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Automatic Transmission: Disassembly: Transmission: Disassembly

  1. Remove the special tool.
    Fig 1: Identifying Torque Converter Retainer
    G01940378Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove torque converter.
    Fig 2: Identifying Torque Converter Handles
    G01940379Courtesy of FORD MOTOR CO.
  3. Using the special tool, mount the transmission to the bench.
    Fig 3: Identifying Transmission Holding Fixture
    G01940380Courtesy of FORD MOTOR CO.
    4. NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
    Fig 4: Identifying Transmission Fluid Pan & Bolts
    G01940381Courtesy of FORD MOTOR CO.
  4. Remove the transmission fluid pan and transmission fluid pan gasket.
    1. Remove the bolts.
    2. Remove the transmission fluid pan and transmission fluid pan to case gasket.
  5. Clean the transmission fluid pan and pan magnet.
    Fig 5: Identifying Transmission Fluid Pan Magnet
    G01940382Courtesy of FORD MOTOR CO.
    6. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
    Fig 6: Removing Transmission Fluid Filter
    G01940383Courtesy of FORD MOTOR CO.
  6. Remove the fluid filter and grommet.
    7. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
    Fig 7: Identifying Shift Solenoid SSA, SSB, Torque Converter Clutch (TCC), Electronic Pressure Control (EPC) Solenoid & Bulkhead Inter-Connector
    G01940384Courtesy of FORD MOTOR CO.
  7. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead inter-connector.
  8. Remove the output shaft speed (OSS) sensor.
    1. Remove the bolt.
    2. Remove the OSS sensor.
    Fig 8: Identifying OSS Sensor Bolt
    G01940385Courtesy of FORD MOTOR CO.
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 9: Identifying Digital TR Sensor & Bolts
    G01940386Courtesy of FORD MOTOR CO.
  10. Remove the manual control valve detent lever spring.
    1. Remove the bolt.
    2. Remove the manual control valve detent lever spring.
    Fig 10: Identifying Control Valve Detent Lever Spring Bolt
    G01940387Courtesy of FORD MOTOR CO.
  11. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 11: Identifying Main Control Valve Body Bolts
    G01940388Courtesy of FORD MOTOR CO.
  12. Remove and discard the pump outlet screen.
    Fig 12: Identifying Pump Outlet Screen
    G01940389Courtesy of FORD MOTOR CO.
    13. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 13: Identifying Manual Lever Shaft Retaining Pin
    G01940390Courtesy of FORD MOTOR CO.
  13. Remove the manual lever shaft retaining pin.
  14. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    Fig 14: Identifying Manual Lever Shaft & Inner Nut
    G01940391Courtesy of FORD MOTOR CO.
  15. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    Fig 15: Identifying Manual Valve Detent & Parking Lever Actuating Rod
    G01940392Courtesy of FORD MOTOR CO.
    16. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged the new seal may leak.
    Fig 16: Identifying Manual Control Lever Shaft Seal
    G01940393Courtesy of FORD MOTOR CO.
  16. Remove the manual control lever shaft seal.
  17. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
    Fig 17: Identifying EPC Solenoid Bracket & Bolt
    G01940394Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator spring retainer.
    Fig 18: Identifying 2-3 Accumulator Spring Retainer
    G01940395Courtesy of FORD MOTOR CO.
  19. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    Fig 19: Identifying 2-3 Accumulator Spring & Piston
    G01940396Courtesy of FORD MOTOR CO.
  20. Using the special tool, remove the reverse band servo retaining ring.
    Fig 20: Identifying Servo Piston Remover/Installer
    G01940397Courtesy of FORD MOTOR CO.
  21. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
    Fig 21: Identifying Reverse Band Servo Cover, Piston & Rod & Spring
    G01940398Courtesy of FORD MOTOR CO.
    22. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
    Fig 22: Identifying Servo Piston Remover/Installer
    G01940399Courtesy of FORD MOTOR CO.
  22. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  23. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    Fig 23: Identifying Overdrive Servo Piston & Return Spring
    G01940400Courtesy of FORD MOTOR CO.
  24. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 24: Identifying 1-2 Accumulator Retaining Ring
    G01940401Courtesy of FORD MOTOR CO.
  25. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the 1-2 accumulator lower spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    Fig 25: Identifying 1-2 Accumulator Spring Cover, Lower Spring, Accumulator & Upper Spring
    G01940402Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the extension housing seal.
    Fig 26: Identifying Transmission Fluid Seal Remover, Slide Hammer & Extension Housing Seal
    G01940403Courtesy of FORD MOTOR CO.
    27. NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
    Fig 27: Identifying Extension Housing Bolts
    G01940404Courtesy of FORD MOTOR CO.
  27. Remove the extension housing.
    1. Remove the four bolts and two nuts.
    2. Remove the extension housing and the extension housing gasket.
  28. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    Fig 28: Identifying Parking Pawl Shaft, Parking Pawl Return Spring & Parking Pawl
    G01940405Courtesy of FORD MOTOR CO.
  29. Rotate the transmission to the vertical position with the output shaft towards the floor.
    30. CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
    Fig 29: Identifying Transmission Connector
    G01940406Courtesy of FORD MOTOR CO.
  30. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  31. Using the special tools, remove the front pump seal.
    Fig 30: Identifying Transmission Fluid Seal Remover, Slide Hammer & Front Pump Seal
    G01940407Courtesy of FORD MOTOR CO.
    32. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 31: Identifying Front Pump Bolts
    G01940408Courtesy of FORD MOTOR CO.
  32. Remove the bolts.
  33. Using the special tools, remove the front pump support.
    Fig 32: Identifying Slide Hammers, Transmission Fluid Pump Removers & Front Fluid Pump
    G01940409Courtesy of FORD MOTOR CO.
  34. Remove and discard the pump gasket.
  35. Remove the intermediate anti-rattle clip, if equipped.
    Fig 33: Identifying Intermediate Anti-Rattle Clip
    G01940410Courtesy of FORD MOTOR CO.
    36. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
    Fig 34: Removing Intermediate Clutch Pack, Intermediate One-Way Clutch, Reverse Clutch & Forward Clutch Assembly
    G01940411Courtesy of FORD MOTOR CO.
  36. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
  37. Disengage and remove the overdrive band.
    Fig 35: Identifying Overdrive Band
    G01940412Courtesy of FORD MOTOR CO.
  38. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 36: Identifying No. 3 Forward Clutch Hub Front Bearing
    G01940413Courtesy of FORD MOTOR CO.
  39. Remove the intermediate stub shaft.
    Fig 37: Identifying Intermediate Stub Shaft
    G01940414Courtesy of FORD MOTOR CO.
  40. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 38: Identifying Reverse Sun Shell & Overdrive Band Anchor Pin
    G01940415Courtesy of FORD MOTOR CO.
  41. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
    Fig 39: Identifying Forward Clutch Sun Gear, Reverse Clutch Sun Gear & No. 4 Forward Clutch Hub Bearing
    G01940416Courtesy of FORD MOTOR CO.
  42. Remove the center support retaining ring and note location for assembly.
    Fig 40: Identifying Center Support Retaining Ring
    G01940417Courtesy of FORD MOTOR CO.
  43. Remove the case to planet support spring.
    Fig 41: Identifying Case To Planet Support Spring
    G01940418Courtesy of FORD MOTOR CO.
  44. Remove the planetary gear support and planetary as an assembly.
    Fig 42: Identifying Planetary Gear Support & Planetary
    G01940419Courtesy of FORD MOTOR CO.
  45. Remove the reverse clutch band.
    Fig 43: Identifying Reverse Clutch Band
    G01940420Courtesy of FORD MOTOR CO.
  46. Remove the retaining ring.
    Fig 44: Identifying Retaining Ring
    G01940421Courtesy of FORD MOTOR CO.
  47. Remove the direct clutch pack.
    Fig 45: Identifying Direct Clutch Pack
    G01940422Courtesy of FORD MOTOR CO.
  48. Remove the No. 8 bearing.
    Fig 46: Identifying No. 8 Bearing
    G01940423Courtesy of FORD MOTOR CO.
  49. Remove the output shaft, output shaft ring gear assembly and direct clutch.
    Fig 47: Identifying Output Shaft, Output Shaft Ring Gear Assembly & Direct Clutch
    G01940424Courtesy of FORD MOTOR CO.
  50. Remove the No. 9 case rear bearing.
    Fig 48: Identifying No. 9 Case Rear Bearing
    G01940425Courtesy of FORD MOTOR CO.
  51. Inspect and if necessary, use the special tools to remove the rear case bushing.
    Fig 49: Identifying Bearing Cup Remover & Slide Hammer
    G01940426Courtesy of FORD MOTOR CO.
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