Torque Converter Housing, Reverse Clutch and Pump Assembly - Disassembly: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

Torque converter housing

Remove the lube tube bolt and remove the secondary shaft and stator needle bearing lube tube from the case.

Fig 1: Locating Lube Tube Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt from the lube tube and discard both the sealing washers.

Fig 2: Locating Bolt, Lube Tube & Sealing Washers
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seals from the lube tube.

Fig 3: Locating O-Ring Seals
Courtesy of FORD MOTOR CO.

NOTE: A new roller bearing will need to be installed only if damage is indicated, it is worn or sufficient contamination is present.

Fig 4: Locating Secondary Variator Shaft Roller Bearing Cage

Courtesy of FORD MOTOR CO.

If required, remove the secondary variator shaft roller bearing cage from the outer race.
If required, use the special tool and remove the roller bearing race.

Fig 5: Identifying Special Tools (100-001, 308-125)
Courtesy of FORD MOTOR CO.

NOTE: A new roller bearing will need to be installed only if damage is indicated, it is worn or sufficient contamination is present.

Fig 6: Locating Side Shaft Gear Roller Bearing Cage

Courtesy of FORD MOTOR CO.

If required, remove the side shaft gear roller bearing cage from the outer race.
Using the special tools, remove the bearing race.

Fig 7: Identifying Special Tools (100-001, 303-D012, 303-D023)
Courtesy of FORD MOTOR CO.
Using a center punch, knock out the differential seal.

Fig 8: Locating Differential Seal
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 9: Identifying Special Tool (307-532)
Courtesy of FORD MOTOR CO.

NOTE: There is a selective shim under the bearing race that will fall out when removing the bearing race. Be careful not to lose the shim.

Fig 10: Identifying Special Tool (307-532)

Courtesy of FORD MOTOR CO.

The selective shim and bearing race will be installed in the case during assembly of the transaxle after differential set up is completed.
From the other side of the case, use a brass punch and knock out the bearing race.

Reverse clutch

Remove the reverse clutch plate snap ring.

Fig 11: Locating Reverse Clutch Plate Snap Ring
Courtesy of FORD MOTOR CO.
Remove the reverse clutch ring gear and the friction plates, steel plates, separator plate and wave spring.

Fig 12: Locating Reverse Clutch Ring Gear
Courtesy of FORD MOTOR CO.
Using the special tool, remove the return spring retainers.

Fig 13: Identifying Special Tool (307-525)
Courtesy of FORD MOTOR CO.
Remove the return spring.

Fig 14: Locating Return Spring
Courtesy of FORD MOTOR CO.

NOTE: A small amount of air pressure may be needed to remove the reverse clutch piston from the drum. Be careful when using the air pressure. Use only regulated air pressure

Fig 15: Identifying Reverse Clutch Piston

Courtesy of FORD MOTOR CO.

Remove the reverse clutch piston.
1. Apply a small amount of air pressure.
2. Remove the reverse clutch piston.
Remove and discard the reverse clutch piston inner and outer O-ring seals.

Fig 16: Locating Reverse Clutch Piston Inner & Outer O-Ring Seals
Courtesy of FORD MOTOR CO.
Clean and inspect all the reverse clutch parts and install new as required.
Stator assembly

NOTE: If the installation of a new stator or pump is being carried out, the reverse clutch plates, piston and return spring must be removed.
Remove and discard the roller bearing cage assembly from the outer race.

Fig 17: Locating Roller Bearing Cage Assembly
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the roller bearing race.

Fig 18: Identifying Special Tools (100-001, 307-540-2)
Courtesy of FORD MOTOR CO.
Remove the 7 bolts from the stator.

Fig 19: Locating Stator Bolts
Courtesy of FORD MOTOR CO.
From the opposite side of the case, use a dead blow hammer and tap the stator assembly out of the case.

Fig 20: Locating Stator Assembly
Courtesy of FORD MOTOR CO.
Inspect the stator assembly for damage, if damage is indicated install new components.

Pump assembly

NOTE: The pump dust cover can be removed using a small punch from the opposite side of the case.

Fig 21: Locating Pump Dust Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 pump dust cover bolts and remove and discard the cover.
Remove the 8 bolts and the pump assembly.

Fig 22: Locating Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
Remove the pump gasket and the feed tube.

Fig 23: Locating Pump Gasket & Feed Tube
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seals from the ends of the feed tube.

Fig 24: Locating O-Ring Seals
Courtesy of FORD MOTOR CO.

NOTE:

Be careful not to damage the sealing surfaces of the pump.
If the pump is going to be reused, the pump/torque converter seal should be removed.

Fig 25: Locating Pump/Torque Converter Seal

Courtesy of FORD MOTOR CO.

Using a suitable tool, remove the pump/torque converter seal.