Special Tool(s)

Courtesy of FORD MOTOR CO.	Compressor, Forward Clutch Spring 307-574 (includes 307-574/1 and 307-574/2)
Courtesy of FORD MOTOR CO.	Compressor, Forward/Intermediate Spring 307-584 (includes 307-584/1 and 307-584/2)
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: Installing Transaxle Onto Bench Using Holding Fixture 307-580

   Courtesy of FORD MOTOR CO.
NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
Fig 2: Locating Torque Converter Bolts
Courtesy of FORD MOTOR CO.
2. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter.
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 3: Removing Torque Converter From Transaxle
Courtesy of FORD MOTOR CO.
3. Remove the torque converter from the transaxle.
4. Remove the nut and the manual lever.
   Fig 4: Locating Manual Lever And Nut

   Courtesy of FORD MOTOR CO.
NOTE: Note the location of the of the studbolts for assembly.
Fig 5: Locating Main Control Cover And Bolts
Courtesy of FORD MOTOR CO.
5. Remove the 14 bolts and the main control cover.
6. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.
   Fig 6: Sliding Transmission Range Sensor Electrical Connector Lock Tab

   Courtesy of FORD MOTOR CO.
7. Disconnect the TR  sensor electrical connector.
   Fig 7: Locating 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 Sensor And OSS Sensor

      Courtesy of FORD MOTOR CO.
9. Remove the OSS  sensor wire from the retainer.
   Fig 9: Locating OSS Sensor Wire From Retainer

   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.
Fig 10: Locating Solenoid Body And Bolts
Courtesy of FORD MOTOR CO.
10. Remove the 11 bolts and the solenoid body.
11. Remove the 10 main control valve body bolts and the valve body.
    Fig 11: Locating Main Control Valve Body Bolts

    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.
Fig 12: Locating TR Sensor Locking Pin
Courtesy of FORD MOTOR CO.
12. Using a suitable tool, remove and discard the TR  sensor locking pin.
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: Sliding 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 Using Suitable Tool

    Courtesy of FORD MOTOR CO.
15. Using a suitable tool, remove the forward clutch feed seal.
    Fig 15: Removing Forward Clutch Feed Seal Using Suitable Tool

    Courtesy of FORD MOTOR CO.
16. Remove the bolt and the OSS  sensor.
    Fig 16: Locating OSS Sensor And Bolt

    Courtesy of FORD MOTOR CO.
17. Remove the 10 cover assembly bolts.
    Fig 17: Locating 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: Removing Cover Assembly

    Courtesy of FORD MOTOR CO.
19. Remove the cover assembly gasket.
    Fig 19: Removing Cover Assembly Gasket

    Courtesy of FORD MOTOR CO.
20. Remove the No. 1 cover assembly thrust bearing.
    Fig 20: Removing No. 1 Cover Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
21. Remove the overdrive/direct clutch hub and turbine shaft assembly.
    Fig 21: Removing Overdrive/Direct Clutch Hub And Turbine Shaft Assembly

    Courtesy of FORD MOTOR CO.
22. Remove No. 3 rear sun gear thrust bearing.
    Fig 22: Removing No. 3 Rear Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
23. Remove the intermediate clutch shell and sun gear assembly.
    Fig 23: Removing Intermediate Clutch Shell And Sun Gear Assembly

    Courtesy of FORD MOTOR CO.
24. Remove the intermediate clutch assembly.
    Fig 24: Removing 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.
Fig 25: Locating Low/Reverse Clutch Assembly
Courtesy of FORD MOTOR CO.
25. Remove the low/reverse clutch assembly.
26. Remove the rear planetary carrier and center ring gear assembly.
    Fig 26: Removing Rear Planetary Carrier And Center Ring Gear 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: Removing No. 6 Center Sun Gear And Rear Planetary Thrust Bearings

    Courtesy of FORD MOTOR CO.
28. Remove the center planetary sun gear.
    Fig 28: Removing Center Planetary Sun Gear

    Courtesy of FORD MOTOR CO.
29. Remove the center planetary carrier and front ring gear assembly.
    Fig 29: Removing 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: Removing Front Planetary Carrier And Rear Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
32. Remove the front planetary sun gear and shell assembly.
    Fig 32: Removing Front Planetary Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
33. Remove the No. 10 front sun gear thrust bearing.
    Fig 33: Removing No. 10 Front Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
34. Remove the front planetary carrier hub assembly.
    Fig 34: Locating Front Planetary Carrier Hub Assembly

    Courtesy of FORD MOTOR CO.
35. Remove the No. 11 support assembly thrust bearing.
    Fig 35: Removing No. 11 Support Assembly 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.
Fig 36: Locating OWC Snap Ring
Courtesy of FORD MOTOR CO.
36. Remove the low OWC  snap ring.
37. Remove the low OWC  .
    Fig 37: Removing Low One-Way Clutch

    Courtesy of FORD MOTOR CO.
38. Remove the forward clutch assembly.
    Fig 38: Locating Forward Clutch Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Intermediate 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.
Fig 39: Compressing Forward Clutch Piston Return Spring
Courtesy of FORD MOTOR CO.
39. Using the Forward/Intermediate 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.
NOTE: The Forward/Intermediate 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 in illustration for clarity.
Fig 40: Locating Forward Clutch Piston Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
40. Remove the forward clutch piston return spring snap ring.
41. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).
    Fig 41: Compressing Forward Clutch Piston Return Spring

    Courtesy of FORD MOTOR CO.
42. Remove the forward clutch piston return spring.
    Fig 42: Locating Forward Clutch Piston Return Spring

    Courtesy of FORD MOTOR CO.
43. Using a suitable tool, remove and discard the forward clutch piston.
    Fig 43: Discarding Forward Clutch Piston Using Suitable Tool

    Courtesy of FORD MOTOR CO.
NOTE: Note the location of the studbolts for assembly.
Fig 44: Locating Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
44. Remove the 19 torque converter housing bolts.
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.
Fig 45: Removing Torque Converter Housing From Transaxle Case
Courtesy of FORD MOTOR CO.
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.
46. Remove the transaxle lube tube.
    Fig 46: Locating Transaxle Lube Tube

    Courtesy of FORD MOTOR CO.
47. Remove the differential and ring gear assembly.
    Fig 47: Locating Differential And Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
48. Remove the transfer shaft and gear assembly.
    Fig 48: Locating Transfer Shaft And Gear Assembly

    Courtesy of FORD MOTOR CO.
49. Remove the pump-to-case seal.
    Fig 49: Removing Pump-To-Case Seal

    Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the oil reservoir.
    Fig 50: Locating Oil Reservoir And Bolts

    Courtesy of FORD MOTOR CO.
51. Using a suitable tool, remove the reservoir O-ring seal.
    Fig 51: Removing Reservoir O-ring Seal Using Suitable Tool

    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.
Fig 52: Locating Transaxle Case Side Transfer Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
52. Inspect the transaxle case side transfer shaft bearing cup for damage.
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: Installing Transfer Gear Bearing Race Remover 307-577 On Bearing Cup

    Courtesy of FORD MOTOR CO.
54. Install Front Wheel Hub Remover/Installer 204-069 and thread it into Transfer Gear Bearing Race Remover 307-577.
    Fig 54: Installing Front Wheel Hub Remover

    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: Removing Transfer Shaft Bearing Cup From Transaxle Case

    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 From Transaxle Case

    Courtesy of FORD MOTOR CO.
58. Using a suitable tool, remove the halfshaft seal from the transaxle case.
    Fig 58: Removing Halfshaft Seal From Transaxle Case Using Suitable Tool

    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.
Fig 59: Inspecting Transaxle Case Side Differential Bearing Cup
Courtesy of FORD MOTOR CO.
59. Inspect the transaxle case side differential bearing cup for damage.
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: Holding Differential Bearing Cup Remover 307-586

       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 Out Of Transaxle Case

    Courtesy of FORD MOTOR CO.
62. Remove the park pawl actuator rod.
    Fig 62: Removing Park Pawl Actuator Rod

    Courtesy of FORD MOTOR CO.
63. Remove the 2 bolts and the park pawl pin retainer.
    Fig 63: Locating Park Pawl Pin Retainer And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Note the orientation of the park pawl spring for assembly.
Fig 64: Locating Park Pawl Spring
Courtesy of FORD MOTOR CO.
64. Remove the park pawl spring.
65. Remove the park pawl pin and the park pawl.
    Fig 65: Locating 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: Locating Park Pawl Abutment Pins And Abutment

    Courtesy of FORD MOTOR CO.
67. Remove the bolt and the fluid baffle from the torque converter housing.
    Fig 67: Locating Torque Converter Housing

    Courtesy of FORD MOTOR CO.
68. Remove the 9 stator support assembly bolts.
    Fig 68: Locating Stator Support Assembly Bolts

    Courtesy of FORD MOTOR CO.
69. Remove the stator support assembly.
    Fig 69: Removing Stator Support Assembly

    Courtesy of FORD MOTOR CO.
70. Remove the 3 bolts and the fluid pump and filter assembly.
    Fig 70: Removing Fluid Pump And Filter Assembly

    Courtesy of FORD MOTOR CO.
71. Remove the fluid pump sprocket and chain assembly.
    Fig 71: Locating 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: Locating Fluid 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: Locating Transfer Gear Bearing Race Remover 307-577

    Courtesy of FORD MOTOR CO.
74. Install the Front Wheel Hub Remover/Installer 204-069 and thread it into Transfer Gear Bearing Race Remover 307-577.
    Fig 74: Installing Front Wheel Hub Remover

    Courtesy of FORD MOTOR CO.
75. Using a wrench, turn the nut on the Front Wheel Hub Remover/Installer 204-069 to remove the transfer shaft bearing cup from the torque converter housing.
    Fig 75: Removing Transfer Shaft Bearing Cup From Torque Converter Housing

    Courtesy of FORD MOTOR CO.
76. Remove the preload shim.
    Fig 76: Removing 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 Using Suitable Tool

    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 From Torque Converter Housing

    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 From Torque Converter Housing Using Suitable Tool

    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: Holding Differential Bearing Cup Remover 307-586

       Courtesy of FORD MOTOR CO.
81. Using a suitable press, press the differential bearing cup out of the torque converter housing.
    Fig 81: Pressing Differential Bearing Cup Out Of Torque Converter Housing

    Courtesy of FORD MOTOR CO.
82. Remove the differential bearing preload shim.
    Fig 82: Removing 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: Removing Torque Converter Hub Seal From Torque Converter Housing

    Courtesy of FORD MOTOR CO.