Transmission, Disassembled View

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Fig 1: Exploded View Of Transmission (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Transmission (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Transmission (3 Of 3)

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6441	Torque converter nut (8 required)
2	7902	Torque converter assembly
3	7017	Shaft - input
4	7L323	Seal - stator support
5	7A248	Seal - pump support
6	7A248	Seal - front pump
7	7N134	Bolt - M8 x 70 hex flange head
8	7A103	Pump assembly - front
9	N606042	Bolts - M8 x 1.25 x 45 - front pump
10	7D014	Washer - pump support No. 1T
11	7A136	Gasket - pump
12	7G402	Seal - coast clutch (2 required)
13	7C096	Race and bearing assembly - sun gear thrust No. 2B and 3B
14	7A262	Piston - overdrive clutch
15	7F222	Spring - overdrive clutch piston return
16	7B164	Plates - overdrive clutch internal spline - friction
17	7B442	Plates - overdrive clutch external spline - steel
18	7B066	Plate - overdrive clutch pressure
19	7D483	Ring - overdrive clutch press plate retaining
20	7G387	Cylinder and bushing assembly - coast clutch
21	7A262	Piston - coast clutch
22	7G299	Spring - coast clutch return
23	7A527	Ring - coast clutch spring retaining
24	7B164	Plates - coast clutch internal spline - friction
25	7B442	Plates - coast clutch external spline - steel
26	7A089	Clutch assembly - coast one-way
27	7D063	Gear - overdrive sun
28	7A577	Ring - 172.5 retainer internal style No. 2
29	W708120	Bolt - coast clutch hub (4 required)
30	7H501	Hub assembly - input coast clutch
31	7B446	Gear assembly - overdrive planetary
32	7F240	Bearing and race assembly - direct clutch No. 4B
33	7A153	Gear - overdrive ring
34	7A658	Shaft - overdrive center
35	7G375	Ring - center support retaining
36	7G178	Bearing and race assembly - sun gear thrust No. 5B
37	7D483	Ring - overdrive ring gear retaining
38	7A130	Support assembly - center
39	7N134	Bolt - M12 x 1.75 x 31 hex flange head (intermediate clutch feed)
40	7N134	Bolt - M12 x 1.75 x 31 hex flange head (forward clutch feed)
41	7D025	Seals - Teflon® (2 required)
42	7L326	Washer - center support thrust No. 6T
43	7E005	Piston - intermediate clutch
44	7F222	Support and spring assembly - intermediate clutch
45	7D483	Ring - intermediate clutch spring
46	7F219	Plates - intermediate clutch internal spline (friction)
47	7B442	Plates - intermediate clutch external spline (steel)
48	7B066	Plate - intermediate clutch pressure
49	7F283	Cylinder and hub assembly - direct clutch
50	7A262	Piston assembly - direct clutch
51	7B070	Spring - direct clutch piston return
52	7H359	Piston - direct clutch balance
53	7C122	Ring - direct clutch balance piston retaining
54	7B164	Plates - direct clutch internal spline - friction
55	7B442	Plates - direct clutch external spline - steel
56	7B066	Plate - direct clutch pressure
57	377127	Ring - direct clutch plate retaining (selective fit)
58	7C096	Washer - intermediate brake thrust No. 7T
59	7F374	Bearing assembly - intermediate clutch No. 8B
60	7D019	Seals - forward clutch cylinder (2 required)
61	7A360	Cylinder assembly - forward clutch
62	7A262	Piston assembly - forward clutch
63	7B070	Spring - forward clutch piston return
64	7H360	Piston assembly - forward clutch balance
65	7H365	Ring - forward clutch balance piston retaining
66	7B070	Spring - forward clutch cushion
67	7B164	Plates - forward clutch internal spline - friction
68	7B442	Plates - forward clutch external spline - steel
69	7B066	Forward clutch pressure plate
70	7D483	Ring - forward clutch plate retaining (selective fit)
71	7D090	Washer - forward clutch hub thrust No. 9T
72	7G375	Ring - retaining (forward ring gear)
73	7D234	Bearing and race assembly - sun gear thrust No. 10B, 12B, 15B
74	7B067	Hub and bushing assembly - forward ring gear
75	7D392	Gear - forward ring
76	7A166	Bearing and race assembly - forward carrier No. 11B
77	7A398	Planet assembly - forward
78	7L339	Lube dam - forward carrier
79	7D062	Shell and sun gear assembly
80	7D483	Ring - reverse clutch plate retaining
81	7D006	Planet assembly - reverse (with clutch plates)
82	7A153	Gear - output shaft ring
83	7D164	Hub - output shaft ring gear
84	7G375	Ring - retaining (reverse ring gear)
85	7G178	Bearing and race assembly No. 16B
86	7D483	Ring - reverse clutch spring retaining
87	7D406	Retainer and spring assembly - reverse clutch
88	7D402	Piston - reverse clutch
89	7D019	Seals - Teflon®
90	7R411	Seal assembly - intermediate brake drum
91	7A020	Indicator - fluid level
92	7A228	Tube assembly - fluid fill
93	391308	O-ring
94	7A160	Tube - fluid inlet short
95	7005	Case assembly
96	7034	Vent assembly - case
97	7D273	Cooler line - case fittings
98	W708418	O-rings - cooler connector
99	7Z101	O-ring - sensor
100	7M101	Sensor -/intermediate shaft speed
101	N805503	Bolts - M6 x 1 x 15.2
102	7034	Case vent assembly PTO only
103	7J122	Valve - air bleed check
104	7025	Snubber - output shaft
105	7E380	Plug - case oil filler
106	7A233	Gears - output shaft parking
107	378259	Plug cups
108	7086	Gaskets - extension housing
109	7Z101	O-ring - OSS sensor
110	7H103	Sensor - OSS
111	N606569	Bolts - M10 x 1.5 x 93.5 extension housing
112	N605803	Bolts - M10 x 1.5 x 40 extension housing
113	7B368	Washer - park gear thrust No. 17 T
114	7060	Shaft - output (model dependent)
115	7A039	Extension assembly
116	7052	Seal assembly - extension housing
117	7085	Retainer assembly - transmission output shaft
118	4K177	Flange - drive shaft RWD
119	W708831	Bolt - M12 x 55 RWD
120	7223	PTO - cover gasket
121	7222	PTO - case cover
122	W708587	Bolt - M10 1.5 x 24 hex flange head
123	N805232	Screw and washer - M8 x 1.25 x 23.5 hex (2 required)
124	7D419	Plate - park rod guide
125	7D070	Spring - park pawl return
126	7D071	Pin - 0.5 x 1.91 dowel ground hardened
127	7A441	Pawl - park
128	N805261	Screw - M8 x 1.25 x 25 pan head
129	7G101	Abutment - park pawl
130	372552	Spring nut
131	7B148	Tag - transmission service identification
132	7A232	Rod assembly - park pawl actuating
133	7A256	Lever assembly - manual control
134	7H557	TR detent assembly
135	N805503	Bolts - M6 x 1.0 x 15.2 hex flange head transmission range
136	7G100	Pin - shaft retaining
137	7B498	Seal - manual lever
138	7B210	Roll pin - manual control lever to case
139	390685	Plug - line pressure
140	7Z302	Seal - filter
141	7G186	Filter and seal assembly
142	7A191	Gasket - fluid pan
143	7A194	Fluid pan
144	7L027	Ceramic magnet - fluid pan
145	6730	Plug - fluid pan drain
146	N811266	Bolt - fluid pan
147	7Z276	O-ring - bulkhead connector
148	7C155	Gasket - control valve body
149	-	Ditch plate
150	7H200	Gasket - filter plate
151	-	Manifold body
152	7E335	W clip - pressure switch plug
153	7E440	Plug - direct clutch
154	7H141	Sensor - TFT
155	7H038	Gasket - backing plate
156	-	Backing plate
157	7D389	Valve - manual
158	W500100	Bolt - M6 x 1 x 30 hex head (5 required)
159	W300512	Bolt - M6 x 15.2 solenoid backing plate-to-ditch plate (5 required)
160	W300513	Bolt - M6 x 27.5 solenoid manifold-to-ditch plate (3 required)
161	N805326	Bolt - M6 x 1.0 x 42.5 hex flange head (3 required)
162	W300511	Bolt - M6 x 55 solenoid manifold-to-ditch plate (1 required)
163	W708500	Bolt - M6 x 68 hex flange (13 required)
164	7G383	VFS - line pressure
165	7J136	VFS - directly proportional (4 required)
166	7J136	VFS - inversely proportional (2 required)
167	7J137	VFS - E clip (7 required)
168	7G276	Wiring harness
169	-	Bolt - T25 holds wire harness to manifold (2 required)
170	-	Overdrive clutch assembly
171	-	Coast clutch assembly
172	-	PTO only
173	-	Intermediate clutch assembly
174	-	Direct clutch assembly
175	-	Forward clutch and planetary assembly
176	-	Reverse clutch and planetary assembly
177	7A039	Extension housing assembly
178	-	PTO model only
179	-	PTO model only

NOTE: Soak all friction clutch plates in transmission fluid.

NOTE: Prior to installation, lightly lubricate all O-ring seals with transmission fluid.

NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

Mount the transmission case into a suitable stand.
If installing a new case, install the transmission fluid cooler tube nut case fittings. Coat the threads with threadlock sealant.
- Tighten to 51 Nm (38 lb-ft).
If removed, use the Fluid Filler Tube Installer to install the short transmission fluid inlet tube.

Fig 4: Installing Short Transmission Fluid Inlet Tube Using Fluid Filler Tube Installer
Courtesy of FORD MOTOR CO.
If removed, use the Output Shaft Seal/Housing Installer to install a new Teflon® seal retainer.
- Install 2 new Teflon® seals.
  
  Fig 5: Installing Teflon® Seal Retainer Using Output Shaft Seal/Housing Installer
  Courtesy of FORD MOTOR CO.
NOTE: Coat the reverse clutch piston seals with petroleum jelly.

Install the reverse clutch piston in the case until it is fully seated in the case.

Fig 6: Locating Reverse Piston
Courtesy of FORD MOTOR CO.
Install the reverse clutch return spring assembly.

Fig 7: Locating Return Spring
Courtesy of FORD MOTOR CO.
NOTE: Do not over compress the return spring or damage to the spring will occur.

Using the Clutch Spring Compressor Aligner and the Clutch Spring Compressor, install the reverse clutch return spring snap ring.

Fig 8: Removing\Installing Reverse Clutch Return Spring Retaining 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.

Install the No. 17 park gear thrust washer.

Fig 9: Locating Output Shaft 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.

Install the output shaft.

Fig 10: 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.

If removed, install the park pawl abutment with a new Torx screw.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 11: Locating Park Pawl Abutment Torx Screw
  Courtesy of FORD MOTOR CO.
Install the park pawl.
1. Install the park pawl shaft.
2. Install the park pawl.
3. Install the park pawl return spring.
  
  Fig 12: Identifying Park Pawl Shaft, Park Pawl And Park Pawl Return Spring
  Courtesy of FORD MOTOR CO.
NOTE: Make sure the dimple on the park guide support plate is facing inward.

Install the park rod guide plate.
1. Install the park rod guide plate.
2. Install the bolts.
  - Tighten to 25 Nm (18 lb-ft).
    
    Fig 13: Identifying Park Rod Guide Plate And Bolts
    Courtesy of FORD MOTOR CO.
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 14: Locating Orifice Lube Plug
Courtesy of FORD MOTOR CO.
Install a new extension housing gasket.

Fig 15: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
Install the extension housing and the transmission extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 16: Locating Extension Housing-To-Case Bolts
  Courtesy of FORD MOTOR CO.
Using the Shift Shaft Fluid Seal Installer, install a new manual control lever seal.

Fig 17: Installing Manual Control Lever Seal Using Shift Shaft Fluid Seal Installer
Courtesy of FORD MOTOR CO.
Install the TR sensor, park rod assembly and loosely install the bolts.

Fig 18: Locating TR Sensor And Park Rod Assembly
Courtesy of FORD MOTOR CO.
Install the manual control lever.

Fig 19: Identifying Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the manual control lever shaft retaining pin into the case.

Fig 20: Locating Manual Control Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
Install a new manual control valve detent lever shaft retaining pin. Leave 2 mm (0.078 in) of the pin exposed.

Fig 21: Locating Manual Control Valve Detent Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
Tighten the TR sensor bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 22: Locating TR Sensor And Park Rod Assembly
  Courtesy of FORD MOTOR CO.
Using the Transmission Extension Housing Seal Installer, install a new extension housing seal.

Fig 23: Installing Extension Housing Seal Using Transmission Extension Housing Seal Installer
Courtesy of FORD MOTOR CO.
Inspect the new output shaft nut O-ring for cuts. If cut, install a new output shaft nut.

Fig 24: Locating Output Shaft Nut O-Ring
Courtesy of FORD MOTOR CO.
Using the Output Shaft Locknut Socket, install a new output shaft nut.
- Tighten to 200 Nm (148 lb-ft).
  
  Fig 25: Removing\Installing Output Shaft Nut Using Output Shaft Locknut Socket
  Courtesy of FORD MOTOR CO.
If equipped, install the output flange and a new output flange bolt.
- Tighten to 130 Nm (96 lb-ft).
  
  Fig 26: Locating Output Shaft Flange Bolt
  Courtesy of FORD MOTOR CO.
Install the No. 16 bearing and race.

Fig 27: Locating Low Reverse No. 16 Thrust Bearing
Courtesy of FORD MOTOR CO.
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 28: Installing No. 15 Hub Bearing Onto Ring Gear Hub
  Courtesy of FORD MOTOR CO.
NOTE: Place the transmission in the horizontal position.

Install the rocker clutch and ring gear assembly into the transmission case.

Fig 29: Installing Rocker Clutch And Ring Gear Assembly Into Transmission Case
Courtesy of FORD MOTOR CO.
NOTE: Do not apply air pressure to move the low/reverse piston without first installing the rocker clutch snap ring, or damage to the snap ring will occur.

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 in illustration.
- 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 30: Locating Reverse Clutch Air Applying Passage
  Courtesy of FORD MOTOR CO.
Using the Transmission Forward Clutch Assembly Installer and Adapter, install the forward geartrain as an assembly.

Fig 31: Installing Forward Geartrain Using Transmission Forward Clutch Assembly Installer And Adapter
Courtesy of FORD MOTOR CO.
Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.
  
  Fig 32: Identifying Intermediate Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the intermediate clutch plates, starting with a friction plate.

Fig 33: Identifying Intermediate Clutch Plates, Starting With Friction Plate
Courtesy of FORD MOTOR CO.
Install the center support with the transmission in a position that will avoid damage to the center support Teflon® seals.

Fig 34: Locating Center Support Teflon® Seals
Courtesy of FORD MOTOR CO.
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 35: Locating Hex Head Intermediate Clutch Feed Bolt And Forward Clutch Feed Bolt
  Courtesy of FORD MOTOR CO.
Using the Retaining Ring Pliers, 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 36: Installing Center Support Snap Ring Using Retaining Ring Pliers
  Courtesy of FORD MOTOR CO.
Tighten the feed bolts.
- Tighten to 32 Nm (24 lb-ft).
  
  Fig 37: Locating Feed Bolts
  Courtesy of FORD MOTOR CO.
Install the No. 5 thrust bearing onto the center support.

Fig 38: Locating No. 5 Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the center shaft and ring gear.

Fig 39: Locating Ring Gear
Courtesy of FORD MOTOR CO.
Install the No. 4 thrust bearing onto the center shaft.

Fig 40: Locating No. 4 Thrust Bearing
Courtesy of FORD MOTOR CO.
Using the Clutch Loading Fixture, install the coast clutch assembly and overdrive carrier.

Fig 41: Removing\Installing Coast Clutch Cylinder Assembly Using Clutch Loading Fixture
Courtesy of FORD MOTOR CO.
Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position.

Fig 42: Locating Overdrive Clutch Assembly Snap Ring
Courtesy of FORD MOTOR CO.
Install the overdrive pressure plate with the notches facing up.

Fig 43: Locating Overdrive Pressure Plate Notches
Courtesy of FORD MOTOR CO.
Install the overdrive clutch.
- Start with a friction plate, alternating with a steel plate.
  
  Fig 44: Locating Overdrive Clutch Friction Plate
  Courtesy of FORD MOTOR CO.
Install a new pump gasket.

Fig 45: Locating Pump Gasket
Courtesy of FORD MOTOR CO.
Install the No. 2 thrust bearing.

Fig 46: Locating No. 2 Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the input shaft into the case.

Fig 47: Locating Input Shaft
Courtesy of FORD MOTOR CO.
NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.

Install the Transmission Fluid Pump Aligner into the case in order to install the pump.

Fig 48: Installing Transmission Fluid Pump Aligner Into Case
Courtesy of FORD MOTOR CO.
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.

Using the Transmission Fluid Pump Aligner, install the pump assembly with the transmission in a position that will avoid damage to the pump stator support Teflon® seals.

Fig 49: Installing Pump Assembly Using Transmission Fluid Pump Aligner
Courtesy of FORD MOTOR CO.
Install new pump body-to-case bolts.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 50: Locating Pump Body-To-Case Bolts
  Courtesy of FORD MOTOR CO.
Install a new main control body gasket.

Fig 51: Locating Main Control Body Gasket
Courtesy of FORD MOTOR CO.

Using the Transmission Air Test Plate along with the Transmission Test Plate Screw Set, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.

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

Fig 52: Identifying Transmission Air Test Plate Components

Courtesy of FORD MOTOR CO.

Using the Valve Body Aligner, install the solenoid body and loosely install the bolts.
- While installing the solenoid body, align the manual valve.
  
  Fig 53: Installing Solenoid Body And Bolts Using Valve Body Aligner
  Courtesy of FORD MOTOR CO.
Tighten all the bolts in the sequence shown in illustration.
- Tighten to 13 Nm (115 lb-in).
  
  Fig 54: Identifying Solenoid Body Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Connect the TR sensor.

Fig 55: Locating TR Sensor
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.

Install a new transmission fluid filter.

Fig 56: Locating Filter And Seal Assembly
Courtesy of FORD MOTOR CO.
NOTE: Reuse the transmission fluid pan gasket unless it is damaged.

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 57: Locating Transmission Fluid Pan Gasket And Magnet
Courtesy of FORD MOTOR CO.
Install the transmission fluid pan.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 58: Locating Transmission Fluid Pan Bolt
  Courtesy of FORD MOTOR CO.
Install the TSS/intermediate shaft speed sensor.
1. Install the TSS/intermediate shaft speed sensor.
2. Install the TSS/intermediate shaft speed sensor bolt.
  - Tighten to 9 Nm (80 lb-in).
    
    Fig 59: Identifying TSS And Intermediate Shaft Speed Sensor And Bolt
    Courtesy of FORD MOTOR CO.
Install the OSS sensor.
1. Install the OSS sensor.
2. Install the OSS sensor bolt.
  - Tighten to 9 Nm (80 lb-in).
    
    Fig 60: Identifying OSS Sensor And Bolt
    Courtesy of FORD MOTOR CO.
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 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.

Lubricate the converter hub with automatic transmission fluid.

Fig 61: Identifying Lubricate Converter Hub With Automatic Transmission Fluid
Courtesy of FORD MOTOR CO.
NOTE: Use care when installing the torque converter to avoid damage to the pump stator support seal.

NOTE: Check the torque converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the torque converter impeller hub for nicks or sharp edges that can damage the pump seal.

Using the Torque Converter Handles, install the torque converter. Push and rotate the torque converter onto the pump assembly until it bottoms out.

Fig 62: Installing Torque Converter Using Torque Converter Handles
Courtesy of FORD MOTOR CO.
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 Torque Converter Handles.
  
  Fig 63: Removing Torque Converter Handles
  Courtesy of FORD MOTOR CO.
Use the Torque Converter Retainer to hold the torque converter in place when installing the transmission.

Fig 64: Installing Transmission Using Torque Converter Retainer
Courtesy of FORD MOTOR CO.
If PTO cover was removed, install a new PTO gasket and install the PTO cover.
- Tighten to 25 Nm (18 lb-ft).