Disassembled Views

Fig 1: Disassembled View Of Transmission - Early Build (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 2: Disassembled View Of Transmission - Early Build (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 3: Disassembled View Of Transmission - Early Build (3 Of 3)

Courtesy of FORD MOTOR CO.

All vehicles 

1. Install the park detent spring and the 2 bolts.
   • Tighten to 12 Nm (106 lb-in).
2. Position the park pawl and spring into the case and install the park pawl pin.
   1. Park pawl
   2. Park pawl return spring
   3. Park pawl pin
3. Install the park pawl pin bolt.
   • Tighten to 23 Nm (17 lb-ft).
4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer.
5. Using the Shifter Fluid Seal Installer, install the manual control lever shaft seal.
6. Assemble the manual control lever detent plate assembly and park pawl actuator rod.
7. Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.
8. Position the manual control lever spacer in place and slide the manual control lever shaft into the case and the manual lever detent plate.
   1. Manual control lever spacer
   2. Manual control lever shaft
   3. Manual control lever detent plate
9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual control lever shaft and install a new roll pin.
10. Install the park rod actuating plate and the 4 bolts.
    • Tighten to 12 Nm (106 lb-in).

    Four-Wheel Drive (4WD) vehicles 

11. If removed, position a new bearing on the Output Shaft Bearing Installer. Install the bearing with the flat bearing surface facing down and the rounded bearing surface facing up so that when installed, the flat surface is on the snap ring side and the rounded surface is on the transmission case side.
    1. Rounded bearing surface facing up
    2. Flat bearing surface facing down
12. Using the Output Shaft Bearing Installer, the Drawbar and the Front Wheel Hub Oil Seal Installer, install the bearing in the transmission case.
13. Install the snap ring.

    Rear Wheel Drive (RWD) vehicles 

14. Install the bearing on the 6R80 Rear Bearing Remover/Installer.
15. Assemble the Front Wheel Hub Oil Seal Installer and the 6R80 Rear Bearing Remover/Installer on the Drawbar and install the bearing in the transmission case.
16. Position the thrust bearing spacer.
17. Using the 6R80 Rear Bearing Remover/Installer and a press, press the thrust bearing spacer in place.
18. Install the T12 thrust bearing.

    All vehicles 

19. Install the T11 bearing, on the planetary ring gear and output shaft assembly.
20. Install the rear planetary ring gear and output shaft assembly.
21. Install the T10 thrust bearing on the output shaft assembly.
22. Install the T9 roller bearing race into the bottom of the carrier.
23. Install the top T8 and the bottom T9 roller bearings onto the sun gear.
24. NOTE: When installing the sun gear, make sure that the TAPERED EDGE is facing UP toward the torque converter housing.

    Install the sun gear into the planetary assembly.

25. NOTE: Be sure the bearing race is installed in the sun gear.

    Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing down.

    1. Low/reverse sun gear
    2. Bearing race
26. NOTE: Place the manual control lever in PARK when installing the rear planetary gearset to hold the rear ring gear stationary.

    Install the planetary carrier.

27. NOTE: Friction and steel plate quantity are model dependent and vary based on engine displacement. For additional information, refer to the CLUTCH PLATE QUANTITY CHART  in the Specifications portion.

    Soak the low/reverse clutch plates in clean automatic transmission fluid.

28. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates and ending with the wave spring plate on the top.
29. NOTE: Inspect the T7 thrust bearing and selective shim for damage or scoring.

    Install the T7 thrust bearing and the selective shim.

30. NOTE: Align the OWC  in the transmission case so the bias spring fits into the transmission case.

    Install the OWC  as shown below so the bias spring can be installed as shown.

31. Install the bias spring.
32. NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.

    Install the center support into the case.

33. NOTE: Install the snap ring with the beveled surface facing up and the snap ring gap in the 3 o'clock or the 9 o'clock position.
    NOTE: Rotate the case to a horizontal position.

    Using the Retaining Ring Pliers, install the center support snap ring. Make sure the snap ring is fully seated.

    Four-Wheel Drive (4WD) vehicles 

34. Install the seal protector provided with the new output shaft seal on the output shaft.
35. Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the output shaft seal protector.
36. Using the 6R80 Rear Seal 4X4 Installer, install the output shaft seal.

    Rear Wheel Drive (RWD) vehicles 

37. Rotate the transmission to the vertical position and install the slip plane washer.
38. Position a new output shaft seal on the 6R80 4X2 Rear Seal Installer.
39. Using the 6R80 Rear Seal 4X2 Installer, install the output shaft seal.
40. Install the output shaft flange and the output shaft flange seal.
41. Loosely install a new output shaft flange retaining nut.

    Rear Wheel Drive (RWD) vehicles 

42. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.
43. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.

    Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading.

    The reading should be within 0.6-0.9 mm (0.024-0.035 in).

    • If the reading is not within specification, install a different (either thinner or thicker) selective shim.
44. Tighten the output shaft flange retaining nut.
    • Tighten to 80 Nm (59 lb-ft).
    • After installing the new output shaft flange retaining nut, stake the slots to prevent it from coming loose.

    Four-Wheel Drive (4WD) vehicles 

45. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft.
46. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).
    • If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.

    All vehicles 

47. Rotate the transmission in the vertical position with the torque converter housing facing up and install the T6 bearing.
48. Install the direct (B) clutch assembly.
49. Install the T5 roller bearing on the direct (B) clutch assembly.
50. Install the forward (A)/overdrive (E) clutch assembly.
51. Install the selective shim.
52. If the front pump was not disassembled and assembled, install a new front pump O-ring seal and lubricate it with petroleum jelly.
53. Install a new front pump seal on the Fluid Pump Seal Installer.
54. Using the Fluid Pump Seal Installer, install the front pump seal.
55. Install the Transmission Fluid Pump Remover on the front pump.
56. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover, position the pump assembly in the case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into the case.
57. NOTE: Failure to replace the fasteners will result in transmission fluid leakage.

    Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.

    • Tighten pump fasteners with washers to 10 Nm (89 lb-in).
    • Tighten fasteners without washers to 10 Nm (89 lb-in).
58. Install the Transmission End Play Gauge on the input shaft to measure the end play.
    • Tighten the wing nut.
59. Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.
    • Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.
    • Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump shim.
    • Measure the original shim, install a thinner or a thicker shim to achieve the correct measurement.
60. Rotate the transmission in the horizontal position with the main control area facing up and install 3 new center support feed tube seals.
    1. Center support feed tube seal (7G199 Black)
    2. Center support feed tube seal (7G087 Green)
    3. Center support feed tube seal (7G084 Blue)
61. NOTE: Make sure the transmission fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.
    NOTE: Add 0.118L (4 oz.) of clean transmission fluid to prime the pump.

    Install the front pump adapter seal and prime the fluid pump.

62. Install the thermal bypass valve into the case.
63. Align the guide pins in the alignment holes in the transmission case and position the mechatronic assembly in place.
    1. Alignment holes
    2. Guide pins
64. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the mechatronic assembly down.

    Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and position the mechatronic in place.

65. Install the 11 mechatronic assembly bolts and tighten in the sequence shown below.
    • Tighten to 8 Nm (71 lb-in).
66. If removed, install the bulkhead connector sleeve seals.
67. With the release tab up and unlocked, push the outer shell of the bulkhead connector sleeve into the transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
68. Press down on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure the locking tab is securely locked.
69. Install a new transmission fluid filter.
70. NOTE: The fluid pan gasket can be reused if not damaged.

    Install a new transmission fluid pan gasket if required.

71. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.
    • Tighten to 9 Nm (80 lb-in).
72. Using the Torque Converter Handle, install the torque converter.
73. If the Overdrive clutch FRICTIONS were replaced, install 1 6R ATF Additive Kit XL-16.