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Section 62 (Automatic Transmission -- F250-F550 Super Duty): Disassembly: Transmission

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03908956
 Roll Pin Set 211-S060 (T78P-3504-N)
G03909293
 Nut Driver, Output Shaft 307-458
G03915058
 Compressor, Clutch Spring 307-015 (T65L-77515-A)
G03922975
 Alignment Cone 307-455
G03922675
 Remover, Transmission Fluid Seal 307-309 (T94P-77001-A)
G03908884
 Legs (used with 307-309) 307-454
G03909034
 Remover, Seal Pack 307-460
G03909203
 Fixture Handle, Coast Clutch 307-384
G03909204
 Fixture Body, Coast Clutch 307-385
G03964078
 Remover, Transmission Fluid Pump 307-221 (T89T-70010-A)
G03909038
 Handle 205-153 (T80T-4000-W)
G03923066
 Retaining Ring Pliers 307-343 (T95P-77001-AHR)
G03908398
 Loading Fixture, Clutch 307-S383
G03914889
 Handle, Torque Converter 307-091 (T81P-7902-C
G03889281
 Remover, Pilot Bearing 308-001 (T58L-101-B)
G03889235
 Retainer, Torque Converter 307-346 (T97T-7902-A)
  1. Remove the special tool.
    Fig 1: Identifying Special Torque Converter Tool
    G03889283Courtesy of FORD MOTOR CO.
    2. 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 2: Removing Torque Converter
    G03889284Courtesy of FORD MOTOR CO.
  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 3: Removing Sensor
      G03889066Courtesy of FORD MOTOR CO.
  4. Remove the output shaft speed sensor (OSS).
    1. Remove the bolt.
    2. Remove the OSS.
      Fig 4: Removing Output Shaft Speed Sensor (OSS)
      G03889286Courtesy of FORD MOTOR CO.
  5. Mount the transmission onto a suitable stand.
  6. Remove the input shaft and discard the stator support seal.
    Fig 5: Removing Input Shaft
    G03889287Courtesy of FORD MOTOR CO.
  7. Install a new drain plug and seal assembly if there is evidence of leaking.
    Fig 6: Identifying Transmission Fluid Drain Plug
    G03889033Courtesy of FORD MOTOR CO.
    8. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 7: Removing Transmission Fluid Pan And Gasket
    G03889037Courtesy of FORD MOTOR CO.
  8. Remove the transmission fluid pan and the gasket. Check and clean the magnet if foreign material is evident.
    9. NOTE: After removal, discard the filter and seal assembly.
    Fig 8: Removing Filter And Seal Assembly
    G03889290Courtesy of FORD MOTOR CO.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
    10. 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 9: Removing Solenoid Body
      G03889053Courtesy of FORD MOTOR CO.
  11. Remove and discard the solenoid body gasket.
    Fig 10: Removing Solenoid Body Gasket
    G03889292Courtesy of FORD MOTOR CO.
  12. Remove the feedbolts.
    Fig 11: Removing Feedbolts
    G03889293Courtesy of FORD MOTOR CO.
  13. Remove the front pump bolts.
    Fig 12: Removing Front Pump Bolts
    G03889294Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the front pump.
    Fig 13: Removing Front Pump
    G03889295Courtesy of FORD MOTOR CO.
    15. 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.
    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 14: Removing No 1 Pump Thrust Washer
      G03889296Courtesy of FORD MOTOR CO.
  16. Remove the overdrive separator plates, clutch plates and overdrive pressure plate.
    Fig 15: Removing Overdrive Separator Plates, Clutch Plates And Overdrive Pressure Plate
    G03889297Courtesy of FORD MOTOR CO.
  17. Remove the overdrive clutch retaining ring.
    Fig 16: Removing Overdrive Clutch Retaining Ring
    G03889298Courtesy of FORD MOTOR CO.
  18. Install the special tool.
    Fig 17: Installing Special Tool
    G03909062Courtesy of FORD MOTOR CO.
    19. 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 18: Removing Coast Clutch Cylinder Assembly
    G03889300Courtesy of FORD MOTOR CO.
  19. Using the special tool, remove the coast clutch cylinder assembly.
  20. Remove the No. 4 thrust bearing.
    Fig 19: Removing No 4 Thrust Bearing
    G03889301Courtesy of FORD MOTOR CO.
  21. Remove the overdrive ring gear and center shaft.
    Fig 20: Removing Overdrive Ring Gear And Center Shaft
    G03889559Courtesy of FORD MOTOR CO.
  22. Remove the No. 5 sun gear thrust bearing.
    Fig 21: Removing No 5 Sun Gear Thrust Bearing
    G03889303Courtesy of FORD MOTOR CO.
  23. Using the special tool, remove the center support retaining ring.
    Fig 22: Removing Center Support Retaining Ring
    G03889304Courtesy of FORD MOTOR CO.
  24. Install the special tools into the center support assembly.
    Fig 23: Installing Special Tools Into Center Support Assembly
    G03889305Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the center support, direct clutch and forward clutch cylinder assembly.
    Fig 24: Removing Center Support, Direct Clutch And Forward Clutch Cylinder Assembly
    G03889306Courtesy of FORD MOTOR CO.
  26. Remove the forward clutch hub and the No. 9 thrust washer.
    Fig 25: Removing Forward Clutch Hub And No 9 Thrust Washer
    G03889307Courtesy of FORD MOTOR CO.
  27. Remove the forward ring gear and hub assembly.
    Fig 26: Removing Forward Ring Gear And Hub Assembly
    G03889308Courtesy of FORD MOTOR CO.
  28. Remove the forward carrier race and the No. 11 bearing assembly.
    Fig 27: Removing Forward Carrier Race And No 11 Bearing Assembly
    G03909072Courtesy of FORD MOTOR CO.
  29. Remove the forward carrier.
    Fig 28: Removing Forward Carrier
    G03909073Courtesy of FORD MOTOR CO.
  30. Remove the sun gear and the No. 12 thrust bearing.
    Fig 29: Removing Sun Gear And No 12 Thrust Bearing
    G03889311Courtesy of FORD MOTOR CO.
  31. Remove the low reverse sun gear and shell assembly.
    Fig 30: Removing Low Reverse Sun Gear And Shell Assembly
    G03889312Courtesy of FORD MOTOR CO.
  32. Remove and discard the low/reverse clutch wavy retaining ring.
    Fig 31: Removing Low/Reverse Clutch Wavy Retaining Ring
    G03889313Courtesy of FORD MOTOR CO.
  33. Remove the low/reverse one-way clutch, clutch pack, carrier and hub assembly.
    Fig 32: Removing Low/Reverse One-Way Clutch, Clutch Pack, Carrier And Hub Assembly
    G03889314Courtesy of FORD MOTOR CO.
  34. Remove the No. 15 thrust bearing and hub.
    Fig 33: Removing No 15 Thrust Bearing And Hub
    G03889315Courtesy 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. Remove the low reverse No. 16 thrust bearing.
    Fig 34: Removing Low Reverse No 16 Thrust Bearing
    G03889316Courtesy of FORD MOTOR CO.
  38. If equipped, remove the output shaft flange.
    1. Remove and discard the bolt.
    2. Remove the output shaft flange.
      Fig 35: Removing Output Shaft Flange
      G03889089Courtesy of FORD MOTOR CO.
  39. If equipped, use the special tool to remove and discard the output shaft nut.
    Fig 36: Removing Output Shaft Nut
    G03889318Courtesy of FORD MOTOR CO.
  40. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
    Fig 37: Removing Output Shaft Seal
    G03889091Courtesy of FORD MOTOR CO.
  41. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
    Fig 38: Removing Output Shaft Seal
    G03889092Courtesy of FORD MOTOR CO.
  42. Remove the nine bolts and the extension housing.
    Fig 39: Identifying 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.
    Fig 40: Inspecting Extension Housing Ball Bearing
    G03889322Courtesy of FORD MOTOR CO.
  44. Remove and discard the extension housing gasket.
    Fig 41: Identifying Extension Housing Gasket
    G03889106Courtesy of FORD MOTOR CO.
  45. Remove the output shaft.
    Fig 42: Removing Output Shaft
    G03889324Courtesy of FORD MOTOR CO.
  46. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer.
    Fig 43: 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.
    Fig 44: Identifying Park Gear Thrust Bearing
    G03889325Courtesy of FORD MOTOR CO.
    48. CAUTION: Do not fully compress the return spring or damage to the spring may occur.
    Fig 45: Removing Reverse Clutch Return Spring Retaining Ring
    G03889327Courtesy of FORD MOTOR CO.
  48. Using the special tools, remove and discard the reverse clutch return spring retaining ring.
  49. Remove the return spring.
    Fig 46: Removing 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.
    Fig 47: Removing Reverse Piston
    G03889329Courtesy of FORD MOTOR CO.
  51. Remove the parking rod guide plate bolts and plate.
    Fig 48: Removing Parking Rod Guide Plate Bolts And Plate
    G03889161Courtesy of FORD MOTOR CO.
  52. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 49: Removing Plastic Orifice Lube Plug From Rear Of Case
    G03889331Courtesy of FORD MOTOR CO.
  53. Remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
      Fig 50: Removing Parking Pawl
      G03889332Courtesy of FORD MOTOR CO.
    54. 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 51: Removing Parking Pawl Abutment
    G03889333Courtesy of FORD MOTOR CO.
  54. Remove the parking pawl abutment.
    55. NOTE: The pin should be driven down into the case.
    Fig 52: Removing Manual Lever Shaft Retaining Pin
    G03889334Courtesy of FORD MOTOR CO.
  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 53: Removing Manual Lever Shaft Retaining Pin
    G03889335Courtesy of FORD MOTOR CO.
  57. Remove the manual control lever shaft.
    Fig 54: Removing Manual Control Lever Shaft
    G03889336Courtesy of FORD MOTOR CO.
  58. Remove the transmission range sensor, manual control lever and park rod as an assembly.
    Fig 55: Removing Transmission Range Sensor, Manual Control Lever And Park Rod As Assembly
    G03889337Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove and discard the manual control lever seal.
    Fig 56: Removing Manual Control Lever Seal
    G03889338Courtesy of FORD MOTOR CO.
    60. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 57: Removing Short Fluid Inlet Tube
    G03889339Courtesy of FORD MOTOR CO.
  60. If required, remove the short fluid inlet tube.
    61. NOTE: The top portion seal groove will work the best when removing the seal pack.
    Fig 58: Removing Seal Retainer
    G03889340Courtesy of FORD MOTOR CO.
  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. Apply air pressure to the extension housing side of the vent.
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