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Section 1010 (Automatic Transmission - 4R100): Disassembly: Transmission: Transmission

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The turbine shaft speed sensor (TSS) will need to be removed or damage to the sensors may occur.
    Fig 1: Removing Turbine Shaft Sensor
    G01539021Courtesy of FORD MOTOR CO.
  1. If equipped, remove the turbine shaft sensor (TSS).
    1. Remove the bolt.
    2. Remove the turbine shaft sensor (TSS).
  2. Remove the vehicle speed sensor (VSS).
    3. NOTE: Remove the torque converter prior to mounting the transmission to the repair stand.
  3. Install the transmission into a suitable stand.
    4. CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.
    Fig 2: Removing Input Shaft
    G01539022Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
    5. CAUTION: Sealing washers may fall off the cooler line case fittings.
    NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
    Fig 3: Removing Cooler Bypass Valve
    G01539023Courtesy of FORD MOTOR CO.
  5. Remove the cooler bypass valve.
    1. Remove the cooler line case fittings.
    2. Remove the cooler bypass valve.
  6. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the transmission range (TR) sensor.
    Fig 4: Removing Transmission Range Sensor
    G01539024Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 5: Removing Transmission Fluid Pan And Gasket
    G01539025Courtesy of FORD MOTOR CO.
  7. Remove the transmission fluid pan and gasket.
    8. CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
    NOTE: After removal, discard the filter and seal assembly.
    Fig 6: Removing Filter And Seal Assembly
    G01539026Courtesy of FORD MOTOR CO.
  8. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
  9. Remove the bolts, nuts and the accumulator body.
    Fig 7: Removing Bolts, Nuts And Accumulator Body
    G01539027Courtesy of FORD MOTOR CO.
    10. NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
    Fig 8: Removing Main Control Valve Body
    G01539028Courtesy of FORD MOTOR CO.
  10. Remove the main control valve body.
    1. Do not remove the two lower-to-upper main control valve body assembly bolts.
  11. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 9: Removing Bolts, Nut And Solenoid Body Assembly
    G01539029Courtesy of FORD MOTOR CO.
  12. Remove the solenoid screen assembly by rotating and pulling.
    Fig 10: Removing Solenoid Screen Assembly
    G01539030Courtesy of FORD MOTOR CO.
    13. CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
    Fig 11: Removing Separator Plate Reinforcing Plate And Valve Body Separator Plate With Gaskets
    G01539031Courtesy of FORD MOTOR CO.
  13. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
    14. NOTE: The steel EPC check ball has a 0.25-inch diameter and is smaller than the other check balls.
    Fig 12: Removing Steel EPC Check Ball And Spring
    G01539032Courtesy of FORD MOTOR CO.
  14. Remove the steel EPC check ball and spring.
    15. CAUTION: Use care not to damage the rubber check balls. Transmission shift problems may occur.
    Fig 13: Removing 8 Rubber Check Balls
    G01539033Courtesy of FORD MOTOR CO.
  15. Using a small screwdriver, carefully remove the 8 rubber check balls.
  16. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 14: Identifying Intermediate Band Servo Assembly Piston
    G01539034Courtesy of FORD MOTOR CO.
    17. CAUTION: After removal, discard the feed bolts. The bolts will not retain torque specification if reused.
    Fig 15: Removing Feed Bolts
    G01539035Courtesy of FORD MOTOR CO.
  17. Remove and discard the feed bolts.
  18. Remove the pump bolts and discard the washers.
    Fig 16: Removing Pump Bolts
    G01539036Courtesy of FORD MOTOR CO.
    19. NOTE: The special tools should be installed into the pump threaded holes as shown.
    Fig 17: Removing Pump Using Special Tool
    G01539037Courtesy of FORD MOTOR CO.
  19. Using the special tools, remove the pump.
    20. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
    Fig 18: Removing No. 1 Pump Thrust Washer
    G01539038Courtesy of FORD MOTOR CO.
  20. 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.
    21. CAUTION: The coast clutch, overdrive ring gear, and centershaft assembly must be removed as an assembly using special service tool or damage to the overdrive one-way clutch could occur.
    Fig 19: Removing Coast Clutch, Overdrive Ring Gear, And Centershaft Assembly Using Special Tool
    G01539039Courtesy of FORD MOTOR CO.
  21. Using the special tool, remove the coast clutch, overdrive ring gear, and centershaft assembly.
    22. NOTE: The No. 5 thrust bearing may remain on the centershaft or the center support.
    Fig 20: Removing No. 5 Overdrive Centershaft Thrust Bearing Assembly
    G01539040Courtesy of FORD MOTOR CO.
  22. Remove the No. 5 overdrive centershaft thrust bearing assembly.
  23. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 21: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring
    G01539041Courtesy of FORD MOTOR CO.
    24. NOTE: Tag the parts for identification during installation.
    Fig 22: Removing Overdrive Clutch Pressure Plate And Clutch Pack
    G01539042Courtesy of FORD MOTOR CO.
  24. Remove the overdrive clutch pressure plate and the clutch pack.
  25. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 23: Removing Intermediate/Overdrive Cylinder Retaining Ring Using Special Tool
    G01539043Courtesy of FORD MOTOR CO.
    26. CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
    Fig 24: Removing Intermediate/Overdrive Cylinder Assembly
    G01539044Courtesy of FORD MOTOR CO.
  26. Remove the intermediate/overdrive cylinder assembly.
  27. Remove the intermediate clutch piston return spring.
    Fig 25: Removing Intermediate Clutch Piston Return Spring
    G01539045Courtesy of FORD MOTOR CO.
    28. CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.
    Fig 26: Removing Center Support Assembly
    G01539046Courtesy of FORD MOTOR CO.
  28. Carefully remove the center support assembly.
  29. Remove the No. 6 center support thrust washer.
    Fig 27: Removing No. 6 Center Support Thrust Washer
    G01539047Courtesy of FORD MOTOR CO.
    30. NOTE: Tag the parts for identification during installation.
    Fig 28: Removing Intermediate Clutch Rear Pressure Plate
    G01539048Courtesy of FORD MOTOR CO.
  30. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate.
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
  31. Remove the intermediate band.
    Fig 29: Removing Intermediate Band
    G01539049Courtesy of FORD MOTOR CO.
    32. NOTE: When installing the special tool, each leg of the special tool must be rotated to engage notches on the input shell prior to tightening the top cross bar.
    Fig 30: Removing Direct Clutch, Forward Clutch And Input Shell Assembly Using Special Tool
    G01539050Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
  33. Remove the reverse planet retaining ring.
    Fig 31: Removing Reverse Planet Retaining Ring
    G01539051Courtesy of FORD MOTOR CO.
  34. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 32: Removing Reverse Planet Assembly, No. 10B, And No. 11 Reverse Planet Carrier Thrust Washers
    G01539052Courtesy of FORD MOTOR CO.
    35. WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
    Fig 33: Removing Output Shaft Retaining Ring
    G01539053Courtesy of FORD MOTOR CO.
  35. Remove the output shaft retaining ring.
  36. Remove the output shaft ring gear and hub assembly.
    Fig 34: Removing Output Shaft Ring Gear And Hub Assembly
    G01539054Courtesy of FORD MOTOR CO.
    37. WARNING: Use care not to drop the output shaft while rotating the transmission.
    Fig 35: Removing Low/Reverse One Way Clutch Assembly
    G01539055Courtesy of FORD MOTOR CO.
  37. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
  38. Using the special tools, remove the extension housing seal.
    Fig 36: Removing Extension Housing Seal Using Special Tool
    G01539056Courtesy of FORD MOTOR CO.
  39. Using the special tool, remove the extension housing bushing.
    Fig 37: Removing Extension Housing Bushing Using Special Tool
    G01539057Courtesy of FORD MOTOR CO.
  40. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 38: Removing Bolts, Stud And Extension Housing
    G01539058Courtesy of FORD MOTOR CO.
    41. NOTE: The parking gear is press fit to the output shaft.
  41. Remove the output shaft and park gear assembly.
  42. Remove the No. 13 thrust bearing.
    Fig 39: Removing No. Thrust Bearing
    G01539059Courtesy of FORD MOTOR CO.
  43. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 40: Removing Plastic Orifice Lube Plug From Rear Of Case
    G01539060Courtesy of FORD MOTOR CO.
  44. Remove the 5 bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 41: Removing Bolts Retaining Low/Reverse One-Way Clutch Inner Race To Case
    G01539061Courtesy of FORD MOTOR CO.
  45. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 42: Removing Low/Reverse One-Way Clutch Inner Race And Reverse Clutch Return Spring Assembly
    G01539062Courtesy of FORD MOTOR CO.
  46. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to restrain the reverse clutch piston.
    Fig 43: Removing Reverse Clutch Piston
    G01539063Courtesy of FORD MOTOR CO.
  47. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 44: Applying Compressed Air, Blow Into Reverse Clutch Feed Port
    G01539064Courtesy of FORD MOTOR CO.
  48. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 45: Removing Reverse Clutch Pressure Plate Retainer Snap Ring
    G01539065Courtesy of FORD MOTOR CO.
  49. If required, remove the parking rod guide plate.
    Fig 46: Removing Parking Rod Guide Plate
    G01539066Courtesy of FORD MOTOR CO.
  50. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
    Fig 47: Removing Parking Pawl Shaft
    G01539067Courtesy of FORD MOTOR CO.
    51. CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.
    Fig 48: Removing Parking Pawl Abutment
    G01539068Courtesy of FORD MOTOR CO.
  51. If required, remove the parking pawl abutment.
    52. NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
    Fig 49: Removing Manual Lever Shaft Retaining Pin Using Special Tool
    G01539069Courtesy of FORD MOTOR CO.
  52. Using the special tool, remove the manual lever shaft retaining pin.
    53. CAUTION: Use care not to damage the manual control lever bore.
    NOTE: The manual control lever and manual control lever shaft are one piece.
    Fig 50: Removing Bolt And Manual Control Valve Detent Lever Spring
    G01539070Courtesy of FORD MOTOR CO.
  53. Remove the manual control lever shaft assembly.
      NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
  54. Using the special tool, remove the manual control lever seal.
    Fig 51: Removing Manual Control Lever Seal Using Special Tool
    G01539071Courtesy of FORD MOTOR CO.
    55. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 52: Removing Short Fluid Inlet Tube
    G01539072Courtesy of FORD MOTOR CO.
  55. If required, remove the short fluid inlet tube.
  56. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
  57. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
  58. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the helicoil kit.
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