Pump Assembly: Disassembly

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.

Using the special tools, remove and discard the front pump seal.

Fig 1: Removing Front Pump Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Remove and discard the front pump stator support seal.

Fig 2: Removing Front Pump Stator Support Seal
Courtesy of FORD MOTOR CO.
Remove and discard the two seals.

Fig 3: Removing Two Seals
Courtesy of FORD MOTOR CO.
Remove and discard the pump outer diameter square-cut front pump seal.

Fig 4: Removing Pump Outer Diameter Square-Cut Front Pump Seal
Courtesy of FORD MOTOR CO.

NOTE: Note the location of the bolts for assembly.

Fig 5: Removing Overdrive Piston Return Spring

Courtesy of FORD MOTOR CO.

Remove the overdrive piston return spring.
Remove and discard the overdrive piston.

Fig 6: Removing Overdrive Piston
Courtesy of FORD MOTOR CO.
Remove bolts and separate the pump control body from the pump body.

Fig 7: Removing Bolts And Separating Pump Control Body From Pump Body
Courtesy of FORD MOTOR CO.

NOTE: If the pump or plate shows any signs of wear or scoring, a new pump assembly must be installed.

Fig 8: Removing And Inspecting Plate

Courtesy of FORD MOTOR CO.

Remove and inspect the plate.

CAUTION: Do not remove any of the remaining cup plugs unless directed to do so in other steps. Do not remove the stator support from the control body. This can distort the surface of the control body.

Remove 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. Remove the retainer clip with a small screwdriver, then remove the main regulator plug, spring and valve.
2. Remove the retainer clip with a small screwdriver, then remove the converter anti-drain back plug, spring and valve.
3. Remove the retainer clip with a small screwdriver, then remove the converter pressure limit plug, spring and valve.
4. Remove the retainer clip with a small screwdriver, then remove thermostat plug, spring and valve.
5. Remove the cooler bypass valve.
6. Remove the retainer clip with a small magnet or screwdriver, then remove the converter clutch control plug with shuttle valve, spring retainer and valve.
  
  Fig 9: Removing Converter Clutch Control Valve, Cooler Bypass Valve And Valve, Converter Pressure Limit Valve
  Courtesy of FORD MOTOR CO.
Remove and inspect the inner and the outer gerotor gears.
- Clean all pump parts in solvent.
- Dry the parts with compressed air.
- Inspect the pump gears, faces, gear teeth, pump housing and mating surfaces for damage or scoring.
- If any parts are damaged or worn, install a new pump.
  
  Fig 10: Inspecting Pump Gears, Faces, Gear Teeth, Pump Housing
  Courtesy of FORD MOTOR CO.
Inspect the converter hub bushing. If scored or excessively worn, install a new pump. Note the orientation of the notch in the bushing. It must face up.

Fig 11: Inspecting Converter Hub Bushing
Courtesy of FORD MOTOR CO.
Inspect the front input shaft bushing. If the bushing is worn or scored, install a new pump.

Fig 12: Inspecting Front Input Shaft Bushing
Courtesy of FORD MOTOR CO.
Inspect the rear input shaft bushing for wear. If scored or worn, install a new pump.

Fig 13: Inspecting Rear Input Shaft Bushing For Wear
Courtesy of FORD MOTOR CO.
Inspect the following:
- All valve and plug bores for scoring or damage.
- All passages for obstructions.
- Mating surfaces for burrs and scoring.
- All springs for distortion.
- When dry, check all valves and plugs for free movement in their respective bores.