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Section 2177 (Automatic Transmission - 5R110W -- F250-F550 Super Duty): Disassembly: Transmission: Disassembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the special tool.
    2. Fig 1: Holding Torque Converter Using Special Tool
    GF0006858Courtesy of FORD MOTOR CO.
    WARNING: Use the special tools when removing the torque converter because it is very heavy. Failure to follow this instruction may result in personal injury.
    NOTE: Fluid loss will occur when removing the torque converter.
  2. Using the special tools, remove the torque converter.
    3. Fig 2: Installing Torque Converter
    GF0006859Courtesy of FORD MOTOR CO.
  3. Remove the turbine shaft speed (TSS) and intermediate shaft speed combination sensor.
    • Remove the bolt.
    • Remove the sensor.
    4. Fig 3: Identifying TSS And Intermediate Shaft Combination Speed Sensor
    GF0006802Courtesy of FORD MOTOR CO.
  4. Remove the output shaft speed (OSS) sensor.
    • Remove the bolt.
    • Remove the OSS.
    5. Fig 4: Identifying Output Shaft Speed (OSS) Sensor
    GF0006807Courtesy of FORD MOTOR CO.
  5. Mount the transmission onto a suitable stand.
  6. Remove the input shaft.
    7. Fig 5: Removing The Input Shaft
    GF0006860Courtesy of FORD MOTOR CO.
  7. Install a new drain plug and seal assembly if there is evidence of leaking.
    8. Fig 6: Identifying Transmission Fluid Drain Plug
    G03889033Courtesy of FORD MOTOR CO.
    NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
  8. Remove the transmission fluid pan and the gasket. Check and clean the magnet if foreign material is evident.
    9. Fig 7: Identifying Transmission Fluid Pan Bolts
    G03889037Courtesy of FORD MOTOR CO.
    NOTE: After removal, discard the filter and seal assembly.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
    10. Fig 8: View Of Transmission Fluid Filter
    G03889290Courtesy of FORD MOTOR CO.
    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.
    • Disconnect the transmission range (TR) position sensor.
    • Remove the solenoid body bolts.
    • Remove the solenoid body.
    11. Fig 9: Locating Solenoid Body Bolts
    GF0006794Courtesy of FORD MOTOR CO.
  11. Remove and discard the solenoid body gasket.
    12. Fig 10: Identifying Main Control Solenoid Body Gasket
    G03889292Courtesy of FORD MOTOR CO.
  12. Remove the feed bolts.
    13. Fig 11: Locating Feed Bolts
    GF0006861Courtesy of FORD MOTOR CO.
  13. Remove and discard the front pump bolts.
    14. Fig 12: Locating Front Pump Bolts
    GF0006862Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the front pump.
    15. Fig 13: Identifying Front Pump
    GF0006863Courtesy of FORD MOTOR CO.
    NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
  15. Remove the No. 1 pump thrust washer.
    • Remove the No. 1 pump thrust washer.
    • Remove the No. 2A overdrive sun gear thrust bearing.
    • Remove the pump gasket and discard.
    16. Fig 14: Identifying Pump Gasket
    GF0006864Courtesy of FORD MOTOR CO.
  16. Remove the overdrive separator plates, clutch plates and overdrive pressure plate.
    17. Fig 15: Locating Clutch Plates And Overdrive Pressure Plate
    GF0006865Courtesy of FORD MOTOR CO.
  17. Remove the overdrive clutch retaining ring.
    18. Fig 16: Locating Overdrive Clutch Retaining Ring
    GF0006866Courtesy of FORD MOTOR CO.
  18. Install the special tool.
    19. Fig 17: Installing Special Tool
    GF0006867Courtesy of FORD MOTOR CO.
    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.
  19. Using the special tool, remove the coast clutch cylinder assembly.
    20. Fig 18: Identifying Coast Clutch Cylinder Assembly
    GF0006868Courtesy of FORD MOTOR CO.
  20. Remove the No. 4 thrust bearing.
    21. Fig 19: Locating Thrust Bearing
    G03889301Courtesy of FORD MOTOR CO.
  21. Remove the overdrive ring gear and center shaft.
    22. Fig 20: Locating Center Shaft And Ring Gear
    G03889559Courtesy of FORD MOTOR CO.
  22. Remove the No. 5 sun gear thrust bearing.
    23. Fig 21: Locating Sun Gear Thrust Bearing
    GF0006869Courtesy of FORD MOTOR CO.
  23. Using the special tool, remove the center support retaining ring.
    24. Fig 22: Locating Center Support Retaining Ring
    GF0006870Courtesy of FORD MOTOR CO.
  24. Install the special tools into the center support assembly.
    25. Fig 23: Identifying Center Support Assembly
    GF0006871Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the center support, direct clutch and forward clutch cylinder assembly.
    26. Fig 24: Identifying Clutch Cylinder Assembly
    GF0006872Courtesy of FORD MOTOR CO.
  26. Remove the forward clutch hub and the No. 9 thrust washer.
    27. Fig 25: Locating Thrust Washer
    GF0006873Courtesy of FORD MOTOR CO.
  27. Remove the forward ring gear and hub assembly.
    28. Fig 26: Locating Forward Ring Gear And Hub
    GF0006874Courtesy of FORD MOTOR CO.
  28. Remove the forward carrier race and the No. 11 bearing assembly.
    29. Fig 27: Identifying Carrier Race And No. 11 Bearing Assembly
    GF0006875Courtesy of FORD MOTOR CO.
  29. Remove the forward carrier.
    30. Fig 28: Identifying Carrier
    GF0006876Courtesy of FORD MOTOR CO.
  30. Remove the sun gear and the No. 12 thrust bearing.
    31. Fig 29: Locating Sun Gear And Thrust Bearing
    GF0006877Courtesy of FORD MOTOR CO.
  31. Remove the low reverse sun gear and shell assembly.
    32. Fig 30: Locating Low Reverse Sun Gear
    GF0006878Courtesy of FORD MOTOR CO.
  32. Remove and discard the low/reverse clutch retaining ring.
    33. Fig 31: Removing Low/Reverse Clutch Wavy Retaining Ring
    GF0006879Courtesy of FORD MOTOR CO.
  33. Remove the low/reverse one-way clutch (OWC), clutch pack and carrier and hub assembly.
    34. Fig 32: Locating Low/Reverse One-Way Clutch
    GF0006880Courtesy of FORD MOTOR CO.
  34. Remove the No. 15 thrust bearing.
    35. Fig 33: Identifying No. 15 Thrust Bearing
    GF0006881Courtesy of FORD MOTOR CO.
  35. Place the transmission manual lever in PARK to lock the output shaft from rotating.
  36. Remove the output hub and ring gear.
    37. Fig 34: Removing The Output Hub And Ring Gear
    GF0006882Courtesy of FORD MOTOR CO.
  37. Remove the low reverse No. 16 thrust bearing.
    38. Fig 35: Locating Low Reverse Thrust Bearing
    G03889316Courtesy of FORD MOTOR CO.
  38. If equipped, remove the output shaft flange.
    • Remove and discard the bolt.
    • Remove the output shaft flange.
    39. Fig 36: Identifying Output Shaft Flange And Bolt
    G04615854Courtesy of FORD MOTOR CO.
  39. If equipped, use the special tool to remove and discard the output shaft retaining nut.
    40. Fig 37: Identifying Output Shaft With Special Tool
    G04649634Courtesy of FORD MOTOR CO.
  40. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
    41. Fig 38: Removing Output Shaft Seal (Fixed Flange)
    GF0006815Courtesy of FORD MOTOR CO.
  41. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
    42. Fig 39: Removing Output Shaft Seal (Slip Yoke)
    GF0006816Courtesy of FORD MOTOR CO.
  42. Remove the 9 bolts and the extension housing.
    43. Fig 40: Locating Transmission Extension Housing Bolts
    G03889104Courtesy of FORD MOTOR CO.
  43. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.
    44. Fig 41: Locating Extension Housing Ball Bearing
    GF0006883Courtesy of FORD MOTOR CO.
  44. Remove and discard the extension housing gasket.
    45. Fig 42: Locating Extension Housing Gasket
    G03889106Courtesy of FORD MOTOR CO.
  45. Remove the output shaft.
    46. Fig 43: Identifying Output Shaft
    G03889324Courtesy of FORD MOTOR CO.
  46. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer.
    47. Fig 44: Identifying Park Gear Thrust Washer
    G03889325Courtesy of FORD MOTOR CO.
  47. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing.
    48. Fig 45: Identifying Park Gear Thrust Washer
    G03889325Courtesy of FORD MOTOR CO.
    CAUTION: Do not fully compress the return spring or damage to the spring may occur.
  48. Using the special tools, remove and discard the reverse clutch return spring retaining ring.
    49. Fig 46: Identifying Reverse Clutch Return Spring Snap Ring
    GF0006884Courtesy of FORD MOTOR CO.
  49. Remove the return spring.
    50. Fig 47: Locating Return Spring
    G03889328Courtesy of FORD MOTOR CO.
  50. While applying air to the extension housing side of the case, remove and discard the reverse piston.
    51. Fig 48: Locating Reverse Clutch Piston Seals
    G03889329Courtesy of FORD MOTOR CO.
  51. Remove the parking rod guide plate bolts and plate.
    52. Fig 49: Locating Parking Rod Guide Plate And Bolts
    G03889161Courtesy of FORD MOTOR CO.
  52. Remove the plastic orifice lube plug from the rear of the case and discard.
    53. Fig 50: Removing Plastic Orifice Lube Plug From Rear Of Case
    GF0006885Courtesy of FORD MOTOR CO.
  53. Remove the parking pawl.
    • Remove the parking pawl return spring.
    • Remove the parking pawl.
    • Remove the parking pawl shaft.
    54. Fig 51: Locating Parking Pawl Return Spring
    GF0006886Courtesy 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.
  54. Remove the parking pawl abutment.
    55. Fig 52: Identifying Parking Pawl Abutment
    GF0006887Courtesy of FORD MOTOR CO.
    NOTE: The pin should be driven down into the case.
  55. Using a suitable tool, remove and discard the manual lever shaft retaining pin.
    56. Fig 53: Identifying Manual Lever Shaft Retaining Pin
    G03889334Courtesy of FORD MOTOR CO.
  56. Using the special tool, remove the manual lever shaft retaining pin.
    57. Fig 54: Identifying Manual Lever Shaft Retaining Pin
    GF0006888Courtesy of FORD MOTOR CO.
  57. Remove the manual control lever shaft.
    58. Fig 55: View Of Manual Control Lever
    G03889336Courtesy of FORD MOTOR CO.
  58. Remove the TR position sensor, manual control lever and park rod as an assembly.
    59. Fig 56: Identifying Manual Control Lever And Park Rod Assembly
    G03889337Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove and discard the manual control lever seal.
    60. Fig 57: Identifying Manual Control Lever Seal With Special Tools
    GF0006889Courtesy of FORD MOTOR CO.
    NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
  60. If required, remove the short fluid inlet tube.
    61. Fig 58: Removing Short Fluid Inlet Tube
    GF0006890Courtesy of FORD MOTOR CO.
    NOTE: The top portion seal groove will work the best when removing the seal pack.
  61. Inspect the rear case Teflon® seal retainer for damage. If damage is evident, use the special tool to remove the seal retainer.
    62. Fig 59: Identifying Seal Retainer
    GF0006891Courtesy of FORD MOTOR CO.
  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. Apply air pressure to the extension housing side of the vent.
  66. If the low/reverse clutch-to-case snap ring has rotated in the case snap ring groove, or is partially dislodged, the case snap ring groove has been damaged. To avoid repeat repairs, use a new case for the overhaul.
  67. If installing a new case, remove the transmission fluid cooler tube fittings.
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