Assembly
ASSEMBLEThrust Washer Identification, (1990 Bronco II And 1990-1991 Aerostar And Ranger, Except 4.0L Engines):
Thrust Washer Identification, (1990-1991 Aerostar And Ranger And 1991 Explorer W/4.0L Engine):
Thrust Washer Identification, (93-95 With 2.3L And 3.0L Engine):
Thrust Washer Identification, (93-95 With 4.0L Engine):
NOTE: Some of the thrust washers used are very similar and could be improperly installed, make sure that the correct thrust washer and bearing are used and installed correctly. The gear train uses ten thrust washers and four needle bearing assemblies. To control endplay, washers No. 1 and 4 can vary in thickness. The torque converter also has thrust washers and a needle bearing between its components. These are not identified by number because they are not individually serviceable.
1. Prior to beginning assembly of transmission, high clutch seal sizing procedure must be performed as follows:
a. Install new high clutch seals on support hub.
NOTE: Seal grooves have a "dovetail" contour with straight side walls on pressure sealing sides.
b. Apply a liberal amount of petroleum jelly to center support hub and seals.
c. Using overdrive brake drum as a sizing tool, carefully rotate center support while inserting into overdrive brake drum.
d. Observe seals as they enter cavity to ensure they do not roll over or become cut.
e. Ensure center support is fully seated into overdrive brake drum, allow to stand for several minutes so that seals seat in grooves, then set aside until required for reassembly.
2. Install transmission case into a suitable swivel type overhaul fixture.
3. Install new manual lever shaft seal using driver tool No. T74P-77498-A or equivalent.
4. Install manual linkage as follows:
a. Install Park Neutral Position (PNP) switch, tighten using a box end type wrench only.
b. Install vacuum throttle control valve, rod and diaphragm into case.
Exploded View Of Manual Lever:
c. Install park pawl actuator rod and manual control detent lever into position, place kick down inner lever into position, then slide manual lever shaft through case, over kick down shaft and into position in inner detent lever.
d. Install manual lever shaft locating pin into transmission case.
e. Tighten manual shaft nut, install external kick down lever with 0-ring seal, then the nut and tighten.
5. Place thrust washer No.11 into back of case.
6. Install collector body in rear of case.
7. Install output shaft and park gear.
8. Install governor on collector body and tighten attaching bolts.
9. Place thrust washer No. 10 into case from the front, then install low/reverse drum using overrunning clutch replacement guide tool No. T74P-77193-A or equivalent.
NOTE: On 4.0L engines, a sprag type overrunning clutch is used and guide tool is not required.
10. Install output shaft ring gear and snap ring onto output shaft, using a new snap ring.
11. On models with 4.0L engines, install output shaft sleeve (lubricant guide).
12. Install thrust washer No. 9, reverse planet assembly and thrust washer No. 8, using petroleum jelly to hold thrust washers in position on planet assembly.
13. Install snap ring in drum to hold planet assembly in place.
NOTE: Models with 4.0L engines do not have a snap ring at this location.
14. Install low reverse band, ensure band is resting on case anchor pins.
15. Replace servo piston or 0-ring, if necessary, then install low reverse servo piston to hold band in position.
16. Install forward gear train assembly.
17. Install intermediate servo apply lever and shaft as follows:
Identification Of Intermediate And Overdrive Shafts And Levers:
a. Locate and identify previously marked intermediate servo apply lever and shaft. Intermediate lever has a boss on shaft hole and is shorter than overdrive shaft.
b. Install intermediate servo apply lever and shaft into case.
18. Turn transmission so that output shaft points downward.
19. Install intermediate band and apply strut, then temporarily the intermediate band anchor strut and input shaft as an alignment guide.
20. Determine size of No. 4 thrust bearing as follows:
a. Place gauge bar tool No. T93T-77003-AH, or equivalent, on holder of case.
b. Place depth micrometer tool No D80P-4201-A, or equivalent, or gauge bar.
No. 4 Thrust Washer Measurement:
c. Extend probe until it contacts thrust washer surface, subtract thickness of gauge bar (0.700 inch), record result as dimension (A).
d. Move depth micrometer to opposite side of gauge bar, repeat above measurement procedure, record reading as dimension (B).
e. Add dimensions (A) and (B) together, then divide by two (take an average) to produce dimension (C).
No. 4 Thrust Washer Identification Chart:
f. Refer to the No. 4 Thrust Washer Identification Chart to determine correct thrust washer.
g. Endplay should be 0.012-0.024 inch.
h. Select and install a thrust washer that will correct endplay to its specified value.
NOTE: If specified end play cannot be obtained, transmission is improperly assembled or parts are missing or out of specification. Disassemble transmission to locate part(s) causing problem.
21. On models with 4.0L engine and a snap together type forward gear train assembly, determine size of No. 5 thrust washer as follows:
a. Place gauge bar T93T-77003-AH or equivalent on shoulder of case.
b. Place depth micrometer tool No. D80P-4201-A or equivalent on gauge bar.
No. 5 Thrust Washer Measurement:
c. Extend probe until it contacts thrust washer surface, then subtract thickness of gauge bar (0.700 inch), record result as dimension (A).
d. Move depth micrometer to opposite side of gauge bar, repeat above measurement procedure, record reading as dimension (B).
e. Add dimensions (A) and (B) together, then devide by two (take an average) to produce dimension (C).
No. 1 And 5 Thrust Washer Identification Chart:
f. Refer to thrust washer identification chart to determine correct size of thrust washer No. 5.
g. Recommended endplay is 0.004-0.024 inch.
h. If specified endplay cannot be obtained, transmission is improperly assembled or parts are missing or out of specification. Disassemble transmission to locate part(s) causing problem.
i. Install selected No. five thrust washer over hub of forward clutch, through bottom of reverse drum.
22. Coat thrust washer No. 4 with petroleum jelly to hold in place, then position washer on center support.
23. Insert input shaft (short splines down) through center support and into forward clutch cylinder splines.
24. Carefully place center support into case without sliding it into the intermediate brake drum. Ensure support is square with case and 5 mm retainer nut is aligned with bolt hole in case.
25. Without applying any pressure to center support, gently wiggle input shaft, allowing center support to slide into intermediate brake drum using its own weight until support is fully seated, then remove input shaft.
Center Support Snap Ring Identification:
26. Install large center support snap ring with taper pointed towards front of transmission. Shallow cavity located at 5 o'clock position.
NOTE: Two types of snap rings are used, they should be positioned as shown in the Center Support Snap Ring Installation image.
27. Place caged nut into position inside case, then install 5 mm Allen head bolt that retains center support to case.
28. Install sun gear and overdrive clutch adapter into overdrive planet assembly and one-way clutch, centering needle bearing race inside of planetary. Ensure it remains centered, positioned with extruded lip in upward position (toward sun gear).
29. Position No. 3 thrust washer on top of center support.
30. Assemble overdrive planet and one-way or over running (sprag) clutch assembly as follows:
Exploded View Of Planet And One-Way Or Over Running Clutch Assembly:
a. One-way or over running (sprag) clutch assembly must be installed into overdrive center shaft so that flanges of inner and outer cages are toward overdrive planet assembly, which is toward front of transmission.
b. Overdrive clutch washer that is positioned between overdrive planet carrier and center shaft must be installed so that the recessed inside diameter faces forward (not against over running or one-way clutch assembly).
Exploded View Of Planet And One-Way Or Over Running Clutch Assembly Proper Build Up Check:
c. Perform proper assembly buildup check by holding planet assembly and ensuring center shaft turns clockwise.
31. Install overdrive planet assembly and one-way clutch into case.
32. On all models, install overdrive drum assembly, then the overdrive bracket, apply lever and shaft.
33. Install overdrive band and apply strut, then the anchor strut.
NOTE: Ensure correct band is installed.
34. Ensure needle bearing race in overdrive planetary is centered and that overdrive clutch is fully seated.
35. Determine No. 1 thrust washer thickness as follows:
a. Place No. 1 selective washer on top of overdrive clutch drum and temporarily install pump assembly into case. Ensure pump body is fully seated.
NOTE: Check for damaged or missing front pump support seal, replace if necessary. There is a rough casting portion of the crescent, this is not a flaw and pump should not be replaced.
b. Place gauge bar tool No. T93T-77003-AH, or equivalent, on gasket surface of case.
c. Place a suitable depth micrometer on gauge bar, extend micrometer tip until it contacts pump body, subtract gauge bar thickness (0.700 inch) from measurement and record as dimension (A).
d. Move gauge bar and micrometer to opposite side, repeat measurement procedure, record as dimension (B).
e. Add dimensions (A) and (B) together, then devide by two (take an average) to produce dimension (C).
f. Refer to the No. 1 And 5 Thrust Washer Identification Chart to determine correct size of thrust washer No. 1 to achieve an end play clearance of 0.007-0.025 inch.
36. Remove pump and selective washer.
37. Install a new pump oil seal using front pump alignment set tool No. T74P-77103-X and front pump seal replacer tool No. T87L-77248-AH or their equivalents, then stake seal in place using tool No. T87L-77248-BH or equivalent in two places between existing stakes.
38. Position separator plate on converter housing.
Oil Pump Gear Identification:
39. Position two pump gears into pump housing. The inside edge of the small gear has a chamfer on one side. This chamfer must be positioned toward front of transmission. The larger gear has a dimple on one side which must be positioned toward rear of transmission.
40. Position pump assembly onto separator plate and converter housing and install attaching bolts finger tight.
NOTE: The pump assembly stator end face has a depression. This is completely interchangeable with a flat stator end face.
41. Using front pump alignment set tool No. T74P-77103-X or equivalent, align pump in converter housing as follows:
a. Select arbor with smallest inside diameter that will fit completely over pump shaft.
b. Assemble common handle to selected arbor and slide tool down over shaft until it bottoms against pump, allowing outside diameter of tool arbor to automatically center pump in converter housing.
c. Tighten five new 6 mm bolts, then remove alignment tool.
42. Insert input shaft into pump, then install converter into pump gears. Rotate converter to ensure free movement, then remove converter and input shaft.
43. Coat converter gasket with petroleum jelly and position on converter housing.
44. Coat No. 1 thrust washer with petroleum jelly, then position on rear of pump.
45. Align converter housing and pump to transmission and install eight 17 mm bolts, with new aluminum washers, tighten bolts.
46. Install overdrive band and intermediate band servos into case using a suitable spring compressor.
47. Using band adjusting torque wrench tool No. T71P-77370-A or equivalent, adjust overdrive band as follows:
Adjusting Overdrive Band:
a. Install new locknut on adjusting screw, but do not tighten at this time, then tighten adjusting screw until wrench clicks (approximately 10 ft lbs).
b. Back off adjusting screw exactly two turns.
c. Hold adjusting screw from turning and tighten locknut.
48. Using tool T71P-77370-A or equivalent, adjust intermediate band as follows:
Adjusting Intermediate Band:
a. Install new locknut on adjusting screw, then tighten adjusting screw until handle clicks (approximately 10 ft lbs).
b. Back off adjusting screw exactly two turns.
c. Hold adjusting screw from turning and tighten locknut.
49. Lubricate seals, then install case multiple pin electrical connector.
50. Install main control valve body.
51. Check reverse servo piston travel as follows:
a. Install reverse servo piston assembly into servo bore together with reverse servo check spring D4ZZ-70031-A or equivalent.
Checking Travel Of Reverse Servo Piston:
b. Install new servo cover gasket and tool No. T74F-77190-A or equivalent, securing with three attaching bolts.
c. Torque servo tool adjusting screw to 36 in lbs.
d. Install dial indicator with bracket TOOL-4201-C or equivalent on transmission case, position indicator on piston pad and zero dial indicator.
e. Back out servo tool adjusting screw until piston bottoms out on tool and record distance of servo piston travel.
Reverse Servo Piston Selection Chart:
f. If piston travel is not within 0.120-0.220 inch, select replacement piston and rod from the Reverse Servo Piston Selection Chart, using next longest piston and rod if piston travel exceeds specification, or next shortest piston and rod if piston travel was less than specification.
g. Repeat procedure using new piston and rod to ensure piston travel is within specifications.
h. Remove servo adjusting tool and the reverse servo piston checking spring.
52. Install servo piston assembly, accumulator spring, gasket, and cover.
53. Install four 10 mm servo retaining bolts and torque.
54. Install filter screen using new 0-rings and torque attaching bolt.
55. Remove any trace of old gasket on case and oil pan, position oil pan gasket on case, and install oil pan, then torque attaching bolts.
56. Remove any trace of old gasket on case and extension housing, then install parking pawl and return spring in housing and preload.
57. Position new gasket on case and install extension housing, being sure to correctly seat operating park rod in extension guide cup. Torque attaching bolts.
58. Replace extension housing seal using seal replacer tool No. T74P-77052-A or equivalent.
59. Install input shaft with long splines out.
60. Install torque converter.
NOTE: Some torque converter installations may result in the converter impeller hubs not being fully engaged in the oil pump drive gears, resulting in broken oil pump gears and damaged converter impeller hubs. To properly install the torque converter, proceed as follows:
a. Rotate and push the converter inward through what feels like two notches or bumps.
b. When fully installed, a rotation of the converter will usually result in a clicking noise being heard, caused by the converter surface touching the housing to case bolts. This clicking noise is normal.
NOTE: A properly installed converter will have a dimension A, converter pilot nose front face to converter housing outer face, of 7/16 to 9/16 inch.