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Section 300 (Automatic Transmission): Disassembly: Transmission: Removal

WARNING: This page is about a different car, the 2003 Mercury Marauder, 2003 Mercury Grand Marquis, and 2003 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tools, remove torque converter.
    Fig 1: Removing Torque Converter
    G01608452Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transmission to the bench.
    Fig 2: Mounting Transmission To Bench
    G01608453Courtesy of FORD MOTOR CO.
    3. NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
    Fig 3: Removing Transmission Fluid Pan And Gasket
    G01608454Courtesy of FORD MOTOR CO.
  3. Remove the transmission fluid pan and transmission fluid pan gasket.
    1. Remove the bolts.
    2. Remove the transmission fluid pan and transmission fluid pan to case gasket.
  4. Clean the transmission fluid pan and pan magnet.
    Fig 4: Locating Magnet
    G01608455Courtesy of FORD MOTOR CO.
    5. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
    Fig 5: Removing Fluid Filter And Grommet
    G01608456Courtesy of FORD MOTOR CO.
  5. Remove the fluid filter and grommet.
    6. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
    Fig 6: Disconnecting Bulkhead Inter-Connector
    G01608457Courtesy of FORD MOTOR CO.
  6. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead inter-connector.
  7. Remove the output shaft speed (OSS) sensor.
    1. Remove the bolt.
    2. Remove the OSS sensor.
    Fig 7: Removing Output Shaft Speed (OSS) Sensor
    G01608458Courtesy of FORD MOTOR CO.
  8. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 8: Removing Digital Transmission Range (TR) Sensor
    G01608459Courtesy of FORD MOTOR CO.
  9. Remove the manual control valve detent lever spring.
    1. Remove the bolt.
    2. Remove the manual control valve detent lever spring.
    Fig 9: Removing Manual Control Valve Detent Lever Spring
    G01608460Courtesy of FORD MOTOR CO.
  10. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 10: Removing Main Control Valve Body Bolts
    G01608461Courtesy of FORD MOTOR CO.
  11. Remove and discard the pump outlet screen.
    Fig 11: Removing Pump Outlet Screen
    G01608462Courtesy of FORD MOTOR CO.
    12. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 12: Removing Manual Lever Shaft Retaining Pin
    G01608463Courtesy of FORD MOTOR CO.
  12. Remove the manual lever shaft retaining pin.
  13. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    Fig 13: Removing Manual Lever Shaft Inner Nut
    G01608464Courtesy of FORD MOTOR CO.
  14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    Fig 14: Removing Parking Lever Actuating Rod
    G01608465Courtesy of FORD MOTOR CO.
    15. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged the new seal may leak.
    Fig 15: Removing Manual Control Lever Shaft Seal
    G01608466Courtesy of FORD MOTOR CO.
  15. Remove the manual control lever shaft seal.
  16. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
    Fig 16: Removing EPC Solenoid
    G01608467Courtesy of FORD MOTOR CO.
  17. Remove the 2-3 accumulator spring retainer.
    Fig 17: Removing 2-3 Accumulator Spring Retainer
    G01608468Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    Fig 18: Removing 2-3 Accumulator Piston
    G01608469Courtesy of FORD MOTOR CO.
  19. Using the special tool, remove the reverse band servo retaining ring.
    Fig 19: Removing Reverse Band Servo Retaining Ring
    G01608470Courtesy of FORD MOTOR CO.
  20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
    Fig 20: Removing Reverse Servo Assembly
    G01608471Courtesy of FORD MOTOR CO.
    21. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
    Fig 21: Compressing Piston Spring
    G01608472Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    Fig 22: Removing Overdrive Servo Piston
    G01608473Courtesy of FORD MOTOR CO.
  23. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 23: Compressing 1-2 Accumulator Cover And Removing Retaining Ring
    G01608474Courtesy of FORD MOTOR CO.
  24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the 1-2 accumulator lower spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    Fig 24: Removing 1-2 Accumulator Upper Spring
    G01608475Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the extension housing seal.
    Fig 25: Removing Extension Housing Seal
    G01608476Courtesy of FORD MOTOR CO.
    26. NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
    Fig 26: Removing Extension Housing
    G01608477Courtesy of FORD MOTOR CO.
  26. Remove the extension housing.
    1. Remove the four bolts and two nuts.
    2. Remove the extension housing and the extension housing gasket.
  27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    Fig 27: Removing Parking Pawl
    G01608478Courtesy of FORD MOTOR CO.
  28. Rotate the transmission to the vertical position with the output shaft towards the floor.
    29. CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
    Fig 28: Pushing Connector Out Through Bottom Of Case
    G01608479Courtesy of FORD MOTOR CO.
  29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  30. Using the special tools, remove the front pump seal.
    Fig 29: Removing Front Pump Seal
    G01608480Courtesy of FORD MOTOR CO.
    31. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 30: Removing Bolts
    G01608481Courtesy of FORD MOTOR CO.
  31. Remove the bolts.
  32. Using the special tools, remove the front pump support.
    Fig 31: Removing Front Pump Support
    G01608482Courtesy of FORD MOTOR CO.
  33. Remove and discard the pump gasket.
  34. Remove the intermediate anti-rattle clip, if equipped.
    Fig 32: Removing Pump Gasket
    G01608483Courtesy of FORD MOTOR CO.
    35. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
    Fig 33: Removing Clutch Pack
    G01608484Courtesy of FORD MOTOR CO.
  35. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
  36. Disengage and remove the overdrive band.
    Fig 34: Disengaging And Removing Overdrive Band
    G01608485Courtesy of FORD MOTOR CO.
  37. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 35: Removing Forward Clutch Hub
    G01608486Courtesy of FORD MOTOR CO.
  38. Remove the intermediate stub shaft.
    Fig 36: Removing Intermediate Stub Shaft
    G01608487Courtesy of FORD MOTOR CO.
  39. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 37: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin
    G01608488Courtesy of FORD MOTOR CO.
  40. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
    Fig 38: Removing Forward Clutch Sun Gear
    G01608489Courtesy of FORD MOTOR CO.
  41. Remove the center support retaining ring and note location for assembly.
    Fig 39: Removing Center Support Retaining Ring
    G01608490Courtesy of FORD MOTOR CO.
  42. Remove the case to planet support spring.
    Fig 40: Removing Case To Planet Support Spring
    G01608491Courtesy of FORD MOTOR CO.
  43. Remove the planetary gear support and planetary as an assembly.
    Fig 41: Removing Planetary Gear Support And Planetary
    G01608492Courtesy of FORD MOTOR CO.
  44. Remove the reverse clutch band.
    Fig 42: Removing Reverse Clutch Band
    G01608493Courtesy of FORD MOTOR CO.
  45. Remove the retaining ring.
    Fig 43: Removing Retaining Ring
    G01608494Courtesy of FORD MOTOR CO.
  46. Remove the direct clutch pack.
    Fig 44: Removing Direct Clutch Pack
    G01608495Courtesy of FORD MOTOR CO.
  47. Remove the No. 8 bearing.
    Fig 45: Removing Bearing
    G01608496Courtesy of FORD MOTOR CO.
  48. Remove the output shaft, output shaft ring gear assembly and direct clutch.
    Fig 46: Removing Output Shaft, Ring Gear Assembly And Direct Clutch
    G01608497Courtesy of FORD MOTOR CO.
  49. Remove the No. 9 case rear bearing.
    Fig 47: Removing Case Rear Bearing
    G01608498Courtesy of FORD MOTOR CO.
  50. Inspect and if necessary, use the special tools to remove the rear case bushing.
    Fig 48: Removing Rear Case Bushing
    G01608499Courtesy of FORD MOTOR CO.
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