Automatic Transmission: Assembly: Transaxle

Special Tools

Illustration	Tool Name	Tool Number
	Dial Indicator Gauge With Holding Fixture	100-002 (TOOL-4201-C)
	Step Plate	205-D014 (D80L-630-3)
	Installer, Steering Gear Pinion Bearing	211-161 (T90C-3504-DH)
	Depth Micrometer	303-D075 (D92P-4201-A)
	Retaining Ring Pliers	307-343 (T95P-77001-AHR)
	Handle, Torque Converter	307-091 (T81P-7902-C)
	Test Plate Screw Set, Transmission	307-126 (T82P-7006-C)
	Air Test Plate, Transmission	307-312 (T94P-77001-EH)
	Gasket, Transmission Air Test Plate	307-313 (T94P-77001-EH1)
	Installer, Halfshaft Output Fluid Seal	307-157 (T86P-1177-B)
	Gauge, Servo Rod	307-162 (T86P-70023-B)
	Holding Fixture Transmission	307-003 (T57L-500-B)
	Lifting Fixture, Clutch Pack	307-171 (T86P-70389-A)
	Installer, Torque Converter Fluid Seal	307-186 (T87L-77837-AH)
	End Play Gauge	307-187 (T87P-70014-AH)
	Remover/Installer, Servo Piston	307-251 (T92P-70023-A)
	Shim Selection Gauge Bar	307-300 (T94P-77000-Q)
	Remover, Reverse Clutch/Planet	307-314 (T94P-77001-FH)
	Remover/Installer, Front Clutch	307-316 (T94P-77001-HH)
	Aligner, Output Shaft Fluid Seal	307-317 (T94P-77001-JH)
	Shim Selection Gauge	307-320 (T94P-77001-MH)
	Shim Depth Gauge	307-321 (T94P-77001-NH)
	Alignment Gauge, TR Sensor	307-351 (T97L-70010-A)
	Remover/Installer Bearing Tube	308-025 (T75L-7025-C)
	Remover, Bearing Collet Sleeve	308-049 (T77F-7025-C)

Fig 1: Exploded View Of Transaxle (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Transaxle (2 Of 4)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Transaxle (3 Of 4)

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Transaxle (4 Of 4)

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	N605890-S1036	Bolt - M6-1.0 x 16.5 hex flange head (2 - attach dust cover to case)
2	7986	Cover - lower converter housing
3	7902	Converter assembly
4	7F401	Seal assembly - converter impeller hub
5	1177	Seal assembly - differential (2 required)
6	N806944-S1036	Stud - M10 - 1.5 x 60.5 pilot
7	7005	Case assembly
8	7G112	Bearing and race assembly - differential carrier thrust No. 19
9	7G103	Washer - differential carrier thrust No. 18
10	7F343	Gear - final drive ring
11	7C144	Rear support spacer
12	7F465	Gear and differential case assembly
13	N803200-S	Ring - 77.3 mm (3.04 in) retaining external (retains pinion shaft in differential case)
14	W706051-S	Ring - 27 mm (1.08 in) retaining external (retains output shaft in differential case assembly)
15	4230	Washers - rear axle differential pinion thrust (2 required)
16	4215	Pinions - front wheel drive differential (2 required)
17	4228	Washers - differential side gear thrust (2 required)
18	4236	Gears - differential side (2 required)
19	67847-S	Pin - coiled spring (retains differential pinion shaft)
20	4211	Shaft - differential pinion
21	7060	Shaft - differential output
22	N804139-S	Circle clip - output shaft retaining
23	7F342	Gear and deflector assembly - final drive sun
24	7A233	Gear - parking
25	7F405	Bearing and race assembly - final drive gear thrust No. 16
26	7F451	Race - final drive gear thrust - front No. 16 (select fit)
27	7A130	Support assembly - rear planetary
28	7G085	Seal assembly - fluid transfer tubes (2 required)
29	7H290	Piston and seal assembly - low/intermediate clutch
30	7H266	Washer - support and spring assembly - low/intermediate clutch (bonded)
31	7D483	Ring - 56.3 mm (2.25 in) retainer type SU external
32	7G178	Bearing and race assembly - sun gear thrust No. 15
33	7D483	Ring - 170 mm (6.8 in) 14.5 degree bevel (retains rear support in case) (select fit)
34	7D171	Race - Low/intermediate one-way clutch - outer
35	7A089	Low/intermediate one-way clutch - race and roller assembly
36	7E085	Spring - low/intermediate clutch cushion
37	7B164	Plate assembly - low/intermediate clutch - internal (4 required) (friction)
38	7B442	Plates - low/intermediate clutch - external (4 required) steel
39	7B066	Plate - low/intermediate clutch - pressure
40	7D483	Retainer - low/intermediate clutch (select fit)
41	7A162	Band assembly - coast
42	7A626	Gear/drum/race assembly - rear sun
43	7A153	Gear - rear ring
44	7D006	Gear assembly - rear planetary
45	7G177	Bearing and race assembly - planetary thrust center No. 13
46	7A398	Gear assembly - front planetary
47	7D483	Ring - front planetary retaining
48	7D483	Ring - 153.9 mm (6.15 in) internal retaining (select fit)
49	7B066	Plate - reverse clutch - pressure
50	7B164	Plate assembly - reverse clutch - internal (4 required) (friction)
51	7B442	Plates - reverse clutch - external (4 required) (steel)
52	7E085	Spring - reverse clutch piston
53	N803048-S	Ring - 67.0 mm (2.68 in) retaining type SU - external (retains support and spring assembly in reverse clutch cylinder)
54	7G335	Support and spring assembly - reverse clutch
55	7D402	Piston - reverse clutch
56	7D403	Seal - reverse clutch piston - outer
57	7D404	Seal - reverse clutch piston - inner
58	7F341	Cylinder - reverse clutch
59	7D064	Gear and shell assembly - front sun
60	7C096	Bearing and race assembly - forward sun gear thrust No. 10 and 11
61	7B067	Hub - intermediate clutch
62	7D483	Rings - 152.26 mm (6.09 in) retainer style - internal (select fit)
63	7B066	Plate - intermediate clutch - pressure
64	7B164	Plate assembly - intermediate/direct clutch - internal (friction)
65	7B442	Plates - intermediate/direct clutch - external (steel)
66	7E085	Spring - intermediate clutch wave
67	7C122	Ring - 72.0 mm (2.88 in) retaining style SU - external
68	7H185	Piston assembly - intermediate clutch balance
69	7F222	Support and spring assembly - intermediate clutch
70	7E005	Piston assembly - intermediate clutch
71	7F225	Seal - intermediate clutch piston - inner
72	7G120	Cylinder and hub assembly - direct/intermediate clutch
73	7G102	Seals - intermediate/direct clutch hub (2 required)
74	7F225	Seal - direct clutch piston - inner
75	7A262	Piston assembly - direct clutch
76	7G448	Ring - direct clutch apply
77	7F235	Support and spring assembly - direct clutch
78	7C122	Ring - 77.0 mm (3.08 in) retaining style SU - external (retains direct clutch support and spring assembly to cylinder)
79	7B066	Plate - direct clutch - pressure
80	7F369	Washer - direct one-way clutch thrust No. 7
81	7D171	Race - direct one-way clutch - outer
82	7A089	Clutch assembly - direct one-way
83	7G156	Race and bushing assembly - direct one-way clutch - inner
84	7A360	Cylinder and valve assembly - forward clutch
85	7A548	Seal - forward clutch piston - inner
86	7A262	Piston assembly - forward clutch
87	7G299	Support and spring assembly - forward clutch
88	N803053-S	Ring - 85.0 mm (3.4 in) retaining type style SU - external (retains forward clutch support and spring assembly in cylinder)
89	7B164	Plate assembly - forward clutch - internal (friction)
90	7B442	Plate assembly - forward clutch - external (steel)
91	7B066	Plate - forward clutch - pressure
92	7A166	Washer - forward clutch thrust No. 6
93	7D171	Race - low one-way clutch - outer
94	7A089	Clutch assembly - low one-way
95	7L669	Drum assembly - overdrive
96	7F240	Bearing and race assembly - direct clutch hub No. 9
97	7G273	Washer - driven sprocket support thrust No. 8 (select fit)
98	7F196	Band assembly - overdrive
99	7D430	Retainer - overdrive band
100	7D019	Seals - forward clutch cylinder (5 required)
101	7D014	Washer - support thrust front No. 5 (select fit)
102	7G166	Support assembly - driven sprocket
103	7G247	Bearing assembly - driven sprocket
104	7G115	Washer - driven sprocket thrust No. 4
105	7G132	Sprocket and race assembly - driven
106	7H150	Wheel - driven sprocket speed sensor
107	7A108	Support assembly - stator (part of 7N825 support assembly)
108	7G233	Bearing assembly - drive sprocket
109	6749	Seal - turbine shaft O-ring
110	7G091	Seal - turbine shaft - rear
111	7F213	Shaft - turbine
112	7G099	Washers - drive sprocket thrust No. 1 and 2
113	7G129	Sprocket assembly - drive
114	N803178-S	Ring - 26.36 mm (1.05 in) retaining style SU - external (retains turbine shaft to drive sprocket)
115	7G090	Seal - turbine shaft - front
116	7G093	Seals - pump shaft - rear (2 required)
117	7B328	Shaft assembly - pump drive
118	7G092	Seals - front pump shaft (2 required)
119	7G089	Collars - fluid level thermostatic retaining (2 required)
120	7G191	Element - fluid level thermostatic
121	7G190	Plate - fluid level thermostatic valve
122	N804184-S	Pins - 4 mm (0.16 in) x 22 coiled (3 required) (retains fluid level thermostatic valve plate and fluid)
123	7G249	Chain assembly - drive
124	7G096	Washer - chain cover thrust No. 3
125	N605890-S1000	Bolt - M6-1.0 x 16.5 hex flange head (attaches detent spring assembly to chain cover)
126	7E332	Spring assembly - manual valve detent
127	7G276	Bulkhead assembly - wiring connector
128	7G303	Gasket - chain cover
129	7G188	Cover assembly - chain
130	7035	Vent assembly - case
131	7L282	Vent cap
132	7Z465	Retainer - clip transaxle cooler tube (2 required)
133	7D273	Connector assembly - cooler 3/8 (2 required)
134	390685-S100	Plugs - 1/8-27 mm hex head special pilot (2 required) (pressure tap plugs for chain cover)
135	N807737-S	Screws - M6-1.0 x 17 pan head pilot (attach separator plate to valve body)
136	7G308	Screen assembly - bypass clutch solenoid (2 required)
137	N807739-S	Pin - 6 mm x 20 spring coiled (part of 7A100)
138	7A100	Control assembly - main
139	7A136	Gasket - pump assembly to valve body
140	7A142	Plate - pump body separator
141	7G331	Gasket - pump body to separator plate
142	7A104	Body, bearing and seal assembly - pump
143	7Z144	Seal - 12.42 x 1.78 O-ring - outer (small)
144	7Z144	Seal - 25.12 x 1.78 O-ring - inner (large)
145	7G383	Solenoid assembly - electronic pressure control (EPC)
146	N803727-S	Bolt - M6-1.0 x 30 hex head (3 - attaches pump assembly to main control)
147	7Z484	Seal - 6.07 x 1.78 O-ring - outer (small) (1 on solenoid assembly (EPC) - 1 on solenoid assembly (TCC) - 3 on solenoid assembly - shift)
148	7Z484	Seals - 15.6 x 1.78 O-ring - inner (large) (1 on solenoid assembly (EPC) - 1 on solenoid assembly (TCC) - 3 on solenoid assembly - shift)
149	7G136	Solenoid assembly - torque converter clutch (TCC)
150	N605772-S	Bolt - M6-1.0 x 16 large hex flange head (attach torque converter solenoid and pressure control solenoid to pump body)
151	7G285	Spring - pump bore ring
152	N803499-S	Pin - 8 mm x 37.7 straight hardened
153	7G287	Rings - pump vane support (2 required)
154	7A146	Rotor - pump
155	7R194	Ring - pump body
156	7G282	Support - pump bore ring side gear
157	7G281	Seal - pump bore ring side
158	7G187	Cover and sleeve assembly - pump
159	N807073-S1100	Bolt - M6-1.0 x 88.5 hex flange head pilot (4 - attach pump cover/pump body/valve body to chain cover)
160	N605892-S21	Bolt - M6-1.0 x 22.5 hex head (2 - attach pump cover to pump body)
161	7G286	Vane - pump (7 required)
162	7G283	Seal - pump bore ring radial
163	7G284	Support - pump bore ring radial seal
164	7H141	Sensor assembly - transmission fluid temperature (TFT)
165	7F396	Gasket - main control cover
166	N811076-S1036	Bolt - M6-1.0 x 16.5 hex flange pilot (19 - attach bottom pan to case)
167	N605893-S309	Bolt - M6-1.0 x 27.5 hex flange pilot (4 - attach main control cover to chain cover)
168	N605908-S101	Bolt - M8-1.25 x 38 hex flange pilot (11- attach main control cover to chain cover)
169	7G004	Cover - main control
170	7G484	Solenoid valve - shift (3 required)
171	N606026-S1000	Bolt - M6-1.0 x 60 hex flange head (15 - attach pump body and main control to chain cover)
172	N606022-S1000	Bolt - M6-1.0 x 40 hex flange head (4 - attach valve body to chain cover)
173	7Z490	Plate assembly - control valve body separator (bonded)
174	7A100	Pump and control assembly
175	N807738-S	Pin - 5 mm (0.2 in) x 14 spring coiled
176	N805551-S101	Stud - M8 x 1.25-1.25 x 81.8 hex head shoulder (attach chain cover assembly to case assembly)
177	N606024-S36	Bolt - M6-1.0 x 50 hex flange head (attach chain cover to case)
178	N605771-S36	Bolt - M6-1.0 x 14 hex flange head (attach turbine shaft speed sensor to chain cover assembly)
179	N803807-S1000	Bolt - M10-1.50 x 43 hex (attach chain cover to driven sprocket and support assembly)
180	N606042-S2	Bolt - M8-1.25 x 45 hex flange head (2 - attach chain cover to driven sprocket support assembly)
181	N811757-S100	Seal - 15.0 x 1.5 O-ring
182	7M101	Sensor - turbine shaft speed (TSS)
183	N605789-S1036	Bolt - M8-1.25 x 35 hex flange head (15 - attach chain cover to case)
184	7A020	Indicator assembly - fluid level
185	N605892-S1036	Bolts - M6-1.0 x 22.5 hex flange head (1 - attach filler tube to case; 3- attach O.D. servo cover to case)
186	7A228	Tube assembly - filler
187	7N243	Grommet - filler tube
188	7D027	Cover - overdrive servo piston
189	7D024	Seal - overdrive servo cover
190	7H188	Piston assembly - overdrive servo
191	7F201	Spring - overdrive servo piston return
192	373907-S2	Nut - 1/4 spring (attach I.D. tag to case)
193	7B148	Tag - service identification
194	N605789-S101	Bolt - M8-1.25 x 35 hex flange head (2 - attach case to chain cover)
195	N808161-S36	Screw - M6-1.0 x 28 pan head (5 required) (5 - attach case to chain cover)
196	N802996-S1000	Screw - M6-1.0 x 20 pan head (6 - attach stator support to converter housing)
197	N605775-S103	Bolt - M6-1.0 x 30 hex flange head (2 - attach transmission range sensor to case)
198	7F293	Sensor assembly - transmission range (TR)
199	7C493	Shaft - manual control lever
200	7H103	Sensor assembly - transmission output shaft sensor (OSS)
201	N605890-S36	Bolts - M6-1.0 x 16.5 hex flange head (attach the OSS sensor)
202	7A434	Heat shield - OSS
203	7F337	Seal assembly - manual control shaft
204	N802998-S	Pins - 12.76 mm (0.51 in) x 25 dowel harden (2 required)
205	7N049	Rod - manual control valve actuating
206	7G100	Pins - shaft retainer (1 used as park pawl shaft retainer, 3 used as manual control shaft pin)
207	7A115	Lever assembly - manual valve detent (inner)
208	7F251	Pistons - 1-2, 2-3 shift accumulator
209	7G095	Seals - 1-2, 2-3 and N-D shift accumulator piston
210	7G267	Spring - 1-2 shift accumulator
211	7F284	Springs - accumulator 1-2 and 2-3 assist
212	7G094	Shaft - shift accumulator piston (4 required)
213	7G267	Spring - 2-3 shift accumulator
214	7F246	Pistons - 3-4 and reverse shift accumulator (2 required)
215	7F248	Seals - 3-4 and reverse shift accumulator piston (2 required)
216	7G266	Spring - reverse shift accumulator
217	7G266	Spring - 3-4 shift accumulator
218	7H276	Shaft - drive shift accumulator
219	7G274	Piston - drive shift accumulator
220	7G300	Spring - drive shift accumulator (outer)
221	7G301	Spring - drive shift accumulator (inner)
222	7H277	Seal - drive shift accumulator cover
223	7H275	Cover - drive shift accumulator
224	N807757	Bolt - M6-1.0 x 60 hex flange head (attaches drive shift accumulator cover to case)
225	N804647-S	Screw - M12 x 1.75 x 45 set hex socket (reverse clutch assembly locator bolt)
226	N620015-S	Nut - M12 x 1.75 hex (reverse clutch assembly locator nut)
227	7A256	Lever assembly - manual control
228	7H291	Spring - coast servo return
229	7H281	Piston and rod assembly - coast servo
230	7H284	Cover and seal assembly - coast servo
231	7H285	Ring - coast servo cover retainer
232	7A232	Rod assembly - parking pawl actuator
233	7G101	Abutment - parking pawl actuator
234	N605787-S1000	Bolt - M8 x 1.25 x 25 hex flange head (2 - attach abutment to case)
235	7D070	Spring - parking pawl return
236	7D071	Shaft - parking pawl
237	7A441	Pawl - parking brake
238	N802947-S	Plug - 13.9 mm (0.55 in) cup
239	7G199	Tube - reverse fluid supply transfer
240	7G087	Tube - servo apply fluid transfer
241	7G463	Tube - low/intermediate clutch apply fluid transfer
242	7G084	Tube - rear lube fluid transfer
243	N808020-S100	Seal - O-ring (used on rear lube fluid tube)
244	N808021-S100	Seal - O-ring (used on reverse fluid supply tube)
245	N808022-S100	Seals - O-ring (used on servo apply tube - reverse supply tube and low/intermediate clutch apply tube)
246	N808023-S100	Seal - O-ring (used on servo apply tube)
247	7G353	Bracket assembly - tube support main
248	7G353	Bracket assembly - tube support (reverse clutch and servo apply)
249	7G353	Bracket assembly - tube support (rear lube and low/intermediate clutch)
250	7Z302	Seal - fluid filter
251	7A098	Filter and seal assembly - fluid
252	7L027	Magnet - ceramic case
253	7A191	Gasket - transaxle pan
254	7A194	Pan - transaxle
255	-	Low/intermediate one-way clutch
256	-	Low/intermediate clutch
257	-	Reverse clutch
258	-	Intermediate clutch
259	-	Direct clutch
260	-	Forward clutch
261	-	Direct one-way clutch

Install the parking pawl assembly.
1. Install the parking pawl and return spring.
2. Install the parking pawl shaft.

Fig 5: Identifying Parking Pawl, Return Spring And Parking Pawl Shaft

Courtesy of FORD MOTOR CO.

Install the park pawl roll pin.

Fig 6: Installing Park Pawl Roll Pin

Courtesy of FORD MOTOR CO.

Using the special tool, install the cup plug.

Fig 7: Installing Cup Plug

Courtesy of FORD MOTOR CO.

NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.

Install the stator support.

Fig 8: Stator Support

Courtesy of FORD MOTOR CO.

Install the stator support bolts.
- Tighten to 13 Nm (10 lb-ft).

Fig 9: Stator Support Bolts

Courtesy of FORD MOTOR CO.

Using the special tool, install the converter impeller hub seal.

Fig 10: Installing Converter Impeller Hub Seal

Courtesy of FORD MOTOR CO.

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 11: Identifying Differential Carrier Thrust Bearing & Race

Courtesy of FORD MOTOR CO.

Install the final drive ring gear.

Fig 12: Locating Final Drive Ring Gear

Courtesy of FORD MOTOR CO.

Install the rear planet support spacer.

Fig 13: Rear Planet Support Spacer

Courtesy of FORD MOTOR CO.

Install the final drive differential assembly.

Fig 14: Identifying Final Drive Differential And Rear Planet Support Assembly

Courtesy of FORD MOTOR CO.

Align the rear lube tube holes in the case window.

Fig 15: Aligning Rear Lube Tube Holes In Case Window

Courtesy of FORD MOTOR CO.

NOTE: The retaining ring must be correctly installed.

Using the special tool, install the beveled retaining ring.

Fig 16: Using Special Tool (307--343) To Install Beveled Retaining Ring

Courtesy of FORD MOTOR CO.

Fig 17: Identifying Proper Bevel Installation

Courtesy of FORD MOTOR CO.

CAUTION: If the support is not visible on the inside diameter of the retaining ring, the low/intermediate piston could be damaged.

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.

Fig 18: Final Drive Support

Courtesy of FORD MOTOR CO.

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 19: Prying To Ensure Ring Is Seated

Courtesy of FORD MOTOR CO.

Install the special tools.

Fig 20: Identifying Special Tool (307-187) And (205-D014)

Courtesy of FORD MOTOR CO.

Remove the No. 15 needle bearing.

Fig 21: No. 15 Needle Bearing

Courtesy of FORD MOTOR CO.

NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.

Install the special tools.

Fig 22: Identifying Special Tool (307-300) And (307-321)

Courtesy of FORD MOTOR CO.

Install the special tool and zero the dial indicator.

Fig 23: Identifying Special Tool (307-300), (100-002) And (307-321)

Courtesy of FORD MOTOR CO.

Tighten the special tool bolt.
- Tighten to 1.13-1.7 Nm (10-15 lb-in).

Fig 24: Tightening Special Tool (307-187)

Courtesy of FORD MOTOR CO.

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 25: Identifying Special Tool (307-300), (100-002) And (307-321)

Courtesy of FORD MOTOR CO.

Select the correct beveled retaining ring.

Item	Part Number	Thickness	Style
1	F5DZ-TD483-E	1.48-1.63 mm (0.058-0.064 in)	Style 5
2	F5DZ-TD483-D	1.54-1.68 mm (0.061-0.067 in)	Style 4
3	F5DZ-TD483-C	1.60-1.75 mm (0.063-0.069 in)	Style 3
4	F5DZ-TD483-B	1.66-1.81 mm (0.065-0.071 in)	Style 2
5	F5DZ-TD483-A	1.72-1.87 mm (0.068-0.074 in)	Style 1

Fig 26: Identifying Beveled Retaining Ring Styles

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.

Install the No. 15 thrust bearing.

Fig 27: No. 15 Needle Bearing

Courtesy of FORD MOTOR CO.

Check the clearance for the No. 16 thrust washer. Mount the special tool with the stylus on the end of the output shaft. Zero the dial indicator.

Fig 28: Identifying Clearance For Thrust Washer Using Special Tool (100--102)

Courtesy of FORD MOTOR CO.

Tighten the special tool bolt. Read and record the dial indicator reading.
- Tighten to 1.13-1.7 Nm (10-15 lb-in).

Fig 29: Tightening Special Tool (307-187)

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.

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)

Fig 30: Checking No. 16 Thrust Washer Clearance (With Specifications)

Courtesy of FORD MOTOR CO.

Install the low-intermediate one-way clutch assembly.

Fig 31: Low/Intermediate One-Way Clutch Assembly

Courtesy of FORD MOTOR CO.

NOTE: The friction plate internal splines will center the one-way clutch.

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 32: Identifying Low/Intermediate Clutch Pressure Plate Components

Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the retaining ring is seated in the case groove.

Install the low-intermediate clutch retaining ring.

Fig 33: Low/Intermediate Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

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).

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.

Fig 34: Applying Air Pressure To Low/Intermediate Apply Port

Courtesy of FORD MOTOR CO.

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

Thickness
1.54-1.64 mm (0.061-0.065 in)
2.08-2.18 mm (0.082-0.086 in)
2.62-2.72 mm (0.103-0.107 in)
3.16-3.26 mm (0.125-0.128 in)
3.68-3.78 mm (0.145-0.149 in)

Fig 35: Checking Clutch Pressure Plate To Low/Intermediate Clutch Retainer Clearance (With Specifications)

Courtesy of FORD MOTOR CO.

Install the coast band.
1. Install the coast band.
2. Align the anchor pin pocket with the anchor pin in the case.

Fig 36: Identifying Coast Band

Courtesy of FORD MOTOR CO.

Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.

Fig 37: Installing Low-Intermediate Drum

Courtesy of FORD MOTOR CO.

Install the park rod abutment and make sure that the park pawl moves freely.
- Tighten to 28 Nm (21 lb-ft).

Fig 38: Locating Park Pawl Abutment Bolts

Courtesy of FORD MOTOR CO.

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 39: Identifying Coast Band Piston Cover

Courtesy of FORD MOTOR CO.

Using the special tool, install the coast servo cover retaining ring.

Fig 40: Installing Coast Servo Cover Retaining Ring Using Special Tool (307-251)

Courtesy of FORD MOTOR CO.

Using the special tools, install the front planetary/reverse clutch assembly.

Fig 41: Installing Front Planetary/Reverse Clutch Assembly Using Special Tool (307-025), (307-314) And (308-049)

Courtesy of FORD MOTOR CO.

Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.

Fig 42: Aligning Reverse Clutch Cylinder Apply Tube Hole With Case Hole

Courtesy of FORD MOTOR CO.

Loosely install the reverse clutch anchor pin.

Fig 43: Reverse Clutch Anchor Pin

Courtesy of FORD MOTOR CO.

Using the special tool, install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.

Fig 44: Installing Forward/Intermediate Clutch Assembly Using Special Tool (307-316) And (307-171)

Courtesy of FORD MOTOR CO.

Install the overdrive band.

Fig 45: Overdrive Band

Courtesy of FORD MOTOR CO.

NOTE: The foot of the overdrive retainer fits against the band.

Install the overdrive band anchor strut with the cross hairs facing upward.

Fig 46: Overdrive Band Anchor Strut

Courtesy of FORD MOTOR CO.

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 47: No. 9 Bearing & Race, & No. 8 Sprocket Support

Courtesy of FORD MOTOR CO.

Install only the No. 9 needle bearing with the outer lip upward.

Fig 48: No. 9 Needle Bearing

Courtesy of FORD MOTOR CO.

Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.

Fig 49: Installing Special Tool (307--320) Over Output Shaft

Courtesy of FORD MOTOR CO.

Install the special tool to make the measurements.

Fig 50: Identifying Special Tools (303--D075), (307--300), And (307--320)

Courtesy of FORD MOTOR CO.

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 51: Taking Measurements Using Special Tool (307-300), (303-D075) And (307-320)

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.

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 in)	1.43-1.53 mm (0.056-0.060 in)	1.48 mm (0.058 in)	Natural (No. 1)
43.11-43.34 mm (1.697-1.706 in)	1.68-1.78 mm (0.066-0.070 in)	1.73 mm (0.068 in)	Dark Green (No. 2)
43.35-43.59 mm (1.707-1.716 in)	1.92-2.02 mm (0.075-0.080 in)	1.97 mm (0.077 in)	Light Blue (No. 3)
43.60-43.77 mm (1.717-1.723 in)	2.17-2.27 mm (0.085-0.089 in)	2.22 mm (0.087 in)	Red (No. 4)
43.78-43.98 mm (1.724-1.731 in)	2.35-2.45 mm (0.093-0.096 in)	2.40 mm (0.094 in)	Black (No. 5)

Remove the special tools.

Fig 52: Identifying Special Tools (303--D075), (307--300), And (307--320)

Courtesy of FORD MOTOR CO.

Install the special tools to take the measurements.

Fig 53: Identifying Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

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 54: Taking Measurements Using Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

Remove the special tools.

Fig 55: Identifying Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.

Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D.


Reading B:
- Reading A:
Difference:
+Dimension C:
Reading D:

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 in)	2.18-2.28 mm (0.086-0.090 in)	Green (No. 1)
26.38-26.61 mm (1.039-1.047 in)	2.43-2.53 mm (0.096-0.100 in)	Black (No. 2)
26.62-26.86 mm (1.048-1.057 in)	2.67-2.77 mm (0.105-0.109 in)	Natural (No. 3)
26.87-27.15 mm (1.058-1.068 in)	2.92-3.02 mm (0.115-0.119 in)	Red (No. 4)
27.16-27.50 mm (1.069-1.083 in)	3.26-3.36 mm (0.128-0.132 in)	Blue (No. 5)

NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.

Install the No. 5 front support thrust washer.

Fig 56: No. 5 Front Support Thrust Washer

Courtesy of FORD MOTOR CO.

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.

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 57: No. 8 Driven Sprocket Support Thrust Washer & No. 9 Direct Clutch Needle Bearing

Courtesy of FORD MOTOR CO.

Install the driven sprocket support assembly.

Fig 58: Driven Sprocket Support Assembly

Courtesy of FORD MOTOR CO.

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 59: Identifying Neutral/Drive Accumulator Spring

Courtesy of FORD MOTOR CO.

Install the neutral/drive accumulator bolt.
- Tighten to 11 Nm (8 lb-ft).

Fig 60: Neutral/Drive Accumulator Bolt

Courtesy of FORD MOTOR CO.

NOTE: All the fluid supply tubes must have new O-rings installed.

Install the fluid supply tubes.

Fig 61: Fluid Supply Tubes

Courtesy of FORD MOTOR CO.

Install the fluid lube tube brackets and bolts.
- Tighten to 11 Nm (8 lb-ft).

Fig 62: Fluid Transfer Tube Brackets

Courtesy of FORD MOTOR CO.

Using the special tool, install the manual control lever shaft seal.

Fig 63: Installing Manual Control Lever Shaft Seal Using Special Tool (211-161)

Courtesy of FORD MOTOR CO.

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 64: 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.

Install the manual control lever shaft.

Fig 65: Locating Manual Control Lever Shaft

Courtesy of FORD MOTOR CO.

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.

Install the roll pins.

Fig 66: Locating Roll Pins

Courtesy of FORD MOTOR CO.

NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.

Install the thrust washers.
1. Install the No. 2 drive sprocket thrust washer.
2. Install the No. 4 driven sprocket thrust washer.

Fig 67: Identifying No. 2 Thrust Washer & No. 4 Thrust Washer

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.

Install the drive chain and sprockets.

Fig 68: Drive Chain & Sprockets Assembly

Courtesy of FORD MOTOR CO.

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 69: Identifying Shift Accumulator Springs

Courtesy of FORD MOTOR CO.

NOTE: Make sure that the alignment pins are installed in the case.

Install the new chain cover gasket.

Fig 70: Locating Chain Cover Gasket

Courtesy of FORD MOTOR CO.

CAUTION: Be extremely careful not to damage the cast iron sealing ring.

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 71: Thrust Washers & 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.

Start the 2 chain cover bolts.

Fig 72: 2 Cover Bolts

Courtesy of FORD MOTOR CO.

Install the remaining bolts.
1. Tighten to 30 Nm (22 lb-ft).
2. Tighten to 13 Nm (10 lb-ft).
3. Tighten to 28 Nm (21 lb-ft).
4. Tighten to 41 Nm (30 lb-ft).

Fig 73: Locating Bolts

Courtesy of FORD MOTOR CO.

Install the bolts.
1. Tighten to 13 Nm (10 lb-ft).
2. Tighten to 30 Nm (22 lb-ft).

Fig 74: 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.

Inspect the spring height.
1. Test spring.
2. Original spring.

Fig 75: Identifying Test Spring & Original Spring

Courtesy of FORD MOTOR CO.

Check overdrive servo travel. Install the overdrive servo piston.
1. Install the test spring.
2. Install the overdrive servo piston.

Fig 76: Test Spring & Overdrive Servo Piston

Courtesy of FORD MOTOR CO.

Install the special tools.
- Tighten to 10 Nm (89 lb-in).

Fig 77: Identifying Special Tool (307-162) And (100-002)

Courtesy of FORD MOTOR CO.

Using the special tools, tighten the center screw and zero out the dial indicator.
- Tighten to 1.13 Nm (10 lb-in).

Fig 78: Identifying Special Tool (307-162) And (100-002)

Courtesy of FORD MOTOR CO.

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 79: Checking Piston Movement (With Specifications)

Courtesy of FORD MOTOR CO.

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^a
mm	Inch	No. of Grooves^a
99.33	3.91	0
98.05	3.86	1
96.78	3.81	2

^a Grooves are at the tip.

CAUTION: Do not assemble the transaxle using the test spring.

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 80: Identifying Overdrive Servo Cover & Bolts

Courtesy of FORD MOTOR CO.

Install the special tools.

Fig 81: Identifying Special Tool (307-313), (307-312) And (307-126)

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.

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	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

Fig 82: Identifying Air Pressure To Appropriate Clutch Ports

Courtesy of FORD MOTOR CO.

CAUTION: The seals must be lapped correctly or internal leakage will occur.

Install the new Teflon® seals on the pump shaft.

Fig 83: Properly Aligned Seal Ends

Courtesy of FORD MOTOR CO.

Install the pump shaft.

Fig 84: Installing Pump Shaft

Courtesy of FORD MOTOR CO.

Install the manual valve detent lever.

Fig 85: Manual Valve Detent Lever

Courtesy of FORD MOTOR CO.

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 86: Main Pump Assembly & Main Control Valve Body

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.

Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolts and tighten in sequence shown.
- Tighten to 13 Nm (10 lb-ft).

Fig 87: Identifying Tightening Sequence Of Pump Cover Bolt

Courtesy of FORD MOTOR CO.

Connect the connectors.

Fig 88: Electrical Connectors

Courtesy of FORD MOTOR CO.

NOTE: The transaxle side cover gasket is reusable if not torn or ripped.

Remove the gasket. Clean and inspect the gasket, and reinstall into the pan.

Fig 89: Locating Transaxle Side Cover Gasket

Courtesy of FORD MOTOR CO.

Loosely install the 15 transaxle side pan bolts.

Fig 90: Locating Remaining Bolts & Main Control Cover

Courtesy of FORD MOTOR CO.

Tighten the 4 transaxle side pan bolts.
- Tighten to 12 Nm (9 lb-ft).

Fig 91: Locating Transaxle Side Pan Bolts

Courtesy of FORD MOTOR CO.

Tighten the 11 transaxle side pan bolts.
- Tighten to 29 Nm (21 lb-ft).

Fig 92: Locating Transaxle Side Pan Bolts

Courtesy of FORD MOTOR CO.

Install the mount bracket and bolts.
- Tighten to 62 Nm (46 lb-ft).

Fig 93: Locating Rear Engine Support Mount Bracket Bolts

Courtesy of FORD MOTOR CO.

Tighten the reverse clutch anchor bolt.
1. Tighten the anchor bolt to 11 Nm (8 lb-ft).
2. Tighten the locknut to 54 Nm (40 lb-ft).

Fig 94: Identifying Reverse Clutch Anchor Bolt

Courtesy of FORD MOTOR CO.

Install the new seal and gasket kit and seal assembly.

Fig 95: Transmission Filter

Courtesy of FORD MOTOR CO.

Install the fluid pan magnet.

Fig 96: Locating Fluid Pan Magnet

Courtesy of FORD MOTOR CO.

NOTE: The gasket is reusable if not damaged or torn.

Install the transmission fluid pan, gasket and bolts.
- Tighten to 12 Nm (9 lb-ft).

Fig 97: Locating Transmission Fluid Pan And Gasket

Courtesy of FORD MOTOR CO.

Install the turbine shaft speed (TSS) sensor.
- Tighten to 11 Nm (8 lb-ft).

Fig 98: Identifying Turbine Shaft Speed (TSS) Sensor & Bolt

Courtesy of FORD MOTOR CO.

NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.

Verify that the shift selector lever is in NEUTRAL.
Install the digital TR sensor and loosely install the bolts.

Fig 99: Digital TR Sensor & Bolts

Courtesy of FORD MOTOR CO.

Using the special tool, align the digital TR sensor.
- Tighten to 11 Nm (8 lb-ft).

Fig 100: Aligning TR Sensor Using Special Tool (307-351)

Courtesy of FORD MOTOR CO.

Install the fluid filler tube with a new grommet.
1. Install the filler tube grommet.
2. Install the fluid filler tube and bolt.
3. Tighten to 13 Nm (10 lb-ft).

Fig 101: Installing Fluid Filler Tube

Courtesy of FORD MOTOR CO.

Using the special tool, install the LH output shaft seal.

Fig 102: Installing LH Output Shaft Seal Using Special Tool (303-157)

Courtesy of FORD MOTOR CO.

Using the special tool, install the RH output shaft seal.

Fig 103: Installing RH Output Shaft Seal Using Special Tool (307-157) And (307-317)

Courtesy of FORD MOTOR CO.

Install the output shaft speed (OSS) sensor and reconnect the harness.

Fig 104: Locating Output Shaft Speed (OSS) Sensor

Courtesy of FORD MOTOR CO.

Install the OSS sensor cover.
1. Install the OSS sensor cover.
2. Install the OSS sensor cover bolt.
  - Tighten to 11 Nm (8 lb-ft).
3. Connect the OSS sensor electrical connector to the bracket.

Fig 105: Identifying OSS Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Install the identification tag, if removed.

Fig 106: Identification Tag

Courtesy of FORD MOTOR CO.

NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.

Using the special tools, install the torque converter.

Fig 107: Identifying Special Tool (307-091)

Courtesy of FORD MOTOR CO.