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Section 325 (Automatic Transmission - 4R70W): Assembly: Transmission

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool(s) (1 Of 3)
G01539965Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool(s) (2 Of 3)
G01539966Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tool(s) (3 Of 3)
G01539967Courtesy of FORD MOTOR CO.

MATERIAL 

Fig 4: Material Specification
G01539968Courtesy of FORD MOTOR CO.
CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.
All fasteners must be tightened to the TORQUE SPECIFICATIONS  indicated. In addition to appearing in the section, the necessary torques can be found in the GENERAL SPECIFICATIONS  Chart.
When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.
  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
      Fig 5: Installing Rear Case Bushing
      G01539969Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    Fig 6: Installing Case Boss
    G01539970Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur.
    Fig 7: Installing Output Shaft And Output Shaft Ring Gear
    G01539971Courtesy of FORD MOTOR CO.
  4. Install the output shaft and output shaft ring gear.
  5. Install the No. 8 bearing.
    Fig 8: Installing No. 8 Bearing
    G01539972Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    Fig 9: Installing Direct Clutch
    G01539973Courtesy of FORD MOTOR CO.
    7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly, it will not affect the operation of the transmission.
    Fig 10: Installing Reverse Band Support Retaining Ring
    G01539974Courtesy of FORD MOTOR CO.
  7. Install the reverse band support retaining ring.
    8. NOTE: Make sure the band is seated on the anchor pins.
    Fig 11: Installing Reverse Band
    G01539975Courtesy of FORD MOTOR CO.
  8. Install the reverse band.
    9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
      Fig 12: Installing Planetary Assembly And Planetary Gear Support
      G01539976Courtesy of FORD MOTOR CO.
    10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.
    Fig 13: Locating Planet Support Spring
    G01539977Courtesy of FORD MOTOR CO.
  10. Install the case to planet support spring located at the 1 o'clock position.
  11. Install the center support retaining ring.
    • Reference the retaining ring tabs to the band anchor pin location.
      Fig 14: Identifying Center Support Retaining Ring
      G01539978Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, No. 5 forward clutch sun gear bearing and the reverse sun gear.
    Fig 15: Installing Forward Clutch Sun Gear And No. 5 Forward Clutch Sun Gear Bearing
    G01539979Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    Fig 16: Installing No. 4 Forward Clutch Hub Bearing
    G01539980Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    Fig 17: Installing Intermediate Stub Shaft
    G01539981Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 18: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G01539982Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    Fig 19: Installing Forward Clutch Assembly
    G01539983Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder assembly.
    2. Install the No. 2 forward clutch bearing.
      Fig 20: Installing Reverse Clutch Cylinder Assembly
      G01539984Courtesy of FORD MOTOR CO.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
      Fig 21: Installing Overdrive Band
      G01539985Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
      Fig 22: Installing Overdrive Servo Spring
      G01539986Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    Fig 23: Identifying Tip Of Piston Assembly
    G01539987Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    Fig 24: Installing Overdrive Servo Retaining Ring
    G01539988Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    Fig 25: Installing Intermediate Clutch Pressure Plate
    G01539989Courtesy of FORD MOTOR CO.
    23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.
    Fig 26: Installing Intermediate Clutch Pack And Selective Steel Plate
    G01539990Courtesy of FORD MOTOR CO.
  23. Install the intermediate clutch pack and selective steel plate.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

    SELECTIVE STEEL PLATES 

    Fig 27: Selective Steel Plates Specification
    G01539991Courtesy of FORD MOTOR CO.
    Fig 28: Measuring Intermediate Clutch Clearance
    G01539992Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

    Use the No. 1 thrust washer chart to select the correct washer.

    NO.1 THRUST WASHER CHART 

    Fig 29: No.1 Thrust Washer Chart
    G01539993Courtesy of FORD MOTOR CO.
    Fig 30: Measuring End Clearance For No. 1 Front Pump Thrust Washer
    G01539994Courtesy of FORD MOTOR CO.
  26. If equipped, install the intermediate clutch anti-rattle clip.
    Fig 31: Installing Intermediate Clutch Anti-Rattle Clip
    G01539995Courtesy of FORD MOTOR CO.
  27. Install the No. 1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
      Fig 32: Installing No. 1 Front Pump Support Thrust Washer
      G01539996Courtesy of FORD MOTOR CO.
    28. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
    Fig 33: Installing An Alignment Pin At Top Of Case
    G01539997Courtesy of FORD MOTOR CO.
  28. Install an alignment pin at the top of the case.
    29. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  29. Install the pump gasket.
    30. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
    Fig 34: Installing Pump Assembly
    G01539998Courtesy of FORD MOTOR CO.
  30. Install the pump assembly.
  31. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
      Fig 35: Installing Front Pump Bolts
      G01539999Courtesy of FORD MOTOR CO.
  32. Rotate the transmission to the horizontal position.
  33. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
      Fig 36: Installing Parking Pawl
      G01540000Courtesy of FORD MOTOR CO.
  34. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the four bolts and two nuts.
      Fig 37: Installing Bolts And Nuts
      G01540001Courtesy of FORD MOTOR CO.
  35. Using the special tool, install a new extension housing seal.
    Fig 38: Installing Extension Housing Seal
    G01540002Courtesy of FORD MOTOR CO.
  36. Install the output shaft speed (OSS) sensor.
    1. Position the OSS sensor.
    2. Install the bolt.
      Fig 39: Installing Bolt
      G01540003Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the manual control lever seal.
    Fig 40: Installing manual control lever seal
    G01540004Courtesy of FORD MOTOR CO.
    38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
  38. Install the EPC solenoid.
    1. Install the EPC solenoid.
    2. Install the EPC solenoid bracket and bolt.
      Fig 41: Installing EPC Solenoid Bracket And Bolt
      G01540005Courtesy of FORD MOTOR CO.
  39. Install the manual valve detent lever and parking lever actuating rod.
    Fig 42: Installing Manual Valve Detent Lever And Parking Lever Actuating Rod
    G01540006Courtesy of FORD MOTOR CO.
  40. Install the manual control lever shaft.
    1. Slide the manual control shaft into the case.
    2. Install the manual lever shaft inner nut.
    3. Install the manual lever shaft retaining pin.
      Fig 43: Installing Manual Control Lever Shaft
      G01540007Courtesy of FORD MOTOR CO.
  41. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator spring.
    2. Install the 1-2 accumulator.
    3. Install the inner and outer 1-2 accumulator springs.
    4. Install the 1-2 accumulator cover and seal.
      Fig 44: Installing 1-2 Accumulator Piston Assembly
      G01540008Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator springs and install the accumulator piston retaining ring.
    Fig 45: Installing Accumulator Piston Retaining Ring
    G01540009Courtesy of FORD MOTOR CO.
    43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When a new piston and rod assembly becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
    Fig 46: Installing Reverse Servo Piston And Return Spring
    G01540010Courtesy of FORD MOTOR CO.
  43. Install the reverse servo piston and return spring.
  44. Install the special tool.
    • Tighten the bolt.
      Fig 47: Tightening Special Tool Bolt
      G01540011Courtesy of FORD MOTOR CO.
  45. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
      Fig 48: Installing Dial Indicator
      G01540012Courtesy of FORD MOTOR CO.
  46. Loosen the bolt until the piston stops against the tool.
    Fig 49: Loosening Bolt
    G01540013Courtesy of FORD MOTOR CO.
  47. Verify the amount of piston travel on the dial indicator is within specification.
    Fig 50: Identifying Piston Travel On Dial Indicator
    G01540014Courtesy of FORD MOTOR CO.
  48. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
      Fig 51: Selecting And Installing Correct Servo Assembly To Bring Servo Piston Travel Within Specification
      G01540015Courtesy of FORD MOTOR CO.
  49. Remove the special tools.
    Fig 52: Removing Special Tools
    G01540016Courtesy of FORD MOTOR CO.
  50. Install the reverse servo assembly.
    1. Install the rod.
    2. Install the piston assembly.
    3. Install the reverse servo piston cover and seal.
      Fig 53: Installing Reverse Servo Piston Cover And Seal
      G01540017Courtesy of FORD MOTOR CO.
  51. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
      Fig 54: Installing Reverse Servo Retaining Ring
      G01540018Courtesy of FORD MOTOR CO.
  52. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
      Fig 55: Installing Accumulator Piston Spring
      G01540019Courtesy of FORD MOTOR CO.
  53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
    Fig 56: Identifying Test Ports
    G01540020Courtesy of FORD MOTOR CO.
    54. NOTE: The tab on the electrical connector is secured by main control valve body.
    Fig 57: Installing Electrical Connector Into Case
    G01540021Courtesy of FORD MOTOR CO.
  54. Install the electrical connector into case.
    55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
    Fig 58: Aligning Main Control Valve Body Alignment Bolts
    G01540022Courtesy of FORD MOTOR CO.
  55. Align the main control valve body alignment bolts and position the main control valve body.
    56. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 59: Installing 11 Long Main Control Valve Body Bolts
    G01540023Courtesy of FORD MOTOR CO.
  56. Loosely install the 11 long main control valve body bolts.
    57. NOTE: The main control valve body bolts will be tightened in later steps.
    Fig 60: Installing 12 Short Main Control Valve Body Bolts
    G01540024Courtesy of FORD MOTOR CO.
  57. Loosely install the 12 short main control valve body bolts.
  58. Install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring.
    2. Install the bolt.
      Fig 61: Installing Bolt
      G01540025Courtesy of FORD MOTOR CO.
  59. Tighten the bolts in the sequence shown.
    Fig 62: Tightening Bolts In Sequence
    G01540026Courtesy of FORD MOTOR CO.
  60. Inspect the lead frame for damage.
    • Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
      Fig 63: Inspecting Lead Frame For Damage
      G01540027Courtesy of FORD MOTOR CO.
  61. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
      Fig 64: Connecting Molded Lead Frame To Solenoids
      G01540028Courtesy of FORD MOTOR CO.
  62. Install the fluid filter and seal assembly.
    Fig 65: Installing Fluid Filter And Seal Assembly
    G01540029Courtesy of FORD MOTOR CO.
  63. Position the pan magnet onto the fluid pan.
    Fig 66: Positioning Pan Magnet Onto Fluid Pan
    G01540030Courtesy of FORD MOTOR CO.
    64. NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.
  64. Install the fluid pan and gasket.
    1. Position the transmission fluid pan with the gasket in place.
    2. Install the bolts.
      Fig 67: Installing Bolts
      G01540031Courtesy of FORD MOTOR CO.
  65. Install the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the digital TR bolts.
      Fig 68: Installing Digital TR Bolts
      G01540032Courtesy of FORD MOTOR CO.
    66. NOTE: The tool is designed to fit snug.
    NOTE: Manual shift lever must be in the neutral position.
    Fig 69: Aligning Digital TR Sensor Slots
    G01540033Courtesy of FORD MOTOR CO.
  66. Using the special tool, align the digital TR sensor slots.
  67. Tighten the bolts.
    Fig 70: Tightening Digital TR Sensor Bolts
    G01540034Courtesy of FORD MOTOR CO.
  68. Install the manual control lever.
    1. Install the manual control lever.
    2. Install the nut.
      Fig 71: Installing Nut
      G01540035Courtesy of FORD MOTOR CO.
  69. Install the transmission vent tube, if equipped.
    1. Install the transmission vent tube.
    2. Install the bolt.
      Fig 72: Installing Transmission Vent Tube Bolt
      G01540036Courtesy of FORD MOTOR CO.
  70. Lightly lubricate the converter hub with clean automatic transmission fluid.
    Fig 73: Lubricating Converter Hub
    G01540037Courtesy of FORD MOTOR CO.
    71. WARNING: The torque converter can fall out if the transmission is tipped.
    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 74: Installing Torque Converter
    G01540038Courtesy of FORD MOTOR CO.
  71. Using special tools, install the torque converter.
  72. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 75: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G01540039Courtesy of FORD MOTOR CO.
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