Disassembly

Special Tools

Disassembly

1. CAUTION: If, during repair work, abrasive particles are found in the transaxle Rued (particles from the clutch or metal chips or foreign material), the transaxle must be disassembled completely and cleaned. Also, clean the fluid pipes, fluid cooler and torque converter carefully. In the case of extreme soiling of the fluid pipes, install a new fluid cooler and torque converter.

NOTE: In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid or equivalent meeting Ford specification MERCON V.

Inspect the transaxle during disassembly.





2. Remove the Output Shaft Speed (OSS) sensor.
1. Remove the bolt.
2. Remove the OSS.





3. Remove the turbine shaft speed (TSS) sensor.

4. CAUTION: Do not use air tools.





Remove the manual control lever.





5. Remove the Transmission Range (TR) sensor.





6. Remove the special tool.

7. CAUTION: Do not tilt the torque converter when removing it, to avoid damaging the torque converter hub.

NOTE: The torque converter is filled with fluid. Drain into a suitable container.





Using the special tool, remove the torque converter.





8. Using the special tool, mount the transaxle to a bench.





9. Remove the bolts.





10. Using the special tool, remove the fluid pump.





11. Remove the fluid pump seals.





12. Remove the forward clutch thrust washer.





13. Remove the forward clutch assembly.





14. NOTE: Small levers will aid in the removal of the forward clutch hub.

Remove the forward clutch hub.
15. Rotate the transaxle 180 degrees.





16. Remove the end cover.
17. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner or equivalent meeting Ford specification.





18. Remove the direct clutch hub bearing shim.





19. Remove the end cover seals.





20. Remove the end cover to case seals.





21. Remove the direct clutch cylinder thrust bearing.





22. Remove the intermediate/overdrive band anchor bolt.





23. Remove the intermediate/overdrive band.





24. Remove the intermediate/overdrive drum assembly.





25. Remove the planet gear assembly.





26. Remove the low/reverse clutch plate retaining ring.





27. Remove the low/reverse clutch plates, pressure plate and bevel ring.





28. Remove the low gear one-way clutch retaining ring.





29. Remove the low one-way clutch inner race.





30. Remove the low/reverse clutch return spring.





31. Remove the low/reverse clutch piston.





32. Remove the transaxle fluid pan.
33. Clean the silicone from the transaxle fluid pan and transaxle case surfaces thoroughly with metal surface cleaner or equivalent Ford specification.





34. Remove the Transmission Fluid Temperature (TFT) sensor.





35. Remove the fluid filter.

36. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.





Remove the ground wire bolt. Disconnect the electrical connectors and remove the wire harness.
1. Solenoid SSC; Color N (Neutral)
2. Solenoid SSE; Color G (Green)
3. Solenoid SSD; Color L (Blue)
4. Solenoid EPC; Color B (Black)
5. Solenoid SSA; Color N (Neutral)
6. Solenoid SSB; Color B (Black)

37. NOTE: Note the locations of the longer bolts.





Remove the 13 main control valve body bolts.

38. NOTE: Squeeze the tabs on the side of the electrical connector.





Remove the transaxle internal harness electrical connector.

39. NOTE: Each of the two accumulators have two springs. All four springs are different sizes.

NOTE: Note the size and location of the accumulator springs for assembly.





Remove the accumulator pistons and springs.





40. Remove the manual lever shaft roll pin.





41. Remove the manual lever shaft.





42. Remove the O-ring seals from the manual lever shaft.





43. Remove the control lever assembly.

44. CAUTION: The intermediate! overdrive band servo cover plate is spring loaded. The bolts should be removed evenly until plate is unloaded, then remove the bolts.





Remove the intermediate/overdrive piston servo cover.
1. Remove the bolts.
2. Remove the intermediate/overdrive piston servo cover.





45. Remove the O-ring seal.





46. Remove the intermediate/overdrive servo piston.





47. Remove the intermediate/overdrive servo piston return spring.
48. Rotate the transaxle 180 degrees.





49. Remove the bolts and separate the converter housing from the transaxle case.





50. Remove the differential assembly.





51. Remove the parking pawl assembly cover.
1. Remove the bolts.
2. Remove the parking pawl assembly cover.





52. Remove the parking pawl abutment.
1. Unclip the spring.
2. Remove the pin.
3. Remove the lever.
4. Remove the parking pawl abutment.





53. Remove the spring.





54. Remove the transfer shaft gears.





55. Using the special tool, lock the final drive input gear.
56. Rotate the transaxle 180 degrees.

57. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.





Using the special tool, remove the final drive input gear bearing retainer nut.
58. Rotate the transaxle 180 degrees.





59. Remove the special tool.

60. CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.

Rotate the transaxle 180 degrees.





61. Remove the final drive input gear bearing by lightly tapping on the end of the final drive input gear and remove the final drive input gear.





62. Remove and discard the collapsible spacer.





63. Remove the final drive input gear bearing.
64. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner or equivalent meeting Ford specification.