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Automatic Transaxle: Disassembly: Transaxle

Fig 1: Special Tool(s) (1 Of 4)
G01820004Courtesy of FORD MOTOR CO.
Fig 2: Special Tool(s) (2 Of 4)
G01820005Courtesy of FORD MOTOR CO.
Fig 3: Special Tool(s) (3 Of 4)
G01820006Courtesy of FORD MOTOR CO.
Fig 4: Special Tool(s) (4 Of 4)
G01820007Courtesy of FORD MOTOR CO.
    CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 5: Removing Torque Converter
    G01820008Courtesy of FORD MOTOR CO.
  1. Using the special tools, remove the torque converter.
  2. Using the special tool, install the transaxle into the bench.
    Fig 6: Attaching Transmission Holding Fixture
    G01820009Courtesy of FORD MOTOR CO.
    3. NOTE: During a case replacement a new identification tag will need to be installed. Use caution not to damage the tag.
    Fig 7: Locating Identification Tag
    G01820010Courtesy of FORD MOTOR CO.
  3. Remove the identification tag.
  4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
    Fig 8: Locating Drain Pan Under Transaxle
    G01820011Courtesy of FORD MOTOR CO.
    5. CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.
    Fig 9: Removing Overdrive Band Servo Piston & Rod
    G01820012Courtesy of FORD MOTOR CO.
  5. Remove the overdrive servo piston and rod.
    • Remove the bolts.
    • Remove the cover.
    • Remove the piston and rod.
  6. Remove the filler tube.
    1. Remove the bolt.
    2. Remove the filler tube.
    3. Remove the filler tube grommet.
    Fig 10: Removing Filler Tube
    G01820013Courtesy of FORD MOTOR CO.
  7. Remove the digital TR sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 11: Removing Digital TR Sensor
    G01820014Courtesy of FORD MOTOR CO.
  8. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
    Fig 12: Removing TSS Sensor
    G01820015Courtesy of FORD MOTOR CO.
    9. NOTE: The differential seal is a two-piece constructed seal.
    Fig 13: Removing Left Differential Seal
    G01820016Courtesy of FORD MOTOR CO.
  9. Using the special tools, remove the LH differential seal.
  10. Using the special tools, remove the LH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector from the LH differential seal and remove protector from special tool.
    Fig 14: Removing Left Differential Seal Metal Detector
    G01820017Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the rubber portion of the LH differential seal.
    1. Install the special tools into the LH differential seal and rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 15: Removing Rubber Portion Of Left Differential Seal
    G01820018Courtesy of FORD MOTOR CO.
  12. Install the special tools into the RH differential seal.
    Fig 16: Installing Special Tools Into Right Differential Seal
    G01820019Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
    Fig 17: Removing Right Differential Seal Metal Protector
    G01820020Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the rubber portion of the seal.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 18: Removing Rubber Portion Of Right Differential Seal
    G01820021Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the converter hub seal.
    Fig 19: Removing Converter Hub Seal
    G01820022Courtesy of FORD MOTOR CO.
  16. Remove the bolts.
    Fig 20: Locating Bolts
    G01820023Courtesy of FORD MOTOR CO.
  17. Rotate the transaxle to a horizontal position.
    18. NOTE: The main control cover gasket is reusable if not torn or damaged.
    Fig 21: Removing Main Control Cover
    G01820024Courtesy of FORD MOTOR CO.
  18. Remove the bolts, main control cover and gasket.
    19. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
    Fig 22: Locating Electrical Connectors
    G01820025Courtesy of FORD MOTOR CO.
  19. Lift the locking tab and disconnect the electrical connectors.
    20. NOTE: The manual valve should be inserted completely.
    Fig 23: Rotating Manual Lever
    G01820026Courtesy of FORD MOTOR CO.
  20. Using a 9 mm wrench rotate the manual control lever to the low detent.
    21. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body.
    CAUTION: Only 4 of the 6 pump cover bolts need to be removed.
    Fig 24: Locating Bolts To Remove Main Control Valve Body
    G01820027Courtesy of FORD MOTOR CO.
  21. Remove the bolts.
  22. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
    Fig 25: Removing Main Control Valve Body
    G01820028Courtesy of FORD MOTOR CO.
  23. Disconnect the manual control valve actuating rod.
    Fig 26: Disconnecting Manual Control Valve Actuating Rod
    G01820029Courtesy of FORD MOTOR CO.
  24. Remove the pump shaft.
    Fig 27: Removing Pump Shaft
    G01820030Courtesy of FORD MOTOR CO.
    25. NOTE: The transaxle pan gasket is reusable if not torn or damaged.
    Fig 28: Removing Transmission Fluid Pan
    G01820031Courtesy of FORD MOTOR CO.
  25. Remove the bolts, transmission fluid pan and gasket.
  26. Remove, clean and inspect the magnet.
    Fig 29: Locating Magnet
    G01820032Courtesy of FORD MOTOR CO.
  27. Remove the filter.
    Fig 30: Removing Filter
    G01820033Courtesy of FORD MOTOR CO.
    28. NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
    Fig 31: Removing Filter Seal
    G01820034Courtesy of FORD MOTOR CO.
  28. Remove the fluid filter seal.
  29. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 32: Locating Reverse Clutch Anchor Pin
    G01820035Courtesy of FORD MOTOR CO.
    30. CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.
    NOTE: Mark bolt size and location for assembly.
    Fig 33: Removing Chain Cover Bolts
    G01820036Courtesy of FORD MOTOR CO.
  30. Remove the bolts.
    31. NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.
    Fig 34: Removing Chain Cover
    G01820037Courtesy of FORD MOTOR CO.
  31. Remove the chain cover and gasket.
  32. Tag and mark the location of the accumulator springs.
    1. Remove the intermediate 1-2 accumulator outer spring.
    2. Remove the direct 2-3 accumulator piston spring.
    3. Remove the neutral reverse shift accumulator spring.
    4. Remove the overdrive 3-4 accumulator spring.
    Fig 35: Identifying Accumulator Springs
    G01820038Courtesy of FORD MOTOR CO.
    33. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
    Fig 36: Removing Chain & Sprockets
    G01820039Courtesy of FORD MOTOR CO.
  33. Remove the drive sprocket, driven sprocket and drive chain as an assembly.
    34. NOTE: The thrust washers may remain on the sprockets.
    Fig 37: Identifying Thrust Washers
    G01820040Courtesy of FORD MOTOR CO.
  34. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
    35. CAUTION: Use care not to damage the machined surface of the case.
    NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
    Fig 38: Locating Roll Pins
    G01820041Courtesy of FORD MOTOR CO.
  35. Remove the roll pins.
    36. NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
    Fig 39: Removing Manual Control Lever Shaft
    G01820042Courtesy of FORD MOTOR CO.
  36. Remove the manual control lever shaft.
  37. Remove the parking lever actuating rod.
    Fig 40: Removing Parking Lever Actuating Rod
    G01820043Courtesy of FORD MOTOR CO.
  38. Remove the manual control lever shaft seal.
    Fig 41: Removing Manual Control Lever Shaft Seal
    G01820044Courtesy of FORD MOTOR CO.
    39. NOTE: During the complete disassembly of the transaxle the fluid transfer tubes must be removed.
    Fig 42: Locating Fluid Transfer Tube Brackets
    G01820045Courtesy of FORD MOTOR CO.
  39. Remove the bolts and brackets.
  40. Using the special tools, remove the fluid lube tubes.
    Fig 43: Removing Fluid Transfer Tubes
    G01820046Courtesy of FORD MOTOR CO.
  41. Remove the bolts and the park pawl abutment.
    Fig 44: Removing Park Pawl Abutment
    G01820047Courtesy of FORD MOTOR CO.
  42. Remove the neutral/drive accumulator bolt.
    Fig 45: Locating Neutral/Drive Accumulator Bolt
    G01820048Courtesy of FORD MOTOR CO.
  43. Remove the neutral/drive accumulator.
    1. Remove the cover.
    2. Remove the springs.
    3. Remove the piston and shaft.
    Fig 46: Removing Neutral/Drive Accumulator
    G01820049Courtesy of FORD MOTOR CO.
  44. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston, and rod as an assembly.
    Fig 47: Removing Coast Band Servo
    G01820050Courtesy of FORD MOTOR CO.
    45. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
    Fig 48: Removing Drive Sprocket Support
    G01820051Courtesy of FORD MOTOR CO.
  45. Remove the drive sprocket support and the No. 5 thrust washer.
    46. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
    Fig 49: Removing Thrust Bearing & Needle Bearing
    G01820052Courtesy of FORD MOTOR CO.
  46. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
  47. Remove the plastic overdrive band retainer.
    Fig 50: Removing Plastic Overdrive Band Retainer
    G01820053Courtesy of FORD MOTOR CO.
  48. Remove the overdrive band.
    Fig 51: Removing Overdrive Band
    G01820054Courtesy of FORD MOTOR CO.
    49. NOTE: Do not overtighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
    Fig 52: Removing Front Clutch Assembly
    G01820055Courtesy of FORD MOTOR CO.
  49. Position the special tool into the case and install the hook end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
  50. Using the special tool, remove the front clutch assembly.
    Fig 53: Removing Front Clutch Assembly
    G01820056Courtesy of FORD MOTOR CO.
  51. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 54: Removing Reverse Clutch & Planet Assembly
    G01820057Courtesy of FORD MOTOR CO.
  52. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 55: Removing Low/Intermediate Drum
    G01820058Courtesy of FORD MOTOR CO.
  53. Remove the coast band.
    Fig 56: Removing Coast Band
    G01820059Courtesy of FORD MOTOR CO.
    54. CAUTION: Use care not to damage any machined surfaces.
    Fig 57: Remove Low/Intermediate Clutch Retaining Ring
    G01820060Courtesy of FORD MOTOR CO.
  54. Remove the low/intermediate clutch retaining ring.
  55. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
    Fig 58: Removing Low/Intermediate Clutch Pack
    G01820061Courtesy of FORD MOTOR CO.
    56. WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
    CAUTION: Use care not to damage the final drive support assembly, transaxle case, or retaining ring during removal.
    Fig 59: Removing Beveled Retaining Ring
    G01820062Courtesy of FORD MOTOR CO.
  56. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
  57. Remove the final drive differential and rear planet support assembly.
    Fig 60: Removing Final Drive Differential & Rear Planet Support Assembly
    G01820063Courtesy of FORD MOTOR CO.
    58. NOTE: The differential carrier thrust washer (7G103) may remain on the differential assembly.
    Fig 61: Removing Differential Carrier Thrust Washer
    G01820064Courtesy of FORD MOTOR CO.
  58. Remove the differential carrier thrust washer.
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
  59. Remove the rear planet support spacer.
    Fig 62: Removing Rear Planet Support Spacer
    G01820065Courtesy of FORD MOTOR CO.
  60. Remove the final drive ring gear.
    Fig 63: Removing Final Drive Ring Gear
    G01820066Courtesy of FORD MOTOR CO.
    61. NOTE: If the drive sprocket bearing is worn or damaged a new component will need to be installed.
    Fig 64: Removing Drive Sprocket Bearing
    G01820067Courtesy of FORD MOTOR CO.
  61. Using the special tools, remove the drive sprocket bearing.
    62. NOTE: The following procedures are done only if a case replacement is necessary.
    Fig 65: Removing Stator Support Bolts
    G01820068Courtesy of FORD MOTOR CO.
  62. Remove the bolts.
  63. Remove the stator support assembly.
    Fig 66: Removing Stator Support Assembly
    G01820069Courtesy of FORD MOTOR CO.
  64. Remove the park pawl shaft retaining pin.
    Fig 67: Locating Park Pawl Shaft Retaining Pin
    G01820070Courtesy of FORD MOTOR CO.
  65. Using the special tools, remove the cup plug.
    Fig 68: Removing Cup Plug
    G01820071Courtesy of FORD MOTOR CO.
  66. Use a magnet to remove the parking pawl shaft.
  67. Remove the parking pawl.
    1. Remove the parking pawl.
    2. Remove the parking pawl return spring.
    Fig 69: Removing Parking Pawl
    G01820072Courtesy of FORD MOTOR CO.
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