Automatic Transmission: Disassembly: Transaxle

Special Tool(s) 

Fig 1: Special Tools Specifications (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Special Tools Specifications (2 Of 2)

Courtesy of FORD MOTOR CO.

CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 3: Removing Torque Converter
Courtesy of FORD MOTOR CO.
1. Using the special tools, remove the torque converter.
2. Using the special tool, install the transaxle onto the bench.
   Fig 4: Installing Transaxle Onto Bench

   Courtesy of FORD MOTOR CO.
NOTE: If installing a new case, a new identification tag will need to be installed. Use caution not to damage the tag.
Fig 5: Removing Identification Tag
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3. Remove the identification tag.
4. If not previously removed, remove the exhaust heat shield.
   Fig 6: Removing Exhaust Heat Shield

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5. Remove the transmission fluid fill tube.
   Fig 7: Removing Transmission Fluid Fill Tube

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CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.
Fig 8: Removing Overdrive Servo Piston And Rod
Courtesy of FORD MOTOR CO.
6. Remove the overdrive servo piston and rod.
   • Remove the bolts.
   • Remove the cover.
   • Remove the piston and rod.
7. Remove the output shaft speed (OSS) sensor cover.
   Fig 9: Removing Output Shaft Speed (OSS) Sensor Cover

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8. Remove the OSS sensor.
   • Unclip the harness.
   • Remove the OSS sensor.
   Fig 10: Removing OSS Sensor

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9. Remove the digital transmission range (TR) sensor.
   1. Remove the two digital TR retaining bolts.
   2. Remove the digital TR sensor.
   Fig 11: Removing Digital Transmission Range (TR) Sensor

   Courtesy of FORD MOTOR CO.
10. Remove the turbine shaft speed (TSS) sensor.
    1. Remove the TSS sensor bolt.
    2. Remove the TSS sensor.
    Fig 12: Removing Turbine Shaft Speed (TSS) Sensor

    Courtesy of FORD MOTOR CO.
NOTE: The differential seal is a two-piece constructed seal.
Fig 13: Removing LH Differential Seal
Courtesy of FORD MOTOR CO.
11. Using the special tools, remove the LH differential seal.
12. Using the special tools, remove the LH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector from the LH differential seal and remove the protector from the tool.
    Fig 14: Removing LH Differential Seal Metal Protector

    Courtesy of FORD MOTOR CO.
13. Using the special tools, remove the rubber portion of LH differential seal.
    1. Install the special tool into the LH differential seal.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
       Fig 15: Removing Rubber Portion Of LH Differential Seal

       Courtesy of FORD MOTOR CO.
14. Install the special tool into the RH differential seal.
    Fig 16: Installing Special Tool Into RH Differential Seal

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15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
    Fig 17: Removing RH Differential Seal Metal Protector

    Courtesy of FORD MOTOR CO.
16. Using the special tool, remove the rubber portion of the seal.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 18: Removing Rubber Portion Of Seal

    Courtesy of FORD MOTOR CO.
17. Using the special tools, remove the converter hub seal.
    Fig 19: Removing Converter Hub Seal

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18. Remove the bolts.
    Fig 20: Removing Bolts

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19. If not previously removed, remove the mount.
    Fig 21: Removing Mount

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20. Remove the bolts and the pan.
    Fig 22: Removing Pan Bolts

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CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
Fig 23: Disconnecting Electrical Connector
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21. Lift the locking tab and disconnect the electrical connectors.
NOTE: The manual valve should be inserted completely.
Fig 24: Rotating Manual Control Lever To Low Detent
Courtesy of FORD MOTOR CO.
22. Using a 9 mm (0.36 in) wrench rotate the manual control lever to the low detent.
CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body.
CAUTION: Only four of the six pump cover bolts need to be removed.
Fig 25: Removing Main Valve And Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
23. Remove the bolts.
24. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting.
    Fig 26: Removing Main Control Valve Body

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25. Disconnect the manual control valve actuating rod.
    Fig 27: Disconnecting Manual Control Valve Actuating Rod

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26. Remove the pump shaft.
    Fig 28: Removing Pump Shaft

    Courtesy of FORD MOTOR CO.
NOTE: The transaxle pan gasket is reusable if not torn or damaged.
Fig 29: Removing Transmission Fluid Pan And Gasket
Courtesy of FORD MOTOR CO.
27. Remove the bolts, transmission fluid pan and gasket.
28. Remove, clean and inspect the magnet.
    Fig 30: Locating Magnet

    Courtesy of FORD MOTOR CO.
29. Remove the filter.
    Fig 31: Removing Filter

    Courtesy of FORD MOTOR CO.
NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
Fig 32: Removing Fluid Filter Seal
Courtesy of FORD MOTOR CO.
30. Remove the fluid filter seal.
31. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 33: Removing Reverse Clutch Anchor Pin

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CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.
NOTE: Mark bolt size and location for assembly.
Fig 34: Removing Chain Cover Bolts
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32. Remove the bolts.
NOTE: The plastic thrust washers No.1 and 3 may stick to the cover or to the sprockets.
Fig 35: Removing Chain Cover And Gasket
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33. Remove the chain cover and gasket.
34. Remove the shift accumulator springs.
    1. Remove the 1-2 shift accumulator piston inner assist springs.
    2. Remove the 1-2 shift accumulator piston outer springs.
    3. Remove the 2-3 shift accumulator piston inner assist spring.
    4. Remove the 2-3 shift accumulator piston outer spring.
    5. Remove the reverse shift accumulator piston spring.
    6. Remove the 3-4 shift accumulator piston spring.
    Fig 36: Removing Shift Accumulator Springs

    Courtesy of FORD MOTOR CO.
CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
Fig 37: Removing Drive Sprocket, Driven Sprocket And Drive Chain As An Assembly
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35. Remove the drive sprocket, driven sprocket and drive chain as an assembly.
NOTE: The thrust washers may remain on the sprockets.
Fig 38: Removing Thrust Washers
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36. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
CAUTION: Use care not to damage the machined surface of the case.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 39: Removing Roll Pins
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37. Remove the roll pins.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 40: Removing Manual Control Lever Shaft
Courtesy of FORD MOTOR CO.
38. Remove the manual control lever shaft.
39. Remove the parking lever actuating rod.
    Fig 41: Removing Parking Lever Actuating Rod

    Courtesy of FORD MOTOR CO.
40. Remove the manual control lever shaft seal.
    Fig 42: Removing Manual Control Lever Shaft Seal

    Courtesy of FORD MOTOR CO.
NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
Fig 43: Removing Bolts And Brackets
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41. Remove the bolts and brackets.
42. Using the special tools, remove the fluid lube tubes.
    Fig 44: Removing Fluid Lube Tubes

    Courtesy of FORD MOTOR CO.
43. Remove the bolts and the park pawl abutment.
    Fig 45: Removing Park Pawl Abutment

    Courtesy of FORD MOTOR CO.
44. Remove the neutral/drive accumulator bolt.
    Fig 46: Removing Neutral/Drive Accumulator Bolt

    Courtesy of FORD MOTOR CO.
45. Remove the neutral/drive accumulator.
    1. Remove the neutral/drive accumulator cover.
    2. Remove the neutral/drive accumulator springs.
    3. Remove the neutral/drive accumulator piston and shaft.
    Fig 47: Removing Neutral/Drive Accumulator

    Courtesy of FORD MOTOR CO.
46. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston and rod as an assembly.
    Fig 48: Removing Coast Band Servo

    Courtesy of FORD MOTOR CO.
NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
Fig 49: Removing Drive Sprocket Support And No. 5 Thrust Washer
Courtesy of FORD MOTOR CO.
47. Remove the drive sprocket support and the No. 5 thrust washer.
NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
Fig 50: Removing No. 8 Driven Sprocket Support Selective Fit Rear Thrust Washer And No. 9 Needle Bearing
Courtesy of FORD MOTOR CO.
48. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
49. Remove the plastic overdrive band retainer.
    Fig 51: Removing Plastic Overdrive Band Retainer

    Courtesy of FORD MOTOR CO.
50. Remove the overdrive band.
    Fig 52: Removing Overdrive Band

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NOTE: Do not over-tighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
Fig 53: Positioning Special Tool Into Case
Courtesy of FORD MOTOR CO.
51. Position the special tool into the case and install the hooked end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
52. Using the special tool, remove the front clutch assembly.
    Fig 54: Removing Front Clutch Assembly

    Courtesy of FORD MOTOR CO.
53. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 55: Removing Reverse Clutch And Planet Assembly

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54. Remove the low/intermediate drum, sun gear and one-way clutch assembly.
    Fig 56: Removing Low/Intermediate Drum, Sun Gear And One-Way Clutch Assembly

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55. Remove the coast band.
    Fig 57: Removing Coast Band

    Courtesy of FORD MOTOR CO.
CAUTION: Use care not to damage any machined surfaces.
Fig 58: Removing Low/Intermediate Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
56. Remove the low/intermediate clutch retaining ring.
57. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
    Fig 59: Removing Low/Intermediate Clutch Pack

    Courtesy of FORD MOTOR CO.
WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
CAUTION: Use care not to damage final drive support assembly, transaxle case, or retaining ring during removal.
Fig 60: Removing Beveled Retaining Ring
Courtesy of FORD MOTOR CO.
58. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
59. Remove the final drive differential and rear planet support assembly.
    Fig 61: Removing Final Drive Differential And Rear Planet Support Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The differential carrier thrust washer may remain on the differential assembly.
Fig 62: Removing Differential Carrier Thrust Washer
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60. Remove the differential carrier thrust washer.
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
61. Remove the rear planet support spacer.
    Fig 63: Removing Rear Planet Support Spacer

    Courtesy of FORD MOTOR CO.
62. Remove the final drive ring gear.
    Fig 64: Removing Final Drive Ring Gear

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63. Remove the bolts.
    Fig 65: Removing Bolts

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NOTE: Inspect the bearing, bushing and the surface of the stator support. If any damage is indicated, install a new stator support.
Fig 66: Removing Stator Support
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64. Remove and inspect the stator support.
    1. Remove the stator support.
    2. Inspect the bearing for damage.
    3. Inspect the surface for damage.
    4. Inspect the bushing for damage.
NOTE: The following procedures are done only if installing a new case.
Fig 67: Removing Park Pawl Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
65. Remove the park pawl shaft retaining pin.
66. Using the special tools, remove the cup plug.
    Fig 68: Removing Cup Plug

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67. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
    Fig 69: Removing Parking Pawl
    Courtesy of FORD MOTOR CO.