Transmission Case Reseal

Courtesy of FORD MOTOR COMPANY	Slide Hammer 100-001 (T50T-100-A)
Courtesy of FORD MOTOR COMPANY	Collet, 7/8 Inch to 1 Inch 303-D020 (D80L-100-R)
Courtesy of FORD MOTOR COMPANY	Handle 205-153 (T80T-4000-W)
Courtesy of FORD MOTOR COMPANY	Retainer, Torque Converter 307-346
Courtesy of FORD MOTOR COMPANY	Converter Seal Installer 307-575
Courtesy of FORD MOTOR COMPANY	Holding Fixture 307-580
Courtesy of FORD MOTOR COMPANY	Installer, Cover Axle Seal 307-582A
Courtesy of FORD MOTOR COMPANY	Support Seal Installer 307-585

Item	Specification
Ultra Silicone Sealant TA-29	-

All Vehicles 

1. 1.
   
   Remove the transmission. For AWD refer to Transmission - All Wheel Drive (AWD) . For FWD refer to Transmission - Front Wheel Drive (FWD) . For 3.5L GTDI refer to Transmission - 3.5L GTDI .

1. 2.
   
   Using the special tool, mount the transmission onto the bench.

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1. 3.
   
   Remove the special tool.

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NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
1. 4.
   Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and remove the torque converter from the transmission.

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1. 5.
   
   Remove and discard the halfshaft seal from the transmission case.

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FWD Vehicles 

1. 6.
   
   Remove and discard the halfshaft seal from the torque converter housing.

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All Vehicles 

1. 7.
   
   Using a dent puller, remove and discard the torque converter hub seal from the torque converter housing.

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NOTE: Note the location of the studbolts for assembly.
1. 8.
   Remove the bolts and the main control cover.

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1. 9.
   
   Disconnect the TSS sensor electrical connector.

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1. 10.
   
   Remove the cover assembly bolts.

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1. 11.
   
   Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transmission case.

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1. 12.
   
   Remove the cover assembly gasket.

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1. 13.
   
   Remove the No. 1 cover assembly thrust bearing.

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1. 14.
   
   Remove the overdrive/direct clutch hub and turbine shaft assembly.

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1. 15.
   
   Remove the No. 3 rear sun gear thrust bearing.

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1. 16.
   
   Remove the intermediate clutch shell and sun gear assembly.

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1. 17.
   
   Remove the intermediate clutch assembly.

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NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low OWC snap ring.
1. 18.
   Remove the low/reverse clutch assembly.

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1. 19.
   
   Remove the rear planetary carrier and center ring gear assembly.

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1. 20.
   
   Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.

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1. 21.
   
   Remove the center planetary sun gear.

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1. 22.
   
   Remove the center planetary carrier and front ring gear assembly.

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1. 23.
   
   Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.

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1. 24.
   
   Remove the front planetary carrier and rear ring gear assembly.

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1. 25.
   
   Remove the front planetary sun gear and shell assembly.

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1. 26.
   
   Remove the No. 10 front sun gear thrust bearing.

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1. 27.
   
   Remove the front planetary carrier hub assembly.

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1. 28.
   
   Remove the No. 11 support assembly thrust bearing.

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NOTE: Note the location of the studbolts for assembly.
1. 29.
   Remove the torque converter housing bolts.

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NOTE: Carefully pry on the transmission torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.
1. 30.
   Carefully pry the torque converter housing off the transmission case just enough to break the seal of the silicone and remove the torque converter housing from the transmission case.

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1. 31.
   
   Remove and discard the pump-to-case seal.

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1. 32.
   
   Remove and discard the stator support assembly seal.

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1. 33.
   
   Assemble the slide hammer, collet 7/8" to 1" and the actuating pin (Dia 3/16"). Using the tools, remove and discard the input shaft seal.

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1. 34.
   
   Install a new input shaft seal on the special tool.

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1. 35.
   
   Using the special tool, install the input shaft seal.

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1. 36.
   
   Install a new stator support assembly seal.

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1. 37.
   
   Install a new pump-to-case seal.

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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
1. 38.
   Make sure that the mating faces are clean and free of foreign material. REFER to Engine System General Information .

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NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.
1. 39.
   Apply a bead of Ultra Silicone Sealant.

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NOTE: Install the 2 studbolts in the correct location as noted during disassembly.
1. 40.
   Install the torque converter housing on top of the transmission case and install the bolts hand tight.

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NOTE: The studbolts are 1 and 16 in the tightening sequence.
1. 41.
   Tighten the bolts in the sequence shown.
   • Tighten to 24 Nm (18 lb-ft).

1. 42.
   
   Install the No. 11 stator support thrust bearing.

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1. 43.
   
   Install the front planetary carrier hub.

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1. 44.
   
   Install the No. 10 front sun gear thrust bearing.

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1. 45.
   
   Install the front sun gear and shell assembly.

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1. 46.
   
   Install the front carrier and rear ring gear assembly.

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1. 47.
   
   Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.

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1. 48.
   
   Install the center planetary carrier and front ring gear assembly.

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NOTE: The groove on the center sun gear is installed facing up.
1. 49.
   Install the center planetary sun gear.

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1. 50.
   
   Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.

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1. 51.
   
   Install the rear planetary gear carrier assembly.

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NOTE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low OWC snap ring may result in damage to the transmission.
1. 52.
   Install the low/reverse clutch pressure plate.

   1. 1.
      
      Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC snap ring.

   1. 2.
      
      Install the low/reverse clutch pressure plate.

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1. 53.
   
   Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.

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1. 54.
   
   Soak the low/reverse clutch pack with transmission fluid.

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1. 55.
   
   Install the low/reverse clutch pack.

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NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
1. 56.
   Correctly install the low/reverse clutch wave spring and pressure plate.

   1. 1.
      
      Wave spring

   1. 2.
      
      Pressure plate

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1. 57.
   
   Install the intermediate clutch pressure plate.

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1. 58.
   
   Soak the intermediate clutch pack assembly in transmission fluid.

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1. 59.
   
   Install the intermediate clutch pack assembly.

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1. 60.
   
   Install the intermediate clutch pack wave spring.

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1. 61.
   
   Install the rear sun gear and shell assembly.

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1. 62.
   
   Install the No. 3 rear sun gear thrust bearing.

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1. 63.
   
   Install the overdrive/direct clutch hub and turbine shaft assembly.

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1. 64.
   
   Install the No. 1 cover assembly thrust bearing.

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1. 65.
   
   Install the cover assembly gasket.

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1. 66.
   
   Route the TSS sensor harness through the transmission case to the valve body area and install the cover assembly.

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1. 67.
   
   Install the cover assembly bolts and tighten the bolts in the sequence shown.
   • Tighten to 12 Nm (106 lb-in).

1. 68.
   
   Connect the TSS sensor electrical connector.

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1. 69.
   
   Inspect the transmission main control cover seal for damage and install new if necessary.

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NOTE: Install the studbolts in the correct locations as noted during disassembly.
1. 70.
   Install the transmission main control cover and loosely install the bolts.

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1. 71.
   
   Tighten the main control cover bolts in the sequence shown.
   • Tighten to 12 Nm (106 lb-in).

1. 72.
   
   Install a new torque converter hub seal on the special tool.

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NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
1. 73.
   Using the special tool and a dead blow hammer, install the torque converter hub seal in the torque converter housing.

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FWD Vehicles 

1. 74.
   
   Assemble the special tools and install a new RH halfshaft seal on the special tool.

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NOTE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.
1. 75.
   Using the special tools, install the new RH halfshaft seal in the torque converter housing.

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All Vehicles 

1. 76.
   
   Assemble the special tools, install a new halfshaft seal on the special tool.

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1. 77.
   
   Using the special tools, install the new halfshaft seal in the transmission case.

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NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
1. 78.
   Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transmission.

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1. 79.
   
   Install the special tool.

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1. 80.
   
   Install the transmission. For AWD refer to Transmission - All Wheel Drive (AWD) . For FWD refer to Transmission - Front Wheel Drive (FWD) . For 3.5L GTDI refer to Transmission - 3.5L GTDI .