Section 900 (Automatic Transmission -- F250-F550 Super Duty): Assembly: Transmission

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Installer, Transmission Extension Housing Fluid Seal (4x2) 307-462
	Installer, Transmission Extension Housing Fluid Seal (4x4) 307-453
	Compressor, Clutch Spring 307-015 (T65L-77515-A)
	Installer, Shift Shaft Fluid Seal 307-002 (TOOL-77288)
	Handle, Torque Converter 307-091 (T81P-7902-C)
	Aligner, Transmission Fluid Pump 307-222 (T89T-70010-B)
	Installer, Fluid Filler Tube 307-376
	Installer, Transmission Forward Clutch Assembly 307-436
	Bridge Adapter (use with 307-436) 307-436-02
	Loading Fixture, Clutch 307-S383
	Air Test Plate 307-457
	Test Plate Screw Set, Transmission 307-126 (T82P-7006-C)
	Alignment Cone 307-455
	Nut Driver, Output Shaft 307-458
	Installer, Seal Pack 307-461
	Retaining Ring Pliers 307-343 (T95P-77001-AHR)
	Retainer, Torque Converter 307-346
	Aligner, Valve Body 307-456

MATERIAL

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

Fig 1: Disassembled View - Transmission (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 2: Disassembled View - Transmission (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 3: Disassembled View - Transmission (3 Of 3)

Courtesy of FORD MOTOR CO.

Fig 4: Disassembled View Legend - Transmission (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 5: Disassembled View Legend - Transmission (2 Of 4)

Courtesy of FORD MOTOR CO.

Fig 6: Disassembled View Legend - Transmission (3 Of 4)

Courtesy of FORD MOTOR CO.

Fig 7: Disassembled View Legend - Transmission (4 Of 4)

Courtesy 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

Mount the transmission case into a suitable stand.
If removed, use the special tool to install the short fluid inlet tube.

Fig 8: Installing Short Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
If removed, use the special tool to install a new Teflon® seal retainer.
- Install two new Teflon® seals.
  
  Fig 9: Installing Teflon® Seal Retainer
  Courtesy of FORD MOTOR CO.

NOTE: Coat the reverse clutch piston seals with clean automatic transmission fluid.

Fig 10: Installing Reverse Clutch Piston In Case

Courtesy of FORD MOTOR CO.

Install the reverse clutch piston in the case until it is fully seated in the case.
Install the reverse clutch return spring assembly.

Fig 11: Installing Reverse Clutch Return Spring Assembly
Courtesy of FORD MOTOR CO.

WARNING: Do not overcompress the return spring, or damage to the spring will occur.

Fig 12: Installing Reverse Clutch Return Spring Snap Ring

Courtesy of FORD MOTOR CO.

Using the special tools, install the reverse clutch return spring snap ring.

NOTE: The use of clean transmission fluid will hold the No. 17 thrust bearing or washer in place during assembly.

Fig 13: Identifying Park Gear Thrust Washer

Courtesy of FORD MOTOR CO.

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.

WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

Fig 14: Installing Output Shaft

Courtesy of FORD MOTOR CO.

Install the output shaft.

CAUTION: The Torx® screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

Fig 15: Installing Parking Pawl Abutment With Torx® Screw

Courtesy of FORD MOTOR CO.

If removed, install the parking pawl abutment with a new Torx® screw.
Install the parking pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the parking pawl return spring.
  
  Fig 16: Installing Parking Pawl
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the dimple on the parking guide support plate is facing inward.

Install the parking rod guide plate.
1. Install the parking rod guide plate.
2. Install the bolts.
  
  Fig 17: Installing Parking Rod Guide Plate
  Courtesy of FORD MOTOR CO.
Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.48 in) 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: Installing Orifice Lube Plug In Rear Of Case
Courtesy of FORD MOTOR CO.
Install a new extension housing gasket.

Fig 19: Identifying Extension Housing Gasket
Courtesy of FORD MOTOR CO.
Install the extension housing.

Fig 20: Extension Housing Bolts - With Torque Specification
Courtesy of FORD MOTOR CO.
Using the special tool, install a new manual control lever seal.

Fig 21: Installing Manual Control Lever Seal
Courtesy of FORD MOTOR CO.
Install the transmission range (TR) sensor, park rod assembly and loosely install the bolts.

Fig 22: Installing Transmission Range (TR) Sensor, Park Rod Assembly And Bolts
Courtesy of FORD MOTOR CO.
Install the manual control lever.

Fig 23: Installing Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the roll pin into the case.

Fig 24: Installing Roll Pin Into Case
Courtesy of FORD MOTOR CO.
Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.

Fig 25: Installing Roll Pin
Courtesy of FORD MOTOR CO.
Tighten the TR sensor bolts.

Fig 26: Tightening TR Sensor Bolts
Courtesy of FORD MOTOR CO.
Use the special tool and install a new extension housing seal.

Fig 27: Installing Extension Housing Seal
Courtesy of FORD MOTOR CO.
Inspect the new output shaft nut O-ring for cuts. A new output shaft nut must be installed.

Fig 28: Inspecting Output Shaft Nut O-Ring For Cuts
Courtesy of FORD MOTOR CO.
Using the special tool, install a new output shaft nut.

Fig 29: Installing Output Shaft Nut
Courtesy of FORD MOTOR CO.
Install the output flange.
1. Install the flange.
2. Install a new bolt.
  
  Fig 30: Installing Output Shaft Flange - With Torque Specification
  Courtesy of FORD MOTOR CO.

Slip yoke transmissions

Install a new extension housing seal using the special tool.

Fig 31: Installing Extension Housing Seal Using Special Tool
Courtesy of FORD MOTOR CO.

All transmissions

Install the No. 16 bearing and race.

Fig 32: Installing No 16 Bearing And Race
Courtesy of FORD MOTOR CO.
Install the ring gear, hub and the No. 15 hub bearing.

Fig 33: Installing Ring Gear, Hub And No 15 Hub Bearing
Courtesy of FORD MOTOR CO.
Install the reverse carrier and hub assembly.

Fig 34: Installing Reverse Carrier And Hub Assembly
Courtesy of FORD MOTOR CO.
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: Installing Low/Reverse Clutch Plates
  Courtesy of FORD MOTOR CO.

Diesel engines

CAUTION: Do not exceed 138 kPa (20 psi) when applying air pressure to the low reverse clutch port.

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.

Install the new snap ring and make sure that the snap ring is fully seated in the case groove. The gap of the retaining ring should be in the one o'clock position.
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: Installing Flat Snap Ring
  Courtesy of FORD MOTOR CO.

Gasoline 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.

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: Installing Wavy Snap Ring
  Courtesy of FORD MOTOR CO.

All engines

Using the special tools, install the forward geartrain as an assembly.

Fig 38: Installing Forward Geartrain As Assembly
Courtesy of FORD MOTOR CO.
Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the three tabs facing downward.
  
  Fig 39: Installing Intermediate Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the intermediate clutch plates, starting with a friction plate.

Fig 40: Installing Intermediate Clutch Plates, Starting With Friction Plate
Courtesy of FORD MOTOR CO.
Install the center support.

Fig 41: Installing Center Support
Courtesy of FORD MOTOR CO.
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: Installing Feed Bolts
  Courtesy of FORD MOTOR CO.
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 six o'clock position. Tap the snap ring securely into the case
  
  Fig 43: Installing Center Support Snap Ring
  Courtesy of FORD MOTOR CO.
Tighten the feed bolts.
- Tighten to 32 Nm (24 lb-ft).
  
  Fig 44: Tightening Feed Bolts
  Courtesy of FORD MOTOR CO.
Install the No. 5 thrust bearing onto the center support.

Fig 45: Installing No 5 Thrust Bearing Onto Center Support
Courtesy of FORD MOTOR CO.
Install the center shaft and ring gear.

Fig 46: Installing Center Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
Install the No. 4 thrust bearing onto the center shaft.

Fig 47: Installing No 4 Thrust Bearing Onto Center Shaft
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch assembly and overdrive carrier.

Fig 48: Installing Coast Clutch Assembly And Overdrive Carrier
Courtesy of FORD MOTOR CO.
Install the overdrive clutch assembly snap ring with the gap in the six o'clock position.

Fig 49: Installing Overdrive Clutch Assembly Snap Ring
Courtesy of FORD MOTOR CO.
Install the overdrive pressure plate with the notches facing up.

Fig 50: Installing Overdrive Pressure Plate
Courtesy of FORD MOTOR CO.
Install the overdrive clutch.
- Start with a friction plate, alternating with a steel plate.
  
  Fig 51: Installing Overdrive Clutch
  Courtesy of FORD MOTOR CO.
Install a new pump gasket.

Fig 52: Installing Pump Gasket
Courtesy of FORD MOTOR CO.
Install the No. 2 thrust bearing.

Fig 53: Installing No 2 Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the input shaft into the case.

Fig 54: Installing Input Shaft Into Case
Courtesy of FORD MOTOR CO.

NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.

Fig 55: Installing Special Tools Into Case

Courtesy of FORD MOTOR CO.

Install the special tools into the case in order to install the pump.
Check to make sure that the No. 1 thrust washer is installed on the pump stator.

NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions.

Fig 56: Installing Pump Assembly

Courtesy of FORD MOTOR CO.

Using the special tools, install the pump assembly.
Install new retaining bolts.

Fig 57: Installing Retaining Bolts
Courtesy of FORD MOTOR CO.
Install a new main control body gasket.

Fig 58: Installing Main Control Body Gasket
Courtesy of FORD MOTOR CO.
Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.

Fig 59: Checking Clutch Function Using Special Tools
Courtesy of FORD MOTOR CO.
Using the special tools, install the solenoid body and loosely install the bolts.
- While installing the solenoid body, align the manual valve.
  
  Fig 60: Installing Solenoid Body
  Courtesy of FORD MOTOR CO.
Tighten all the bolts in the sequence shown.

Fig 61: Identifying Solenoid Body Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
Connect the transmission range sensor connector.

Fig 62: Connecting Transmission Range Sensor Connector
Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the fluid filter, make sure that the old seal is not stuck in the case.

Fig 63: Installing Transmission Fluid Filter

Courtesy of FORD MOTOR CO.

Install a new transmission fluid filter.

NOTE: Reuse the fluid pan gasket unless it is damaged.

Fig 64: Positioning The Gasket Onto The Clean Fluid Pan

Courtesy of FORD MOTOR CO.

Install the transmission fluid pan gasket to the fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
Install the transmission fluid pan.

Fig 65: Installing Transmission Fluid Pan
Courtesy of FORD MOTOR CO.
Install the intermediate shaft and turbine shaft speed (TSS) sensor.

Fig 66: Installing Intermediate Shaft And Turbine Shaft Speed (TSS) Sensor
Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.

Fig 67: Installing Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the fluid pump gear O-ring 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: Lubricating Converter Hub

Courtesy of FORD MOTOR CO.

Lubricate the converter hub with clean automatic transmission fluid.

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: Installing Torque Converter

Courtesy of FORD MOTOR CO.

Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
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: Checking Seating Of Torque Converter
  Courtesy of FORD MOTOR CO.
Use the special tool to hold the torque converter in place when installing the transmission.

Fig 71: Identifying Special Torque Converter Tool
Courtesy of FORD MOTOR CO.