Section 1394 (Automatic Transmission - Theory & Operation, & Disassembly & Assembly): Disassembly: Transaxle

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	2-6 Spring Compressor	307-584 (includes 307-584/1 and 307-584/2)
Courtesy of FORD MOTOR CO.	Compressor, Forward Clutch Spring	307-574 (includes 307-574/1 and 307-574/2)
Courtesy of FORD MOTOR CO.	Differential Bearing Cup Remover	307-586
Courtesy of FORD MOTOR CO.	Holding Fixture	307-580
Courtesy of FORD MOTOR CO.	Remover/Installer, Front Wheel Hub	204-069 (T81P-1104-C)
Courtesy of FORD MOTOR CO.	Transfer Gear Bearing Race Remover	307-577

All vehicles 

1. Using the Holding Fixture 307-580, install the transaxle onto the bench.
Fig 1: Identifying Transaxle
Courtesy of FORD MOTOR CO.
NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.47 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
2. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter.
Fig 2: Identifying Torque Converter Bolts
Courtesy of FORD MOTOR CO.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
3. Remove the torque converter from the transaxle.
Fig 3: Identifying Torque Converter Clutch Surface
Courtesy of FORD MOTOR CO.
4. Remove the nut and the manual lever.
Fig 4: Identifying Nut And Manual Lever
Courtesy of FORD MOTOR CO.
NOTE: Note the location of the of the studbolts for assembly.
5. Remove the 14 bolts and the main control cover.
Fig 5: Identifying Main Control Cover
Courtesy of FORD MOTOR CO.
6. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.
Fig 6: Identifying TR Sensor Electrical Connector Lock Tab
Courtesy of FORD MOTOR CO.
7. Disconnect the TR sensor electrical connector.
Fig 7: Identifying TR Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
8. Disconnect the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensor electrical connectors.
   1. TSS sensor.
   2. OSS sensor.
Fig 8: Identifying TSS And OSS Sensors
Courtesy of FORD MOTOR CO.
9. Remove the OSS sensor wire from the retainer.
Fig 9: Identifying OSS Sensor Wiring Harness
Courtesy of FORD MOTOR CO.
NOTE: Handle the solenoid body with care or damage to the solenoid body may occur.
NOTE: Note the location of the different length bolts for assembly.
10. Remove the 11 bolts and the solenoid body.
Fig 10: Identifying Solenoid Body
Courtesy of FORD MOTOR CO.
11. Remove the 10 main control valve body bolts and the valve body.
Fig 11: Identifying Valve Body
Courtesy of FORD MOTOR CO.
NOTE: Gently pry the pin out of the hole from under the head on each side with a suitable tool or the pin may be broken off in the hole.
12. Using a suitable tool, remove and discard the TR sensor locking pin.
Fig 12: Identifying TR Sensor Locking Pin
Courtesy of FORD MOTOR CO.
13. Remove the TR sensor.
    1. Slide the TR sensor out of the transaxle case.
    2. Rotate the TR sensor detent plate until it rests against the transaxle case.
    3. Remove the park pawl actuator rod from the detent lever and remove the TR sensor.
Fig 13: Identifying TR Sensor
Courtesy of FORD MOTOR CO.
14. Using a suitable tool, remove the manual lever shaft seal.
Fig 14: Removing Manual Lever Shaft Seal
Courtesy of FORD MOTOR CO.
15. Using a suitable tool, remove the forward clutch feed seal.
Fig 15: Removing Forward Clutch Feed Seal
Courtesy of FORD MOTOR CO.
16. Remove the bolt and the OSS sensor.
Fig 16: Identifying OSS Sensor
Courtesy of FORD MOTOR CO.
17. Remove the 10 cover assembly bolts.
Fig 17: Identifying Cover Assembly Bolts
Courtesy of FORD MOTOR CO.
18. Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transaxle case.
Fig 18: Identifying Turbine Shaft Speed (TSS) Sensor Harness
Courtesy of FORD MOTOR CO.
19. Remove the cover assembly gasket.
Fig 19: Identifying Cover Assembly Gasket
Courtesy of FORD MOTOR CO.
20. Remove the No. 1 cover assembly thrust bearing.
Fig 20: Identifying No. 1 Cover Assembly Thrust Bearing
Courtesy of FORD MOTOR CO.
21. Remove the overdrive/direct clutch hub and turbine shaft assembly.
Fig 21: Identifying Overdrive/direct Clutch Hub And Turbine Shaft Assembly
Courtesy of FORD MOTOR CO.
22. Remove No. 3 rear sun gear thrust bearing.
Fig 22: Identifying No. 3 Rear Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
23. Remove the intermediate clutch shell and sun gear assembly.
Fig 23: Identifying Rear Sun Gear And Shell Assembly
Courtesy of FORD MOTOR CO.
24. Remove the intermediate clutch assembly.
Fig 24: Identifying Intermediate Clutch Assembly
Courtesy of FORD MOTOR CO.
NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low One-Way Clutch (OWC) snap ring.
25. Remove the low/reverse clutch assembly.
Fig 25: Identifying Low/Reverse Clutch Assembly
Courtesy of FORD MOTOR CO.
26. Remove the rear planetary carrier and center ring gear assembly.
Fig 26: Identifying Rear Planetary Gear Carrier Assembly
Courtesy of FORD MOTOR CO.
27. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
Fig 27: Identifying No. 6 Center Sun Gear
Courtesy of FORD MOTOR CO.
28. Remove the center planetary sun gear.
Fig 28: Identifying Center Planetary Sun Gear
Courtesy of FORD MOTOR CO.
29. Remove the center planetary carrier and front ring gear assembly.
Fig 29: Identifying Center Planetary Carrier And Front Ring Gear Assembly
Courtesy of FORD MOTOR CO.
30. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
Fig 30: Identifying No. 7 Center Sun Gear
Courtesy of FORD MOTOR CO.
31. Remove the front planetary carrier and rear ring gear assembly.
Fig 31: Identifying Front Carrier And Rear Ring Gear Assembly
Courtesy of FORD MOTOR CO.
32. Remove the front planetary sun gear and shell assembly.
Fig 32: Identifying Front Sun Gear And Shell Assembly
Courtesy of FORD MOTOR CO.
33. Remove the No. 10 front sun gear thrust bearing.
Fig 33: Identifying No. 10 Front Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
34. Remove the front planetary carrier hub assembly.
Fig 34: Identifying Front Planetary Carrier Hub Assembly
Courtesy of FORD MOTOR CO.
35. Remove the No. 11 support assembly thrust bearing.
Fig 35: Identifying No. 11 Stator Support Thrust Bearing
Courtesy of FORD MOTOR CO.
NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.
36. Remove the low OWC snap ring.
Fig 36: Identifying Low OWC Snap Ring
Courtesy of FORD MOTOR CO.
37. Remove the low OWC.
Fig 37: Identifying Low OWC
Courtesy of FORD MOTOR CO.
38. Remove the forward clutch assembly.
Fig 38: Identifying Forward Clutch Assembly
Courtesy of FORD MOTOR CO.
NOTE: Install the 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
39. Using the 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) compress the forward clutch piston return spring.
Fig 39: Identifying Forward Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
NOTE: The 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) are not shown for clarity.
40. Remove the forward clutch piston return spring snap ring.
Fig 40: Identifying Forward Clutch Piston Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
41. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2).
Fig 41: Identifying Forward Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
42. Remove the forward clutch piston return spring.
Fig 42: Identifying Forward Clutch Piston Return Spring
Courtesy of FORD MOTOR CO.
43. Using a suitable tool, remove and discard the forward clutch piston.
Fig 43: Identifying Forward Clutch Piston
Courtesy of FORD MOTOR CO.
NOTE: Note the location of the studbolts for assembly.
44. Remove the 19 torque converter housing bolts.
Fig 44: Identifying Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
NOTE: Carefully pry on the transaxle torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.
45. Using a suitable tool, carefully pry the torque converter housing off the transaxle case just enough to break the seal of the silicone and remove the torque converter housing from the transaxle case.
Fig 45: Prying Torque Converter Housing
Courtesy of FORD MOTOR CO.
46. Remove the transaxle lube tube.
Fig 46: Identifying Transaxle Lube Tube
Courtesy of FORD MOTOR CO.
47. Remove the differential and ring gear assembly.
Fig 47: Identifying Differential And Ring Gear Assembly
Courtesy of FORD MOTOR CO.
48. Remove the transfer shaft and gear assembly.
Fig 48: Identifying Transfer Shaft And Gear Assembly
Courtesy of FORD MOTOR CO.
49. Remove the pump-to-case seal.
Fig 49: Identifying Pump-to-case Seal
Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the oil reservoir.
Fig 50: Identifying Oil Reservoir Bolts
Courtesy of FORD MOTOR CO.
51. Using a suitable tool, remove the reservoir O-ring seal.
Fig 51: Identifying Reservoir O-ring Seal
Courtesy of FORD MOTOR CO.
NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed or excessive noise or transaxle failure may occur.
52. Inspect the transaxle case side transfer shaft bearing cup for damage.
Fig 52: Identifying Transfer Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
53. If the transaxle case side transfer shaft bearing cup is damaged, install Transfer Gear Bearing Race Remover 307-577 on the bearing cup.
Fig 53: Identifying Transfer Gear Bearing Race Remover
Courtesy of FORD MOTOR CO.
54. Install Front Wheel Hub Remover/Installer 204-069.
Fig 54: Identifying Front Wheel Hub Remover/Installer
Courtesy of FORD MOTOR CO.
55. Using a wrench, turn the nut on Front Wheel Hub Remover/Installer 204-069 to remove the transfer shaft bearing cup from the transaxle case.
Fig 55: Identifying Front Wheel Hub Remover/Installer
Courtesy of FORD MOTOR CO.
56. If the transaxle case side transfer shaft bearing cup was removed, using a suitable tool, punch a hole in the fluid dam.
Fig 56: Punching Hole In Fluid Dam
Courtesy of FORD MOTOR CO.
57. If the transfer shaft bearing cup was removed, using a suitable dent puller, remove the fluid dam from the transaxle case.
Fig 57: Removing Fluid Dam
Courtesy of FORD MOTOR CO.
58. Using a suitable tool, remove the halfshaft seal from the transaxle case.
Fig 58: Identifying Halfshaft Seal
Courtesy of FORD MOTOR CO.
NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed or excessive noise or transaxle failure may occur.
59. Inspect the transaxle case side differential bearing cup for damage.
Fig 59: Identifying Side Differential Bearing Cup
Courtesy of FORD MOTOR CO.
60. If the transaxle case side differential bearing cup is damaged, install the Differential Bearing Cup Remover 307-586 on the bearing cup.
    1. Position the Differential Bearing Cup Remover 307-586 in the transaxle case with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the transaxle case.
    2. Expand the Differential Bearing Cup Remover 307-586 by hand.
    3. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the transaxle case, tighten the nut.
Fig 60: Identifying Differential Bearing Cup Remover
Courtesy of FORD MOTOR CO.
61. Using a suitable press, press the differential bearing cup out of the transaxle case.
Fig 61: Pressing Differential Bearing Cup
Courtesy of FORD MOTOR CO.
62. Remove the park pawl actuator rod.
Fig 62: Identifying Park Pawl Actuator Rod
Courtesy of FORD MOTOR CO.
63. Remove the 2 bolts and the park pawl pin retainer.
Fig 63: Identifying Park Pawl Pin Retainer
Courtesy of FORD MOTOR CO.
NOTE: Note the orientation of the park pawl spring for assembly.
64. Remove the park pawl spring.
Fig 64: Identifying Park Pawl Spring
Courtesy of FORD MOTOR CO.
65. Remove the park pawl pin and the park pawl.
Fig 65: Identifying Park Pawl Pin And Park Pawl
Courtesy of FORD MOTOR CO.
66. Using a magnet, remove the park pawl abutment pins and the abutment.
Fig 66: Identifying Park Pawl Abutment Pins
Courtesy of FORD MOTOR CO.
67. Remove the bolt and the fluid baffle from the torque converter housing.
Fig 67: Identifying Bolt And Fluid Baffle
Courtesy of FORD MOTOR CO.
68. Remove the 10 stator support assembly bolts.
Fig 68: Identifying Stator Support Assembly Bolts
Courtesy of FORD MOTOR CO.
69. Remove the stator support assembly.
Fig 69: Identifying Stator Support Assembly
Courtesy of FORD MOTOR CO.
70. Remove the 3 bolts and the fluid pump and filter assembly.
Fig 70: Identifying Fluid Pump And Filter Assembly
Courtesy of FORD MOTOR CO.
71. Remove the fluid pump sprocket and chain assembly.
Fig 71: Identifying Fluid Pump Sprocket And Chain Assembly
Courtesy of FORD MOTOR CO.
72. Remove the fluid pump drive sprocket and driven sprocket thrust washers.
Fig 72: Identifying Pump Drive Sprocket And Driven Sprocket Thrust Washers
Courtesy of FORD MOTOR CO.
73. Install the Transfer Gear Bearing Race Remover 307-577 on the bearing cup.
Fig 73: Identifying Transfer Gear Bearing Race Remover
Courtesy of FORD MOTOR CO.
74. Install Front Wheel Hub Remover/Installer 204-069.
Fig 74: Identifying Front Wheel Hub Remover/Installer
Courtesy of FORD MOTOR CO.
75. Using a wrench, turn the nut on Front Wheel Hub Remover/Installer 204-069 to remove the transfer shaft bearing cup from the torque converter housing.
Fig 75: Identifying Front Wheel Hub Remover/Installer
Courtesy of FORD MOTOR CO.
76. Remove the preload shim.
Fig 76: Identifying Transfer Shaft Preload Shim
Courtesy of FORD MOTOR CO.
77. Using a suitable tool, punch a hole in the fluid dam.
Fig 77: Punching Hole In Fluid Dam
Courtesy of FORD MOTOR CO.
78. If the transfer shaft bearing cup was removed, using a suitable dent puller, remove the fluid dam from the torque converter housing.
Fig 78: Removing Fluid Dam
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

79. Using a suitable tool, remove the halfshaft seal from the torque converter housing.
Fig 79: Removing Halfshaft Seal
Courtesy of FORD MOTOR CO.

All vehicles 

80. Install the Differential Bearing Cup Remover 307-586 on the bearing cup.
    1. Position the Differential Bearing Cup Remover 307-586 in the torque converter housing with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the transaxle case.
    2. Expand the Differential Bearing Cup Remover 307-586 by hand.
    3. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the transaxle case, tighten the nut.
Fig 80: Tightening Nut
Courtesy of FORD MOTOR CO.
81. Using a suitable press, press the differential bearing cup out of the torque converter housing.
Fig 81: Identifying Differential Bearing Cup
Courtesy of FORD MOTOR CO.
82. Remove the differential bearing preload shim.
Fig 82: Identifying Differential Bearing Preload Shim
Courtesy of FORD MOTOR CO.
83. Using a suitable dent puller, remove the torque converter hub seal from the torque converter housing.
Fig 83: Identifying Torque Converter Hub Seal
Courtesy of FORD MOTOR CO.