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Section 974 (Automatic Transmission -- F150 Pickup): Disassembly: Transmission

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G03889235
 Retainer, Torque Converter 307-346 (T97T-7902-A)
G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03912866
 Holding Fixture, Transmission 07-003 (T57L-500-B)
G03990108
 Slide Hammer 307-005 (T59L-100-B)
G03888701
 Remover, Transmission Fluid Seal 307-048 (T74P-77248-A)
G03914889
 Handle, Torque Converter 307-091 (T81P-7902-C)
G03964078
 Remover, Transmission Fluid Pump 307-221 (T89T-70010-A)
G03929773
 Remover/Installer, Servo Piston 307-251 (T92P-70023-A)
G03888701
 Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH)
G03960920
 Remover, Bearing Cup 308-047 (T77F-1102-A)
  1. If equipped, remove the vent tube.
  2. Remove the special tool.
    Fig 1: Removing Special Tool
    G03908389Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove torque converter.
    Fig 2: Removing Torque Converter Using Special Tools
    G03882883Courtesy of FORD MOTOR CO.
  4. Using the special tool, mount the transmission to the bench.
    Fig 3: Mounting Transmission To Bench Using Special Tool
    G04016831Courtesy of FORD MOTOR CO.
    5. NOTE: If the transmission fluid pan gasket is not damaged, it can be reused.
    Fig 4: Removing Transmission Fluid Pan And Transmission Fluid Pan Gasket
    G03888706Courtesy of FORD MOTOR CO.
  5. Remove the transmission fluid pan and transmission fluid pan gasket.
    1. Remove the bolts.
    2. Remove the transmission fluid pan and transmission fluid pan-to-case gasket.
  6. Clean the transmission fluid pan and pan magnet.
    Fig 5: Cleaning Transmission Fluid Pan And Pan Magnet
    G03888537Courtesy of FORD MOTOR CO.
    7. CAUTION: If installing a new filter and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter can be reused if no excessive contamination is present.
    Fig 6: Removing Fluid Filter And Grommet
    G04016834Courtesy of FORD MOTOR CO.
  7. Remove the fluid filter and grommet.
    8. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
    Fig 7: Disconnecting Molded Lead Frame From Solenoids
    G03888595Courtesy of FORD MOTOR CO.
  8. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead inter-connector.
  9. Remove the speed sensors.
    • Remove the output shaft speed (OSS) sensor bolt.
    • Remove the OSS sensor.
    • Remove the turbine shaft speed (TSS) sensor bolt.
    • Remove the TSS sensor bracket and sensor.
    Fig 8: Removing Speed Sensors
    G03882630Courtesy of FORD MOTOR CO.
    10. CAUTION: Discard the manual lever shaft outer nut. Do not reuse.
    Fig 9: Removing Outer Manual Control Lever
    G03964090Courtesy of FORD MOTOR CO.
  10. Remove the outer manual control lever.
    1. Remove the manual lever shaft outer nut.
    2. Remove the outer manual control lever.
  11. Remove the digital transmission range (TR) sensor.
    1. Remove the digital TR sensor bolts.
    2. Remove the digital TR sensor.
    Fig 10: Removing Digital Transmission Range (TR) Sensor
    G03888711Courtesy of FORD MOTOR CO.
  12. Remove the manual control valve detent lever spring.
    1. Remove the manual control valve detent lever spring bolt.
    2. Remove the manual control valve detent lever spring.
    Fig 11: Removing Manual Control Valve Detent Lever Spring
    G03888712Courtesy of FORD MOTOR CO.
  13. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 12: Removing 24 Main Control Valve Body Bolts And Main Control Valve Body
    G03882633Courtesy of FORD MOTOR CO.
  14. Remove and discard the pump outlet screen.
    Fig 13: Removing Pump Outlet Screen
    G03888559Courtesy of FORD MOTOR CO.
    15. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 14: Removing Manual Lever Shaft Retaining Pin
    G03888608Courtesy of FORD MOTOR CO.
  15. Remove the manual lever shaft retaining pin.
  16. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    Fig 15: Removing Manual Lever Shaft Inner Nut
    G03888609Courtesy of FORD MOTOR CO.
  17. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    Fig 16: Removing Parking Lever Actuating Rod
    G03888717Courtesy of FORD MOTOR CO.
    18. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged the new seal may leak.
    Fig 17: Removing Manual Control Lever Shaft Seal
    G03929870Courtesy of FORD MOTOR CO.
  18. Remove the manual control lever shaft seal.
  19. Remove the EPC solenoid.
    Fig 18: Removing EPC Solenoid
    G03929871Courtesy of FORD MOTOR CO.
  20. Remove the 2-3 accumulator spring retainer.
    Fig 19: Removing 2-3 Accumulator Spring Retainer
    G03888720Courtesy of FORD MOTOR CO.
  21. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    Fig 20: Removing 2-3 Accumulator Piston And Spring
    G04016847Courtesy of FORD MOTOR CO.
  22. Using the special tool, remove the reverse band servo retaining ring.
    Fig 21: Removing Reverse Band Servo Retaining Ring Using Special Tool
    G03882642Courtesy of FORD MOTOR CO.
  23. Remove the reverse band servo.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod assembly.
    3. Remove the reverse band servo spring.
    Fig 22: Removing Reverse Band Servo
    G03888723Courtesy of FORD MOTOR CO.
    24. CAUTION: If the tool is not available, extreme care must be taken. Spring pressure will force the overdrive servo piston assembly out of the case. Case bore damage may result from trying to pry on the internal retaining ring.
    Fig 23: Using Special Tool To Remove Overdrive Servo Piston Retainer
    G03882644Courtesy of FORD MOTOR CO.
  24. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  25. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    Fig 24: Removing Overdrive Servo Piston
    G04016851Courtesy of FORD MOTOR CO.
  26. Compress the 1-2 accumulator cover and remove the 1-2 accumulator piston retaining ring.
    Fig 25: Compressing 1-2 Accumulator Cover And Removing 1-2 Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
  27. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the inner and outer 1-2 accumulator springs.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    Fig 26: Removing 1-2 Accumulator Upper Spring
    G03929879Courtesy of FORD MOTOR CO.
  28. Using the special tools, remove the extension housing seal.
    Fig 27: Removing Extension Housing Seal Using Special Tools
    G03882648Courtesy of FORD MOTOR CO.
    29. NOTE: The 4x2 extension is shown, the 4x4 extension housing is similar.
    NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
    Fig 28: Removing Extension Housing
    G03888729Courtesy of FORD MOTOR CO.
  29. Remove the extension housing.
    1. Remove the 4 bolts and 2 nuts.
    2. Remove the extension housing and the extension housing gasket.
  30. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    Fig 29: Removing Parking PAWL
    G04016856Courtesy of FORD MOTOR CO.
  31. Rotate the transmission to the vertical position with the output shaft toward the floor.
    32. CAUTION: Extreme care must be taken during transmission connector removal. Do not pull on wires or use a hammer on the connector body.
    Fig 30: Placing Screwdriver On Flat Portion Of Connector And Pushing Connector Out Through Bottom Of Case
    G03888731Courtesy of FORD MOTOR CO.
  32. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  33. Using the special tools, remove the front pump seal.
    Fig 31: Removing Front Pump Seal Using Special Tools
    G03888732Courtesy of FORD MOTOR CO.
    34. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 32: Removing Front Bolts
    G03888733Courtesy of FORD MOTOR CO.
  34. Remove the front bolts.
  35. Using the special tools, remove the front pump support.
    Fig 33: Removing Front Pump Support Using Special Tools
    G03882654Courtesy of FORD MOTOR CO.
  36. Remove and discard the pump gasket.
    • Remove the intermediate clutch piston return spring.
    • Remove the intermediate clutch piston return spring support.
  37. If equipped, remove the intermediate clutch anti-rattle clip.
    Fig 34: Removing Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
    38. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
  38. Remove the following components as an assembly:
    • Intermediate clutch pack
    • Intermediate one-way clutch
    • Reverse clutch
    • Forward clutch assembly
      Fig 35: Removing Forward Clutch Assembly
      G03888736Courtesy of FORD MOTOR CO.
  39. Disengage and remove the overdrive band.
    Fig 36: Removing Overdrive Band
    G03888737Courtesy of FORD MOTOR CO.
  40. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 37: Removing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G03888738Courtesy of FORD MOTOR CO.
  41. Remove the intermediate stub shaft.
    Fig 38: Removing Intermediate Stub Shaft
    G03888739Courtesy of FORD MOTOR CO.
  42. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 39: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin For Removal
    G04016866Courtesy of FORD MOTOR CO.
  43. Remove the following components as an assembly:
    • Forward clutch sun gear
    • No. 5 forward clutch sun gear bearing
    • Reverse clutch sun gear
    • No. 4 forward clutch hub bearing
    Fig 40: Removing Assembly Components
    G03888741Courtesy of FORD MOTOR CO.
  44. Remove the center support retaining ring and note location for assembly.
    Fig 41: Removing Center Support Retaining Ring
    G03888742Courtesy of FORD MOTOR CO.
  45. Remove the case-to-planet support spring.
    Fig 42: Removing Case-To-Planet Support Spring
    G03888743Courtesy of FORD MOTOR CO.
  46. Remove the planetary gear support and planetary as an assembly.
    Fig 43: Removing Planetary Gear Support And Planetary Assembly
    G03888744Courtesy of FORD MOTOR CO.
  47. Remove the reverse clutch band.
    Fig 44: Removing Reverse Clutch Band
    G03888745Courtesy of FORD MOTOR CO.
  48. Remove the retaining ring.
    Fig 45: Removing Retaining Ring
    G03888746Courtesy of FORD MOTOR CO.
  49. Remove the direct clutch pack.
    Fig 46: Removing Direct Clutch Pack
    G03888747Courtesy of FORD MOTOR CO.
  50. Remove the No. 8 bearing.
    Fig 47: Removing No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  51. Remove the output shaft and output shaft ring gear assembly.
    Fig 48: Removing Output Shaft And Output Shaft Ring Gear Assembly
    G03888749Courtesy of FORD MOTOR CO.
  52. Remove the No. 9 case rear bearing.
    Fig 49: Removing No. 9 Case Rear Bearing
    G03888750Courtesy of FORD MOTOR CO.
  53. Inspect and if necessary, using the special tools, remove the rear case bushing.
    Fig 50: Removing Rear Case Bushing Using Special Tools
    G03888751Courtesy of FORD MOTOR CO.
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