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Assembly Procedure

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Inspect the transmission case and extension housing for the following:
  • Stripped screw hole threads
  • Gasket and mating surfaces for burrs or nicks
  • Obstructions to vent and fluid passages
  • Cracks or warpage
NOTE: Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
NOTE: Lubricate all seals and the servo bores with clean automatic transmission fluid.
  1. Assemble the parts in the order indicated in the following illustrations and tables. See Fig 1-Fig 5 .
    Fig 1: Lubricating All Seals And Servo Bores With Clean Automatic Transmission Fluid (1 Of 5)
    G03201951Courtesy of FORD MOTOR CO.
    Fig 2: Lubricating All Seals And Servo Bores With Clean Automatic Transmission Fluid (2 Of 5)
    G03201952Courtesy of FORD MOTOR CO.
    Fig 3: Lubricating All Seals And Servo Bores With Clean Automatic Transmission Fluid (3 Of 5)
    G03201953Courtesy of FORD MOTOR CO.
    Fig 4: Lubricating All Seals And Servo Bores With Clean Automatic Transmission Fluid (4 Of 5)
    G03201954Courtesy of FORD MOTOR CO.
    Fig 5: Lubricating All Seals And Servo Bores With Clean Automatic Transmission Fluid (5 Of 5)
    G03201955Courtesy of FORD MOTOR CO.

Item 1: Transmission Case Assembly Note 

    WARNING: Make sure the lock pin on the bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.
    Fig 6: Installing Transmission Into Bench With Converter Housing Facing Up
    G03201956Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the transmission into the bench with the converter housing facing up.
  2. Inspect the rear case bearing for damage. If damage to the component is indicated, install a new case.
    Fig 7: Inspecting Rear Case Bearing For Damage
    G03201957Courtesy of FORD MOTOR CO.

Item 2: Manual Control Lever Seal Assembly Note 

  1. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
    Fig 8: Installing Manual Control Lever Shaft Seal And Lubricate With Petroleum Jelly
    G03201958Courtesy of FORD MOTOR CO.

Item 3: Park Pawl Actuating Rod Assembly Note 

  1. Install the parking lever rod.
    Fig 9: Installing Parking Lever Rod
    G03201959Courtesy of FORD MOTOR CO.

Item 4: Manual Control Valve Inner Lever Assembly Note 

  1. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 10: Assembling Manual Valve Inner Lever And Parking Lever Actuating Rod
    G03201960Courtesy of FORD MOTOR CO.

Item 5: Manual Control Lever Shaft Assembly Note 

    CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 11: Aligning Flats On Manual Valve Inner Lever With Flats On Manual Control Lever Shaft
    G03201961Courtesy of FORD MOTOR CO.
  1. Install the manual control lever shaft.

Item 6: Manual Control Lever Inner Nut Assembly Note 

  1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
    Fig 12: Installing Manual Valve Inner Lever Onto Manual Shaft
    G03201962Courtesy of FORD MOTOR CO.

Item 7: Manual Control Lever Shaft Retaining Pin Assembly Note 

    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 13: Installing Manual Control Lever Shaft Spring Pin
    G03201963Courtesy of FORD MOTOR CO.
  1. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.

Item 8: Manual Control Lever Inner Nut Assembly Note 

    CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 14: Allowing Wrench To Strike Manual Valve Inner Lever Pin
    G03201964Courtesy of FORD MOTOR CO.
  1. Tighten the nut.

Item 9: Output Shaft Thrust Washer No. 11 Assembly Note 

    CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
    Fig 15: Installing Output Shaft Thrust Washer
    G03201965Courtesy of FORD MOTOR CO.
  1. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.

Item 12: Reverse Band Assembly Note 

    CAUTION: Make sure band is resting on the two anchor pins in the case.
  1. Install the low/reverse band over the low/reverse brake drum.
    2. Fig 16: Installing Low/Reverse Band Over Low/Reverse Brake Drum
    G03201966Courtesy of FORD MOTOR CO.

Item 13: Reverse Brake Drum and Clutch Assembly Note 

  1. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    Fig 17: Installing Low/Reverse Brake Drum
    G03201967Courtesy of FORD MOTOR CO.

Item 14: Reverse Brake Drum Lever Assembly Note 

    NOTE: The reverse band actuating lever must fit into the notches in the band.
    Fig 18: Installing Reverse Band Actuating Lever
    G03201968Courtesy of FORD MOTOR CO.
  1. Install the reverse band actuating lever into the reverse band.

Item 17: Output Shaft Ring Gear Assembly Note 

    CAUTION: Do not damage the seal against the case during assembly.
    Fig 19: Installing Output Shaft Ring Gear Hub And Seal
    G03201969Courtesy of FORD MOTOR CO.
  1. Install the output shaft ring gear, hub and seal.

Item 18: Output Shaft Retaining Ring Assembly Note 

    CAUTION: Always install a new output shaft retaining ring.
    Fig 20: Installing A New Output Shaft Retaining Ring
    G03201970Courtesy of FORD MOTOR CO.
  1. Install a new output shaft retaining ring.

Item 19: Output Shaft Sleeve Assembly Note 

    NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
    Fig 21: Installing Output Shaft Sleeve
    G03201971Courtesy of FORD MOTOR CO.
  1. Install the output shaft sleeve.

Item 22: Reverse Brake Drum Retaining Ring Assembly Note 

    CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 22: Installing Retaining Ring
    G03201972Courtesy of FORD MOTOR CO.
  1. Install the retaining ring.

Item 26: Forward Planet Assembly Note 

    NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
    Fig 23: Installing Forward Planetary Assembly
    G03201973Courtesy of FORD MOTOR CO.
  1. Install the forward planetary assembly.

Item 35: Intermediate Servo Retaining Ring Assembly Note 

  1. Install the intermediate servo cover seal and lubricate it with clean automatic transmission fluid.
  2. Using the special tool, install the retaining ring.
    Fig 24: Installing Retaining Ring
    G03201974Courtesy of FORD MOTOR CO.

Item 37: Intermediate Clutch Drum Bearing No. 4 Assembly Note 

  1. Using the special tools, measure from the top of the gauge bar to center support ledge in case at four places 90 degrees apart.
    • Add the four measurements, divide by four, and record as dimension A.
    Fig 25: Measuring From Top Of Gauge Bar To Center Support Ledge In Case At Four Places
    G03201975Courtesy of FORD MOTOR CO.
    2. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
    Fig 26: Tightening Center Screw
    G03201976Courtesy of FORD MOTOR CO.
  2. Install the special tool.
    1. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions.
    2. Tighten the center screw.
    3. NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
    Fig 27: Aligning Disc Holes On Special Tools With Slot In Gauge Bar For Correct Measurement
    G03201977Courtesy of FORD MOTOR CO.
  3. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
  4. Add dimension B to C, divide by two and record as dimension D.
  5. Subtract A from D, and record as dimension E.
  6. Select bearing from the following chart, using dimension "E". See DIMENSION SPECIFICATION .
    DIMENSION "E" SPECIFICATION

    Dimension E Service Part Number (7D014) Bearing Thickness Identification (Notches)
    1.69-1.87 mm (0.066-0.074 in) XW4Z-CA 2.65-2.80 mm (0.104-0.110 in) None
    1.88-2.04 mm (0.073-0.080 in) XW4X-DA 2.83-2.98 mm (0.111-0.116 in) One
    2.05-2.22 mm (0.081-0.088 in) XW4Z-EA 3.01-3.16 mm (0.118-0.124 in) Two
    2.23-2.43 mm (0.088-0.096 in) XW4Z-FA 3.21-3.36 mm (0.126-0.132 in) Three
  7. Install the selected No. 4 thrust washer on the direct clutch drum.
    • Coat the thrust washer with petroleum jelly.
    8. Fig 28: Coating Thrust Washer With Petroleum Jelly
    G03201978Courtesy of FORD MOTOR CO.

Item 38: Intermediate Brake Band Assembly Note 

    NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
    NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
    NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 29: Installing Intermediate Band
    G03201979Courtesy of FORD MOTOR CO.
  1. Install the intermediate band.

Item 39: Intermediate Brake Band Anchor Strut Assembly Note 

  1. Install the intermediate band anchor strut.
    Fig 30: Installing Intermediate Band Anchor Strut
    G03201980Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 31: Checking Make Sure Intermediate Band Anchor Strut
    G03201981Courtesy of FORD MOTOR CO.
  2. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 40: Intermediate Brake Band Adjusting Screw Assembly Note 

  1. Loosely install the screw.
    Fig 32: Installing Screw
    G03201982Courtesy of FORD MOTOR CO.

Item 41: Intermediate Brake Band Apply Strut Assembly Note 

  1. Install the intermediate band apply strut.
    Fig 33: Installing Intermediate Band
    G03201983Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 34: Checking Make Sure Intermediate Band
    G03201984Courtesy of FORD MOTOR CO.
  2. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.

Item 42: Center Support Assembly Note 

    NOTE: Align the center support screw hole with correct case hole.
    Fig 35: Aligning Center Support Screw Hole With Correct Case Hole
    G03201985Courtesy of FORD MOTOR CO.
  1. Install the center support.

Item 43: Nut and Cage Assembly Note 

  1. Install the center support locknut and cage.
    Fig 36: Installing Center Support Locknut And Cage
    G03201986Courtesy of FORD MOTOR CO.

Item 44: Bolt Assembly Note 

  1. Loosely install the screw.
    Fig 37: Loosing Install Screw
    G03201987Courtesy of FORD MOTOR CO.

Item 45: Retaining Ring Assembly Note 

    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 38: Installing Center Support Retaining Ring With Tapered Side Facing
    G03201988Courtesy of FORD MOTOR CO.
  1. Install the center support retaining ring.
    1. Make sure the center support retaining ring is installed with the tapered side facing up.
    2. Make sure the opening of the center support retaining ring is positioned correctly.

Item 49: Overdrive Servo Retaining Ring Assembly Note 

  1. Install the overdrive servo cover seals and lubricate them with clean automatic transmission fluid.
  2. Using the special tools, install the retaining ring.
    Fig 39: Installing Retaining Ring
    G03201989Courtesy of FORD MOTOR CO.

Item 51: Overdrive Planetary Gear Carrier Assembly Note 

    CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
    Fig 40: Installing Planetary Gear Overdrive Carrier
    G03201990Courtesy of FORD MOTOR CO.
  1. Install the planetary gear overdrive carrier.

Item 53: Overdrive Brake Band Assembly Note 

    NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
    NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
    NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 41: Installing Overdrive Band
    G03201991Courtesy of FORD MOTOR CO.
  1. Install the overdrive band.

Item 54: Overdrive Brake Band Anchor Strut Assembly Note 

  1. Install the overdrive anchor strut.
    Fig 42: Installing Overdrive Anchor Strut
    G03201992Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 43: Checking Make Sure Overdrive Band Anchor Strut
    G03201993Courtesy of FORD MOTOR CO.
  2. Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 55: Overdrive Brake Band Adjusting Screw Assembly Note 

  1. Loosely install the screw.
    Fig 44: Installing Screw
    G03201994Courtesy of FORD MOTOR CO.

Item 56: Overdrive Brake Band Apply Strut Assembly Note 

  1. Install the overdrive apply strut.
    Fig 45: Installing Overdrive
    G03201995Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 46: Checking Make Sure Overdrive Band
    G03201996Courtesy of FORD MOTOR CO.
  2. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.

Item 57: Fluid Pump Support Thrust Washer No. 1 Assembly Note 

    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
    Fig 47: Installing Special Tools And Screws Using Two Pump Screw
    G03201997Courtesy of FORD MOTOR CO.
  1. Install the special tool.
    1. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions.
    2. Tighten the center screw.
    2. NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
    Fig 48: Aligning Disc Holes On Special Tools With Slot In Gauge
    G03201998Courtesy of FORD MOTOR CO.
  2. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension "A". Repeat measurement 180 degrees opposite side of the special tool and record as dimension "B".
  3. Add dimension "A" to "B", divide by two and record as dimension "C".
  4. Subtract the thickness of the gauge bar 17.78 mm (0.71 in) from dimension "C", and record as dimension "D".
  5. Select the No.1 thrust bearing from the following chart using dimension "D". See DIMENSION SPECIFICATION .
    DIMENSION "D" SPECIFICATION

    Dimension D Service Part Number (7D014) Bearing Thickness Identification (Color/ID)
    38.05-38.24 mm (1.50-1.51 in) XW4Z-XA 1.70-1.75 mm (0.06 in) Brown/8
    38.25-38.40 mm (1.51 in) XW4Z-NA 1.85-1.90 mm (0.07 in) Red/4
    38.44-38.59 mm (1.51-1.52 in) XW4Z-RA 2.05-2.10 mm (0.08 in) Black/6
    38.60-38.76 mm (1.52-1.53 in) XW4Z-YA 2.20-2.25 mm (0.09 in) Orange/9
    38.77-38.97 mm (1.53 in) XW4Z-ZA 2.40-2.45 mm (0.10 in) Purple/10
  6. Install the selected No. 1 fluid pump input thrust washer.
    • Coat the fluid pump input thrust washer with petroleum jelly.
    Fig 49: Coating Fluid Pump Input Thrust Washer With Petroleum Jelly
    G03201999Courtesy of FORD MOTOR CO.

Item 58: Fluid Pump Gasket Assembly Note 

  1. Install the special tools into the transmission case.
    Fig 50: Installing Special Tool(s) Into Transmission Case
    G03202000Courtesy of FORD MOTOR CO.
  2. Install the pump gasket.
    Fig 51: Installing Pump Gasket
    G03202001Courtesy of FORD MOTOR CO.

Items 59 and 60: Fluid Pump Assembly and Fluid Pump Screws Assembly Note 

    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 seal remain in the correct position throughout this step.
    Fig 52: Installing Fluid Pump
    G03202002Courtesy of FORD MOTOR CO.
  1. Install the fluid pump.
    2. CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure, and leakage.
    Fig 53: Aligning Fluid Pump To Adapter Plate
    G03202003Courtesy of FORD MOTOR CO.
  2. Using the special tool, align the fluid pump to the adapter plate.
  3. Install screws. Tighten the screws in a star pattern.
    Fig 54: Installing Screws Tighten Screws In A Star Pattern
    G03202004Courtesy of FORD MOTOR CO.
  4. Remove the special tools and install the two remaining screws.
    Fig 55: Removing Special Tool(s) And Install Two Remaining Screws
    G03202005Courtesy of FORD MOTOR CO.

Item 61: Band Adjusting Locknut Assembly Note 

    CAUTION: Do not allow overdrive band adjustment 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 56: Installing A New Locknut On Band Adjustment Screw
    G03202006Courtesy of FORD MOTOR CO.
  1. Install a new locknut on the band adjustment screw.
    2. CAUTION: The overdrive servo must be installed prior to band adjustment.
    Fig 57: Tightening Overdrive Band Adjustment Screw
    G03202007Courtesy of FORD MOTOR CO.
  2. Using the special tool, tighten the overdrive band adjustment screw. Then back off the screw exactly (1.5) turns and hold that position.
  3. Tighten the overdrive band locknut.
    1. Hold the overdrive band adjustment screw stationary.
    2. Tighten the overdrive band locknut.
      Fig 58: Tightening Overdrive Band Locknut
      G03202008Courtesy of FORD MOTOR CO.

Item 62: Band Adjusting Locknut Assembly Note 

    CAUTION: Do not allow the 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 59: Installing New Nut On Band
    G03202009Courtesy of FORD MOTOR CO.
  1. Install new nut on the band adjustment screw.
    2. CAUTION: The intermediate servo must be installed prior to band adjustment.
    Fig 60: Tightening Intermediate Band Adjustment Screw
    G03202010Courtesy of FORD MOTOR CO.
  2. Tighten the intermediate band adjustment screw. Then back off the screw exactly (1.5) turns and hold that position.
  3. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
    Fig 61: Tightening Intermediate Band Locknut
    G03202011Courtesy of FORD MOTOR CO.

Item 63: Bolt Assembly Note 

  1. Tighten the center support bolt.
    Fig 62: Tightening Center Support Bolt
    G03202012Courtesy of FORD MOTOR CO.

Items 64-67: Main Control and Screws Assembly Note 

  1. Using the special tools, carry out the air pressure test procedure. For additional information, refer to SPECIAL TESTING PROCEDURES  in this section.
    Fig 63: Carrying Out Air Pressure
    G03202013Courtesy of FORD MOTOR CO.
  2. Install the special tools into the transmission case.
    Fig 64: Installing Special Tool(s) Into Transmission Case
    G03202014Courtesy of FORD MOTOR CO.
  3. Using the special tools, install the main control valve body and loosely install the screws.
    1. Install the short screw.
    2. Install the screw with the larger head.
    3. Install the remaining screws.
    Fig 65: Installing Screw With The Larger Head
    G03202015Courtesy of FORD MOTOR CO.
  4. Remove the special tools, and loosely install the screw.
    Fig 66: Removing Special Tool(s)
    G03202016Courtesy of FORD MOTOR CO.
  5. Tighten the screws in the sequence shown.
    Fig 67: Tightening Screws In Sequence
    G03202017Courtesy of FORD MOTOR CO.

Items 68 and 69: Manual Valve Detent Spring and Screw Assembly Note 

  1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
    Fig 68: Installing Manual Valve Detent Spring
    G03202018Courtesy of FORD MOTOR CO.

Items 71-73: Solenoid Body and Screws Assembly Note 

    CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, a transmission leak may occur.
    Fig 69: Installing Solenoid Body
    G03202019Courtesy of FORD MOTOR CO.
  1. Install the solenoid body. Tighten screws in sequence shown.

Item 75: Reverse Servo Screws Assembly Note 

  1. Install the reverse servo. Tighten the screws in the sequence shown in two stages.
    • Stage 1: Tighten screws to 5 N.m (44 lb-in).
    • Stage 2: Tighten screws to 11 N.m (8 lb-ft).
    Fig 70: Installing Reverse Servo
    G03202020Courtesy of FORD MOTOR CO.

Items 76 and 77: Transmission Fluid Filter and Screws Assembly Note 

    CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
    NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
    Fig 71: Installing Transmission Fluid Filter
    G03202021Courtesy of FORD MOTOR CO.
  1. Lubricate the seals and install the transmission fluid filter.

Item 78: Transmission Fluid Pan Gasket Assembly Note 

    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
  1. Install the transmission fluid pan and gasket.

Item 79: Transmission Fluid Pan Assembly Note 

  1. Install the transmission fluid pan and loosely install the screws.
    Fig 72: Installing Transmission Fluid Pan
    G03202022Courtesy of FORD MOTOR CO.

Item 80: Transmission Fluid Pan Screws Assembly Note 

  1. Tighten the 16 screws in a crisscross sequence.
    Fig 73: Identifying Transmission Fluid Pan
    G03202023Courtesy of FORD MOTOR CO.

Items 81-84: Park Pawl and Extension Housing Gasket Assembly Note 

    NOTE: The 4x2 vehicle is shown, the 4x4 is similar.
    Fig 74: Installing Parking Pawl Return Spring
    G03202024Courtesy of FORD MOTOR CO.
  1. Install the parking pawl assembly and gasket.
    1. Install the parking pawl shaft.
    2. Install the parking pawl return spring.
    3. Install the parking pawl.
    4. Install a new gasket.

Item 87: Extension Housing Seal Assembly Note 

  1. Using the special tool, install the extension housing seal.
    Fig 75: Installing Extension Housing Seal
    G03202025Courtesy of FORD MOTOR CO.

Item 88: Output Shaft Flange Assembly Note 

  1. Using the special tools, install the output shaft flange.
    Fig 76: Installing Output Shaft Flange
    G03202026Courtesy of FORD MOTOR CO.

Items 90 and 91: Transmission Range (TR) Sensor Screws Assembly Note 

    CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.
    Fig 77: Installing Digital Transmission Range (TR) Sensor
    G03202027Courtesy of FORD MOTOR CO.
  1. Install the digital transmission range (TR) sensor and loosely install the screws.
    2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
    Fig 78: Aligning Digital TR Sensor
    G03202028Courtesy of FORD MOTOR CO.
  2. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Item 92: Input Shaft Assembly Note 

    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 79: Installing Input Shaft
    G03202029Courtesy of FORD MOTOR CO.
  1. Install the input shaft.

Item 93: Front Fluid Pump Seal Assembly Note 

    NOTE: Check and make sure that the garter spring in the seal has not popped off of the converter hub seal.
    Fig 80: Installing A New Seal Onto Special Tools
    G03202030Courtesy of FORD MOTOR CO.
  1. Install a new seal onto the special tool.
  2. Using the special tool, install a new converter hub seal.
    Fig 81: Installing A New Converter Hub Seal
    G03202031Courtesy of FORD MOTOR CO.

Item 94: Fluid Pump Assembly Note 

  1. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
    Fig 82: Identifying Fluid Pump Assembly
    G03202032Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 83: Removing Special Tools
    G03202033Courtesy of FORD MOTOR CO.

Item 95: Torque Converter Assembly Note 

    CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may become damaged.
    Fig 84: Lubricating Converter Hub With Clean Automatic Transmission Fluid
    G03202034Courtesy of FORD MOTOR CO.
  1. Lubricate the converter hub with clean automatic transmission fluid.
    2. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.
    Fig 85: Installing Torque Converter
    G03202035Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the torque converter by pushing and rotating.
  3. Lubricate the torque converter pilot hub with multipurpose grease.
    Fig 86: Lubricating Torque Converter Pilot Hub With Multipurpose Grease
    G03202036Courtesy of FORD MOTOR CO.

Items 96 and 97: Flexplate Adapter Plate and Nuts Assembly Note 

    CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.
    In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.
    NOTE: Align the identifying mark made on the nut, stud, and adapter plate during disassembly for correct installation.
    Fig 87: Installing Torque Converter Flexplate Adapter Plate Assembly
    G03202037Courtesy of FORD MOTOR CO.
  1. If the vehicle is equipped and the adapter plate was removed, use the special tool to install the torque converter flexplate adapter plate assembly and the eight nuts.
  2. Install two torque converter flexplate adapter plate nuts.
    Fig 88: Installing Two Torque Converter Flexplate Adapter Plate Nuts
    G03202038Courtesy of FORD MOTOR CO.

Item 98 and 99: Speed Sensor and Screws Assembly Note 

  1. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.
    Fig 89: Filling Transmission With Of Automatic Transmission Fluid
    G03202039Courtesy of FORD MOTOR CO.
    2. NOTE: Inspect the speed sensor O-ring seals for damage. If damage to the seal is found, install a new seal. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
    Fig 90: Installing Speed Sensors
    G03202040Courtesy of FORD MOTOR CO.
  2. Install the speed sensors.
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