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Automatic Transmission: Assembly: Transmission: Procedure

CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in the section, the necessary torques can be found in SPECIFICATIONS . When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.
  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
    Fig 1: Identifying Transmission Extension Housing Remover/Installer & Slide Hammer
    G01940572Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    Fig 2: Identifying No. 9 Case Rear Bearing
    G01940573Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in OUTPUT SHAFT & DIRECT CLUTCH CYLINDER . Internal damage and shift problems may occur.
    Fig 3: Installing Output Shaft & Output Shaft Ring Gear
    G01940574Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 4: Identifying No. 8 Bearing
    G01940575Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 5: Identifying Direct Clutch
    G01940576Courtesy of FORD MOTOR CO.
    7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
    Fig 6: Identifying Reverse Band Support Retaining Ring
    G01940577Courtesy of FORD MOTOR CO.
  7. Install the reverse band support retaining ring.
    8. NOTE: Make sure the band is seated on the anchor pins.
    Fig 7: Installing Reverse Band
    G01940578Courtesy of FORD MOTOR CO.
  8. Install the reverse band.
    9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
    Fig 8: Installing Planetary Assembly & Planetary Gear Support As A Unit
    G01940579Courtesy of FORD MOTOR CO.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
    10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
    Fig 9: Installing Planet Support Spring
    G01940580Courtesy of FORD MOTOR CO.
  10. Install the case to the planet support spring located at the 1 o'clock position.
  11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
    Fig 10: Identifying Center Support Retaining Ring
    G01940581Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse sun gear.
    Fig 11: Installing Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear Bearing & Reverse Sun Gear
    G01940582Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 12: Identifying No. 4 Forward Clutch Hub Bearing
    G01940583Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 13: Installing Intermediate Stub Shaft
    G01940584Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 14: Installing Forward Clutch Hub & No. 3 Forward Clutch Hub Front Bearing
    G01940585Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 15: Installing Forward Clutch Assembly
    G01940586Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
    Fig 16: Identifying Reverse Clutch Cylinder & No. 2 Forward Clutch Bearing
    G01940587Courtesy of FORD MOTOR CO.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
    Fig 17: Installing Overdrive Band
    G01940588Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
    Fig 18: Installing Overdrive Servo Spring
    G01940589Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 19: Identifying Tip Of Piston Assembly
    G01940590Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 20: Identifying Overdrive Servo Retaining Ring
    G01940591Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 21: Installing Intermediate Clutch Pressure Plate
    G01940592Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.
    Fig 22: Installing Intermediate Clutch Pack & Selective Steel Plate
    G01940593Courtesy of FORD MOTOR CO.
  23. Install the intermediate clutch pack and selective steel plate.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

    Fig 23: Identifying Selective Steel Plates Specifications
    G01940594Courtesy of FORD MOTOR CO.
    Fig 24: Checking Intermediate Clutch Clearance
    G01940595Courtesy of FORD MOTOR CO.
  25. Install the intermediate anti-rattle clip, if equipped.
    Fig 25: Identifying Intermediate Anti-Rattle Clip
    G01940596Courtesy of FORD MOTOR CO.
  26. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

      Use the No. 1 thrust washer chart to select the correct washer.

    Fig 26: No.1 Thrust Washer Chart
    G01940597Courtesy of FORD MOTOR CO.
    Fig 27: Measure End Clearance For No. 1 Front Pump Thrust Washer
    G01940598Courtesy of FORD MOTOR CO.
  27. Install the No.1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
    Fig 28: Installing No.1 Front Pump Support Thrust Washer
    G01940599Courtesy of FORD MOTOR CO.
    28. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 29: Identifying Alignment Pin
    G01940600Courtesy of FORD MOTOR CO.
  28. Install an alignment pin at the top of the case.
    29. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  29. Install the pump gasket.
    30. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 30: Installing Pump Assembly
    G01940601Courtesy of FORD MOTOR CO.
  30. Install the pump assembly.
  31. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
    Fig 31: Tightening Front Pump Bolts
    G01940602Courtesy of FORD MOTOR CO.
  32. Rotate the transmission to the horizontal position.
  33. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
    Fig 32: Identifying Parking Pawl Return Spring, Parking Pawl & Parking Pawl Shaft
    G01940603Courtesy of FORD MOTOR CO.
  34. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
    Fig 33: Tightening Extension Housing
    G01940604Courtesy of FORD MOTOR CO.
  35. Using the special tool, install a new extension housing seal.
    Fig 34: Identifying Transmission Extension Housing Oil Seal Installer
    G01940605Courtesy of FORD MOTOR CO.
  36. Install the output shaft speed (OSS) sensor.
    1. Position the OSS sensor.
    2. Install the bolt.
    Fig 35: Tightening OSS Sensor Bolt
    G01940606Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the manual control lever seal.
    Fig 36: Identifying Shift Shaft Fluid Seal Installer
    G01940607Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
    Fig 37: Tightening EPC Solenoid Bracket Bolt
    G01940608Courtesy of FORD MOTOR CO.
  38. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the EPC solenoid bracket and bolt.
  39. Install the manual valve detent lever and parking lever actuating rod.
    Fig 38: Identifying Manual Valve Detent Lever & Parking Lever Actuating Rod
    G01940609Courtesy of FORD MOTOR CO.
  40. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
    Fig 39: Installing Manual Control Lever Shaft
    G01940610Courtesy of FORD MOTOR CO.
  41. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the 1-2 accumulator lower spring.
    4. Install the 1-2 accumulator cover and seal.
    Fig 40: Identifying 1-2 Accumulator Upper Spring, Accumulator, Lower Spring, Cover & Seal
    G01940611Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator retaining ring.
    Fig 41: Identifying 1-2 Accumulator Retaining Ring
    G01940612Courtesy of FORD MOTOR CO.
    43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
    NOTE: Do not install the reverse servo piston cover and seal at this time.
    Fig 42: Installing Reverse Servo Piston & Rod Assembly
    G01940613Courtesy of FORD MOTOR CO.
  43. Install the reverse servo piston and rod assembly.
  44. Install the special tool.
    • Tighten the bolt.
    Fig 43: Tightening Bolt On Servo Piston Installer
    G01940614Courtesy of FORD MOTOR CO.
  45. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
    Fig 44: Identifying Dial Indicator Gauge With Mounting Device & Servo Piston Installer
    G01940615Courtesy of FORD MOTOR CO.
  46. Loosen the bolt until the piston stops against the tool.
    Fig 45: Adjusting Servo Piston Installer
    G01940616Courtesy of FORD MOTOR CO.
  47. Verify that the amount of piston travel on the dial indicator is within specification.
    Fig 46: Identifying Piston Travel Is Within Specification
    G01940617Courtesy of FORD MOTOR CO.
  48. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
    Fig 47: Identifying Servo Piston Travel Specifications
    G01940618Courtesy of FORD MOTOR CO.
  49. Remove the special tools.
    Fig 48: Removing Special Tools
    G01940619Courtesy of FORD MOTOR CO.
  50. Install the reverse servo piston cover and seal assembly.
    Fig 49: Identifying Dial Indicator Gauge With Mounting Device & Servo Piston Installer
    G01940620Courtesy of FORD MOTOR CO.
  51. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
    Fig 50: Installing Reverse Servo Retaining Ring
    G01940621Courtesy of FORD MOTOR CO.
  52. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
    Fig 51: Identifying Accumulator Piston, Piston Spring & Spring Retainer
    G01940622Courtesy of FORD MOTOR CO.
  53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 52: Applying Regulated Air Pressure To Test Ports
    G01940623Courtesy of FORD MOTOR CO.
    54. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 53: Installing Electrical Connector Into Case
    G01940624Courtesy of FORD MOTOR CO.
  54. Install the electrical connector into the case.
    55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 54: Identifying Main Control Valve Body
    G01940625Courtesy of FORD MOTOR CO.
  55. Align the main control valve body alignment bolts and position the main control valve body.
    56. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 55: Identifying Long Main Control Valve Body Bolts
    G01940626Courtesy of FORD MOTOR CO.
  56. Loosely install the 11 long main control valve body bolts.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 56: Identifying Short Main Control Valve Body Bolts
    G01940627Courtesy of FORD MOTOR CO.
  57. Loosely install the 12 short main control valve body bolts.
  58. Install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring.
    2. Install the bolt.
    Fig 57: Tightening Manual Control Valve Detent Lever Spring
    G01940628Courtesy of FORD MOTOR CO.
  59. Tighten the bolts in the sequence shown.
    Fig 58: Main Control Valve Body Bolt Tightening Sequence
    G01940629Courtesy of FORD MOTOR CO.
  60. Inspect the lead frame for damage.
    • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
    Fig 59: Inspecting Lead Frame For Damage
    G01940630Courtesy of FORD MOTOR CO.
  61. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    Fig 60: Identifying Molded Lead Frame
    G01940631Courtesy of FORD MOTOR CO.
  62. Install the fluid filter and seal assembly.
    Fig 61: Install Fluid Filter & Seal Assembly
    G01940632Courtesy of FORD MOTOR CO.
  63. Position the pan magnet onto the fluid pan.
    Fig 62: Identifying Transmission Fluid Pan Magnet
    G01940633Courtesy of FORD MOTOR CO.
    64. NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.
    Fig 63: Tightening Transmission Fluid Pan Bolts
    G01940634Courtesy of FORD MOTOR CO.
  64. Install the fluid pan.
    1. Position the transmission fluid pan.
    2. Install the 14 transmission fluid pan bolts.
  65. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
    Fig 64: Identifying Digital TR Sensor & Bolts
    G01940635Courtesy of FORD MOTOR CO.
    66. NOTE: The tool is designed to fit snugly.
    NOTE: Manual shift lever must be in the neutral position.
    Fig 65: Identifying TR Sensor Alignment Gauge
    G01940636Courtesy of FORD MOTOR CO.
  66. Using the special tool, align the digital TR sensor slots.
  67. Tighten the bolts.
    Fig 66: Tightening TR Sensor Bolts
    G01940637Courtesy of FORD MOTOR CO.
  68. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 67: Identifying Torque Converter Hub
    G01940638Courtesy of FORD MOTOR CO.
    69. WARNING: The torque converter can fall out if the transmission is tipped.
    CAUTION: Make sure the converter hub is fully engaged in the front 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.
    Fig 68: Identifying Torque Converter Handles
    G01940639Courtesy of FORD MOTOR CO.
  69. Using the special tools, install the torque converter.
  70. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 69: Lubricating Torque Converter Pilot Hub
    G01940640Courtesy of FORD MOTOR CO.
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