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Section 666 (Automatic Transmission - 5R110W - Excursion & F250-F550 Super Duty): Disassembly: Transmission

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) 

Fig 1: Identifying Special Tool (1 Of 2)
G02775809Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool (2 Of 2)
G02775810Courtesy of FORD MOTOR CO.
NOTE: The pressure switches shown in this procedure will not be applicable to all vehicle applications. Some vehicles will not have the pressure switches or the harness installed in the valve body.
  1. Remove the special tool.
    Fig 3: Removing Special Tool
    G02775811Courtesy of FORD MOTOR CO.
    2. WARNING: Use the special tools when removing the torque converter because it is very heavy. Failure to follow may result in personal injury.
    NOTE: Fluid loss will occur when removing the torque converter.
    Fig 4: Removing Torque Converter
    G02775812Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the torque converter.
  3. Remove the intermediate shaft and turbine shaft speed combination sensor.
    1. Remove the bolt.
    2. Remove the sensor.
      Fig 5: Removing Bolt And Sensor
      G02775813Courtesy of FORD MOTOR CO.
  4. Remove the output shaft speed sensor (OSS).
    1. Remove the bolt.
    2. Remove the output shaft speed sensor (OSS).
      Fig 6: Removing Output Shaft Speed Sensor
      G02775814Courtesy of FORD MOTOR CO.
  5. Mount the transmission onto a suitable stand.
  6. Remove the input shaft and discard the stator support seal.
    Fig 7: Removing Input Shaft Stator Support Seal
    G02775815Courtesy of FORD MOTOR CO.
  7. Install a new drain plug and seal if there is evidence of leaking.
    Fig 8: Installing Drain Plug And Seal
    G02775816Courtesy of FORD MOTOR CO.
    8. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 9: Removing Transmission Fluid Pan And Gasket
    G02775817Courtesy of FORD MOTOR CO.
  8. Remove the transmission fluid pan and the gasket. Check and clean the magnet if debris is evident.
    9. NOTE: After removal, discard the filter and seal assembly.
    Fig 10: Removing Filter And Seal Assembly
    G02775818Courtesy of FORD MOTOR CO.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
    10. CAUTION: There is no retainer on the manual valve. Hold the manual valve in place while removing the solenoid assembly from the transmission to avoid dropping the valve.
  10. Remove the solenoid body.
    1. Disconnect the transmission range sensor.
    2. Remove the solenoid body bolts.
    3. Remove the solenoid body.
      Fig 11: Removing Solenoid Body
      G02775819Courtesy of FORD MOTOR CO.
  11. Remove and discard the solenoid body gasket.
    Fig 12: Removing Solenoid Body Gasket
    G02775820Courtesy of FORD MOTOR CO.
  12. Remove the forward clutch orifice.
    Fig 13: Removing Forward Clutch Orifice
    G02775821Courtesy of FORD MOTOR CO.
  13. Remove the feedbolts.
    Fig 14: Removing Feedbolts
    G02775822Courtesy of FORD MOTOR CO.
  14. Remove and discard the front pump bolts.
    Fig 15: Removing Front Pump Bolts
    G02775823Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the front pump.
    Fig 16: Removing Front Pump
    G02775824Courtesy of FORD MOTOR CO.
    16. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
  16. 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 17: Illustration Steps-1, 2, And 3
      G02775825Courtesy of FORD MOTOR CO.
  17. Remove the overdrive separator plates, clutch plates and overdrive pressure plate.
    Fig 18: Removing Overdrive Separator Plates, Clutch Plates And Overdrive Pressure Plate
    G02775826Courtesy of FORD MOTOR CO.
  18. Remove the overdrive clutch retaining ring.
    Fig 19: Removing Overdrive Clutch Retaining Ring
    G02775827Courtesy of FORD MOTOR CO.
  19. Install the special tool.
    Fig 20: Installing Special Tool
    G02775828Courtesy of FORD MOTOR CO.
    20. NOTE: The No. 3 overdrive carrier thrust bearing and race assembly may come out with the coast clutch cylinder assembly or it may stay in the transmission.
    Fig 21: Removing Coast Clutch Cylinder Assembly
    G02775829Courtesy of FORD MOTOR CO.
  20. Using the special tool, remove the coast clutch cylinder assembly.
  21. Remove the No. 4 thrust bearing.
    Fig 22: Removing No. 4 Thrust Bearing
    G02775830Courtesy of FORD MOTOR CO.
  22. Remove the overdrive ring gear and center shaft.
    Fig 23: Removing Overdrive Ring Gear And Center Shaft
    G02775831Courtesy of FORD MOTOR CO.
  23. Remove the No. 5 sun gear thrust bearing.
    Fig 24: Removing No. 5 Sun Gear Thrust Bearing
    G02775832Courtesy of FORD MOTOR CO.
  24. Using the special tool, remove the center support retaining ring.
    Fig 25: Removing Center Support Retaining Ring
    G02775833Courtesy of FORD MOTOR CO.
  25. Install the special tools into the center support assembly.
    Fig 26: Installing Special Tools Into Center Support Assembly
    G02775834Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the center support, direct clutch and forward clutch cylinder assembly.
    Fig 27: Removing Center Support, Direct Clutch And Forward Clutch Cylinder Assembly
    G02775835Courtesy of FORD MOTOR CO.
  27. Remove the forward clutch hub and the No. 9 thrust washer.
    Fig 28: Removing Forward Clutch Hub And No. 9 Thrust Washer
    G02775836Courtesy of FORD MOTOR CO.
  28. Remove the forward ring gear and hub assembly.
    Fig 29: Removing Forward Ring Gear And Hub Assembly
    G02775837Courtesy of FORD MOTOR CO.
  29. Remove the forward carrier race and the No. 11 bearing assembly.
    Fig 30: Removing Forward Carrier Race And No. 11 Bearing Assembly
    G02775838Courtesy of FORD MOTOR CO.
  30. Remove the forward carrier.
    Fig 31: Removing Forward Carrier
    G02775839Courtesy of FORD MOTOR CO.
  31. Remove the sun gear and the No. 12 thrust bearing.
    Fig 32: Removing Sun Gear And No. 12 Thrust Bearing
    G02775840Courtesy of FORD MOTOR CO.
  32. Remove the low reverse sun gear and shell assembly.
    Fig 33: Removing Low Reverse Sun Gear And Shell Assembly
    G02775841Courtesy of FORD MOTOR CO.
  33. Remove and discard the low/reverse clutch retaining ring.
    Fig 34: Removing Low/Reverse Clutch Retaining Ring
    G02775842Courtesy of FORD MOTOR CO.
  34. Remove the low/reverse one-way clutch, clutch pack, carrier and hub assembly.
    Fig 35: Removing Low/Reverse One-Way Clutch, Clutch Pack, Carrier And Hub Assembly
    G02775843Courtesy of FORD MOTOR CO.
  35. Remove the No. 15 thrust bearing and hub.
    Fig 36: Removing No. 15 Thrust Bearing And Hub
    G02775844Courtesy of FORD MOTOR CO.
  36. Place the transmission manual lever in park to lock the output shaft from rotating.
  37. Remove the output hub and ring gear.
  38. Remove the low reverse No.16 thrust bearing.
    Fig 37: Removing Low Reverse No.16 Thrust Bearing
    G02775845Courtesy of FORD MOTOR CO.
  39. If equipped, remove the output shaft flange.
    1. Remove and discard the bolt.
    2. Remove the output shaft flange.
      Fig 38: Removing Output Shaft Flange
      G02775846Courtesy of FORD MOTOR CO.
  40. If equipped, use the special tool to remove the output shaft retaining nut.
    Fig 39: Removing Output Shaft Retaining Nut
    G02775847Courtesy of FORD MOTOR CO.
  41. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
    Fig 40: Removing Output Shaft Seal
    G02775848Courtesy of FORD MOTOR CO.
  42. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
    Fig 41: Removing Output Shaft Seal
    G02775849Courtesy of FORD MOTOR CO.
  43. Remove the nine bolts and the extension housing.
    Fig 42: Removing Bolts And Extension Housing
    G02775850Courtesy of FORD MOTOR CO.
  44. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.
    Fig 43: Inspecting Extension Housing Ball Bearing
    G02775851Courtesy of FORD MOTOR CO.
  45. Remove and discard the extension housing gasket.
    Fig 44: Removing And Extension Housing Gasket
    G02775852Courtesy of FORD MOTOR CO.
  46. Remove the output shaft.
    Fig 45: Removing Output Shaft
    G02775853Courtesy of FORD MOTOR CO.
  47. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing
    Fig 46: Removing No. 17 Park Gear Thrust Washer And Bearing
    G02775854Courtesy of FORD MOTOR CO.
    48. CAUTION: Do not fully compress the return spring or damage to the spring may occur.
    Fig 47: Removing Reverse Clutch Drum Retaining Ring
    G02775855Courtesy of FORD MOTOR CO.
  48. Using the special tools, remove the reverse clutch drum retaining ring.
  49. Remove the return spring.
    Fig 48: Removing Return Spring
    G02775856Courtesy of FORD MOTOR CO.
  50. While applying air to the case, remove and discard the reverse piston.
    Fig 49: Removing Reverse Piston
    G02775857Courtesy of FORD MOTOR CO.
  51. Remove the parking rod guide plate bolts and plate.
    Fig 50: Removing Parking Rod Guide Plate Bolts And Plate
    G02775858Courtesy of FORD MOTOR CO.
  52. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 51: Removing Plastic Orifice Lube Plug From Rear Of Case
    G02775859Courtesy of FORD MOTOR CO.
  53. 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 Shaft
      G02775860Courtesy of FORD MOTOR CO.
    54. CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new bolt installed.
    Fig 53: Removing Parking Pawl Abutment
    G02775861Courtesy of FORD MOTOR CO.
  54. Remove the parking pawl abutment.
    55. NOTE: The pin should be driven down into the case.
    Fig 54: Removing Manual Lever Shaft Retaining Pin
    G02775862Courtesy of FORD MOTOR CO.
  55. Using a suitable tool, remove and discard the manual lever shaft retaining pin.
  56. Using the special tool, remove the manual lever shaft retaining pin.
    Fig 55: Removing Manual Lever Shaft Retaining Pin
    G02775863Courtesy of FORD MOTOR CO.
  57. Remove the manual control lever shaft.
    Fig 56: Removing Manual Control Lever Shaft
    G02775864Courtesy of FORD MOTOR CO.
  58. Remove the transmission range sensor, manual control lever and park rod as an assembly.
    Fig 57: Removing Transmission Range Sensor, Manual Control Lever And Park Rod
    G02775865Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove and discard the manual control lever seal.
    Fig 58: Removing Manual Control Lever Seal
    G02775866Courtesy of FORD MOTOR CO.
    60. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 59: Removing Short Fluid Inlet Tube
    G02775867Courtesy of FORD MOTOR CO.
  60. If required, remove the short fluid inlet tube.
    61. NOTE: The top portion seal groove will work the best when removing the seal pack.
    Fig 60: Removing Seal Retainer Using Special Tool
    G02775868Courtesy of FORD MOTOR CO.
  61. Inspect the rear case Teflon® seal retainer for damage. If damage is evident, use the special tool to remove the seal retainer.
  62. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case fluid passages for obstructions.
  63. Inspect the rear case snubber bushing. If damage is found, install a new transmission case.
  64. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
  65. Inspect the reverse clutch case vent for blockage. The vent is located in the case at the 12 o'clock position. If evidence of blockage is found, use low air pressure to clear out the blockage. Apply air pressure to the extension housing side of the vent.
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