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Automatic Transaxle/Transmission: Disassembly: Transaxle: Procedure

NOTE: Thoroughly clean the exterior of the transmission and dry it with compressed air.
    NOTE: Position the transmission in Bench Mounted Holding Fixure in its normal upright position.
    Fig 1: Installing Bench Mounted Holding Fixure On Transmission Case
    G01371754Courtesy of FORD MOTOR CO.
  1. Install Bench Mounted Holding Fixure on the transmission case.
    • Position a drain pan under the transmission.
    2. CAUTION: The torque converter (7902) is heavy. Be careful not to drop it.
    Fig 2: Removing Torque Converter
    G01371755Courtesy of FORD MOTOR CO.
  2. Remove the torque converter.
    • Drain the fluid from the torque converter.
  3. Remove the oil pump shaft (7B328).
    Fig 3: Removing Oil Pump Shaft
    G01371756Courtesy of FORD MOTOR CO.
  4. Remove and discard the converter turbine shaft seal.
    Fig 4: Removing Converter Turbine Shaft Seal
    G01371757Courtesy of FORD MOTOR CO.
  5. Install Turbine Shaft Holder.
    Fig 5: Installing Turbine Shaft Holder
    G01371758Courtesy of FORD MOTOR CO.
  6. Remove the fluid level indicator (7A020) and oil filler tube (7A228).
    1. Remove the fluid filler tube bolts.
    2. Remove the fluid level indicator and oil filler tube.
    Fig 6: Removing Fluid Level Indicator And Oil Filler Tube
    G01371759Courtesy of FORD MOTOR CO.
  7. Remove the turbine shaft speed (TSS) sensor.
    1. Remove the TSS sensor bolt.
    2. Remove the TSS sensor.
    Fig 7: Removing Turbine Shaft Speed Sensor
    G01371760Courtesy of FORD MOTOR CO.
  8. Remove the vehicle speed sensor (VSS).
    1. Remove the bolt.
    2. Remove the VSS.
    Fig 8: Removing Vehicle Speed Sensor
    G01371761Courtesy of FORD MOTOR CO.
  9. Remove the transmission range (TR) sensor.
    1. Remove the TR sensor bolts.
    2. Remove the TR sensor.
    Fig 9: Removing Transmission Range Sensor
    G01371762Courtesy of FORD MOTOR CO.
  10. Disconnect the solenoid electrical connector.
    Fig 10: Disconnecting Solenoid Electrical Connector
    G01371763Courtesy of FORD MOTOR CO.
  11. Remove the fluid cooler tube (7A031).
    1. Remove the fluid cooler tube bolt and washer.
    2. Remove the fluid cooler tube nut.
    3. Remove the drain back valve spring.
    4. Remove the steel ball.
    Fig 11: Removing Fluid Cooler Tube
    G01371764Courtesy of FORD MOTOR CO.
    12. CAUTION: Remove the transmission fluid pan (7A194) before turning the transmission over. This will ensure that any foreign material remains in the pan.
    NOTE: Slowly loosen the transmission oil pan bolts, working from the LH front corner to the rear, allowing the transmission fluid pan to gradually drop and the ATF to drain.
    Fig 12: Removing Transmission Fluid Pan And Oil Pan To Case Gasket
    G01371765Courtesy of FORD MOTOR CO.
  12. Remove the transmission fluid pan and the oil pan to case gasket (7A191).
    1. Remove the oil pan bolts.
    2. Remove the transmission fluid pan and oil pan to case gasket. Discard the oil pan to case gasket.
    13. NOTE: If large amounts of material are found, replace the torque converter and check the transmission for cause.
    Fig 13: Identifying Material Cause Table
    G01371766Courtesy of FORD MOTOR CO.
    Fig 14: Inspecting Material Found In Transmission Fluid Pan
    G01371767Courtesy of FORD MOTOR CO.
  13. Examine any material found in the transmission fluid pan to determine the condition of the transmission.
  14. Disconnect the solenoid valve electrical connectors.
    Fig 15: Disconnecting Solenoid Valve Electrical Connectors
    G01371768Courtesy of FORD MOTOR CO.
    15. NOTE: Do not reuse or clean the filter; replace it with a new one.
    Fig 16: Removing Oil Filter Bolts
    G01371769Courtesy of FORD MOTOR CO.
  15. Remove the oil filter bolts and remove the filter.
  16. Remove the electronic pressure control (EPC) solenoid.
    1. Remove the bolt.
    2. Remove the EPC solenoid.
    Fig 17: Removing Electronic Pressure Control Solenoid
    G01371770Courtesy of FORD MOTOR CO.
    17. NOTE: Loosen the main control valve body bolts evenly and gradually.
    Fig 18: Removing Main Control Valve Body
    G01371771Courtesy of FORD MOTOR CO.
  17. Remove the main control valve body (7A100).
    1. Remove the bolts.
    2. Remove the main control valve body.
  18. Remove the manual shaft nut and washer and the manual shaft.
    1. Remove the manual shaft nut and washer.
    2. Pull the manual shaft out.
    Fig 19: Removing Manual Shaft Nut And Washer And Manual Shaft
    G01371772Courtesy of FORD MOTOR CO.
  19. Remove the manual shaft plate and the lever holder.
    1. Remove the lever holder nut.
    2. Remove the manual shaft plate.
    3. Remove the lever holder.
    Fig 20: Removing Manual Shaft Plate And Lever Holder
    G01371773Courtesy of FORD MOTOR CO.
  20. Remove the detent lever.
    Fig 21: Removing Detent Lever
    G01371774Courtesy of FORD MOTOR CO.
  21. Remove the detent lever spring and actuator support.
    1. Remove the detent lever spring.
    2. Remove the actuator support bolt.
    3. Remove the actuator support.
    Fig 22: Removing Detent Lever Spring And Actuator Support
    G01371775Courtesy of FORD MOTOR CO.
  22. Remove the orifice valve.
    Fig 23: Removing Orifice Valve
    G01371776Courtesy of FORD MOTOR CO.
  23. Disassemble the orifice valve assembly.
    1. Remove the orifice valve.
    2. Remove the spring.
    3. Remove and discard the washer.
    Fig 24: Disassembled View Of Orifice Valve Assembly
    G01371777Courtesy of FORD MOTOR CO.
  24. Remove the front pump support and gear (7A103) and oil pump gasket (7A136). Discard the oil pump gasket.
    1. Remove the oil pump bolts.
    2. Remove the front pump support and gear.
    Fig 25: Removing Oil Pump Bolts
    G01371778Courtesy of FORD MOTOR CO.
  25. Remove the planet gear thrust bearing.
    Fig 26: Removing Planet Gear Thrust Bearing
    G01371779Courtesy of FORD MOTOR CO.
  26. Remove the forward/coast/reverse clutch drum assembly.
    1. Carefully remove the turbine shaft snap ring.
    2. Remove the forward/coast/reverse clutch drum assembly.
    Fig 27: Removing Forward/Coast/Reverse Clutch Drum Assembly
    G01371780Courtesy of FORD MOTOR CO.
  27. Remove the servo assembly.
    1. Remove the servo piston snap ring.
    2. Remove the servo assembly.
    Fig 28: Removing Servo Assembly
    G01371781Courtesy of FORD MOTOR CO.
  28. Remove the primary sun gear (7A399) and one-way clutch assembly.
    Fig 29: Removing Primary Sun Gear And One-Way Clutch Assembly
    G01371782Courtesy of FORD MOTOR CO.
  29. Remove the 2-4 band.
    Fig 30: Removing 2-4 Band
    G01371783Courtesy of FORD MOTOR CO.
  30. Secure the 2-4 band with a small piece of wire to keep the 2-4 band from stretching.
    Fig 31: Securing 2-4 Band With A Small Piece Of Wire
    G01371784Courtesy of FORD MOTOR CO.
  31. Remove the anchor strut shaft and the anchor strut.
    1. Pull the anchor strut shaft while holding the anchor strut.
    2. Remove the anchor strut.
    Fig 32: Removing Anchor Strut Shaft And Anchor Strut
    G01371785Courtesy of FORD MOTOR CO.
  32. Remove the one-way clutch and one-way clutch retainer snap ring.
    Fig 33: Removing One-Way Clutch And One-Way Clutch Retainer Snap Ring
    G01371786Courtesy of FORD MOTOR CO.
  33. Remove the one-way clutch (7A089).
    Fig 34: Removing One-Way Clutch
    G01371787Courtesy of FORD MOTOR CO.
  34. Remove the wave washer.
    Fig 35: Removing Wave Washer
    G01371788Courtesy of FORD MOTOR CO.
  35. Remove the one-way clutch inner race.
    Fig 36: Removing One-Way Clutch Inner Race
    G01371789Courtesy of FORD MOTOR CO.
  36. Remove the low/reverse clutch retainer snap ring.
    Fig 37: Removing Low/Reverse Clutch Retainer Snap Ring
    G01371790Courtesy of FORD MOTOR CO.
  37. Remove the low/reverse clutch pressure plate.
    Fig 38: Removing Low/Reverse Clutch Pressure Plate
    G01371791Courtesy of FORD MOTOR CO.
  38. Remove the external spline clutch plate and the internal spline clutch plate.
    • Inspect the external spline discs for burn marks, scorings, or warpage.
    • Check for worn or damaged external spline clutch plates and internal spline clutch plates. Measure the facing thickness in three places and calculate the average. The minimum allowable internal spline clutch plate thickness is 1.4 mm (0.055 in). The standard thickness is 1.6 mm (0.063 in). If the plates are not within the specification, replace the plates.
    Fig 39: Removing External Spline Clutch Plate And Internal Spline Clutch Plate
    G01371792Courtesy of FORD MOTOR CO.
  39. Remove the ring gear retainer snap ring.
    Fig 40: Removing Ring Gear Retainer Snap Ring
    G01371793Courtesy of FORD MOTOR CO.
  40. Remove the ring gear (7A153).
    Fig 41: Removing Ring Gear
    G01371794Courtesy of FORD MOTOR CO.
  41. Remove the turbine shaft (7F351) and 3-4 clutch assembly.
    • Slide the 3-4 clutch off the turbine shaft after removal.
    Fig 42: Removing Turbine Shaft And 3-4 Clutch Assembly
    G01371795Courtesy of FORD MOTOR CO.
    42. NOTE: Tap the two halves lightly with a plastic hammer to separate.
    Fig 43: Removing Transmission Case Bolts
    G01371796Courtesy of FORD MOTOR CO.
  42. Remove the 13 transmission case bolts and separate the transmission case.
  43. Remove the eight O-rings and discard them.
    Fig 44: Removing O-Rings
    G01371797Courtesy of FORD MOTOR CO.
  44. Remove the output shell from the output gear.
    Fig 45: Removing Output Shell From Output Gear
    G01371798Courtesy of FORD MOTOR CO.
  45. Use Return Spring Compressor to remove the low/reverse clutch assembly.
    1. Install Return Spring Compressor.
    2. Compress the low/reverse clutch support and spring and remove the snap ring.
    Fig 46: Removing Low/Reverse Clutch Assembly
    G01371799Courtesy of FORD MOTOR CO.
  46. Remove the low/reverse clutch spring and support.
    Fig 47: Removing Low/Reverse Clutch Spring And Support
    G01371800Courtesy of FORD MOTOR CO.
  47. Remove the low/reverse clutch piston.
    Fig 48: Removing Low/Reverse Clutch Piston
    G01371801Courtesy of FORD MOTOR CO.
  48. Remove the parking pawl (7A441).
    1. Remove the parking pawl shaft E-clip.
    2. Remove the parking pawl return spring (7D070).
    3. Remove the parking pawl shaft (7D071).
    4. Remove the parking pawl.
    Fig 49: Removing Parking Pawl
    G01371802Courtesy of FORD MOTOR CO.
  49. Remove the differential (4026).
    Fig 50: Removing Differential
    G01371803Courtesy of FORD MOTOR CO.
  50. Remove the bearing housing roll pin.
    Fig 51: Removing Bearing Housing Roll Pin
    G01371804Courtesy of FORD MOTOR CO.
  51. Remove the bearing housing.
    1. Remove the bearing housing bolts.
    2. Remove the bearing housing.
    Fig 52: Removing Bearing Housing Bolts
    G01371805Courtesy of FORD MOTOR CO.
  52. Remove the idler gear (7F475) and output gear.
    • Remove the idler gear and output gear by tapping them out from the torque converter side.
    Fig 53: Removing Idler Gear And Output Gear
    G01371806Courtesy of FORD MOTOR CO.
    53. NOTE: Loosen the bolts evenly and gradually.
    Fig 54: Removing Torque Converter Stator Bolts
    G01371807Courtesy of FORD MOTOR CO.
  53. Remove the eight torque converter stator bolts and the torque converter stator.
  54. Remove the converter housing from the transmission holding fixture.
  55. Use Step Plate Adapter to press the stator support out of the converter housing.
    Fig 55: Pressing Stator Support Out Of Converter Housing
    G01371808Courtesy of FORD MOTOR CO.
  56. Use Step Plate Adapter to press out the bearing race.
    Fig 56: Pressing Out Bearing Race
    G01371809Courtesy of FORD MOTOR CO.
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