Section 1301 (Automatic Transmission - 5R110W (TORQSHIFT(R))): Assembly: Transmission

Illustration	Tool Name	Tool Number
	Adapter for 307-436 (use with 307-436)	307-436-02
	Air Test Plate, Transmission	307-457
	Aligner, Clutch Spring Compressor	307-455
	Aligner, Transmission Fluid Pump	307-222 (T89T-70010-B)
	Aligner, Valve Body	307-456
	Compressor, Clutch Spring	307-015 (T65L-77515-A)
	Handle, Torque Converter	307-091 (T81P-7902-C)
	Installer, Fluid Filler Tube	307-376
	Installer, Output Shaft Seal	307-462
	Installer, Output Shaft Seal/Housing	307-461
	Installer, Shift Shaft Fluid Seal	307-002 (TOOL-77288)
	Installer, Transmission Extension Housing Seal	307-453
	Installer, Transmission Forward Clutch Assembly	307-436
	Loading Fixture, Clutch	307-S383
	Retainer, Torque Converter	307-346
	Retaining Ring Pliers	307-343 (T95P-77001-AHR)
	Socket, Output Shaft Lock nut	307-458
	Test Plate Screw Set, Transmission	307-126 (T82P-7006-C)

Fig 1: Transmission, Disassembled View - Early Build Vehicles (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 2: Transmission, Disassembled View - Early Build Vehicles (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 3: Transmission, Disassembled View - Early Build Vehicles (3 Of 3)

Courtesy of FORD MOTOR CO.

Fig 4: Transmission, Disassembled View - Late Build Vehicles (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 5: Transmission, Disassembled View - Late Build Vehicles (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 6: Transmission, Disassembled View - Late Build Vehicles (3 Of 3)

Courtesy of FORD MOTOR CO.

Fig 7: Late Build Vehicles Without Remote Filter and With Serviceable High Efficiency Sump Filter (HESF)

Courtesy of FORD MOTOR CO.

All transmissions 

1. Mount the transmission case into a suitable stand.
2. If removed, use the special tool to install the short transmission fluid inlet tube.
Fig 8: Identifying Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
3. If removed, use the special tool to install a new Teflon® seal retainer.
   • Install 2 new Teflon® seals.
Fig 9: Installing Teflon Seal Retainer With Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Coat the reverse clutch piston seals with petroleum jelly.
4. Install the reverse clutch piston in the case until it is fully seated in the case.
Fig 10: Locating Reverse Clutch Piston Seals
Courtesy of FORD MOTOR CO.
5. Install the reverse clutch return spring assembly.
Fig 11: Locating Return Spring
Courtesy of FORD MOTOR CO.
NOTE: Do not over compress the return spring or damage to the spring will occur.
6. Using the special tools, install the reverse clutch return spring snap ring.
Fig 12: Identifying Reverse Clutch Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.
7. For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.
Fig 13: Identifying Park Gear Thrust Washer
Courtesy of FORD MOTOR CO.
NOTE: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

8. Install the output shaft.

Fig 14: Identifying Output Shaft
Courtesy of FORD MOTOR CO.
NOTE: The Torx screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.
9. If removed, install the parking pawl abutment with a new Torx screw.
   • Tighten to 25 Nm (18 lb-ft).
Fig 15: Locating Parking Pawl Abutment
Courtesy of FORD MOTOR CO.
10. Install the parking pawl.
    1. Install the parking pawl shaft.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
Fig 16: Identifying Parking Pawl Return Spring And Parking Pawl Shaft
Courtesy of FORD MOTOR CO.
NOTE: Make sure the dimple on the parking guide support plate is facing inward.
11. Install the parking rod guide plate.
    1. Install the parking rod guide plate.
    2. Install the bolts.
       • Tighten to 25 Nm (18 lb-ft).
Fig 17: Identifying Parking Rod Guide Plate And Bolts
Courtesy of FORD MOTOR CO.
12. Install a new orifice lube plug in the rear of the case. Using a 12-mm socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.
Fig 18: Installing Orifice Lube Plug In Rear Of Case
Courtesy of FORD MOTOR CO.
13. Install a new extension housing gasket.
Fig 19: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
14. Install the extension housing.
    • Tighten to 48 Nm (35 lb-ft).
Fig 20: Locating Transmission Extension Housing Bolts
Courtesy of FORD MOTOR CO.
15. Using the special tool, install a new manual control lever seal.
Fig 21: Installing Manual Control Lever Seal Using Special Tool
Courtesy of FORD MOTOR CO.
16. Install the transmission range (TR) sensor, park rod assembly and loosely install the bolts.
Fig 22: Identifying Manual Control Lever And Park Rod Assembly
Courtesy of FORD MOTOR CO.
17. Install the manual control lever.
Fig 23: View Of Manual Control Lever
Courtesy of FORD MOTOR CO.
18. Install the roll pin into the case.
Fig 24: Installing Roll Pin Into Case
Courtesy of FORD MOTOR CO.
19. Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.
Fig 25: Identifying Manual Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
20. Tighten the TR sensor bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 26: Identifying Manual Control Lever And Park Rod Assembly
Courtesy of FORD MOTOR CO.

Fixed yoke transmissions 

21. Using the special tool, install a new extension housing seal.
Fig 27: Identifying Output Shaft Seal
Courtesy of FORD MOTOR CO.
22. Inspect the new output shaft nut O-ring for cuts. A new nut must be installed.
Fig 28: Inspecting New Output Shaft Nut O-Ring For Cuts
Courtesy of FORD MOTOR CO.
23. Using the special tool, install a new output shaft nut.
    • Tighten to 200 Nm (148 lb-ft).
Fig 29: Identifying Output Shaft With Special Tool
Courtesy of FORD MOTOR CO.
24. Install the output flange and a new bolt.
    • Tighten to 130 Nm (96 lb-ft).
Fig 30: Locating Output Shaft Flange Bolt
Courtesy of FORD MOTOR CO.

Slip yoke transmissions 

25. Install a new extension housing seal using the special tool.
Fig 31: Identifying Extension Housing Seal
Courtesy of FORD MOTOR CO.

All transmissions 

26. Install the No. 16 bearing and race.
Fig 32: Locating Low Reverse Thrust Bearing
Courtesy of FORD MOTOR CO.

Early build vehicles 

27. Install the output hub and ring gear assembly and the No. 15 hub bearing.
Fig 33: Installing Ring Gear, Hub And No. 15 Hub Bearing
Courtesy of FORD MOTOR CO.
28. Install the reverse carrier and hub assembly.
Fig 34: Reverse Carrier And Hub Assembly
Courtesy of FORD MOTOR CO.
29. Install the low/reverse clutch plates.
    • Start with a steel plate on the bottom, followed by a friction plate.
    • Alternately stack the remaining steel and friction plates.
Fig 35: Low/Reverse Clutch Plates
Courtesy of FORD MOTOR CO.
30. Install the pressure plate (low/reverse one-way clutch [OWC]) on the last friction plate, with THIS SIDE UP facing upward and with the partial tooth located between 10 and 2 o'clock.
    1. For gasoline engine vehicles, install the 12 strut OWC.
    2. For diesel engine vehicles, install the 6 strut OWC.
Fig 36: Identifying Strut OWC For Gasoline/Diesel Engine Vehicles
Courtesy of FORD MOTOR CO.

Late build vehicles 

31. Assemble the rocker clutch and ring gear assembly.
    1. Install the No. 15 hub bearing onto the ring gear hub.
    2. Install the rocker clutch, low/reverse clutch pack and carrier and hub assembly into the output hub and ring gear assembly.
Fig 37: Installing No. 15 Hub Bearing Onto Ring Gear Hub
Courtesy of FORD MOTOR CO.
NOTE: Place the transmission in the horizontal position.
32. Install the rocker clutch and ring gear assembly into the transmission case.
Fig 38: Installing Rocker Clutch & Ring Gear Assembly Into Transmission Case
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur.
33. Install a new flat snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

    Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.

    • Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.
Fig 39: Installing Flat Snap Ring
Courtesy of FORD MOTOR CO.
34. Using the special tools, install the forward geartrain as an assembly.
Fig 40: Positioning Of Transmission Assembly Using Special Tools
Courtesy of FORD MOTOR CO.
35. Install the intermediate clutch pressure plate.
    • Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.
Fig 41: Intermediate Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
36. Install the intermediate clutch plates, starting with a friction plate.
Fig 42: Installing Intermediate Clutch Plates, Starting With Friction Plate
Courtesy of FORD MOTOR CO.
37. Install the center support with the transmission in a vertical position to avoid damage to the center support Teflon® seals.
Fig 43: Installing Center Support
Courtesy of FORD MOTOR CO.
38. Loosely install the feed bolts.
    1. Loosely install the Torx head forward clutch feed bolt into the case toward the rear of the case.
    2. Loosely install the hex head intermediate clutch feed bolt into the case toward the front of the case.
Fig 44: Forward Clutch Feed Bolt And Intermediate Clutch Feed Bolt
Courtesy of FORD MOTOR CO.
39. Using the special tool, install the center support snap ring.
    • The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case.
Fig 45: Center Support Snap Ring And Special Tool
Courtesy of FORD MOTOR CO.
40. Tighten the feed bolts.
    • Tighten to 33 Nm (24 lb-ft).
Fig 46: Forward Clutch Feed Bolt And Intermediate Clutch Feed Bolt
Courtesy of FORD MOTOR CO.
41. Install the No. 5 thrust bearing onto the center support.
Fig 47: Installing No 5 Thrust Bearing Onto Center Support
Courtesy of FORD MOTOR CO.
42. Install the center shaft and ring gear.
Fig 48: Locating Center Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
43. Install the No. 4 thrust bearing onto the center shaft.
Fig 49: Locating Thrust Bearing
Courtesy of FORD MOTOR CO.
44. Using the special tool, install the coast clutch assembly and overdrive carrier.
Fig 50: Special Tool And Coast Clutch Cylinder Assembly
Courtesy of FORD MOTOR CO.
45. Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position.
Fig 51: Locating Overdrive Clutch Assembly Snap Ring
Courtesy of FORD MOTOR CO.
46. Install the overdrive pressure plate with the notches facing up.
Fig 52: Installing Overdrive Pressure Plate With Notches Facing Up
Courtesy of FORD MOTOR CO.
47. Install the overdrive clutch.
    • Start with a friction plate, alternating with a steel plate.
Fig 53: Overdrive Clutch Friction Plate And Steel Plate
Courtesy of FORD MOTOR CO.
48. Install a new pump gasket.
Fig 54: Locating Pump Gasket
Courtesy of FORD MOTOR CO.
49. Install the No. 2 thrust bearing.
Fig 55: Installing No. 2 Thrust Bearing
Courtesy of FORD MOTOR CO.
50. Install the input shaft into the case.
Fig 56: Installing Input Shaft Into Case
Courtesy of FORD MOTOR CO.
NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.
51. Install the special tools into the case in order to install the pump.
Fig 57: Locating Alignment Pins Case Holes
Courtesy of FORD MOTOR CO.
52. Check to make sure that the No. 1 thrust washer is installed on the pump stator, and make sure that the No. 2A bearing is installed onto the pump support.
NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions.
53. Using the special tools, install the pump assembly with the transmission in a vertical position to avoid damage to the pump stator support Teflon® seals.
Fig 58: Identifying Pump Assembly With Special Tools
Courtesy of FORD MOTOR CO.
54. Install new pump body-to-case retaining bolts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 59: Locating Front Pump Bolts
Courtesy of FORD MOTOR CO.
55. Install a new main control body gasket.
Fig 60: Locating Solenoid Body Gasket
Courtesy of FORD MOTOR CO.
56. Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.

    Item	Part Number	Description
    1	-	Coast clutch
    2	-	Intermediate clutch
    3	-	Reverse clutch
    4	-	Forward clutch
    5	-	Direct clutch
    6	-	Overdrive clutch

Fig 61: Air Pressure Test Port Locations
Courtesy of FORD MOTOR CO.
57. Using the special tools, install the solenoid body and loosely install the bolts.
    • While installing the solenoid body, align the manual valve.
Fig 62: Locating Solenoid Body Bolts
Courtesy of FORD MOTOR CO.
58. Tighten all the bolts in the sequence shown.
    • Tighten to 13 Nm (10 lb-ft).
Fig 63: Identifying Solenoid Body Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
59. Connect the TR sensor connector.
Fig 64: Connecting Transmission Range Sensor Connector
Courtesy of FORD MOTOR CO.
NOTE: Prior to installing the transmission fluid filter, make sure that the old seal is not stuck in the case.
60. Install a new transmission fluid filter.
Fig 65: Locating Transmission Fluid Filter & Seal Assembly
Courtesy of FORD MOTOR CO.
NOTE: Reuse the transmission fluid pan gasket unless it is damaged.
61. Install the transmission fluid pan gasket to the transmission fluid pan. Make sure the magnet is positioned over the dimple in the transmission fluid pan.
Fig 66: Locating Transmission Fluid Pan Gasket To Transmission Fluid Pan
Courtesy of FORD MOTOR CO.
62. Install the transmission fluid pan.
    • Tighten to 20 Nm (15 lb-ft).
Fig 67: Locating Transmission Fluid Pan & Gasket
Courtesy of FORD MOTOR CO.
63. Install the intermediate shaft and turbine shaft speed (TSS) combination sensor.
    1. Install the speed sensor.
    2. Install the speed sensor bolt.
       • Tighten to 9 Nm (80 lb-in).
Fig 68: Identifying Intermediate Shaft And Turbine Shaft Speed (TSS) Sensor
Courtesy of FORD MOTOR CO.
64. Install the output shaft speed (OSS) sensor.
    1. Install the OSS sensor.
    2. Install the OSS sensor bolt.
       • Tighten to 9 Nm (80 lb-in).
Fig 69: Output Shaft Speed Sensor
Courtesy of FORD MOTOR CO.
65. If a new case was installed, wipe cooler tube case fittings dry. Install new O-rings onto the cooler tube case fittings, apply threadlock and sealer onto the threads and install into the new case.
    • Tighten to 52 Nm (38 lb-ft).
NOTE: Do not damage the fluid pump gear stator support seal when installing the torque converter.
NOTE: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
NOTE: If the torque converter slides out, the hub seal may be damaged.
66. Lubricate the converter hub with clean automatic transmission fluid.
Fig 70: Lubricating Converter Hub With Clean Automatic Transmission Fluid
Courtesy of FORD MOTOR CO.
NOTE: Use care when installing the torque converter to avoid damage to the front pump stator support seal.
NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.
67. Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
Fig 71: Installing Torque Converter Using Special Tools
Courtesy of FORD MOTOR CO.
68. Check the seating of the torque converter.
    1. Place the straightedge across the converter housing.
    2. Make sure there is a gap between the converter pilot face and the straightedge.
    3. Remove the special tools.
Fig 72: Checking If Torque Converter Is Seated
Courtesy of FORD MOTOR CO.
69. Use the special tool to hold the torque converter in place when installing the transmission.
Fig 73: Holding Torque Converter Using Special Tool
Courtesy of FORD MOTOR CO.