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Home >> Ford >> 1996 >> Aerostar Van Window >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Overhaul - 4R44E & 4R55E Automatic Transmission >> Transmission Reassembly

Transmission Reassembly

NOTE: Lubricate all parts with transmission fluid during reassembly. Thrust washers and gaskets should be held in place with petroleum jelly. See Fig 8 and Fig 9 for location of thrust washers & bearings.
  1. Before installing center support into case, install new seals on support hub. It is necessary to size these seals. Apply liberal amount of petroleum jelly to center support hub and seals.
    NOTE: If sizing is not done, the seals may be cut or rolled over when entering intermediate brake drum cavity.
  2. Use overdrive brake drum for sizing. Carefully rotate center support while inserting it into drum housing. Observe seals as they enter cavity to ensure that they do not roll over or get cut.
  3. Ensure center support is seated fully into overdrive drum. Allow assembly to stand for several minutes for seals to seat in grooves. Set aside until required for reassembly.
    NOTE: If new output shaft is being installed, ensure correct shaft is used. The shaft for the 4.0L model does not have a lubrication hole.
  4. Install manual control lever shaft seal. Install control lever shaft and retaining pin. Assemble manual valve inner lever and parking pawl actuating rod. Install manual valve inner lever and nut. Tighten nut to specification. See TORQUE SPECIFICATIONS  .
  5. Position No. 11 thrust washer in rear of case. Install park gear. Using Clutch Replacement Guide (T74P-77193-A), install low-reverse brake drum (guide not required on 4.0L models). Install No. 10 thrust washer with tabs facing one-way clutch. Install output shaft. Install output shaft ring gear and hub Install new snap ring. On 4.0L models, install output shaft sleeve with cone facing up.
  6. On all models, install No. 9 thrust washer, reverse planet assembly and No. 8 thrust washer. Tabs on thrust washers face into planet assembly. On all models except 4.0L, install snap ring in drum to hold planet assembly. On all models, install low-reverse band as marked at disassembly. Replace piston "O" ring and install low-reverse servo piston assembly to hold band in position.
  7. Install previously assembled forward geartrain assembly. Check transmission rear end play to determine amount of space between thrust washer surface of overdrive center support and intermediate brake drum. The No. 4 selective thrust washer is used to obtain end play of .004-.022" (.10-.55 mm). See Fig 8 or Fig 9 .
  8. Temporarily install low-reverse band servo piston and rod to hold band in position. Install forward gear train assembly. Turn transmission so output shaft points downward. Place Gauge Bar (T93L-77003-AH) on case shoulder. See Fig 1 .
    Fig 1: Measuring No. 4 Thrust Washer Clearance
    G94J38835Courtesy of FORD MOTOR CO.
  9. Using depth micrometer, measure between gauge bar and intermediate brake drum No. 4 thrust bearing mating surface at 2 locations, 180 degrees apart. Use the following formula to determine clearance: "T" = (("A" + "B")/ 2) - "C"  Record reading.
    • "A" = Depth measurement to one side thrust bearing mating surface.
    • "B" = Depth measurement of opposite thrust bearing mating surface.
    • "C" = Gauge bar thickness.
    • "T" = Thrust bearing clearance.
  10. Place gauge bar across center support. Using depth micrometer, measure between gauge bar and center support No. 4 thrust bearing mating surface at 2 locations, 180 degrees apart. See Fig 2 . Use the following formula to determine clearance: "E" = (("D" + "F")/ 2) - "C"  . Record reading.
    • "D" = Depth measurement to one side thrust bearing mating surface.
    • "F" = Depth measurement of opposite thrust bearing mating surface.
    • "C" = Gauge bar thickness.
    • "E" = Thrust bearing clearance.
    Fig 2: Measuring Center Support No. 4 Thrust Bearing Clearance
    G99I54369Courtesy of FORD MOTOR CO.
  11. Add readings "T" and "E". Total equals No. 4 thrust bearing clearance between intermediate brake drum and center support. Select and install No. 4 thrust bearing onto center support. See SELECTIVE THRUST WASHER NO. 4  table.
    SELECTIVE THRUST WASHER NO. 4

    Average Reading In. (mm) Thrust Washer Thickness In. (mm)
    .070-.075 (1.79-1.90) .104-.110 (2.65-2.80)
    .075-.083 (1.91-2.10) .110-.116 (2.80-2.95)
    .083-.090 (2.11-2.30) .118-.124 (3.00-3.15)
    .091-.095 (2.31-2.43) .126-.132 (3.20-3.35)
  12. Install intermediate servo apply lever and shaft into case. Install intermediate band apply strut. Install intermediate band, anchor strut, and adjusting screw. Install selected No. 4 thrust washer on center support and retain with petroleum jelly.
  13. Temporarily insert input shaft (short splines down), through intermediate brake drum and into splines of forward clutch cylinder. Carefully place center support into case. DO NOT  seat it into intermediate brake drum. Ensure it is square with case and 5 mm Allen bolt retainer nut aligns with hole in case.
  14. DO NOT  apply pressure to center support. Gently wiggle input shaft, allowing center support to slide into intermediate brake drum of its own weight. Perform this operation until support is fully seated. Remove input shaft.
  15. Install snap ring to retain center support. Snap ring taper should face front of transmission. Ends of snap ring should be positioned in wide shallow cavity located in the 5 o'clock position. Install 5 mm Allen head bolt that retains center support to case. See Fig 3 .
    Fig 3: Installing Center Support Retaining Ring
    G96C04221Courtesy of FORD MOTOR CO.
  16. Install turbine shaft speed sensor. Position No. 3 thrust washer on top of center support. Carefully install overdrive planet, one-way clutch, and overdrive center shaft assembly into case. DO NOT  bend TSS exciter wheel.
  17. Place thin blade of TSS Gauge (T95L-70010-F) over speed sensor. Rotate exciter wheel, exciter wheel triggering window should pass over gauge. Place thick blade of gauge over speed sensor. Rotate exciter wheel, exciter wheel triggering window should not pass over gauge. Repeat for remaining exciter wheel triggering windows.
  18. If TSS air gap clearance is not as specified, replace planet gear overdrive carrier and exciter wheel. Align clutch plates and overdrive adapter gear. Install overdrive brake and coast clutch drum assembly. Install overdrive bracket, apply lever and shaft. Install overdrive band (tagged at disassembly), and apply strut. Install anchor strut and adjusting screw.
  19. Using petroleum jelly, place No. 1 selective washer on rear of pump with tabs into pump face. Temporarily install pump assembly (without gasket) into case. Ensure pump assembly is fully seated in case and pump body is below level of case gasket surface.
    NOTE: Check for damaged or missing front pump support seal. Replace if necessary.
  20. Place appropriate gauge bar on case shoulder. See Fig 4 . Using depth micrometer, measure between gauge bar and pump surface at 2 locations, 180 degrees apart. Average measurements and subtract thickness of gauge bar to select correct thickness thrust washer.
    Fig 4: Checking End Play
    G96E04222Courtesy of FORD MOTOR CO.
  21. End play range is .007-.025" (.18-.64 mm). If end play is above specification, use thicker No. 1 selective thrust washer. If end play is below specification, use thinner No. 1 selective thrust washer. See NO. 1 SELECTIVE THRUST WASHER  .
    NO. 1 SELECTIVE THRUST WASHER

    Identification Number Thickness: In. (mm)
    1 .053-.055 (1.35-1.40)
    2 .061-.063 (1.55-1.60)
    3 .065-.067 (1.65-1.70)
    4 .069-.071 (1.75-1.80)
    5 .073-.075 (1.85-1.90)
    6 .077-.079 (1.95-2.00)
    7 .081-.083 (2.05-2.10)
  22. After end play check has been completed, remove oil pump and install correct No. 1 selective thrust washer. Install new drive gear "O" ring. Lubricate Front Pump Seal Sizing Tool (T95L-70010-G) and place into drive gear to seat "O ring".
  23. Remove front pump seal sizing tool. Place pump gears into pump housing. The inside edge of small gear has a chamfer on one side. This chamfer must face toward front of transmission. The larger gear has a dimple on one side which must face toward rear of transmission.
  24. Install pump adaptor plate. Position pump housing and adaptor plate onto converter housing. Notch on outside of adaptor plate will be at 9 o'clock position relative to convertor housing. Install bolts finger tight.
  25. To prevent seal leakage, pump gear breakage or bushing failure, align pump in converter housing with Pump Alignment Set (T74P-77103-X). Select smallest I.D. sleeve which will fit completely over pump shaft. Outside diameter of sleeve will center pump in converter housing.
  26. Install 6 new Allen bolts. Tighten to specification. See TORQUE SPECIFICATIONS  . Remove alignment tool. Install overdrive brake drum seal rings. Ensure seal ring ends are properly overlapped and ring gaps are placed 180 degrees apart. Coat converter housing gasket with petroleum jelly and position on converter housing.
  27. Install seal ring on converter housing. Position No. 1 selected thrust washer on rear of pump. Turn convertor housing over and install front pump support seal ring. Install input shaft and convertor guide pins. Align converter housing and pump to transmission case. Remove alignment pins. Install 8 new bolts with "O" rings and tighten to specification.
  28. Replace piston "O" ring and install intermediate servo piston assembly. Install piston cover and snap ring. Replace piston "O" ring and install overdrive servo piston assembly. Install piston cover and snap ring. DO NOT  press servo cover and "O" ring past relief hole in case. "O" ring damage may occur.
  29. Install new lock nut on overdrive band adjusting screw. Apply petroleum jelly to lock nut seal. Tighten adjusting screw to 120 INCH lbs. (14 N.m) and back off exactly 2 turns. Hold adjusting screw and tighten lock nut to 35-45 ft. lbs. (47-61 N.m). Repeat procedure for intermediate band. Air pressure tests may be performed to ensure proper transmission operation. See AIR PRESSURE TESTS  under TESTING.
  30. Lubricate and install 16-pin connector. Ensure tab locks in place. Install case connector retaining ring. Install TSS connector into 16-pin case connector.
  31. Align valve body to separator plate and gasket using tapered punches. Use a small amount of petroleum jelly to hold gasket in place. Install alignment pins into case. Install valve body onto case while aligning manual valve with manual valve inner lever pin.
    NOTE: Valve body bolts are of different lengths. Ensure each bolt is installed in its correct location.
  32. Install and finger tighten bolts "A", "B", and "C". See Figure and Figure . Remove valve body alignment pins. Install and finger tighten remaining bolts. DO NOT  install filter screen bolt at this time. Tighten all bolts to specification in sequence. See Figure and Figure . Install manual lever detent spring.
    NOTE: If low-reverse servo piston rod is to be checked, perform steps 31) through 35). Ensure A4LD Servo Check Spring (D4ZZ-7D031-A) is removed after checking piston rod travel.
  33. Remove low-reverse servo piston assembly. Install low-reverse servo piston assembly into bore along with A4LD Servo Check Spring (D4ZZ-7D031-A). Ensure piston rod is seated correctly in low-reverse band apply end. Install Servo Rod Selecting Gauge (T74P-77190-A) with new servo cover gasket. See Fig 5 .
    Fig 5: Selecting Servo Piston & Rod
    G92G14437Courtesy of FORD MOTOR CO.
  34. Tighten select gauge adjusting screw to 35 INCH lbs. (4 N.m). Install dial indicator onto case. Position indicator tip on one of 3 servo piston pads accessible through cut-out of guide. Zero dial indicator.
  35. Back out adjusting screw until servo piston bottoms out on guide. Record distance servo piston moved. Servo piston travel should be .120-.220" (3.05-5.59 mm).
  36. If piston travel is greater than specification, use next longest piston and rod. If less than specification, use next shorter piston and rod. Rods are identified by their number of grooves. Rods with 2 grooves are shortest in length; rods with no grooves are medium in length; rods with one groove are longest.
  37. Install selected piston and rod. Recheck piston travel. If correct, remove guide and test spring. Reinstall servo assembly, accumulator spring, gasket and cover. Install servo cover bolts and tighten to specification. Install solenoid connectors. Install wiring protector and guide.
  38. Install new "O" rings on filter screen and lube with petroleum jelly. Install filter screen and bolt. Connect Transmission Tester (007-0085C) to 16-pin case connector. Perform solenoid static function check. See appropriate DIAGNOSIS article AUTOMATIC TRANSMISSIONS. Install oil pan with new gasket. Tighten pan bolts to specification in 2 steps. See TORQUE SPECIFICATIONS  . Install heat shield (if equipped).
  39. Install parking pawl and return spring in extension housing and preload. Using new gasket, install extension housing. Ensure operating parking rod is correctly seated in extension guide cup. Install and tighten bolts. Install extension housing bushing (if removed). Ensure lube hole in bushing is aligned with slot in extension housing. Install rear seal.
  40. Install transmission range sensor on manual lever. Install sensor bolts finger tight. Rotate manual lever to neutral position (2 detents rearward). Install TR Sensor Alignment Tool (T93P-70010-A) into 3 slots on sensor. Tighten TR sensor bolts to specification and remove alignment tool. Install manual control outer lever. Tighten nut to specification.
  41. Install input shaft and torque converter. Ensure torque converter is properly installed. When installation is correct, measurement between torque converter pilot nose and front face of housing will be .40-.57" (10.23-14.43 mm).
Fig 6: Exploded View Of 4R44E/4R55E Transmission (1 Of 2)
G96G04223Courtesy of FORD MOTOR CO.
Fig 7: Legend For View Of 4R44E/4R55E Transmission (2 Of 2)
G96I04224Courtesy of FORD MOTOR CO.
Fig 8: Thrust Bearing & Washer Locations (2.3L & 3.0L - 4R44E)
G96B04225Courtesy of FORD MOTOR CO.
Fig 9: Thrust Bearing & Washer Locations (4.0L - 4R55E)
G96D04226Courtesy of FORD MOTOR CO.
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