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

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.
    WARNING: Do not remove the torque converter from the transmission while still on the jack. Doing so could cause the transmission to fail. Failure to follow these instructions may result in personal injury.
    Fig 1: Placing Transmission On Workbench
    G02152687Courtesy of FORD MOTOR CO.
  1. Place the transmission on a workbench.
  2. Remove the special tool.
    Fig 2: Removing Special Tool
    G02152688Courtesy of FORD MOTOR CO.
    3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury.
    Fig 3: Removing Torque Converter
    G02152689Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the torque converter.
    4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
    Fig 4: Removing Input Shaft
    G02152690Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
  5. Remove Output Shaft Speed (OSS) sensor.
    1. Remove the OSS screw.
    2. Remove OSS sensor.
    Fig 5: Removing OSS Sensor
    G02152691Courtesy of FORD MOTOR CO.
  6. If equipped, remove the Intermediate Shaft Speed (ISS) sensor.
    1. Remove the ISS screw.
    2. Remove ISS sensor.
    Fig 6: Removing ISS Sensor
    G02152692Courtesy of FORD MOTOR CO.
  7. If equipped, remove the heat shield.
    1. Remove the nut.
    2. Remove the heat shield.
    Fig 7: Removing Heat Shield
    G02152693Courtesy of FORD MOTOR CO.
  8. Remove manual control outer lever nut and manual control outer lever.
    Fig 8: Removing Manual Control Outer Lever Nut & Manual Control Outer Lever
    G02152694Courtesy of FORD MOTOR CO.
  9. Remove the digital Transmission Range (TR) sensor.
    1. Remove the screws.
    2. Remove the digital TR sensor.
    Fig 9: Removing Digital TR Sensor
    G02152695Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the extension housing seal.
    Fig 10: Removing Extension Housing Seal
    G02152696Courtesy of FORD MOTOR CO.
    11. NOTE: Remove the extension housing bushing only if service is required.
    Fig 11: Removing Extension Housing Bushing
    G02152697Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the extension housing bushing.
    • Inspect the extension housing bushing and driveshaft slip yoke for nicks, gauges, scoring and wear.
    12. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 12: Removing Screws, Studs & Extension Housing
    G02152698Courtesy of FORD MOTOR CO.
  12. Remove the screws, studs, and the extension housing.
    • Discard the extension housing gasket.
  13. Remove the parking pawl assembly.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    Fig 13: Removing Parking Pawl Assembly
    G02152699Courtesy of FORD MOTOR CO.
    14. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
    Fig 14: Installing Special Tool
    G02152700Courtesy of FORD MOTOR CO.
  14. Install the special tool.
  15. Assemble the special tools.
    Fig 15: Assembling Special Tools
    G02152701Courtesy of FORD MOTOR CO.
    16. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 16: Installing Transmission Onto Special Tool
    G02152702Courtesy of FORD MOTOR CO.
  16. Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.
    17. CAUTION: Do not reuse the fluid pan gasket.
    Fig 17: Removing Transmission Fluid Pan & Gasket
    G02152703Courtesy of FORD MOTOR CO.
  17. Remove the transmission fluid pan and transmission pan gasket and then discard gasket.
  18. Remove the transmission fluid filter and discard.
    1. Remove the screw.
    2. Remove the transmission fluid filter.
    Fig 18: Removing Transmission Fluid Filter
    G02152704Courtesy of FORD MOTOR CO.
  19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
    Fig 19: Lifting Up On Wire Loom Guide & Protector
    G02152705Courtesy of FORD MOTOR CO.
  20. Disconnect the solenoid electrical connectors.
    1. Disconnect the SSA, SSB, SSC and the SSD electrical connectors.
    2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector.
    3. Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector.
    Fig 20: Disconnecting Solenoid Electrical Connectors
    G02152706Courtesy of FORD MOTOR CO.
  21. Remove the manual control valve detent lever spring.
    1. Remove the screw.
    2. Remove the manual control valve detent lever spring.
    Fig 21: Removing Manual Control Valve Detent Lever Spring
    G02152707Courtesy of FORD MOTOR CO.
  22. Remove the low/reverse band servo cover.
    1. Remove the screws.
    2. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
      • Discard the low/reverse servo separator plate cover gasket.
    Fig 22: Removing Low/Reverse Band Servo Cover
    G02152708Courtesy of FORD MOTOR CO.
  23. Remove the low/reverse band servo piston and rod assembly.
    Fig 23: Removing Low/Reverse Band Servo Piston & Rod Assembly
    G02152709Courtesy of FORD MOTOR CO.
    24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.
    Fig 24: Locating Gold Colored Screws
    G02152710Courtesy of FORD MOTOR CO.
  24. Do not remove the two (Gold colored) screws specified.
  25. Remove the twenty-three valve body screws.
    Fig 25: Removing Valve Body Screws
    G02152711Courtesy of FORD MOTOR CO.
  26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket.
    • Discard gaskets.
    Fig 26: Removing Main Control Valve Body, Valve Body Separator Plate & Main Control To Separator Plate Gasket
    G02152712Courtesy of FORD MOTOR CO.
    27. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 27: Removing Locknuts
    G02152713Courtesy of FORD MOTOR CO.
  27. Remove the locknuts. Back off the screws.
    28. CAUTION: The servo cover is under spring tension.
    Fig 28: Removing Intermediate Servo Cover Retaining Ring
    G02152714Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the intermediate servo cover retaining ring.
    • Remove the special tool.
    29. NOTE: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo, cover and bore.
    Fig 29: Releasing Intermediate Band Servo Piston
    G02152715Courtesy of FORD MOTOR CO.
  29. Using the special tool, release the intermediate band servo piston.
  30. Remove the intermediate band servo cover, piston and spring.
    Fig 30: Removing Intermediate Band Servo Cover, Piston & Spring
    G02152716Courtesy of FORD MOTOR CO.
    31. CAUTION: Servo cover is under spring tension.
    Fig 31: Removing Overdrive Servo Retaining Ring & Cover
    G02152717Courtesy of FORD MOTOR CO.
  31. Using the special tool, remove the overdrive servo retaining ring and cover.
    32. NOTE: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo piston and bore.
    Fig 32: Releasing Overdrive Band Servo Piston
    G02152718Courtesy of FORD MOTOR CO.
  32. Using the special tool, release the overdrive band servo piston.
  33. Remove the overdrive band servo cover, piston and spring.
    Fig 33: Removing Overdrive Band Servo Cover, Piston & Spring
    G02152719Courtesy of FORD MOTOR CO.
    34. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury.
  34. Rotate the transmission so the converter housing faces up.
    35. CAUTION: Discard the screws. The screws are not reusable for assembly.
    Fig 34: Removing Converter Housing Screws
    G02152720Courtesy of FORD MOTOR CO.
  35. Remove and discard the screws.
  36. Remove the converter housing and fluid pump support.
    • Turn and lift the converter housing and fluid pump support from the case.
    Fig 35: Removing Converter Housing & Fluid Pump Support
    G02152721Courtesy of FORD MOTOR CO.
  37. Remove the fluid pump input thrust washer (No. 1).
    • Tag and identify the thrust washer.
    Fig 36: Removing Fluid Pump Input Thrust Washer
    G02152722Courtesy of FORD MOTOR CO.
  38. Remove the front band adjusting screw.
    Fig 37: Removing Front Band Adjusting Screw
    G02152723Courtesy of FORD MOTOR CO.
  39. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
    Fig 38: Removing Front Band Anchor Strut
    G02152724Courtesy of FORD MOTOR CO.
    40. CAUTION: Identify the anchor and apply ends of the front band.
    Fig 39: Removing Front Band
    G02152725Courtesy of FORD MOTOR CO.
  40. Remove the front band.
  41. Remove the front brake and coast clutch drum.
    Fig 40: Removing Front Brake & Coast Clutch Drum
    G02152726Courtesy of FORD MOTOR CO.
  42. Remove the front band apply strut.
    Fig 41: Removing Front Band Apply Strut
    G02152727Courtesy of FORD MOTOR CO.
    43. NOTE: The front band lever shaft is longer than the intermediate band lever shaft.
    Fig 42: Removing Front Band Actuating Lever Shaft
    G02152728Courtesy of FORD MOTOR CO.
  43. Remove the front band actuating lever shaft.
    44. CAUTION: Do not bend trigger wheel.
    NOTE: The No. 2 thrust bearing is in this assembly.
    Fig 43: Removing Planetary Gear Overdrive Carrier
    G02152729Courtesy of FORD MOTOR CO.
  44. Remove the planetary gear overdrive carrier.
    45. NOTE: Tag and identify the front band servo lever. The front band servo lever has a letter stamped on the side.
    Fig 44: Removing Front Band Servo Lever & Front Band Lever To Case Bracket
    G02152730Courtesy of FORD MOTOR CO.
  45. Remove the front band servo lever and front band lever to case bracket.
  46. Remove the front planet thrust bearing (No. 2).
    Fig 45: Removing Front Planet Thrust Bearing
    G02152731Courtesy of FORD MOTOR CO.
  47. Remove the front ring gear, front one-way clutch assembly, and center shaft as an assembly.
    Fig 46: Removing Front Ring Gear, Front One-Way Clutch Assembly & Center Shaft
    G02152732Courtesy of FORD MOTOR CO.
    48. NOTE: Tag and identify the center shaft thrust bearing (No. 3) for assembly.
    Fig 47: Removing Center Shaft Thrust Bearing
    G02152733Courtesy of FORD MOTOR CO.
  48. Remove the No. 3 center shaft thrust bearing.
    49. CAUTION: The center support locknut can fall into the remaining assembly if not removed.
    Fig 48: Removing Center Support Cap Screw
    G02152734Courtesy of FORD MOTOR CO.
  49. Remove the center support cap screw.
  50. Remove the locknut and cage.
    Fig 49: Removing Locknut & Cage
    G02152735Courtesy of FORD MOTOR CO.
    51. CAUTION: Do not pry on other wires or damage the connector or case surface.
    Fig 50: Disconnecting TSS Sensor Electrical Connector
    G02152736Courtesy of FORD MOTOR CO.
  51. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
    1. Remove the TSS sensor electrical connector from the transmission case (16 pin) electrical connector.
    2. Remove the TSS sensor connector wires from wire locator.
    52. CAUTION: Carefully route the TSS connector and wiring into the transmission through the opening in the case.
    Fig 51: Removing TSS Sensor
    G02152737Courtesy of FORD MOTOR CO.
  52. Remove the TSS sensor.
    1. Remove the screw.
    2. Remove the TSS sensor.
    53. CAUTION: Do not overstretch the retaining spring.
    Fig 52: Removing Transmission Case Electrical Connector Retaining Spring
    G02152738Courtesy of FORD MOTOR CO.
  53. Remove the transmission case (16 pin) electrical connector retaining spring.
    54. CAUTION: Do not damage the connector or harness.
    Fig 53: Compressing Tabs On Transmission Case Electrical Connector
    G02152739Courtesy of FORD MOTOR CO.
  54. Compress the tabs on the transmission case (16 pin) electrical connector.

    Push the transmission case (16 pin) electrical connector out of transmission case.

  55. Remove the center support retaining ring.
    Fig 54: Removing Center Support Retaining Ring
    G02152740Courtesy of FORD MOTOR CO.
    56. NOTE: When removing the center support, pull evenly around the center support web.
    Fig 55: Removing Center Support
    G02152741Courtesy of FORD MOTOR CO.
  56. Remove the center support.
    57. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 56: Removing Intermediate Brake Drum Thrust Bearing
    G02152742Courtesy of FORD MOTOR CO.
  57. Remove the intermediate brake drum thrust bearing (No. 4).
  58. Remove the intermediate band anchor strut and adjusting screw.
    Fig 57: Removing Intermediate Band Anchor Strut & Adjusting Screw
    G02152743Courtesy of FORD MOTOR CO.
    59. CAUTION: Identify the anchor and apply ends of the intermediate band.
    Fig 58: Removing Intermediate Band
    G02152744Courtesy of FORD MOTOR CO.
  59. Remove the intermediate band.
  60. Remove the intermediate band apply strut.
    Fig 59: Removing Intermediate Band Apply Strut
    G02152745Courtesy of FORD MOTOR CO.
    61. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 60: Removing Intermediate Band Actuating Lever Shaft
    G02152746Courtesy of FORD MOTOR CO.
  61. Remove the intermediate band actuating lever shaft.
    62. NOTE: Tag and identify the intermediate servo band lever. The intermediate servo band lever has a letter stamped into its side.
    Fig 61: Removing Intermediate Servo Actuating Lever
    G02152747Courtesy of FORD MOTOR CO.
  62. Remove the intermediate servo actuating lever.
    63. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury.
    Fig 62: Rotating Transmission So Transmission Fluid Pan Surface Is Facing Up
    G02152748Courtesy of FORD MOTOR CO.
  63. Rotate the transmission so the transmission fluid pan surface is facing up.
    64. NOTE: The forward clutch cylinder thrust bearing (No. 5) may come out with the intermediate brake and direct clutch drum.
    Fig 63: Removing Intermediate Brake & Direct Clutch Drum
    G02152749Courtesy of FORD MOTOR CO.
  64. Remove the intermediate brake and direct clutch drum.
  65. Remove the forward clutch cylinder thrust bearing (No. 5) tag and identify.
    Fig 64: Removing Forward Clutch Cylinder Thrust Bearing
    G02152750Courtesy of FORD MOTOR CO.
  66. Remove the forward clutch cylinder.
    Fig 65: Removing Forward Clutch Cylinder
    G02152751Courtesy of FORD MOTOR CO.
  67. Remove the forward ring gear hub thrust bearing (No. 6A).
    Fig 66: Removing Forward Ring Gear Hub Thrust Bearing
    G02152752Courtesy of FORD MOTOR CO.
  68. Remove the forward ring gear and forward ring gear hub as an assembly.
    Fig 67: Removing Forward Ring Gear & Forward Ring Gear Hub
    G02152753Courtesy of FORD MOTOR CO.
  69. Remove forward clutch thrust washer (No. 6B) from the forward ring gear hub.
    Fig 68: Removing Forward Clutch Thrust Washer From Forward Ring Gear Hub
    G02152754Courtesy of FORD MOTOR CO.
    70. NOTE: Check black oxidized side during removal to ensure correct placement during reassembly. Black oxidized side must be toward planetary assembly. The uncoated side must face up.
    Fig 69: Removing Forward Planet Thrust Bearing
    G02152755Courtesy of FORD MOTOR CO.
  70. Remove the forward planet thrust bearing (No. 7).
  71. Remove the forward planetary assembly.
    Fig 70: Removing Forward Planetary Assembly
    G02152756Courtesy of FORD MOTOR CO.
  72. Remove input shell with the forward sun gear.
    Fig 71: Removing Input Shell With Forward Sun Gear
    G02152757Courtesy of FORD MOTOR CO.
    73. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 8).
    Fig 72: Removing Low/Reverse Planetary Carrier Thrust Bearing
    G02152758Courtesy of FORD MOTOR CO.
  73. Remove the low/reverse planetary carrier thrust bearing (No. 8).
  74. Remove the low/reverse planetary retaining ring.
    Fig 73: Removing Low/Reverse Planetary Retaining Ring
    G02152759Courtesy of FORD MOTOR CO.
  75. Remove low/reverse planetary assembly.
    Fig 74: Removing Low/Reverse Planetary Assembly
    G02152760Courtesy of FORD MOTOR CO.
    76. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 9).
    Fig 75: Removing Low/Reverse Planetary Carrier Thrust Bearing
    G02152761Courtesy of FORD MOTOR CO.
  76. Remove the low/reverse planetary carrier thrust bearing (No. 9).
  77. Remove the output shaft sleeve.
    Fig 76: Removing Output Shaft Sleeve
    G02152762Courtesy of FORD MOTOR CO.
    78. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 77: Removing Output Shaft Retaining Ring
    G02152763Courtesy of FORD MOTOR CO.
  78. Remove and discard the output shaft retaining ring.
  79. Remove the output shaft ring gear and the output shaft hub.
    Fig 78: Removing Output Shaft Ring Gear & Output Shaft Hub
    G02152764Courtesy of FORD MOTOR CO.
    80. NOTE: Tag and identify the output shaft hub thrust bearing (No. 10).
    Fig 79: Removing Output Shaft Thrust Bearing
    G02152765Courtesy of FORD MOTOR CO.
  80. Remove the output shaft thrust bearing (No. 10).
    81. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
    Fig 80: Removing Low/Reverse Brake Drum & One-Way Clutch Assembly
    G02152766Courtesy of FORD MOTOR CO.
  81. Remove the low/reverse brake drum and one-way clutch assembly.
  82. Remove the reverse band.
    Fig 81: Removing Reverse Band
    G02152767Courtesy of FORD MOTOR CO.
  83. Remove the output shaft.
    Fig 82: Removing Output Shaft
    G02152768Courtesy of FORD MOTOR CO.
  84. Remove the park gear.
    Fig 83: Removing Park Gear
    G02152769Courtesy of FORD MOTOR CO.
    85. NOTE: Tag and identify the output shaft thrust washer (No. 11).
    Fig 84: Removing Output Shaft Thrust Washer
    G02152770Courtesy of FORD MOTOR CO.
  85. Remove the output shaft thrust washer (No. 11).
    86. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.
    Fig 85: Removing Manual Control Valve Inner Lever Nut
    G02152771Courtesy of FORD MOTOR CO.
  86. Remove the manual control valve inner lever nut.
  87. Remove the manual control valve inner lever and the parking lever actuating rod.
    Fig 86: Removing Manual Control Valve Inner Lever & Parking Lever Actuating Rod
    G02152772Courtesy of FORD MOTOR CO.
    88. CAUTION: Do not damage the case fluid pan rail.
    Fig 87: Prying Spring Pin Out Of Its Bore
    G02152773Courtesy of FORD MOTOR CO.
  88. Remove the manual control lever shaft spring pin.
    • Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
    • Pry the spring pin out of its bore.
  89. Remove the manual control lever shaft.
    Fig 88: Removing Manual Control Lever Shaft
    G02152774Courtesy of FORD MOTOR CO.
    90. CAUTION: Do not damage the bore.
    Fig 89: Removing Manual Control Lever Seal
    G02152775Courtesy of FORD MOTOR CO.
  90. Remove the manual control lever seal.
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