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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - 6F50/6F55 >> Disassembly And Assembly >> Transaxle - Overhaul >> Disassembled Views

Disassembled Views

GFD36385Courtesy of FORD MOTOR COMPANY
GFD36386Courtesy of FORD MOTOR COMPANY
GFD36387Courtesy of FORD MOTOR COMPANY
GFD36388Courtesy of FORD MOTOR COMPANY
GFD36389Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 7902 Torque converter assembly
2 7F401 Seal assembly - converter hub
3 1177 Seal assembly - transmission differential (front)
4 7J287 Bolt - M8 x 30 (converter housing)
5 W704941 Studbolt - M8 x 30 (converter housing)
6 7005 Torque converter housing
7 7H389 Plug - transmission orifice cup
8 W711931 Bolt - torque converter housing
9 7G099 Washer - drive sprocket thrust
10 7G273 Washer - driven sprocket support thrust
11 7G249 Sprocket and chain assembly - pump
12 7L323 Seal - support assembly-to-torque converter
13 7D014 Washer - stator support thrust
14 7A108 Support and gear assembly - stator
15 7J284 Bolt - hex-head stator support feed tube
16 7J330 Bolt - Torx ®-head stator support feed tube
17 7N147 Transmission fluid feed tube assembly - stator support
18 7J246 Gasket - feed tube
19 7F363 Support assembly - torque converter reactor
20 7J246 Seal - stator support assembly
21 7J285 Bolt - M8 x 25
22 7048 Seal assembly - input shaft
23 7N281 Ring - input bearing retainer
24 7A452 Bearing assembly - main drive gear front
25 7F342 Gear - final drive input
26 7B364 Nut - bearing retainer
27 7A098 Filter - transmission fluid
28 7Z302 Seal - transmission fluid filter
29 7A103 Pump assembly - transmission fluid
30 7J283 Bolts - M6 x 25
31 7A248 Seal - pump
32 7978 Baffle - sump
33 4067 Shim - transmission differential bearing
34 4222 Cup - differential bearing
35 7F465 Differential and gear assembly
36 4221 Bearing - differential assembly
37 7J286 Bolt - M10 x 25
38 7F343 Gear - transmission final drive output
39 4207 Gear and case - differential assembly
40 4221 Bearing - differential assembly
41 4222 Cup - differential bearing
42 7L276 Fluid dams - transfer shaft tube
43 7A209 Tube - transfer shaft
44 7H367 Shim - transfer shaft roller bearing
45 7H344 Cups - transfer shaft roller bearing
46 7H348 Gear and bearing assembly - transfer shaft
47 7H338 Cone and roller assembly - transfer shaft bearing
48 7059 Ring - transmission final drive retaining
49 7H348 Gear assembly - transfer shaft
50 7H349 Gear - transfer shaft input
51 7H346 Gear - transfer shaft output
52 7A233 Gear - output shaft parking
53 7D419 Plate - parking rod guide
54 7D071 Shaft - parking pawl
55 7D070 Spring - parking pawl return
56 7A441 Pawl - parking brake
57 7H389 Plug - transmission case orifice
58 7J387 Reservoir - transmission fluid
59 7L280 Seal - transmission fluid reservoir
60 7D412 Pin - parking pawl abutment
61 7G101 Abutment - parking pawl actuator
62 7A010 Plugs - transmission drain
63 7B362 Pin - transmission case dowel
64 7005 700 Case
65 7G342 Tag - transmission service identification
66 W711892-S441 Nut - M10
67 7A256 Lever - manual control
68 7F337 Seal assembly - manual control shaft
69 7H103 Sensor assembly - OSS
70 7N266 Seal - valve body
71 7J282 Bolts - M6 x 63
72 7E332 Spring assembly - manual valve detent
73 7H557 Sensor - TR
74 7A232 Rod assembly - park pawl actuator
75 7B210 Pin - manual control lever
76 1177 Seal - transmission differential
77 7D090 Bearing assembly - thrust
78 7B067 Hub assembly - planetary carrier
79 7D064 Sun gear and shell assembly - planetary carrier
80 7D491 Carrier and gear assembly - planetary
81 7M022 Shell - planetary carrier
82 7N470 Carrier - planetary gear
83 7L487 Ring - planetary carrier guide
84 7C122 Snap ring - planetary carrier
85 7G211 Gear - front planetary ring
86 7H375 Bearing and race assembly - forward planetary carrier thrust
87 7F241 Bearing and race assembly - forward planetary sun gear thrust
88 7G304 Gear - forward planetary sun
89 7L192 Carrier and ring gear assembly - forward planetary
90 7A153 Ring gear - planetary
91 7H318 Retainer - snap ring
92 7D055 Carrier assembly - forward planetary
93 - Clutch assembly - forward
94 7C096 Bearing - forward planetary sun gear thrust (rear)
95 7G177 Bearing - front planetary carrier thrust
96 7D491 Gear and carrier assembly - front
97 7D491 Ring gear assembly - forward
98 7H361 Snap ring - forward planetary ring gear
99 7G226 Carrier - front planetary gear
100 7A262 Piston assembly - forward clutch
101 7B070 Spring - forward clutch piston return
102 7H365 Ring - forward clutch balance piston snap
103 7B070 Spring - forward clutch cushion
104 7B442 Plates - forward clutch (steel)
105 7B164 Plates - forward clutch (friction)
106 7A089 Clutch - low one-way
107 7D483 Ring - low OWC
108 7B066 Plate - low reverse clutch pressure
109 7B164 Plates - low reverse clutch (friction)
110 7B442 Plates - low reverse clutch (steel)
111 7B066 Plate - low reverse clutch pressure
112 7J701 Spring - low reverse clutch cushion (if equipped)
113 7B066 Plate - intermediate clutch pressure
114 7B164 Plates - intermediate clutch (friction)
115 7B442 Plates - intermediate clutch (steel)
116 7E085 Spring - intermediate clutch cushion
117 7A019 Sun gear and shell assembly - front planetary gear assembly
118 7H351 Hub assembly - direct clutch
119 7C096 Bearing - direct clutch hub thrust
120 7D483 Snap ring - overdrive clutch
121 7B066 Plate - overdrive pressure
122 7B164 Plates - overdrive pressure (friction)
123 7B442 Plates - overdrive pressure (steel)
124 7D483 Snap ring - direct clutch
125 7B066 Plate - direct clutch pressure
126 7B442 Plates - direct clutch (friction)
127 7B164 Plates - direct clutch (steel)
128 7E085 Spring - direct clutch wave
129 7C122 Snap ring - balance piston
130 7H360 Piston - balance
131 7F222 Spring - overdrive clutch piston return
132 7A262 Piston - overdrive clutch
133 7A548 Seal - overdrive clutch piston outer (front)
134 7A548 Seal - overdrive clutch piston outer (rear)
135 7A548 Seal - overdrive clutch piston inner
136 7G384 Hub and shaft assembly - input direct and overdrive clutch
137 7A548 Seal - direct clutch piston outer
138 7C099 Seal - direct clutch piston inner (front)
139 7C099 Seal - direct clutch piston inner (rear)
140 7F235 Return spring assembly - direct clutch
141 7A262 Piston assembly - direct clutch
142 7F283 Cylinder - direct clutch piston
143 7C122 Snap ring - direct clutch piston cylinder
144 7C122 Snap ring - reverse clutch piston return spring
145 7B070 Spring - reverse clutch piston return
146 7D402 Piston - reverse clutch
147 7D483 Snap ring - intermediate clutch return spring
148 7F222 Spring - intermediate clutch piston return
149 7E005 Piston - intermediate clutch
150 7D019 Seals - transmission cover
151 7H026 Bearing - turbine shaft thrust
152 7223 Gasket - cover assembly
153 7222 Cover assembly
154 7J289 Bolts - M6 x 30
155 7M101 Sensor assembly - TSS
156 7J356 Bolt - M6 x 25
157 7A100 Body assembly - main control valve
158 7A099 Body assembly - lower main control valve
159 7Z490 Plate assembly - lower valve body separator
160 7A091 Body - main control valve
161 7B431 Pin - transfer plate alignment
162 7E195 5 Ball - check
163 7Z490 Plate - transfer plate separator
164 7H195 Plate - transfer
165 7J291 Bolt - M6 x 35
166 7Z490 Cover assembly - main control valve body
167 7H200 Plate - solenoid filter
168 7G391 Body assembly - solenoid
169 7J295 7J29 Bolt - M6 x 95
170 7J364 Bolt - M6 x 42
171 7J293 Bolt - M6 x 80
172 7F396 Gasket - main control cover
173 7B329 Seal - solenoid body-to-main control cover
174 7G004 Cover assembly - main control
175 W708442 Stud - hex flange
176 7A020 Indicator - transmission fluid level

All vehicles 

  1. 1.

    Using the special tool, mount the transmission onto the bench. Special Tool(s): Holding Fixture 307-580
GFD36171Courtesy of FORD MOTOR COMPANY

  1. 2.

    Remove the special tool. Special Tool(s): Retainer, Torque Converter 307-346
GFD36172Courtesy of FORD MOTOR COMPANY
    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. 3.
    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.
GFD36173Courtesy of FORD MOTOR COMPANY

  1. 4.

    A new or remanufactured torque converter must be installed if one or more of the following statements is true:
    • The sealing surface has a groove worn from the seal.
    • A torque converter malfunction has been determined based on complete diagnostic procedures.
    • The torque converter stud or studs, threaded pads, impeller hub or bushing are damaged.
    • The torque converter exhibits external discoloration (due to overheating).
    • There is evidence of water or antifreeze contamination.
GFD35831Courtesy of FORD MOTOR COMPANY

Flush The Torque Converter With The Transmission Cooling System Heated Flusher 

    NOTE: Use transmission fluid specified for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail, which will affect the operation of the transmission.

  1. 5.
    The torque converter must be flushed every time the transmission is overhauled. It is mandatory that proper equipment and procedures be followed when flushing the torque converter. The flushing equipment used MUST:
    • Maintain the transmission fluid at 140 °F or above
    • Pulsate the transmission fluid during cleaning
    • Have a GPM flow meter
    • Have a filter with a rating of 100 micron or less
    • Have air purge capability before and after flushing

  1. 6.

    If equipment meeting the specifications above is not available, the torque converter must be flushed by hand. Go to Flush The Torque Converter By Hand steps later in this procedure.

  1. 7.

    Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.

  1. 8.

    Turn on the heater and allow the transmission fluid in the transmission cooling system heated flusher 15-30 minutes to heat up to 60 °C (140 °F) before using.

  1. 9.

    Place the torque converter in an arbor press. Support the torque converter on the mounting pads.
GFD35832Courtesy of FORD MOTOR COMPANY

  1. 10.

    Using the special tools, assemble the correct turbine shaft simulator to the torque converter flush main hub and place it on the torque converter hub. Special Tool(s): Tool Kit, Torque Converter Flusher 307-732
GFD35833Courtesy of FORD MOTOR COMPANY

  1. 11.

    Using the special tool, install the slotted cap. Special Tool(s): Tool Kit, Leak Tester, Torque Converter 307-691
GFD35834Courtesy of FORD MOTOR COMPANY

  1. 12.

    Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.
GFD35835Courtesy of FORD MOTOR COMPANY

  1. 13.

    Connect the flush machine to the main hub.

    1. 1.

      Red hose on top.

    1. 2.

      Blue hose on bottom.
GFD35836Courtesy of FORD MOTOR COMPANY

  1. 14.

    Follow the equipment instructions to purge the transmission fluid from the torque converter prior to starting the flushing procedure.
    NOTE: Maintain visual contact with torque converter during the entire flush procedure. Immediately stop the flush machine if a leak develops. Repeat set up steps to reseal the tool to the converter hub and continue flushing.
    WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.

  1. 15.

    Forward flush the converter for 15 minutes.

  1. 16.

    Monitor GPM flow meter periodically during the flush procedure. Flow rate above 2.0 gallons per minute is required to break up and dislodge any contamination trapped behind the TCC (torque converter clutch) plate. Service flush machine filter(s) if flow rate drops below 2 GPM.

  1. 17.

    Follow the equipment instructions to purge the torque converter.

  1. 18.

    WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.

    Allow torque converter and equipment to cool for 30 minutes before handling.

  1. 19.

    Disconnect the hoses and remove the special tools.

Flush The Torque Converter By Hand 

NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.
NOTE: Only flush the torque converter by hand when the transmission cooling system heated flusher is not available.

  1. 20.

    Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.

  1. 21.

    Examine the transmission fluid for contaminants. The transmission fluid must be free of metallic contaminants. If metallic contaminants are present, do not continue with hand flushing. The torque converter must be flushed with the transmission cooling system heated flusher.

  1. 22.

    Drain the remaining transmission fluid from the torque converter.

  1. 23.

    Using only the recommended transmission fluid, add 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand.
GFD35837Courtesy of FORD MOTOR COMPANY

  1. 24.

    Thoroughly drain the transmission fluid.

All Vehicles 

    NOTE: Note the location of the studbolts for assembly.

  1. 25.
    Remove the bolts and the main control cover.
GFD36177Courtesy of FORD MOTOR COMPANY

  1. 26.

    Slide the TR sensor electrical connector lock tab over to unlock the connector and disconnect the TR sensor electrical connector.
GFD36267Courtesy of FORD MOTOR COMPANY

  1. 27.

    Disconnect the TSS sensor and the OSS sensor electrical connectors.
GFD36268Courtesy of FORD MOTOR COMPANY

  1. 28.

    Remove the OSS sensor wire from the retainer.
GFD36275Courtesy of FORD MOTOR COMPANY
    NOTE: Note the location of the different length bolts for assembly.
    NOTE: Handle the solenoid body with care or damage to the solenoid body may occur.

  1. 29.
    Remove the bolts and the solenoid body.
GFD36269Courtesy of FORD MOTOR COMPANY

  1. 30.

    Remove the main control valve body bolts and the valve body.
GFD36270Courtesy of FORD MOTOR COMPANY

  1. 31.

    Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. Refer to Main Control - Overhaul .

  1. 32.

    Remove and discard the forward clutch feed seal.
GFD36390Courtesy of FORD MOTOR COMPANY

  1. 33.

    Remove the bolt and the OSS sensor.
GFD36279Courtesy of FORD MOTOR COMPANY

  1. 34.

    Remove the cover assembly bolts.
GFD36179Courtesy of FORD MOTOR COMPANY

  1. 35.

    Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transmission case.
GFD36391Courtesy of FORD MOTOR COMPANY

  1. 36.

    Remove the cover assembly gasket.
GFD36181Courtesy of FORD MOTOR COMPANY

  1. 37.

    Remove the No. 1 cover assembly thrust bearing
GFD36182Courtesy of FORD MOTOR COMPANY

  1. 38.

    Remove the overdrive/direct clutch hub and turbine shaft assembly.
GFD36183Courtesy of FORD MOTOR COMPANY

  1. 39.

    Remove the No. 3 rear sun gear thrust bearing.
GFD36184Courtesy of FORD MOTOR COMPANY

  1. 40.

    Remove the intermediate clutch shell and sun gear assembly.
GFD36185Courtesy of FORD MOTOR COMPANY

  1. 41.

    Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, as necessary.
    • Gear teeth
    • Shell-to-clutch pack surfaces
    • Thrust bearing surfaces
GFD36392Courtesy of FORD MOTOR COMPANY

  1. 42.

    Remove the intermediate clutch assembly.
GFD36393Courtesy of FORD MOTOR COMPANY
    NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low OWC snap ring.

  1. 43.
    Remove the low/reverse clutch assembly.
GFD36187Courtesy of FORD MOTOR COMPANY

  1. 44.

    Remove the rear planetary carrier and center ring gear assembly.
GFD36188Courtesy of FORD MOTOR COMPANY

  1. 45.

    Clean and inspect the rear planetary gear carrier assembly for damage or wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Spline teeth
    • Thrust bearing
    • Thrust bearing surfaces
    • Ring gear teeth
GFD36394Courtesy of FORD MOTOR COMPANY

  1. 46.

    Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
GFD36189Courtesy of FORD MOTOR COMPANY

  1. 47.

    Remove the center planetary sun gear.
GFD36190Courtesy of FORD MOTOR COMPANY

  1. 48.

    Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary.
    • Sun gear teeth
    • Spline teeth
GFD36395Courtesy of FORD MOTOR COMPANY

  1. 49.

    Remove the center planetary carrier and front ring gear assembly.
GFD36191Courtesy of FORD MOTOR COMPANY

  1. 50.

    Clean and inspect the center planetary gear carrier assembly for damage or wear and install new, as necessary.
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing surfaces
    • Ring gear teeth
GFD36396Courtesy of FORD MOTOR COMPANY

  1. 51.

    Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
GFD36192Courtesy of FORD MOTOR COMPANY

  1. 52.

    Remove the front planetary carrier and rear ring gear assembly.
GFD36193Courtesy of FORD MOTOR COMPANY

  1. 53.

    Clean and inspect the front planetary gear carrier assembly for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Ring gear teeth
    • Shell-to-clutch pack surfaces
    • Pinion gear teeth
    • Pinion gear surfaces
    • Pinion gear bearings
    • Thrust bearing
GFD36397Courtesy of FORD MOTOR COMPANY

  1. 54.

    Remove the front planetary sun gear and shell assembly.
GFD36194Courtesy of FORD MOTOR COMPANY

  1. 55.

    Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, if necessary.
    • Sun gear teeth
    • Shell-to-clutch pack surfaces
    • Bearing surfaces
GFD36398Courtesy of FORD MOTOR COMPANY

  1. 56.

    Remove the No. 10 front sun gear thrust bearing.
GFD36195Courtesy of FORD MOTOR COMPANY

  1. 57.

    Remove the front planetary carrier hub assembly.
GFD36196Courtesy of FORD MOTOR COMPANY

  1. 58.

    Clean and inspect the front planetary carrier hub for damage or wear and install new, if necessary.
    • Spline teeth
    • Thrust bearing surfaces
    • Hub-to-stator support surfaces
GFD36399Courtesy of FORD MOTOR COMPANY

  1. 59.

    Remove the No. 11 support assembly thrust bearing.
GFD36197Courtesy of FORD MOTOR COMPANY
    NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.

  1. 60.
    Remove the low OWC snap ring.
GFD36400Courtesy of FORD MOTOR COMPANY

  1. 61.

    Remove the low OWC.
GFD36401Courtesy of FORD MOTOR COMPANY
    NOTE: The low OWC cannot be disassembled.
    NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.

  1. 62.
    Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should rotate counterclockwise and lock when rotated clockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC.
GFD36402Courtesy of FORD MOTOR COMPANY

  1. 63.

    Inspect the forward clutch surface for damage. If the surface is burned or worn excessively, install a new OWC.
GFD36403Courtesy of FORD MOTOR COMPANY

  1. 64.

    Remove the forward clutch assembly.
GFD36404Courtesy of FORD MOTOR COMPANY
    NOTE: Install the Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

  1. 65.
    Using the special tools, compress the forward clutch piston return spring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (includes 307-584/1 and 307-584/2), Compressor, Forward Clutch Spring 307-574
GFD36405Courtesy of FORD MOTOR COMPANY
    NOTE: The special tools are not shown for clarity.

  1. 66.
    Remove the forward clutch piston return spring snap ring.
GFD36406Courtesy of FORD MOTOR COMPANY

  1. 67.

    Remove the forward clutch piston return spring.
GFD36407Courtesy of FORD MOTOR COMPANY

  1. 68.

    Remove and discard the forward clutch piston.
GFD36408Courtesy of FORD MOTOR COMPANY
    NOTE: Note the location of the studbolts for assembly.

  1. 69.
    Remove the torque converter housing bolts.
GFD36198Courtesy of FORD MOTOR COMPANY
    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. 70.
    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.
GFD36199Courtesy of FORD MOTOR COMPANY

  1. 71.

    Remove the transmission lube tube.
GFD36409Courtesy of FORD MOTOR COMPANY

  1. 72.

    Remove the differential and ring gear assembly.
GFD36410Courtesy of FORD MOTOR COMPANY

  1. 73.

    Remove the transfer shaft and gear assembly.
GFD36411Courtesy of FORD MOTOR COMPANY
    NOTE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

  1. 74.
    Inspect the differential for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the ring gear for damage. Install new bearings or a ring gear on the differential if damage or excessive wear is found. Refer to Differential Gear Assembly . If the differential bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to Transaxle Case  and Torque Converter Housing . If the differential ring gear is replaced, the transfer shaft must also be replaced. Refer to Transfer Shaft and Gear .
GFD36412Courtesy of FORD MOTOR COMPANY
    NOTE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

  1. 75.
    Inspect the transfer shaft for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the park pawl wheel, transfer shaft and transfer shaft input gear for damage. Install new bearings, park pawl wheel, transfer shaft or transfer shaft input gear if damage or excessive wear is found. Refer to Transfer Shaft and Gear . If the transfer shaft bearings are replaced the bearing races in the transmission case and the torque converter housing case must also be replaced. Refer to Transaxle Case  and Torque Converter Housing . If the transfer shaft is replaced, the differential ring gear must also be replaced. Refer to Differential Gear Assembly .

    1. 1.

      Bearings

    1. 2.

      Transfer shaft input gear

    1. 3.

      Transfer shaft

    1. 4.

      Park pawl wheel
GFD36413Courtesy of FORD MOTOR COMPANY

  1. 76.

    Remove and discard the pump-to-case seal.
GFD36200Courtesy of FORD MOTOR COMPANY

  1. 77.

    Remove the bolts and the oil reservoir.
GFD36414Courtesy of FORD MOTOR COMPANY

  1. 78.

    Remove and discard the reservoir O-ring seal.
GFD36415Courtesy of FORD MOTOR COMPANY
    NOTE: Gently pry the pin out of the hole from under the head on each side with the special tool or the pin may be broken off in the hole.

  1. 79.
    Using the special tool, remove and discard the TR sensor locking pin. Special tool(s): Remover, TRS Retaining Pin 307-696
GFD36360Courtesy of FORD MOTOR COMPANY

  1. 80.

    Remove the TR sensor.

    1. 1.

      Slide the TR sensor out of the transmission case.

    1. 2.

      Rotate the TR sensor detent plate until it rests against the transmission case.

    1. 3.

      Remove the park pawl actuator rod from the detent lever and remove the TR sensor.
GFD36361Courtesy of FORD MOTOR COMPANY

  1. 81.

    Remove the park pawl actuator rod.
GFD36416Courtesy of FORD MOTOR COMPANY

  1. 82.

    Remove and discard the manual lever shaft seal.
GFD36277Courtesy of FORD MOTOR COMPANY
    NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

  1. 83.
    Check the transmission case side transfer shaft bearing cup for damage. If the transmission case side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to Transaxle Case . If a new bearing cup is installed in the transmission case, install a new transfer shaft bearing cup in the torque converter housing. Refer to Torque Converter Housing . Install new bearings on the transfer shaft. Refer to Transfer Shaft and Gear .
GFD36417Courtesy of FORD MOTOR COMPANY

  1. 84.

    Remove and discard the halfshaft seal.
GFD36418Courtesy of FORD MOTOR COMPANY
    NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.

  1. 85.
    Inspect the transmission case side differential bearing cup for damage. If the transmission case side differential bearing cup is damaged, install a new bearing cup. Refer to Transaxle Case . If a new bearing cup is installed in the transmission case, install a new differential bearing cup in the torque converter housing. Refer to Torque Converter Housing . If a new bearing cup was installed, the differential bearings must also be replaced. Refer to Differential Gear Assembly .
GFD36419Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the bolt and the fluid baffle from the torque converter housing.
GFD36420Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the stator support assembly bolts and remove the stator support assembly.
GFD36421Courtesy of FORD MOTOR COMPANY

  1. 88.

    Remove the bolts and the fluid pump and filter assembly.
GFD36422Courtesy of FORD MOTOR COMPANY
    NOTE: Note the orientation of the fluid filter to the fluid pump.

  1. 89.
    Remove and discard the fluid filter.

    1. 1.

      Pull the filter out of the bore of the fluid pump.

    1. 2.

      If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.
GFD36423Courtesy of FORD MOTOR COMPANY

  1. 90.

    Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.

  1. 91.

    Remove the fluid pump sprocket and chain assembly.
GFD36424Courtesy of FORD MOTOR COMPANY

  1. 92.

    Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
    • Check the drive chain for wear, damage, stretching or tightness of the chain links.
    • Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.
GFD36425Courtesy of FORD MOTOR COMPANY

  1. 93.

    Remove the fluid pump drive sprocket and driven sprocket thrust washers.
GFD36426Courtesy of FORD MOTOR COMPANY
    NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

  1. 94.
    Inspect the torque converter housing side transfer shaft bearing cup for damage. If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to Torque Converter Housing . If a new bearing cup is installed in the torque converter housing, install a new transfer shaft bearing cup in the transmission case. Refer to Transaxle Case . Install new bearings on the transfer shaft. Refer to Transfer Shaft and Gear .
GFD36427Courtesy of FORD MOTOR COMPANY

FWD vehicles 

  1. 95.

    Remove and discard the halfshaft seal.
GFD36428Courtesy of FORD MOTOR COMPANY

All vehicles 

    NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.

  1. 96.
    Inspect the torque converter housing side differential bearing cup for damage. If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. Refer to Torque Converter Housing . If a new bearing cup is installed in the torque converter housing, install a new differential bearing cup in the transmission case. Refer to Transaxle Case . If a new bearing cup was installed, the differential bearings must also be replaced. Refer to Differential Gear Assembly .
GFD36429Courtesy of FORD MOTOR COMPANY

  1. 97.

    Using a dent puller, remove and discard the torque converter hub seal from the torque converter housing.
GFD36430Courtesy of FORD MOTOR COMPANY
    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. 98.
    • Clean and inspect the transmission case and torque converter housing for damage and install a new transmission case or torque converter housing if necessary. If a new transmission case or torque converter housing is installed, refer to Transaxle Case  for bearing cup installation and Torque Converter Housing  for torque converter housing bearing cup installation and differential/transfer gear bearing shim measurement.
    • Make sure that the mating faces are clean and free of foreign material. Refer to RTV Sealing Surface Cleaning and Preparation in Engine System General Information .
    • Clean and inspect the thrust bearings and washers for damage and install new bearings or washers as necessary.

  1. 99.

    Remove the overdrive clutch snap ring.
GFD36431Courtesy of FORD MOTOR COMPANY

  1. 100.

    Remove the overdrive clutch hub and clutch assembly.
GFD36432Courtesy of FORD MOTOR COMPANY

  1. 101.

    Remove the bottom overdrive clutch steel plate.
GFD36433Courtesy of FORD MOTOR COMPANY

  1. 102.

    Remove the No. 2 rear sun gear thrust bearing.
GFD36434Courtesy of FORD MOTOR COMPANY

  1. 103.

    Install the special tools on the balance piston. Using a press, compress the overdrive piston return spring. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/1), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
GFD36435Courtesy of FORD MOTOR COMPANY

  1. 104.

    With the overdrive piston return spring compressed, remove the balance piston snap ring.
GFD36436Courtesy of FORD MOTOR COMPANY

  1. 105.

    Remove and discard the balance piston.
GFD36437Courtesy of FORD MOTOR COMPANY

  1. 106.

    Remove the overdrive piston return spring.
GFD36438Courtesy of FORD MOTOR COMPANY

  1. 107.

    Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
GFD36439Courtesy of FORD MOTOR COMPANY

  1. 108.

    Position the overdrive/direct clutch assembly in the rear cover.
GFD36440Courtesy of FORD MOTOR COMPANY

  1. 109.

    Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
GFD36441Courtesy of FORD MOTOR COMPANY

  1. 110.

    Remove and discard the overdrive clutch piston inner seal.
GFD36442Courtesy of FORD MOTOR COMPANY

  1. 111.

    Remove and discard the overdrive clutch piston outer seals from the piston.
GFD36443Courtesy of FORD MOTOR COMPANY
    NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

  1. 112.
    Install the special tools on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder to remove the snap ring.

    1. 1.

      Piston alignment tab

    1. 2.

      Snap ring
    • Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/2), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
GFD36444Courtesy of FORD MOTOR COMPANY

  1. 113.

    Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
GFD36439Courtesy of FORD MOTOR COMPANY

  1. 114.

    Position the overdrive/direct clutch assembly in the rear cover.
GFD36445Courtesy of FORD MOTOR COMPANY

  1. 115.

    Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port and remove the direct clutch cylinder from the overdrive/direct clutch assembly.
GFD36446Courtesy of FORD MOTOR COMPANY

  1. 116.

    Remove and discard the rear direct clutch cylinder seal.
GFD36447Courtesy of FORD MOTOR COMPANY

  1. 117.

    Remove and discard the direct clutch piston.
GFD36448Courtesy of FORD MOTOR COMPANY

  1. 118.

    Remove the direct clutch piston return spring.
GFD36449Courtesy of FORD MOTOR COMPANY

  1. 119.

    Remove and discard the direct clutch piston seals.
GFD36450Courtesy of FORD MOTOR COMPANY

  1. 120.

    Remove the direct clutch snap ring.
GFD36451Courtesy of FORD MOTOR COMPANY

  1. 121.

    Remove the direct clutch pressure plate, clutch assembly and wave spring.
GFD36452Courtesy of FORD MOTOR COMPANY

  1. 122.

    Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.

  1. 123.

    Install the direct clutch wave spring.
GFD36453Courtesy of FORD MOTOR COMPANY

  1. 124.

    Soak the direct clutch pack in clean transmission fluid.
GFD36454Courtesy of FORD MOTOR COMPANY

  1. 125.

    Install the direct clutch assembly and pressure plate.
GFD36452Courtesy of FORD MOTOR COMPANY

  1. 126.

    Install the direct clutch snap ring.
GFD36451Courtesy of FORD MOTOR COMPANY

  1. 127.

    Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
GFD36455Courtesy of FORD MOTOR COMPANY

  1. 128.

    Install the direct clutch piston return spring.
GFD36449Courtesy of FORD MOTOR COMPANY

  1. 129.

    Lubricate a new direct clutch piston with petroleum jelly and install the piston.
GFD36456Courtesy of FORD MOTOR COMPANY

  1. 130.

    Install a new rear direct clutch cylinder seal and lubricate it with petroleum jelly.
GFD36457Courtesy of FORD MOTOR COMPANY

  1. 131.

    Install the direct clutch cylinder.
GFD36458Courtesy of FORD MOTOR COMPANY
    NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
    NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

  1. 132.
    Install the special tools on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.

    1. 1.

      Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.

    1. 2.

      Install the snap ring.
    • Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/2), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
GFD36444Courtesy of FORD MOTOR COMPANY

  1. 133.

    Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
GFD36459Courtesy of FORD MOTOR COMPANY

  1. 134.

    Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
GFD36460Courtesy of FORD MOTOR COMPANY

  1. 135.

    Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the special tool. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/1)
GFD36461Courtesy of FORD MOTOR COMPANY
    NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.

  1. 136.
    Install the overdrive clutch piston return spring.
GFD36438Courtesy of FORD MOTOR COMPANY

  1. 137.

    Lubricate the seals on a new balance piston with petroleum jelly.
GFD36462Courtesy of FORD MOTOR COMPANY

  1. 138.

    Install the new balance piston and install the special tools. Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589 (307-589/1), Compressor, Forward/Intermediate Spring 307-584 (307-584/2)
GFD36463Courtesy of FORD MOTOR COMPANY

  1. 139.

    Using a press and the special tools, compress the overdrive clutch piston return spring and install the snap ring.
GFD36436Courtesy of FORD MOTOR COMPANY

  1. 140.

    Install the No. 2 rear sun gear thrust bearing
GFD36434Courtesy of FORD MOTOR COMPANY

  1. 141.

    Install the overdrive clutch hub.
GFD36464Courtesy of FORD MOTOR COMPANY

  1. 142.

    Soak the overdrive clutch pack in clean transmission fluid.
GFD36465Courtesy of FORD MOTOR COMPANY

  1. 143.

    Install the overdrive clutch pack assembly and the pressure plate.
GFD36466Courtesy of FORD MOTOR COMPANY

  1. 144.

    Install the overdrive clutch pack snap ring.
GFD36467Courtesy of FORD MOTOR COMPANY

  1. 145.

    Remove the bolt and the TSS sensor.
GFD36468Courtesy of FORD MOTOR COMPANY

  1. 146.

    Using a press and the special tools, compress the intermediate clutch return spring and remove the snap ring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2)
GFD36469Courtesy of FORD MOTOR COMPANY

  1. 147.

    Remove the intermediate clutch return spring.
GFD36470Courtesy of FORD MOTOR COMPANY

  1. 148.

    Remove and discard the intermediate clutch piston.
GFD36471Courtesy of FORD MOTOR COMPANY

  1. 149.

    Install the special tools, using a press, compress the low/reverse clutch return spring and remove the snap ring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/2), Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)
GFD36472Courtesy of FORD MOTOR COMPANY

  1. 150.

    Remove the low/reverse clutch return spring.
GFD36473Courtesy of FORD MOTOR COMPANY

  1. 151.

    Remove and discard the low/reverse clutch piston.
GFD36474Courtesy of FORD MOTOR COMPANY

  1. 152.

    Remove and discard the 4 Teflon ® seals.
GFD36475Courtesy of FORD MOTOR COMPANY

  1. 153.

    Clean and inspect the cover for damage. Install a new cover, if damaged.

  1. 154.

    Install the new Teflon ® seals.

    1. 1.

      Install 307-578 /3 on the cover and adjust 307-578 /3 to align the bottom edge of 307-578 /3 with the top edge of the bottom Teflon ® seal groove.

    1. 2.

      Install a new Teflon ® seal on 307-578 /3.

    1. 3.

      Install 307-578 /2 over 307-578 /3. Using 307-578 /2, slide the Teflon ® seal over the cover and into the groove.

    1. 4.

      Repeat Steps 1 through 3 for the other 3 Teflon ® seals.
    • Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578 (307-578/2, 307-578/3)
GFD36476Courtesy of FORD MOTOR COMPANY

  1. 155.

    Install the special tool on the cover to size the 4 Teflon ® seals. Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578 (307-578/1)
GFD36477Courtesy of FORD MOTOR COMPANY

  1. 156.

    Install the special tools. Special Tool(s): Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)
GFD36478Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure the low/reverse piston bleed hole and semicircle area are aligned with the indentation in the cover and the intermediate cylinder fill hole.

  1. 157.
    Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly, align the piston bleed hole with the indentation in the cover and push the piston in the cylinder using the special tools. Special Tool(s): Reverse Clutch Piston and Retaining Ring Set 307-588 (307-588/3)
GFD36479Courtesy of FORD MOTOR COMPANY

  1. 158.

    Install the low/reverse piston return spring with the tabs facing down.
GFD36480Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

  1. 159.
    Using the special tools and a press, compress the low/reverse piston return spring and install the snap ring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/2) and the Reverse Clutch Piston and Retaining Ring Set (307-588) 307-588/3
GFD36481Courtesy of FORD MOTOR COMPANY

  1. 160.

    Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.
GFD36482Courtesy of FORD MOTOR COMPANY

  1. 161.

    Install the intermediate clutch piston.
GFD36483Courtesy of FORD MOTOR COMPANY

  1. 162.

    Install the intermediate clutch piston return spring.
GFD36484Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.

  1. 163.
    Install the special tools. Using a press, compress the intermediate clutch piston return spring and install the snap ring. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584
GFD36485Courtesy of FORD MOTOR COMPANY

  1. 164.

    Remove the special tool. Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578 (307-578/1)
GFD36486Courtesy of FORD MOTOR COMPANY

  1. 165.

    Lubricate the O-ring seal on TSS sensor with clean transmission fluid and install the TSS sensor in the cover and install the bolt.
    • Tighten to 12 Nm (106 lb-in).
GFD36487Courtesy of FORD MOTOR COMPANY

  1. 166.

    Remove and discard the stator support assembly seal.
GFD36488Courtesy of FORD MOTOR COMPANY

  1. 167.

    Assemble the special tools, using the tools remove and discard the input shaft seal. Special Tool(s): Slide Hammer 100-001, Collet 7/8" to 1" 303-D020, Actuating Pin (Dia 3/16") 303-D011
GFD36489Courtesy of FORD MOTOR COMPANY

  1. 168.

    Remove the drive sprocket thrust washer.
GFD36490Courtesy of FORD MOTOR COMPANY

  1. 169.

    Remove and discard the stator support-to-torque converter seal.
GFD36491Courtesy of FORD MOTOR COMPANY
    NOTE: Note the location of the Torx ® head and the hex head bolts for assembly.

  1. 170.
    Remove the bolts and the stator support feed tube.
GFD36492Courtesy of FORD MOTOR COMPANY

  1. 171.

    Remove and discard the gasket for the feed tube assembly.
GFD36493Courtesy of FORD MOTOR COMPANY

  1. 172.

    Clean and inspect the stator support assembly for damage and install new, if necessary.

  1. 173.

    Install a new stator support-to-torque converter seal.

    1. 1.

      Install 307-579 /3 on the stator support assembly.

    1. 2.

      Install a new seal on 307-579 /3.

    1. 3.

      Install 307-579 /2 on 307-579 /3 and slide the seal in to the groove on the stator support assembly.
    • Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/2 and 307-579/3)
GFD36494Courtesy of FORD MOTOR COMPANY

  1. 174.

    Install the special tool. Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/1)
GFD36495Courtesy of FORD MOTOR COMPANY

  1. 175.

    Install a new gasket on the stator support assembly.
GFD36496Courtesy of FORD MOTOR COMPANY
    NOTE: Install the Torx ® and the hex bolts in the correct locations as noted during disassembly.

  1. 176.
    Position the stator support feed tube assembly in place and install the bolts hand-tight.
GFD36497Courtesy of FORD MOTOR COMPANY

  1. 177.

    Tighten the stator support feed tube Torx ® head bolts.
    • Tighten to 7 Nm (62 lb-in).
GFD36498Courtesy of FORD MOTOR COMPANY

  1. 178.

    Tighten the stator support feed tube hex-head bolts.
    • Tighten to 12 Nm (106 lb-in).
GFD36499Courtesy of FORD MOTOR COMPANY

  1. 179.

    Install a new input shaft seal on the special tool. Special Tool(s): Support Seal Installer 307-585
GFD36203Courtesy of FORD MOTOR COMPANY

  1. 180.

    Using the special tool, install the input shaft seal. Special Tool(s): Support Seal Installer 307-585
GFD36500Courtesy of FORD MOTOR COMPANY

  1. 181.

    Remove the special tool from the stator support assembly. Special Tool(s): Support Solid Seal Installer (Single Seal) 307-579 (307-579/1)
GFD36501Courtesy of FORD MOTOR COMPANY

  1. 182.

    Install the drive sprocket thrust washer.
GFD36490Courtesy of FORD MOTOR COMPANY

  1. 183.

    Install a new stator support assembly seal.
GFD36502Courtesy of FORD MOTOR COMPANY
    NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.
    NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.
    NOTE: The solenoid body should be handled with care or damage to the solenoid body may occur.

  1. 184.
    Remove the solenoid body filter assembly by pulling it straight up from the alignment tabs. Discard the filter.
GFD36503Courtesy of FORD MOTOR COMPANY

  1. 185.

    Remove and discard the solenoid body assembly electrical connector seal.
GFD36504Courtesy of FORD MOTOR COMPANY

  1. 186.

    Clean and inspect the solenoid body assembly for damage and install new if necessary.
GFD36505Courtesy of FORD MOTOR COMPANY

  1. 187.

    If replacing the solenoid body, install the replacement service tag on the transmission case over the current solenoid body strategy tag.
GFD36280Courtesy of FORD MOTOR COMPANY

  1. 188.

    Install a new solenoid body assembly electrical connector seal.
GFD36506Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transmission will occur if the filter passages are not clean.
    NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.
    NOTE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.

  1. 189.
    Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.
GFD36507Courtesy of FORD MOTOR COMPANY

  1. 190.

    Slide the park pawl over and install the park pawl actuator rod.
GFD36508Courtesy of FORD MOTOR COMPANY

  1. 191.

    Using the special tool, install the manual lever shaft seal in the transmission case.

    1. 1.

      Lubricate a new manual shaft seal and the special tool with petroleum jelly.

    1. 2.

      Install the seal on the special tool and install the seal in the transmission case.
    • Special Tool(s): Manual Lever Seal Installer 307-581
GFD36278Courtesy of FORD MOTOR COMPANY

  1. 192.

    Install the TR sensor.

    1. 1.

      Position the park pawl actuating rod in the TR sensor detent plate.

    1. 2.

      Install the TR sensor in the transmission case.
GFD36362Courtesy of FORD MOTOR COMPANY

  1. 193.

    Install a new TR sensor locking pin in the transmission case.
    • Use the special tool to drive the TR sensor locking pin into the transmission case.
    • Special Tool(s): Manual Lever Seal Installer 307-581
GFD36363Courtesy of FORD MOTOR COMPANY

  1. 194.

    Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.
GFD36509Courtesy of FORD MOTOR COMPANY

  1. 195.

    Install the transmission fluid reservoir and the bolts.
    • Tighten to 12 Nm (106 lb-in).
GFD36414Courtesy of FORD MOTOR COMPANY

  1. 196.

    Install a new pump-to-case seal.
GFD36206Courtesy of FORD MOTOR COMPANY

  1. 197.

    Install the transfer shaft and gear assembly.
GFD36411Courtesy of FORD MOTOR COMPANY

  1. 198.

    Tilt the transfer shaft and gear assembly over and install the differential assembly.
GFD36410Courtesy of FORD MOTOR COMPANY

  1. 199.

    Install a new torque converter hub seal on the special tool. Special Tool(s): Converter Seal Installer 307-575
GFD36222Courtesy of FORD MOTOR COMPANY
    NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

  1. 200.
    Using the special tool and a dead blow hammer, install the torque converter hub seal in the torque converter housing. Special Tool(s): Converter Seal Installer 307-575
GFD36223Courtesy of FORD MOTOR COMPANY

FWD vehicles 

  1. 201.

    Assemble the special tools and install a new RH halfshaft seal on the special tool. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A
GFD36224Courtesy of FORD MOTOR COMPANY
    NOTE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.

  1. 202.
    Using the special tools, install the new RH halfshaft seal in the torque converter housing. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A
GFD36225Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 203.

    Install the pump drive sprocket and driven sprocket thrust washers.
GFD36426Courtesy of FORD MOTOR COMPANY
    NOTE: The dot on the pump sprocket is installed facing upward.

  1. 204.
    Install the pump sprocket and chain assembly.
GFD36424Courtesy of FORD MOTOR COMPANY

  1. 205.

    Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
    NOTE: Lubricate the seal with clean transmission fluid.

  1. 206.
    Install the fluid filter seal in the fluid pump.
GFD36510Courtesy of FORD MOTOR COMPANY
    NOTE: Install the filter in the correct orientation as noted in removal.

  1. 207.
    Install the fluid filter in the fluid pump.
GFD36511Courtesy of FORD MOTOR COMPANY

  1. 208.

    Position the pump and filter assembly in place and install the bolts.
    • Tighten to 12 Nm (106 lb-in).
GFD36422Courtesy of FORD MOTOR COMPANY
    NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.

  1. 209.
    Position the stator support assembly in place on the torque converter housing. Install the stator support bolts. Tighten in the sequence shown.
    • Tighten to 41 Nm (30 lb-ft).
Fig 1: Stator Support Assembly Bolts Tightening Sequence
GFD36512Courtesy of FORD MOTOR CO.

  1. 210.

    Position the differential carrier baffle in place and install the bolt.
    • Tighten to 12 Nm (106 lb-in).
GFD36420Courtesy of FORD MOTOR COMPANY

  1. 211.

    Lubricate the ends of the transmission fluid tube with petroleum jelly and install it in the transmission.
GFD36513Courtesy of FORD MOTOR COMPANY
    NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.

  1. 212.
    Apply a bead of the Ultra Silicone Sealant.
GFD36514Courtesy of FORD MOTOR COMPANY
    NOTE: Install the 2 studbolts in the correct location as noted during disassembly.

  1. 213.
    Install the torque converter housing on top of the transmission case and install the bolts hand tight.
GFD36198Courtesy of FORD MOTOR COMPANY
    NOTE: The studbolts are 1 and 16 in the tightening sequence.

  1. 214.
    Tighten the bolts in the sequence shown.
    • Tighten to 24 Nm (18 lb-ft).
Fig 2: Torque Converter Housing Bolts Tightening Sequence
GFD36209Courtesy of FORD MOTOR CO.

  1. 215.

    Assemble the special tools, install a new halfshaft seal on the special tool. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A
GFD36226Courtesy of FORD MOTOR COMPANY

  1. 216.

    Using the special tools, install the new halfshaft seal in the transmission case. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Cover Axle Seal 307-582A
GFD36515Courtesy of FORD MOTOR COMPANY

  1. 217.

    Lubricate the forward clutch piston seals with petroleum jelly.
GFD36516Courtesy of FORD MOTOR COMPANY
    NOTE: Install the Compressor, Forward/Intermediate Spring 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.

  1. 218.
    Position the forward clutch piston in place in the transmission case. Using the special tool, push the forward clutch piston down into the bore. Special Tool(s): Compressor, Forward/Intermediate Spring 307-584 (307-584/1)
GFD36517Courtesy of FORD MOTOR COMPANY
    NOTE: Install the Compressor, Forward/Intermediate Spring with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

  1. 219.
    Install the forward clutch piston return spring with the tabs facing downward.
GFD36407Courtesy of FORD MOTOR COMPANY
    NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
    NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

  1. 220.
    Install the special tools and compress the forward clutch piston return spring. Special Tool(s): Compressor, Forward Clutch Spring 307-574 Compressor, Forward/Intermediate Spring 307-584 (includes 307-584/1 and 307-584/2)
GFD36405Courtesy of FORD MOTOR COMPANY
    NOTE: The special tools not shown for clarity.

  1. 221.
    Install the forward clutch piston return spring snap ring.
    • Install the snap ring.
    • The snap ring gap should be at the top of the transmission case.
GFD36406Courtesy of FORD MOTOR COMPANY

  1. 222.

    Install the forward clutch wave spring.
GFD36518Courtesy of FORD MOTOR COMPANY

  1. 223.

    Soak the forward clutch pack in clean transmission fluid.
GFD36519Courtesy of FORD MOTOR COMPANY

  1. 224.

    Install the forward clutch pack assembly.

    1. 1.

      Position the forward clutch pack assembly in the case.

    1. 2.

      Make sure the alignment tab on the clutch pack is positioned in the correct location.
GFD36520Courtesy of FORD MOTOR COMPANY

  1. 225.

    Install the low OWC.
GFD36401Courtesy of FORD MOTOR COMPANY
    NOTE: The low OWC snap ring gap must be positioned as shown below so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.

  1. 226.
    Install the low OWC snap ring.
GFD36400Courtesy of FORD MOTOR COMPANY

  1. 227.

    Compare the position of the low OWC snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
GFD36521Courtesy of FORD MOTOR COMPANY

  1. 228.

    Install the special tool on the transmission case and position the plunger on a top friction disc tab. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD36522Courtesy of FORD MOTOR COMPANY

  1. 229.

    Install a new forward clutch feed seal.
GFD36523Courtesy of FORD MOTOR COMPANY

  1. 230.

    Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low OWC for correct installation. If the forward clutch pack and low OWC is correctly installed, install a new forward clutch pack. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD36524Courtesy of FORD MOTOR COMPANY

  1. 231.

    Install the No. 11 stator support thrust bearing.
GFD36197Courtesy of FORD MOTOR COMPANY

  1. 232.

    Install the front planetary carrier hub.
GFD36196Courtesy of FORD MOTOR COMPANY

  1. 233.

    Install the No. 10 front sun gear thrust bearing.
GFD36195Courtesy of FORD MOTOR COMPANY

  1. 234.

    Install the front sun gear and shell assembly.
GFD36194Courtesy of FORD MOTOR COMPANY

  1. 235.

    Install the front carrier and rear ring gear assembly.
GFD36193Courtesy of FORD MOTOR COMPANY

  1. 236.

    Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
GFD36192Courtesy of FORD MOTOR COMPANY

  1. 237.

    Install the center planetary carrier and front ring gear assembly.
GFD36191Courtesy of FORD MOTOR COMPANY
    NOTE: The groove on the center sun gear is installed facing up.

  1. 238.
    Install the center planetary sun gear.
GFD36190Courtesy of FORD MOTOR COMPANY

  1. 239.

    Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
GFD36189Courtesy of FORD MOTOR COMPANY

  1. 240.

    Install the rear planetary gear carrier assembly.
GFD36188Courtesy of FORD MOTOR COMPANY
    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. 241.
    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.
GFD36210Courtesy of FORD MOTOR COMPANY

  1. 242.

    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.
GFD36211Courtesy of FORD MOTOR COMPANY

  1. 243.

    Soak the low/reverse clutch pack with clean transmission fluid.
GFD36212Courtesy of FORD MOTOR COMPANY

  1. 244.

    Install the low/reverse clutch pack.
GFD36213Courtesy of FORD MOTOR COMPANY
    NOTE: The low/reverse clutch wave spring and pressure plate are temporarily reversely installed to measure the low/reverse clutch clearance.

  1. 245.
    Temporarily install the low/reverse clutch wave spring and pressure plate with the pressure plate on top of the wave spring.

    1. 1.

      Pressure plate

    1. 2.

      Wave spring
GFD36525Courtesy of FORD MOTOR COMPANY

  1. 246.

    Using a straightedge and the Depth Micrometer, measure and record as measurement A, the distance from the transmission case deck surface to the low/reverse pressure plate. Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A
GFD36526Courtesy of FORD MOTOR COMPANY

  1. 247.

    Using the same straightedge and the Depth Micrometer, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface. Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A
GFD36527Courtesy of FORD MOTOR COMPANY

  1. 248.

    Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 0.83 mm (0.032 in) and 2.43 mm (0.095 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 low/reverse clutch pack.
    Description Reading
    Measurement A
    Measurement B
    Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the low/reverse clutch clearance.
    NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.

  1. 249.
    Correctly install the low/reverse clutch wave spring and pressure plate.

    1. 1.

      Wave spring

    1. 2.

      Pressure plate
GFD36214Courtesy of FORD MOTOR COMPANY

  1. 250.

    Install the intermediate clutch pressure plate.
GFD36528Courtesy of FORD MOTOR COMPANY

  1. 251.

    Soak the intermediate clutch pack assembly in clean transmission fluid.
GFD36216Courtesy of FORD MOTOR COMPANY

  1. 252.

    Install the intermediate clutch pack assembly.
GFD36393Courtesy of FORD MOTOR COMPANY

  1. 253.

    Install the intermediate clutch pack wave spring.
GFD36529Courtesy of FORD MOTOR COMPANY

  1. 254.

    Using a straightedge and the Depth Micrometer, measure and record as measurement A, the distance from the transmission case deck surface to a low point on the intermediate clutch wave spring. Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A
GFD36530Courtesy of FORD MOTOR COMPANY

  1. 255.

    Using the straightedge and the Depth Micrometer, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface. Special Tool(s): Depth Micrometer 303-D075 D92P-4201-A
GFD36531Courtesy of FORD MOTOR COMPANY

  1. 256.

    Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.038 in) and 2.56 mm (0.1 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
    Description Reading
    Measurement A
    Measurement B
    Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the intermediate clutch clearance.

  1. 257.

    Install the rear sun gear and shell assembly.
GFD36185Courtesy of FORD MOTOR COMPANY

  1. 258.

    Install the No. 3 rear sun gear thrust bearing.
GFD36184Courtesy of FORD MOTOR COMPANY

  1. 259.

    Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
GFD36439Courtesy of FORD MOTOR COMPANY

  1. 260.

    Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD36532Courtesy of FORD MOTOR COMPANY

  1. 261.

    Position the Dial Indicator plunger on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD36533Courtesy of FORD MOTOR COMPANY

  1. 262.

    Install the overdrive/direct clutch hub and turbine shaft assembly.
GFD36183Courtesy of FORD MOTOR COMPANY

  1. 263.

    Install the No. 1 cover assembly thrust bearing.
GFD36182Courtesy of FORD MOTOR COMPANY

  1. 264.

    Install the cover assembly gasket.
GFD36181Courtesy of FORD MOTOR COMPANY

  1. 265.

    Route the TSS sensor harness through the transmission case to the valve body area and install the cover assembly.
GFD36391Courtesy of FORD MOTOR COMPANY

  1. 266.

    Install the cover assembly bolts and tighten the bolts in the sequence shown.
    • Tighten to 12 Nm (106 lb-in).
Fig 3: Cover Assembly Bolts Tightening Sequence
GFD36219Courtesy of FORD MOTOR CO.

  1. 267.

    Install the OSS sensor and the bolt.
    • Tighten to 12 Nm (106 lb-in).
GFD36534Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
    NOTE: Be careful not to pinch the TSS, OSS or TR sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.

  1. 268.
    Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.

    1. 1.

      Manual valve

    1. 2.

      Manual pin
GFD36271Courtesy of FORD MOTOR COMPANY

  1. 269.

    Install the main control valve body bolts. Tighten the bolts in the sequence shown.
    • Tighten to 12 Nm (106 lb-in).
Fig 4: Main Control Valve Body Bolts Tightening Sequence
GFD36272Courtesy of FORD MOTOR CO.
    NOTE: Install the different length bolts in the locations noted during disassembly.
    NOTE: Make sure not to pinch the TSS, OSS or TR sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.

  1. 270.
    Install the solenoid body bolts hand-tight.

    1. 1.

      42 mm (1.653 in) bolt

    1. 2.

      63 mm (2.48 in) bolts

    1. 3.

      80 mm (3.149 in) bolts

    1. 4.

      95 mm (3.74 in) bolts
GFD36273Courtesy of FORD MOTOR COMPANY

  1. 271.

    Tighten the solenoid body bolts in the sequence shown.
    • Tighten to 12 Nm (106 lb-in).
Fig 5: Solenoid Body Bolts Tightening Sequence
GFD36274Courtesy of FORD MOTOR CO.

  1. 272.

    Route the OSS sensor wiring harness into the retainer.
GFD36275Courtesy of FORD MOTOR COMPANY

  1. 273.

    Connect the TSS and OSS sensor electrical connectors.
GFD36268Courtesy of FORD MOTOR COMPANY

  1. 274.

    Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
GFD36276Courtesy of FORD MOTOR COMPANY

  1. 275.

    Inspect the transmission main control cover seal for damage and install new if necessary.
GFD36220Courtesy of FORD MOTOR COMPANY
    NOTE: Install the studbolts in the correct locations as noted during disassembly.

  1. 276.
    Install the transmission main control cover and loosely install the bolts.
GFD36177Courtesy of FORD MOTOR COMPANY

  1. 277.

    Tighten the main control cover bolts in the sequence shown.
    • Tighten to 12 Nm (106 lb-in).
Fig 6: Main Control Cover Bolts Tightening Sequence
GFD36221Courtesy of FORD MOTOR CO.
    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. 278.
    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.
GFD36173Courtesy of FORD MOTOR COMPANY

  1. 279.

    Install the special tool. Special Tool(s): Retainer, Torque Converter 307-346
GFD36172Courtesy of FORD MOTOR COMPANY
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