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Automatic Transaxle/Transmission: Disassembly: Transmission

Fig 1: Identifying Special Tool
G03234457Courtesy of FORD MOTOR CO.

    ALL VEHICLES 

    WARNING: Do not remove the torque converter from the transmission while still on the jack. Doing so could cause the transmission to fall. Failure to follow these instructions may result in personal injury.
    Fig 2: Identifying Transmission
    G03234458Courtesy of FORD MOTOR CO.
  1. Place the transmission on a workbench.
  2. Remove the special tool.
    Fig 3: Removing Special Tool
    G03234459Courtesy of FORD MOTOR CO.
    3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury.
    Fig 4: Removing Torque Converter
    G03234460Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the torque converter.
    4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
    Fig 5: Removing Input Shaft
    G03234461Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
  5. Remove the output shaft speed (OSS) sensor.
    1. Remove the OSS screw.
    2. Remove OSS sensor.
    Fig 6: Removing Output Shaft Speed (OSS) Sensor
    G03234462Courtesy of FORD MOTOR CO.
  6. Remove the intermediate shaft speed sensor.
    1. Remove the intermediate shaft speed screw.
    2. Remove intermediate shaft speed sensor.
    Fig 7: Removing Intermediate Shaft Speed Sensor
    G03234463Courtesy of FORD MOTOR CO.
  7. If equipped, remove the heat shield.
    1. Remove the nut.
    2. Remove the heat shield.
    Fig 8: Removing Heat Shield
    G03234464Courtesy of FORD MOTOR CO.
  8. Remove manual control outer lever nut and manual control outer lever.
    Fig 9: Removing Manual Control Outer Lever Nut And Manual Control Outer Lever
    G03234465Courtesy of FORD MOTOR CO.
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the screws.
    2. Remove the digital TR sensor.
    Fig 10: Removing Digital Transmission Range Sensor
    G03234466Courtesy of FORD MOTOR CO.

    10. 4X2 VEHICLES 

  10. Using the special tools, remove the extension housing seal.
    Fig 11: Removing Extension Housing Seal
    G03234467Courtesy of FORD MOTOR CO.
    11. NOTE: Remove the extension housing bushing only if service is required.
    Fig 12: Removing Extension Housing Bushing
    G03234468Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the extension housing bushing.
    • Inspect the extension housing bushing and driveshaft slip yoke for nicks, gouges, scoring and wear.

    12. ALL VEHICLES 

    CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 13: Removing Screws, Studs And Extension Housing
    G03234469Courtesy of FORD MOTOR CO.
  12. Remove the screws, studs and the extension housing.
    • Discard the extension housing gasket.
  13. Remove the parking pawl assembly.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    Fig 14: Removing Parking Pawl Assembly
    G03234470Courtesy of FORD MOTOR CO.
    14. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
    Fig 15: Installing Special Tool
    G03234471Courtesy of FORD MOTOR CO.
  14. Install the special tool.
  15. Assemble the special tools.
    Fig 16: Assembling Special Tools
    G03234472Courtesy of FORD MOTOR CO.
    16. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 17: Installing Transmission Into Special Tool
    G03234473Courtesy of FORD MOTOR CO.
  16. Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.
    17. CAUTION: Do not reuse the fluid pan gasket.
    Fig 18: Removing Transmission Fluid Pan Screws
    G03234474Courtesy of FORD MOTOR CO.
  17. Remove the transmission fluid pan screws, pan and transmission pan gasket and then discard the gasket.
  18. Remove the transmission fluid filter and discard.
    1. Remove the screw.
    2. Remove the transmission fluid filter.
    Fig 19: Removing Transmission Fluid Filter
    G03234475Courtesy of FORD MOTOR CO.
  19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
    Fig 20: Identifying Wire Loom Guide And Protector
    G03234476Courtesy of FORD MOTOR CO.
  20. Disconnect the solenoid electrical connectors.
    1. Disconnect the SSA, SSB, SSC and SSD electrical connectors.
    2. Disconnect the torque converter clutch (TCC) solenoid electrical connector.
    3. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
    Fig 21: Disconnecting Solenoid Electrical Connectors
    G03234477Courtesy of FORD MOTOR CO.
  21. Remove the manual control valve detent lever spring.
    1. Remove the screw.
    2. Remove the manual control valve detent lever spring.
    Fig 22: Removing Manual Control Valve Detent Lever Spring
    G03234478Courtesy of FORD MOTOR CO.
  22. Remove the low/reverse band servo cover.
    1. Remove the screws.
    2. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
      • Discard the low/reverse servo separator plate cover gasket.
    Fig 23: Removing Low/Reverse Band Servo Cover
    G03234479Courtesy of FORD MOTOR CO.
  23. Remove the low/reverse band servo piston and rod assembly.
    Fig 24: Removing Low/Reverse Band Servo Piston And Rod Assembly
    G03234480Courtesy of FORD MOTOR CO.
    24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.
    Fig 25: Identifying (Gold Colored) Screws
    G03234481Courtesy of FORD MOTOR CO.
  24. Do not remove the two (gold colored) screws specified.
  25. Remove the twenty-three valve body screws.
    Fig 26: Removing Valve Body Screws
    G03234482Courtesy of FORD MOTOR CO.
  26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket.
    • Discard gaskets.
    Fig 27: Removing Main Control Valve Body Separator Plate
    G03234483Courtesy of FORD MOTOR CO.
    27. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 28: Removing Locknuts And Screws
    G03234484Courtesy of FORD MOTOR CO.
  27. Remove the locknuts and the screws.
    28. CAUTION: The servo cover is under spring tension.
    Fig 29: Removing Intermediate Servo Cover Retaining Ring
    G03234485Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the intermediate servo cover retaining ring.
    29. NOTE: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo, cover and bore.
    Fig 30: Removing Intermediate Band Servo Piston, Spring And Cover
    G03234486Courtesy of FORD MOTOR CO.
  29. Using the special tool, remove the intermediate band servo piston, spring and cover.
    30. CAUTION: Servo cover is under spring tension.
    Fig 31: Removing Overdrive Servo Retaining Ring And Cover
    G03234487Courtesy of FORD MOTOR CO.
  30. Using the special tool, remove the overdrive servo retaining ring and cover.
    31. NOTE: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo piston and bore.
    Fig 32: Removing Overdrive Band Servo Piston, Spring And Cover
    G03234488Courtesy of FORD MOTOR CO.
  31. Using the special tool, remove the overdrive band servo piston, spring and cover.
    32. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  32. Rotate the transmission so the converter housing faces up.
    33. CAUTION: Discard the screws. The screws are not reusable for assembly.
    Fig 33: Removing Screws
    G03234489Courtesy of FORD MOTOR CO.
  33. Remove and discard the screws.
  34. Remove the converter housing and fluid pump support.
    • Turn and lift the converter housing and fluid pump support from the case.
    Fig 34: Removing Converter Housing And Fluid Pump Support
    G03234490Courtesy of FORD MOTOR CO.
  35. Remove the No. 1 fluid pump input thrust washer.
    Fig 35: Removing No. 1 Fluid Pump Input Thrust Washer
    G03234491Courtesy of FORD MOTOR CO.
  36. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
    Fig 36: Removing Front Band Anchor Strut
    G03234492Courtesy of FORD MOTOR CO.
    37. CAUTION: Identify the anchor and apply ends of the front band.
    Fig 37: Removing Front Band
    G03234493Courtesy of FORD MOTOR CO.
  37. Remove the front band.
  38. Remove the front brake and coast clutch drum.
    Fig 38: Removing Front Brake And Coast Clutch Drum
    G03234494Courtesy of FORD MOTOR CO.
  39. Remove the front band apply strut.
    Fig 39: Removing Front Band Apply Strut
    G03234495Courtesy of FORD MOTOR CO.
    40. NOTE: The front band lever shaft is longer than the intermediate band lever shaft.
    Fig 40: Removing Front Band Actuating Lever Shaft
    G03234496Courtesy of FORD MOTOR CO.
  40. Remove the front band actuating lever shaft.
    41. CAUTION: Do not bend trigger wheel.
    NOTE: The No. 2 thrust bearing is in this assembly.
    Fig 41: Removing Planetary Gear Overdrive Carrier
    G03234497Courtesy of FORD MOTOR CO.
  41. Remove the planetary gear overdrive carrier.
    42. NOTE: Tag and identify the front band servo lever. The front band servo lever has a letter stamped on the side.
    Fig 42: Removing Front Band Servo Lever And Front Band Lever To Case Bracket
    G03234498Courtesy of FORD MOTOR CO.
  42. Remove the front band servo lever and front band lever to case bracket.
  43. Remove the No. 2 front planet thrust bearing.
    Fig 43: Removing No. 2 Front Planet Thrust Bearing
    G03234499Courtesy of FORD MOTOR CO.
  44. Remove the front ring gear, front one-way clutch assembly and center shaft as an assembly.
    Fig 44: Removing Front Ring Gear, Front One-Way Clutch Assembly
    G03234500Courtesy of FORD MOTOR CO.
    45. NOTE: Tag and identify the No. 3 center shaft thrust bearing for assembly.
    Fig 45: Removing No. 3 Center Shaft Thrust Bearing
    G03234501Courtesy of FORD MOTOR CO.
  45. Remove the No. 3 center shaft thrust bearing.
    46. CAUTION: The center support locknut can fall into the remaining assembly if not removed.
    Fig 46: Removing Center Support Cap Screw
    G03234502Courtesy of FORD MOTOR CO.
  46. Remove the center support cap screw.
  47. Remove the locknut and cage.
    Fig 47: Removing Locknut And Cage
    G03234503Courtesy of FORD MOTOR CO.
    48. CAUTION: Do not pry on other wires or damage the connector or case surface.
    Fig 48: Removing TSS Sensor Connector Wires From Wire Locator
    G03234504Courtesy of FORD MOTOR CO.
  48. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    1. Remove the TSS sensor electrical connector from the transmission case (16-pin) electrical connector.
    2. Remove the TSS sensor connector wires from wire locator.
    49. CAUTION: Carefully route the TSS connector and wiring into the transmission through the opening in the case.
    Fig 49: Removing TSS Sensor
    G03234505Courtesy of FORD MOTOR CO.
  49. Remove the TSS sensor.
    1. Remove the screw.
    2. Remove the TSS sensor.
    50. CAUTION: Do not overstretch the retaining spring.
    Fig 50: Removing Transmission Case (16-Pin) Electrical Connector Retaining Spring
    G03234506Courtesy of FORD MOTOR CO.
  50. Remove the transmission case (16-pin) electrical connector retaining spring.
    51. CAUTION: Do not damage the connector or harness.
    Fig 51: Compressing Tabs On Transmission Case (16-Pin) Electrical Connector
    G03234507Courtesy of FORD MOTOR CO.
  51. Compress the tabs on the transmission case (16-pin) electrical connector.

    Push the transmission case (16-pin) electrical connector out of transmission case.

  52. Remove the center support retaining ring.
    Fig 52: Removing Center Support Retaining Ring
    G03234508Courtesy of FORD MOTOR CO.
    53. NOTE: When removing the center support, pull evenly around the center support web.
    Fig 53: Removing Center Support
    G03234509Courtesy of FORD MOTOR CO.
  53. Remove the center support.
    54. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 54: Removing Center Support
    G03234510Courtesy of FORD MOTOR CO.
  54. Remove the No. 4 intermediate brake drum thrust bearing.
  55. Remove the intermediate band anchor strut.
    Fig 55: Removing Intermediate Band Anchor Strut
    G03234511Courtesy of FORD MOTOR CO.
    56. CAUTION: Identify the anchor and apply ends of the intermediate band.
    Fig 56: Removing Intermediate Band
    G03234512Courtesy of FORD MOTOR CO.
  56. Remove the intermediate band.
  57. Remove the intermediate band apply strut.
    Fig 57: Removing Intermediate Band Apply Strut
    G03234513Courtesy of FORD MOTOR CO.
    58. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 58: Removing Intermediate Band Actuating Lever Shaft
    G03234514Courtesy of FORD MOTOR CO.
  58. Remove the intermediate band actuating lever shaft.
    59. NOTE: Tag and identify the intermediate servo band lever. The intermediate servo band lever has a letter stamped into its side.
    Fig 59: Removing Intermediate Servo Actuating Lever
    G03234515Courtesy of FORD MOTOR CO.
  59. Remove the intermediate servo actuating lever.
    60. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
    Fig 60: Removing Intermediate Brake And Direct Clutch Drum
    G03234516Courtesy of FORD MOTOR CO.
  60. Remove the intermediate brake and direct clutch drum.
  61. Remove the No. 5 forward clutch cylinder thrust bearing tag and identify.
    Fig 61: Removing No. 5 Forward Clutch Cylinder Thrust Bearing Tag
    G03234517Courtesy of FORD MOTOR CO.
  62. Remove the forward clutch cylinder.
    Fig 62: Removing Forward Clutch Cylinder
    G03234518Courtesy of FORD MOTOR CO.
  63. Remove the No. 6A forward ring gear hub thrust bearing.
    Fig 63: Removing No. 6A Forward Ring Gear Hub Thrust Bearing
    G03234519Courtesy of FORD MOTOR CO.
  64. Remove the forward ring gear and forward ring gear hub as an assembly.
    Fig 64: Removing Forward Ring Gear And Forward Ring Gear Hub As An Assembly
    G03234520Courtesy of FORD MOTOR CO.
  65. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
    Fig 65: Removing No. 6B Forward Clutch Thrust Washer From Forward Ring Gear Hub
    G03234521Courtesy of FORD MOTOR CO.
    66. NOTE: Check the black oxidized side during removal to make sure of correct placement during reassembly. The black oxidized side must be toward planetary assembly. The uncoated side must face up.
    Fig 66: Removing No. 7 Forward Planet Thrust Bearing
    G03234522Courtesy of FORD MOTOR CO.
  66. Remove the No. 7 forward planet thrust bearing.
  67. Remove the forward planetary assembly.
    Fig 67: Removing Forward Planetary Assembly
    G03234523Courtesy of FORD MOTOR CO.
  68. Remove input shell with the forward sun gear.
    Fig 68: Removing Input Shell With Forward Sun Gear
    G03234524Courtesy of FORD MOTOR CO.
    69. NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
    Fig 69: Removing No. 8 Low/Reverse Planetary Carrier Thrust Bearing
    G03234525Courtesy of FORD MOTOR CO.
  69. Remove the No. 8 low/reverse planetary carrier thrust bearing.
  70. Remove the low/reverse planetary retaining ring.
    Fig 70: Removing Low/Reverse Planetary Retaining Ring
    G03234526Courtesy of FORD MOTOR CO.
  71. Remove low/reverse planetary assembly.
    Fig 71: Removing Low/Reverse Planetary Assembly
    G03234527Courtesy of FORD MOTOR CO.
    72. NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
    Fig 72: Removing No. 9 Low/Reverse Planetary Carrier Thrust Bearing
    G03234528Courtesy of FORD MOTOR CO.
  72. Remove the No. 9 low/reverse planetary carrier thrust bearing.
  73. Remove the output shaft sleeve.
    Fig 73: Removing Output Shaft Sleeve
    G03234529Courtesy of FORD MOTOR CO.
    74. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 74: Removing Output Shaft Retaining Ring
    G03234530Courtesy of FORD MOTOR CO.
  74. Remove and discard the output shaft retaining ring.
  75. Remove the output shaft ring gear and the output shaft hub.
    Fig 75: Removing Output Shaft Ring Gear And Output Shaft Hub
    G03234531Courtesy of FORD MOTOR CO.
    76. NOTE: Tag and identify the No. 10 output shaft hub thrust bearing.
    Fig 76: Removing No. 10 Output Shaft Thrust Bearing
    G03234532Courtesy of FORD MOTOR CO.
  76. Remove the No. 10 output shaft thrust bearing.
    77. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
    Fig 77: Removing Low/Reverse Brake Drum And One-Way Clutch Assembly
    G03234533Courtesy of FORD MOTOR CO.
  77. Remove the low/reverse brake drum and one-way clutch assembly.
  78. Remove the reverse band.
    Fig 78: Removing Reverse Band
    G03234534Courtesy of FORD MOTOR CO.
  79. Remove the output shaft.
    Fig 79: Removing Output Shaft
    G03234535Courtesy of FORD MOTOR CO.
  80. Remove the park gear.
    Fig 80: Removing Park Gear
    G03234536Courtesy of FORD MOTOR CO.
    81. NOTE: Tag and identify the No. 11 output shaft thrust washer.
    Fig 81: Removing No. 11 Output Shaft Thrust Washer
    G03234537Courtesy of FORD MOTOR CO.
  81. Remove the No. 11 output shaft thrust washer.
    82. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.
    Fig 82: Removing Manual Control Valve Inner Lever Nut
    G03234538Courtesy of FORD MOTOR CO.
  82. Remove the manual control valve inner lever nut.
  83. Remove the manual control valve inner lever and the parking lever actuating rod.
    Fig 83: Removing Manual Control Valve Inner Lever And Parking Lever Actuating Rod
    G03234539Courtesy of FORD MOTOR CO.
    84. CAUTION: Do not damage the case fluid pan rail.
    Fig 84: Prying Spring Pin Out Of Its Bore
    G03234540Courtesy of FORD MOTOR CO.
  84. Remove the manual control lever shaft spring pin.
    • Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
    • Pry the spring pin out of its bore.
  85. Remove the manual control lever shaft.
    Fig 85: Removing Manual Control Lever Shaft
    G03234541Courtesy of FORD MOTOR CO.
    86. CAUTION: Do not damage the bore.
    Fig 86: Removing Manual Control Lever Seal
    G03234542Courtesy of FORD MOTOR CO.
  86. Remove the manual control lever seal.
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