Torque Converter Housing, Reverse Clutch and Pump Assembly - Disassembly: Disassembly

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Reverse Clutch Assembly - Disassembled View

Courtesy of FORD MOTOR CO.

Torque converter housing

Remove the lube tube bolt and remove the secondary shaft and stator needle bearing lube tube from the case.

Fig 2: Removing Lube Tube Bolt And Secondary Shaft
Courtesy of FORD MOTOR CO.
Remove the bolt from the lube tube and discard both the sealing washers.

Fig 3: Removing Bolt From Lube Tube
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seals from the lube tube.

Fig 4: Removing O-Ring Seals From Lube Tube
Courtesy of FORD MOTOR CO.

NOTE: A new roller bearing will need to be installed only if damage is indicated, worn or sufficient contamination is present.

Fig 5: Removing Secondary Variator Shaft Roller Bearing Cage

Courtesy of FORD MOTOR CO.

If required, remove the secondary variator shaft roller bearing cage from the outer race.
If required, use the special tool and remove the roller bearing race.

Fig 6: Removing Roller Bearing Race
Courtesy of FORD MOTOR CO.

NOTE: A new roller bearing will need to be installed only if damage is indicated, worn or sufficient contamination is present.

Fig 7: Removing Side Shaft Gear Roller Bearing Cage

Courtesy of FORD MOTOR CO.

If required, remove the side shaft gear roller bearing cage from the outer race.
Using the special tools, remove the bearing race.

Fig 8: Removing Bearing Race
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Using a center punch, knock out the differential seal.

Fig 9: Removing Differential Seal Using Center Punch
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Install the special tool.

Fig 10: Installing Special Tool
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NOTE: There is a selective shim under the bearing race that will fall out when removing the bearing race. Be careful not to lose the shim.

Fig 11: Removing Bearing Race

Courtesy of FORD MOTOR CO.

The selective shim and bearing race will be installed in the case during assembly of the transaxle after differential set up is completed.
From the other side of the case, use a brass punch and knock out the bearing race.

Reverse clutch

Remove the reverse clutch plate snap ring.

Fig 12: Removing Reverse Clutch Plate Snap Ring
Courtesy of FORD MOTOR CO.
Remove the reverse clutch ring gear and the friction plates, steel plates, separator plate and wave spring.

Fig 13: Removing Reverse Clutch Ring Gear And Friction Plates
Courtesy of FORD MOTOR CO.
Using the special tool, remove the return spring retainers.

Fig 14: Removing Return Spring Retainers
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Remove the return spring.

Fig 15: Removing Return Spring
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NOTE: A small amount of air pressure may be needed to remove the reverse clutch piston from the drum. Be careful when using the air pressure. Use only regulated air pressure

Remove the reverse clutch piston.
1. Apply a small amount of air pressure.
2. Remove the reverse clutch piston.
  
  Fig 16: Removing Reverse Clutch Piston
  Courtesy of FORD MOTOR CO.
Remove and discard the reverse clutch piston inner and outer O-ring seals.

Fig 17: Removing Reverse Clutch Piston Inner And Outer O-Ring Seals
Courtesy of FORD MOTOR CO.
Clean and inspect all the reverse clutch parts and install new as required.

Stator assembly

NOTE: If the installation of a new stator or pump is being carried out, the reverse clutch plates, piston and return spring must be removed.

Fig 18: Removing Roller Bearing Cage Assembly From Outer Race

Courtesy of FORD MOTOR CO.

Remove and discard the roller bearing cage assembly from the outer race.
Using the special tools, remove and discard the roller bearing race.

Fig 19: Removing Roller Bearing Race
Courtesy of FORD MOTOR CO.
Remove the 7 bolts from the stator.

Fig 20: Removing Bolts From Stator
Courtesy of FORD MOTOR CO.
From the opposite side of the case, use a dead blow hammer and tap the stator assembly out of the case.

Fig 21: Removing Stator Assembly
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Inspect the stator assembly for damage, if damage is indicated install new components.

Pump assembly

NOTE: The pump dust cover can be removed using a small punch from the opposite side of the case.

Fig 22: Removing Pump Dust Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 pump dust cover bolts and remove and discard the cover.
Remove the 8 bolts and the pump assembly.

Fig 23: Removing Bolts And Pump Assembly
Courtesy of FORD MOTOR CO.
Remove the pump gasket and the feed tube.

Fig 24: Removing Pump Gasket And Feed Tube
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seals from the ends of the feed tube.

Fig 25: Removing O-Ring Seals From Ends Of Feed Tube
Courtesy of FORD MOTOR CO.

NOTE: Be careful not to damage the sealing surfaces of the pump.

NOTE: If the pump is going to be reused, the pump/torque converter seal should be removed.

Fig 26: Removing Pump/Torque Converter Seal

Courtesy of FORD MOTOR CO.

Using a suitable tool, remove the pump/torque converter seal.