Section 34 (Automatic Transmission - 6F50/6F55 - Fusion (Except Hybrid)): Overhaul: Transmission
WARNING: This page is about a different variant/trim than selected.
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A) Slide Hammer | |
|---|---|
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
| 205-153 (T80T-4000-W) Handle | |
| 303-D020 (D80L-100-R) Collet, 7/8 to 1 | |
| 303-D075 Depth Micrometer | |
| 307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (Navigator), TKIT-1997-F/FLM/LT |
|
| 307-574 Forward Clutch Spring Compressor TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-575 Converter Seal Installer TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings) TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-579 Support Solid seal installer (single seal) TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-580 Holding Fixture TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-581 Manual lever seal installer TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-582 A Cover Axle Seal Installer TKIT-2008AS-FLM |
|
| 307-5842-6 Spring Compressor TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-585 Support seal installer TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-588 Reverse clutch piston and retaining ring set TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-589 Overdrive clutch and balance piston service set TKIT-2006UF-FLM, TKIT-2006UF-ROW |
|
| 307-691 Tester, Torque Convertor Leak | |
| 307-696 Remover, TRS Retaining Pin TKIT-2012D-FL, TKIT-2012D-ROW |
|
| 307-732 Tool Kit, Torque Converter Flusher | |
| Hydraulic Press | |
| Puller | |
| Wooden Block |
Materials
| Name | Specification |
|---|---|
| Motorcraft ® Ultra Silicone Sealant TA-29 | - |
| Motorcraft ® MERCON ® LV Automatic Transmission Fluid XT-10-QLVC |
MERCON ® LV WSS-M2C938-A |
All vehicles
- Using the special tool, install the transmission onto the bench. Use Special Service Tool: 307-580 Holding Fixture.
- Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
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NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and remove the torque converter.
- A new or remanufactured torque converter must be installed if one or more of the following statements are true:
- The sealing surface has a groove worn from the seal.
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, threaded pads, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of water or antifreeze contamination.
Flush The Torque Converter With The Transmission Cooling System Heated Flusher
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NOTE: Use transmission fluid specified for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail, which will affect the operation of the transmission.
The torque converter must be flushed every time the transmission is overhauled. It is mandatory that proper equipment and procedures be followed when flushing the torque converter. The flushing equipment used MUST:
- Maintain the transmission fluid at 140 °F or above
- Pulsate the transmission fluid during cleaning
- Have a GPM flow meter
- Have a filter with a rating of 100 micron or less
- Have air purge capability before and after flushing
- If equipment meeting the specifications above is not available, the torque converter must be flushed by hand. Go to Flush The Torque Converter By Hand steps later in this procedure.
- Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.
- Turn on the heater and allow the transmission fluid in the transmission cooling system heated flusher 15-30 minutes to heat up to 60 °C (140 °F) before using.
- Place the torque converter in an arbor press. Support the torque converter on the mounting pads.
- Using the special tools, assemble the correct turbine shaft simulator to the torque converter flush main hub and place it on the torque converter hub. Use Special Service Tool: 307-732 Tool Kit, Torque Converter Flusher.
- Using the special tool, install the slotted cap. Use Special Service Tool: 307-691 Tester, Torque Convertor Leak.
- Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.
- Connect the flush machine to the main hub.
- Red hose on top.
- Blue hose on bottom.
- Follow the equipment instructions to purge transmission fluid from the torque converter prior to starting the flushing procedure.
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WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.NOTE: Maintain visual contact with torque converter during the entire flush procedure. Immediately stop the flush machine if a leak develops. Repeat set up steps to reseal the tool to the converter hub and continue flushing.
Forward flush the converter for 15 minutes.
- Monitor GPM flow meter periodically during the flush procedure. Flow rate above 2.0 gallons per minute is required to break up and dislodge any contamination trapped behind the TCC plate. Service flush machine filter(s) if flow rate drops below 2 GPM.
- Follow the equipment instructions to purge the torque converter.
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WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.
Allow torque converter and equipment to cool for 30 minutes before handling.
- Disconnect the hoses and remove the special tools.
Flush The Torque Converter By Hand
NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.NOTE: Only flush the torque converter by hand when the transmission cooling system heated flusher is not available. - Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
- Examine the transmission fluid for contaminants. The transmission fluid must be free of metallic contaminants. If metallic contaminants are present, do not continue with hand flushing. The torque converter must be flushed with the transmission cooling system heated flusher.
- Drain the remaining transmission fluid from the torque converter.
- Using only the recommended transmission fluid, add 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Thoroughly drain the transmission fluid.
All vehicles
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NOTE: Note the location of the studbolts for assembly.
Remove the studbolts, bolts and the main control cover.
- Slide the electrical connector lock tab over and disconnect the TR sensor.
- Disconnect the TSS and OSS sensor electrical connectors.
- Remove the OSS sensor wire from the retainer.
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NOTE: Handle the solenoid body with care or damage to the solenoid body may occur.NOTE: Note the location of the different length bolts for assembly.
Remove the bolts and the solenoid body.
- Remove the 10 main control valve body bolts and the valve body.
- Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. Refer to: Main Control Valve Body .
- Remove and discard the forward clutch feed seal.
- Remove the bolt and the OSS sensor.
- Remove the cover assembly bolts.
- Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transmission case.
- Remove the cover assembly gasket.
- Remove the No. 1 cover assembly thrust bearing.
- Remove the overdrive/direct clutch hub and turbine shaft assembly.
- Remove No. 3 rear sun gear thrust bearing.
- Remove the intermediate clutch shell and sun gear assembly.
- Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, as necessary.
- Gear teeth
- Shell-to-clutch pack surfaces
- Thrust bearing surfaces
- Remove the intermediate clutch assembly.
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NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low One-Way Clutch (OWC) snap ring.
Remove the low/reverse clutch assembly.
- Remove the rear planetary carrier and center ring gear assembly.
- Check that the bearings spin freely and do not move back and forth or side to side excessively.
- Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
- Remove the center planetary sun gear.
- Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary.
- Remove the center planetary carrier and front ring gear assembly.
- Check that the bearings spin freely and do not move back and forth or side to side excessively.
- Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
- Remove the front planetary carrier and rear ring gear assembly.
- Check that the bearings spin freely and do not move back and forth or side to side excessively.
- Remove the front planetary sun gear and shell assembly.
- Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, if necessary.
- Remove the No. 10 front sun gear thrust bearing.
- Remove the front planetary carrier hub assembly.
- Clean and inspect the front planetary carrier hub for damage or wear and install new, if necessary.
- Remove the No. 11 support assembly thrust bearing.
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NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.
Remove the low One-Way Clutch (OWC) snap ring.
- Remove the low One-Way Clutch (OWC).
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NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.NOTE: The low One-Way Clutch (OWC) cannot be disassembled.
Check for cracks and damaged splines. The internal splined section should rotate counterclockwise and lock when rotated clockwise.
- Check for burned or excessively worn surface.
- Remove the forward clutch assembly.
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NOTE: Install the Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
Using the special tool, compress the forward clutch piston return spring. Use Special Service Tool: 307-574 Forward Clutch Spring Compressor., 307-584 2-6 Spring Compressor.
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NOTE: The Compressor, Forward/Intermediate Spring 307-584 (307-584/1 and 307-584/2) and the Compressor, Forward Clutch Spring 307-574 (307-574/1 and 307-574/2) are not shown for clarity.
Remove the forward clutch piston return spring snap ring.
- Remove the forward clutch piston return spring.
- Remove and discard the forward clutch piston.
- Remove the 19 torque converter housing bolts.
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NOTE: Carefully pry on the transmission torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.
Carefully pry the torque converter housing off the transmission case just enough to break the seal of the silicone and remove the torque converter housing from the transmission case.
- Remove the transmission lube tube.
- Remove the differential and ring gear assembly.
- Remove the transfer shaft and gear assembly.
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NOTE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.
- Install new bearings or a ring gear on the differential if damage or excessive wear is found. Refer to: Differential .
- If the differential bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to: Transmission Case .
- If the differential ring gear is replaced, the transfer shaft must also be replaced. Refer to: Transfer Shaft .
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NOTE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
- Bearings
- Transfer shaft input gear
- Transfer shaft
- Park pawl wheel
- If the transfer shaft bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to: Transmission Case .
- If the transfer shaft is replaced, the differential ring gear must also be replaced. Refer to: Differential .
- Remove and discard the pump-to-case seal.
- Remove the bolts and the oil reservoir.
- Remove and discard the reservoir O-ring seal.
- Using the special tool, remove and discard the TR sensor retaining pin. Use Special Service Tool: 307-696 Remover, TRS Retaining Pin.
- Remove the TR sensor.
- Remove the park pawl actuator rod.
- Remove and discard the manual lever shaft seal.
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NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
If the transmission case side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to: Transmission Case .
- Remove and discard the halfshaft seal from the transmission case.
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NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.
If the transmission case side differential bearing cup is damaged, install a new bearing cup. Refer to: Transmission Case .
- Remove the bolt and the fluid baffle from the torque converter housing.
- Remove the bolts and the stator support assembly.
- Remove the bolts and the fluid pump and filter assembly.
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NOTE: Note the orientation of the fluid filter to the fluid pump.
Remove and discard the fluid filter.
- Pull the filter out of the bore of the fluid pump.
- If the filter seal did not come off with the filter, remove and discard the seal from the pump.
- Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.
- Remove the fluid pump sprocket and chain assembly.
- Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
- Check the drive chain for wear, damage, stretching or tightness of the chain links.
- Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.
- Remove the fluid pump drive sprocket and driven sprocket thrust washers.
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NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to: Torque Converter Housing .
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NOTE: FWD vehicles
Remove and discard the halfshaft seal from the torque converter housing.
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NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.
If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. Refer to: Torque Converter Housing .
- Remove and discard the torque converter hub seal from the torque converter housing. Use the General Equipment: Puller
- Clean and inspect the transmission case and torque converter housing for damage and install a new transmission case or torque converter housing if necessary.
- Remove the overdrive clutch snap ring.
- Remove the overdrive clutch hub and clutch assembly.
- Remove the bottom overdrive clutch steel plate.
- Remove the No. 2 rear sun gear thrust bearing.
- Using the special tool, compress the overdrive piston return spring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set. Use the General Equipment: Hydraulic Press
- With the overdrive piston return spring compressed, remove the balance piston snap ring.
- Remove and discard the balance piston.
- Remove the overdrive piston return spring.
- Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
- Install the overdrive/direct clutch assembly in the rear cover.
- Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
- Remove and discard the overdrive clutch piston inner seal.
- Remove and discard the overdrive clutch piston outer seals from the piston.
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NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Using the special tools and a press, compress the direct clutch piston return spring, and remove the snap ring.
- Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- Remove the snap ring.
- Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
- Position the overdrive/direct clutch assembly in the cover assembly.
- Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port to remove the direct clutch cylinder from the overdrive/direct clutch assembly. Remove the overdrive/direct clutch assembly from the rear cover and remove the direct clutch cylinder.
- Remove and discard the rear direct clutch piston seal.
- Remove and discard the direct clutch piston.
- Remove the direct clutch piston return spring.
- Remove and discard the direct clutch piston seals.
- Remove the direct clutch snap ring.
- Remove the direct clutch pressure plate, clutch assembly and wave spring.
- Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.
- Install the direct clutch wave spring.
- Soak the clutch plates.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the direct clutch assembly and pressure plate.
- Install the direct clutch snap ring.
- Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
- Install the direct clutch piston return spring.
- Lubricate a new direct clutch piston with petroleum jelly and install the piston.
- Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
- Install the direct clutch cylinder.
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NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
Install the Overdrive Clutch.
- Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- Install the snap ring.
- Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
- Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
- Using the special tool, push the overdrive clutch piston in the cylinder by hand. Use Special Service Tool: 307-589 Overdrive clutch and balance piston service set.
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NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
Install the overdrive clutch piston return spring.
- Lubricate the seals on a new balance piston with petroleum jelly.
- Using the special tool, compress the overdrive clutch piston return spring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- Using a press, compress the overdrive clutch piston return spring and install the snap ring.
- Install the No. 2 rear sun gear thrust bearing.
- Install the overdrive clutch hub.
- Soak the clutch plates.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the overdrive clutch pack assembly and the pressure plate.
- Install the overdrive clutch pack snap ring.
- Remove the bolt and the TSS sensor.
- Using the special tools, compress the intermediate clutch return spring, using a press and remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor. Use the General Equipment: Hydraulic Press
- Remove the intermediate clutch return spring.
- Remove and discard the intermediate clutch piston.
- Using the special tools, compress the low/reverse clutch return spring and remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-588 Reverse clutch piston and retaining ring set. Use the General Equipment: Hydraulic Press
- Remove the low/reverse clutch return spring.
- Remove and discard the low/reverse clutch piston.
- Remove and discard the 4 Teflon ® seals.
- Adjust the Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3 and repeat step to install the other 3 seals. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Using the special tool, size all 4 Teflon ® seals. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Install the special tools. Use Special Service Tool: 307-588 Reverse clutch piston and retaining ring set.
- Align the piston bleed hole with the indentation in the cover and push the piston in the cylinder using the Reverse Clutch Piston and Retaining Ring Set 307-588/3. Apply petroleum jelly. Use Special Service Tool: 307-588 Reverse clutch piston and retaining ring set.
- Install the low/reverse piston return spring with the tabs facing down.
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NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Using the special tools, compress the low/reverse piston return spring and install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-588 Reverse clutch piston and retaining ring set. Use the General Equipment: Hydraulic Press
- Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.
- Install the intermediate clutch piston.
- Install the intermediate clutch piston return spring.
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NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Using the special tool, compress the intermediate clutch piston return spring, install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor. Use the General Equipment: Hydraulic Press
- Remove the special tool. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Lubricate the O-ring seal on the TSS sensor with petroleum jelly and install the TSS sensor in the cover and install the bolt.
Torque: 106 lb.in (12 Nm)
- Remove and discard the stator support assembly seal.
- Remove and discard the input shaft seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 303-D020 (D80L-100-R) Collet, 7/8 to 1.
- Remove the drive sprocket thrust washer.
- Remove and discard the stator support-to-torque converter seal.
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NOTE: Note the location of the Torx ® head and the hex head bolts for assembly.
Remove the bolts and the stator support feed tube.
- Remove and discard the gasket for the feed tube assembly.
- Clean and inspect the stator support assembly for damage and install new, if necessary.
- Using the special tool, slide the seal in to the groove on the stator support assembly. Use Special Service Tool: 307-579 Support Solid seal installer (single seal).
- Using the special tool, size the seal. Use Special Service Tool: 307-579 Support Solid seal installer (single seal).
- Install a new gasket on the stator support assembly.
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NOTE: Install the Torx ® and the hex bolts in the correct locations as noted during disassembly.
Position the stator support feed tube assembly in place and install the bolts hand-tight.
- Tighten the stator support feed tube Torx ® head bolts.
Torque: 62 lb.in (7 Nm)
- Tighten the stator support feed tube hex-head bolts.
Torque: 106 lb.in (12 Nm)
- Install a new input shaft seal on the special tool. Use Special Service Tool: 307-585 Support seal installer.
- Using the special tool, install the input shaft seal. Use Special Service Tool: 307-585 Support seal installer.
- Remove the special tool. Remove Special Service Tool: 307-579 Support Solid seal installer (single seal).
- Install the drive sprocket thrust washer.
- Install a new stator support assembly seal.
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NOTE: The solenoid body should be handled with care or damage to the solenoid body may occur.NOTE: Do not handle the solenoid body in the internal wiring harness frame area or by the screens of the solenoid body filter or damage to the solenoid body may occur.NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.
Remove the solenoid body filter assembly by pulling it straight up from the alignment tabs. Discard the filter.
- Remove and discard the solenoid body assembly electrical connector seal.
- Clean and inspect the solenoid body assembly for damage and install new if necessary.
- If replacing the solenoid body, install the replacement service tag on the transmission case over the current solenoid body strategy tag.
- Install a new solenoid body assembly electrical connector seal.
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NOTE: Do not handle the solenoid body in the internal wiring harness frame area or by the screens of the solenoid body filter or damage to the solenoid body may occur.NOTE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transmission will occur if the solenoid body is not correctly aligned.NOTE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transmission will occur if the filter passages are not clean.
Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.
- Slide the park pawl over and install the park pawl actuator rod.
- Lubricate a new manual shaft seal and the special tool with petroleum jelly and install the seal. Use Special Service Tool: 307-581 Manual lever seal installer.
- Install the TR sensor.
- Using the special tool, install a new TR sensor locking pin in the transmission case. Use Special Service Tool: 307-581 Manual lever seal installer.
- Install a new O-ring seal on the reservoir. Lubricate the seal with transmission fluid.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the transmission fluid reservoir and the bolt.
Torque: 106 lb.in (12 Nm)
- Install a new pump-to-case seal.
- Install the transfer shaft and gear assembly.
- Tilt the transfer shaft and gear assembly over and install the differential assembly.
- Install a new torque converter hub seal on the special tool. Use Special Service Tool: 307-575 Converter Seal Installer.
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NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Using the special tool, install the torque converter hub seal in the torque converter housing. Use Special Service Tool: 307-575 Converter Seal Installer. Use the General Equipment: Wooden Block
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NOTE: FWD vehicles
Install a new RH halfshaft seal on the special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
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NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Using the special tool, install the RH halfshaft seal in the torque converter housing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer. Use the General Equipment: Wooden Block
- Install the pump drive sprocket and driven sprocket thrust washers.
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NOTE: The dot on the pump sprocket is installed facing upward.
Install the pump sprocket and chain assembly.
- Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Lubricate the seal with transmission fluid and install a new fluid filter seal in the fluid pump.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
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NOTE: Install the filter in the correct orientation as noted in removal.
Install the new fluid filter in the fluid pump.
- Position the pump and filter assembly in place and install the bolts.
Torque: 106 lb.in (12 Nm)
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NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Position the stator support assembly in place on the torque converter housing and install the stator support bolts. Tighten in the sequence displayed.
Torque: 30 lb.ft (41 Nm)
- Position the differential carrier baffle in place and install the bolt.
Torque: 106 lb.in (12 Nm)
- Lubricate the ends of the transmission fluid tube with petroleum jelly and install it in the transmission.
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
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NOTE: Make sure the sealing surface of both the transmission case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transmission case.
Apply a bead of silicone sealant to the machined surface of the transmission case.
Material: Motorcraft ® Ultra Silicone Sealant / TA-29
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NOTE: Install the 2 studbolts in the correct location as noted during disassembly.NOTE: Hand tighten the bolts only.
Install the torque converter housing on top of the transmission case and install the bolts.
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NOTE: The studbolts are 1 and 16 in the tightening sequence.
Tighten the bolts in the sequence displayed below.
Torque: 18 lb.ft (24 Nm)
- Install a new halfshaft seal on special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
- Using the special tool, install the halfshaft seal in the transmission case. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
- Lubricate the forward clutch piston seals with petroleum jelly.
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NOTE: Install the Compressor, Forward/Intermediate Spring 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.
Using the special tool, install the forward clutch piston in place in the transmission case. Use Special Service Tool: 307-584 2-6 Spring Compressor.
- Install the forward clutch piston return spring with the tabs facing downward.
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NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
Using the special tool, compress the forward clutch piston return spring. Use Special Service Tool: 307-574 Forward Clutch Spring Compressor., 307-584 2-6 Spring Compressor.
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NOTE: The Compressor, Forward Clutch Spring and the Compressor, Forward/Intermediate Spring not shown for clarity.NOTE: The snap ring gap should be at the top of the transmission case.
Install the forward clutch piston return spring snap ring.
- Install the forward clutch wave spring.
- Soak the clutch plates.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the forward clutch pack assembly.
- Position the forward clutch pack assembly in the case.
- Make sure the alignment tab on the clutch pack is positioned in the correct location.
- Install the low One-Way Clutch (OWC).
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NOTE: The low One-Way Clutch (OWC) snap ring gap must be positioned as displayed so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.
Install the low One-Way Clutch (OWC) snap ring.
- Compare the position of the low One-Way Clutch (OWC) snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
- Install the special tool on the transmission case and position the plunger on a top friction disc tab. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Install a new forward clutch feed seal.
- Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low One-Way Clutch (OWC) for correct installation. If the forward clutch pack and low One-Way Clutch (OWC) is correctly installed, install a new forward clutch pack. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Install the No. 11 stator support thrust bearing.
- Install the front planetary carrier hub.
- Install the No. 10 front sun gear thrust bearing.
- Install the front sun gear and shell assembly.
- Install the front carrier and rear ring gear assembly.
- Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
- Install the center planetary carrier and front ring gear assembly.
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NOTE: The groove on the center sun gear is installed facing up.
Install the center planetary sun gear.
- Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
- Install the rear planetary gear carrier assembly.
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NOTE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low One-Way Clutch (OWC) snap ring may result in damage to the transmission.
Install the low/reverse clutch pressure plate.
- Make sure the tab on the bottom of the pressure plate fits in the gap of the low One-Way Clutch (OWC) snap ring.
- Install the low/reverse clutch pressure plate.
- Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low One-Way Clutch (OWC) snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
- Soak the clutch plates.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the low/reverse clutch.
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NOTE: The low/reverse clutch wave spring and pressure plate are temporarily reversely installed to measure the low/reverse clutch clearance.NOTE: Temporarily install the low/reverse clutch wave spring and pressure plate with the pressure plate on top of the wave spring.
Install the low/reverse pressure plate.
- Pressure plate
- Wave spring
- Using a straightedge and the Depth Micrometer 303-D075 (D92P-4201-A), measure and record as measurement A, the distance from the transmission case deck surface to the low/reverse pressure plate. Use Special Service Tool: 303-D075 Depth Micrometer.
- Using the same straightedge and the Depth Micrometer 303-D075 (D92P-4201-A), measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface. Use Special Service Tool: 303-D075 Depth Micrometer.
- Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 0.83 mm (0.032 in) and 2.43 mm (0.095 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and add 1.6 mm (0.062 in), check to see if it is within range of 0.83 mm (0.032 in) and 2.43 mm (0.095 in) -
NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Install the low/reverse clutch.
- Wave spring
- Pressure plate
- Install the intermediate clutch pressure plate.
- Soak the clutch plates.
Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
- Install the intermediate clutch pack assembly.
- Install the intermediate clutch pack wave spring.
- Using a straightedge and the Depth Micrometer 303-D075 (D92P-4201-A), measure and record as measurement A, the distance from the transmission case deck surface to a low point on the intermediate clutch wave spring. Use Special Service Tool: 303-D075 Depth Micrometer.
- Using the straightedge and the Depth Micrometer 303-D075 (D92P-4201-A), measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface. Use Special Service Tool: 303-D075 Depth Micrometer.
- Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.038 in) and 2.56 mm (0.1 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and add 1.6 mm (0.062 in), check to see if it is within range of 0.99 mm (0.038 in) and 2.56 mm (0.1 in) - Install the rear sun gear and shell assembly.
- Install the No. 3 rear sun gear thrust bearing.
- Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
- Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
- Position the Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
- Install the overdrive/direct clutch hub and turbine shaft assembly.
- Install the No. 1 cover assembly thrust bearing.
- Install the cover assembly gasket.
- Route the TSS sensor harness through the transmission case to the valve body area and install the cover assembly.
- Install the cover assembly bolts and tighten the bolts in the sequence displayed.
Torque: 106 lb.in (12 Nm)
- Install the OSS sensor and the bolt.
Torque: 106 lb.in (12 Nm)
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NOTE: Be careful not to pinch the TSS, OSS or TR sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.
- Manual valve
- Manual pin
- Install the main control valve body bolts. Tighten the bolts in the sequence displayed below.
Torque: 106 lb.in (12 Nm)
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NOTE: Make sure not to pinch the TSS, OSS or TR sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
Install the solenoid body bolts hand-tight.
- Bolt
Distance: 1.65in (42mm)
- Bolt
Distance: 2.48in (63mm)
- Bolt
Distance: 3.15in (80mm)
- Bolt
Distance: 3.74in (95mm)
- Bolt
- Tighten the solenoid body bolts in the sequence displayed below.
Torque: 106 lb.in (12 Nm)
- Route the OSS sensor wiring harness into the retainer.
- Connect the TSS and OSS sensor electrical connectors.
- Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
- Inspect the transmission main control cover seal for damage and install new if necessary.
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NOTE: Install the studbolts in the correct locations as noted during disassembly.
Install the transmission main control cover and install the studbolts and the bolts.
- Tighten the main control cover bolts in the sequence displayed below.
Torque: 106 lb.in (12 Nm)
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NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transmission.
- Install the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.