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Section 303 (Overhaul - Automatic Transmission): Assembly: Transmission: Assembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.
  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    1. Stripped bolt hole threads.
    2. Gasket and mating surfaces for burrs or nicks.
    3. Obstructions to vent and fluid passages.
      • Cracks or warpage.
    Fig 1: Inspecting Transmission Case
    G02152995Courtesy of FORD MOTOR CO.
  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 2: Inspecting Extension Housing For Cracks, Burrs Or Warpage
    G02152996Courtesy of FORD MOTOR CO.
  4. Inspect case bearing for damage. Install new components as needed. Follow steps  6- 8 if replacing the case bearing. If not replacing the case bearing, proceed to step  8.
    Fig 3: Inspecting Case Bearing For Damage
    G02152997Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the case bearing.
    • Use an oil stone to remove any nicks or burrs in the bearing case bore.
    Fig 4: Removing Case Bearing
    G02152998Courtesy of FORD MOTOR CO.
  6. Inspect the rear case inner race for burrs, nicks and scoring. If any damage has been found a new case will need to be installed.
    Fig 5: Inspecting Rear Case Inner Race For Burrs, Nicks & Scoring
    G02152999Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure bearing seal ring is facing drive handle.
    Fig 6: Installing Case Bearing Onto Special Tool
    G02153000Courtesy of FORD MOTOR CO.
  7. Install a new case bearing.
    1. Assemble the special tool.
    2. Position new case bearing onto special tool.
  8. Using the special tool, tap case bearing into case bearing bore.
    Fig 7: Installing Case Bearing
    G02153001Courtesy of FORD MOTOR CO.
  9. Install the special tool on the rear of the transmission case.
    Fig 8: Installing Special Tool On Rear Of Transmission Case
    G02153002Courtesy of FORD MOTOR CO.
  10. Attach the fixture arm of the special tool as shown.
    Fig 9: Attaching Fixture Arm Of Special Tool
    G02153003Courtesy of FORD MOTOR CO.
    11. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 10: Installing Transmission Into Special Tool
    G02153004Courtesy of FORD MOTOR CO.
  11. Install transmission into the special tool.
    • Rotate the transmission so that the fluid pan rail is facing up.
  12. Using the special tool, install the manual control lever shaft seal.
    • Lubricate the manual control lever shaft seal with petroleum jelly.
    Fig 11: Installing Manual Control Lever Shaft Seal
    G02153005Courtesy of FORD MOTOR CO.
  13. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 12: Assembling Manual Valve Inner Lever & Parking Lever Actuating Rod
    G02153006Courtesy of FORD MOTOR CO.
  14. Install the manual control lever shaft.
    Fig 13: Installing Manual Control Lever Shaft
    G02153007Courtesy of FORD MOTOR CO.
    15. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
    Fig 14: Installing Manual Control Lever Shaft Spring Pin
    G02153008Courtesy of FORD MOTOR CO.
  15. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
    16. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 15: Installing Manual Valve Inner Lever & Parking Lever Actuating Rod On To Manual Control Lever Shaft
    G02153009Courtesy of FORD MOTOR CO.
  16. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.
    17. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 16: Installing Manual Valve Inner Lever Nut On Manual Control Lever Shaft
    G02153010Courtesy of FORD MOTOR CO.
  17. Install the manual valve inner lever nut on the manual control lever shaft and tighten.
    18. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
    Fig 17: Installing Output Shaft Thrust Washer
    G02153011Courtesy of FORD MOTOR CO.
  18. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
  19. Install the park gear.
    Fig 18: Installing Park Gear
    G02153012Courtesy of FORD MOTOR CO.
  20. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    Fig 19: Installing Low/Reverse Brake Drum
    G02153013Courtesy of FORD MOTOR CO.
  21. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly.
    • Coat the needle bearing with petroleum jelly.
    Fig 20: Installing Needle Bearing Onto Output Shaft Ring Gear & Hub Assembly
    G02153014Courtesy of FORD MOTOR CO.
  22. Install the output shaft through the output shaft park gear.
    Fig 21: Installing Output Shaft Through Output Shaft Park Gear
    G02153015Courtesy of FORD MOTOR CO.
  23. Install the output shaft ring gear and output shaft hub.
    Fig 22: Installing Output Shaft Ring Gear & Output Shaft Hub
    G02153016Courtesy of FORD MOTOR CO.
    24. CAUTION: Always install a new output shaft retaining ring.
    Fig 23: Installing Output Shaft Retaining Ring
    G02153017Courtesy of FORD MOTOR CO.
  24. Install a new output shaft retaining ring.
    25. NOTE: Install the output shaft sleeve with the cone facing up.
    Fig 24: Installing Output Shaft Sleeve
    G02153018Courtesy of FORD MOTOR CO.
  25. Install the output shaft sleeve.
  26. Install low/reverse planetary carrier needle bearings.
    1. Install low/reverse planetary carrier needle bearing (No. 8) on the front face of the low/reverse planetary.
    2. Install low/reverse planetary carrier needle bearing (No. 9) on the rear face of the low/reverse planetary.
      • Coat the low/reverse planet carrier needle bearing (No. 8) and low/reverse planetary carrier needle bearing (No. 9) with petroleum jelly.
    Fig 25: Installing Low/Reverse Planetary Carrier Needle Bearings
    G02153019Courtesy of FORD MOTOR CO.
    27. CAUTION: Make sure needle bearings stay in place.
    Fig 26: Installing Low/Reverse Planetary Assembly With Low/Reverse Planetary Carrier Needle Bearings Into Output Shaft Ring Gear
    G02153020Courtesy of FORD MOTOR CO.
  27. Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier needle bearings into the output shaft ring gear.
    28. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 27: Installing Low/Reverse Retaining Ring Into Low/Reverse Brake Drum Groove
    G02153021Courtesy of FORD MOTOR CO.
  28. Install the low/reverse retaining ring into the low/reverse brake drum groove.
    29. CAUTION: Make sure band is resting on the two anchor pins in the case.
    Fig 28: Installing Low/Reverse Band Over Low/Reverse Brake Drum
    G02153022Courtesy of FORD MOTOR CO.
  29. Install the low/reverse band over the low/reverse brake drum.
  30. Temporarily install the low/reverse band servo piston and rod to hold the low/reverse band in position.
    Fig 29: Installing Low/Reverse Band Servo Piston & Rod
    G02153023Courtesy of FORD MOTOR CO.
  31. Install the previously assembled forward geartrain assembly.
    Fig 30: Installing Previously Assembled Forward Geartrain Assembly
    G02153024Courtesy of FORD MOTOR CO.
    32. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  32. Rotate transmission assembly so that the converter housing surface is facing up.
  33. Select the intermediate brake drum thrust bearing (No. 4) as follows:
    1. Install the special tool on case assembly shoulder.
    2. Set the special tool on top as shown.
    Fig 31: Installing Special Tool On Case Assembly Shoulder
    G02153025Courtesy of FORD MOTOR CO.
  34. Calculate the thrust bearing thickness.
    • Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.
    Fig 32: Calculating Thrust Bearing Thickness (Dimension A)
    G02153026Courtesy of FORD MOTOR CO.
  35. Place the micrometer on the opposite side of the special tool and repeat measurement. This is dimension B.
    Fig 33: Calculating Thrust Bearing Thickness (Dimension B)
    G02153027Courtesy of FORD MOTOR CO.
  36. Add dimension A and B, divide the total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 in). Record this reading as dimension C.
  37. Place the special tool across the center support. Place the micrometer on the top of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.
    Fig 34: Placing Special Tool To Calculate Dimension D
    G02153028Courtesy of FORD MOTOR CO.
  38. Place the special tool on the opposite side of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.
    Fig 35: Placing Special Tool To Calculate Dimension F
    G02153029Courtesy of FORD MOTOR CO.
  39. Add dimensions D and F. Divide the total of D and F by two. Subtract the special tool thickness 17.78 mm (0.700 in) dimension E. The result is dimension G.
    Fig 36: Calculating Dimension G
    G02153030Courtesy of FORD MOTOR CO.
  40. Add dimensions C and G. This total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.008-0.021 in).
    Fig 37: Thrust Bearing Specification Chart
    G02153031Courtesy of FORD MOTOR CO.
  41. Install the intermediate servo actuating lever.
    Fig 38: Installing Intermediate Servo Actuating Lever
    G02153032Courtesy of FORD MOTOR CO.
    42. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 39: Installing Intermediate Band Actuating Lever Shaft
    G02153033Courtesy of FORD MOTOR CO.
  42. Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.
  43. Install the intermediate band apply strut on the intermediate servo actuating lever.
    Fig 40: Installing Intermediate Band Apply Strut
    G02153034Courtesy of FORD MOTOR CO.
    44. NOTE: Make sure that the intermediate apply strut is aligned with the band notch.
    Fig 41: Installing Intermediate Band
    G02153035Courtesy of FORD MOTOR CO.
  44. Install the intermediate band.
    45. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.
    NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.
    Fig 42: Installing Intermediate Band Anchor Strut & Intermediate Band Adjustment Screw
    G02153036Courtesy of FORD MOTOR CO.
  45. Install the intermediate band anchor strut and the intermediate band adjustment screw.
  46. Install the selected intermediate brake drum thrust washer (No. 4) on the center support.
    • Coat the intermediate brake drum thrust washer with petroleum jelly.
    Fig 43: Installing Selected Intermediate Brake Drum Thrust Washer
    G02153037Courtesy of FORD MOTOR CO.
    47. CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings could result. Make sure the rear planetary support is seated.
    NOTE: Align the center support screw hole with correct case hole.
    Fig 44: Installing Center Support
    G02153038Courtesy of FORD MOTOR CO.
  47. Install the center support.
    1. Position the center support into the intermediate brake and direct clutch drum.
    2. Temporarily insert input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
    48. CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
    Fig 45: Installing Center Support Retaining Ring
    G02153039Courtesy of FORD MOTOR CO.
  48. Install the center support retaining ring.
    1. Position center support retaining ring with the tapered side facing up.
    2. Install the center support retaining ring so that the notch opening is not obstructed.
  49. Install the center support locknut and cage.
    Fig 46: Installing Center Support Locknut & Cage
    G02153040Courtesy of FORD MOTOR CO.
  50. Install the center support-to-case capscrew.
    Fig 47: Installing Center Support-To-Case Capscrew
    G02153041Courtesy of FORD MOTOR CO.
    51. CAUTION: Carefully route the Turbine Shaft Speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
    NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.
    Fig 48: Installing TSS Sensor
    G02153042Courtesy of FORD MOTOR CO.
  51. Install the Turbine Shaft Speed (TSS) sensor.
    1. Install the TSS sensor.
    2. Install TSS sensor screw.
    52. CAUTION: Use only the center shaft thrust bearing (No. 3).
    NOTE: The center shaft thrust bearing (No. 3) has no notches on the outer race.
    Fig 49: Installing Center Shaft Thrust Bearing
    G02153043Courtesy of FORD MOTOR CO.
  52. Install the center shaft thrust bearing (No. 3).
    53. CAUTION: Do not bend the trigger wheel.
    Fig 50: Installing Overdrive Planetary & One-Way Clutch Assembly
    G02153044Courtesy of FORD MOTOR CO.
  53. Install the overdrive planetary and one-way clutch assembly.
    54. CAUTION: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, the installation of a new overdrive planetary carrier and trigger wheel will need to be carried out.
    Fig 51: Checking TSS Sensor Air Gap
    G02153045Courtesy of FORD MOTOR CO.
  54. Using the special tool, check TSS sensor air gap.
    1. Place the thin blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    55. CAUTION: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does not, the installation of a new overdrive planetary carrier and trigger wheel will need to be carried out.
    Fig 52: Checking TSS Sensor Air Gap Using Special Tool
    G02153046Courtesy of FORD MOTOR CO.
  55. Using the special tool, check TSS sensor air gap.
    1. Place the thick blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    56. NOTE: Align the clutch plates and front adapter gear.
    Fig 53: Installing Front Brake Drum & Coast Clutch Drum Assembly
    G02153047Courtesy of FORD MOTOR CO.
  56. Install the front brake drum and coast clutch drum assembly.
  57. Install the front servo band lever and front band lever-to-case bracket into the transmission case.
    Fig 54: Installing Front Servo Band Lever & Front Band Lever-To-Case Bracket
    G02153048Courtesy of FORD MOTOR CO.
    58. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.
    Fig 55: Installing Front Band Actuating Lever Shaft
    G02153049Courtesy of FORD MOTOR CO.
  58. Install the front band actuating lever shaft through the front servo band lever.
  59. Install the front band apply strut.
    Fig 56: Installing Front Band Apply Strut
    G02153050Courtesy of FORD MOTOR CO.
    60. NOTE: If the front band is reused, it must be installed in the same position as when removed.
    Fig 57: Installing Front Band
    G02153051Courtesy of FORD MOTOR CO.
  60. Install the front band over the front brake and coast clutch drum.
    61. NOTE: Use the band adjustment screw as a temporary alignment guide.
    Fig 58: Installing Front Band Anchor Strut
    G02153052Courtesy of FORD MOTOR CO.
  61. Install the front band anchor strut.
  62. Install the front band adjusting screw.
    Fig 59: Installing Front Band Adjusting Screw
    G02153053Courtesy of FORD MOTOR CO.
    63. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 60: Installing Fluid Pump Inlet Thrust Washer
    G02153054Courtesy of FORD MOTOR CO.
  63. Perform front end play check procedure as follows:
    • Coat the fluid pump inlet thrust washer (No. 1) with petroleum jelly.
    • Install the fluid pump inlet thrust washer (No. 1) on the rear of the fluid pump and place pump into position in case.
    64. CAUTION: The special tool must rest on the gasket surface.
    Fig 61: Measuring Front End Play Clearance
    G02153055Courtesy of FORD MOTOR CO.
  64. Measure the front end play clearance.
    1. Place special tool across the case.
    2. Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
      • Read the measurement and subtract special tool thickness 17.78 mm (0.700 in). This is dimension A.
      • Repeat the measurement at the opposite side of the transmission case. This is dimension B.
      • Add dimensions A and B together and divide by two. This is front end clearance dimension C.
    65. CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
    NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 in).
    Fig 62: Front End Play Selective Thrust Washer No. 1 Specification Chart
    G02153056Courtesy of FORD MOTOR CO.
  65. Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).
    66. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 63: Installing Thrust Washer Onto Pump
    G02153057Courtesy of FORD MOTOR CO.
  66. Remove pump and install No. 1 thrust washer onto pump. After installing selected front pump thrust washer No. 1, repeat front end play check. Make sure correct end play, then remove pump for assembly.
  67. Install a new O-ring in fluid pump drive gear.
    Fig 64: Installing O-Ring In Fluid Pump Drive Gear
    G02153058Courtesy of FORD MOTOR CO.
    68. CAUTION: Lubricate the special tool with multi-purpose grease.
    Fig 65: Installing Fluid Pump Drive Gear On Special Tool
    G02153059Courtesy of FORD MOTOR CO.
  68. Install the fluid pump drive gear on special tool to seat O-ring. Remove the tool.
    69. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.
    Fig 66: Installing Pump Gears
    G02153060Courtesy of FORD MOTOR CO.
  69. Install the pump gears into the fluid pump housing. Apply multi-purpose grease to pump gear to prevent scoring at start-up.
    70. CAUTION: Make sure the holes in the plate line up with the holes in the pump.
    Fig 67: Installing Fluid Pump Adapter Plate
    G02153061Courtesy of FORD MOTOR CO.
  70. Install the fluid pump adapter plate.
    71. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.
    NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.
    Fig 68: Installing Fluid Pump
    G02153062Courtesy of FORD MOTOR CO.
  71. Install the fluid pump on the converter housing.
    • Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.
  72. Loosely install the fluid pump screws.
    Fig 69: Installing Fluid Pump Screws
    G02153063Courtesy of FORD MOTOR CO.
    73. CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.
    Fig 70: Aligning Fluid Pump To Fluid Pump Adapter Plate
    G02153064Courtesy of FORD MOTOR CO.
  73. Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.
  74. Thread the gauge into special tool and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.
    Fig 71: Sliding Tool Over Fluid Pump Until It Bottoms Out In Fluid Pump Gear Pocket
    G02153065Courtesy of FORD MOTOR CO.
  75. Tighten the fluid pump bolts in a star pattern and remove the pump alignment handle.
    Fig 72: Tightening Fluid Pump Bolts
    G02153066Courtesy of FORD MOTOR CO.
  76. Install a new fluid pump seal ring.
    • Coat the fluid pump seal ring with petroleum jelly.
    Fig 73: Installing Fluid Pump Seal Ring
    G02153067Courtesy of FORD MOTOR CO.
    77. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.
    Fig 74: Installing Fluid Pump Gasket
    G02153068Courtesy of FORD MOTOR CO.
  77. Install a new fluid pump gasket.
    • Hold the fluid pump gasket in place with petroleum jelly.
    78. NOTE: The overdrive brake drum seal ring gaps must be placed 180 degrees apart. Make sure the seal grooves are clean and free of burrs.
    Fig 75: Installing Overdrive Brake Drum Seals
    G02153069Courtesy of FORD MOTOR CO.
  78. Install the overdrive brake drum seals.
    79. CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.
    Fig 76: Installing Front Pump Support Seal
    G02153070Courtesy of FORD MOTOR CO.
  79. Install the front pump support seal.
  80. Install the selected No. 1 fluid pump thrust washer.
    • Coat the fluid pump thrust washer with petroleum jelly.
    Fig 77: Installing Selected Fluid Pump Thrust Washer
    G02153071Courtesy of FORD MOTOR CO.
  81. Install the special tools into the transmission case.
    Fig 78: Installing Special Tools Into Transmission Case
    G02153072Courtesy of FORD MOTOR CO.
    82. CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.
    Fig 79: Installing Input Shaft
    G02153073Courtesy of FORD MOTOR CO.
  82. Install the input shaft.
    83. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1) selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring remain in the correct position throughout this step.
    Fig 80: Installing Fluid Pump & Converter Housing
    G02153074Courtesy of FORD MOTOR CO.
  83. Install the fluid pump and converter housing onto the case.
    84. NOTE: Lubricate O-rings on converter housing screws.
    Fig 81: Installing Converter Housing-To-Case Screws
    G02153075Courtesy of FORD MOTOR CO.
  84. Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.
  85. Remove the input shaft.
    Fig 82: Removing Input Shaft
    G02153076Courtesy of FORD MOTOR CO.
    86. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  86. Rotate the transmission assembly so the fluid pan rails are facing up.
  87. Assemble the front servo assembly.
    1. Install the front servo cover O-ring on front servo cover. Coat the front servo cover O-ring with petroleum jelly.
    2. Install front servo piston into the front servo cover.
    3. Install the front servo piston spring on the front servo piston.
    Fig 83: Assembling Front Servo Assembly
    G02153077Courtesy of FORD MOTOR CO.
    88. CAUTION: Do not damage the front servo to case O-ring during installation.
    CAUTION: Do not press the front servo cover and O-ring past the relief hole in the case or O-ring damage may occur.
    Fig 84: Installing Front Servo Assembly
    G02153078Courtesy of FORD MOTOR CO.
  88. Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.
  89. Assemble the intermediate servo assembly.
    1. Install the intermediate servo cover O-ring on intermediate servo cover. Coat the intermediate servo cover O-ring with petroleum jelly.
    2. Install intermediate servo piston into the intermediate servo cover.
    3. Install the intermediate servo piston spring on the intermediate servo piston.
    Fig 85: Assembling Intermediate Servo Assembly
    G02153079Courtesy of FORD MOTOR CO.
    90. CAUTION: Do not damage servo cover to case O-ring during installation.
    CAUTION: Do not press the intermediate servo cover and O-ring past the relief hole in the case or O-ring damage may occur.
    Fig 86: Installing Intermediate Servo Assembly
    G02153080Courtesy of FORD MOTOR CO.
  90. Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.
    91. CAUTION: Do not allow front band adjustment screw to back out. Band strut can fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 87: Installing Locknut On Band Adjustment Screw
    G02153081Courtesy of FORD MOTOR CO.
  91. Install new locknut on the band adjustment screw.
    92. CAUTION: The front servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 88: Tightening Front Band Adjustment Screw
    G02153082Courtesy of FORD MOTOR CO.
  92. Tighten front band adjustment screw using the special tool and back off front band adjustment screw exactly two (2) turns and hold that position.
  93. Tighten the front band locknut.
    1. Hold the front band adjustment screw stationary.
    2. Tighten the front band locknut.
    Fig 89: Tightening Front Band Locknut
    G02153083Courtesy of FORD MOTOR CO.
    94. CAUTION: Do not allow intermediate band adjusting screw to back out. Band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 90: Installing Nut On Band Adjustment Screw
    G02153084Courtesy of FORD MOTOR CO.
  94. Install new nut on the band adjustment screw.
    95. CAUTION: The intermediate servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 91: Tightening Intermediate Band Adjusting Screw
    G02153085Courtesy of FORD MOTOR CO.
  95. Tighten intermediate band adjusting screw using the special tool and back off intermediate band adjusting screw exactly two (2) turns and hold that position.
  96. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
    Fig 92: Tightening Intermediate Band Locknut
    G02153086Courtesy of FORD MOTOR CO.
    97. CAUTION: Install new O-rings on the 16-pin electrical connector. Coat the O-rings with petroleum jelly.
    NOTE: Make sure that the tab is in the lock position.
    Fig 93: Pressing Transmission Case Electrical Connector
    G02153087Courtesy of FORD MOTOR CO.
  97. Position the transmission case (16-pin) electrical connector into the case bore.
    • Press the transmission case (16-pin) electrical connector through the case until a click is heard.
    98. CAUTION: Do not overstretch the retaining spring.
    Fig 94: Installing Electrical Connector Retaining Spring
    G02153088Courtesy of FORD MOTOR CO.
  98. Install the 16-pin electrical connector retaining spring.
    99. CAUTION: Align the slot on the Turbine Shaft Speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.
    Fig 95: Installing TSS Sensor Electrical Connector
    G02153089Courtesy of FORD MOTOR CO.
  99. Install the TSS sensor electrical connector into the transmission case (16-pin) electrical connector.
    1. Connect the TSS sensor electrical connector.
    2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.
  100. Install the special tools into the transmission case.
    Fig 96: Installing Special Tools Into Transmission Case
    G02153090Courtesy of FORD MOTOR CO.
    101. CAUTION: Make sure main control valve body gasket is aligned.
    CAUTION: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.
    Fig 97: Positioning Main Control Valve Body Into Transmission Case
    G02153091Courtesy of FORD MOTOR CO.
  101. Position the main control valve body into the transmission case.
    102. NOTE: The screws will be tightened in later steps.
    Fig 98: Installing Four M6X45 mm Screws
    G02153092Courtesy of FORD MOTOR CO.
  102. Loosely install the four M6x45 mm screws.
    103. NOTE: The main control valve body screws will be tightened in later steps.
    Fig 99: Installing Two M6X35 mm Screws
    G02153093Courtesy of FORD MOTOR CO.
  103. Loosely install the two M6x35 mm screws.
    104. NOTE: The main control valve body screw will be tightened in later steps.
    Fig 100: Installing M6X30 mm Screw
    G02153094Courtesy of FORD MOTOR CO.
  104. Loosely install the M6x30 mm screw.
  105. Remove the special tools.
    Fig 101: Removing Special Tools
    G02153095Courtesy of FORD MOTOR CO.
    106. NOTE: The main control valve body screws will be tightened in later steps.
    Fig 102: Installing M6X40 mm Screws
    G02153096Courtesy of FORD MOTOR CO.
  106. Loosely install the sixteen M6x40 mm screws.
  107. Tighten the screws in the sequence shown.
    Fig 103: Main Control Valve Body Screw Tightening Sequence
    G02153097Courtesy of FORD MOTOR CO.
  108. Rotate the manual lever into the NEUTRAL position, then install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring on the main control valve body.
    2. Install the screw.
    Fig 104: Installing Manual Control Valve Detent Lever Spring
    G02153098Courtesy of FORD MOTOR CO.
  109. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
    1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
    2. Loosely install the screws.
    Fig 105: Installing Low/Reverse Band Servo Cover
    G02153099Courtesy of FORD MOTOR CO.
  110. Tighten the screws in the sequence shown.
    Fig 106: Low/Reverse Band Servo Screws Tightening Sequence
    G02153100Courtesy of FORD MOTOR CO.
  111. Connect the solenoid electrical connectors.
    1. Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
    2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector.
    3. Connect the Electronic Pressure Control (EPC) solenoid electrical connector.
    Fig 107: Connecting Solenoid Electrical Connectors
    G02153101Courtesy of FORD MOTOR CO.
    112. CAUTION: Excessive pressure may break the locating pins.
    Fig 108: Installing Wiring Loom Protector & Guide
    G02153102Courtesy of FORD MOTOR CO.
  112. Install wiring loom protector and guide.
    • Align the pins in the holes of the solenoid clamps and gently push down.
    113. CAUTION: Make sure that both fluid pan filter O-rings are correctly installed on the fluid pan filter prior to installation.
    Fig 109: Installing Fluid Pan Filter O-Rings
    G02153103Courtesy of FORD MOTOR CO.
  113. Install the fluid pan filter O-rings.
    • Coat the fluid pan filter O-rings with clean automatic transmission fluid.
  114. Install the fluid pan filter.
    1. Position fluid pan filter on the main control valve body.
    2. Install the screw.
    Fig 110: Installing Fluid Pan Filter
    G02153104Courtesy of FORD MOTOR CO.
  115. Install the transmission fluid pan and transmission fluid pan gasket.
    • Loosely install the screws.
    Fig 111: Installing Transmission Fluid Pan & Gasket
    G02153105Courtesy of FORD MOTOR CO.
  116. Tighten the transmission fluid pan screws.
    • Tighten the transmission fluid pan screws in a crisscross sequence.
    Fig 112: Tightening Transmission Fluid Pan Screws
    G02153106Courtesy of FORD MOTOR CO.
  117. Remove the transmission from the bench and place on a flat surface.
    Fig 113: Removing Transmission From Bench
    G02153107Courtesy of FORD MOTOR CO.
  118. Remove the special tools from the transmission case.
    Fig 114: Removing Special Tools From Transmission Case
    G02153108Courtesy of FORD MOTOR CO.
    119. NOTE: Use petroleum jelly to hold the gasket in place.
    Fig 115: Installing Extension Housing Gasket
    G02153109Courtesy of FORD MOTOR CO.
  119. Install a new extension housing gasket.
    120. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.
    Fig 116: Installing Parking Pawl Assembly
    G02153110Courtesy of FORD MOTOR CO.
  120. Install the parking pawl assembly.
    1. Install the parking pawl shaft into the extension housing.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
    121. CAUTION: Make sure the parking lever actuating rod is correctly seated into the transmission case parking rod guide cup.
    Fig 117: Installing Extension Housing
    G02153111Courtesy of FORD MOTOR CO.
  121. Install the extension housing.
    1. Install the extension housing and gasket.
    2. Install the screws.
    3. Install the stud(s).
    122. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.
    NOTE: Install the extension housing bushing only if removed in disassembly.
    NOTE: Remove any burrs from the extension housing counterbore.
    Fig 118: Aligning Extension Housing Bushing Lube Hole With Lube Groove In Extension Housing
    G02153112Courtesy of FORD MOTOR CO.
  122. Align lube hole with the lube groove in extension housing. This groove is located at the 3 o'clock position when viewed from the rear.
    123. CAUTION: Tool will bottom when bushing is in the correct position.
    Fig 119: Installing Extension Housing Bushing
    G02153113Courtesy of FORD MOTOR CO.
  123. Using the special tool, install the extension housing bushing.
  124. Position new extension housing seal with drain hole in the 6 o'clock position.
    Fig 120: Positioning Extension Housing Seal
    G02153114Courtesy of FORD MOTOR CO.
  125. Using the special tool, install a new extension housing seal.
    Fig 121: Installing Extension Housing Seal
    G02153115Courtesy of FORD MOTOR CO.
  126. Install the digital Transmission Range (TR) sensor.
    1. Position the digital TR sensor on the transmission.
    2. Loosely install the screws.
    3. Rotate manual lever to neutral position (two detents rearward).
    Fig 122: Installing Digital TR Sensor
    G02153116Courtesy of FORD MOTOR CO.
    127. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the neutral position.
    Fig 123: Aligning TR Sensor Screws
    G02153117Courtesy of FORD MOTOR CO.
  127. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
  128. Install the manual control lever.
    1. Install the lever.
    2. Install the nut.
    Fig 124: Tightening Manual Control Lever Nut
    G02153118Courtesy of FORD MOTOR CO.
  129. If equipped, install transmission servo heat shield and nut.
    Fig 125: Installing Transmission Servo Heat Shield
    G02153119Courtesy of FORD MOTOR CO.
    130. NOTE: Inspect O-ring for damage. Install a new component if damaged.
    Fig 126: Installing OSS Sensor
    G02153120Courtesy of FORD MOTOR CO.
  130. If equipped, install the Output Shaft Speed (OSS) sensor.
    1. Install the sensor.
    2. Install the screw.
    131. NOTE: Inspect O-ring for damage. Install a new component if damaged.
    Fig 127: Installing ISS Sensor
    G02153121Courtesy of FORD MOTOR CO.
  131. Install the Intermediate Shaft Speed (ISS) sensor.
    1. Install the sensor.
    2. Install the screw.
    132. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
    Fig 128: Installing Input Shaft
    G02153122Courtesy of FORD MOTOR CO.
  132. Install the input shaft.
  133. Using the special tool, check that the fluid pump gear seal ring is seated.
    Fig 129: Checking That Fluid Pump Gear Seal Ring Is Seated
    G02153123Courtesy of FORD MOTOR CO.
    134. CAUTION: Do not damage the fluid pump gear O-ring when installing 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 can be damaged.
    Fig 130: Lubricating Converter Hub
    G02153124Courtesy of FORD MOTOR CO.
  134. Lubricate the converter hub with clean automatic transmission fluid.
    135. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions can result in personal injury.
    Fig 131: Installing Torque Converter
    G02153125Courtesy of FORD MOTOR CO.
  135. Use the special tools to install the torque converter by pushing and rotating.
  136. Make sure the torque converter is installed to specification.
    Fig 132: Checking Torque Converter Installation
    G02153126Courtesy of FORD MOTOR CO.
  137. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 133: Lubricating Torque Converter Pilot Hub
    G02153127Courtesy of FORD MOTOR CO.
  138. Before installing transmission, make sure that the transmission cooling system (lines and cooler ). Refer to TRANSMISSION COOLING.
  139. Install the special tool on case.
    Fig 134: Installing Special Tool
    G02153128Courtesy of FORD MOTOR CO.
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