Section 194 (Automatic Transmission, Transfer Case And Power Transfer Unit - 6-Speed Automatic Transmission - 6R100): Overhaul: Transmission

For information on Ford Color Coded Illustrations, refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-001 (T50T-100-A)Slide Hammer
Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	204-029Drawbar
Courtesy of FORD MOTOR COMPANY	205-199 (T83T-3132-A1)Installer, Spindle/Axle ShaftT83-4000-A | TKIT-1983-F | TKIT-1983-FLM | TKIT-1983-FX
Courtesy of FORD MOTOR COMPANY	205-219 (T85L-1225-AH)Remover, Axle Bearing | TKIT-1985-FH-2
Courtesy of FORD MOTOR COMPANY	205-256Installer, Front Wheel Hub Seal | TKIT-1988-FESTIVAT88C-1000-ST | TKIT-1988-TRACER
Courtesy of FORD MOTOR COMPANY	205-276Installer, Front Wheel Hub Seal | TKIT-1988-FH | TKIT-1988-FLMH
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B)Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	307-015Compressor, Clutch Spring
Courtesy of FORD MOTOR COMPANY	307-091Handle, Torque Converter | TKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	307-209Compressor, Spring Washer | TKIT-2005U-LM1 | TKIT-2-MEX | TKIT-2000-F/FM/FLM
Courtesy of FORD MOTOR COMPANY	307-343Retaining Ring Pliers | TKIT-1995-FH/FLMH | TKIT-1995-LMH/MH
Courtesy of FORD MOTOR COMPANY	307-525Compressor, Clutch Spring | TKIT-2005D2-F
Courtesy of FORD MOTOR COMPANY	307-534End Play Gauge, Transmission | TKIT-2005D2-F
Courtesy of FORD MOTOR COMPANY	307-552Compressor, Clutch Spring | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-553Remover, Transmission Fluid Pump | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-554Gauge, D-Clutch Measurement | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-555End Play Gauge, Clutch | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-556Installer, Fluid Pump Seal | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-559Installer, Shifter Fluid Seal | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-562Remover, Needle Bearing | TKIT-2005U-FLM | TKIT-2005U-LM | TKIT-2006U-FLM/LM | TKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-637Installer, Rear Seal, 4x4 | TKIT-2008ET-FLM | TKIT-2008ET-ROW
Courtesy of FORD MOTOR COMPANY	307-691Tester, Torque Convertor Leak
Courtesy of FORD MOTOR COMPANY	307-713Installer, Roller Bearing | TKIT-2013B-FL | TKIT-2013B-ROW
Courtesy of FORD MOTOR COMPANY	307-714Installer, Needle Bearing | TKIT-2013B-FL | TKIT-2013B-ROW
Courtesy of FORD MOTOR COMPANY	307-715Installer, Output Seal (4X2) | TKIT-2013B-FL | TKIT-2013B-ROW
Courtesy of FORD MOTOR COMPANY	307-716Installer, Teflon Seal | TKIT-2013B-FL | TKIT-2013B-ROW
Courtesy of FORD MOTOR COMPANY	307-717Remover, Kostal Sleeve | TKIT-2013B-FL | TKIT-2013B-ROW
Courtesy of FORD MOTOR COMPANY	307-732Tool Kit, Torque Converter Flusher
Courtesy of FORD MOTOR COMPANY	308-375Remover, Input Shaft Seal | TKIT-2005U-M | TKIT-1999-F/FLM/LT
Flat Headed Screw Driver
Depth Gauge
Punch

Materials 

All vehicles 

1. Transmission overhaul includes the following:
   • Complete disassembly of the transmission
   • Cleaning and inspecting of all components
   • Replacement of all seals, gaskets, and one time use components. Use gasket kit -7153-
   • Complete assembly with clearances adjusted to specification
   • Replacement of any additional parts that may be required if worn or damaged

2. For information on component views and base part numbers. Refer to: Transmission Description .
3. Install the special tool on the torque converter housing and install the transmission on a bench. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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4. Using the special tool, remove the torque converter. Use Special Service Tool: 307-091 Handle, Torque Converter.

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5. 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.

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   Flush The Torque Converter With The Transmission Cooling System Heated Flusher 

6. 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 deg. 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

7. 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.
8. Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.
9. Turn on the heater and allow the transmission fluid in the transmission cooling system heated flusher 15-30 minutes to heat up to 60 deg. C (140 deg. F) before using.
10. Place the torque converter in an arbor press. Support the torque converter on the mounting pads.

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11. 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.

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12. Using the special tool, install the slotted cap. Use Special Service Tool: 307-691 Tester, Torque Convertor Leak.

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13. Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.

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14. Connect the flush machine to the main hub.
    1. Red hose on top.
    2. Blue hose on bottom.

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15. Follow the equipment instructions to purge transmission fluid from the torque converter prior to starting the flushing procedure.
16. 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.

17. 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.
18. Follow the equipment instructions to purge the torque converter.
19. 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.

20. 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.
21. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
22. 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.
23. Drain the remaining transmission fluid from the torque converter.
24. 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 (WSS-M2C938-A) (MERCON® LV,)

    Courtesy of FORD MOTOR COMPANY

25. Thoroughly drain the transmission fluid.

    All vehicles 

26. Remove the transmission fluid pan bolts and the transmission fluid pan.

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27. Remove the transmission fluid pan gasket.

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28. Remove and discard the transmission fluid filter.

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29. Press the release tab and lift up on the bulkhead electrical connector retainer to release the bulkhead electrical connector shell.

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30. With the transmission bulkhead connector sleeve retainer released, use the special tool to pull the outer shell of the bulkhead connector sleeve out of the transmission. Use Special Service Tool: 307-717 Remover, Kostal Sleeve.

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31. Inspect the bulkhead connector sleeve seals. If necessary, replace the seals.

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32. Remove the bolts from the main control assembly and remove the main control assembly.

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33. Clean and inspect the main control for damage. Refer to: Main Control Valve Body .
34. Remove and discard the front pump adapter seal.

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35. NOTE: The green (7G087) center support feed tube seal may be replaced with an orange (7G087) center support feed tube seal.
    1. Center support feed tube seal (7G199 Black)
    2. Center support feed tube seal (7G087 Green or Orange)
    3. Center support feed tube seal (7G084 Blue)
    • Remove and discard the feed tubes.

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36. Remove the thermal bypass valve from the case. Inspect the thermal bypass valve for damage and discard the valve if damaged.

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37. Using the special tools, remove and discard the front pump seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 308-375 Remover, Input Shaft Seal.

    Courtesy of FORD MOTOR COMPANY

38. Remove and discard the front pump-to-case bolts and washers.

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39. Using the special tools, remove the pump. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 307-553 Remover, Transmission Fluid Pump.

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40. NOTE: The selective shim may come out while removing the front pump.

    Inspect the back of the front pump for the selective shim and remove if necessary.

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41. If the selective shim is not on the pump, using a magnet, remove it from the forward (A)/overdrive (E) clutch assembly.

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42. Remove the forward (A)/overdrive (E) clutch assembly.

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43. Remove the caged T5 roller bearing from the direct (B) clutch assembly.

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44. Remove the direct (B) clutch assembly.

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45. Remove the bias spring.

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46. Using the special tools, remove the center support snap ring. Use Special Service Tool: 307-343 Retaining Ring Pliers.

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47. Remove the center support and T6 bearing.

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48. NOTE: The selective shim might stick to the T7 thrust bearing during removal of the center support.

    Remove the thrust gear shim, thrust bearing (T7) and sun gear No. 2.

    1. Thrust gear shim (select fit)
    2. Thrust bearing (T7)
    3. Sun gear No. 2

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49. NOTE: The selective shim might stick to the back of the center support assembly during removal.

    Remove the selective shim from the center support assembly.

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50. NOTE: Do not separate inner and outer races, lift the one-way clutch from the inside inner race.
    NOTE: When removing the one-way clutch, note the position for assembly.

    Remove the one-way clutch.

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51. NOTE: Some of the clutch plates may stay in the case when removing the planetary carrier and the low/reverse clutch pack. Remove any clutch plates from the transmission that were not removed with the carrier and keep the clutch plates together.

    Remove the planetary carrier and the low/reverse clutch pack as an assembly. Inspect the clutch plates for excessive wear or damage. If the clutch plates are excessively worn or damaged replace as necessary. If the clutch plates are not excessively worn or damaged, they can be reused.

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52. NOTE: Remove the bearings with the sun gear.
    NOTE: When removing the sun gear, note that the tapered edge is facing up toward the torque converter housing.

    Remove the No. 3 sun gear.

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53. Remove the top T8 and the bottom T9 roller bearings from the sun gear.

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54. Remove the T9 roller bearing race from the bottom of the carrier.

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55. NOTE: The T10 thrust bearing can stick to the planetary carrier.

    Remove the T10 thrust bearing.

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    Rear Wheel Drive (RWD) vehicles 

56. Remove the stakes from the output shaft flange retaining nut. Use the General Equipment: Punch

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57. NOTE: The output shaft flange retaining nut has been staked to prevent it from coming loose. Prior to removing the nut, remove the stake to prevent damage to the output shaft.

    Place the manual control lever in the PARK position and remove and discard the output shaft flange retaining nut.

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58. Remove the output shaft flange seal and flange.

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59. Remove the planetary carrier hub, output shaft assembly and T11 bearing.

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60. Remove and discard the output shaft seal and remove the slip plane washer.

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61. Remove the output shaft ball bearing snap ring.

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62. Using the special tools, remove the output shaft ball bearing. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 205-219 (T85L-1225-AH) Remover, Axle Bearing.

    Courtesy of FORD MOTOR COMPANY

    Four-Wheel Drive (4WD) vehicles 

63. Remove the planetary carrier hub, output shaft assembly and T11 bearing.

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64. Remove and discard the output shaft seal.

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    All vehicles 

65. Remove the snap ring.

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66. NOTE: Use care when installing the Needle Bearing Remover. Look inside the transmission case to make sure that the Needle Bearing Remover contacts the bearing only and not the lip of the case, or damage to the case will occur.

    Install the special tools on the bearing and remove the bearing. Use Special Service Tool: 205-256 Installer, Front Wheel Hub Seal., 307-562 Remover, Needle Bearing.

    Courtesy of FORD MOTOR COMPANY

67. Disconnect the park pawl return spring. Remove and discard the park rod actuating plate bolts and remove the park rod actuating plate.

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68. 1. Remove and discard the roll pin.
    2. Hold the manual control lever spacer to keep it from falling into the case.
    3. Slide the manual control lever shaft out of the case.
    • Remove the manual valve detent lever and park pawl actuator rod as an assembly.

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69. Remove and discard the manual control lever shaft seal.

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70. Remove the bolt from the back of the case to access to the park pawl pin.

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71. 1. Push the park pawl pin out toward the back side of the case and remove the pin.
    2. Remove the park pawl.

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72. Remove and discard the bolts and remove the park detent spring.

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73. Position the forward/overdrive clutch assembly in the special tool. Use Special Service Tool: 307-555 End Play Gauge, Clutch.

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74. 1. Locate the snap ring gap.
    2. Index-mark the direct clutch outer shell snap ring gap location to the side of the forward clutch hub using a paint marker.

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75. 1. Locate the snap ring gap.
    2. Pry the snap ring out of the groove 180 deg. from the snap ring gap and remove and discard the snap ring.

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76. Remove and discard the direct clutch hub.

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77. Remove the forward clutch and sun shaft assembly.

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78. NOTE: The bearing may stick in the forward clutch drum.

    Remove the intermediate shaft T4 thrust bearing.

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79. Remove the intermediate shaft assembly.

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80. If the T3 thrust bearing stuck to the intermediate shaft assembly, remove it from the intermediate shaft assembly. If the T3 thrust bearing is on the overdrive clutch, remove it from the overdrive clutch assembly.

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81. Remove the overdrive clutch pack from the forward clutch pack.

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82. If the T2 thrust bearing is on the forward clutch assembly, remove it from the forward clutch assembly.

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83. Remove the front planetary carrier and sun gear from the forward clutch assembly. Use a small screwdriver or a pick inserted into the front planetary assembly, push on the retaining ring in 4 places while lifting up on the front planetary assembly. Use the General Equipment: Flat Headed Screw Driver

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84. Remove the forward clutch pack snap ring.

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85. Remove the forward clutch steel and friction plates. Inspect the clutch plates for excessive wear or damage. If the clutch plates are excessively worn or damaged replace as necessary. If the clutch plates are not excessively worn or damaged, they can be reused.

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86. For correct alignment during assembly, make an identifying mark on the balance dam and the center part of the housing.

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87. 1. Assemble the special tools on the forward clutch cylinder. Use Special Service Tool: 307-525 Compressor, Clutch Spring., 307-015 Compressor, Clutch Spring.
    2. Using the special tool, slightly collapse the balance dam to access to the retaining ring and remove the retaining ring.

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88. Remove the balance dam.

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89. Remove and discard the O-ring seal from the balance dam.

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90. Remove the forward clutch return spring.

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91. Install the forward clutch on the front pump to remove the forward clutch piston. Apply a small amount of shop air to remove the piston.

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92. Remove and discard the inner and outer piston O-ring seals.

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93. Remove the sun gear from the planetary carrier.

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94. NOTE: The T1 thrust bearing may have stuck to the sun gear when it was removed.

    Remove the T1 bearing from the planetary carrier.

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95. Remove the transmission fluid collector plate from the front planetary carrier.

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96. Clean and inspect the components of the forward clutch assembly for damage and install new components as necessary.
97. NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come with the snap ring installed.

    Install the planetary assembly snap ring, if necessary. Make sure the planetary snap ring is oriented correctly.

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98. Install the transmission fluid collector plate on the front planetary carrier.

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99. Install the T1 bearing onto the sun gear.

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100. Install the sun gear into the planet assembly with the T1 bearing facing down and the recessed part of the gear up.

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101. Install new O-ring seals onto the forward clutch piston. Lightly coat the O-ring seal with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

102. Install the forward clutch piston into the forward clutch drum.

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103. Install the forward clutch return spring.

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104. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

105. Align the marks made during disassembly and install the balance dam into the forward clutch drum.

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106. 1. Assemble the special tools on the forward clutch cylinder. Use Special Service Tool: 307-525 Compressor, Clutch Spring., 307-015 Compressor, Clutch Spring.
     2. NOTE: Prior to releasing the special tool, make sure that the snap ring is fully seated.

        Using the special tool, slightly collapse the balance dam and install the retaining ring.

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107. NOTE: Friction and steel plate quantity will vary based on engine displacement.

     Soak the forward clutch plates in clean transmission fluid. For friction and steel plate quantity, refer to the Clutch Plate Quantity Chart. Refer to: Specifications .

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

108. Install the forward clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates.

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109. Install the forward clutch plate snap ring.

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110. NOTE: All forward clutch plates, friction and steel are of a wave-type design.

     Install the forward clutch assembly on the Clutch End Play Gauge and install the dial indicator gauge. Position the plunger so it fits into the snap ring gap. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

111. With the dial indicator gauge set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

112. Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

     Description	Reading
     Reading A
     Reading B
     Average reading A and B for a total end clearance

113. NOTE: If the end clearance is not within specification, install a new snap ring until the correct specification is achieved.
     • 0.71-1.10 mm (0.028-0.043 in)
     • If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, re-measure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, re-measure using a thinner select fit snap ring.

114. Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks in place.

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115. Install the T2 thrust bearing.

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116. Position the overdrive clutch assembly into the special tool and remove the T3 thrust bearing. Use Special Service Tool: 307-555 End Play Gauge, Clutch.

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117. Remove the overdrive clutch pack snap ring.

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118. Remove the overdrive clutch pack. Inspect the clutch plates for excessive wear or damage. If the clutch plates are excessively worn or damaged replace as necessary. If the clutch plates are not excessively worn or damaged, they can be reused.

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119. Using the special tool and a press, remove and discard the overdrive clutch balance piston retaining ring. Use Special Service Tool: 307-209 Compressor, Spring Washer.

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120. Remove the overdrive clutch balance piston.

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121. Remove the overdrive clutch return spring.

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122. Remove the overdrive clutch apply piston.

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123. Remove and discard the overdrive clutch balance piston O-ring seal.

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124. Remove and discard the O-ring seals from the clutch apply piston.

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125. Remove and discard the Teflon® seals.

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126. Install the special tool and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove. Use Special Service Tool: 307-716 Installer, Teflon Seal.

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127. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-716 Installer, Teflon Seal.

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128. Using the top half of the special tool, slide the Teflon® seal into the groove. Remove the special tools and repeat the steps for the other 2 Teflon® seals. Use Special Service Tool: 307-716 Installer, Teflon Seal.

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129. Install the special tool to size the 3 Teflon® seals. Use Special Service Tool: 307-716 Installer, Teflon Seal.

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130. Install a new outer O-ring seal on the overdrive clutch balance piston. Lightly coat the O-ring seal with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

131. Install a new outer O-ring seal on the overdrive clutch balance piston. Lightly coat the O-ring seals with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

132. Install the overdrive clutch apply piston into the drum with the O-ring seals and the 3 pads facing down.

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133. NOTE: The fingers on the return spring are facing down toward the piston.

     Install the overdrive clutch return spring.

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134. NOTE: The cone shape of the balance piston must face up when installed correctly.

     Install the overdrive clutch balance piston.

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135. Using the special tool and a press, install the balance piston retaining ring. Use Special Service Tool: 307-209 Compressor, Spring Washer.

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136. NOTE: Friction and steel plate quantity will vary based on engine displacement.

     Soak the overdrive clutch in clean transmission fluid. For friction and steel plate quantity, refer to the Clutch Plate Quantity Chart. Refer to: Specifications .

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

137. Install the overdrive clutch plates, starting with a steel plate and alternating between friction and steel plates and ending with the pressure plate on the top.

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138. Install the overdrive clutch pack snap ring.

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139. Install the overdrive assembly on the Clutch End Play Gauge and install the dial indicator gauge. Position the plunger so it fits into the opening of the snap ring. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

140. Rotate the overdrive clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

     Description	Reading
     Reading A
     Reading B
     Average reading A and B for a total end clearance

141. • 0.5-0.9 mm (0.019-0.035 in)
     • If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, re-measure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, re-measure using a thinner select fit snap ring.

142. Install the T3 thrust bearing.

     Courtesy of FORD MOTOR COMPANY

143. Position the forward clutch assembly in the special tool and install the overdrive clutch pack onto the forward clutch and planetary gear set. Use Special Service Tool: 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

144. Install the intermediate shaft assembly.

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145. NOTE: Inspect and install new thrust bearings as required.

     Install the T4 intermediate shaft bearing.

     Courtesy of FORD MOTOR COMPANY

146. Install the forward clutch hub and sun shaft assembly.

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147. Install a new direct clutch hub.

     Courtesy of FORD MOTOR COMPANY

148. NOTE: Do not install the snap ring on the forward clutch hub with the snap ring gap in the same position as the original snap ring or damage to the transmission can occur.
     1. Install the snap ring with the snap ring gap approximately 120 deg. away from the mark made on the forward clutch hub during disassembly.
     2. Index mark from original snap ring gap location.

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149. Remove and discard the 2 scarf cut seals and remove the roller bearing.

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150. Remove the T5 thrust bearing.

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151. Remove the direct clutch snap ring.

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152. Remove the direct clutch steel and friction plates. Inspect the clutch plates for excessive wear or damage. If the clutch plates are excessively worn or damaged replace as necessary. If the clutch plates are not excessively worn or damaged, they can be reused.

     Courtesy of FORD MOTOR COMPANY

153. Install the special tools and remove the direct clutch balance piston snap ring. Use Special Service Tool: 307-015 Compressor, Clutch Spring., 307-552 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

154. Remove the balance piston.

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155. Remove the direct clutch return spring.

     Courtesy of FORD MOTOR COMPANY

156. Remove the direct clutch piston.

     Courtesy of FORD MOTOR COMPANY

157. Remove and discard the outer O-ring seal from the balance piston.

     Courtesy of FORD MOTOR COMPANY

158. Remove and discard the O-ring seals from the apply piston.

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159. Inspect the components of the direct clutch for damage. If damage is indicated, install new components as necessary.
160. Install new O-ring seals on the apply piston. Lightly coat the O-ring seals with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

161. Install a new O-ring seal on the balance piston. Lightly coat the O-ring seal with clean transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

162. Install the direct clutch piston.

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163. Install the direct clutch return spring.

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164. Install the balance piston.

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165. Install the special tools the direct clutch assembly and install a the balance piston snap ring. Use Special Service Tool: 307-015 Compressor, Clutch Spring., 307-552 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

166. NOTE: Friction and steel plate quantity will vary based on engine displacement.

     Soak the direct clutch in clean transmission fluid. For friction and steel plate quantity, refer to the Clutch Plate Quantity Chart. Refer to: Specifications .

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

167. Install the direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.

     Courtesy of FORD MOTOR COMPANY

168. Install the direct clutch snap ring.

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169. NOTE: Inspect the thrust bearing for damage and install a new thrust bearing if damage is found.

     Install the T5 thrust bearing.

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170. NOTE: All direct clutch plates, friction and steel are of a wave-type design.

     Install the direct clutch assembly on the Clutch End Play Gauge and install the dial indicator gauge. Position the plunger so it fits into the opening of the snap ring. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

171. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

172. Rotate the direct clutch assembly 180 deg. from the opening of the snap ring, take a second reading and record this reading as reading B.

     Description	Reading
     Reading A
     Reading B
     Average reading A and B for a total end clearance

173. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
     • 0.5-1.3 mm (0.019-0.051 in)
     • If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, re-measure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, re-measure using a thinner select fit snap ring.

174. Install 2 new scarf cut seals and the roller bearing.

     Courtesy of FORD MOTOR COMPANY

     NOTE: The intermediate clutch plate quantity is model dependent on engine size. Failure to install the correct clutch plate quantity will result in transmission failure.
     NOTE: The intermediate clutch piston is model dependent on engine size due to the different quantity of intermediate clutch plates. If installing a new intermediate clutch piston, check to make sure the height of the new piston is the same as the original piston. Failure to install the correct piston will result in transmission failure.
175. Remove the T6 thrust bearing.

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176. Remove the intermediate clutch plate snap ring.

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177. Remove the intermediate clutch plates. Inspect the clutch plates for excessive wear or damage. If the clutch plates are excessively worn or damaged replace as necessary. If the clutch plates are not excessively worn or damaged, they can be reused.

     Courtesy of FORD MOTOR COMPANY

178. Using the special tool, remove and discard the intermediate clutch return spring retainer. Use Special Service Tool: 307-525 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

179. Remove the intermediate clutch return spring top plate.

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180. Remove the intermediate clutch return spring.

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181. Applying a slight amount of air to the port, remove the intermediate clutch piston.

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182. Remove and discard the inner and outer intermediate clutch piston O-ring seals.

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183. Install the inner and outer intermediate clutch piston O-ring seals.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

184. Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch piston.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

185. Install the intermediate clutch return spring.

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186. Install the intermediate clutch return spring top plate.

     Courtesy of FORD MOTOR COMPANY

187. Using the special tool, install a new intermediate clutch return spring retainer. Use Special Service Tool: 307-525 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

188. NOTE: Friction and steel plate quantity will vary based on engine displacement.

     Soak the intermediate clutch plates in clean automatic transmission fluid. For friction and steel plate quantity, refer to the Clutch Plate Quantity Chart. Refer to: Specifications .

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

189. Install the intermediate clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate.

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190. Install the intermediate clutch plate snap ring.

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191. NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.

     Install the intermediate clutch assembly on the Clutch End Play Gauge and install the dial indicator gauge. Position the plunger so it fits into the opening of the snap ring. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

192. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.

     Courtesy of FORD MOTOR COMPANY

193. Rotate the intermediate clutch assembly 180 deg. from the opening of the snap ring, take a second reading and record this reading as reading B.

     Description	Reading
     Reading A
     Reading B
     Average reading A and B for a total end clearance

194. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
     • 0.7-1.1 mm (0.027-0.043 in)
     • If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, re-measure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, re-measure using a thinner select fit snap ring.

195. Install the T6 thrust bearing.

     Courtesy of FORD MOTOR COMPANY

     NOTE: The low/reverse clutch plate quantity is model dependent on engine size. Failure to install the correct clutch plate quantity will result in transmission failure.
     NOTE: The low/reverse clutch plates are installed in the case during the transmission assembly procedure.
196. Using the special tool, remove and discard the low/reverse clutch return spring retainer. Use Special Service Tool: 307-525 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

197. Remove and discard the low/reverse clutch return spring retainer.

     Courtesy of FORD MOTOR COMPANY

198. Remove the low/reverse clutch return spring.

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199. Apply a slight amount of air to the port, remove the low/reverse clutch piston from the low/reverse clutch drum.

     Courtesy of FORD MOTOR COMPANY

200. Remove and discard the low/reverse outer piston O-ring seal.

     Courtesy of FORD MOTOR COMPANY

201. Remove and discard the low/reverse drum O-ring seal.

     Courtesy of FORD MOTOR COMPANY

202. Install new low/reverse outer piston O-ring seal.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

203. Install a new low/reverse drum inner O-ring seal.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

204. Align the alignment tab on the piston with the groove in the center support and install the low/reverse piston.

     Courtesy of FORD MOTOR COMPANY

205. Install the low/reverse clutch return spring.

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206. Install a new low/reverse clutch return spring retainer. Align the alignment tab on the retainer with the groove in the center support and install the low/reverse piston return spring retainer.

     Courtesy of FORD MOTOR COMPANY

207. Using the special tool, compress the low/reverse clutch return spring and install the retaining ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring.

     Courtesy of FORD MOTOR COMPANY

208. NOTE: All low/reverse clutch plates, friction and steel are of a wave-type design.

     Install the special tool into the case. Use Special Service Tool: 307-554 Gauge, D-Clutch Measurement.

     Courtesy of FORD MOTOR COMPANY

209. With the special tool positioned in the case, use the depth gauge to measure the case stop depth.

     Description	Reading
     Measure the distance from the top of the upper gauge bar to the top of the lower gauge bar. Record this reading as the case measurement. Record as reading A.

     Use Special Service Tool: 307-554 Gauge, D-Clutch Measurement. Use the General Equipment: Depth Gauge

     Courtesy of FORD MOTOR COMPANY

210. Measure the clutch pack height.

     Description

     Reading

     Place the low/reverse clutch pack on the Clutch End Play Gauge with the wave spring down and the pressure plate on top. Place the plunger of the dial indicator on the pressure plate. Slide the clutch to the side so the plunger of the dial indicator is touching the gauge plate of Clutch End Play Gauge. Zero out the dial indicator. Carefully lift the plunger enough to slide the clutch pack under the plunger to take a reading. Record this reading. Rotate the clutch pack 180 degrees and take a second reading. Average the readings. Record this as B.

     Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-555 End Play Gauge, Clutch.

     Courtesy of FORD MOTOR COMPANY

211. Using a depth gauge, measure the piston to center support shoulder height.

     Description	Reading
     Measure the piston to center support shoulder height. Record this measurement. Rotate the center support 180 degrees and record this measurement. Average the 2 measurements. Record this as C.

     Use the General Equipment: Depth Gauge

     Courtesy of FORD MOTOR COMPANY

212. Calculate the end clearance. Compare the end clearance to the specification. If the end clearance is out of specification, select the next thinner or thicker plate as required and repeat the steps to measure the clutch height.

     Description	Reading
     Subtract B and C from A to determine end clearance
     Total C measurement
     End clearance specification	1.0-1.6 mm (0.039-0.062 in)

213. Remove and discard the front pump O-ring seal.

     Courtesy of FORD MOTOR COMPANY

214. Remove and discard the front pump seal rings.

     Courtesy of FORD MOTOR COMPANY

215. 1. Pump body
     2. Pump plate assembly
     3. Index-mark the pump body to the pump plate assembly.

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216. 1. Loosen the pump plate assembly-to-pump body bolts.
     2. Push down on the loose pump plate assembly-to-pump body bolts to remove the pump body from the pump plate assembly.
     3. Remove the bolts and the pump body.

     Courtesy of FORD MOTOR COMPANY

217. Remove and discard the pump body outer seal and remove the fluid pump gears.

     Courtesy of FORD MOTOR COMPANY

218. NOTE: Clean all pump components in solvent and dry the parts with compressed air. Inspect the pump gears, faces, gear teeth and mating surfaces for damage or scoring. Install a new pump if necessary.
     1. NOTE: Some pump internal wear mark or light scratches is normal.

        Acceptable wear.

     2. If the gears are burned, discolored or scored or if the teeth are damaged, install a new pump.

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219. • Inspect the pump body for damage or scoring.
     • Inspect the pump plate assembly for damage or scoring.
     • Inspect the pump gear thrust surfaces for damage or scoring.
     • Install a new pump if necessary.

     Courtesy of FORD MOTOR COMPANY

220. Inspect the input shaft bushing for damage or scoring. If the bushing is damaged, install a new pump.

     Courtesy of FORD MOTOR COMPANY

221. Inspect the torque converter hub bushing for damage or scoring. If the bushing is damaged, install a new pump.

     Courtesy of FORD MOTOR COMPANY

222. NOTE: Prior to installation, lightly lubricate the pump gears with clean automatic transmission fluid.

     Install the pump gears with the dot facing the pump plate assembly and install a new pump body outer seal. Lubricate the pump gears and the seal with clean automatic transmission fluid.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

223. 1. Pump body
     2. Pump plate assembly
     3. Align the marks made during disassembly to correctly assemble the pump. Press the pump body into the pump plate assembly.
     • Visually inspect the pump body-to-pump plate assembly bolt holes to be sure that the pump body and pump plate are correctly aligned.

     Courtesy of FORD MOTOR COMPANY

224. Install the pump plate assembly-to-front pump body bolts.

     Torque:

     133 lb.in (15 Nm)

     Courtesy of FORD MOTOR COMPANY

225. NOTE: Make sure that the seal ends of each seal ring are hooked together or fluid leakage can occur.

     Install the front pump seal rings onto the stator support. Make sure the seals are fully seated in the stator support seal grooves and the seal ends are oriented 180 degrees apart.

     Courtesy of FORD MOTOR COMPANY

226. Install the pump outer diameter front pump O-ring seal.

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

227. Install a new front pump seal on the special tool. Use Special Service Tool: 307-556 Installer, Fluid Pump Seal.

     Courtesy of FORD MOTOR COMPANY

228. Using the special tool, install the front pump seal. Use Special Service Tool: 307-556 Installer, Fluid Pump Seal.

     Courtesy of FORD MOTOR COMPANY

229. Install the park detent spring and the bolts.

     Torque:

     106 lb.in (12 Nm)

     Courtesy of FORD MOTOR COMPANY

230. Position the park pawl and into the case and install the park pawl pin.

     Courtesy of FORD MOTOR COMPANY

231. Position the park pawl and spring into the case and install the park pawl pin.

     Torque:

     17 lb.ft (23 Nm)

     Courtesy of FORD MOTOR COMPANY

232. Install a new manual control lever shaft seal on the special tool. Use Special Service Tool: 307-559 Installer, Shifter Fluid Seal.

     Courtesy of FORD MOTOR COMPANY

233. Using the special tool, install the manual control lever shaft seal. Use Special Service Tool: 307-559 Installer, Shifter Fluid Seal.

     Courtesy of FORD MOTOR COMPANY

234. Assemble the manual control lever detent plate assembly and park pawl actuator rod.

     Courtesy of FORD MOTOR COMPANY

235. Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.

     Courtesy of FORD MOTOR COMPANY

236. Position the manual control lever spacer in place and slide the manual control lever shaft into the case and the manual lever detent plate. 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.

     Courtesy of FORD MOTOR COMPANY

237. Install the park rod actuating plate and the bolts. And connect the park pawl return spring.

     Torque:

     106 lb.in (12 Nm)

     Courtesy of FORD MOTOR COMPANY

238. • Install the needle bearing on the special tool so that the rounded end faces up.
     • Flat bearing surface (snap ring side) facing down. Use Special Service Tool: 307-714 Installer, Needle Bearing.

     Courtesy of FORD MOTOR COMPANY

239. Assemble the special tools and install the bearing in the transmission case. Use Special Service Tool: 204-029 Drawbar., 205-276 Installer, Front Wheel Hub Seal., 307-714 Installer, Needle Bearing.

     Courtesy of FORD MOTOR COMPANY

240. Install the snap ring.

     Courtesy of FORD MOTOR COMPANY

     Rear Wheel Drive (RWD) vehicles 

241. Install the bearing on the special tool. Use Special Service Tool: 307-713 Installer, Roller Bearing.

     Courtesy of FORD MOTOR COMPANY

242. Assemble the special tools and install the bearing in the transmission case. Use Special Service Tool: 204-029 Drawbar., 205-276 Installer, Front Wheel Hub Seal., 307-713 Installer, Roller Bearing.

     Courtesy of FORD MOTOR COMPANY

243. Install the snap ring.

     Courtesy of FORD MOTOR COMPANY

     All vehicles 

244. Install the T11 bearing, on the planetary ring gear and output shaft assembly.

     Courtesy of FORD MOTOR COMPANY

245. Install the rear planetary ring gear and output shaft assembly.

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246. Install the T10 thrust bearing on the output shaft assembly.

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247. Install the T9 roller bearing race into the bottom of the carrier.

     Courtesy of FORD MOTOR COMPANY

248. Install the top T8 and the bottom T9 roller bearings onto the sun gear.

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249. 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.

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250. NOTE: Be sure the bearing race is installed in the sun gear.
     1. low/reverse sun gear
     2. bearing race
     • Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing down.

     Courtesy of FORD MOTOR COMPANY

251. 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.

     Courtesy of FORD MOTOR COMPANY

252. NOTE: Friction and steel plate quantity are model dependent and vary based on engine displacement.

     Soak the low/reverse clutch plates in clean automatic transmission fluid. For friction and steel plate quantity, refer to the Clutch Plate Quantity Chart. Refer to: Specifications .

     Material

     Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

     Courtesy of FORD MOTOR COMPANY

253. 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.

     Courtesy of FORD MOTOR COMPANY

254. NOTE: Inspect the T7 thrust bearing and selective shim for damage or scoring.

     Install the T7 thrust bearing and the selective shim.

     Courtesy of FORD MOTOR COMPANY

255. NOTE: Do not separate inner and outer races, lift the one-way clutch from the inside inner race.
     NOTE: Align the one-way clutch in the transmission case so the bias spring fits into the transmission case.

     Install the one-way clutch clocked so that the bias spring can engage the one-way clutch and the case.

     Courtesy of FORD MOTOR COMPANY

256. Install the bias spring.

     Courtesy of FORD MOTOR COMPANY

257. NOTE: Make sure the center support feed holes are lined up with the feed holes in the case.

     Install the center support into the case.

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258. 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 special tool, install the center support snap ring. Using a tool, make sure the snap ring is fully seated. Use Special Service Tool: 307-343 Retaining Ring Pliers. Use the General Equipment: Flat Headed Screw Driver

     Courtesy of FORD MOTOR COMPANY

     Four-Wheel Drive (4WD) vehicles 

259. Install the seal protector provided with the new output shaft seal on the output shaft.

     Courtesy of FORD MOTOR COMPANY

260. Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the output shaft seal protector.

     Courtesy of FORD MOTOR COMPANY

261. Using the special tool, install the output shaft seal. Use Special Service Tool: 307-637 Installer, Rear Seal, 4x4.

     Courtesy of FORD MOTOR COMPANY

     Rear Wheel Drive (RWD) vehicles 

262. NOTE: Rotate the case to a vertical position.

     Install the slip plane washer.

     Courtesy of FORD MOTOR COMPANY

263. Position a new output shaft seal on the special tool. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft., 307-715 Installer, Output Seal (4X2).

     Courtesy of FORD MOTOR COMPANY

264. Using the special tools, install the output shaft seal. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft., 307-715 Installer, Output Seal (4X2).

     Courtesy of FORD MOTOR COMPANY

265. Install the output shaft flange and the output shaft flange seal.

     Courtesy of FORD MOTOR COMPANY

266. Loosely install a new output shaft flange retaining nut.

     Courtesy of FORD MOTOR COMPANY

267. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.

     Install the special tool on the transmission case and position the plunger on the output shaft flange. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

     Courtesy of FORD MOTOR COMPANY

268. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.

     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) rear planetary gearset selective shim. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

     Courtesy of FORD MOTOR COMPANY

269. Tighten the output shaft flange nut.

     Torque:

     59 lb.ft (80 Nm)

     Courtesy of FORD MOTOR COMPANY

270. After installing the new output shaft flange retaining nut, stake the slots to prevent it from coming loose. Use the General Equipment: Punch

     Courtesy of FORD MOTOR COMPANY

     Four-Wheel Drive (4WD) vehicles 

271. Install the special tool on the transmission case and position the plunger on the output shaft flange. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

     Courtesy of FORD MOTOR COMPANY

272. 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.

     Courtesy of FORD MOTOR COMPANY

     All vehicles 

273. NOTE: Rotate the transmission in the vertical position with the torque converter housing facing up.

     Install the T6 bearing.

     Courtesy of FORD MOTOR COMPANY

274. Install the direct clutch assembly.

     Courtesy of FORD MOTOR COMPANY

275. Install the T5 roller bearing on the direct clutch assembly.

     Courtesy of FORD MOTOR COMPANY

276. Install the forward/overdrive clutch assembly.

     Courtesy of FORD MOTOR COMPANY

277. Install the selective shim.

     Courtesy of FORD MOTOR COMPANY

278. Install the special tool on the front pump. Use Special Service Tool: 307-553 Remover, Transmission Fluid Pump.

     Courtesy of FORD MOTOR COMPANY

279. Lubricate the transmission case pump bore with petroleum jelly. Using the special tool, 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. Use Special Service Tool: 307-553 Remover, Transmission Fluid Pump.

     Courtesy of FORD MOTOR COMPANY

280. NOTE: Failure to replace the fasteners will result in transmission fluid leakage.

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

     Torque:

     89 lb.in (10 Nm)

     Courtesy of FORD MOTOR COMPANY

281. Install the special tool on the input shaft. Use Special Service Tool: 307-534 End Play Gauge, Transmission.

     Courtesy of FORD MOTOR COMPANY

282. Install the special tools. Push down on the Transmission End Play Gauge and zero the dial indicator. Lift up on the Transmission End Play Gauge and record the measurement on the dial indicator. The specification should be between 0.2-0.4 mm. If the Measurement is not within specification, remove the pump and install a new selective shim. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-534 End Play Gauge, Transmission.

     Courtesy of FORD MOTOR COMPANY

283. NOTE: The green (7G087) center support feed tube seal may be replaced with an orange (7G087) center support feed tube seal.
     1. Install a new center support feed tube seal (7G199 Black).
     2. Install a new center support feed tube seal (7G087 Green or Orange).
     3. Install a new center support feed tube seal (7G084 Blue).

     Courtesy of FORD MOTOR COMPANY

284. Install a new front pump adapter seal.

     Courtesy of FORD MOTOR COMPANY

285. Install the thermal bypass valve into the case.

     Courtesy of FORD MOTOR COMPANY

286. 1. Alignment holes
     2. Guide pins

     Courtesy of FORD MOTOR COMPANY

287. NOTE: The main control assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the main control assembly down.

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

     Courtesy of FORD MOTOR COMPANY

288. Install the main control assembly bolts and tighten in the sequence shown.

     Torque:

     71 lb.in (8 Nm)

     Fig 1: Main Control Assembly Bolts Tightening Sequence

     Courtesy of FORD MOTOR COMPANY
289. If removed, install the bulkhead connector sleeve seals.

     Courtesy of FORD MOTOR COMPANY

290. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure the bulkhead connector is fully seated into the molded leadframe. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure the locking tab is securely locked.

     Courtesy of FORD MOTOR COMPANY

291. Install a new transmission fluid filter.

     Courtesy of FORD MOTOR COMPANY

292. NOTE: The fluid pan gasket can be reused if not damaged.

     Install the transmission fluid pan gasket.

     Courtesy of FORD MOTOR COMPANY

293. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.

     Torque:

     80 lb.in (9 Nm)

     Courtesy of FORD MOTOR COMPANY

294. Using the special tool, install the torque converter. Use Special Service Tool: 307-091 Handle, Torque Converter.

     Courtesy of FORD MOTOR COMPANY

295. NOTE: Only 9-10 ml of the "Additive F" part of Motorcraft® 6R ATF Additive F (XL-16) should be used after the overdrive frictions are replaced. Too much "Additive F" in the fluid can result in converter clutch slip issues.
     NOTE: The Motorcraft® 6R ATF Additive F (XL-16) contains two syringes. The "Additive F" syringe is used only if the overdrive frictions are replaced. The "Additive T" syringe contains a tracer that is not is not used.

     If the Overdrive clutch FRICTIONS were replaced, add 9-10 ml of the "Additive F" part of Motorcraft® 6R ATF Additive F (XL-16) to the transmission.

     Material

     Motorcraft® 6R ATF Additive F / XL-16