Pump Assembly Non-PTO

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Pump Assembly Non-PTO

Courtesy 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	7A248-B	Teflon® seal
14	7A248-C	O-ring seal

All vehicles

Mount the transmission on the Car/Truck Engine Stand.

Fig 2: Mounting Transmission On Car/Truck Engine Stand
Courtesy of FORD MOTOR CO.
Position the transmission upright and remove the Torque Converter Retainer.

Fig 3: Removing Torque Converter Retainer
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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: Lifting Torque Converter Using Heavy Duty Floor Crane
Courtesy of FORD MOTOR CO.

NOTE: The transmission fluid pan gasket is a reusable gasket. Do not discard the transmission fluid pan gasket.

Fig 6: Locating Transmission Fluid Pan Bolts

Courtesy of FORD MOTOR CO.

Remove the 19 transmission fluid pan bolts and the transmission fluid pan and gasket.
Remove the 3 bolts and the transmission fluid filter.

Fig 7: Locating Transmission Fluid Filter Bolts
Courtesy of FORD MOTOR CO.
Disconnect the 7 solenoid electrical connectors, 2 speed sensor electrical connectors, Transmission Fluid Temperature (TFT) sensor electrical connector and the Transmission Range (TR) sensor electrical connector and position the transmission wiring harness retainer aside.

Fig 8: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.

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
  
  Fig 9: Removing Manual Valve Rod
  Courtesy of FORD MOTOR CO.
Remove the 6 main control bolts and remove the main control assembly.

Fig 10: Locating Main Control Bolts
Courtesy of FORD MOTOR CO.

NOTE: Slip yoke shown in illustration, fixed flange/Four-Wheel Drive (4WD) similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.

Fig 11: Locating Fluid Supply Feed Tube Assembly

Courtesy of FORD MOTOR CO.

Remove the fluid supply feed tube assembly.
Remove the intermediate (2, 6) clutch fluid supply feed tube.

Fig 12: Locating Intermediate (2, 6) Clutch Fluid Supply Feed Tube
Courtesy of FORD MOTOR CO.
Remove and discard the O-rings from the fluid supply feed tubes.

Fig 13: Locating Fluid Supply Feed Tubes O-Rings
Courtesy of FORD MOTOR CO.
Remove the 4 seals.

Fig 14: Locating Seals
Courtesy of FORD MOTOR CO.
Clean and inspect the main control for damage. For additional information, refer to MAIN CONTROL - OVERHAUL .

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.

Fig 15: Locating Clutch Feed Seals

Courtesy of FORD MOTOR CO.

Remove the 4 clutch feed seals.
Remove the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) speed sensors.

Fig 16: Locating Turbine Shaft Speed And Output Shaft Speed Sensors
Courtesy of FORD MOTOR CO.

Vehicles equipped with a fixed flange transmission
Remove the bolt and the output shaft flange.

Fig 17: Locating Output Shaft Flange Bolt
Courtesy of FORD MOTOR CO.

Vehicles equipped with a slip yoke transmission
Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the output shaft seal.

Fig 18: Removing Output Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the 8 extension housing bolts and the extension housing.

Fig 19: Locating Extension Housing Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seal from the extension housing.

Fig 20: Locating Extension Housing O-Ring Seal
Courtesy of FORD MOTOR CO.
Remove and discard the rubber grommet from the output shaft.

Fig 21: Locating Output Shaft Rubber Grommet
Courtesy of FORD MOTOR CO.
Remove and discard the rear bushing fluid feed seal.

Fig 22: Locating Rear Bushing Fluid Feed Seal
Courtesy of FORD MOTOR CO.

All vehicles

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/Four-Wheel Drive (4WD) shown in illustration, slip yoke similar.

Fig 23: Removing Output Shaft Nut

Courtesy of FORD MOTOR CO.

Apply heat to the output shaft nut to soften the Loctite®. Using the Output Shaft Nut Socket, remove the output shaft nut.
Remove the 4 park pawl abutment plate bolts and remove the park pawl abutment plate and the park pawl spring.

Fig 24: Locating Park Pawl Abutment Plate Bolts
Courtesy of FORD MOTOR CO.
Remove the manual control lever nut and the manual control lever.

Fig 25: Locating Manual Control Lever Nut
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove and discard the manual shaft seal.

Fig 26: Removing Manual Shaft Seal
Courtesy of FORD MOTOR CO.
Compress the 2 black tabs and push the wiring harness bulkhead through the transmission case and remove the transmission wiring harness.

Fig 27: Locating Wiring Harness Bulkhead Black Tabs
Courtesy of FORD MOTOR CO.
Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the torque converter hub seal.

Fig 28: Removing Torque Converter Hub Seal
Courtesy of FORD MOTOR CO.
Remove the 8 pump bolts.

Fig 29: Locating Pump Bolts
Courtesy of FORD MOTOR CO.
Install the Pump Remover/Installer Bracket on the pump. Install the pin in the top hole.

Fig 30: Installing Pump Remover/Installer Bracket On Pump
Courtesy of FORD MOTOR CO.
Use a Heavy Duty Floor Crane and the Pump Remover/Installer Bracket to lift the pump out of the transmission case.

Fig 31: Lifting Pump Out Of Transmission Case
Courtesy of FORD MOTOR CO.
Install the Pump Remover/Installer Bracket on the forward/overdrive clutch assembly. Install the pin in the center hole.

Fig 32: Installing Pump Remover/Installer Bracket On Forward/Overdrive Clutch Assembly
Courtesy of FORD MOTOR CO.
Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, lift the forward/overdrive clutch assembly out of the transmission case.

Fig 33: Lifting Forward/Overdrive Clutch Assembly Out Of Transmission Case
Courtesy of FORD MOTOR CO.
If the direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing is in the transmission, remove the clutch thrust bearing.

Fig 34: Locating Direct (3, 5, R)/Intermediate (2, 6) Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
Using a suitable tool, 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 35: Locating Center Support Beveled Retaining Ring
Courtesy of FORD MOTOR CO.

WARNING: Use caution when unloading the beveled retaining ring. Failure to follow this instruction may result in serious personal injury.

Fig 36: Removing Beveled Retaining Ring

Courtesy of FORD MOTOR CO.

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.
Remove the center support assembly.

Fig 37: Locating Center Support Assembly
Courtesy of FORD MOTOR CO.

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.

Fig 38: Installing Center Support Bearing Installer On Center Support

Courtesy of FORD MOTOR CO.

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 .
Remove the anti-clunk clip.

Fig 39: Locating Anti-Clunk Clip
Courtesy of FORD MOTOR CO.
Remove the No. 2 sun gear thrust bearing, rear selective shim and the No. 2 sun gear.

Fig 40: Locating No. 2 Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
Inspect the No. 2 sun gear teeth, splines and thrust bearing race for damage.
1. Teeth
2. Splines
3. Thrust bearing race
  
  Fig 41: Identifying Teeth, Splines And Thrust Bearing Race
  Courtesy of FORD MOTOR CO.
Remove the rear planetary gearset.

Fig 42: Locating Rear Planetary Gearset
Courtesy of FORD MOTOR CO.
Remove the thrust bearing and the No. 3 sun gear.
1. Thrust bearing
2. No. 3 sun gear
  
  Fig 43: Identifying Thrust Bearing And No. 3 Sun Gear
  Courtesy of FORD MOTOR CO.
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 44: Identifying Teeth, Splines And Thrust Bearing
  Courtesy of FORD MOTOR CO.
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.
    
    Fig 45: Inspecting Rear Planetary Gearset For Damage
    Courtesy of FORD MOTOR CO.
Remove the low/reverse (1, R) clutch assembly.

Fig 46: Locating Low/Reverse (1, R) Clutch Assembly
Courtesy of FORD MOTOR CO.
Remove the rear planetary gearset thrust bearing.

Fig 47: Locating Rear Planetary Gearset Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 48: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Remove the output shaft thrust bearing.

Fig 49: Locating Output Shaft Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the low/reverse clutch piston assembly bolt.

Fig 50: Locating Low/Reverse Clutch Piston Assembly Bolt
Courtesy of FORD MOTOR CO.
Remove the low/reverse clutch piston assembly.

Fig 51: Locating Low/Reverse Clutch Piston Assembly
Courtesy of FORD MOTOR CO.

Vehicles equipped with a fixed flange or 4WD
Using the Torque Converter Fluid Seal Remover and the Slide Hammer, remove and discard the output shaft seal.

Fig 52: Removing Output Shaft Seal
Courtesy of FORD MOTOR CO.

All vehicles
Remove the output shaft thrust bearing and washer.

Fig 53: Locating Output Shaft Thrust Bearing And Washer
Courtesy of FORD MOTOR CO.

NOTE: There are 2 different types of vent tubes. Both tubes are removed by sliding it off of the vent fitting.

Fig 54: Locating Vent Tube

Courtesy of FORD MOTOR CO.

Remove the vent tube.
Inspect the vent tube to be sure it is not restricted. Install a new vent tube if necessary.
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. For additional information, refer to TRANSMISSION CASE .
If the forward/overdrive clutch assembly thrust bearing is stuck to the bottom of the forward/overdrive clutch assembly, remove the thrust bearing.

Fig 55: Locating Forward/Overdrive Clutch Assembly Thrust Bearing
Courtesy of FORD MOTOR CO.
Assemble the Clutch Pack End Play Gauge and the Transmission Holding Fixture and install the forward/overdrive clutch assembly.

Fig 56: Installing Forward/Overdrive Clutch Assembly
Courtesy of FORD MOTOR CO.
Remove the direct (3, 5, R) clutch snap ring.

Fig 57: Locating Direct (3, 5, R) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
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 58: Locating Direct (3, 5, R) Clutch Hub And Direct (3, 5, R) Clutch Plates
Courtesy of FORD MOTOR CO.
Remove the direct (3, 5, R) clutch hub thrust bearing.

Fig 59: Locating Direct (3, 5, R) Clutch Hub Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch hub.

Fig 60: Locating Forward (1, 2, 3, 4) Clutch Hub
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch hub thrust bearing.

Fig 61: Locating Forward (1, 2, 3, 4) Clutch Hub Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the overdrive (4, 5, 6) clutch hub and center shaft assembly.

Fig 62: Locating Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
Courtesy of FORD MOTOR CO.

Early build vehicles
Remove the thrust bearing from the overdrive (4, 5, 6) clutch hub and center shaft assembly.

Fig 63: Locating Thrust Bearing Of Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
Courtesy of FORD MOTOR CO.

Late build vehicles
Remove the thrust bearing from the overdrive (4, 5, 6) clutch/input shaft assembly.

Fig 64: Identifying Thrust Bearing Of Overdrive (4, 5, 6) Clutch/Input Shaft Assembly
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: Early build shown in illustration, late build similar.

Fig 65: Locating Overdrive (4, 5, 6) Clutch/Input Shaft Assembly

Courtesy of FORD MOTOR CO.

Remove the overdrive (4, 5, 6) clutch/input shaft assembly.
Remove the front planetary carrier thrust bearing.

Fig 66: Locating Front Planetary Carrier Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the direct (3, 5, R) clutch apply ring.

Fig 67: Locating Direct (3, 5, R) Clutch Apply Ring
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch snap ring.

Fig 68: Locating Forward (1, 2, 3, 4) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.

Fig 69: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate, Clutch Assembly And Wave Spring
Courtesy of FORD MOTOR CO.
Remove the front planetary snap ring and the front planetary carrier from the forward (1, 2, 3, 4) clutch cylinder.

Fig 70: Locating Front Planetary Snap Ring And Front Planetary Carrier
Courtesy of FORD MOTOR CO.
Remove the front planetary sun gear from the front planetary carrier.

Fig 71: Locating Front Planetary Sun Gear
Courtesy of FORD MOTOR CO.
Remove the front planetary sun gear selective shim from the front planetary sun gear.

Fig 72: Locating Front Planetary Sun Gear Selective Shim
Courtesy of FORD MOTOR CO.
Install the Clutch Spring Compressor and compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring.

Fig 73: Installing Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch balance piston from the forward (1, 2, 3, 4) cylinder.

Fig 74: Locating Forward (1, 2, 3, 4) Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seal and the lip seal from the forward (1, 2, 3, 4) clutch balance piston.

Fig 75: Locating O-Ring Seal And Lip Seal
Courtesy of FORD MOTOR CO.
Remove the forward (1, 2, 3, 4) clutch return spring.

Fig 76: Locating Forward (1, 2, 3, 4) Clutch Return Spring
Courtesy of FORD MOTOR CO.
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.

Fig 77: Locating Forward (1, 2, 3, 4) Clutch Piston Cylinder
Courtesy of FORD MOTOR CO.
Remove and discard the lip seal from the forward (1, 2, 3, 4) clutch piston.

Fig 78: Locating Lip Seal Of Forward (1, 2, 3, 4) Clutch Piston
Courtesy of FORD MOTOR CO.
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 using a suitable tool 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.

Fig 79: Removing Clutch Spring Compressor And Direct (3, 5, R) Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Remove and discard the direct (3, 5, R) clutch balance piston seal.

Fig 80: Locating Direct (3, 5, R) Clutch Balance Piston Seal
Courtesy of FORD MOTOR CO.
Remove the direct (3, 5, R) clutch return spring.

Fig 81: Locating (3, 5, R) Clutch Return Spring
Courtesy of FORD MOTOR CO.
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.

Fig 82: Locating Forward (1, 2, 3, 4) Clutch Piston Cylinder
Courtesy of FORD MOTOR CO.
Remove and discard the direct (3, 5, R) clutch piston seal from the direct (3, 5, R) clutch piston.

Fig 83: Locating Direct (3, 5, R) Clutch Piston Seal
Courtesy of FORD MOTOR CO.
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
  
  Fig 84: Identifying Seals And O-Ring Of Forward (1, 2, 3, 4) Clutch Cylinder
  Courtesy of FORD MOTOR CO.
Clean and inspect the forward (1, 2, 3, 4) clutch cylinder for damage.
1. Inspect the piston sealing surfaces for damage.
2. Inspect the Turbine Shaft Speed (TSS) sensor tone wheel for damage.
3. Inspect the bushing and Teflon® sealing surfaces for damage.
  
  Fig 85: Inspecting Forward (1, 2, 3, 4) Clutch Cylinder For Damage
  Courtesy of FORD MOTOR CO.
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
  
  Fig 86: Identifying Seals And O-Ring Of Forward (1, 2, 3, 4) Clutch Cylinder
  Courtesy of FORD MOTOR CO.
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.

Fig 87: Locating Direct (3, 5, R) Clutch Piston Seal
Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R) clutch piston in the forward (1, 2, 3, 4) clutch cylinder.

Fig 88: Locating Forward (1, 2, 3, 4) Clutch Piston Cylinder
Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R) clutch return spring.

Fig 89: Locating (3, 5, R) Clutch Return Spring
Courtesy of FORD MOTOR CO.
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.

Fig 90: Locating Direct (3, 5, R) Clutch Balance Piston Seal
Courtesy of FORD MOTOR CO.
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 91: Installing Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
Install a new lip seal on the forward (1, 2, 3, 4) clutch piston and lubricate it with clean transmission fluid.

Fig 92: Locating Lip Seal Of Forward (1, 2, 3, 4) Clutch Piston
Courtesy of FORD MOTOR CO.
Install the forward (1, 2, 3, 4) clutch piston in the forward (1, 2, 3, 4) cylinder.

Fig 93: Locating Forward (1, 2, 3, 4) Clutch Piston Cylinder
Courtesy of FORD MOTOR CO.
Install the forward (1, 2, 3, 4) clutch piston return spring on the forward (1, 2, 3, 4) clutch piston.

Fig 94: Locating Forward (1, 2, 3, 4) Clutch Return Spring
Courtesy of FORD MOTOR CO.
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 95: Locating O-Ring Seal And Lip Seal
Courtesy of FORD MOTOR CO.
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 96: Installing Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
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 97: Locating Front Planetary Gearset Inspection Area
    Courtesy of FORD MOTOR CO.

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.

Fig 98: Locating Front Planetary Sun Gear

Courtesy of FORD MOTOR CO.

Install the front planetary sun gear in the front planetary carrier with the selective shim surface facing up.
Install the front planetary carrier in the forward (1, 2, 3, 4) clutch cylinder and install the snap ring.

Fig 99: Locating Front Planetary Snap Ring And Front Planetary Carrier
Courtesy of FORD MOTOR CO.
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 100: Identifying Wave Spring, Steel Clutch Plates, Clutches And Pressure Plate
  Courtesy of FORD MOTOR CO.

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.

Fig 101: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate, Clutch Assembly And Wave Spring

Courtesy of FORD MOTOR CO.

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.
Install the forward (1, 2, 3, 4) clutch snap ring.

Fig 102: Locating Forward (1, 2, 3, 4) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
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 103: Installing Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.

Fig 104: Measuring Clutch Clearance
Courtesy of FORD MOTOR CO.
Average the 3 recorded clutch clearance measurements and compare it to the forward (1, 2, 3, 4) clutch clearance specification. For additional information, 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.
Install the direct (3, 5, R) clutch apply ring.

Fig 105: Locating Direct (3, 5, R) Clutch Apply Ring
Courtesy of FORD MOTOR CO.
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 106: Identifying Wave Spring, Steel Clutch Plates, Clutches And Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate in the forward (1, 2, 3, 4) clutch cylinder.

Fig 107: Locating Direct (3, 5, R) Clutch Wave Spring, Clutch Assembly And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R) clutch snap ring.

Fig 108: Locating Direct (3, 5, R) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
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 109: Installing Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.

Fig 110: Measuring Clutch Clearance
Courtesy of FORD MOTOR CO.
Average the 3 recorded clutch clearance measurements and compare it to the direct (3, 5, R) clutch clearance specification. For additional information, 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.
Remove the direct (3, 5, R) clutch snap ring and remove the direct (3, 5, R) clutch assembly.

Fig 111: Locating Direct (3, 5, R) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
Install the overdrive (4, 5, 6) clutch cylinder on the Clutch Pack End Play Gauge.

Fig 112: Installing Overdrive (4, 5, 6) Clutch Cylinder On Clutch Pack End Play Gauge
Courtesy of FORD MOTOR CO.
Remove the overdrive (4, 5, 6) clutch snap ring.

Fig 113: Locating Overdrive (4, 5, 6) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
Remove the overdrive (4, 5, 6) clutch assembly and pressure plate.

Fig 114: Locating Overdrive (4, 5, 6) Clutch Assembly And Pressure Plate
Courtesy of FORD MOTOR CO.
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 115: Compressing Overdrive (4, 5, 6) Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Remove the overdrive (4, 5, 6) return spring.

Fig 116: Locating Overdrive (4, 5, 6) Return Spring
Courtesy of FORD MOTOR CO.
Remove and discard the overdrive (4, 5, 6) clutch piston.

Fig 117: Locating Overdrive (4, 5, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
Reposition the overdrive (4, 5, 6) clutch cylinder and input shaft assembly in the Clutch Pack End Play Gauge. Using a suitable tool, remove the 4 input shaft Teflon® seals and 1 Torque Converter Clutch (TCC) Teflon® seal.

Fig 118: Removing Input Shaft Teflon® Seals And Torque Converter Clutch Teflon® Seal
Courtesy of FORD MOTOR CO.
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 119: Identifying Overdrive (4, 5, 6) Clutch Cylinder And Input Shaft Assembly Inspection Area
  Courtesy of FORD MOTOR CO.
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 120: Installing Input Shaft Teflon® Seal Sizer On Input Shaft
Courtesy of FORD MOTOR CO.
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 121: Installing Input Shaft Teflon® Seal Sizer On End Of Input Shaft
Courtesy of FORD MOTOR CO.
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 122: Positioning Overdrive (4, 5, 6) Clutch Cylinder And Input Shaft Assembly In Clutch Pack End Play Gauge
Courtesy of FORD MOTOR CO.
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.

Fig 123: Locating Transmission Fluid Lubrication Area On Overdrive (4, 5, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
Install the overdrive (4, 5, 6) clutch piston return spring with the circles facing up.

Fig 124: Locating Overdrive (4, 5, 6) Return Spring
Courtesy of FORD MOTOR CO.
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.

Fig 125: Locating Transmission Fluid Lubrication Area N Overdrive (4, 5, 6) Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor and a press, compress the overdrive (4, 5, 6) clutch piston return spring and install the snap ring.

Fig 126: Compressing Overdrive (4, 5, 6) Clutch Balance Piston
Courtesy of FORD MOTOR CO.
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 127: Identifying Steel Clutch Plates, Clutches And Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the overdrive (4, 5, 6) clutch assembly and pressure plate in the overdrive (4, 5, 6) clutch cylinder and input shaft assembly.

Fig 128: Locating Overdrive (4, 5, 6) Clutch Assembly And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the overdrive (4, 5, 6) clutch snap ring.

Fig 129: Locating Overdrive (4, 5, 6) Clutch Snap Ring
Courtesy of FORD MOTOR CO.
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 130: Installing Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.

Fig 131: Measuring Clutch Clearance
Courtesy of FORD MOTOR CO.
Average the 3 recorded clutch clearance measurements and compare it to the overdrive (4, 5, 6) clutch clearance specification. For additional information, 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.

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

Fig 132: Identifying Bearing Surfaces, Splined Surfaces. Clutch Splined Surfaces And Bushing Surfaces

Courtesy of FORD MOTOR CO.

Position the forward (1, 2, 3, 4) clutch assembly in the Clutch Pack End Play Gauge and the Transmission Holding Fixture.

Fig 133: Positioning Forward (1, 2, 3, 4) Clutch Assembly In Clutch Pack End Play Gauge And Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Install the front planetary carrier thrust bearing.

Fig 134: Locating Front Planetary Carrier Thrust Bearing
Courtesy of FORD MOTOR CO.

NOTE: Early build shown in illustration, late build similar.

Fig 135: Locating Overdrive (4, 5, 6) Clutch/Input Shaft Assembly

Courtesy of FORD MOTOR CO.

Install the overdrive (4, 5, 6) clutch/input shaft assembly in the forward (1, 2, 3, 4) clutch.
Late build vehicles
Install the thrust bearing on the overdrive (4, 5, 6) clutch/input shaft assembly.

Fig 136: Identifying Thrust Bearing Of Overdrive (4, 5, 6) Clutch/Input Shaft Assembly
Courtesy of FORD MOTOR CO.

Early build vehicles
Install the thrust bearing on the overdrive (4, 5, 6) clutch hub and center shaft assembly.

Fig 137: Locating Thrust Bearing Of Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
Courtesy of FORD MOTOR CO.

All vehicles
Install the overdrive (4, 5, 6) clutch hub and center shaft assembly in the overdrive (4, 5, 6) clutch.

Fig 138: Locating Overdrive (4, 5, 6) Clutch Hub And Center Shaft Assembly
Courtesy of FORD MOTOR CO.
Install the forward (1, 2, 3, 4) clutch hub thrust bearing.

Fig 139: Locating Forward (1, 2, 3, 4) Clutch Hub Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the forward (1, 2, 3, 4) clutch hub.

Fig 140: Locating Forward (1, 2, 3, 4) Clutch Hub
Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R) clutch hub thrust bearing.

Fig 141: Locating Direct (3, 5, R) Clutch Hub Thrust Bearing
Courtesy of FORD MOTOR CO.
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 142: Installing Low/Reverse Clutch Piston Assembly On Clutch Pack End Play Gauge
Courtesy of FORD MOTOR CO.
Remove the low/reverse (1, R) piston return spring.

Fig 143: Locating Low/Reverse (1, R) Piston Return Spring
Courtesy of FORD MOTOR CO.
Using compressed air, remove the low/reverse (1, R) piston from the low/reverse cylinder.

Fig 144: Removing Low/Reverse (1, R) Piston From Low/Reverse Cylinder
Courtesy of FORD MOTOR CO.
Remove and discard the lip seal from the low/reverse (1, R) cylinder.

Fig 145: Locating Low/Reverse (1, R) Cylinder Lip Seal
Courtesy of FORD MOTOR CO.
Remove and discard the 2 lip seals from the low/reverse (1, R) piston.

Fig 146: Locating Low/Reverse (1, R) Piston Lip Seals
Courtesy of FORD MOTOR CO.

NOTE: Inspect the air bleed orifice and make sure it is not blocked by any debris.

Fig 147: Locating Lip Seal Sealing Surfaces On Low/Reverse (1, R) Piston And Cylinder

Courtesy of FORD MOTOR CO.

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.
Install 2 new lip seals on the low/reverse (1, R) piston and lubricate with clean transmission fluid.

Fig 148: Locating Low/Reverse (1, R) Piston Lip Seals
Courtesy of FORD MOTOR CO.
Install a new lip seal on the low/reverse (1, R) cylinder and lubricate with clean transmission fluid.

Fig 149: Locating Low/Reverse (1, R) Cylinder Lip Seal
Courtesy of FORD MOTOR CO.

NOTE: Be sure to align the alignment marks on the low/reverse (1, R) cylinder and piston when installing the piston in the cylinder.

Fig 150: Installing Low/Reverse (1, R) Piston In Cylinder

Courtesy of FORD MOTOR CO.

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

Fig 151: Locating Low/Reverse (1, R) Piston Return Spring
Courtesy of FORD MOTOR CO.
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 152: Compressing Low/Reverse (1, R) Return Spring
Courtesy of FORD MOTOR CO.
Remove the intermediate (2, 6) clutch pack snap ring.

Fig 153: Locating Intermediate (2, 6) Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.
Remove the intermediate (2, 6) clutch pressure plate, clutch assembly and wave spring from the intermediate (2, 6) clutch center support.

Fig 154: Locating Intermediate (2, 6) Clutch Pressure Plate, Clutch Assembly And Wave Spring
Courtesy of FORD MOTOR CO.
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 155: Compressing Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
Remove the intermediate (2, 6) clutch return spring.

Fig 156: Locating Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
Using compressed air, remove the intermediate (2, 6) clutch piston.

Fig 157: Locating Intermediate (2, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
Remove and discard the intermediate (2, 6) clutch inner and outer piston seals from the intermediate (2, 6) clutch piston.

Fig 158: Locating Intermediate (2, 6) Clutch Inner And Outer Piston Seals
Courtesy of FORD MOTOR CO.
Clean and inspect the intermediate (2, 6) clutch piston sealing surfaces for damage. If damage is found, install a new center support.

Fig 159: Locating Intermediate (2, 6) Clutch Piston Sealing Surfaces Inspection Area
Courtesy of FORD MOTOR CO.
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 160: Locating Intermediate (2, 6) Clutch Inner And Outer Piston Seals
Courtesy of FORD MOTOR CO.
Install the intermediate (2, 6) clutch piston.

Fig 161: Locating Intermediate (2, 6) Clutch Piston
Courtesy of FORD MOTOR CO.
Install the intermediate (2, 6) clutch return spring.

Fig 162: Locating Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
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 163: Compressing Intermediate (2, 6) Clutch Return Spring
Courtesy of FORD MOTOR CO.
Lubricate the intermediate (2, 6) clutch assembly with clean transmission fluid.
1. Pressure plate
2. Friction plates
3. Steel plates
4. Wave spring
  
  Fig 164: Identifying Pressure Plate, Friction Plates, Steel Plates And Wave Spring
  Courtesy of FORD MOTOR CO.

NOTE: The intermediate (2, 6) clutch pressure plate is installed with the step facing up.

Fig 165: Locating Intermediate (2, 6) Clutch Pressure Plate, Clutch Assembly And Wave Spring

Courtesy of FORD MOTOR CO.

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

Fig 166: Locating Intermediate (2, 6) Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.
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 167: Positioning Plunger Of Dial Indicator On Intermediate (2, 6) Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Pull up on the intermediate (2, 6) clutch pressure plate and measure and record the clutch clearance in 3 different places.

Fig 168: Measuring Clutch Clearance
Courtesy of FORD MOTOR CO.
Average the 3 recorded clutch clearance measurements and compare it to the intermediate (2, 6) clutch clearance specification. For additional information, 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.
Remove the pump housing seal.

Fig 169: Locating Pump Housing Seal
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the 3 Teflon® seals.

Fig 170: Removing Teflon® Seals
Courtesy of FORD MOTOR CO.

NOTE: Note the location of the different pump bolt lengths for assembly.

Fig 171: Locating Pump Bolts

Courtesy of FORD MOTOR CO.

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

Fig 172: Locating Pump Gasket
Courtesy of FORD MOTOR CO.

NOTE: Non-Power Take-Off (PTO) pump shown in illustration, PTO pump similar.

Fig 173: Separating Pump Housing From Pump Body

Courtesy of FORD MOTOR CO.

Thread 4 of the long bolts in the pump body by hand and position the pump housing on 2 blocks of wood or a suitable stand. 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.

NOTE: Observe the position of the locating dots on the pump gears. Dots must be facing up.

Fig 174: Locating Pump Gears Of Pump Body

Courtesy of FORD MOTOR CO.

Remove the pump gears from the pump body.
Remove the pump body seal from the pump body.

Fig 175: Locating Pump Body Seal Of Pump Body
Courtesy of FORD MOTOR CO.

Vehicles equipped with Power Take-Off (PTO)
Remove the thrust bearing from the PTO drive gear.

Fig 176: Locating Thrust Bearing Of PTO Drive Gear
Courtesy of FORD MOTOR CO.
Remove the PTO drive gear from the pump housing.

Fig 177: Locating PTO Drive Gear Of Pump Housing
Courtesy of FORD MOTOR CO.
Remove the PTO drive gear thrust washer from the pump housing.

Fig 178: Locating PTO Drive Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove and discard the O-ring seal and the 2 Teflon® seals from the stator support.
1. O-ring seal
2. Teflon® seals
  
  Fig 179: Locating O-Ring Seal And Teflon® Seals
  Courtesy of FORD MOTOR CO.
Vehicles not equipped with PTO
Remove and discard the O-ring seal and the Teflon® seal from the stator support.
1. Teflon® seal
2. O-ring seal
  
  Fig 180: Identifying O-Ring Seal And Teflon® Seals
  Courtesy of FORD MOTOR CO.
All vehicles
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 181: Identifying Pump Housing, Gear Surfaces, Stator Support And Sealing Surfaces
  Courtesy of FORD MOTOR CO.

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 182: Identifying Pump Body, Torque Converter Hub Bearing And Pump Gears
  Courtesy of FORD MOTOR CO.
Vehicles not equipped with PTO
Install a new O-ring seal on the stator support and lubricate it with clean transmission fluid.

Fig 183: Locating O-Ring Seal On Stator Support
Courtesy of FORD MOTOR CO.
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 184: Installing Teflon® Seal On Non-PTO Pump Seal Installer
Courtesy of FORD MOTOR CO.
Install the Non-PTO Pump Seal Installer to size the Teflon® seal.

Fig 185: Installing Non-PTO Pump Seal Installer To Teflon® Seal
Courtesy of FORD MOTOR CO.

Vehicles equipped with PTO
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 186: Identifying Teeth, Thrust Bearing Surface And Thrust Washer Surface
  Courtesy of FORD MOTOR CO.
Install a new O-ring seal on the PTO drive gear and lubricate it with clean transmission fluid.

Fig 187: Locating O-Ring Seal On PTO Drive Gear
Courtesy of FORD MOTOR CO.
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 188: Installing PTO Pump Seal Installer/Sizer On PTO Drive Gear
Courtesy of FORD MOTOR CO.
Install the PTO Pump Seal Installer/Sizer to size the 2 Teflon® seals.

Fig 189: Installing PTO Pump Seal Installer/Sizer On Teflon® Seals
Courtesy of FORD MOTOR CO.
Install the PTO drive gear thrust washer in the pump housing.

Fig 190: Locating PTO Drive Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the PTO Pump Seal Installer/Sizer.

Fig 191: Removing PTO Pump Seal Installer/Sizer
Courtesy of FORD MOTOR CO.
Install the PTO drive gear in the pump housing.

Fig 192: Locating PTO Drive Gear Of Pump Housing
Courtesy of FORD MOTOR CO.
Install the thrust bearing on the PTO drive gear.

Fig 193: Locating Thrust Bearing Of PTO Drive Gear
Courtesy of FORD MOTOR CO.

All vehicles
Install a new pump body seal and lubricate it with clean transmission fluid.

Fig 194: Locating Pump Body Seal Of Pump Body
Courtesy of FORD MOTOR CO.
Lubricate the pump gears with clean transmission fluid and install the pump gears in the pump body with the dots facing up.

Fig 195: Locating Transmission Fluid Lubrication Area On Pump Gears
Courtesy of FORD MOTOR CO.
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 196: Identifying Pump Housing, Pump Body, Alignment Hole And Alignment Pin
  Courtesy of FORD MOTOR CO.
Install the pump gasket.

Fig 197: Locating Pump Gasket
Courtesy of FORD MOTOR CO.

Vehicles not equipped with a PTO
Remove the Non-PTO Pump Seal Installer from the stator support.

Fig 198: Removing Non-PTO Pump Seal Installer From Stator Support
Courtesy of FORD MOTOR CO.

All vehicles

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 199: Locating Pump Bolts
  Courtesy of FORD MOTOR CO.
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 200: Installing Non-PTO Pump Seal Installer With PTO Pump Seal Installer/Sizer On Stator Support
Courtesy of FORD MOTOR CO.
Using the Non-PTO Pump Seal Installer size the 3 Teflon® seals.

Fig 201: Installing Non-PTO Pump Seal Installer Size On Teflon® Seals
Courtesy of FORD MOTOR CO.
Install a new pump housing seal and lubricate it with clean transmission fluid.

Fig 202: Locating Pump Housing Seal
Courtesy of FORD MOTOR CO.
Using the Front Pump Seal Installer, install a new hub seal.

Fig 203: Installing Torque Converter Hub Seal
Courtesy of FORD MOTOR CO.

NOTE: There are 2 different types of vent tubes. Both tubes are installed by sliding it on the vent fitting.

Fig 204: Locating Vent Tube

Courtesy of FORD MOTOR CO.

Install the vent tube.
Rotate the transmission upright and install the low/reverse clutch piston assembly in the transmission case.

Fig 205: Locating Low/Reverse Clutch Piston Assembly
Courtesy of FORD MOTOR CO.
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 206: Identifying Long Feed Tube And Low/Reverse Clutch Piston Assembly Bolt
  Courtesy of FORD MOTOR CO.
Install the output shaft thrust bearing.

Fig 207: Locating Output Shaft Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the output shaft.

Fig 208: Locating Output Shaft
Courtesy of FORD MOTOR CO.

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 209: Identifying Thrust Washer, Thrust Bearing And Output Shaft Nut
  Courtesy of FORD MOTOR CO.
Install the rear planetary gearset thrust bearing.

Fig 210: Locating Rear Planetary Gearset Thrust Bearing
Courtesy of FORD MOTOR CO.
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 One-Way Clutch (OWC).
1. Center support
2. Rear planetary carrier
3. Low/reverse (1, R) clutch
4. OWC
  
  Fig 211: Identifying Center Support, Rear Planetary Carrier, Low/Reverse (1, R) Clutch And OWC
  Courtesy of FORD MOTOR CO.

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.

Fig 212: Measuring Distance From Piston Contact Surface Of Apply Ring To Center Support Surface Using Suitable Depth Gauge

Courtesy of FORD MOTOR CO.

Using a suitable 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.
Compare the low/reverse (1, R) clutch measurement to the low/reverse (1, R) clutch measurement specification. For additional information, refer to SPECIFICATIONS . If the low/reverse (1, R) clearance is out of specification, install a new low/reverse (1, R) clutch assembly.
Lubricate the low/reverse (1, R) clutch in clean transmission fluid.
1. Apply plate
2. Steel plates
3. Clutch plates
  
  Fig 213: Identifying Apply Plate, Steel Plates And Clutch Plates
  Courtesy of FORD MOTOR CO.
Position the transmission in the upright position and install the low/reverse (1, R) apply plate and clutch assembly.

Fig 214: Locating Low/Reverse (1, R) Clutch Assembly
Courtesy of FORD MOTOR CO.

NOTE: The anti-clunk clip is NOT installed in this step.

NOTE: Make sure the outer One-Way Clutch (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
  
  Fig 215: Identifying OWC Spline And Transmission Case Spline
  Courtesy of FORD MOTOR CO.
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
  
  Fig 216: Identifying No. 3 Sun Gear And No. 3 Sun Gear Thrust Bearing
  Courtesy of FORD MOTOR CO.
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.

Fig 217: Locating Thrust Washer On No. 2 Sun Gear
Courtesy of FORD MOTOR CO.
Install the No. 2 sun gear thrust bearing on top of the No. 2 sun gear.

Fig 218: Locating No. 2 Sun Gear Thrust Bearing On Top Of No. 2 Sun Gear
Courtesy of FORD MOTOR CO.
Install the End Play Gauge on the transmission case.

Fig 219: Installing End Play Gauge On Transmission Case
Courtesy of FORD MOTOR CO.

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.

Fig 220: Positioning Suitable Depth Dial Indicator On End Play Gauge

Courtesy of FORD MOTOR CO.

Position a suitable 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.
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 221: Sliding Dial Indicator Over
Courtesy of FORD MOTOR CO.
With measurement A recorded, calculate the selective shim thickness and find the part number.
1. Zero
2. Measurement A
- 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).
Install the rear selective shim on top of the thrust bearing.

Fig 223: Locating Rear Selective Shim On Top Of Thrust Bearing
Courtesy of FORD MOTOR CO.

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.

Fig 224: Locating Center Support Assembly

Courtesy of FORD MOTOR CO.

Install the center support assembly.

WARNING: Use caution when unloading the beveled retaining ring. Failure to follow this instruction may result in serious 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.

Fig 225: Installing Beveled Retaining Ring

Courtesy of FORD MOTOR CO.

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.
Using a suitable tool, tap on the center support snap ring to make sure it is seated in the groove.

Fig 226: Locating Center Support Snap Ring
Courtesy of FORD MOTOR CO.
Install direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing.

Fig 227: Locating Direct (3, 5, R)/Intermediate (2, 6) Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the direct (3, 5, R)/intermediate (2, 6) clutch hub in the intermediate (2, 6) clutch.

Fig 228: Identifying Direct (3, 5, R)/Intermediate (2, 6) Clutch Hub In Intermediate (2, 6) Clutch
Courtesy of FORD MOTOR CO.
Install the intermediate clutch feed tube.

Fig 229: Locating Intermediate Clutch Feed Tube
Courtesy of FORD MOTOR CO.

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

Fig 230: Installing C-Clutch Air Plate

Courtesy of FORD MOTOR CO.

Install the C-Clutch Air Plate and apply 276 kPa (40 psi) of shop air to the C-Clutch Air Plate.
Remove the direct (3, 5, R)/intermediate (2, 6) clutch hub.

Fig 231: Identifying Direct (3, 5, R)/Intermediate (2, 6) Clutch Hub In Intermediate (2, 6) Clutch
Courtesy of FORD MOTOR CO.
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 232: Installing Direct (3, 5, R)/Intermediate (2, 6) Clutch Hub In Forward/Overdrive Clutch Assembly
Courtesy of FORD MOTOR CO.
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 233: Identifying Direct (3, 5, R) Clutch Wave Spring, Clutch Assembly, Pressure Plate And Snap Ring
  Courtesy of FORD MOTOR CO.
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 234: Installing Pump Remover/Installer Bracket On Forward/Overdrive Clutch Assembly
Courtesy of FORD MOTOR CO.
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 235: Installing Forward/Overdrive Clutch Assembly In Transmission Case
Courtesy of FORD MOTOR CO.
Remove the C-Clutch Air Plate.

Fig 236: Removing C-Clutch Air Plate
Courtesy of FORD MOTOR CO.
Install the anti-clunk clip.

Fig 237: Locating Anti-Clunk Clip
Courtesy of FORD MOTOR CO.

NOTE: Non-Power Take-Off (PTO) pump shown in illustration with 307-657/3, PTO pump with 307-659/2 similar.

Fig 238: Positioning Pump Assembly On Blocks Of Wood Or Suitable Stand

Courtesy of FORD MOTOR CO.

Position the pump assembly on 2 blocks of wood or a suitable stand and remove the Non-PTO Pump Seal Installer or PTO Pump Seal Installer/Sizer.
Position the End Play Gauge on the pump with it centered to the center of the stator support. Using a suitable 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 239: Positioning End Play Gauge On Pump
Courtesy of FORD MOTOR CO.

NOTE: Apply pressure to the End Play Gauge to hold it flush against the stator support when measuring to the deck surface.

Fig 240: Measuring Distance From Top Of End Play Gauge To Deck Surface

Courtesy of FORD MOTOR CO.

Using a suitable 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.
Subtract measurement A from measurement B and record as measurement C.
Position the End Play Gauge on the transmission case pump deck surface. Using a suitable 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 241: Positioning End Play Gauge On Transmission Case Pump Deck Surface
Courtesy of FORD MOTOR CO.
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).
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 242: Installing Selective Shim On Top Of No. 1 Sun Gear
Courtesy of FORD MOTOR CO.
Install the Pump Remover/Installer Bracket on the pump with the pin in the top hole.

Fig 243: Installing Pump Remover/Installer Bracket On Pump With Pin In Top Hole
Courtesy of FORD MOTOR CO.
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 244: Positioning Pump In Transmission Case
Courtesy of FORD MOTOR CO.
Align the bolt holes and loosely install 2 bolts. Using a suitable tool, gently tap the pump until it is seated on the deck surface of the transmission case.

Fig 245: Aligning Bolt Holes
Courtesy of FORD MOTOR CO.
Install the rest of the bolts and tighten in a crisscross pattern.
- Tighten bolts to 25 Nm (18 lb-ft).
  
  Fig 246: Locating Pump Bolts
  Courtesy of FORD MOTOR CO.
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 247: Locating Torque Converter Hub Seal Material
Courtesy of FORD MOTOR CO.
Install the Pump Remover/Installer Bracket on the torque converter with the pin in the bottom hole.

Fig 248: Installing Pump Remover/Installer Bracket On Torque Converter With Pin In Bottom Hole
Courtesy of FORD MOTOR CO.
Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, install the torque converter.

Fig 249: Installing Torque Converter Using Heavy Duty Floor Crane
Courtesy of FORD MOTOR CO.
Install the Torque Converter Retainer.

Fig 250: Installing Torque Converter Retainer
Courtesy of FORD MOTOR CO.

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.

Fig 251: Locating Clutch Feed Seals

Courtesy of FORD MOTOR CO.

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

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

Fig 252: Checking Low/Reverse (1, R) Clutch Feed Ports Pressure

Courtesy of FORD MOTOR CO.

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.

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

Fig 253: Checking Intermediate (2, 6) Clutch Feed Port Pressure

Courtesy of FORD MOTOR CO.

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.

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 254: Identifying Forward (1, 2, 3, 4) Clutch Port, Overdrive (4, 5, 6) Clutch Port And Direct (3, 5, R) Clutch Port
  Courtesy of FORD MOTOR CO.
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 255: Locating Wiring Harness Bulkhead O-Ring
Courtesy of FORD MOTOR CO.
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).
  
  Fig 256: Locating Park Pawl Abutment Plate Bolts
  Courtesy of FORD MOTOR CO.
Install a new manual shaft seal.

Fig 257: Locating Transmission Fluid Lubrication Area On Manual Shaft Seal
Courtesy of FORD MOTOR CO.
Install the manual control lever and the nut.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 258: Locating Manual Control Lever Nut
  Courtesy of FORD MOTOR CO.

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

Fig 259: Locating Output Shaft Nut

Courtesy of FORD MOTOR CO.

Remove the output shaft nut.
Vehicles equipped with a fixed flange transmission or 4WD
Using the Output Shaft Seal Installer and the Drive Pinion Oil Seal Remover/Installer, install the output shaft seal.

Fig 260: Installing Output Shaft Seal
Courtesy of FORD MOTOR CO.

All vehicles

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

Fig 261: Locating Output Shaft Nut O-Ring

Courtesy of FORD MOTOR CO.

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.

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 262: Installing Output Shaft Nut
  Courtesy of FORD MOTOR CO.
Vehicles equipped with a slip yoke transmission
Install a new feed seal.

Fig 263: Locating Rear Bushing Fluid Feed Seal
Courtesy of FORD MOTOR CO.
Install a new O-ring seal on the extension housing and lubricate it with clean transmission fluid.

Fig 264: Locating Extension Housing O-Ring Seal
Courtesy of FORD MOTOR CO.
Install the extension housing and the 8 bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 265: Locating Extension Housing Bolts
  Courtesy of FORD MOTOR CO.
Using the Output Shaft Seal Installer and the Drive Pinion Oil Seal Remover/Installer, install a new output shaft seal.

Fig 266: Installing Output Shaft Seal
Courtesy of FORD MOTOR CO.

All vehicles
Install the TSS and OSS sensors and the bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 267: Locating Turbine Shaft Speed And Output Shaft Speed Sensors
  Courtesy of FORD MOTOR CO.

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.

Fig 268: Locating Seals

Courtesy of FORD MOTOR CO.

Install the 4 seals.
Clean and inspect the fluid supply feed tubes.

Fig 269: Identifying Fluid Supply Feed Tubes
Courtesy of FORD MOTOR CO.
Install new O-rings on the fluid supply feed tubes and lubricate the O-rings with clean transmission fluid.

Fig 270: Locating Fluid Supply Feed Tubes O-Rings
Courtesy of FORD MOTOR CO.
Install the intermediate (2, 6) clutch fluid supply feed tube.

Fig 271: Locating Intermediate (2, 6) Clutch Fluid Supply Feed Tube
Courtesy of FORD MOTOR CO.

NOTE: Slip yoke shown in illustration, fixed flange/4WD similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.

Fig 272: Locating Fluid Supply Feed Tube Assembly

Courtesy of FORD MOTOR CO.

Install the fluid supply feed tube assembly.

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).
  
  Fig 273: Locating Main Control Bolts
  Courtesy of FORD MOTOR CO.

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 274: Installing Manual Valve Rod Into Manual Valve And TR Sensor
  Courtesy of FORD MOTOR CO.
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.

Fig 275: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.

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 276: Locating Transmission Fluid Filter Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The transmission fluid pan gasket is a reusable gasket.

Fig 277: Locating Transmission Pan And Gasket

Courtesy of FORD MOTOR CO.

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.
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 278: Locating Transmission Fluid Pan Bolts
  Courtesy of FORD MOTOR CO.
Vehicles equipped with fixed flange transmission
Install the output shaft flange and install the bolt.
- Tighten to 133 Nm (98 lb-ft).
  
  Fig 279: Locating Output Shaft Flange Bolt
  Courtesy of FORD MOTOR CO.
All vehicles
If the Overdrive clutch was replaced, install 1 bottle of XL-16 Automatic Transmission Fluid Additive.