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Disassembled Views

Fig 1: Exploded View Of Transaxle (1 Of 3)
G06278960Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transaxle (2 Of 3)
G06278961Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle (3 Of 3)
G06278962Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION

Item Part Number Description
1 7005 Transaxle case
2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal
15 7C099 Direct (3, 5, R) clutch piston inner (front) seal
16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/Overdrive (O/D) (4, 5, 6) clutch cylinder and hub assembly
19 7A548 O/D  (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
21 7D234 No. 2 thrust bearing
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 O/D  (4, 5, 6) clutch piston outer (rear) seal
28 7A548 O/D  (4, 5, 6) clutch piston outer (front) seal
29 7A262 O/D  (4, 5, 6) clutch piston
30 7F222 O/D  (4, 5, 6) clutch piston return spring
31 7H360 O/D  (4, 5, 6) clutch balance piston
32 7C122 O/D  (4, 5, 6) clutch piston snap ring
33 7B164 O/D  (4, 5, 6) clutch friction plates (5 required)
34 7B442 O/D  (4, 5, 6) clutch steel plates (5 required)
35 7B066 O/D  (4, 5, 6) clutch pressure plate
36 7D483 O/D  (4, 5, 6) clutch snap ring
37 7H351 O/D  (4, 5, 6) clutch hub
38 7D234 No. 3 thrust bearing
39 7A019 Rear planetary sun gear and shell assembly
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2 required)
42 7B442 Intermediate (2, 6) clutch steel plates (2 required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
45 7C096 No. 6 thrust bearing
46 7G177 No. 5 thrust bearing
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7B070 Low/reverse clutch piston return spring
53 7D402 Low/reverse clutch piston
54 7L328 Center support
55 7A262 Forward (1, 2, 3, 4) clutch piston
56 7B070 Forward (1, 2, 3, 4) clutch piston return spring
57 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
58 7D491 Center planetary carrier/front ring gear
59 7D063 Center planetary sun gear
60 7C096 No. 7 thrust bearing
61 7C096 No. 8 thrust bearing
62 7D491 Front planetary carrier/rear ring gear
63 7A019 Front planetary sun gear and shell assembly
64 7D234 No. 10 thrust bearing
65 7B070 Forward (1, 2, 3, 4) clutch wave spring
66 7B164 Forward (1, 2, 3, 4) clutch friction plates (2 required)
67 7B442 Forward (1, 2, 3, 4) clutch steel plates (2 required)
68 7B066 Forward (1, 2, 3, 4) clutch pressure plate
69 7D483 Forward (1, 2, 3, 4) clutch snap ring
70 7978 Transmission fluid baffle
71 W500214 Transmission fluid baffle bolt (2 required)
72 7060 Park gear
73 7G132 Drive chain drive sprocket
74 7C122 Drive sprocket snap ring
75 7G099 No. 13 thrust washer
76 7G249 Drive chain
77 7D234 No. 11 thrust washer
78 7048 Input shaft seal
79 7A098 Transmission fluid filter
80 W302860 Pump-to-torque converter housing bolt (8 required)
81 7A103 Pump assembly
82 7A248 Pump assembly-to-torque converter housing O-ring seal
83 7A248 Torque converter hub seal
84 7F343 Different ring gear
85 7C122 Differential ring gear snap ring
86 7H245 Differential transmission fluid baffle
87 W500214 Differential transmission fluid baffle bolt (2 required)
88 7975 Torque converter housing
89 W701606 Torque converter housing stud bolt
90 7A443 Torque converter housing bolt (16 required)
91 7902 Torque converter
92 1177 RH halfshaft seal
93 391308-S Transaxle filler tube O-ring
94 7A228 Transaxle filler tube
95 W520101 Transaxle filler tube nut
96 7A020 Transmission fluid level indicator
97 7G355 No. 12 thrust bearing
98 7G132 Drive chain driven sprocket
99 7F342 Differential sun gear
100 7F465 Differential assembly
101 7G112 No. 15 thrust bearing
102 7B362 Torque converter housing-to-transaxle case guide pins
103 7D070 Park pawl spring
104 7A441 Park pawl
105 7D071 Park pawl pin
106 7F337 Manual control shaft seal
107 7A232 Park pawl actuator rod
108 7H155 Transmission Range (TR) sensor
109 7C493 Manual control shaft
110 7G100 Manual control shaft pin
111 7A256 Manual control lever
112 W708455 Manual control lever nut
113 7E332 Manual valve detent spring
114 W711235 Manual valve detent spring bolt
115 7J387 Lubrication funnel
116 7A248 Torque converter housing-to-transaxle case seal (large)
117 7A248 Torque converter housing-to-transaxle case seal (small) (4 required)
118 7B431 Main control alignment pin
119 7C207 Main control stud
120 7G199 Main control-to-center support seal (2 required)
121 7H322 Thermal bypass valve and sleeve
122 - Thermal bypass valve spring (part of 7H322)
123 W713644 Output Shaft Speed (OSS) sensor bolt
124 7H103 OSS  sensor
125 7Z490 Main control-to-transaxle case separator plate
126 7A100 Main control valve body
127 N605770 Separator plate-to-soledoid body bolt (2 required)
128 7Z490 Main control valve body-to-solenoid body
129 7G391 Solenoid body
130 W500303 Solenoid body-to-valve body bolt (2 required)
131 W302863 Main control-to-transaxle case bolt (long) (10 required)
132 W302862 Main control-to-transaxle case bolt (short) (12 required)
133 W520412 Main control nut
134 7G276 Main control leadframe
135 W505513 Main control leadframe screw (5 required)
136 7B329 Main control-to-cover seal
137 7G004 Main control cover
138 W714629 Main control cover stud bolt (5 required)
139 W500214 Main control cover bolt (8 required)
140 7010 Drain plug
141 7H398 Line pressure tap
142 7D273 Transmission fluid cooler tube fittings (2 required)
143 1177 LH halfshaft seal
144 7M101 Turbine Shaft Speed (TSS) sensor
145 W500214 TSS  bolt
146 7A246 Vent tube
147 7L027 Magnet
148 7A033 Lubrication funnel bracket
149 7G342 Solenoid body strategy tag
150 7B148 Transaxle service identification tag
151 - Direct clutch (3, 5, R)
152 - Intermediate clutch (2, 6)
153 - O/D  clutch (4, 5, 6)
154 - Forward clutch (1, 2, 3, 4)
155 - Low/reverse clutch

All vehicles 

  1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.
    Fig 4: Locating Transaxle Case-To-Torque Converter Housing Sealing Surface And Main Control Cover Sealing Surface
    G06278963Courtesy of FORD MOTOR CO.
  2. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH seal on the Differential Seal Installer 307-626.
    Fig 5: Identifying Handle 205-153 And Seal Installer 307-626
    G06278964Courtesy of FORD MOTOR CO.
  3. Using the Differential Seal Installer 307-626 and Handle 205-153, install the halfshaft seal in the transaxle case.
    Fig 6: Identifying Seal Installer 307-626 And Handle 205-153
    G06278965Courtesy of FORD MOTOR CO.
  4. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.
    Fig 7: Locating Manual Control Shaft Seal On Manual Lever Seal Installer 307-581
    G06278966Courtesy of FORD MOTOR CO.
  5. Using the Manual Lever Seal Installer 307-581, install the manual control shaft seal in the transaxle case.
    Fig 8: Identifying Manual Lever Seal Installer 307-581
    G06278967Courtesy of FORD MOTOR CO.
  6. If not previously installed, install the clutch support tower and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 9: Locating Clutch Support Tower
    G06278968Courtesy of FORD MOTOR CO.
  7. Remove Input Shaft Support Seal Installer 307-578/1.
    Fig 10: Identifying Input Shaft Support Seal Installer 307-578/1
    G06278969Courtesy of FORD MOTOR CO.
  8. Install 2-6 Piston Seal Protector 307-632.
    Fig 11: Identifying 2-6 Piston Seal Protector 307-632
    G06278970Courtesy of FORD MOTOR CO.
  9. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.
    Fig 12: Locating Seals On Intermediate (2, 6) Clutch Piston
    G06278971Courtesy of FORD MOTOR CO.
  10. NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.

    Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.

    Fig 13: Locating Intermediate (2, 6) Clutch Piston On Seal Protector
    G06278972Courtesy of FORD MOTOR CO.
  11. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Open area at the bottom of the transaxle case
    3. Bleed hole
    4. Inner double tabs
    Fig 14: Identifying Intermediate (2, 6) Clutch Piston Return Spring On Piston
    G06278973Courtesy of FORD MOTOR CO.
  12. Remove the intermediate (2, 6) clutch piston return spring.
    Fig 15: Locating Intermediate (2, 6) Clutch Piston Return Spring
    G06278974Courtesy of FORD MOTOR CO.
  13. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.
    Fig 16: Identifying Forward/Intermediate Spring Compressor 307-584/1
    G06278975Courtesy of FORD MOTOR CO.
  14. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
    Fig 17: Pushing Intermediate (2, 6) Clutch Piston Into Clutch Cylinder
    G06278976Courtesy of FORD MOTOR CO.
  15. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector 307-632.
    Fig 18: Identifying Forward/Intermediate Spring Compressor 307-584/1 And Clutch Piston Seal Protector 307-632
    G06278977Courtesy of FORD MOTOR CO.
  16. NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.

    Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.

    1. Outer tabs
    2. Bleed hole
    3. Inner double tabs
    Fig 19: Identifying Intermediate (2, 6) Clutch Piston Return Spring
    G06278978Courtesy of FORD MOTOR CO.
  17. NOTE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.

    Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.

    1. Snap ring
    2. Snap ring gap
    3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)
    Fig 20: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Hydraulic Ports
    G06278979Courtesy of FORD MOTOR CO.
  18. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the intermediate (2, 6) clutch return spring.
    Fig 21: Identifying 2-6 Piston Return Spring Compressor 307-633/2
    G06278980Courtesy of FORD MOTOR CO.
  19. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.
    Fig 22: Identifying 2-6 Piston Return Spring Compressor 307-633/2
    G06278981Courtesy of FORD MOTOR CO.
  20. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.
    Fig 23: Identifying Forward Clutch Spring Compressor 307-574/1 On Transaxle Case
    G06278982Courtesy of FORD MOTOR CO.
  21. NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.

    Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.

    Fig 24: Identifying Forward Clutch Spring Compressor 307-574/1 And Snap Ring Installer 307-633
    G06278983Courtesy of FORD MOTOR CO.
  22. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633.
    Fig 25: Identifying Forward Clutch Spring Compressor 307-574/1 And Snap Ring Installer 307-633
    G06278984Courtesy of FORD MOTOR CO.
  23. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.
    Fig 26: Locating Intermediate (2, 6) Clutch Apply Ring
    G06278985Courtesy of FORD MOTOR CO.
  24. NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.

    Install the No. 1 thrust bearing with the flat side facing up.

    Fig 27: Locating No. 1 Thrust Bearing
    G06278986Courtesy of FORD MOTOR CO.
  25. Install the overdrive/direct clutch assembly.
    Fig 28: Locating Overdrive/Direct Clutch Assembly
    G06278987Courtesy of FORD MOTOR CO.
  26. NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.

    Install the No. 3 thrust bearing with the flat side facing down.

    Fig 29: Locating No. 3 Thrust Bearing
    G06278988Courtesy of FORD MOTOR CO.
  27. Install the direct/intermediate clutch hub and rear sun gear assembly.
    Fig 30: Locating Direct/Intermediate Clutch Hub And Rear Sun Gear Assembly
    G06278989Courtesy of FORD MOTOR CO.
  28. Install the intermediate (2, 6) wave spring assembly.
    Fig 31: Locating Intermediate (2, 6) Wave Spring Assembly
    G06278990Courtesy of FORD MOTOR CO.
  29. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.
    Fig 32: Identifying Intermediate (2, 6) Clutch Assembly
    G06278991Courtesy of FORD MOTOR CO.
  30. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    Fig 33: Locating Intermediate (2, 6) Clutch Assembly
    G06278992Courtesy of FORD MOTOR CO.
  31. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 34: Identifying Shim Selection Gauge 307-300
    G06278993Courtesy of FORD MOTOR CO.
  32. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
    Fig 35: Measuring Measurement A Using Shim Selection Gauge 307-300
    G06278994Courtesy of FORD MOTOR CO.
  33. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
    Fig 36: Measuring Measurement B Using Shim Selection Gauge 307-300
    G06278995Courtesy of FORD MOTOR CO.
  34. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
    READING DESCRIPTION

    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in)  
  35. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.

    Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.

    Fig 37: Removing Top Intermediate (2, 6) Clutch Friction And Steel Plate
    G06278996Courtesy of FORD MOTOR CO.
  36. Install the One-Way Clutch (OWC) assembly.
    Fig 38: Locating Low One-Way Clutch (OWC) Assembly
    G06278997Courtesy of FORD MOTOR CO.
  37. Install the rear planetary carrier/center ring gear assembly.
    Fig 39: Locating Rear Planetary Carrier/Center Ring Gear Assembly
    G06278998Courtesy of FORD MOTOR CO.
  38. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC  .

    Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC  and install the low/reverse pressure plate.

    Fig 40: Locating Low/Reverse Pressure Plate
    G06278999Courtesy of FORD MOTOR CO.
  39. Soak the low/reverse clutch in clean automatic transmission fluid.
    Fig 41: Identifying Low/Reverse Clutch
    G06279000Courtesy of FORD MOTOR CO.
  40. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.
    Fig 42: Locating Low/Reverse Clutch Pack
    G06279001Courtesy of FORD MOTOR CO.
  41. Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs.
    Fig 43: Identifying Shim Selection Gauge 307-300
    G06279002Courtesy of FORD MOTOR CO.
  42. Using a suitable depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
    Fig 44: Measuring Measurement A Using Shim Selection Gauge 307-300
    G06279003Courtesy of FORD MOTOR CO.
  43. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.
    Fig 45: Measuring Measurement B Using Shim Selection Gauge 307-300
    G06279004Courtesy of FORD MOTOR CO.
  44. Subtract measurement B from measurement A and record as measurement C.
    READING DESCRIPTION

    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and record as measurement C.  
  45. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 46: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G06279005Courtesy of FORD MOTOR CO.
  46. Using a suitable depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge 307-300 to the top of the OWC  .
    Fig 47: Measuring Measurement D Using Shim Selection Gauge 307-300
    G06279006Courtesy of FORD MOTOR CO.
  47. Using a suitable depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average the 3 distances.
    Fig 48: Measuring Measurement E Using Shim Selection Gauge 307-300
    G06279007Courtesy of FORD MOTOR CO.
  48. Subtract measurement E from measurement D and record as measurement F.
    READING DESCRIPTION

    Description Reading
    Measurement D  
    Measurement E  
    Subtract measurement E from measurement D and record as measurement F  
  49. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
    READING DESCRIPTION

    Description Reading
    Measurement C  
    Measurement F  
    Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in)  
  50. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.

    Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.

    Fig 49: Removing Top Low/Reverse Clutch Steel Plate And Wave Spring
    G06279008Courtesy of FORD MOTOR CO.
  51. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.

    Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.

    1. Long center support legs face down
    2. Feed holes face the front of the transaxle case
    Fig 50: Installing Center Support With Long Legs Facing Down
    G06279009Courtesy of FORD MOTOR CO.
  52. Install the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
    Fig 51: Identifying No. 5 And No. 6 Thrust Bearings
    G06279010Courtesy of FORD MOTOR CO.
  53. Install the center sun gear.
    Fig 52: Locating Center Sun Gear
    G06279011Courtesy of FORD MOTOR CO.
  54. Install the center carrier/front ring gear assembly.
    Fig 53: Locating Center Carrier/Front Ring Gear Assembly
    G06279012Courtesy of FORD MOTOR CO.
  55. Install the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
    Fig 54: Identifying No. 7 And No. 8 Thrust Bearings
    G06279013Courtesy of FORD MOTOR CO.
  56. Install the front planetary/rear ring gear assembly.
    Fig 55: Locating Front Planetary Carrier/Rear Ring Gear Assembly
    G06279014Courtesy of FORD MOTOR CO.
  57. Install the forward (1, 2, 3, 4) clutch wave spring.
    Fig 56: Locating Forward (1, 2, 3, 4) Clutch Wave Spring
    G06279015Courtesy of FORD MOTOR CO.
  58. Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid.
    Fig 57: Identifying Forward (1, 2, 3, 4) Clutch Pack
    G06279016Courtesy of FORD MOTOR CO.
  59. Install the forward (1, 2, 3, 4) clutch pack.
    Fig 58: Locating Forward (1, 2, 3, 4) Clutch Pack
    G06279017Courtesy of FORD MOTOR CO.
  60. Install the forward (1, 2, 3, 4) clutch pressure plate.
    Fig 59: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate
    G06279018Courtesy of FORD MOTOR CO.
  61. NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.

    Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.

    1. Forward (1, 2, 3, 4) clutch snap ring
    2. Forward (1, 2, 3, 4) clutch snap ring gap
    Fig 60: Identifying Forward (1, 2, 3, 4) Clutch Snap Ring
    G06279019Courtesy of FORD MOTOR CO.
  62. Using a suitable tool, seat the snap ring in the snap ring groove.
    Fig 61: Seating Snap Ring In Snap Ring Groove
    G06279020Courtesy of FORD MOTOR CO.
  63. Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
    Fig 62: Identifying Dial Indicator Gauge With Holding Fixture 100-002
    G06279021Courtesy of FORD MOTOR CO.
  64. Install the low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.
    Fig 63: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Feed Seals
    G06279022Courtesy of FORD MOTOR CO.
  65. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
    Fig 64: Applying Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
    G06279023Courtesy of FORD MOTOR CO.
  66. Install the front planetary sun gear and shell assembly.
    Fig 65: Locating Front Planetary Sun Gear And Shell Assembly
    G06279024Courtesy of FORD MOTOR CO.
  67. Install the No. 10 thrust bearing.
    Fig 66: Locating No. 10 Thrust Bearing
    G06279025Courtesy of FORD MOTOR CO.
  68. Install the park pawl.
    Fig 67: Locating Park Pawl
    G06279026Courtesy of FORD MOTOR CO.
  69. Install the park pawl pin and spring.
    Fig 68: Locating Park Pawl Pin And Spring
    G06279027Courtesy of FORD MOTOR CO.
  70. Install the park pawl actuator rod in the Transmission Range (TR) sensor.
    Fig 69: Locating Park Pawl Actuator Rod
    G06279028Courtesy of FORD MOTOR CO.
  71. Position the park pawl aside and position the park pawl actuator rod and the TR  sensor in the transaxle case.
    Fig 70: Positioning Park Pawl Actuator Rod And TR Sensor In Transaxle Case
    G06279029Courtesy of FORD MOTOR CO.
  72. Install the manual control shaft and align the roll pin holes.
    Fig 71: Installing Manual Control Shaft
    G06279030Courtesy of FORD MOTOR CO.
  73. Install the manual control shaft roll pin.
    Fig 72: Locating Manual Control Shaft Roll Pin
    G06279031Courtesy of FORD MOTOR CO.
  74. NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.

    Install the manual control lever and the nut.

    • Tighten to 24 Nm (18 lb-ft).
    Fig 73: Locating Manual Control Lever And Nut
    G06279032Courtesy of FORD MOTOR CO.
  75. Install the 5 clutch feed seals.
    Fig 74: Locating Clutch Feed Seals
    G06279033Courtesy of FORD MOTOR CO.
  76. Position the transmission fluid baffle in place.
    Fig 75: Locating Transmission Fluid Baffle
    G06279034Courtesy of FORD MOTOR CO.
  77. Install the lube funnel and position the alignment pin in the alignment hole.
    Fig 76: Locating Lube Funnel
    G06279035Courtesy of FORD MOTOR CO.
  78. Position the lube funnel hold-down bracket in place and install the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 77: Locating Lube Funnel Hold-Down Bracket Bolts
    G06279036Courtesy of FORD MOTOR CO.
  79. Install the No. 12 thrust bearing.
    Fig 78: Locating No. 12 Thrust Bearing
    G06279037Courtesy of FORD MOTOR CO.
  80. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
    Fig 79: Installing Drive/Driven Sprocket And Chain Assembly
    G06279038Courtesy of FORD MOTOR CO.
  81. Install the No. 11 thrust bearing.
    Fig 80: Installing No. 11 Thrust Bearing
    G06279039Courtesy of FORD MOTOR CO.
  82. Install the No. 13 thrust washer.
    Fig 81: Identifying No. 13 Thrust Washer
    G06279040Courtesy of FORD MOTOR CO.
  83. Install the final drive sun gear.
    Fig 82: Locating Final Drive Sun Gear
    G06279041Courtesy of FORD MOTOR CO.
  84. Install the differential assembly.
    Fig 83: Locating Differential Assembly
    G06279042Courtesy of FORD MOTOR CO.
  85. Install the No. 15 thrust bearing.
    Fig 84: Locating No. 15 Thrust Bearing
    G06279043Courtesy of FORD MOTOR CO.
  86. Install the Turbine Shaft Seal Protector 307-635 on the input shaft.
    Fig 85: Identifying Turbine Shaft Seal Protector 307-635
    G06279044Courtesy of FORD MOTOR CO.
  87. Clean the torque converter housing sealing surface.
    Fig 86: Locating Torque Converter Housing Sealing Surface
    G06279045Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  88. Assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the Seal Installer 307-626.
    Fig 87: Identifying Handle 205-153 And Differential Seal Installer 307-626
    G06279046Courtesy of FORD MOTOR CO.
  89. Using the Handle 205-153 and Differential Seal Installer 307-626, install the RH halfshaft seal.
    Fig 88: Installing RH Halfshaft Seal
    G06279047Courtesy of FORD MOTOR CO.
  90. Install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428.
    Fig 89: Locating RH Seal On RH Halfshaft Fluid Seal Installer 307-428
    G06279048Courtesy of FORD MOTOR CO.
  91. Using the RH Halfshaft Fluid Seal Installer 307-428, install the RH halfshaft seal.
    Fig 90: Installing RH Halfshaft Seal Using RH Halfshaft Fluid Seal Installer 307-428
    G06279049Courtesy of FORD MOTOR CO.

    All vehicles 

  92. Install the differential ring gear in the torque converter housing.
    Fig 91: Installing Differential Ring Gear
    G06279050Courtesy of FORD MOTOR CO.
  93. NOTE: Be sure the flat side of the beveled snap ring is facing down or the ring can come loose, causing damage to the transaxle.

    Install the beveled differential ring gear snap ring with the flat side facing down.

    Fig 92: Locating Differential Ring Gear Snap Ring
    G06279051Courtesy of FORD MOTOR CO.
  94. Seat the snap ring using a suitable tool.
    Fig 93: Seating Snap Ring
    G06279052Courtesy of FORD MOTOR CO.
  95. Install the pump and filter assembly in the torque converter housing and install the pump bolts.
    1. Tighten to 35 Nm (26 lb-ft).
    2. Tighten to 10 Nm (89 lb-in).
    Fig 94: Identifying Pump Bolts
    G06279053Courtesy of FORD MOTOR CO.
  96. Install the transmission fluid baffle and the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 95: Locating Bolts And Transmission Fluid Baffle
    G06279054Courtesy of FORD MOTOR CO.
  97. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.

    Apply silicone to the sealing surface of the transaxle case.

    Fig 96: Locating Sealing Surface Of Transaxle Case
    G06279055Courtesy of FORD MOTOR CO.
  98. NOTE: Be sure the stud bolt is in the correct location as noted during disassembly.

    Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque converter housing bolts.

    1. Tighten to 24 Nm (18 lb-ft).
    2. Stud bolt location.
    Fig 97: Locating Transaxle Case-To-Torque Converter Housing Bolts
    G06279056Courtesy of FORD MOTOR CO.
  99. Remove the Turbine Shaft Seal Protector 307-635.
    Fig 98: Identifying Turbine Shaft Seal Protector 307-635
    G06279057Courtesy of FORD MOTOR CO.
  100. Install the Turbine Shaft Speed (TSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 99: Locating Turbine Shaft Speed (TSS) Sensor And Bolt
    G06279058Courtesy of FORD MOTOR CO.
  101. Install the Output Shaft Speed (OSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 100: Locating Output Shaft Speed (OSS) Sensor And Bolt
    G06279059Courtesy of FORD MOTOR CO.
  102. Assemble the bypass valve in the sleeve and install the assembly in the case.
    1. Bypass valve
    2. Bypass valve sleeve
    Fig 101: Identifying Bypass Valve And Sleeve
    G06279060Courtesy of FORD MOTOR CO.
  103. Install the bypass valve spring.
    Fig 102: Installing Bypass Valve Spring
    G06279061Courtesy of FORD MOTOR CO.
  104. Install the separator plate and align it on the stud and the guide pin.
    Fig 103: Locating Separator Plate And Stud
    G06279062Courtesy of FORD MOTOR CO.
  105. NOTE: Be sure that the manual pin (part of the TR  sensor) is correctly installed in the manual valve.

    Position the main control assembly in place and align the manual valve on the TR  sensor.

    Fig 104: Locating Manual Pin
    G06279063Courtesy of FORD MOTOR CO.
  106. Install the nut hand-tight.
    Fig 105: Locating Nut
    G06279064Courtesy of FORD MOTOR CO.
  107. Install the short bolts hand-tight.
    Fig 106: Locating Short Bolts
    G06279065Courtesy of FORD MOTOR CO.
  108. Install the long bolts hand-tight.
    Fig 107: Locating Long Bolts
    G06279066Courtesy of FORD MOTOR CO.
  109. Tighten the main control bolts and the nut in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
    Fig 108: Locating Main Control Bolts And Nut
    G06279067Courtesy of FORD MOTOR CO.
  110. Position the TR  sensor detent spring in place with the alignment tab in the alignment hole and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
    Fig 109: Locating TR Sensor Detent Spring
    G06279068Courtesy of FORD MOTOR CO.
  111. NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.

    Install the solenoid body-to-main control cover seal.

    Fig 110: Locating Solenoid Body-To-Main Control Cover Seal
    G06279069Courtesy of FORD MOTOR CO.
  112. Connect the TR  sensor electrical connector.
    Fig 111: Locating TR Sensor Electrical Connector
    G06279070Courtesy of FORD MOTOR CO.
  113. Connect the OSS  sensor electrical connector.
    Fig 112: Identifying OSS Sensor Electrical Connector
    G06279071Courtesy of FORD MOTOR CO.
  114. Clean the main control cover sealing surface.
    Fig 113: Locating Main Control Cover Sealing Surface
    G06279072Courtesy of FORD MOTOR CO.
  115. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 114: Locating Main Control Sealing Surface Of Transaxle Case
    G06279073Courtesy of FORD MOTOR CO.
  116. Position the main control cover in place.
    Fig 115: Locating Main Control Cover
    G06279074Courtesy of FORD MOTOR CO.
  117. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.

    Install the main control cover bolts.

    1. Bolt location
    2. Stud bolt location
    • Tighten to 12 Nm (106 lb-in).
    Fig 116: Identifying Main Control Cover Bolts
    G06279075Courtesy of FORD MOTOR CO.
  118. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.

    Using the Torque Converter Handle 307-091, install the torque converter.

    Fig 117: Installing Torque Converter
    G06279076Courtesy of FORD MOTOR CO.
  119. Remove the Torque Converter Handle 307-091.
    Fig 118: Identifying Torque Converter Handle 307-091
    G06279077Courtesy of FORD MOTOR CO.
  120. Install the Torque Converter Retainer 307-566.
    Fig 119: Identifying Torque Converter Retainer 307-566
    G06279078Courtesy of FORD MOTOR CO.
  121. Remove the transaxle from the bench-mounted holding fixture.
    Fig 120: Identifying Transaxle
    G06279079Courtesy of FORD MOTOR CO.
  122. Remove the Holding Fixture 307-625.
Fig 121: Identifying Holding Fixture 307-625
G06279080Courtesy of FORD MOTOR CO.
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