Steps 69 - 137

69. Install the center support locknut and cage.





70. Loosely install the screw.

71. CAUTION: Install the center support retaining ring with the tapered side facing up.

CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.





Install the center support retaining ring.





72. Install the center shaft thrust bearing (No. 3).





73. Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.

74. CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.





Install the planetary gear overdrive carrier.





75. Install the overdrive brake drum and coast clutch drum assembly.





76. Note: If the overdrive band is reused, it must be installed in the same position as when removed.

Install the overdrive band.





77. Install the overdrive anchor strut.

78. CAUTION: If the strut is installed incorrectly, transmission damage will occur.





Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.





79. Loosely install the screw.





80. Install the overdrive apply strut.

81. CAUTION: If the strut is installed incorrectly, transmission damage will occur.





Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.

82. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.





Install the special tool.
1 Install the special tool and the bolts using the two pump screw locations at approximately 6 and 12 o'clock positions.
2 Tighten the center screw.

83. Note: Align the disc holes on special tool with the slot in gauge bar for correct measurement.





Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension "A". Repeat measurement 180 degrees opposite side of the special tool and record as dimension "B".
84. Add dimension "A" to "B", divide by two and record as dimension "C".
85. Subtract the thickness of the gauge bar (17.78 mm or 0.700 inch) from dimension "C" from "D", and record as dimension "D".





86. Select the #1 thrust bearing from the following chart using dimension "D".





87. Install the selected No. 1 fluid pump input thrust washer.
- Coat the fluid pump input thrust washer with petroleum jelly.





88. Install the special tools into the transmission case.





89. Install the pump gasket.

90. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.





Install the fluid pump.

91. CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure, and leakage.





Using the special tool, align the fluid pump to the adapter plate.





92. Install screws. Tighten the screws in a star pattern.





93. Remove the special tools, install the two remaining screws.

94. CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.





Install a new locknut on the band adjustment screw.

95. CAUTION: The overdrive servo must be installed prior to band adjustment.





Using the special tool, tighten the overdrive band adjustment screw then back off the screw exactly (2) turns and hold that position.





96. Tighten the overdrive band locknut.
1 Hold the overdrive band adjustment screw stationary.
2 Tighten the overdrive band locknut.

97. CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.





Install new nut on the band adjustment screw.

98. CAUTION: The intermediate servo must be installed prior to band adjustment.





Tighten the intermediate band adjustment screw then back off the screw exactly (2) turns and hold that position.





99. Tighten the intermediate band locknut.
1 Hold the intermediate band adjustment screw stationary.
2 Tighten the intermediate band locknut.





100. Tighten the center support screw.
101. CAUTION: The intermediate clutch fluid inlet tube seal and spring must be correctly seated in the case. Failure to correctly seat the inlet tube seal and spring will cause an internal fluid leak and transmission damage.






Using a drift punch, correctly install and seat the intermediate clutch fluid inlet tube seal and spring into the case.








102. Install the special tools into the transmission case.





103. Refer to the chart for bolt locations.





104. Install the main control valve body and loosely install the screws.





105. Remove the special tools, and loosely install the screws.





106. Install the valve body cover plate and gasket and loosely install the screws.





107. Install a new reverse pressure switch and loosely install the screws.





108. Tighten the screws in the sequence shown.





109. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.

110. CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, transmission leak may occur.





Install the solenoid body. Tighten bolts in sequence shown.





111. Install the reverse servo.
- Install the bolts in the sequence shown.





112. Connect the reverse pressure switch connector.





113. Install the manual valve detent spring.

114. CAUTION: Lubricate the fluid filter O-ring seals with MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V or they may be damaged.

Note: Make sure that the fluid filter O-ring seals are correctly seated on the filter.





Lubricate the seals and install the transmission fluid filter.





115. Note: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket.





116. Using a crisscross sequence, tighten the screws.





117. Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl.
3 Install the parking pawl return spring.
4 Install the gasket.





118. Install the extension housing.





119. Using the special tool, install the extension housing seal.





120. Using the special tools, install the output shaft flange.





121. Install a new nut.

122. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.





Install the digital transmission range (TR) sensor and loosely install the screws.

123. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.

Note: The manual lever must be in the Neutral position.





Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

124. Note: Inspect O-ring seal for damage. Install new if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.





Install the sensors.

125. CAUTION: The splices of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.





Install the input shaft.





126. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.





127. Remove the special tool.

128. CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.

CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.





Lubricate the converter hub with MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.

129. Note: A new converter drain plug must be used to prevent leakage.





Install the drain plug.





130. Install the converter housing access plug.

131. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.





Using the special tools, install the torque converter by pushing and rotating.





132. Lubricate the torque converter pilot hub with Ford Multi-Purpose Grease DOAZ-19584-AA meeting specification ESB-M1C93-B.

133. CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.





In order to correctly install the special service tool it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.
If the vehicle is equipped, use the special tool to install the torque converter flex plate adapter assembly and eight nuts.





134. Note: Use the 5/16 inch Allen key to remove the fill plug.

Remove the fill plug.





135. Fill the transmission with 8.5L (9 quarts) of fluid.
- Use MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.

136. CAUTION: When installing the fill plug, make sure not to cross thread the plug to prevent damage.

Note: Use a 5/16 inch Allen key to install the fill plug.





Install the fill plug.
137. Before installing transmission, make sure that the transmission cooling system (tube and cooler[s]) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler(s) and/or tubes.