CAUTION: If the clutch plates or the intermediate band are replaced, soak the new parts in the specified automatic transmission fluid (ATF) for at least two hours before assembly. Apply the specified ATF to all seal rings, rotating parts, O-rings and sliding parts.
NOTE: Clean all bearings thoroughly in solvent and blow dry with compressed air. Inspect the bearings for pitting and rough operation. Replace as necessary.
NOTE: All O-rings, seals, and gaskets must be replaced with new ones.
Prior to installation, inspect the transmission case for damage, cracks, or wear. Replace as necessary.
Use (A) Valve Body Guide Pins to align the torque converter stator support. Use (B) Step Plate to press the (C) torque converter stator support into the converter housing.
Use (A) Driver Handle and (B) Bearing Cup Replacer to install the bearing cup into the converter housing.
NOTE: Tighten the torque converter stator support bolts evenly and gradually.
Install the eight bearing cover bolts.
Install the (A) idler gear and (B) output shaft as an assembly.
Install the idler gear and output shaft by tapping them in with a plastic hammer.
NOTE: Tighten the bearing housing bolts evenly and gradually.
Install the bearing housing onto the converter housing.
Install the bearing housing onto the converter housing.
Install the bolts.
Install a new bearing housing roll pin.
Align the holes on the idler gear shaft with the mark on the bearing housing. Tap the roll pin in using a 5/32 inch pin punch and hammer.
NOTE: Move the manual shaft and verify that the parking pawl operates.
Install the parking pawl assembly.
Install the parking pawl.
Install the parking pawl shaft.
Install the parking pawl return spring.
Install the parking pawl shaft E-clip.
Install the detent lever spring and actuator support.
Install the actuator support.
Install new actuator support bolts.
Install the detent lever spring.
Install the detent lever. Attach the detent lever spring to the detent lever.
Install the manual shaft plate and the lever holder.
Install the lever holder.
Install the manual shaft plate.
Install the lever holder nut.
Install the manual shaft.
Push the manual shaft into the manual shaft plate.
Install the manual shaft washer and nut.
Install the output shell. Set the thrust bearing onto the output shell.
The output shell thrust washer outer diameter is 72.1 mm (2.84 inch) .
Apply a small bead of Silicone Gasket and Sealant to the surfaces of the (A) converter housing and transmission case. Carefully install new (B) O-rings.
NOTE: Tighten the transmission bolts evenly and gradually.
Attach the transmission case to the converter housing and install the transmission case bolts.
Install Turbine Shaft Holder.
Install the (A) turbine shaft and direct clutch assembly with the (B) thrust bearing between the direct clutch and output shell.
Assemble the turbine shaft and direct clutch assembly.
Install the turbine shaft and direct clutch assembly into the transmission case.
Install the ring gear to the output shell. Install the ring gear with the external gear side down.
Install the ring gear retainer snap ring.
NOTE: Install the carrier hub into the 3-4 clutch cylinder by rotating it to align the carrier hub with the 3-4 clutch pack.
NOTE: Hold the turbine shaft with one hand to keep it from rotating while installing the carrier hub.
Install the carrier hub assembly.
Use petroleum jelly to install the thrust washer to the carrier hub assembly.
Install the thrust bearing between the carrier hub assembly and the direct clutch assembly.
Install the carrier hub assembly.
Install the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.
Install the low/reverse clutch pressure plate snap ring.
Install the wave washer.
CAUTION: The one-way clutch can be installed improperly. Be certain that after installing the one-way clutch, you can rotate the carrier by hand in a counterclockwise direction while working from the rear side of the transmission. If the one-way clutch is installed improperly, gear ranges may not function or the gear train may lock up. This may cause overheating of the transmission and unnecessary overhauling of the unit.
Install the one-way clutch horizontally. Use the rear sun gear to rotate the carrier counterclockwise while installing the one-way clutch.
Install the one-way clutch and one-way clutch retaining snap ring.
Adjust the servo piston stem.
Mark the servo piston stem at the point that it exits the transmission case.
Apply compressed air through the fluid passage. If the stroke exceeds 1.0 - 1.7 mm (0.0394 - 0.0669 inch) replace it with the appropriate length servo piston stem.
Servo Piston Stem Lengths
Install the (A) anchor strut and the (B) anchor strut shaft into the transmission case.
Interlock one end of the 2-4 band and the anchor strut.
Interlock the other end of the 2-4 band to the servo apply pin.
NOTE: Use petroleum jelly to hold the thrust bearing and thrust washer in position.
Install the (A) primary sun gear and one-way clutch assembly.
Verify that the (B) thrust bearing and the (C) thrust washer are installed in the correct positions.
Install the primary sun gear and one-way clutch assembly while rotating it.
Install the (A) forward/coast/reverse clutch assembly.
Verify that the (B) thrust bearing is installed in the correct position.
Install the forward and reverse clutch drum assembly while rotating it.
Rotate the rear sun gear, the one-way clutch, and the reverse clutch drum assembly to line up to the clutch pack and gears.
Carefully install the turbine shaft snap ring into the bottom ring groove of the turbine shaft.
Remove Turbine Shaft Holder.
NOTE: If the clearance is greater than the specification, recheck/reassemble the clutch pack(s) as needed.
Measure the height difference between the reverse clutch drum and the transmission case.
NOTE: Use petroleum jelly to hold the thrust bearing in position.
Install the reverse clutch drum thrust bearing.
Set the thickest thrust washer, 2.2 mm (0.087 inch) onto the oil pump. Set the oil pump onto the forward/coast/reverse clutch drum assembly.
NOTE: Take several measurements and calculate the average value.
Use the following procedure to adjust the total end play and select a suitable bearing race.
Measure the clearance between the transmission case and the oil pump. Select a suitable thrust washer from the following chart:
Thrust Washer Chart
Remove the oil pump.
NOTE: Use petroleum jelly to hold the thrust washer in position.
Place the selected (A) thrust washer and a new (B) oil pump gasket onto the oil pump.
NOTE: Tighten the oil pump bolts evenly and gradually in a crosshatch pattern.
Install the oil pump onto the forward and reverse clutch drum assembly.
Install the (A) solenoid connector with a new O-ring in the transmission case, then connect the (B) solenoid electrical connector.
Position the main valve body to the transmission case. Align the (A) manual valve with the (B) pin on the manual valve detent lever.
NOTE: Tighten the main control valve body bolts evenly and gradually.
Install the main control valve body bolts and a new filter. Connect the solenoid electrical connectors.
Bolt length (measured from below the head) A: 30 mm (1.18 inch) .
C: 50 mm (1.97 inch) .
Install the EPC solenoid.
Install the EPC solenoid.
Install the bolt.
NOTE: Tighten the transmission oil pan bolts evenly and gradually.
NOTE: Apply a thin coat of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to each side of the new gasket.
Install the oil pan and new oil pan gasket.
Install the turbine shaft speed (TSS) sensor.
Install the sensor.
Install the bolt.
Install the vehicle speed sensor (VSS) .
Install the transmission range (TR) sensor.
Rotate the manual shaft to the N position.
Turn the TR sensor so that the Neutral mark is in line with the flat, straight surfaces on either side of the manual shaft.
Hand-tighten the TR sensor, then tighten the TR sensor mounting bolts.
Install the manual shaft lever.
Position the manual shaft lever.
Install the spring washer and manual control lever nut.
Install a new O-ring on the fluid filler tube, then install the fluid filler tube and dipstick assembly.
Install the fluid cooler line.
Install the check ball.
Install the drain back valve spring.
Install the fluid cooler line washers.
Install the fluid cooler line bolt.
Install the fluid cooler line nut.
Install the oil pump shaft.
Install a new converter turbine shaft seal on the turbine shaft.
The converter turbine shaft seal inner diameter is 20 mm (0.787 inch) .
CAUTION: If a new torque converter is being installed or the torque converter has been drained and washed, pour 0.5L (0.53 qt.) of Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON into the torque converter before installation. Hold the torque converter in an erect position when filling it with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. MERCON (R) Automatic Transmission Fluid is being replaced by MERCON (R) V as a service fluid, as per TSB 06-14-4.
NOTE: The torque converter should slide into the transmission easily. Do not force the torque converter into the transmission.
Install the torque converter into the converter housing while rotating it to align the splines.
To ensure that the torque converter is installed properly, measure the distance between the torque converter and the edge of the converter housing.
Remove the transmission from Bench Mounted Holding Fixture.
