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Section 1564 (Automatic Transmission - F250-F550 Super Duty): Assembly: Transmission

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) SPECIFICATIONS

G04650029Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Seal (4x2)
307-462
G04650030Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Seal (4x4)
307-453
G04650031Courtesy of FORD MOTOR CO.
 Compressor, Clutch Spring
307-015 (T65L-77515-A)
G04650032Courtesy of FORD MOTOR CO.
 Installer, Shift Shaft Fluid Seal
307-002 (TOOL-77288)
G04650033Courtesy of FORD MOTOR CO.
 Handle, Torque Converter
307-091 (T81P-7902-C)
G04650034Courtesy of FORD MOTOR CO.
 Aligner, Transmission Fluid Pump
307-222 (T89T-70010-B)
G04650035Courtesy of FORD MOTOR CO.
 Installer, Fluid Filler Tube
307-376
G04650036Courtesy of FORD MOTOR CO.
 Installer, Transmission Forward Clutch Assembly
307-436
G04650037Courtesy of FORD MOTOR CO.
 Adapter (use with 307-436)
307-436-02
G04650038Courtesy of FORD MOTOR CO.
 Loading Fixture, Clutch
307-S383
G04650039Courtesy of FORD MOTOR CO.
 Air Test Plate
307-457
G04650040Courtesy of FORD MOTOR CO.
 Test Plate Screw Set, Transmission
307-126 (T82P-7006-C)
G04650041Courtesy of FORD MOTOR CO.
 Aligner, Clutch Spring Compressor
307-455
G04650042Courtesy of FORD MOTOR CO.
 Socket, Output Shaft Locknut
307-458
G04650043Courtesy of FORD MOTOR CO.
 Installer, Seal Pack
307-461
G04650044Courtesy of FORD MOTOR CO.
 Retaining Ring Pliers
307-343 (T95P-77001-AHR)
G04650045Courtesy of FORD MOTOR CO.
 Retainer, Torque Converter
307-346
G04650046Courtesy of FORD MOTOR CO.
 Aligner, Valve Body
307-456
MATERIAL SPECIFICATIONS

Item Specification
MERCON® SP Automatic Transmission Fluid XT-6-QSP MERCON® SP

Transmission, Disassembled View 

Fig 1: Exploded View Of Transmission (1 Of 3)
G04650047Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transmission (2 Of 3)
G04650048Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transmission (3 Of 3)
G04650049Courtesy of FORD MOTOR CO.
Fig 4: Transmission Components Description Chart (1 Of 4)
G04650050Courtesy of FORD MOTOR CO.
Fig 5: Transmission Components Description Chart (2 Of 4)
G04650051Courtesy of FORD MOTOR CO.
Fig 6: Transmission Components Description Chart (3 Of 4)
G04650052Courtesy of FORD MOTOR CO.
Fig 7: Transmission Components Description Chart (4 Of 4)
G04650053Courtesy of FORD MOTOR CO.
NOTE: Soak all friction clutch plates in clean automatic transmission fluid.
NOTE: Prior to installation, lightly lubricate all O-ring seals with clean automatic transmission fluid.
NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

    All transmissions 

  1. Mount the transmission case into a suitable stand.
  2. If removed, use the special tool to install the short fluid inlet tube.
    Fig 8: Identifying Short Fluid Inlet Tube With Special Tools
    G04650054Courtesy of FORD MOTOR CO.
  3. If removed, use the special tool to install a new Teflon® seal retainer.
    • Install 2 new Teflon® seals.
      Fig 9: Identifying Teflon® Seals With Special Tools
      G04650055Courtesy of FORD MOTOR CO.
    4. NOTE: Coat the reverse clutch piston seals with petroleum jelly.
    Fig 10: Locating Reverse Clutch Piston Seals
    G03889329Courtesy of FORD MOTOR CO.
  4. Install the reverse clutch piston in the case until it is fully seated in the case.
  5. Install the reverse clutch return spring assembly.
    Fig 11: Locating Return Spring
    G03889328Courtesy of FORD MOTOR CO.
    6. WARNING: Do not over compress the return spring or damage to the spring will occur.
    Fig 12: Identifying Reverse Clutch Return Spring Snap Ring With Special Tools
    G04650058Courtesy of FORD MOTOR CO.
  6. Using the special tools, install the reverse clutch return spring snap ring.
    7. NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.
    Fig 13: Identifying Park Gear Thrust Washer
    G03889325Courtesy of FORD MOTOR CO.
  7. For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.
    8. WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.
    Fig 14: Identifying Output Shaft
    G03889324Courtesy of FORD MOTOR CO.
  8. Install the output shaft.
    9. CAUTION: The Torx® screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.
  9. If removed, install the parking pawl abutment with a new Torx® screw.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 15: Identifying Parking Pawl, Torx® Screw With Special Tools
      G04650061Courtesy of FORD MOTOR CO.
  10. Install the parking pawl.
    1. Install the parking pawl shaft.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
      Fig 16: Identifying Parking Pawl Shaft, Parking Pawl And Parking Pawl Return Spring
      G04650062Courtesy of FORD MOTOR CO.
    11. NOTE: Make sure the dimple on the parking guide support plate is facing inward.
  11. Install the parking rod guide plate.
    1. Install the parking rod guide plate.
    2. Install the bolts.
      • Tighten to 25 Nm (18 lb-ft).
        Fig 17: Identifying Parking Rod Guide Plate And Bolts
        G04650063Courtesy of FORD MOTOR CO.
  12. Install a new orifice lube plug in the rear of the case. Using a 12 mm socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.
    Fig 18: Locating Orifice Lube Plug
    G04650064Courtesy of FORD MOTOR CO.
  13. Install a new extension housing gasket.
    Fig 19: Locating Extension Housing Gasket
    G03889106Courtesy of FORD MOTOR CO.
  14. Install the extension housing.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 20: Locating Transmission Extension Housing Bolts
      G03889104Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new manual control lever seal.
    Fig 21: Identifying Manual Control Lever Seal With Special Tools
    G04650067Courtesy of FORD MOTOR CO.
  16. Install the transmission range (TR) sensor, park rod assembly and loosely install the bolts.
    Fig 22: Identifying Manual Control Lever And Park Rod Assembly
    G03889337Courtesy of FORD MOTOR CO.
  17. Install the manual control lever.
    Fig 23: View Of Manual Control Lever
    G03889336Courtesy of FORD MOTOR CO.
  18. Install the roll pin into the case.
    Fig 24: Identifying Roll Pin Into Case
    G04650070Courtesy of FORD MOTOR CO.
  19. Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.
    Fig 25: Identifying Manual Lever Shaft Retaining Pin
    G03889334Courtesy of FORD MOTOR CO.
  20. Tighten the TR sensor bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 26: Identifying Manual Control Lever And Park Rod Assembly
      G03889337Courtesy of FORD MOTOR CO.
  21. Using the special tool, install a new extension housing seal.
    Fig 27: Identifying Extension Housing Seal With Special Tools
    G04650073Courtesy of FORD MOTOR CO.
  22. Inspect the new output shaft nut O-ring for cuts. A new nut must be installed.
    Fig 28: Locating Output Shaft O-Ring
    G04650074Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the output shaft nut.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 29: Identifying Output Shaft With Special Tool
      G04649634Courtesy of FORD MOTOR CO.
  24. Install the output flange and a new bolt.
    • Tighten to 135 Nm (100 lb-ft).
      Fig 30: Locating Output Shaft Flange Bolt
      G04650076Courtesy of FORD MOTOR CO.

    25. Slip yoke transmissions 

  25. Install a new extension housing seal using the special tool.
    Fig 31: Identifying Extension Housing Seal With Special Tools
    G04650077Courtesy of FORD MOTOR CO.

    26. All transmissions 

  26. Install the No. 16 bearing and race.
    Fig 32: Locating Low Reverse Thrust Bearing
    G03889316Courtesy of FORD MOTOR CO.
  27. Install the ring gear, hub and the No. 15 hub bearing.
    Fig 33: Locating Ring Gear, Thrust Bearing And Hub
    G03889315Courtesy of FORD MOTOR CO.
  28. Install the reverse carrier and hub assembly.
    Fig 34: Locating Reverse Carrier
    G04650080Courtesy of FORD MOTOR CO.
  29. Install the low/reverse clutch plates.
    • Start with a steel plate on the bottom, followed by a friction plate.
    • Alternately stack the remaining steel and friction plates.
    • Add the pressure plate (low/reverse one-way clutch) on the last friction plate, with THIS SIDE UP facing upward.
      Fig 35: Locating Low/Reverse Clutch Plates
      G04650081Courtesy of FORD MOTOR CO.

    30. Diesel engines 

    CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur.
  30. Install a new snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

    Diesel applications: Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.

    • Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.
      Fig 36: Identifying Snap Ring Gaps To Right And Left Of Case Spline
      G04650082Courtesy of FORD MOTOR CO.
    31. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur.
  31. Install a new snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

    Gas applications: Install a new wavy snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown. The circle ID mark must be installed upwards on the left hand side.

    • Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.
      Fig 37: Identifying Snap Ring Gaps To Right And Left Of Case Spline
      G04650083Courtesy of FORD MOTOR CO.

    32. All engines 

  32. Using the special tools, install the forward geartrain as an assembly.
    Fig 38: Identifying Forward Geartrain Assembly With Special Tools
    G04650084Courtesy of FORD MOTOR CO.
  33. Install the intermediate clutch pressure plate.
    • Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.
      Fig 39: Identifying Intermediate Clutch Pressure Plate
      G04650085Courtesy of FORD MOTOR CO.
  34. Install the intermediate clutch plates, starting with a friction plate.
    Fig 40: Identifying Intermediate Clutch Plates, Starting With Friction Plate
    G04650086Courtesy of FORD MOTOR CO.
  35. Install the center support.
    Fig 41: Locating Center Support
    G04650087Courtesy of FORD MOTOR CO.
  36. Loosely install the feed bolts.
    1. Loosely install the Torx® head forward clutch feed bolt into the case toward the rear of the case.
    2. Loosely install the hex head intermediate clutch feed bolt into the case toward the front of the case.
      Fig 42: Locating Feed Bolts
      G04650088Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the center support snap ring.
    • The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case.
      Fig 43: Identifying Center Support Snap Ring With Special Tools
      G04650089Courtesy of FORD MOTOR CO.
  38. Tighten the feed bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 44: Identifying Feed Bolts
      G04650090Courtesy of FORD MOTOR CO.
  39. Install the No. 5 thrust bearing onto the center support.
    Fig 45: Locating No. 5 Thrust Bearing
    G04650091Courtesy of FORD MOTOR CO.
  40. Install the center shaft and ring gear.
    Fig 46: Locating Center Shaft And Ring Gear
    G03889559Courtesy of FORD MOTOR CO.
  41. Install the No. 4 thrust bearing onto the center shaft.
    Fig 47: Locating Thrust Bearing
    G03889301Courtesy of FORD MOTOR CO.
  42. Using the special tool, install the coast clutch assembly and overdrive carrier.
    Fig 48: Identifying Coast Clutch Assembly With Special Tools
    G04650094Courtesy of FORD MOTOR CO.
  43. Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position.
    Fig 49: Locating Overdrive Clutch Assembly Snap Ring
    G04650095Courtesy of FORD MOTOR CO.
  44. Install the overdrive pressure plate with the notches facing up.
    Fig 50: Locating Overdrive Pressure Plate With Facing Up
    G04650096Courtesy of FORD MOTOR CO.
  45. Install the overdrive clutch.
    • Start with a friction plate, alternating with a steel plate.
      Fig 51: Locating Friction Plate, Alternating With Steel Plate
      G04650097Courtesy of FORD MOTOR CO.
  46. Install a new pump gasket.
    Fig 52: Locating Pump Gasket
    G03889565Courtesy of FORD MOTOR CO.
  47. Install the No. 2 thrust bearing.
    Fig 53: Locating Pump Gasket
    G03889565Courtesy of FORD MOTOR CO.
  48. Install the input shaft into the case.
    Fig 54: Locating Input Shaft
    G04650100Courtesy of FORD MOTOR CO.
    49. NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.
    Fig 55: Identifying Special Tools
    G04650101Courtesy of FORD MOTOR CO.
  49. Install the special tools into the case in order to install the pump.
  50. Check to make sure that the No. 1 thrust washer is installed on the pump stator.
    51. NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions.
    Fig 56: Identifying Pump Assembly With Special Tools
    G04650102Courtesy of FORD MOTOR CO.
  51. Using the special tools, install the pump assembly.
  52. Install new pump body-to-case retaining bolts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 57: Locating Pump Body-To-Case Retaining Bolts
      G04650103Courtesy of FORD MOTOR CO.
  53. Install a new main control body gasket.
    Fig 58: Identifying Main Control Solenoid Body Gasket
    G03889292Courtesy of FORD MOTOR CO.
  54. Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.
    Fig 59: Identifying Special Tools
    G04650105Courtesy of FORD MOTOR CO.
  55. Using the special tools, install the solenoid body and loosely install the bolts.
    • While installing the solenoid body, align the manual valve.
      Fig 60: Identifying Solenoid Body Bolts With Special Tools
      G04650106Courtesy of FORD MOTOR CO.
  56. Tighten all the bolts in the sequence shown.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 61: Identifying Tightening Sequence For Solenoid Body Bolts
      G04650107Courtesy of FORD MOTOR CO.
  57. Connect the TR sensor connector.
    Fig 62: Locating TR Sensor Connector
    G04650108Courtesy of FORD MOTOR CO.
    58. NOTE: Prior to installing the fluid filter, make sure that the old seal is not stuck in the case.
    Fig 63: View Of Transmission Fluid Filter
    G03889290Courtesy of FORD MOTOR CO.
  58. Install a new transmission fluid filter.
    59. NOTE: Reuse the fluid pan gasket unless it is damaged.
    Fig 64: Locating Transmission Fluid Pan Gasket
    G04650110Courtesy of FORD MOTOR CO.
  59. Install the transmission fluid pan gasket to the fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
  60. Install the transmission fluid pan.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 65: Identifying Transmission Fluid Pan Bolts
      G03889037Courtesy of FORD MOTOR CO.
  61. Install the intermediate shaft and turbine shaft speed (TSS) sensor.
    1. Install the TSS sensor.
    2. Install the TSS sensor bolt.
      • Tighten to 9 Nm (80 lb-in).
        Fig 66: Identifying TSS Sensor And Bolt
        G04650112Courtesy of FORD MOTOR CO.
  62. Install the output shaft speed (OSS) sensor.
    1. Install the OSS sensor.
    2. Install the OSS sensor bolt.
      • Tighten to 9 Nm (80 lb-in).
        Fig 67: Identifying OSS Sensor And Bolt
        G04650113Courtesy of FORD MOTOR CO.
    63. CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.
    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 Clean Converter Hub
    G04650114Courtesy of FORD MOTOR CO.
  63. Lubricate the converter hub with clean automatic transmission fluid.
    64. CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.
    NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.
    Fig 69: Identifying Special Tool (307-091)
    G04650115Courtesy of FORD MOTOR CO.
  64. Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
  65. Check the seating of the torque converter.
    1. Place the straightedge across the converter housing.
    2. Make sure there is a gap between the converter pilot face and the straightedge.
    3. Remove the special tools.
      Fig 70: Identifying Special Tool (307-091)
      G04650116Courtesy of FORD MOTOR CO.
  66. Use the special tool to hold the torque converter in place when installing the transmission.
    Fig 71: Identifying Special Tool (307-346)
    G04650117Courtesy of FORD MOTOR CO.
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