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Automatic Transmission: Assembly: Transaxle

SPECIAL TOOL(S)

G04661554Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge With Holding Fixture
100-002 (TOOL-4201-C)
G04661555Courtesy of FORD MOTOR CO.
 Step Plate
205-D014 (D80L-630-3)
G04661556Courtesy of FORD MOTOR CO.
 Installer, Steering Gear Pinion Bearing
211-161 (T90C-3504-DH)
G04661557Courtesy of FORD MOTOR CO.
 Depth Micrometer
303-D075 (D92P-4201-A)
G04661558Courtesy of FORD MOTOR CO.
 Retaining Ring Pliers
307-343 (T95P-77001-AHR)
G04661559Courtesy of FORD MOTOR CO.
 Handle, Torque Converter
307-091 (T81P-7902-C)
G04661560Courtesy of FORD MOTOR CO.
 Test Plate Screw Set, Transmission
307-126 (T82P-7006-C)
G04661561Courtesy of FORD MOTOR CO.
 Air Test Plate, Transmission
307-312 (T94P-77001-EH)
G04661562Courtesy of FORD MOTOR CO.
 Gasket, Transmission Air Test Plate
307-313 (T94P-77001-EH1)
G04661563Courtesy of FORD MOTOR CO.
 Installer, Halfshaft Output Fluid Seal
307-157 (T86P-1177-B)
G04661564Courtesy of FORD MOTOR CO.
 Gauge, Servo Rod
307-162 (T86P-70023-B)
G04661565Courtesy of FORD MOTOR CO.
 Holding Fixture Transmission
307-003 (T57L-500-B)
G04661566Courtesy of FORD MOTOR CO.
 Lifting Fixture, Clutch Pack
307-171 (T86P-70389-A)
G04661567Courtesy of FORD MOTOR CO.
 Installer, Torque Converter Fluid Seal
307-186 (T87L-77837-AH)
G04661568Courtesy of FORD MOTOR CO.
 End Play Gauge
307-187 (T87P-70014-AH)
G04661569Courtesy of FORD MOTOR CO.
 Remover/Installer, Servo Piston
307-251 (T92P-70023-A)
G04661570Courtesy of FORD MOTOR CO.
 Shim Selection Gauge Bar
307-300 (T94P-77000-Q)
G04661571Courtesy of FORD MOTOR CO.
 Remover, Reverse Clutch/Planet
307-314 (T94P-77001-FH)
G04661572Courtesy of FORD MOTOR CO.
 Aligner, Output Shaft Fluid Seal
307-317 (T94P-77001-JH)
G04661573Courtesy of FORD MOTOR CO.
 Shim Selection Gauge
307-320 (T94P-77001-MH)
G04661574Courtesy of FORD MOTOR CO.
 Shim Depth Gauge
307-321 (T94P-77001-NH)
G04661575Courtesy of FORD MOTOR CO.
 Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
G04661576Courtesy of FORD MOTOR CO.
 Remover/Installer Bearing Tube
308-025 (T75L-7025-C)
G04661577Courtesy of FORD MOTOR CO.
 Remover, Bearing Collet Sleeve
308-049 (T77F-7025-C)
Fig 1: Exploded View Of Transaxle Components (1 Of 4)
G04661578Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transaxle Components (2 Of 4)
G04661579Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle Components (3 Of 4)
G04661580Courtesy of FORD MOTOR CO.
Fig 4: Exploded View Of Transaxle Components (4 Of 4)
G04661581Courtesy of FORD MOTOR CO.
Fig 5: Identifying Transaxle Components Legends (Items 1-48)
G04661582Courtesy of FORD MOTOR CO.
Fig 6: Identifying Transaxle Components Legends (Items 49-93)
G04661583Courtesy of FORD MOTOR CO.
Fig 7: Identifying Transaxle Components Legends (Items 94-143)
G04661584Courtesy of FORD MOTOR CO.
Fig 8: Identifying Transaxle Components Legends (Items 144-184)
G04661585Courtesy of FORD MOTOR CO.
Fig 9: Identifying Transaxle Components Legends (Items 185-229)
G04661586Courtesy of FORD MOTOR CO.
Fig 10: Identifying Transaxle Components Legends (Items 230-264)
G04661587Courtesy of FORD MOTOR CO.
  1. Install the parking pawl assembly.
    1. Install the parking pawl and return spring.
    2. Install the parking pawl shaft.
      Fig 11: Identifying Parking Pawl Assembly
      G04661588Courtesy of FORD MOTOR CO.
  2. Install the park pawl roll pin.
    Fig 12: Installing Park Pawl Roll Pin
    G04661589Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the cup plug.
    Fig 13: Installing Cup Plug Using Special Tool (211-161)
    G04661590Courtesy of FORD MOTOR CO.
    4. NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.
    Fig 14: Installing Stator Support
    G04661591Courtesy of FORD MOTOR CO.
  4. Install the stator support.
  5. Install the stator support bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 15: Installing Stator Support Bolts
      G04661592Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the converter impeller hub seal.
    Fig 16: Installing Converter Impeller Hub Seal Using Special Tools (307-003) And (307-186)
    G04661593Courtesy of FORD MOTOR CO.
  7. 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 17: Identifying Differential Carrier Thrust Bearing
      G04661594Courtesy of FORD MOTOR CO.
  8. Install the final drive ring gear.
    Fig 18: Locating Final Drive Ring Gear
    G04661595Courtesy of FORD MOTOR CO.
  9. Install the rear planet support spacer.
    Fig 19: Locating Rear Planet Support Spacer
    G04661596Courtesy of FORD MOTOR CO.
  10. Install the final drive differential assembly.
    Fig 20: Locating Final Drive Differential Assembly
    G04661597Courtesy of FORD MOTOR CO.
  11. Align the rear lube tube holes in the case window.
    Fig 21: Locating Rear Lube Tube Holes In Case Window
    G04661598Courtesy of FORD MOTOR CO.
    12. NOTE: The retaining ring must be correctly installed.
    Fig 22: Using Special Tool (307-343) To Install Beveled Retaining Ring
    G04661599Courtesy of FORD MOTOR CO.
    Fig 23: Locating Retaining Ring Seats
    G04661600Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the beveled retaining ring.
    13. CAUTION: If the support is not visible on the inside diameter of the retaining ring, the low/intermediate piston could be damaged.
    Fig 24: Identifying Retaining Ring Seats
    G04661601Courtesy of FORD MOTOR CO.
  13. Make sure that the beveled retaining ring seats correctly in the case groove with the bevel down. The final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall.
  14. 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 25: Locating Differential Case
    G04661602Courtesy of FORD MOTOR CO.
  15. Install the special tools.
    Fig 26: Identifying Special Tools (205-D014) And (307-187)
    G04661603Courtesy of FORD MOTOR CO.
  16. Remove the No. 15 needle bearing.
    Fig 27: Locating Needle Bearing
    G04661604Courtesy of FORD MOTOR CO.
    17. NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.
    Fig 28: Identifying Special Tools (307-300) And (307-321)
    G04661605Courtesy of FORD MOTOR CO.
  17. Install the special tools.
  18. Install the special tool and zero the dial indicator.
    Fig 29: Identifying Special Tools (307-300), (100-002), And (307-321)
    G04661606Courtesy of FORD MOTOR CO.
  19. Tighten the bolt.
    • Tighten to 1.5 Nm (12 lb-in).
      Fig 30: Tightening Bolts On Special Tool (307-187) To Torque Specification
      G04661607Courtesy of FORD MOTOR CO.
  20. 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 31: Identifying Special Tools (100-002), (307-300), And (307-321)
    G04661608Courtesy of FORD MOTOR CO.
  21. Select the correct beveled retaining ring.
    ITEM DESCRIPTION

    Item Part Number Thickness Style
    1 F5DZ-TD483-E 1.48-1.63 mm (0.058-0.064 inch) Style 5
    2 F5DZ-TD483-D 1.54-1.68 mm (0.061-0.067 inch) Style 4
    3 F5DZ-TD483-C 1.60-1.75 mm (0.063-0.069 inch) Style 3
    4 F5DZ-TD483-B 1.66-1.81 mm (0.065-0.071 inch) Style 2
    5 F5DZ-TD483-A 1.72-1.87 mm (0.068-0.074 inch) Style 1
    Fig 32: Identifying Retaining Ring
    G04661609Courtesy of FORD MOTOR CO.
    22. 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 33: Identifying Thrust Bearing
    G04661610Courtesy of FORD MOTOR CO.
  22. Install the No. 15 thrust bearing.
  23. 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 34: Identifying Clearance For Thrust Washer Using Special Tool (100-102)
    G04661611Courtesy of FORD MOTOR CO.
  24. Tighten the bolt. Read and record the dial indicator reading.
    • Tighten to 1.5 Nm (12 lb-in).
      Fig 35: Tightening Bolts On Special Tool (307-187) To Torque Specification
      G04661612Courtesy of FORD MOTOR CO.
    25. NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.
    Fig 36: Identifying Clearance For Thrust Washer Using Special Tool (100-102)
    G04661613Courtesy of FORD MOTOR CO.
  25. If the clearance is not within specification a thicker or thinner washer will need to be added.
    NO. 16 THRUST RACE (WASHER)

    Thickness ID
    2.25-2.15 mm Green (No. 1)
    2.37-2.27 mm Blue (No. 2)
    2.49-2.39 mm Black (No. 3)
    2.61-2.51 mm White (No. 4)
    2.73-2.63 mm Brown (No. 5)
    2.85-2.75 mm Gold (No. 6)
  26. Install the low/intermediate one-way clutch assembly.
    Fig 37: Identifying Low/Intermediate One-Way Clutch Assembly
    G04661614Courtesy of FORD MOTOR CO.
    27. NOTE: The friction plate internal splines will center the one-way clutch.
  27. 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 38: Identifying Low/Intermediate Clutch Pressure Plate Components
      G04661615Courtesy of FORD MOTOR CO.
    28. CAUTION: Make sure that the retaining ring is seated in the case groove.
    Fig 39: Identifying Low/Intermediate Clutch Retaining Ring
    G04661616Courtesy of FORD MOTOR CO.
  28. Install the low/intermediate clutch retaining ring.
    29. 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 40: Identifying Air Pressure To Low/Intermediate
    G04661617Courtesy of FORD MOTOR CO.
  29. 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.
  30. 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.
    SELECTIVE RETAINING RINGS SPECIFICATION

    Thickness
    1.54-1.64 mm (0.061-0.065 inch)
    2.08-2.18 mm (0.082-0.086 inch)
    2.62-2.72 mm (0.103-0.107 inch)
    3.16-3.26 mm (0.125-0.128 inch)
    3.68-3.78 mm (0.145-0.149 inch)
    Fig 41: Identifying Selective Retaining Rings
    G04661618Courtesy of FORD MOTOR CO.
  31. Install the coast band.
    1. Install the coast band.
    2. Align the anchor pin pocket with the anchor pin in the case.
      Fig 42: Identifying Coast Band
      G04661619Courtesy of FORD MOTOR CO.
  32. Install the low/intermediate drum. Rotate the low/intermediate drum and sun gear into the low/intermediate one-way clutch.
    Fig 43: Identifying Low/Intermediate Drum
    G04661620Courtesy of FORD MOTOR CO.
  33. Install the park rod abutment and make sure that the park pawl moves freely.
    • Tighten to 28 Nm (21 lb-ft).
      Fig 44: Identifying Park Pawl Moves
      G04661621Courtesy of FORD MOTOR CO.
  34. 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 45: Identifying Coast Band Piston Cover
      G04661622Courtesy of FORD MOTOR CO.
  35. Using the special tool, install the coast servo cover retaining ring.
    Fig 46: Identifying Coast Servo Cover Retaining Ring With Special Tool (307-251)
    G04661623Courtesy of FORD MOTOR CO.
  36. Using the special tools, install the front planetary/reverse clutch assembly.
    Fig 47: Installing Front Planetary/Reverse Clutch Assembly With Special Tools (307-314), (308-025), And (308-049)
    G04661624Courtesy of FORD MOTOR CO.
  37. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.
    Fig 48: Locating Tube Hole
    G04661625Courtesy of FORD MOTOR CO.
  38. Loosely install the reverse clutch anchor pin.
    Fig 49: Locating Reverse Clutch Anchor Pin
    G04661626Courtesy of FORD MOTOR CO.
  39. Using the special tool, install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.
    Fig 50: Installing Forward/Intermediate Clutch Assembly Using Special Tool (307-171)
    G04661627Courtesy of FORD MOTOR CO.
  40. Install the overdrive band.
    Fig 51: Locating Overdrive Band
    G04661628Courtesy of FORD MOTOR CO.
    41. NOTE: The foot of the overdrive retainer fits against the band.
    Fig 52: Locating Overdrive Band Anchor Strut
    G04661629Courtesy of FORD MOTOR CO.
  41. Install the overdrive band anchor strut with the cross hairs facing upward.
  42. 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 53: Identifying Sprocket Thrust Washer
      G04661630Courtesy of FORD MOTOR CO.
  43. Install only the No. 9 needle bearing with the outer lip upward.
    Fig 54: Locating Needle Bearing With Outer Lip
    G04661631Courtesy of FORD MOTOR CO.
  44. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.
    Fig 55: Installing Special Tool (307-320) Over Output Shaft
    G04661632Courtesy of FORD MOTOR CO.
  45. Install the special tool to make the measurements.
    Fig 56: Identifying Special Tools (303-D075), (307-300), And (307-320)
    G04661633Courtesy of FORD MOTOR CO.
  46. 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 2 to obtain reading A.
    Fig 57: Identifying Special Tools (303-D075), (307-300), And (307-320)
    G04661634Courtesy of FORD MOTOR CO.
    47. NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.
  47. Use reading A to select the correct No. 8 thrust washer from the chart.
    NO. 8 THRUST WASHER SELECTION CHART

    Reading A Washer Thickness Dimension C Color/ID
    42.88-43.10 mm (1.688-1.696 inch) 1.43-1.53 mm (0.056-0.060 inch) 1.48 mm (0.058 inch) Natural (No. 1)
    43.11-43.34 mm (1.697-1.706 inch) 1.68-1.78 mm (0.066-0.070 inch) 1.73 mm (0.068 inch) Dark Green (No. 2)
    43.35-43.59 mm (1.707-1.716 inch) 1.92-2.02 mm (0.075-0.080 inch) 1.97 mm (0.077 inch) Light Blue (No. 3)
    43.60-43.77 mm (1.717-1.723 inch) 2.17-2.27 mm (0.085-0.089 inch) 2.22 mm (0.087 inch) Red (No. 4)
    43.78-43.98 mm (1.724-1.731 inch) 2.35-2.45 mm (0.093-0.096 inch) 2.40 mm (0.094) Black (No. 5)
  48. Remove the special tools.
    Fig 58: Identifying Special Tools (303-D075), (307-300), And (307-320)
    G04661635Courtesy of FORD MOTOR CO.
  49. Install the special tools to take the measurements.
    Fig 59: Identifying Special Tools (303-D075) And (307-300)
    G04661636Courtesy of FORD MOTOR CO.
  50. 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 2 to obtain reading B.
    Fig 60: Identifying Special Tool (303-D075) And (307-300)
    G04661637Courtesy of FORD MOTOR CO.
  51. Remove the special tools.
    Fig 61: Identifying Special Tool (303-D075) And (307-300)
    G04661638Courtesy of FORD MOTOR CO.
    52. NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
  52. Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D.
    READING REFERENCE

    Reading B:_____
    - Reading A:_____
    Difference:_____
    +Dimension C:_____
    Reading D:_____
  53. Use Reading D to select the correct No. 5 thrust washer.
    NO. 5 SUPPORT THRUST WASHER CHART

    Reading D Washer Thickness Color/ID
    26.08-26.37 mm (1.027-1.038 inch) 2.18-2.28 mm (0.086-0.090 inch) Green (No. 1)
    26.38-26.61 mm (1.039-1.047 inch) 2.43-2.53 mm (0.096-0.100 inch) Black (No. 2)
    26.62-26.86 mm (1.048-1.057 inch) 2.67-2.77 mm (0.105-0.109 inch) Natural (No. 3)
    26.87-27.15 mm (1.058-1.068 inch) 2.92-3.02 mm (0.115-0.119 inch) Red (No. 4)
    27.16-27.50 mm (1.069-1.083 inch) 3.26-3.36 mm (0.128-0.132 inch) Blue (No. 5)
    54. NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
    Fig 62: Identifying Front Support Thrust Washer
    G04661639Courtesy of FORD MOTOR CO.
  54. Install the No. 5 front support thrust washer.
    55. 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.
  55. 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 63: Identifying Correct Bearing
      G04661640Courtesy of FORD MOTOR CO.
  56. Install the driven sprocket support assembly.
    Fig 64: Installing Driven Sprocket Support Assembly
    G04661641Courtesy of FORD MOTOR CO.
  57. Install the neutral/drive accumulator cover.
    1. Install the neutral/drive accumulator piston.
    2. Install the neutral/drive accumulator spring.
      • The outer spring is yellow in color.
      • The inner spring is grey in color.
    3. Install the neutral/drive accumulator cover.
      Fig 65: Installing Neutral/Drive Accumulator Cover
      G04661642Courtesy of FORD MOTOR CO.
  58. Install the bolt.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 66: Identifying Bolt
      G04661643Courtesy of FORD MOTOR CO.
    59. NOTE: All the fluid supply tubes must have new O-rings installed.
    Fig 67: Identifying Fluid Supply Tubes
    G04661644Courtesy of FORD MOTOR CO.
  59. Install the fluid supply tubes.
  60. Install the brackets and bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 68: Locating Brackets And Bolts
      G04661645Courtesy of FORD MOTOR CO.
  61. Using the special tool, install the manual control lever shaft seal.
    Fig 69: Installing Manual Control Lever Shaft Seal Using Special Tool (211-161)
    G04661646Courtesy of FORD MOTOR CO.
  62. Install the parking lever actuating rod.
    • Push in on the park pawl.
    • Slide the parking lever actuating rod down to fit in the park pawl.
      Fig 70: Installing Parking Lever Actuating Rod
      G04661647Courtesy of FORD MOTOR CO.
    63. NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.
    Fig 71: Locating Manual Control Lever Shaft
    G04661648Courtesy of FORD MOTOR CO.
  63. Install the manual control lever shaft.
    64. 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 72: Locating Roll Pins
    G04661649Courtesy of FORD MOTOR CO.
  64. Install the roll pins.
    65. NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
  65. Install the thrust washers.
    1. Install the No. 2 drive sprocket thrust washer.
    2. Install the No. 4 driven sprocket thrust washer.
      Fig 73: Identifying Thrust Washers
      G04661650Courtesy of FORD MOTOR CO.
    66. 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 74: Installing Drive Chain And Sprockets
    G04661651Courtesy of FORD MOTOR CO.
  66. Install the drive chain and sprockets.
  67. Install the shift accumulator springs.
    1. Install the 1-2 shift accumulator piston spring (no color or brown).
    2. Install the 2-3 shift accumulator piston spring (no color or brown).
    3. Install the reverse shift accumulator piston spring (pink).
    4. Install the 3-4 shift accumulator piston spring (pink).
      Fig 75: Identifying Shift Accumulator Springs
      G04661652Courtesy of FORD MOTOR CO.
    68. NOTE: Make sure that the alignment pins are installed in the case.
    Fig 76: Locating Chain Cover Gasket
    G04661653Courtesy of FORD MOTOR CO.
  68. Install the new chain cover gasket.
    69. CAUTION: Be extremely careful not to damage the cast iron sealing ring.
  69. 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 77: Installing Thrust Washer
      G04661654Courtesy of FORD MOTOR CO.
    70. 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 78: Identifying Chain Cover Bolts
    G04661655Courtesy of FORD MOTOR CO.
  70. Start the 2 bolts.
  71. Install the remaining bolts.
    • Tighten No. 1 to 30 Nm (22 lb-ft).
    • Tighten No. 2 to 41 Nm (30 lb-ft).
    • Tighten No. 3 to 28 Nm (21 lb-ft).
    • Tighten No. 4 to 13 Nm (10 lb-ft).
      Fig 79: Locating Remaining Bolts
      G04661656Courtesy of FORD MOTOR CO.
  72. Install the bolts.
    • Tighten No. 1 to 30 Nm (22 lb-ft).
    • Tighten No. 2 to 13 Nm (10 lb-ft).
      Fig 80: Identifying Special Tool (307-003) And Bolts
      G04661657Courtesy of FORD MOTOR CO.
    73. 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.
  73. Inspect the spring height.
    1. Test spring.
    2. Original spring.
      Fig 81: Identifying Test Spring And Original Spring
      G04661658Courtesy of FORD MOTOR CO.
  74. Check overdrive servo travel. Install the overdrive servo piston.
    1. Install the test spring.
    2. Install the overdrive servo piston.
      Fig 82: Identifying Overdrive Servo Piston
      G04661659Courtesy of FORD MOTOR CO.
  75. Install the special tools.
    • Tighten to 10 Nm (89 lb-in).
      Fig 83: Identifying Special Tool (307-162) And (100-002)
      G04661660Courtesy of FORD MOTOR CO.
  76. Using the special tools, tighten the center screw and zero out the dial indicator.
    • Tighten to 1.13 Nm (10 lb-in).
      Fig 84: Identifying Special Tool (307-162) And (100-002)
      G04661661Courtesy of FORD MOTOR CO.
  77. 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 85: Identifying Special Tool (307-162) And (100-002)
    G04661662Courtesy of FORD MOTOR CO.
  78. 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.
    OVERDRIVE PISTON ROD SELECTION CHART

    Overdrive Servo Rod Length No. of Grooves(1)
    mm Inch
    99.33 3.91 0
    98.05 3.86 1
    96.78 3.81 2
    (1) Grooves are at the tip.
    79. CAUTION: Do not assemble the transaxle using the test spring.
  79. Install the overdrive servo.
    1. Install the overdrive servo spring.
    2. Install the overdrive servo.
    3. Install the overdrive servo cover and bolts.
      • Tighten to 13 Nm (10 lb-ft).
        Fig 86: Identifying Overdrive Servo
        G04661663Courtesy of FORD MOTOR CO.
  80. Install the transmission test plate.
    Fig 87: Installing Special Tool (307-313), (307-312) And (307-126)
    G04661664Courtesy of FORD MOTOR CO.
    81. 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 88: Identifying Air Pressure To Appropriate Clutch Ports
    G04661665Courtesy of FORD MOTOR CO.
  81. 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.
    ITEM DESCRIPTION

    Item Part Number Description
    1 - 1-2 accumulator test passage
    2 - Overdrive servo test passage
    3 - Direct clutch test passage
    4 - Low/intermediate clutch and accumulator test passage
    5 - Coast band test passage
    6 - Reverse clutch test passage
    7 - 3-4 accumulator test passage
    8 - Neutral/reverse accumulator test passage
    9 - Vent hole
    10 - Forward clutch test passage
    11 - Intermediate clutch test passage
    12 - 2-3 accumulator test passage
    82. CAUTION: The seals must be lapped correctly or internal leakage will occur.
    Fig 89: Identifying Seal Ring Mating
    G04661666Courtesy of FORD MOTOR CO.
  82. Install the new Teflon® seals on the pump shaft.
  83. Install the pump shaft.
    Fig 90: Installing Pump Shaft
    G04661667Courtesy of FORD MOTOR CO.
  84. Install the manual valve detent lever.
    Fig 91: Installing Manual Valve Detent Lever
    G04661668Courtesy of FORD MOTOR CO.
  85. 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 92: Installing Main Control Valve Body Over Pump Shaft
    G04661669Courtesy of FORD MOTOR CO.
    86. CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.
  86. Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolts and tighten in sequence.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 93: Identifying Main Control Valve Body Bolts
      G04661670Courtesy of FORD MOTOR CO.
  87. Connect the connectors.
    Fig 94: Locating Connectors
    G04661671Courtesy of FORD MOTOR CO.
    88. NOTE: The transaxle side cover gasket is reusable if not torn or ripped.
    Fig 95: Locating Gasket
    G04661672Courtesy of FORD MOTOR CO.
  88. Remove the gasket. Clean and inspect the gasket, and reinstall into the pan.
  89. Install the M6 x 1.00 pan bolts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 96: Locating Pan Bolts
      G04661673Courtesy of FORD MOTOR CO.
  90. Install the M8 x 1.25 pan bolts.
    • Tighten to 29 Nm (21 lb-ft).
      Fig 97: Identifying M8 X 1.25 Pan Bolts
      G04661674Courtesy of FORD MOTOR CO.
  91. Install the mounting bracket and bolts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 98: Locating Mounting Bracket And Bolts
      G04661675Courtesy of FORD MOTOR CO.
  92. Tighten the reverse clutch anchor bolt.
    1. Tighten the anchor bolt.
      • Tighten to 11 Nm (8 lb-ft).
    2. Tighten the locknut.
      • Tighten to 54 Nm (40 lb-ft).
        Fig 99: Identifying Reverse Clutch Anchor Bolt
        G04661676Courtesy of FORD MOTOR CO.
  93. Install the new seal and gasket kit and seal assembly.
    Fig 100: Identifying Seal And Gasket Kit And Seal Assembly
    G04661677Courtesy of FORD MOTOR CO.
  94. Install the fluid pan magnet.
    Fig 101: Locating Fluid Pan Magnet
    G04661678Courtesy of FORD MOTOR CO.
    95. NOTE: The gasket is reusable if not damaged or torn.
  95. Install the transmission fluid pan and gasket.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 102: Locating Transmission Fluid Pan And Gasket
      G04661679Courtesy of FORD MOTOR CO.
  96. Install the turbine shaft speed (TSS) sensor and bolt.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 103: Identifying Turbine Shaft Speed (TSS) Sensor And Bolt
      G04661680Courtesy of FORD MOTOR CO.
    97. NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.
  97. Verify that the shift selector lever is in NEUTRAL.
  98. Install the digital TR sensor and loosely install the bolts.
    Fig 104: Identifying Digital TR Sensor
    G04661681Courtesy of FORD MOTOR CO.
  99. Using the special tool, align the digital TR sensor and tighten the bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 105: Aligning TR Sensor Using Special Tool (307-351)
      G04661682Courtesy of FORD MOTOR CO.
  100. Install the fluid filler tube with a new grommet.
    1. Install the grommet.
    2. Install the fluid filler tube and bolt.
      • Tighten to 13 Nm (10 lb-ft).
        Fig 106: Identifying Fluid Filler Tube With Grommet
        G04661683Courtesy of FORD MOTOR CO.
  101. Using the special tool, install the LH output shaft seal.
    Fig 107: Installing LH Output Shaft Seal Using Special Tool (303-157)
    G04661684Courtesy of FORD MOTOR CO.
  102. Using the special tool, install the RH output shaft seal.
    Fig 108: Installing RH Output Shaft Seal Using Special Tool (307-157) And (307-317)
    G04661685Courtesy of FORD MOTOR CO.
  103. Install the output shaft speed (OSS) sensor and reconnect the harness.
    Fig 109: Locating Output Shaft Speed (OSS) Sensor
    G04661686Courtesy of FORD MOTOR CO.
  104. Install the OSS sensor cover.
    1. Install the OSS cover.
    2. Install the bolt.
      • Tighten to 11 Nm (8 lb-ft).
    3. Connect the connector to the bracket.
      Fig 110: Identifying Connector Bracket
      G04661687Courtesy of FORD MOTOR CO.
  105. Install the identification tag, if removed.
    Fig 111: Identifying Identification Tag
    G04661688Courtesy of FORD MOTOR CO.
    106. NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.
    Fig 112: Identifying Torque Converter
    G04661689Courtesy of FORD MOTOR CO.
  106. Using the special tools, install the torque converter.
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