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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 27 (Automatic Transmission - 6R140 (TORQSHIFT-R-6)) >> Disassembly & Assembly >> Transmission - Overhaul >> Pump Assembly Non-PTO

Pump Assembly Non-PTO

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exploded View Of Pump Assembly Non-PTO
G08595033Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7A248-A Torque converter hub seal
2 7A248-D Pump housing seal
3 7L323 Teflon® seals (3 required)
4 W500318 Long pump bolts (7 required)
5 W500525 Short pump bolts (6 required)
6 - Stator support (part of 7A103)
7 - Pump gasket (part of 7A103)
8 - Pump body (part of 7A103)
9 - Pump housing (part of 7A103)
10 - Inner pump gear (part of 7A103)
11 - Outer pump gear (part of 7A103)
12 7A248-E Pump body seal
13 7J021 Anti-drain back valve
14 7A248-B Teflon® seal
15 7A248-C O-ring seal

All vehicles 

  1. Mount the transmission on the Car/Truck Engine Stand.
    Fig 2: Mounting Transmission On Car/Truck Engine Stand
    G08594879Courtesy of FORD MOTOR CO.
  2. Position the transmission upright and remove the Torque Converter Retainer.
    Fig 3: Removing/Installing Torque Converter Retainer
    G08594880Courtesy of FORD MOTOR CO.
  3. Install the Pump Remover/Installer Bracket on the torque converter. Install the pin in the bottom hole.
    Fig 4: Installing Pump Remover/Installer Bracket On Torque Converter
    G08594881Courtesy of FORD MOTOR CO.
  4. Using a Heavy Duty Floor Crane, lift the torque converter. Use enough pressure to break the torque converter hub seal loose and raise the torque converter high enough to allow the torque converter to drain. Remove the torque converter.
    Fig 5: Removing/Installing Torque Converter Using Heavy Duty Floor Crane
    G08594882Courtesy of FORD MOTOR CO.
  5. NOTE: The transmission fluid pan gasket is a reusable gasket. Do not discard the transmission fluid pan gasket.

    Remove the 19 transmission fluid pan bolts and the transmission fluid pan and gasket.

    Fig 6: Locating Transmission Fluid Pan Bolts
    G08595038Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts and the transmission fluid filter.
    Fig 7: Locating Transmission Fluid Filter Mounting Bolts
    G08595039Courtesy of FORD MOTOR CO.
  7. Disconnect the 7 solenoid electrical connectors, 2 speed sensor electrical connectors, TFT sensor electrical connector and the TR sensor electrical connector and position the transmission wiring harness retainer aside.
    G08595040
  8. NOTE: Do not bend the manual valve rod clip when removing the manual valve rod. If the manual valve rod clip is bent back to remove the manual valve rod instead of sliding it off, the manual valve rod clip will become permanently distorted causing total loss of transmission control or transmission failure. If the manual valve rod clip is bent, install a new manual valve rod clip.

    Remove the manual valve rod. Pull the manual valve rod clip tab out of the TR sensor, slide the manual valve rod clip off of the manual valve rod and remove the manual valve rod from the TR sensor and the manual valve.

    1. Manual valve rod clip tab
    2. Manual valve rod clip
    3. TR sensor
    4. Manual valve rod
      G08595041
  9. Remove the 6 main control bolts and remove the main control assembly.
    G08595042
  10. NOTE: Slip yoke shown in illustration, fixed flange/4WD similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.

    Remove the fluid supply feed tube assembly.

    G08595043
  11. Remove the intermediate (2, 6) clutch fluid supply feed tube.
    G08595044
  12. Remove and discard the O-rings from the fluid supply feed tubes.
    Fig 8: Locating Fluid Supply Feed Tube O-Rings
    G08595045Courtesy of FORD MOTOR CO.
  13. Remove the 4 seals.
    G08595046
  14. Clean and inspect the main control for damage. Refer to MAIN CONTROL - OVERHAUL .
  15. NOTE: Note the ports where the different length feed seals are removed from. Failure to install the correct length feed seals in the ports that they were removed from can result in pressure loss and transmission failure.

    Remove the 4 clutch feed seals.

    G08595047
  16. Remove the TSS and OSS sensors.
    G08595048

    Vehicles equipped with a fixed flange transmission 

  17. Remove the bolt and the output shaft flange.
    G08595049

    Vehicles equipped with a slip yoke transmission 

  18. Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the output shaft seal.
    Fig 9: Removing Output Shaft Seal Using Torque Converter Fluid Seal Remover And Slide Hammer
    G08595050Courtesy of FORD MOTOR CO.
  19. Remove the 8 extension housing bolts and the extension housing.
    G08595051
  20. Remove and discard the O-ring seal from the extension housing.
    Fig 10: Locating Extension Housing O-Ring Seal
    G08595052Courtesy of FORD MOTOR CO.
  21. Remove and discard the rubber grommet from the output shaft.
    G08595053
  22. Remove and discard the rear bushing fluid feed seal.
    G08595054

    All vehicles 

  23. NOTE: The output shaft nut is coated with Loctite®. Failure to loosen the Loctite® by applying heat to the output shaft nut can cause damage to the Output Shaft Nut Socket.
    NOTE: Make sure to clean any debris from the Loctite® that may have fallen into the transmission case when removing the output shaft nut. Failure to clean the debris can result in transmission fluid or filter contamination or damage to the transmission.
    NOTE: Fixed flange/4WD shown in illustration, slip yoke similar.

    Apply heat to the output shaft nut to soften the Loctite®. Using the Output Shaft Nut Socket, remove the output shaft nut.

    Fig 11: Removing/Installing Output Shaft Nut Using Socket
    G08595055Courtesy of FORD MOTOR CO.
  24. Remove the 4 park pawl abutment plate bolts and remove the park pawl abutment plate and the park pawl spring.
    G08595056
  25. Remove the manual control lever nut and the manual control lever.
    G08595057
  26. Remove and discard the manual shaft seal.
    Fig 12: Removing Manual Shaft Seal
    G07482833Courtesy of FORD MOTOR CO.
  27. Compress the 2 black tabs and push the wiring harness bulkhead through the transmission case and remove the transmission wiring harness.
    Fig 13: Locating Wiring Harness Bulkhead Black Tabs
    G07483098Courtesy of FORD MOTOR CO.
  28. Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the torque converter hub seal.
    Fig 14: Removing Torque Converter Hub Seal Using Fluid Seal Remover And Slide Hammer
    G07482928Courtesy of FORD MOTOR CO.
  29. Remove the 8 pump bolts.
    G08595061
  30. Install the Pump Remover/Installer Bracket on the pump. Install the pin in the top hole.
    Fig 15: Installing Pump Remover/Installer Bracket On Pump
    G07483101Courtesy of FORD MOTOR CO.
  31. Use a Heavy Duty Floor Crane and the Pump Remover/Installer Bracket to lift the pump out of the transmission case.
    Fig 16: Lifting Pump From Transmission Case Using Heavy Duty Floor Crane And Pump Remover/Installer Bracket
    G08595063Courtesy of FORD MOTOR CO.
  32. Install the Pump Remover/Installer Bracket on the forward/overdrive clutch assembly. Install the pin in the center hole.
    Fig 17: Installing Pump Remover/Installer Bracket On Forward/Overdrive Clutch Assembly
    G08595064Courtesy of FORD MOTOR CO.
  33. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, lift the forward/overdrive clutch assembly out of the transmission case.
    Fig 18: Lifting Forward/Overdrive Clutch Assembly Out Of Transmission Case Using Heavy Duty Floor Crane And Pump Remover/Installer Bracket
    G07483104Courtesy of FORD MOTOR CO.
  34. If the direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing is in the transmission, remove the clutch thrust bearing.
    G08595066
  35. Pry through the transmission case on the ends of the center support beveled retaining ring to unseat the beveled retaining ring from the groove.
    Fig 19: Prying Transmission Case On Ends Of Center Support Beveled Retaining Ring
    G08595067Courtesy of FORD MOTOR CO.
  36. WARNING: The beveled retaining ring has a strong spring force and could cause injury if not released carefully. Use the tool indicated in the procedure. Release the retaining ring tension only while it is contained within the transmission housing to restrain any unintended movement. Failure to follow this instruction may result in personal injury.

    Using the Snap Ring Pliers, remove the beveled retaining ring. Release the tension on the beveled retaining ring when the snap ring is in the torque converter housing area.

    Fig 20: Removing/Installing Beveled Retaining Ring Using Snap Ring Pliers
    G08595068Courtesy of FORD MOTOR CO.
  37. Remove the center support assembly.
    G08595069
  38. NOTE: If the bearing is not damaged, the Center Support Bearing Installer is installed to keep the bearing from being slid on the center support too far from handling the center support during disassembly and assembly. Dropping the center support on the bearing can cause it to slide too far on the center support causing damage to the bearing.
    NOTE: Inspect the air bleed orifice to be sure it is not blocked by any debris.

    Inspect the center support bearing for damage. If the bearing is not damaged, install the Center Support Bearing Installer on the center support. Inspect the center support alignment lugs to be sure they are installed securely in the center support. If the bearing is damaged, or if the center support alignment lugs are loose, refer to CENTER SUPPORT .

    Fig 21: Installing Center Support Bearing Installer On Center Support
    G08595070Courtesy of FORD MOTOR CO.
  39. Remove the anti-clunk clip.
    Fig 22: Locating Anti-Clunk Clip
    G08595071Courtesy of FORD MOTOR CO.
  40. Remove the No. 2 sun gear thrust bearing, rear selective shim and the No. 2 sun gear.
    G08595072
  41. Inspect the No. 2 sun gear teeth, splines and thrust bearing race for damage.
    1. Teeth
    2. Splines
    3. Thrust bearing race
      Fig 23: Identifying No. 2 Sun Gear Teeth, Splines And Thrust Bearing Race
      G08595073Courtesy of FORD MOTOR CO.
  42. Remove the rear planetary gearset.
    G08595074
  43. Remove the thrust bearing and the No. 3 sun gear.
    1. Thrust bearing
    2. No. 3 sun gear
      G08595075
  44. Inspect the No. 3 sun gear teeth, splines and thrust bearing for damage. Be sure the thrust bearing spins freely.
    1. Teeth
    2. Splines
    3. Thrust bearing
      Fig 24: Identifying No. 3 Sun Gear Teeth, Splines And Thrust Bearing
      G08595076Courtesy of FORD MOTOR CO.
  45. Inspect the rear planetary gearset for damage.
    1. Inspect the bearing surfaces for damage.
    2. Inspect the pinion gear teeth for damage. Make sure that there is not any excessive end play and the pinion gears spin freely.
    3. Inspect the low/reverse (1, R) clutch pressure plate surface for damage or burnt surfaces.
    4. Lock
    5. Rotate
      • The one-way clutch should rotate counterclockwise and lock clockwise.
    G08595077
  46. Remove the low/reverse (1, R) clutch assembly.
    G08595078
  47. Remove the rear planetary gearset thrust bearing.
    G08595079
  48. Remove the output shaft.
    G08595080
  49. Remove the output shaft thrust bearing.
    G08595081
  50. Remove the low/reverse clutch piston assembly bolt.
    Fig 25: Locating Low/Reverse Clutch Piston Assembly Bolt
    G07483121Courtesy of FORD MOTOR CO.
  51. Remove the low/reverse clutch piston assembly.
    G08595083

    Vehicles equipped with a fixed flange or 4WD 

  52. Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the output shaft seal.
    Fig 26: Removing Output Shaft Seal Using Torque Converter Fluid Seal Remover And Slide Hammer
    G08595084Courtesy of FORD MOTOR CO.

    All vehicles 

  53. Remove the output shaft thrust bearing and washer.
    G08595085
  54. NOTE: There are 2 different types of vent tubes. Both tubes are removed by sliding it off of the vent fitting.

    Remove the vent tube.

    G08595086
  55. Inspect the vent tube to be sure it is not restricted. Install a new vent tube if necessary.
  56. Clean and inspect the transmission case for damage. Inspect the output shaft bearing and the manual control linkage for damage and install new components as necessary. Refer to TRANSMISSION CASE .
  57. If the forward/overdrive clutch assembly thrust bearing is stuck to the bottom of the forward/overdrive clutch assembly, remove the thrust bearing.
    Fig 27: Locating Forward/Overdrive Clutch Assembly Thrust Bearing
    G08595087Courtesy of FORD MOTOR CO.
  58. Assemble the Clutch Pack End Play Gauge and the Transmission Holding Fixture and install the forward/overdrive clutch assembly.
    Fig 28: Installing Forward/Overdrive Clutch Assembly Using Clutch Pack End Play Gauge And Transmission Holding Fixture
    G08595088Courtesy of FORD MOTOR CO.
  59. Remove the direct (3, 5, R) clutch snap ring.
    G08595089
  60. Remove the direct (3, 5, R) clutch hub and the direct (3, 5, R) clutch plates as an assembly from the forward/overdrive clutch assembly. Remove the direct (3, 5, R) clutch plates from the direct (3, 5, R) clutch hub.
    Fig 29: Locating Direct (3, 5, R) Clutch Plates
    G08595090Courtesy of FORD MOTOR CO.
  61. Remove the direct (3, 5, R) clutch hub thrust bearing.
    G08595091
  62. Remove the forward (1, 2, 3, 4) clutch hub.
    Fig 30: Locating Forward (1, 2, 3, 4) Clutch Hub
    G08595092Courtesy of FORD MOTOR CO.
  63. Remove the forward (1, 2, 3, 4) clutch hub thrust bearing.
    G08595093
  64. Remove the overdrive (4, 5, 6) clutch hub and center shaft assembly.
    Fig 31: Locating Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
    G08595094Courtesy of FORD MOTOR CO.
  65. Remove the thrust bearing from the overdrive (4, 5, 6) clutch/input shaft assembly.
    G08595095
  66. Remove the overdrive (4, 5, 6) clutch/input shaft assembly.
    Fig 32: Locating Overdrive (4, 5, 6) Clutch/Input Shaft Assembly
    G08595096Courtesy of FORD MOTOR CO.
  67. Remove the front planetary carrier thrust bearing.
    G08595097
  68. Remove the direct (3, 5, R) clutch apply ring.
    G08595098
  69. Remove the forward (1, 2, 3, 4) clutch snap ring.
    G08595099
  70. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
    G08595100
  71. Remove the front planetary snap ring and the front planetary carrier from the forward (1, 2, 3, 4) clutch cylinder.
    Fig 33: Locating Front Planetary Carrier And Snap Ring
    G08595101Courtesy of FORD MOTOR CO.
  72. Remove the front planetary sun gear from the front planetary carrier.
    G08595102
  73. Remove the front planetary sun gear selective shim from the front planetary sun gear.
    G08595103
  74. Install the Clutch Spring Compressor and compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring.
    Fig 34: Compressing Forward (1, 2, 3, 4) Clutch Return Spring Using Clutch Spring Compressor
    G08595104Courtesy of FORD MOTOR CO.
  75. Remove the forward (1, 2, 3, 4) clutch balance piston from the forward (1, 2, 3, 4) cylinder.
    G08595105
  76. Remove and discard the O-ring seal and the lip seal from the forward (1, 2, 3, 4) clutch balance piston.
    G08595106
  77. Remove the forward (1, 2, 3, 4) clutch return spring.
    G08595107
  78. Gently tap the forward (1, 2, 3, 4) clutch piston cylinder upside down on a bench to remove the forward (1, 2, 3, 4) clutch piston from the forward (1, 2, 3, 4) clutch cylinder.
    G08595108
  79. Remove and discard the lip seal from the forward (1, 2, 3, 4) clutch piston.
    G08595109
  80. Install the Clutch Spring Compressor on the direct (3, 5, R) clutch balance piston. Apply slight pressure to the balance piston by tightening the Clutch Spring Compressor by hand. Compress the retaining ring by pushing the retaining ring inward to remove the direct (3, 5, R) clutch balance piston. Adjust tension on the Clutch Spring Compressor by hand while compressing the retaining ring as needed. Remove the Clutch Spring Compressor and the direct (3, 5, R) clutch balance piston.
    G08595110
  81. Remove and discard the direct (3, 5, R) clutch balance piston seal.
    G08595111
  82. Remove the direct (3, 5, R) clutch return spring.
    G08595112
  83. Gently tap the forward (1, 2, 3, 4) clutch piston cylinder upside down on a bench to remove the direct (3, 5, R) clutch piston from the forward (1, 2, 3, 4) clutch cylinder.
    G08595113
  84. Remove and discard the direct (3, 5, R) clutch piston seal from the direct (3, 5, R) clutch piston.
    G08595114
  85. Remove and discard the 2 seals and the O-ring from the forward (1, 2, 3, 4) clutch cylinder.
    1. Forward (1, 2, 3, 4) clutch piston inner lip seal
    2. Direct (3, 5, R) clutch balance piston inner O-ring seal
    3. Direct (3, 5, R) clutch piston inner lip seal
      G08595115
  86. Clean and inspect the forward (1, 2, 3, 4) clutch cylinder for damage.
    1. Inspect the piston sealing surfaces for damage.
    2. Inspect the TSS sensor tone wheel for damage.
    3. Inspect the bushing and Teflon® sealing surfaces for damage.
      Fig 35: Identifying TSS Sensor Tone Wheel, Forward (1, 2, 3, 4) Clutch Cylinder Piston, Bushing And Teflon® Sealing Surfaces
      G08595116Courtesy of FORD MOTOR CO.
  87. Install 2 new seals and an O-ring on the forward (1, 2, 3, 4) clutch cylinder and lubricate them with clean transmission fluid.
    1. Forward (1, 2, 3, 4) clutch piston inner lip seal
    2. Direct (3, 5, R) clutch balance piston inner O-ring seal
    3. Direct (3, 5, R) clutch piston inner lip seal
      G08595115
  88. Install a new direct (3, 5, R) clutch piston seal on the direct (3, 5, R) clutch piston and lubricate it with clean transmission fluid.
    G08595114
  89. Install the direct (3, 5, R) clutch piston in the forward (1, 2, 3, 4) clutch cylinder.
    G08595113
  90. Install the direct (3, 5, R) clutch return spring.
    G08595112
  91. Install a new direct (3, 5, R) clutch balance piston seal on the direct (3, 5, R) clutch balance piston and lubricate it with clean transmission fluid.
    G08595111
  92. Position the direct (3, 5, R) clutch balance piston on the direct (3, 5, R) clutch return spring. Install the Clutch Spring Compressor and compress the direct (3, 5, R) clutch piston return spring until the snap ring retains the direct (3, 5, R) clutch balance piston.
    Fig 36: Compressing Direct (3, 5, R) Clutch Piston Return Spring Using Clutch Spring Compressor
    G08595122Courtesy of FORD MOTOR CO.
  93. Install a new lip seal on the forward (1, 2, 3, 4) clutch piston and lubricate it with clean transmission fluid.
    G08595109
  94. Install the forward (1, 2, 3, 4) clutch piston in the forward (1, 2, 3, 4) cylinder.
    G08595108
  95. Install the forward (1, 2, 3, 4) clutch piston return spring on the forward (1, 2, 3, 4) clutch piston.
    G08595107
  96. Install a new O-ring seal and lip seal on the forward (1, 2, 3, 4) clutch balance piston and lubricate them with clean transmission fluid.
    Fig 37: Locating Forward (1, 2, 3, 4) Clutch Balance Piston O-Ring Seal And Lip Seal
    G08595126Courtesy of FORD MOTOR CO.
  97. Position the forward (1, 2, 3, 4) clutch balance piston on the forward (1, 2, 3, 4) clutch piston return spring. Install the Clutch Spring Compressor and compress the forward (1, 2, 3, 4) clutch return spring and install the forward (1, 2, 3, 4) clutch piston snap ring.
    Fig 38: Compressing Forward (1, 2, 3, 4) Clutch Return Spring Using Clutch Spring Compressor
    G08595104Courtesy of FORD MOTOR CO.
  98. Inspect the front planetary gearset for damage.
    1. Inspect the planetary carrier.
      • Make sure the gears spin freely.
    2. Inspect the sun gear for damage.
      • Inspect the gear face for damage
      • Inspect the splines for damage.
        Fig 39: Locating Front Planetary Gearset
        G08595128Courtesy of FORD MOTOR CO.
  99. NOTE: Be sure the sun gear is installed correctly in the planetary carrier or the selective shim cannot be installed in the sun gear and damage to the front planetary gearset will occur.

    Install the front planetary sun gear in the front planetary carrier with the selective shim surface facing up.

    G08595129
  100. Install the front planetary carrier in the forward (1, 2, 3, 4) clutch cylinder and install the snap ring.
    Fig 40: Locating Front Planetary Carrier And Snap Ring
    G08595101Courtesy of FORD MOTOR CO.
  101. Lubricate the forward (1, 2, 3, 4) clutch wave spring, clutch assembly and pressure plate with clean transmission fluid.
    1. Wave spring
    2. Steel clutch plates
    3. Clutches
    4. Pressure plate
      Fig 41: Identifying Forward (1, 2, 3, 4) Clutch Wave Spring, Clutch Assembly And Pressure Plate
      G08595131Courtesy of FORD MOTOR CO.
  102. NOTE: Align the tabs on the steel clutch plates and the pressure plate with the wave spring when installing the forward (1, 2, 3, 4) clutch assembly or the direct (3, 5, R) clutch apply ring will not fit on the direct (3, 5, R) clutch piston.

    Install the forward (1, 2, 3, 4) clutch wave spring. Install the forward (1, 2, 3, 4) clutch assembly with all steel clutch plate tabs aligned with the wave spring. Install the forward (1, 2, 3, 4) clutch pressure plate with the tabs aligned with the steel clutch plates.

    G08595100
  103. Install the forward (1, 2, 3, 4) clutch snap ring.
    G08595099
  104. Install the Dial Indicator Gauge with Holding Fixture. Position the plunger of the dial indicator on the forward (1, 2, 3, 4) clutch pressure plate. Zero the dial indicator.
    Fig 42: Positioning Plunger Of Dial Indicator On Forward (1, 2, 3, 4) Clutch Pressure Plate
    G07483174Courtesy of FORD MOTOR CO.
  105. Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.
    Fig 43: Measuring Clutch Clearance Using Dial Indicator
    G08595135Courtesy of FORD MOTOR CO.
  106. Average the 3 recorded clutch clearance measurements and compare it to the forward (1, 2, 3, 4) clutch clearance specification, refer to SPECIFICATIONS . If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new forward (1, 2, 3, 4) clutch snap ring to adjust the clutch clearance.
  107. Install the direct (3, 5, R) clutch apply ring.
    G08595098
  108. Lubricate the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate with clean transmission fluid.
    1. Wave spring
    2. Steel clutch plates
    3. Clutches
    4. Pressure plate
      Fig 44: Identifying Direct (3, 5, R) Clutch Wave Spring, Clutch Assembly And Pressure Plate
      G08595137Courtesy of FORD MOTOR CO.
  109. Install the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate in the forward (1, 2, 3, 4) clutch cylinder.
    G08595138
  110. Install the direct (3, 5, R) clutch snap ring.
    Fig 45: Locating Direct (3, 5, R) Clutch Snap Ring
    G08595139Courtesy of FORD MOTOR CO.
  111. Install the Dial Indicator Gauge with Holding Fixture. Position the plunger of the dial indicator on the direct (3, 5, R) clutch pressure plate. Zero the dial indicator.
    Fig 46: Positioning Plunger Of Dial Indicator On Direct (3, 5, R) Clutch Pressure Plate
    G08595140Courtesy of FORD MOTOR CO.
  112. Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.
    Fig 47: Measuring Clutch Clearance Using Dial Indicator
    G08595141Courtesy of FORD MOTOR CO.
  113. Average the 3 recorded clutch clearance measurements and compare it to the direct (3, 5, R) clutch clearance specification, refer to SPECIFICATIONS . If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new direct (3, 5, R) clutch snap ring to adjust the clutch clearance.
  114. Remove the direct (3, 5, R) clutch snap ring and remove the direct (3, 5, R) clutch assembly.
    G08595142
  115. Install the overdrive (4, 5, 6) clutch cylinder on the Clutch Pack End Play Gauge.
    Fig 48: Installing Overdrive (4, 5, 6) Clutch Cylinder On Clutch Pack End Play Gauge
    G08595143Courtesy of FORD MOTOR CO.
  116. Remove the overdrive (4, 5, 6) clutch snap ring.
    Fig 49: Locating Overdrive (4, 5, 6) Clutch Snap Ring
    G08595144Courtesy of FORD MOTOR CO.
  117. Remove the overdrive (4, 5, 6) clutch assembly and pressure plate.
    G08595145
  118. Using the Clutch Spring Compressor and a press, compress the overdrive (4, 5, 6) clutch balance piston and remove the snap ring. Remove and discard the overdrive (4, 5, 6) clutch balance piston.
    Fig 50: Compressing Overdrive (4, 5, 6) Clutch Balance Piston Using Clutch Spring Compressor And Press
    G08595146Courtesy of FORD MOTOR CO.
  119. Remove the overdrive (4, 5, 6) return spring.
    G08595147
  120. Remove and discard the overdrive (4, 5, 6) clutch piston.
    G08595148
  121. Reposition the overdrive (4, 5, 6) clutch cylinder and input shaft assembly in the Clutch Pack End Play Gauge. Remove the 4 input shaft Teflon® seals and 1 TCC Teflon® seal.
    Fig 51: Removing Input Shaft Teflon® Seals And TCC Teflon® Seal
    G08595149Courtesy of FORD MOTOR CO.
  122. Inspect the overdrive (4, 5, 6) clutch cylinder and input shaft assembly for damage. Inspect the bearing surfaces, Teflon® seal surfaces, ring gear and bushing surfaces for excessive wear or damage. If damage or excessive wear is found, install new components as necessary.
    1. Bearing/bushing surfaces
    2. Ring gear
    3. Teflon® seal surfaces
      Fig 52: Identifying Bearing/Bushing Surfaces, Ring Gear And Teflon® Seal Surfaces
      G08595150Courtesy of FORD MOTOR CO.
  123. Install the Input Shaft Teflon® Seal Sizer on the input shaft and adjust it so the bottom edge is lined up just above the top edge of the bottom Teflon® seal groove. Lubricate the Input Shaft Teflon® Seal Sizer with clean transmission fluid and install a new Teflon® seal by sliding it down the Input Shaft Teflon® Seal Sizer into the groove. Adjust the Input Shaft Teflon® Seal Sizer and install the remaining 3 input shaft Teflon® seals into the grooves. Lubricate the Input Shaft Teflon® Seal Sizer with clean transmission fluid and install it over the Teflon® seals to size the seals.
    Fig 53: Installing Input Shaft Teflon® Seal On Input Shaft
    G08595151Courtesy of FORD MOTOR CO.
  124. Install the Input Shaft Teflon® Seal Sizer on the end of the input shaft. Lubricate the Input Shaft Teflon® Seal Sizer with clean transmission fluid and install a new Teflon® seal into the groove. Lubricate the Input Shaft Teflon® Seal Sizer with clean transmission fluid and install it over the Teflon® seal to size the seal.
    Fig 54: Installing Input Shaft Teflon® Seal On End Of Input Shaft
    G08595152Courtesy of FORD MOTOR CO.
  125. Position the overdrive (4, 5, 6) clutch cylinder and input shaft assembly in the Clutch Pack End Play Gauge with the input shaft facing down.
    Fig 55: Positioning Overdrive (4, 5, 6) Clutch Cylinder And Input Shaft Assembly In Clutch Pack End Play Gauge
    G08595153Courtesy of FORD MOTOR CO.
  126. Lubricate the sealing surfaces of a new overdrive (4, 5, 6) clutch piston with clean transmission fluid and install it in the overdrive (4, 5, 6) clutch cylinder and input shaft assembly.
    G08595154
  127. Install the overdrive (4, 5, 6) clutch piston return spring with the circles facing up.
    G08595147
  128. Lubricate the sealing surfaces of a new overdrive (4, 5, 6) clutch balance piston with clean transmission fluid and position the clutch balance piston on top of the clutch piston return spring.
    G08595156
  129. Using the Clutch Spring Compressor and a press, compress the overdrive (4, 5, 6) clutch piston return spring and install the snap ring.
    Fig 56: Compressing Overdrive (4, 5, 6) Clutch Piston Return Spring Using Clutch Spring Compressor And Press
    G08595146Courtesy of FORD MOTOR CO.
  130. Lubricate the overdrive (4, 5, 6) clutch assembly and pressure plate with clean transmission fluid.
    1. Steel clutch plates
    2. Clutches
    3. Pressure plate
      Fig 57: Identifying Overdrive (4, 5, 6) Clutch Assembly And Pressure Plate
      G08595158Courtesy of FORD MOTOR CO.
  131. Install the overdrive (4, 5, 6) clutch assembly and pressure plate in the overdrive (4, 5, 6) clutch cylinder and input shaft assembly.
    G08595145
  132. Install the overdrive (4, 5, 6) clutch snap ring.
    Fig 58: Locating Overdrive (4, 5, 6) Clutch Snap Ring
    G08595144Courtesy of FORD MOTOR CO.
  133. Install the Dial Indicator Gauge with Holding Fixture. Position the plunger of the dial indicator on the overdrive (4, 5, 6) clutch pressure plate. Zero the dial indicator.
    Fig 59: Positioning Plunger Of Dial Indicator On Overdrive (4, 5, 6) Clutch Pressure Plate
    G08595161Courtesy of FORD MOTOR CO.
  134. Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.
    Fig 60: Measuring Clutch Clearance Using Dial Indicator
    G08595162Courtesy of FORD MOTOR CO.
  135. Average the 3 recorded clutch clearance measurements and compare it to the overdrive (4, 5, 6) clutch clearance specification, refer to SPECIFICATIONS . If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the overdrive (4, 5, 6) clutch selective snap ring chart in specifications and install a new direct (3, 5, R) clutch snap ring to adjust the clutch clearance.
  136. Inspect the overdrive (4, 5, 6) clutch hub/center shaft assembly, direct (3, 5, R) clutch hub and forward (1, 2, 3, 4) clutch hub for damage or excessive wear. Inspect the bushing, bearing and splined surfaces. Install new components as necessary.
    Item Description
    1 Bearing surfaces
    2 Splined surfaces
    3 Clutch splined surfaces
    4 Bushing surfaces
    G08595163
  137. Position the forward (1, 2, 3, 4) clutch assembly in the Clutch Pack End Play Gauge and the Transmission Holding Fixture.
    Fig 61: Positioning Forward (1, 2, 3, 4) Clutch Assembly In Clutch Pack End Play Gauge And Transmission Holding Fixture
    G08595164Courtesy of FORD MOTOR CO.
  138. Install the front planetary carrier thrust bearing.
    G08595097
  139. Install the overdrive (4, 5, 6) clutch/input shaft assembly in the forward (1, 2, 3, 4) clutch.
    Fig 62: Locating Overdrive (4, 5, 6) Clutch/Input Shaft Assembly
    G08595096Courtesy of FORD MOTOR CO.
  140. Install the thrust bearing on the overdrive (4, 5, 6) clutch/input shaft assembly.
    G08595095
  141. Install the overdrive (4, 5, 6) clutch hub and center shaft assembly in the overdrive (4, 5, 6) clutch.
    Fig 63: Locating Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
    G08595094Courtesy of FORD MOTOR CO.
  142. Install the forward (1, 2, 3, 4) clutch hub thrust bearing.
    G08595093
  143. Install the forward (1, 2, 3, 4) clutch hub.
    Fig 64: Locating Forward (1, 2, 3, 4) Clutch Hub
    G08595092Courtesy of FORD MOTOR CO.
  144. Install the direct (3, 5, R) clutch hub thrust bearing.
    G08595091
  145. Install the low/reverse clutch piston assembly on the Clutch Pack End Play Gauge. Using the Clutch Spring Compressor, compress the low/reverse (1, R) return spring and remove the snap ring.
    Fig 65: Compressing Low/Reverse (1, R) Return Spring Using Clutch Spring Compressor
    G07972480Courtesy of FORD MOTOR CO.
  146. Remove the low/reverse (1, R) piston return spring.
    G07972481
  147. Using compressed air, remove the low/reverse (1, R) piston from the low/reverse cylinder.
    Fig 66: Removing Low/Reverse (1, R) Piston From Low/Reverse Cylinder Using Compressed Air
    G07972482Courtesy of FORD MOTOR CO.
  148. Remove and discard the lip seal from the low/reverse (1, R) cylinder.
    Fig 67: Locating Low/Reverse (1, R) Cylinder Lip Seal
    G07972483Courtesy of FORD MOTOR CO.
  149. Remove and discard the 2 lip seals from the low/reverse (1, R) piston.
    Fig 68: Locating Low/Reverse (1, R) Piston Lip Seals
    G07972484Courtesy of FORD MOTOR CO.
  150. NOTE: Inspect the air bleed orifice and make sure it is not blocked by any debris.

    Clean and inspect the 3 lip seal sealing surfaces on both the low/reverse (1, R) piston and cylinder for damage and install new components as necessary.

    Fig 69: Locating Low/Reverse (1, R) Piston And Cylinder Lip Seal Sealing Surfaces
    G07972485Courtesy of FORD MOTOR CO.
  151. Install 2 new lip seals on the low/reverse (1, R) piston and lubricate with clean transmission fluid.
    Fig 70: Locating Low/Reverse (1, R) Piston Lip Seals
    G07972484Courtesy of FORD MOTOR CO.
  152. Install a new lip seal on the low/reverse (1, R) cylinder and lubricate with clean transmission fluid.
    Fig 71: Locating Low/Reverse (1, R) Cylinder Lip Seal
    G07972483Courtesy of FORD MOTOR CO.
  153. NOTE: Be sure to align the alignment marks on the low/reverse (1, R) cylinder and piston when installing the piston in the cylinder.

    Align the marks and install the low/reverse (1, R) piston in the cylinder.

    Fig 72: Installing Low/Reverse (1, R) Piston In Cylinder
    G07972488Courtesy of FORD MOTOR CO.
  154. Install the low/reverse (1, R) piston return spring.
    G07972481
  155. Using the Clutch Spring Compressor and Clutch Pack End Play Gauge, compress the low/reverse (1, R) return spring and install the snap ring.
    Fig 73: Compressing Low/Reverse (1, R) Return Spring Using Clutch Spring Compressor And Clutch Pack End Play Gauge
    G07972490Courtesy of FORD MOTOR CO.
  156. Remove the intermediate (2, 6) clutch pack snap ring.
    Fig 74: Locating Intermediate (2, 6) Clutch Pack Snap Ring
    G07972491Courtesy of FORD MOTOR CO.
  157. Remove the intermediate (2, 6) clutch pressure plate, clutch assembly and wave spring from the intermediate (2, 6) clutch center support.
    G07972492
  158. Using the C Clutch Return Spring Compressor and the Clutch Spring Compressor with the Center Support Bearing Installer, compress the intermediate (2, 6) clutch return spring and remove the intermediate (2, 6) clutch 2-piece retaining ring.
    Fig 75: Compressing Intermediate (2, 6) Clutch Return Spring Using Clutch Return Spring Compressor
    G07972493Courtesy of FORD MOTOR CO.
  159. Remove the intermediate (2, 6) clutch return spring.
    G07972494
  160. Using compressed air, remove the intermediate (2, 6) clutch piston.
    G07972495
  161. Remove and discard the intermediate (2, 6) clutch inner and outer piston seals from the intermediate (2, 6) clutch piston.
    Fig 76: Locating Intermediate (2, 6) Clutch Inner And Outer Piston Seals
    G07972496Courtesy of FORD MOTOR CO.
  162. Clean and inspect the intermediate (2, 6) clutch piston sealing surfaces for damage. If damage is found, install a new center support.
    G07972497
  163. Lubricate new intermediate (2, 6) clutch inner and outer piston seals with clean transmission fluid and install on the intermediate (2, 6) clutch piston.
    Fig 77: Locating Intermediate (2, 6) Clutch Inner And Outer Piston Seals
    G07972496Courtesy of FORD MOTOR CO.
  164. Install the intermediate (2, 6) clutch piston.
    G07972499
  165. Install the intermediate (2, 6) clutch return spring.
    G07972494
  166. Using the C Clutch Return Spring Compressor and the Clutch Spring Compressor with the Center Support Bearing Installer, compress the intermediate (2, 6) clutch return spring and install the 2 piece retaining ring.
    Fig 78: Compressing Intermediate (2, 6) Clutch Return Spring Using Clutch Spring Compressor
    G07972493Courtesy of FORD MOTOR CO.
  167. Lubricate the intermediate (2, 6) clutch assembly with clean transmission fluid.
    1. Pressure plate
    2. Friction plates
    3. Steel plates
    4. Wave spring
      Fig 79: Identifying Intermediate (2, 6) Clutch Assembly Pressure Plate, Friction Plates, Steel Plates And Wave Spring
      G07972502Courtesy of FORD MOTOR CO.
  168. NOTE: The intermediate (2, 6) clutch pressure plate is installed with the step facing up.

    Install the intermediate (2, 6) clutch wave spring, clutch assembly and pressure plate.

    G07972492
  169. Install the intermediate (2, 6) clutch pack snap ring.
    Fig 80: Locating Intermediate (2, 6) Clutch Pack Snap Ring
    G07972491Courtesy of FORD MOTOR CO.
  170. Assemble the Clutch Pack End Play Gauge and the Transmission Holding Fixture and install the intermediate (2, 6) clutch assembly in the Clutch Pack End Play Gauge. Using the Dial Indicator Gauge with Holding Fixture, position the plunger of the dial indicator on the intermediate (2, 6) clutch pressure plate and zero the dial indicator.
    Fig 81: Positioning Plunger Of Dial Indicator On Intermediate (2, 6) Clutch Pressure Plate Using Dial Indicator Gauge And Holding Fixture
    G07972505Courtesy of FORD MOTOR CO.
  171. Pull up on the intermediate (2, 6) clutch pressure plate and measure and record the clutch clearance in 3 different places.
    Fig 82: Measuring Clutch Clearance Using Dial Indicator
    G07972506Courtesy of FORD MOTOR CO.
  172. Average the 3 recorded clutch clearance measurements and compare it to the intermediate (2, 6) clutch clearance specification, refer to SPECIFICATIONS . If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new intermediate (2, 6) clutch snap ring to adjust the clutch clearance.
  173. Remove the pump housing seal.
    Fig 83: Locating Pump Housing Seal
    G07972507Courtesy of FORD MOTOR CO.
  174. Remove the 3 Teflon® seals.
    Fig 84: Removing Teflon® Seals
    G07972508Courtesy of FORD MOTOR CO.
  175. NOTE: Note the location of the different pump bolt lengths for assembly.

    Remove the 13 pump bolts and separate the stator support from the pump housing and body.

    Fig 85: Separating Stator Support From Pump Housing And Body
    G07972509Courtesy of FORD MOTOR CO.
  176. Remove the pump gasket.
    Fig 86: Locating Pump Gasket
    G07972510Courtesy of FORD MOTOR CO.
  177. NOTE: Non-PTO pump shown in illustration, PTO pump similar.

    Thread 4 of the long bolts in the pump body by hand and position the pump housing on 2 blocks of wood. Tap the bolts with a rubber mallet to separate the pump housing from the pump body. Remove the 4 bolts and remove the pump body from the pump housing.

    Fig 87: Removing Pump Body From Pump Housing
    G07972511Courtesy of FORD MOTOR CO.
  178. NOTE: Observe the position of the locating dots on the pump gears. Dots must be facing up.

    Remove the pump gears from the pump body.

    Fig 88: Locating Pump Gears And Pump Body
    G07972512Courtesy of FORD MOTOR CO.
  179. Remove the pump body seal from the pump body.
    Fig 89: Locating Pump Body Seal
    G07972513Courtesy of FORD MOTOR CO.
  180. Remove and discard the anti-drain back valve.
    Fig 90: Locating Anti-Drain Back Valve
    G08595206Courtesy of FORD MOTOR CO.

    Vehicles equipped with PTO 

  181. Remove the thrust bearing from the PTO drive gear.
    G07972514
  182. Remove the PTO drive gear from the pump housing.
    G07972515
  183. Remove the PTO drive gear thrust washer from the pump housing.
    Fig 91: Locating PTO Drive Gear Thrust Washer
    G07972516Courtesy of FORD MOTOR CO.
  184. Remove and discard the O-ring seal and the 2 Teflon® seals from the stator support.
    1. O-ring seal
    2. Teflon® seals
      Fig 92: Locating O-Ring Seal And Teflon® Seals
      G07972517Courtesy of FORD MOTOR CO.

    Vehicles not equipped with PTO 

  185. Remove and discard the O-ring seal and the Teflon® seal from the stator support.
    1. Teflon® seal
    2. O-ring seal
      Fig 93: Identifying Stator Support O-Ring And Teflon® Seal
      G07972518Courtesy of FORD MOTOR CO.

    All vehicles 

  186. Clean and inspect the pump housing and stator support for damage. Inspect the pump gear surfaces for scoring or damage. Inspect the sealing surfaces for damage. Install a new pump if necessary.
    1. Pump housing
    2. Gear surfaces
    3. Stator support
    4. Sealing surfaces
      Fig 94: Identifying Pump Housing, Gear Surfaces, Stator Support And Sealing Surfaces
      G07972519Courtesy of FORD MOTOR CO.
  187. NOTE: The pump gears must be installed in the pump body with the locating dots facing up or damage may occur.

    Inspect the pump body and pump gears for damage. Inspect the torque converter hub bearing to be sure it spins freely and does not have excessive wear. Inspect the pump gears for scoring or excessive wear. Install a new pump if necessary.

    1. Pump body
    2. Torque converter hub bearing
    3. Pump gears
      Fig 95: Identifying Pump Body, Gears And Torque Converter Hub Bearing
      G07972520Courtesy of FORD MOTOR CO.

    Vehicles not equipped with PTO 

  188. Install a new O-ring seal on the stator support and lubricate it with clean transmission fluid.
    Fig 96: Locating Stator Support O-Ring Seal
    G07972521Courtesy of FORD MOTOR CO.
  189. Lubricate the Non PTO Pump Seal Installer with clean transmission fluid and install it on the stator support. Install a new Teflon® seal on the Non-PTO Pump Seal Installer and slide it down into the groove.
    Fig 97: Installing Teflon® Seal On Non-PTO Pump Seal Installer
    G07972522Courtesy of FORD MOTOR CO.
  190. NOTE: The small side of the PTO Pump Seal Installer/Sizer is used to size the Non-PTO pump stator support seal.

    Install the PTO Pump Seal Installer/Sizer to size the Teflon® seal.

    Fig 98: Sizing Teflon® Seal Using PTO Pump Seal Installer/Sizer
    G08595216Courtesy of FORD MOTOR CO.

    Vehicles equipped with PTO 

  191. Inspect the PTO drive gear for damage. Inspect the gear teeth for damage and inspect the thrust washer and bearing surface for excessive wear. If damage is found, install a new pump.
    1. Teeth
    2. Thrust bearing surface
    3. Thrust washer surface
      Fig 99: Identifying PTO Drive Gear Teeth, Thrust Bearing And Washer Surface
      G07972524Courtesy of FORD MOTOR CO.
  192. Install a new O-ring seal on the PTO drive gear and lubricate it with clean transmission fluid.
    Fig 100: Locating PTO Drive Gear O-Ring Seal
    G07972525Courtesy of FORD MOTOR CO.
  193. Install the PTO Pump Seal Installer/Sizer on the PTO drive gear and lubricate it with clean transmission fluid. Adjust the PTO Pump Seal Installer/Sizer so that the bottom edge is just above the bottom groove. Install a new Teflon® seal on the PTO Pump Seal Installer/Sizer and slide it down into the groove. Using the PTO Pump Seal Installer/Sizer, install a new Teflon® seals in the top groove. Remove the PTO Pump Seal Installer/Sizer.
    Fig 101: Installing Teflon® Seals In Top Groove Using PTO Pump Seal Installer/Sizer
    G07972526Courtesy of FORD MOTOR CO.
  194. Install the PTO Pump Seal Installer/Sizer to size the 2 Teflon® seals.
    Fig 102: Sizing Teflon® Seals Using PTO Pump Seal Installer/Sizer
    G07972527Courtesy of FORD MOTOR CO.
  195. Install the PTO drive gear thrust washer in the pump housing.
    G07972516
  196. Remove the PTO Pump Seal Installer/Sizer.
    Fig 103: Removing PTO Pump Seal Installer/Sizer
    G07972527Courtesy of FORD MOTOR CO.
  197. Install the PTO drive gear in the pump housing.
    G07972515
  198. Install the thrust bearing on the PTO drive gear.
    G07972514

    All vehicles 

  199. Install a new pump body seal and lubricate it with clean transmission fluid.
    Fig 104: Locating Pump Body Seal
    G07972513Courtesy of FORD MOTOR CO.
  200. Lubricate the pump gears with clean transmission fluid and install the pump gears in the pump body with the dots facing up.
    Fig 105: Locating Pump Gears And Pump Body With Dots
    G07972533Courtesy of FORD MOTOR CO.
  201. Install the new anti-drain back valve.
    Fig 106: Locating Anti-Drain Back Valve
    G08595206Courtesy of FORD MOTOR CO.
  202. Position the pump housing on the pump body with the alignment pin lined up with the alignment hole and push the pump housing until it is seated on the pump body.
    1. Pump housing
    2. Pump body
    3. Alignment hole
    4. Alignment pin
      Fig 107: Positioning Pump Housing On Pump Body
      G07972534Courtesy of FORD MOTOR CO.
  203. Install the pump gasket.
    Fig 108: Locating Pump Gasket
    G07972510Courtesy of FORD MOTOR CO.

    Vehicles not equipped with a PTO 

  204. Remove the PTO Pump Seal Installer/Sizer from the stator support.
    Fig 109: Removing PTO Pump Seal Installer/Sizer From Stator Support
    G08595216Courtesy of FORD MOTOR CO.

    All vehicles 

  205. NOTE: Install the bolts in the locations noted during disassembly.

    Position the stator support in the pump housing and body and install the 13 pump bolts.

    • Tighten the bolts in a crisscross pattern.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 110: Positioning Stator Support In Pump Housing And Body
      G07972509Courtesy of FORD MOTOR CO.
  206. Install the Non-PTO Pump Seal Installer with PTO Pump Seal Installer/Sizer on the stator support and adjust it so the innermost Teflon® seal can be installed. Lubricate the Non-PTO Pump Seal Installer with clean transmission fluid. Position a new Teflon® seal on the Non-PTO Pump Seal Installer and gently slide it down to the bottom groove. Using the Non-PTO Pump Seal Installer, install 2 new Teflon® seals in the remaining grooves.
    Fig 111: Installing Teflon® Seals In Grooves Using Non-PTO Pump Seal Installer
    G07972538Courtesy of FORD MOTOR CO.
  207. Using the Non-PTO Pump Seal Installer size the 3 Teflon® seals.
    Fig 112: Sizing Teflon® Seals Using Non-PTO Pump Seal Installer
    G07972539Courtesy of FORD MOTOR CO.
  208. Install a new pump housing seal and lubricate it with clean transmission fluid.
    Fig 113: Locating Pump Housing Seal
    G07972507Courtesy of FORD MOTOR CO.
  209. Using the Front Pump Seal Installer, install a new hub seal.
    Fig 114: Installing Torque Converter Hub Seal Using Front Pump Seal Installer
    G08595235Courtesy of FORD MOTOR CO.
  210. NOTE: There are 2 different types of vent tubes. Both tubes are installed by sliding it on the vent fitting.

    Install the vent tube.

    G08595086
  211. Rotate the transmission upright and install the low/reverse clutch piston assembly in the transmission case.
    G08595083
  212. Install the longest clutch feed tube in the low/reverse feed tube port to align the low/reverse piston assembly. Install the low/reverse cylinder alignment bolt. Remove the feed tube.
    1. Long feed tube
    2. Low/reverse clutch piston assembly bolt
      • Tighten to 11 Nm (97 lb-in).
        Fig 115: Identifying Long Feed Tube And Low/Reverse Clutch Piston Assembly Bolt
        G07972544Courtesy of FORD MOTOR CO.
  213. Install the output shaft thrust bearing.
    G08595081
  214. Install the output shaft.
    G08595080
  215. NOTE: Fixed flange/4WD shown in illustration, slip yoke similar.

    Rotate the transmission to access the output shaft and install the thrust washer, the thrust bearing and loosely install the output shaft nut.

    1. Thrust washer
    2. Thrust bearing
    3. Output shaft nut
      Fig 116: Identifying Thrust Washer, Thrust Bearing And Output Shaft Nut
      G07972547Courtesy of FORD MOTOR CO.
  216. Install the rear planetary gearset thrust bearing.
    G08595079
  217. Position the center support up side down on a bench. Install the rear planetary carrier onto the center support. Install the low/reverse (1, R) clutch assembly onto the rear planetary carrier so that it rests on the OWC.
    1. Center support
    2. Rear planetary carrier
    3. Low/reverse (1, R) clutch
    4. OWC
      Fig 117: Identifying Low/Reverse (1, R) Clutch, One Way Clutch, Center Support And Rear Planetary Carrier
      G07972549Courtesy of FORD MOTOR CO.
  218. NOTE: Do NOT measure from the top of the lugs on the apply ring.
    NOTE: The low/reverse clutch measurement in specifications is a measurement of the clutch height and is NOT the clutch clearance.

    Using a depth gauge, measure the distance from the piston contact surface of the apply ring to the center support surface in 3 different places. Average the 3 measurements and record as the low/reverse clutch measurement.

    Fig 118: Measuring Low/Reverse Clutch Height Using Depth Gauge
    G07972550Courtesy of FORD MOTOR CO.
  219. Compare the low/reverse (1, R) clutch measurement to the low/reverse (1, R) clutch measurement specification, refer to SPECIFICATIONS . If the low/reverse (1, R) clearance is out of specification, install a new low/reverse (1, R) clutch assembly.
  220. Lubricate the low/reverse (1, R) clutch in clean transmission fluid.
    1. Apply plate
    2. Steel plates
    3. Clutch plates
      Fig 119: Identifying Low/Reverse (1, R) Clutch Plates, Apply Plate And Steel Plates
      G07972551Courtesy of FORD MOTOR CO.
  221. Position the transmission in the upright position and install the low/reverse (1, R) apply plate and clutch assembly.
    G08595078
  222. NOTE: The anti-clunk clip is NOT installed in this step.
    NOTE: Make sure the outer OWC splines are aligned as shown in illustration or the anti-clunk clip will not fit into the transmission case.

    Install the rear planetary gearset with the outer OWC splines aligned so the anti-clunk clip can be installed correctly. Inspect the OWC to be sure it is aligned correctly for installation of the anti clunk spring. The anti clunk spring should rest against both a spline of the OWC and an inner spline of the transmission case.

    1. OWC spline
    2. Transmission case spline
      G07972553
  223. Install the No. 3 sun gear with the beveled end facing down and install the No. 3 sun gear thrust bearing.
    1. No. 3 sun gear
    2. No. 3 sun gear thrust bearing
      G07972554
  224. Install the thrust washer on the No. 2 sun gear. Use petroleum jelly if needed to hold the thrust washer to the sun gear and install the No. 2 sun gear in the rear planetary gearset with the thrust washer facing down.
    G07972555
  225. Install the No. 2 sun gear thrust bearing on top of the No. 2 sun gear.
    G07972556
  226. Install the End Play Gauge on the transmission case.
    Fig 120: Installing End Play Gauge On Transmission Case
    G07972557Courtesy of FORD MOTOR CO.
  227. NOTE: Make sure to zero the dial indicator on the transmission case and not the rear planetary gearset or inaccurate measurements can be recorded causing damage to the transmission.

    Position a depth dial indicator on the End Play Gauge with the plunger positioned on the top of the transmission case step that the center support rests on. Zero the dial indicator.

    Fig 121: Positioning Depth Dial Indicator On End Play Gauge With Plunger Positioned On Top Of Transmission Case
    G07972558Courtesy of FORD MOTOR CO.
  228. Gently lift the plunger of the dial indicator off the transmission case step, slide the dial indicator over and drop the plunger onto the No. 2 sun gear thrust bearing. Record this distance as measurement A.
    Fig 122: Sliding Dial Indicator Over And Drop Plunger Onto No. 2 Sun Gear Thrust Bearing
    G07972559Courtesy of FORD MOTOR CO.
  229. With measurement A recorded, calculate the selective shim thickness and find the part number.
    1. Zero
    2. Measurement A
      • NOTE: The distance on the center support from the transmission case surface to the No. 2 sun gear thrust bearing surface equals 8.55 mm (0.336 in). 8.55 mm (0.336 in) is subtracted from measurement A to compensate for the offset of the center support.

        Subtract 8.55 mm (0.336 in) from measurement A to get the clearance for the rear shim. Compare the clearance of the rear shim to the Rear Selective Shim Part Number Chart in Specifications to get the correct selective shim dimension and part number. The target clearance with the correct rear shim installed should be between 0.8-1.1 mm (0.031-0.043 in).

    Fig 123: Calculating Selective Shim Thickness Using Special Tool
    G07972560Courtesy of FORD MOTOR CO.
  230. Install the rear selective shim on top of the thrust bearing.
    G07972561
  231. NOTE: When installing the center support, make sure the alignment lugs are lined up with the slots in the transmission case and the feed hole is facing down.
    NOTE: Inspect the alignment lugs to be sure they are installed in the center support and are not loose. If the alignment lugs are loose, use petroleum jelly to hold them in place when installing the center support.

    Install the center support assembly.

    G08595069
  232. WARNING: The beveled retaining ring has a strong spring force and could cause injury if not released carefully. Use the tool indicated in the procedure. Release the retaining ring tension only while it is contained within the transmission housing to restrain any unintended movement. Failure to follow this instruction may result in personal injury.
    NOTE: Be sure the beveled retaining ring is installed with the beveled end facing up or the beveled retaining ring can come loose and damage to the transmission can occur.

    Place the beveled retaining ring in the torque converter housing. Using the Center Support Snap Ring Pliers, compress the beveled retaining ring in the torque converter housing and install the beveled retaining ring with the beveled retaining ring gap in the 12 o'clock position and the beveled side facing up.

    Fig 124: Removing/Installing Beveled Retaining Ring Using Snap Ring Pliers
    G08595068Courtesy of FORD MOTOR CO.
  233. Tap on the center support snap ring to make sure it is seated in the groove.
    Fig 125: Locating Center Support Snap Ring
    G07972564Courtesy of FORD MOTOR CO.
  234. Install direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing.
    G08595066
  235. Install the direct (3, 5, R)/intermediate (2, 6) clutch hub in the intermediate (2, 6) clutch.
    G07972566
  236. Install the intermediate clutch feed tube.
    Fig 126: Locating Intermediate Clutch Feed Tube
    G07972567Courtesy of FORD MOTOR CO.
  237. NOTE: Be sure to turn the shop air supply down to 276 kPa (40 psi) or damage to the clutch seals can occur.

    Install the C-Clutch Air Plate and apply 276 kPa (40 psi) of shop air to the C-Clutch Air Plate.

    Fig 127: Removing/Installing C-Clutch Air Plate Using Special Tools
    G07972568Courtesy of FORD MOTOR CO.
  238. Remove the direct (3, 5, R)/intermediate (2, 6) clutch hub.
    G07972566
  239. Using the Transmission Holding Fixture and the Clutch Pack End Play Gauge, install the direct (3, 5, R)/intermediate (2, 6) clutch hub in the forward/overdrive clutch assembly.
    Fig 128: Installing Direct (3, 5, R)/Intermediate (2, 6) Clutch Hub In Forward/Overdrive Clutch Assembly Using Special Tools
    G07972570Courtesy of FORD MOTOR CO.
  240. Install the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate in the forward/overdrive clutch assembly. Install the direct (3, 5, R) clutch snap ring.
    1. Direct (3, 5, R) clutch wave spring
    2. Clutch assembly
    3. Pressure plate
    4. Snap ring
      Fig 129: Identifying Direct (3, 5, R) Clutch Wave Spring, Clutch Assembly, Pressure Plate And Snap Ring
      G07972571Courtesy of FORD MOTOR CO.
  241. Install the Pump Remover/Installer Bracket on the forward/overdrive clutch assembly with the pin installed in the center hole and support it with a Heavy Duty Floor Crane.
    Fig 130: Installing Pump Remover/Installer Bracket On Forward/Overdrive Clutch Assembly
    G07972572Courtesy of FORD MOTOR CO.
  242. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, gently install the forward/overdrive clutch assembly in the transmission case. Make sure the forward/overdrive clutch assembly is seated all the way by making sure it rests slightly above the rib of the transmission case as shown in illustration.
    Fig 131: Installing Forward/Overdrive Clutch Assembly In Transmission Case Using Heavy Duty Floor Crane And Pump Remover/Installer Bracket
    G07972573Courtesy of FORD MOTOR CO.
  243. Remove the C-Clutch Air Plate.
    Fig 132: Removing/Installing C-Clutch Air Plate Using Special Tools
    G07972568Courtesy of FORD MOTOR CO.
  244. Install the anti-clunk clip.
    Fig 133: Locating Anti-Clunk Clip
    G08595071Courtesy of FORD MOTOR CO.
  245. Position the pump assembly on 2 blocks of wood and remove the Non-PTO Pump Seal Installer.
    Fig 134: Positioning Pump Assembly On Blocks Of Wood Or Suitable Stand
    G07972576Courtesy of FORD MOTOR CO.
  246. Position the End Play Gauge on the pump with it centered to the center of the stator support. Using a depth gauge, measure the distance from the top of the End Play Gauge to the front shim surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement A.
    Fig 135: Measuring Distance From Top Of End Play Gauge To Front Shim Surface Using Depth Gauge
    G07972577Courtesy of FORD MOTOR CO.
  247. NOTE: Apply pressure to the End Play Gauge to hold it flush against the stator support when measuring to the deck surface.

    Using a depth gauge, measure the distance from the top of the End Play Gauge to the deck surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement B.

    Fig 136: Measuring Distance From Top Of End Play Gauge To Deck Surface Using Depth Gauge
    G07972578Courtesy of FORD MOTOR CO.
  248. Subtract measurement A from measurement B and record as measurement C.
  249. Position the End Play Gauge on the transmission case pump deck surface. Using a depth gauge, measure the distance from the top of the End Play Gauge to the selective shim surface on the No. 1 sun gear. Subtract the height of the End Play Gauge 12.7 mm (0.5 in) from the measurement and record as measurement D. Remove the End Play Gauge.
    Fig 137: Positioning End Play Gauge On Transmission Case Pump Deck Surface
    G07972579Courtesy of FORD MOTOR CO.
  250. Subtract measurement C from measurement D and record that distance as the front selective shim thickness. Compare the thickness of the center support shim to the Front Selective Shim Part Number Chart in Specifications to get the correct front selective shim part number. The target clearance with the correct front shim installed should be between 0.15-0.45 mm (0.006-0.018 in).
  251. Install the selective shim on top of the No. 1 sun gear. Make sure the selective shim is positioned correctly in the No. 1 sun gear groove.
    Fig 138: Installing Selective Shim On Top Of No. 1 Sun Gear
    G07972580Courtesy of FORD MOTOR CO.
  252. Install the Pump Remover/Installer Bracket on the pump with the pin in the top hole.
    Fig 139: Installing Pump Remover/Installer Bracket On Pump With Pin In Top Hole
    G07972581Courtesy of FORD MOTOR CO.
  253. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, gently position the pump in the transmission case with the feed tube surface facing the bottom of the transmission.
    Fig 140: Lifting Pump Out Of Transmission Case
    G08595063Courtesy of FORD MOTOR CO.
  254. Align the bolt holes and loosely install 2 bolts. Gently tap the pump until it is seated on the deck surface of the transmission case.
    Fig 141: Aligning Bolt Holes
    G07972583Courtesy of FORD MOTOR CO.
  255. Install the rest of the bolts and tighten in a crisscross pattern.
    • Tighten bolts to 25 Nm (18 lb-ft).
      G08595061
  256. If reusing the original torque converter, use an emery cloth to clean the torque converter hub seal material off of the torque converter hub.
    Fig 142: Locating Torque Converter Hub Seal Material
    G08594888Courtesy of FORD MOTOR CO.
  257. Install the Pump Remover/Installer Bracket on the torque converter with the pin in the bottom hole.
    Fig 143: Installing Pump Remover/Installer Bracket On Torque Converter With Pin In Bottom Hole
    G08594891Courtesy of FORD MOTOR CO.
  258. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, install the torque converter.
    Fig 144: Lifting Torque Converter Using Heavy Duty Floor Crane
    G08594882Courtesy of FORD MOTOR CO.
  259. Install the Torque Converter Retainer.
    Fig 145: Removing/Installing Torque Converter Retainer
    G08594880Courtesy of FORD MOTOR CO.
  260. NOTE: Note the ports where the feed seals are removed from. Failure to install the feed seals in the ports they were removed from can result in pressure loss and transmission failure.

    Rotate the transmission to access the main control area. Install the 3 clutch feed seals.

    G07972589
  261. NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.

    Pressure check both low/reverse (1, R) clutch feed ports using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the low/reverse piston assembly and inspect the clutch piston seals and sealing surfaces for damage.

    G07972590
  262. NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.

    Pressure check the intermediate (2, 6) clutch feed port using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the center support and inspect the clutch piston seals and sealing surfaces for damage.

    G07972591
  263. NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.

    Pressure check the forward, overdrive, and direct clutch feed ports using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the forward/overdrive clutch assembly and inspect the forward (1, 2, 3, 4), overdrive (4, 5, 6) and direct (3, 5, R) clutch piston seals and sealing surfaces for damage.

    1. Forward (1, 2, 3, 4) clutch port
    2. Overdrive (4, 5, 6) clutch port
    3. Direct (3, 5, R) clutch port
      Fig 146: Identifying Forward (1, 2, 3, 4) Clutch Port, Overdrive (4, 5, 6) Clutch Port And Direct (3, 5, R) Clutch Port
      G07972592Courtesy of FORD MOTOR CO.
  264. Inspect the wiring harness bulkhead O-ring for damage and install a new O-ring if necessary. Lubricate the wiring harness O-ring with clean transmission fluid and install the wiring harness bulkhead in the transmission case. Make sure the 2 tabs lock the bulkhead in the transmission case.
    Fig 147: Locating Wiring Harness Bulkhead O-Ring
    G07972593Courtesy of FORD MOTOR CO.
  265. Install the park pawl spring on the park pawl and position the park pawl abutment plate in place and install the 4 bolts.
    • Tighten to 11 Nm (97 lb-in).
      G08595056
  266. Install a new manual shaft seal.
    Fig 148: Locating Manual Shaft Seal
    G07482834Courtesy of FORD MOTOR CO.
  267. Install the manual control lever and the nut.
    • Tighten to 24 Nm (18 lb-ft).
      G08595057
  268. NOTE: Fixed flange/4WD shown in illustration, slip yoke similar.

    Remove the output shaft nut.

    G07972597

    Vehicles equipped with a fixed flange transmission or 4WD 

  269. Using the Output Shaft Seal Installer and the Drive Pinion Oil Seal Remover/Installer, install the output shaft seal.
    Fig 149: Installing Output Shaft Seal Using Output Shaft Seal Installer And Drive Pinion Oil Seal Remover/Installer
    G07972598Courtesy of FORD MOTOR CO.

    All vehicles 

  270. NOTE: Fixed flange/4WD shown in illustration, slip yoke similar.

    Inspect the output shaft nut O-ring for damage and install a new output shaft nut if necessary. Lubricate the output shaft nut O-ring with clean transmission fluid.

    Fig 150: Locating Output Shaft Nut O-Ring
    G07972599Courtesy of FORD MOTOR CO.
  271. NOTE: Fixed flange/4WD shown in illustration, slip yoke similar.

    Place the manual control lever in PARK and install the output shaft nut using the Output Shaft Nut Socket.

    • Tighten the nut to 200 Nm (148 lb-ft).
      Fig 151: Removing/Installing Output Shaft Nut Using Socket
      G08595055Courtesy of FORD MOTOR CO.

    Vehicles equipped with a slip yoke transmission 

  272. Install a new feed seal.
    G08595054
  273. Install a new O-ring seal on the extension housing and lubricate it with clean transmission fluid.
    Fig 152: Locating Extension Housing O-Ring Seal
    G08595052Courtesy of FORD MOTOR CO.
  274. Install the extension housing and the 8 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G08595051
  275. Using the Output Shaft Seal Installer and the Drive Pinion Oil Seal Remover/Installer, install a new output shaft seal.
    Fig 153: Installing Output Shaft Seal Using Output Shaft Seal Installer And Drive Pinion Oil Seal Remover/Installer
    G07972604Courtesy of FORD MOTOR CO.

    All vehicles 

  276. Install the TSS and OSS sensors and the bolts.
    • Tighten to 11 Nm (97 lb-in).
      G08595048
  277. NOTE: Do not push seals all the way down into main control valve body. Seals will be seated when main control valve body is installed to the transmission.

    Install the 4 seals.

    G08595046
  278. Clean and inspect the fluid supply feed tubes.
    Fig 154: Identifying Fluid Supply Feed Tubes
    G07972607Courtesy of FORD MOTOR CO.
  279. Install new O-rings on the fluid supply feed tubes and lubricate the O-rings with clean transmission fluid.
    Fig 155: Locating Fluid Supply Feed Tubes O-Rings
    G08595045Courtesy of FORD MOTOR CO.
  280. Install the intermediate (2, 6) clutch fluid supply feed tube.
    G08595044
  281. NOTE: Slip yoke shown in illustration, fixed flange/4WD similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.

    Install the fluid supply feed tube assembly.

    G08595043
  282. NOTE: The 3 long bolts hold the valve body in and the 3 short bolts hold the feed tubes in.

    Position the main control in place and install the 6 bolts.

    • Tighten to 11 Nm (97 lb-in).
      G08595042
  283. NOTE: Do not bend the manual valve rod clip when installing the manual valve rod. If the manual valve rod clip is bent back to install the manual valve rod instead of sliding it off, the manual valve rod clip will become permanently distorted causing total loss of transmission control or transmission failure. If the manual valve rod clip is bent, install a new manual valve rod clip.

    Install the manual valve rod into the manual valve and the TR sensor. Slide the manual valve rod clip over the manual valve rod until the manual valve rod clip tab goes through the TR sensor to hold the manual valve rod in place.

    1. Manual valve rod
    2. Manual valve
    3. TR sensor
    4. Manual valve rod clip
    5. Manual valve rod clip tab
      Fig 156: Installing Manual Valve Rod Into Manual Valve And TR Sensor
      G07972612Courtesy of FORD MOTOR CO.
  284. Position the wiring harness inside the transmission and connect the 7 solenoid electrical connectors, 2 speed sensor electrical connectors, TFT sensor electrical connector and the TR sensor electrical connector.
    G08595040
  285. NOTE: The long bolt is installed in the back of the filter.

    Install the transmission fluid filter and the 3 bolts.

    • Tighten to 11 Nm (97 lb-in).
      Fig 157: Locating Transmission Fluid Filter Bolts
      G08595039Courtesy of FORD MOTOR CO.
  286. NOTE: The transmission fluid pan gasket is a reusable gasket.

    Clean the transmission pan and gasket. Inspect the transmission fluid pan gasket for damage and install a new transmission fluid pan gasket if necessary. Make sure the magnet is clean and free of debris.

    Fig 158: Locating Transmission Pan And Gasket
    G07972615Courtesy of FORD MOTOR CO.
  287. Install the transmission fluid pan gasket, install the transmission fluid pan and the 19 bolts. Tighten the bolts in a crisscross pattern.
    • Tighten to 9 Nm (80 lb-in).
      Fig 159: Locating Transmission Fluid Pan Bolts
      G08595038Courtesy of FORD MOTOR CO.

    Vehicles equipped with fixed flange transmission 

  288. Install the output shaft flange and install the bolt.
    • Tighten to 133 Nm (98 lb-ft).
      G08595049

      All vehicles 

  289. If the Overdrive clutch was replaced, install 1 6R ATF Additive Kit XL-16 (2 syringes).
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