Pump Assembly: Assembly

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.

NOTE: All the valves should drop into their bores freely without hanging up.

Install the converter clutch control valve, cooler bypass valve and thermostat valve, converter pressure limit valve, converter anti-drain back valve and the main regulator valve.
1. Install the main regulator boost valve spring, plug and install the retainer clip.
2. Install the converter anti-drain back valve, spring, plug and install the retainer clip.
3. Install the converter pressure limit valve, spring, plug and install the retainer clip.
4. Install the thermostat spring and valve.
5. Install the cooler bypass valve, plug and clip.
6. Install the converter clutch control valve, spring, plug and install the retainer clip.
  
  Fig 1: Installing Converter Clutch Control Valve, Spring, Plug
  Courtesy of FORD MOTOR CO.

NOTE: Prior to installation, lightly lubricate the gerotor gears with clean automatic transmission fluid.

Fig 2: Installing Gerotor Gearset With Both Dots Facing Up

Courtesy of FORD MOTOR CO.

Install the gerotor gearset with both dots facing up.
Using the special tool, measure the pump gear to pump body clearance.

Fig 3: Measuring Pump Gear To Pump Body Clearance
Courtesy of FORD MOTOR CO.
Install the separator plate.

Fig 4: Installing Separator Plate
Courtesy of FORD MOTOR CO.

CAUTION: Prior to pump assembly, make sure all cup plugs are installed.

CAUTION: Inspect mating surfaces of the pump body and the control body to make sure they are clean and free of nicks and burrs.

NOTE: Note the location of the alignment pins. The alignment pins should move freely when installing the band strap.

Fig 5: Assembling Control Body And Stator Assembly Onto Pump Body

Courtesy of FORD MOTOR CO.

Using the special tools, assemble the control body and stator assembly onto the pump body.

NOTE: Make sure that the outer edges of the pump body and the outer bolt holes are aligned during assembly.

Assemble the pump and loosely install the bolts.
- Check that the outer edges of the pump body and the bolt holes are aligned. Tighten the bolts.
  
  Fig 6: Checking Outer Edges Of Pump Body And Bolt Holes Aligned
  Courtesy of FORD MOTOR CO.
Lubricate and install a new overdrive piston.

Fig 7: Installing Overdrive Piston
Courtesy of FORD MOTOR CO.
Install the overdrive piston return spring.

Fig 8: Installing Overdrive Piston Return Spring
Courtesy of FORD MOTOR CO.
Install new pump seals.

Fig 9: Installing Pump Seals
Courtesy of FORD MOTOR CO.
Install the pump outer diameter square-cut front pump seal with the white stripe facing out.

Fig 10: Installing Pump Outer Diameter Square-Cut Front Pump Seal
Courtesy of FORD MOTOR CO.
Install the a new front pump seal, using the special tool.

Fig 11: Installing Front Pump Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Install a new front pump stator support seal.

Fig 12: Installing Front Pump Stator Support Seal
Courtesy of FORD MOTOR CO.

NOTE: Lightly lubricate the thrust washer and the bearing with petroleum jelly to hold them in place during assembly.

Fig 13: Installing No. 1 Pump Thrust Washer And No. 2A Overdrive Sun Gear Thrust Bearing

Courtesy of FORD MOTOR CO.

Install the No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing.