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

Special Tool(s) 

Fig 1: Identifying Special Tool (1 Of 2)

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Fig 2: Identifying Special Tool (2 Of 2)

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1. Remove the special tool.
   Fig 3: Removing Special Tool

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WARNING: Use the special tools when removing the torque converter because it is very heavy. Failure to follow may result in personal injury.
NOTE: Fluid loss will occur when removing the torque converter.
Fig 4: Removing Torque Converter Using Special Tool
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2. Using the special tools, remove the torque converter.
3. Remove the intermediate shaft and turbine shaft speed combination sensor.
   1. Remove the bolt.
   2. Remove the sensor.
      Fig 5: Removing Bolt And Sensor

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4. Remove the output shaft speed sensor (OSS).
   1. Remove the bolt.
   2. Remove the output shaft speed sensor (OSS).
      Fig 6: Removing Output Shaft Speed Sensor (OSS)

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5. Mount the transmission onto a suitable stand.
6. Remove the input shaft. Remove and discard the stator support seal.
   Fig 7: Removing Input Shaft

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7. Install a new drain plug and seal if there is evidence of leaking.
   Fig 8: Installing Drain Plug And Seal

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NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
Fig 9: Removing Transmission Fluid Pan And Gasket
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8. Remove the transmission fluid pan and the gasket. Check and clean the magnet if debris is evident.
NOTE: After removal, discard the filter and seal assembly.
Fig 10: Removing Filter And Seal Assembly
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9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
CAUTION: There is no retainer on the manual valve. Hold the manual valve in place while removing the solenoid assembly from the transmission to avoid dropping the valve.
10. Remove the solenoid body.
    1. Disconnect the transmission range sensor.
    2. Remove the solenoid body bolts.
    3. Remove the solenoid body.
       Fig 11: Removing Solenoid Body Bolts And Solenoid Body

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11. Remove and discard the solenoid body gasket.
    Fig 12: Removing Solenoid Body Gasket

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12. Remove the forward clutch orifice.
    Fig 13: Removing Forward Clutch Orifice

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13. Remove the feedbolts.
    Fig 14: Removing Feedbolts

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14. Remove and discard the front pump bolts.
    Fig 15: Removing Front Pump Bolts

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15. Using the special tools, remove the front pump.
    Fig 16: Removing Front Pump Using Special Tool

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NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
16. 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.
       Fig 17: Removing Pump Gasket

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17. Remove the overdrive separator plates, clutch plates and overdrive pressure plate.
    Fig 18: Removing Overdrive Separator Plates, Clutch Plates And Overdrive Pressure Plate

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18. Remove the overdrive clutch retaining ring.
    Fig 19: Removing Overdrive Clutch Retaining Ring

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19. Install the special tool.
    Fig 20: Installing Special Tool

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NOTE: The No. 3 overdrive carrier thrust bearing and race assembly may come out with the coast clutch cylinder assembly or it may stay in the transmission.
Fig 21: Removing Coast Clutch Cylinder Assembly
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20. Using the special tool, remove the coast clutch cylinder assembly.
21. Remove the No. 4 thrust bearing.
    Fig 22: Removing No. 4 Thrust Bearing

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22. Remove the overdrive ring gear and center shaft.
    Fig 23: Removing Overdrive Ring Gear And Center Shaft

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23. Remove the No. 5 sun gear thrust bearing.
    Fig 24: Removing No. 5 Sun Gear Thrust Bearing

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24. Using the special tool, remove the center support retaining ring.
    Fig 25: Removing Center Support Retaining Ring Using Special Tool

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25. Install the special tools into the center support assembly.
    Fig 26: Installing Special Tools Into Center Support Assembly

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26. Using the special tools, remove the center support, direct clutch and forward clutch cylinder assembly.
    Fig 27: Removing Center Support, Direct Clutch And Forward Clutch Cylinder Assembly

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27. Remove the forward clutch hub No. 9 thrust washer.
    Fig 28: Removing Forward Clutch Hub No. 9 Thrust Washer

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28. Remove the forward ring gear and hub assembly.
    Fig 29: Removing Forward Ring Gear And Hub Assembly

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29. Remove the forward carrier race and the No. 11 bearing assembly.
    Fig 30: Removing Forward Carrier Race And No. 11 Bearing Assembly

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30. Remove the forward carrier.
    Fig 31: Removing Forward Carrier

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31. Remove the sun gear and the No. 12 thrust bearing.
    Fig 32: Removing Sun Gear And No. 12 Thrust Bearing

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32. Remove the low reverse sun gear and shell assembly.
    Fig 33: Removing Low Reverse Sun Gear And Shell Assembly

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33. Remove and discard the low reverse clutch retaining ring.
    Fig 34: Removing Low Reverse Clutch Retaining Ring

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34. Remove the low reverse one-way clutch, clutch pack, carrier and hub assembly.
    Fig 35: Removing Low Reverse One-Way Clutch, Clutch Pack, Carrier And Hub Assembly

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35. Remove the No. 15 thrust bearing and hub.
    Fig 36: Removing No. 15 Thrust Bearing And Hub

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36. Remove the output hub and ring gear.
37. Place the transmission manual lever in park to lock the output shaft from rotating.
38. Remove the low reverse No.16 thrust bearing.
    Fig 37: Removing Low Reverse No.16 Thrust Bearing

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39. If equipped, remove the output shaft flange.
    1. Remove and discard the bolt.
    2. Remove the output shaft flange.
       Fig 38: Removing Output Shaft Flange

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40. If equipped, use the special tool to remove and discard the output shaft nut.
    Fig 39: Removing Output Shaft Nut

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41. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
    Fig 40: Removing Output Shaft Seal

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42. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
    Fig 41: Removing Output Shaft Seal

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43. Remove the nine bolts and the extension housing.
    Fig 42: Removing Nine Bolts And Extension Housing

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44. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.
    Fig 43: Installing Extension Housing and Checking Output Shaft Journal

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45. Remove and discard the extension housing gasket.
    Fig 44: Removing Extension Housing Gasket

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46. Remove the output shaft.
    Fig 45: Removing Output Shaft

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47. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing
    Fig 46: Removing No. 17 Park Gear Thrust Washer

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CAUTION: Do not fully compress the return spring or damage to the spring may occur.
Fig 47: Removing Reverse Clutch Drum Retaining Ring Using Special Tool
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48. Using the special tool, remove the reverse clutch drum retaining ring.
49. Remove the return spring.
    Fig 48: Removing Return Spring

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50. While applying air to the case, remove and discard the reverse piston.
    Fig 49: Removing Reverse Piston

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51. Remove the parking rod guide plate bolts and plate.
    Fig 50: Removing Parking Rod Guide Plate Bolts And Plate

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52. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 51: Removing Plastic Orifice Lube Plug From Rear Of Case

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53. Remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
       Fig 52: Removing Parking Pawl Shaft, Pawl And Return Spring

       Courtesy of FORD MOTOR CO.
CAUTION: The Torx-head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new bolt installed.
Fig 53: Removing Parking Pawl Abutment
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54. Remove the parking pawl abutment.
NOTE: The pin should be driven down into the case.
Fig 54: Removing Manual Lever Shaft Retaining Pin
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55. Using a suitable tool, remove and discard the manual lever shaft retaining pin.
56. Using the special tool, remove the manual lever shaft retaining pin.
    Fig 55: Removing Manual Lever Shaft Retaining Pin

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57. Remove the manual control lever shaft.
    Fig 56: Removing Manual Control Lever Shaft

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58. Remove the transmission range sensor, manual control lever and park rod as an assembly.
    Fig 57: Removing Transmission Range Sensor, Manual Control Lever And Park Rod

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59. Using the special tool, remove and discard the manual control lever seal.
    Fig 58: Removing Manual Control Lever Seal Using Special Tool

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NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
Fig 59: Removing Short Fluid Inlet Tube
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60. If required, remove the short fluid inlet tube.
NOTE: The top portion seal groove will work the best when removing the seal pack.
Fig 60: Removing Seal Retainer Using Special Tool
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61. Inspect the rear case Teflon seal retainer for damage. If damage is evident, use the special tool to remove the seal retainer.
62. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly and all fluid passages for obstructions.
63. Inspect the rear case snubber bushing. If damage is found, install a new transmission case.
64. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
65. Inspect the reverse clutch case vent for blockage. The vent is located in the case at the 12 o'clock position. If evidence of blockage is found, use low air pressure to clear out the blockage by applying air to the extension side of the vent.