      Fig 7: Installing Parking Pawl Assembly

      Courtesy of FORD MOTOR CO.
2. Install the park pawl roll pin.
   Fig 8: Installing Park Pawl Roll Pin

   Courtesy of FORD MOTOR CO.
3. Using the special tool, install the cup plug.
   Fig 9: Installing Cup Plug

   Courtesy of FORD MOTOR CO.
4. Using the special tools, install the new drive sprocket bearing, if it was removed.
   Fig 10: Installing Drive Sprocket Bearing

   Courtesy of FORD MOTOR CO.
NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.
Fig 11: Installing Driven Sprocket Support
Courtesy of FORD MOTOR CO.
5. Install the driven sprocket support.
6. Install the bolts.
   Fig 12: Installing Bolts

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7. Using the special tool, install the converter impeller hub seal.
   Fig 13: Installing Converter Impeller Hub Seal

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8. Install the differential carrier thrust bearing.
   1. Install the differential carrier thrust washer.
   2. Install the differential carrier thrust bearing and race (tabs down).
      Fig 14: Installing Differential Carrier Thrust Bearing

      Courtesy of FORD MOTOR CO.
9. Install the final drive ring gear.
   Fig 15: Installing Final Drive Ring Gear

   Courtesy of FORD MOTOR CO.
10. Install the rear planet support spacer.
    Fig 16: Installing Rear Planet Support Spacer

    Courtesy of FORD MOTOR CO.
11. Install the final drive differential assembly.
    Fig 17: Installing Final Drive Differential Assembly

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12. Align the rear lube tube holes in the case window.
    Fig 18: Aligning Rear Lube Tube Holes In Case Window

    Courtesy of FORD MOTOR CO.
NOTE: The retaining ring must be correctly installed.
Fig 19: Installing Beveled Retaining Ring (1 Of 2)
Courtesy of FORD MOTOR CO.
Fig 20: Installing Beveled Retaining Ring (2 Of 2)
Courtesy of FORD MOTOR CO.
13. Using the special tool install the beveled retaining ring.
CAUTION: If support is not visible on inside diameter of the retaining ring the low/intermediate piston could be damaged.
Fig 21: Checking Beveled Retaining Ring Seats
Courtesy of FORD MOTOR CO.
14. Make sure that the beveled retaining ring seats correctly in case groove with the bevel down and final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall.
15. Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove.
    Fig 22: Checking Retaining Ring

    Courtesy of FORD MOTOR CO.
16. Install the special tools.
    Fig 23: Installing Special Tools

    Courtesy of FORD MOTOR CO.
17. Remove the No. 15 needle bearing.
    Fig 24: Removing Needle Bearing

    Courtesy of FORD MOTOR CO.
NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.
Fig 25: Installing Special Tools
Courtesy of FORD MOTOR CO.
18. Install the special tools.
19. Install the special tools and zero the dial indicator.
    Fig 26: Installing Special Tools

    Courtesy of FORD MOTOR CO.
20. Tighten the bolt.
    Fig 27: Tightening Bolt

    Courtesy of FORD MOTOR CO.
21. Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification the next larger beveled ring retainer will need to be used.
    Fig 28: Checking Dial Indicator Reading

    Courtesy of FORD MOTOR CO.
22. Select the correct beveled retaining ring.
    Fig 29: Identifying Beveled Retaining Rings

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer.
Fig 30: Installing Thrust Bearing
Courtesy of FORD MOTOR CO.
23. Install the No. 15 thrust bearing.
24. Check the clearance for the No. 16 thrust washer. Mount the Dial Indicator with the stylus on the end of the output shaft. Zero the dial indicator.
    Fig 31: Checking Clearance For Thrust Washer

    Courtesy of FORD MOTOR CO.
25. Tighten the bolt. Read and record the dial indicator reading.
    Fig 32: Tightening Bolt

    Courtesy of FORD MOTOR CO.
NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.
26. If the clearance is not within specification a thicker or thinner washer will need to be added.
Fig 33: No. 16 Thrust Race (Washer) Specifications
Courtesy of FORD MOTOR CO.
Fig 34: Checking Clearance For Thrust Washer
Courtesy of FORD MOTOR CO.
27. Install the low-intermediate one-way clutch assembly.
    Fig 35: Installing Low-Intermediate One-Way Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The friction plate internal splines will center the one-way clutch.
28. Install the low-intermediate clutch pressure plate.
    1. Install the low-intermediate clutch wave spring.
    2. Install the low-intermediate clutch pack.
    3. Install the low-intermediate clutch pressure plate.
       Fig 36: Installing Low-Intermediate Clutch Pressure Plate

       Courtesy of FORD MOTOR CO.
CAUTION: Make sure that the retaining ring is seated in the case groove.
Fig 37: Installing Low-Intermediate Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
29. Install the low-intermediate clutch retaining ring.
WARNING: To prevent injury, wear eye protection when using pressurized air.
NOTE: Be sure the pressurized air is dry and regulated at 276 kPa (40 psi).
Fig 38: Applying Air Pressure To Low-Intermediate Apply Port
Courtesy of FORD MOTOR CO.
30. Apply regulated air pressure to the low-intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal.
31. Measure the clearance between the clutch pressure plate and the low-intermediate clutch retainer. If the clearance is not within specification a thicker or thinner retainer may be needed.
Fig 39: Selective Retaining Ring Specifications
Courtesy of FORD MOTOR CO.
Fig 40: Measuring Clearance Between Clutch Pressure Plate And Low-Intermediate Clutch Retainer
Courtesy of FORD MOTOR CO.
32. Install the coast band.
    1. Install the coast band.
    2. Align the anchor pin pocket with the anchor pin in the case.
       Fig 41: Installing Coast Band

       Courtesy of FORD MOTOR CO.
33. Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.
    Fig 42: Installing Low-Intermediate Drum

    Courtesy of FORD MOTOR CO.
34. Install the park rod abutment and make sure that the park pawl moves freely.
    Fig 43: Installing Park Rod Abutment

    Courtesy of FORD MOTOR CO.
35. Install the coast band piston cover.
    1. Install the coast band servo piston spring.
    2. Install the coast band servo piston.
    3. Install the coast band servo piston cover.
       Fig 44: Installing Coast Band Piston Cover

       Courtesy of FORD MOTOR CO.
36. Using the special tool, install the coast servo cover retaining ring.
    Fig 45: Installing Coast Servo Cover Retaining Ring

    Courtesy of FORD MOTOR CO.
37. Using the special tools, install the front planetary/reverse clutch assembly.
    Fig 46: Installing Front Planetary/Reverse Clutch Assembly

    Courtesy of FORD MOTOR CO.
38. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.
    Fig 47: Checking Reverse Clutch Cylinder Apply Tube Hole Alignment

    Courtesy of FORD MOTOR CO.
39. Loosely install the reverse clutch anchor pin.
    Fig 48: Installing Reverse Clutch Anchor Pin

    Courtesy of FORD MOTOR CO.
40. Using the special tool install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.
    Fig 49: Installing Forward/Intermediate Clutch Assembly

    Courtesy of FORD MOTOR CO.
41. Install the overdrive band.
    Fig 50: Installing Overdrive Band

    Courtesy of FORD MOTOR CO.
NOTE: The foot of the overdrive retainer goes down against the band.
Fig 51: Installing Overdrive Band Anchor Strut
Courtesy of FORD MOTOR CO.
42. Install the overdrive band anchor strut with the cross hairs facing up.
43. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
    1. Remove the No. 9 bearing and race.
    2. Remove the No. 8 sprocket support.
       Fig 52: Removing Sprocket Thrust Washer And Bearing And Race From Driven Sprocket Support

       Courtesy of FORD MOTOR CO.
44. Install only the No. 9 needle bearing with the outer lip up.
    Fig 53: Installing Needle Bearing With Outer Lip Up

    Courtesy of FORD MOTOR CO.
45. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.
    Fig 54: Installing Special Tool Over Output Shaft

    Courtesy of FORD MOTOR CO.
46. Install the special tool to make the measurements.
    Fig 55: Installing Special Tool To Make Measurements

    Courtesy of FORD MOTOR CO.
47. When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by two to obtain reading A.
    Fig 56: Measuring Both Sides Of Output Shaft

    Courtesy of FORD MOTOR CO.
NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.
48. Use the reading A to select the correct No. 8 thrust washer from the chart.
Fig 57: No. 8 Thrust Washer Selection Chart
Courtesy of FORD MOTOR CO.
49. Remove the special tools.
    Fig 58: Removing Special Tools

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50. Install the special tools to make the measurements.
    Fig 59: Installing Special Tools To Make Measurements

    Courtesy of FORD MOTOR CO.
51. Measure down to the No. 5 thrust washer mating surface of the overdrive drum. Take another reading on the other side of the drum 180 degrees from the first one. Add both readings and divide by two to obtain reading B.
    Fig 60: Measuring Down To Thrust Washer Mating Surface Of Overdrive Drum

    Courtesy of FORD MOTOR CO.
52. Remove the special tools.
    Fig 61: Removing Special Tools

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NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
Fig 62: Reading Calculation Chart
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53. Subtract reading A from reading B and add the difference between A and B to dimension C. Record this reading as D.
54. Use Reading D to select the correct No. 5 thrust washer.
Fig 63: No. 5 Support Thrust Washer Chart
Courtesy of FORD MOTOR CO.
NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
Fig 64: Installing Front Support Thrust Washer
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55. Install the No. 5 front support thrust washer.
CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure. Use petroleum jelly to hold bearing and washer in place.
56. Install the correct bearing.
    1. Install the correct No. 8 driven sprocket support thrust washer.
    2. Install the No. 9 direct clutch needle bearing.
       Fig 65: Installing Correct Bearing

       Courtesy of FORD MOTOR CO.
57. Install the driven sprocket support assembly.
    Fig 66: Installing Driven Sprocket Support Assembly

    Courtesy of FORD MOTOR CO.
58. Install the neutral/drive accumulator cover.
    1. Install the neutral/drive accumulator piston.
    2. Install the neutral/drive accumulator springs.
       • The outer spring is yellow in color.
       • The inner spring is grey in color.
    3. Install the neutral/drive accumulator cover.
       Fig 67: Installing Neutral/Drive Accumulator Cover

       Courtesy of FORD MOTOR CO.
59. Install the bolt.
    Fig 68: Installing bolt

    Courtesy of FORD MOTOR CO.
NOTE: All the fluid supply tubes must have new O-rings installed.
Fig 69: Installing Fluid Supply Tubes
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60. Install the fluid supply tubes.
61. Install the brackets.
    Fig 70: Installing Brackets

    Courtesy of FORD MOTOR CO.
62. Using the special tool, install the manual control lever shaft seal.
    Fig 71: Installing Manual Control Lever Shaft Seal

    Courtesy of FORD MOTOR CO.
63. Install the parking lever actuating rod.
    • Push in on the park pawl.
    • Slide down the parking lever actuating rod to fit in the park pawl.
      Fig 72: Installing Parking Lever Actuating Rod

      Courtesy of FORD MOTOR CO.
NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.
Fig 73: Installing Manual Control Lever Shaft
Courtesy of FORD MOTOR CO.
64. Install the manual control lever shaft.
NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.
Fig 74: Installing Roll Pins
Courtesy of FORD MOTOR CO.
65. Install the roll pins.
NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
66. Install the thrust washers.
    1. Install the No. 2 drive sprocket thrust washer.
    2. Install the No. 4 driven sprocket thrust washer.
       Fig 75: Installing Thrust Washers

       Courtesy of FORD MOTOR CO.
CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent.
NOTE: Lower the assembly into the sprocket supports simultaneously.
Fig 76: Installing Drive Chain And Sprockets
Courtesy of FORD MOTOR CO.
67. Install the drive chain and sprockets.
68. Install the shift accumulator springs.
    1. Install the 1-2 accumulator outer spring (no color or pink).
    2. Install the 2-3 accumulator piston spring (orange).
    3. Install the reverse shift accumulator spring.
    4. Install the 3-4 accumulator spring (blue).
       Fig 77: Installing Shift Accumulator Springs

       Courtesy of FORD MOTOR CO.
NOTE: Make sure that the alignment pins are installed in case.
Fig 78: Installing Chain Cover Gasket
Courtesy of FORD MOTOR CO.
69. Install the new chain cover gasket.
CAUTION: Be extremely careful not to damage the cast iron sealing ring.
70. Use petroleum jelly to hold thrust washers in place during assembly.
    1. Install the No. 1 thrust washer.
    2. Install the No. 2 thrust washer.
    3. Install the chain cover.
       Fig 79: Installing Chain Cover

       Courtesy of FORD MOTOR CO.
NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.
Fig 80: Locating Bolts
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71. Start two bolts.
72. Install the remaining bolts.
    Fig 81: Installing Bolts

    Courtesy of FORD MOTOR CO.
73. Install the bolts.
    Fig 82: Installing Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: The test spring from the overdrive servo rod tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
74. Inspect the spring height.
    1. Test spring.
    2. Original spring.
       Fig 83: Inspecting Spring Height

       Courtesy of FORD MOTOR CO.
75. Overdrive servo travel check. Install the overdrive servo piston.
    1. Install the test spring.
    2. Install the overdrive servo piston.
       Fig 84: Installing Overdrive Servo Piston

       Courtesy of FORD MOTOR CO.
76. Install the special tools.
    Fig 85: Installing Special Tools

    Courtesy of FORD MOTOR CO.
77. Using the special tools, tighten the center screw and zero out the dial indicator.
    Fig 86: Tightening Center Screw

    Courtesy of FORD MOTOR CO.
78. Using the special tools, back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, see the overdrive specification chart and determine which overdrive servo rod to use.
    Fig 87: Checking Overdrive Servo Travel

    Courtesy of FORD MOTOR CO.
79. If the overdrive servo travel was incorrect install a new overdrive servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.
Fig 88: Overdrive Piston Rod Selection Chart
Courtesy of FORD MOTOR CO.
CAUTION: Do not assemble the transaxle using the test spring.
80. Install the overdrive servo.
    1. Install the overdrive servo spring.
    2. Install the overdrive servo.
    3. Install the overdrive servo cover and bolts.
       Fig 89: Installing Overdrive Servo

       Courtesy of FORD MOTOR CO.
81. Install the special tool.
    Fig 90: Installing Special Tool

    Courtesy of FORD MOTOR CO.
WARNING: Wear safety glasses while carrying out this procedure to prevent personal injury.
NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies.
NOTE: Plugging the vent hole during the test will provide an inaccurate result.
Fig 91: Locating Test Passages
Courtesy of FORD MOTOR CO.
82. Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate clutch ports.
CAUTION: The seals must be lapped correctly or internal leakage will occur.
Fig 92: Identifying Correct Seal Installation
Courtesy of FORD MOTOR CO.
83. Install the new Teflon® seals on the pump shaft.
84. Install the pump shaft.
    Fig 93: Installing Pump Shaft

    Courtesy of FORD MOTOR CO.
85. Install the manual valve detent lever.
    Fig 94: Installing Manual Valve Detent Lever

    Courtesy of FORD MOTOR CO.
86. Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.
    Fig 95: Installing Main Control Valve Body Over Pump Shaft

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.
Fig 96: Tightening Sequence Of Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
87. Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolt and tighten in sequence.
88. Connect the connectors.
    Fig 97: Connecting Connectors

    Courtesy of FORD MOTOR CO.
NOTE: The transaxle side cover gasket is reusable if not torn or ripped.
Fig 98: Removing Gasket
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89. Remove the gasket. Clean and inspect the gasket, reinstall into the pan.
90. Install the pan.
    Fig 99: Installing Pan

    Courtesy of FORD MOTOR CO.
91. Install the mount.
    Fig 100: Installing Mount

    Courtesy of FORD MOTOR CO.
92. Tighten the reverse clutch anchor bolt.
    1. Tighten the anchor bolt.
    2. Tighten the locknut.
       Fig 101: Tightening Reverse Clutch Anchor Bolt

       Courtesy of FORD MOTOR CO.
93. Install the new seal and gasket kit and seal assembly.
    Fig 102: Installing Seal And Gasket Kit And Seal Assembly

    Courtesy of FORD MOTOR CO.
94. Install the fluid pan magnet.
    Fig 103: Installing Fluid Pan Magnet

    Courtesy of FORD MOTOR CO.
NOTE: The gasket is reusable if not damaged or torn.
Fig 104: Installing Transmission Fluid Pan And Gasket
Courtesy of FORD MOTOR CO.
95. Install the transmission fluid pan and gasket.
96. Install the turbine shaft speed (TSS) sensor.
    1. Install the sensor.
    2. Install the bolt.
       Fig 105: Installing Turbine Shaft Speed Sensor

       Courtesy of FORD MOTOR CO.
97. Verify that the shift selector lever is in NEUTRAL.
98. Install the digital TR sensor and loosely install the bolts.
    Fig 106: Installing Digital TR Sensor

    Courtesy of FORD MOTOR CO.
99. Using the special tool, align the digital TR sensor and tighten the bolts.
    Fig 107: Aligning Digital TR Sensor And Tightening Bolts

    Courtesy of FORD MOTOR CO.
100. Install the fluid filler tube with a new grommet.
     Fig 108: Installing Fluid Filler Tube

     Courtesy of FORD MOTOR CO.
101. Using the special tool install the LH output shaft seal.
     Fig 109: Installing LH Output Shaft Seal

     Courtesy of FORD MOTOR CO.
102. Using the special tool install the RH output shaft seal.
     Fig 110: Installing RH Output Shaft Seal

     Courtesy of FORD MOTOR CO.
103. Install the output shaft speed (OSS) sensor and reconnect the harness.
     Fig 111: Installing Output Shaft Speed Sensor

     Courtesy of FORD MOTOR CO.
104. Install the output shaft speed (OSS) sensor cover.
     Fig 112: Installing Output Shaft Speed Sensor Cover

     Courtesy of FORD MOTOR CO.
105. Install the identification tag, if removed.
Fig 113: Installing Identification Tag
Courtesy of FORD MOTOR CO.
106. Using the special tools, install the torque converter.
     Fig 114: Installing Torque Converter

     Courtesy of FORD MOTOR CO.