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Section 727 (Automatic Transmission - 5R110W): Assembly: Transmission

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool (1 Of 2)
G03381370Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool (2 Of 2)
G03381371Courtesy of FORD MOTOR CO.

MATERIAL 

MATERIALS

Item Specification
MERCON® SP Automatic
Transmission Fluid
XT -6-QSP		 MERCON®
SP
NOTE: Soak all friction clutch plates in clean automatic transmission fluid.
NOTE: Prior to installation, lightly lubricate all O-ring seals with clean automatic transmission fluid.
NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

    ALL TRANSMISSIONS 

  1. Mount the transmission case into a suitable stand.
  2. If removed, use the special tool to install the short fluid inlet tube.
    Fig 3: Installing Short Fluid Inlet Tube
    G03381372Courtesy of FORD MOTOR CO.
  3. If removed, use the special tool to install a new Teflon® seal retainer.
    • Install two new Teflon® seals.
    Fig 4: Installing Two New Teflon® Seals
    G03381373Courtesy of FORD MOTOR CO.
    4. NOTE: Coat the reverse clutch piston seals with petroleum jelly.
    Fig 5: Installing Reverse Clutch Piston
    G03381374Courtesy of FORD MOTOR CO.
  4. Install the reverse clutch piston in the case until it is fully seated in the case.
  5. Install the reverse clutch return spring assembly.
    Fig 6: Installing Reverse Clutch Return Spring Assembly
    G03381375Courtesy of FORD MOTOR CO.
    6. WARNING: Do not overcompress the return spring, damage to the spring will occur.
    Fig 7: Installing Reverse Clutch Return Spring Snap Ring
    G03381376Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the reverse clutch return spring snap ring.
    7. NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.
    Fig 8: Installing No. 17 Park Gear Thrust Bearing
    G03381377Courtesy of FORD MOTOR CO.
  7. For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.
    8. WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.
    Fig 9: Installing Output Shaft
    G03381378Courtesy of FORD MOTOR CO.
  8. Install the output shaft.
    9. CAUTION: The Torx® screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.
    Fig 10: Installing Parking Pawl Abutment With New Torx® Screw
    G03381379Courtesy of FORD MOTOR CO.
  9. If removed, install the parking pawl abutment with a new Torx® screw.
  10. Install the parking pawl.
    1. Install the parking pawl shaft.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
      Fig 11: Installing Parking Pawl, Pawl Shaft And Return Spring
      G03381380Courtesy of FORD MOTOR CO.
    11. NOTE: Make sure the dimple on the parking guide support plate is facing inward.
  11. Install the parking rod guide plate.
    1. Install the parking rod guide plate.
    2. Install the bolts.
      Fig 12: Installing Parking Rod Guide Plate And Bolt
      G03381381Courtesy of FORD MOTOR CO.
  12. Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.48 in) socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.
    Fig 13: Installing New Orifice Lube Plug In Rear Of Case
    G03381382Courtesy of FORD MOTOR CO.
  13. Install a new extension housing gasket.
    Fig 14: Installing New Extension Housing Gasket
    G03381383Courtesy of FORD MOTOR CO.
  14. Install the extension housing.
    Fig 15: Installing Extension Housing
    G03381384Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new manual control lever seal.
    Fig 16: Installing Manual Control Lever Seal
    G03381385Courtesy of FORD MOTOR CO.
  16. Install the transmission range sensor, park rod assembly and loosely install the bolts.
    Fig 17: Installing Transmission Range Sensor, Park Rod Assembly
    G03381386Courtesy of FORD MOTOR CO.
  17. Install the manual control lever.
    Fig 18: Installing Manual Control Lever
    G03381387Courtesy of FORD MOTOR CO.
  18. Install the roll pin into the case.
    Fig 19: Installing Roll Pin Into Case
    G03381388Courtesy of FORD MOTOR CO.
  19. Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.
    Fig 20: Installing Roll Pin Leave 2 Mm (0.08 In) Of Pin Exposed
    G03381389Courtesy of FORD MOTOR CO.
  20. Tighten the transmission range sensor bolts.
    Fig 21: Tightening Transmission Range Sensor Bolts
    G03381390Courtesy of FORD MOTOR CO.

    21. FIXED YOKE TRANSMISSIONS 

  21. Use the special tool and install a new extension housing seal.
    Fig 22: Installing Extension Housing Seal
    G03381391Courtesy of FORD MOTOR CO.
  22. Inspect the output shaft nut O-ring for cuts. If there is any damage to the nut or seal, a new nut must be installed.
    23. Fig 23: Inspecting Output Shaft Nut O-Ring For Cuts
    G03381392Courtesy of FORD MOTOR CO.
  23. Using the special tool, install a new output shaft nut.
    Fig 24: Installing Output Shaft Nut
    G03381393Courtesy of FORD MOTOR CO.
  24. If the vehicle is equipped with a fixed yoke, install the output flange.
    1. Install the flange.
    2. Install a new bolt.
      Fig 25: Installing Flange And Bolt
      G03381394Courtesy of FORD MOTOR CO.

    25. SLIP YOKE TRANSMISSIONS 

  25. If removed, install a new output shaft bushing using the special tool.
    Fig 26: Installing Output Shaft Bushing Using Special Tool
    G03381395Courtesy of FORD MOTOR CO.
  26. Install a new output shaft seal using the special tool.
    Fig 27: Installing Output Shaft Seal Using Special Tool
    G03381396Courtesy of FORD MOTOR CO.

    27. ALL TRANSMISSIONS 

  27. Install the No. 16 bearing and race.
    Fig 28: Installing No. 16 Bearing And Race
    G03381397Courtesy of FORD MOTOR CO.
  28. Install the ring gear, hub and the No. 15 hub bearing.
    Fig 29: Installing Ring Gear, Hub And No. 15 Hub Bearing
    G03381398Courtesy of FORD MOTOR CO.
  29. Install the reverse carrier and hub assembly.
    Fig 30: Installing Reverse Carrier And Hub Assembly
    G03381399Courtesy of FORD MOTOR CO.
  30. Install the low/reverse clutch plates.
    • Start with a steel plate on the bottom, followed by a friction plate.
    • Alternately stack the remaining steel and friction plates.
    • Add the pressure plate (low/reverse one way clutch) on the last friction plate with THIS SIDE UP facing upward.
      Fig 31: Installing Low/Reverse Clutch Plates
      G03381400Courtesy of FORD MOTOR CO.
    31. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, damage to the snap ring will occur.
  31. Install the new snap ring. Make sure the snap ring opening is in the one o'clock position, between 2 teeth on the case.
    • Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.
      Fig 32: Installing New Snap Ring
      G03381401Courtesy of FORD MOTOR CO.
  32. Using the special tools, install the forward geartrain as an assembly.
    Fig 33: Installing Forward Geartrain An Assembly Using Special Tool
    G03381402Courtesy of FORD MOTOR CO.
  33. Install the intermediate clutch pressure plate.
    • Position the intermediate clutch pressure plate in the case with the stepped edge facing downward.
      Fig 34: Installing Intermediate Clutch Pressure Plate
      G03381403Courtesy of FORD MOTOR CO.
  34. Install the intermediate clutch plates, starting with a friction plate.
    35. Fig 35: Installing Intermediate Clutch Plates, Starting With Friction Plate
    G03381404Courtesy of FORD MOTOR CO.
  35. Install the center support.
    Fig 36: Installing Center Support
    G03381405Courtesy of FORD MOTOR CO.
  36. Loosely install the feed bolts.
    Fig 37: Installing Feed Bolts
    G03381406Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the center support snap ring.
    • The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the six o'clock position. Tap the snap ring securely into the case.
      Fig 38: Installing Center Support Snap Ring Using Special Tool
      G03381407Courtesy of FORD MOTOR CO.
  38. Tighten the feed bolts.
    Fig 39: Tightening Feed Bolts
    G03381408Courtesy of FORD MOTOR CO.
  39. Install the No. 5 thrust bearing onto the center support.
    Fig 40: Installing No. 5 Thrust Bearing Onto Center Support
    G03381409Courtesy of FORD MOTOR CO.
  40. Install the center shaft and ring gear.
    Fig 41: Installing Center Shaft And Ring Gear
    G03381410Courtesy of FORD MOTOR CO.
  41. Install the No. 4 thrust bearing onto the center shaft.
    Fig 42: Installing No. 4 Thrust Bearing Onto Center Shaft
    G03381411Courtesy of FORD MOTOR CO.
  42. Using the special tool, install the coast clutch assembly and overdrive carrier.
    Fig 43: Installing Coast Clutch Assembly And Overdrive Carrier
    G03381412Courtesy of FORD MOTOR CO.
  43. Install the overdrive clutch assembly snap ring with the gap in the six o'clock position.
    Fig 44: Installing Overdrive Clutch Assembly Snap Ring With Gap In Six O'Clock Position
    G03381413Courtesy of FORD MOTOR CO.
  44. Install the overdrive pressure plate with the notches facing up.
    Fig 45: Installing Overdrive Pressure Plate With Notches Facing Up
    G03381414Courtesy of FORD MOTOR CO.
  45. Install the overdrive clutch.
    • Start with a friction plate, alternating with a steel plate.
      Fig 46: Installing Overdrive Clutch
      G03381415Courtesy of FORD MOTOR CO.
  46. Install a new pump gasket.
    Fig 47: Installing New Pump Gasket
    G03381416Courtesy of FORD MOTOR CO.
  47. Install the No. 2 thrust bearing.
    Fig 48: Installing No. 2 Thrust Bearing
    G03381417Courtesy of FORD MOTOR CO.
  48. Install the input shaft into the case.
    Fig 49: Installing Input Shaft Into Case
    G03381418Courtesy of FORD MOTOR CO.
  49. Install the special tools into the case in order to install the pump.
    Fig 50: Installing Special Tools Into Case In Order
    G03381419Courtesy of FORD MOTOR CO.
  50. Check to make sure that the No. 1 thrust washer is installed on the pump stator.
  51. Using the special tools, install the pump assembly.
    Fig 51: Installing Pump Assembly Using Special Tool
    G03381420Courtesy of FORD MOTOR CO.
  52. Install new retaining bolts.
    Fig 52: Installing Retaining Bolts
    G03381421Courtesy of FORD MOTOR CO.
  53. Install a new main control body gasket.
    Fig 53: Installing Main Control Body Gasket
    G03381422Courtesy of FORD MOTOR CO.
  54. Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.
    Fig 54: Checking Function Of Each Clutch
    G03381423Courtesy of FORD MOTOR CO.
  55. Use petroleum jelly to hold the forward clutch orifice in place on the top of the forward clutch feed bolt.
    Fig 55: Identifying Forward Clutch Feed Bolt
    G03381424Courtesy of FORD MOTOR CO.
  56. Using the special tools, install the solenoid body and loosely install the bolts.
    • While installing the solenoid body, align the manual valve.
      Fig 56: Installing Solenoid Body And Bolts
      G03381425Courtesy of FORD MOTOR CO.
  57. Tighten all the bolts in the sequence shown.
    Fig 57: Tightening Bolts In Sequence
    G03381426Courtesy of FORD MOTOR CO.
  58. Connect the transmission range sensor connector.
    Fig 58: Connecting Transmission Range Sensor Connector
    G03381427Courtesy of FORD MOTOR CO.
    59. NOTE: Prior to installing the fluid filter, make sure that the old seal is not stuck in the case.
    Fig 59: Installing New Transmission Fluid Filter
    G03381428Courtesy of FORD MOTOR CO.
  59. Install a new transmission fluid filter.
    60. NOTE: Do not discard the fluid pan gasket. It is reusable.
    Fig 60: Installing Transmission Fluid Pan Gasket To Fluid Pan
    G03381429Courtesy of FORD MOTOR CO.
  60. Install the transmission fluid pan gasket to the fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
  61. Install the transmission fluid pan.
    Fig 61: Installing Transmission Fluid Pan
    G03381430Courtesy of FORD MOTOR CO.
  62. Install the intermediate shaft and turbine shaft speed (TSS) sensor.
    Fig 62: Installing Intermediate Shaft And Turbine Shaft Speed (TSS) Sensor
    G03381431Courtesy of FORD MOTOR CO.
  63. Install the output shaft speed (OSS) sensor.
    Fig 63: Installing Output Shaft Speed (OSS) Sensor
    G03381432Courtesy of FORD MOTOR CO.
    64. CAUTION: Do not damage the fluid pump gear O-ring when installing the 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 may be damaged.
    Fig 64: Lubricating Converter Hub With Clean Automatic Transmission Fluid
    G03381433Courtesy of FORD MOTOR CO.
  64. Lubricate the converter hub with clean automatic transmission fluid.
    65. CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.
    NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.
    Fig 65: Installing Torque Converter Using Special Tool
    G03381434Courtesy of FORD MOTOR CO.
  65. Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
  66. Check the seating of the torque converter.
    1. Place the straightedge across the converter housing.
    2. Make sure there is a gap between the converter pilot face and the straightedge.
    3. Remove the special tools.
    Fig 66: Identifying Special Tools
    G03381435Courtesy of FORD MOTOR CO.
  67. Use the special tool to hold the torque converter in place when installing the transmission.
    Fig 67: Using Special Tool To Hold Torque Converter
    G03381436Courtesy of FORD MOTOR CO.
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