Section 665 (Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty): Disassembly: Transmission

Special Tool(s) 

Fig 1: Identifying Transmission Special Tool(s)

Courtesy of FORD MOTOR CO.

All applications 

CAUTION: The turbine shaft speed sensor (TSS) will need to be removed or damage to the sensors will occur.
1. Remove the turbine shaft sensor (TSS).
   1. Remove the bolt.
   2. Remove the turbine shaft sensor (TSS).
      Fig 2: Removing Turbine Shaft Sensor (TSS)

      Courtesy of FORD MOTOR CO.
CAUTION: The output shaft speed sensor (OSS) will need to be removed or damage to the sensors will occur.
2. Remove the output shaft speed sensor (OSS).
   1. Remove the bolt.
   2. Remove the output shaft speed sensor (OSS).
      Fig 3: Removing Output Shaft Speed Sensor (OSS)

      Courtesy of FORD MOTOR CO.
3. Mount the transmission onto a suitable stand.
CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.
Fig 4: Removing Input Shaft
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4. Remove the input shaft.
CAUTION: The sealing washers may fall off the cooler line case fittings.
NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
5. Remove the cooler bypass valve.
   1. Remove the cooler line case fittings.
   2. Remove the cooler bypass valve.
      Fig 5: Removing Cooler Line Case Fittings

      Courtesy of FORD MOTOR CO.
6. Remove the transmission range (TR) sensor.
   1. Remove the bolts.
   2. Remove the transmission range (TR) sensor.
      Fig 6: Removing Transmission Range (TR) Sensor

      Courtesy of FORD MOTOR CO.
NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
Fig 7: Removing Transmission Fluid Pan And Gasket
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7. Remove the transmission fluid pan and the gasket.
CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
NOTE: After removal, discard the filter and seal assembly.
Fig 8: Removing Filter And Seal Assembly
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8. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
9. Remove the bolts, nuts and the accumulator body.
   Fig 9: Removing Bolts Nuts And Accumulator Body

   Courtesy of FORD MOTOR CO.
NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
10. Remove the main control valve body.
    1. Do not remove the two lower-to-upper main control valve body assembly bolts.
       Fig 10: Removing Main Control Valve Body

       Courtesy of FORD MOTOR CO.
11. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 11: Removing Bolts, Nut And Solenoid Body Assembly

    Courtesy of FORD MOTOR CO.
12. Remove the solenoid screen assembly by rotating and pulling.
    Fig 12: Removing Solenoid Screen Assembly

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CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
Fig 13: Discarding Both Gaskets
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13. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets.

    Discard both gaskets.

NOTE: The steel EPC check ball has a 0.5 mm (0.02 in) diameter and is smaller than the other check balls.
Fig 14: Removing Steel EPC Check Ball And Spring
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14. Remove the steel EPC check ball and spring.
CAUTION: Use care not to damage the rubber check balls. Transmission shift problems may occur.
Fig 15: Removing Rubber Check Balls
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15. Using a small screwdriver, carefully remove the 8 rubber check balls.
16. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 16: Identifying Intermediate Band Servo Assembly

    Courtesy of FORD MOTOR CO.
CAUTION: After removal, discard the feedbolts. The bolts will not retain torque specification if reused.
Fig 17: Removing And Discard Feedbolts
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17. Remove and discard the feedbolts.
18. Remove the pump bolts and discard the washers.
    Fig 18: Removing Pump Bolts And Discard Washers

    Courtesy of FORD MOTOR CO.
NOTE: The special tools should be installed into the pump threaded holes as shown.
Fig 19: Removing Pump
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19. Using the special tools, remove the pump.
NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
20. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
       Fig 20: Removing Pump Gasket

       Courtesy of FORD MOTOR CO.
CAUTION: The coast clutch, overdrive ring gear, centershaft assembly must be removed as an assembly using special service tool or damage to the overdrive one-way clutch could occur.
Fig 21: Removing Coast Clutch Overdrive Ring Gear And Centershaft As An Assembly
Courtesy of FORD MOTOR CO.
21. Using the special tool remove, the coast clutch, overdrive ring gear and centershaft as an assembly.
NOTE: The No. 5 thrust bearing may remaining on the center shaft or the center support.
Fig 22: Removing Overdrive Center Shaft Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.
22. Remove the No. 5 overdrive center shaft thrust bearing assembly.

    Applications equipped with a PTO 

CAUTION: The coast clutch, overdrive ring gear, centershaft assembly must be removed as an assembly using special service tool or damage to the overdrive one-way clutch could occur.
Fig 23: Removing Coast Clutch, Overdrive Ring Gear And Centershaft As Assembly
Courtesy of FORD MOTOR CO.
23. Using the special tool remove the coast clutch, overdrive ring gear and centershaft as an assembly.
NOTE: The No. 5 thrust bearing may remain on the center shaft or the center support.
Fig 24: Removing Overdrive Center Shaft Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.
24. Remove the No. 5 overdrive center shaft thrust bearing assembly.

    All applications 

25. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 25: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring

    Courtesy of FORD MOTOR CO.
NOTE: Tag the parts for identification during installation.
Fig 26: Removing Overdrive Clutch Pressure Plate And Clutch Pack
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26. Remove the overdrive clutch pressure plate and the clutch pack.
27. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 27: Removing Intermediate/Overdrive Cylinder Retaining Ring

    Courtesy of FORD MOTOR CO.
CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
Fig 28: Removing Intermediate/Overdrive Cylinder Assembly
Courtesy of FORD MOTOR CO.
28. Remove the intermediate/overdrive cylinder assembly.
29. Remove the intermediate clutch piston return spring.
    Fig 29: Removing Intermediate Clutch Piston Return Spring

    Courtesy of FORD MOTOR CO.
CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.
Fig 30: Removing Center Support Assembly
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30. Carefully remove the center support assembly.
31. Remove the No. 6 center support thrust washer.
    Fig 31: Removing Center Support Thrust Washer

    Courtesy of FORD MOTOR CO.
NOTE: Tag the parts for identification during installation.
32. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
       Fig 32: Removing Intermediate Clutch Rear Pressure Plate

       Courtesy of FORD MOTOR CO.
33. Remove the intermediate band.
    Fig 33: Removing Intermediate Band

    Courtesy of FORD MOTOR CO.
NOTE: When installing the special tool, each leg of the tool must be rotated separately to engage notches on the input shell prior to tightening the top cross bar.
Fig 34: Removing Direct Clutch Forward Clutch And Input Shell As Assembly
Courtesy of FORD MOTOR CO.
34. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
35. Remove the reverse planet retaining ring.
    Fig 35: Removing Reverse Planet Retaining Ring

    Courtesy of FORD MOTOR CO.
36. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 36: Removing Reverse Planet Assembly

    Courtesy of FORD MOTOR CO.
WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
Fig 37: Removing Output Shaft Retaining Ring
Courtesy of FORD MOTOR CO.
37. Remove the output shaft retaining ring.
38. Remove the output shaft ring gear and hub assembly.
    Fig 38: Removing Output Shaft Ring Gear And Hub Assembly

    Courtesy of FORD MOTOR CO.
WARNING: Use care not to drop the output shaft while rotating the transmission.
39. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
       Fig 39: Removing Following Parts As An Assembly

       Courtesy of FORD MOTOR CO.
40. Using the special tools, remove the extension housing seal.
    Fig 40: Removing Extension Housing Seal

    Courtesy of FORD MOTOR CO.
41. Using the special tool, remove the extension housing bushing.
    Fig 41: Removing Extension Housing Bushing

    Courtesy of FORD MOTOR CO.
42. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 42: Removing Eight Bolts One Stud And Extension Housing

    Courtesy of FORD MOTOR CO.
NOTE: Be sure not to damage the output shaft drive sprocket speed sensor wheel or the park gear.
NOTE: The parking gear and output shaft drive sprocket speed sensor wheel are press fit to the output shaft.
Fig 43: Removing Output Shaft
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43. Remove the output shaft.
44. Remove the No. 13 thrust bearing.
    Fig 44: Removing Thrust Bearing

    Courtesy of FORD MOTOR CO.
45. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 45: Removing Plastic Orifice Lube Plug From Rear Of Case

    Courtesy of FORD MOTOR CO.
46. Remove the five bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 46: Removing Five Bolts Retaining Low/Reverse One-Way Clutch Inner Race

    Courtesy of FORD MOTOR CO.
47. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 47: Removing Low/Reverse One-Way Clutch Inner Race

    Courtesy of FORD MOTOR CO.
48. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to restrain the reverse clutch piston.
    Fig 48: Removing Reverse Clutch Piston

    Courtesy of FORD MOTOR CO.
49. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 49: Compressing Air Blow Into Reverse Clutch Feed Port-Blow

    Courtesy of FORD MOTOR CO.
50. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 50: Removing Reverse Clutch Pressure Plate Retainer Snap Ring

    Courtesy of FORD MOTOR CO.
51. If required, remove the parking rod guide plate.
    Fig 51: Removing Parking Rod Guide Plate

    Courtesy of FORD MOTOR CO.
52. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
       Fig 52: Removing Parking Pawl Return Spring

       Courtesy of FORD MOTOR CO.
CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.
Fig 53: Removing Parking Pawl Abutment
Courtesy of FORD MOTOR CO.
53. If required, remove the parking pawl abutment.
NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
Fig 54: Removing Manual Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
54. Using the special tool, remove the manual lever shaft retaining pin.
CAUTION: Use care not to damage the manual control lever bore.
NOTE: The manual control lever and manual control lever shaft are one piece.
55. Remove the manual control lever shaft assembly.
    NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
       Fig 55: Removing Bolt And Manual Control Valve Detent Lever Spring

       Courtesy of FORD MOTOR CO.
56. Using the special tool, remove the manual control lever seal.
    Fig 56: Removing Manual Control Lever Seal

    Courtesy of FORD MOTOR CO.
NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
Fig 57: Removing Short Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
57. If required, remove the short fluid inlet tube.
58. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly and all fluid passages for obstructions.
59. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
60. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers.-repair a damaged thread, follow procedures furnished in the helicoil kit.