Section 599 (Automatic Transmission - 4R100): Disassembly: Transmission

SPECIAL TOOL(S) 

Fig 1: Identifying Transmission Special Tool(s)

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CAUTION: The turbine shaft speed (TSS) sensor will need to be removed or damage to the sensors may occur.
Fig 2: Removing TSS Sensor
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1. If equipped, remove the TSS sensor.
   1. Remove the bolt.
   2. Remove the TSS sensor.
NOTE: Remove the torque converter prior to mounting the transmission to the repair stand.
2. Install the transmission into a suitable stand.
CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.
Fig 3: Removing Input Shaft
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3. Remove the input shaft.
CAUTION: Sealing washers may fall off the cooler line case fittings.
NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
Fig 4: Removing Cooler Bypass Valve
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4. Remove the cooler bypass valve.
   • Remove and discard the sealing washers and the cooler line case fittings.
5. Remove the transmission range (TR) sensor.
   1. Remove the bolts.
   2. Remove the TR sensor.
   Fig 5: Removing TR Sensor

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CAUTION: Do not discard the gasket unless damaged. This is a reusable gasket.
Fig 6: Removing Transmission Fluid Pan And Gasket
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6. Remove the transmission fluid pan and gasket.
CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
NOTE: After removal, discard the filter and seal assembly.
Fig 7: Removing Filter And Seal Assembly
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7. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
8. Remove the bolts, nuts and the accumulator body.
   Fig 8: Removing Accumulator Body

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NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
Fig 9: Removing Main Control Valve Body
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9. Remove the main control valve body.
   1. Do not remove the two lower-to-upper main control valve body assembly bolts.
10. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 10: Removing Bolts, Nut And Solenoid Body Assembly

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11. Remove the solenoid screen assembly by rotating and pulling.
    Fig 11: Removing Solenoid Screen Assembly

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CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
Fig 12: Removing Separator Plate Reinforcing Plate And Valve Body Separator Plate With Two Gaskets
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12. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
NOTE: The steel EPC check ball has a 0.25-inch diameter and is smaller than the other check balls.
Fig 13: Removing Steel EPC Check Ball And Spring
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13. Remove the steel EPC check ball and spring.
CAUTION: Use care not to damage the rubber check balls. Transmission shift problems may occur.
Fig 14: Removing Rubber Check Balls
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14. Using a small screwdriver, carefully remove the 8 rubber check balls.
15. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 15: Removing Plastic Or Rubber-Headed Hammer, Tap Gently On Intermediate Band Servo Assembly

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CAUTION: After removal, discard the feedbolts. The bolts will not retain torque specification if reused.
Fig 16: Removing And Discard Feedbolts
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16. Remove and discard the feedbolts.
17. Remove the pump bolts and discard the washers.
    Fig 17: Removing Pump Bolts And Discard Washers

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NOTE: The special tools should be installed into the pump threaded holes as shown.
Fig 18: Removing Pump
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18. Using the special tools, remove the pump.
NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
Fig 19: Removing No. 2A Overdrive Sun Gear Thrust Bearing
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19. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
CAUTION: The coast clutch, overdrive ring gear, and centershaft assembly must be removed as an assembly using special service tool or damage to the overdrive one-way clutch could occur.
Fig 20: Removing Coast Clutch, Overdrive Ring Gear And Centershaft Assembly
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20. Using the special tool, remove the coast clutch, overdrive ring gear, and centershaft assembly.
NOTE: The No. 5 thrust bearing may remain on the centershaft or the center support.
Fig 21: Removing Overdrive Centershaft Thrust Bearing Assembly
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21. Remove the No. 5 overdrive centershaft thrust bearing assembly.
22. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 22: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring

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NOTE: Tag the parts for identification during installation.
Fig 23: Removing Overdrive Clutch Pressure Plate And Clutch Pack
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23. Remove the overdrive clutch pressure plate and the clutch pack.
24. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 24: Removing Intermediate/Overdrive Cylinder Retaining Ring

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CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
Fig 25: Removing Intermediate/Overdrive Cylinder Assembly
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25. Remove the intermediate/overdrive cylinder assembly.
26. Remove the intermediate clutch piston return spring.
    Fig 26: Removing Intermediate Clutch Piston Return Spring

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CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.
Fig 27: Removing Center Support Assembly
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27. Carefully remove the center support assembly.
28. Remove the No. 6 center support thrust washer.
    Fig 28: Removing Center Support Thrust Washer

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NOTE: Tag the parts for identification during installation.
Fig 29: Removing Intermediate Clutch Rear Pressure Plate
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29. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate.
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
30. Remove the intermediate band.
    Fig 30: Removing Intermediate Band

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NOTE: When installing the special tool, each leg of the special tool must be rotated to engage notches on the input shell prior to tightening the top cross bar.
Fig 31: Removing Direct Clutch Forward Clutch And Input Shell An Assembly
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31. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
32. Remove the reverse planet retaining ring.
    Fig 32: Removing Reverse Planet Retaining Ring

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33. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 33: Removing Reverse Planet Assembly

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WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
Fig 34: Removing Output Shaft Retaining Ring
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34. Remove the output shaft retaining ring.
35. Remove the output shaft ring gear and hub assembly
    Fig 35: Removing Output Shaft Ring Gear And Hub Assembly

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WARNING: Use care not to drop the output shaft while rotating the transmission.
Fig 36: Removing Following Parts As An Assembly
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36. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
37. Using the special tools, remove the extension housing seal.
    Fig 37: Removing Extension Housing Seal

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38. Using the special tool, remove the extension housing bushing.
    Fig 38: Removing Extension Housing Bushing

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39. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 39: Removing Eight Bolts, One Stud And Extension Housing

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NOTE: The parking gear is press fit to the output shaft.
40. Remove the output shaft and park gear assembly.
41. Remove the No. 13 thrust bearing.
    Fig 40: Removing Thrust Bearing

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42. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 41: Removing Plastic Orifice Lube Plug From Rear Of Case

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43. Remove the 5 bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 42: Removing 5 Bolts Retaining Low/Reverse One-Way Clutch Inner Race To Case

    Courtesy of FORD MOTOR CO.
44. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 43: Removing Low/Reverse One-Way Clutch Inner Race And Reverse Clutch Return Spring Assembly

    Courtesy of FORD MOTOR CO.
45. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to restrain the reverse clutch piston.
    Fig 44: Installing Reverse Clutch Pressure Plate

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46. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 45: Compressing Air Blow Into Reverse Clutch Feed Port To Blow Out Reverse Clutch Piston

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47. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 46: Removing Reverse Clutch Pressure Plate Retainer Snap Ring

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48. If required, remove the parking rod guide plate.
    Fig 47: Removing Parking Rod Guide Plate

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49. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
    Fig 48: Removing Parking Pawl Return Spring

    Courtesy of FORD MOTOR CO.
CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.
Fig 49: Removing Parking Pawl Abutment
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50. If required, remove the parking pawl abutment.
NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
Fig 50: Removing Manual Lever Shaft Retaining Pin
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51. Using the special tool, remove the manual lever shaft retaining pin.
CAUTION: Use care not to damage the manual control lever bore.
NOTE: The manual control lever and manual control lever shaft are one piece.
Fig 51: Removing Manual Control Lever Shaft Assembly
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52. Remove the manual control lever shaft assembly.
    NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
53. Using the special tool, remove the manual control lever seal.
    Fig 52: Removing Manual Control Lever Seal

    Courtesy of FORD MOTOR CO.
NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
Fig 53: Removing Short Fluid Inlet Tube
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54. If required, remove the short fluid inlet tube.
55. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
56. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
57. If the transmission case assembly thread is damaged, repair kits (heli-coil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the heli-coil kit.