Section 195 (Automatic Transmission, Transfer Case And Power Transfer Unit - 6-Speed Automatic Transmission - 6R140 (2 Of 2)): Overhaul: Transmission
WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations, refer to OEM COLOR CODING
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A)Slide Hammer | |
|---|---|
| 100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge | |
| 205-440Remover/Installer, Drive Pinion Oil Seal | TKIT-1999-F/FLM/LT | |
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 307-003 (T57L-500-B)Holding Fixture, Transmission | |
| 307-309Remover, Torque Converter Seal | TKIT-1994-FMH/FLMH | TKIT-1994-LMH/MH | TKIT-1994-FH | |
| 307-346 (T97T-7902-A)Retainer, Torque Converter | TKIT-1998-LM (Navigator) | TKIT-1997-F/FLM/LT | |
| 307-525Compressor, Clutch Spring | TKIT-2005D2-F | |
| 307-649Socket, Output Shaft Nut | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-650Installer, Output Shaft Seal | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-651Bracket, Pump Remover/Installer | |
| 307-652Plate, C-Clutch Air | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-653Sizer, Input Shaft Teflon Seal | |
| 307-654Pliers, Snap Ring | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-655Installer, Center Support Bearing | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-657Installer, Pump Seal - Non-PTO | |
| 307-658Compressor, C Clutch Return Spring | |
| 307-659Installer/Sizer, Pump Seal PTO | |
| 307-660Installer, Front Pump Seal | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-661Gauge, End Play | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-662Gauge, Clutch Pack Endplay | TKIT-2009C-F | TKIT-2009C-ROW | |
| 307-691Tester, Torque Convertor Leak | |
| 307-732Tool Kit, Torque Converter Flusher | |
| Rubber Mallet | |
| Depth Gauge | |
| Mounting Stand | |
| Hydraulic Press | |
| Wooden Block |
Materials
| Name | Specification |
|---|---|
| Motorcraft® 6R ATF Additive FXL-16 | - |
| Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVC | WSS-M2C938-AMERCON® LV, |
All vehicles
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NOTE: Clutch plate quantity is model dependent based on engine displacement.
For the clutch plate quantity. Refer to: Specifications .
- For information on component views and base part numbers. Refer to: Transmission Description .
- Mount the transmission to a mounting stand.
- Position the transmission upright. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
- Install the special tools on the torque converter. Install the pin in the bottom hole. Install Special Service Tool: 307-651 Bracket, Pump Remover/Installer.
- Using a special tool, lift the torque converter. Use enough pressure to break the torque converter hub seal loose and raise the torque converter high enough to allow the torque converter to drain. Remove the torque converter. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away. Use the General Equipment: Mounting Stand
- 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 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
- 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. Go to Step 22
- 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 deg. C (140 deg. F) before using.
- Place the torque converter in an shop 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 (WSS-M2C938-A) (MERCON® LV,)
- Thoroughly drain the transmission fluid.
All vehicles
- Remove the transmission fluid pan bolts and the transmission fluid pan.
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NOTE: The transmission fluid pan gasket is a reusable gasket. Do not discard the transmission fluid pan gasket.
Remove the transmission fluid pan gasket.
- Remove the bolts and the transmission fluid filter.
- Disconnect the electrical connectors and position the transmission wiring harness retainer aside.
- Disconnect the solenoid electrical connectors.
- Disconnect the TR sensor electrical connector.
- Disconnect the TFT sensor electrical connector.
- Disconnect the OSS electrical connectors.
- Disconnect the TSS electrical connectors.
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NOTE: Do not bend the manual valve rod clip when removing the manual valve rod. If the manual valve rod clip is bent back to remove the manual valve rod instead of sliding it off, the manual valve rod clip will become permanently distorted causing total loss of transmission control or transmission failure. If the manual valve rod clip is bent, install a new manual valve rod clip.
Remove the manual valve rod.
- Pull the manual valve rod clip tab out of the TR sensor.
- Slide the manual valve rod clip off of the manual valve rod.
- Push and remove the manual valve rod from the TR sensor and the manual valve.
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NOTE: Slip yoke transmissions have 3 feed tubes and fixed flange /4WD transmissions have 2 feed tubes.
Remove the main control bolts, feed tube bolts and remove the main control and feed tube assemblies.
- Vehicle with slip yoke transmission
- Vehicle with fixed flange / 4WD transmission
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NOTE: Slip yoke shown, fixed flange /4WD similar. Slip yoke transmissions have 3 tubes, fixed flange / 4WD transmissions have 2 tubes.
Remove the fluid supply feed tube assembly.
- Remove the intermediate clutch fluid supply feed tube.
- Remove and discard the O-rings from the fluid supply feed tubes.
- Remove and discard the seals.
- Clean and inspect the main control for damage. Refer to: Main Control Valve Body .
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NOTE: Note the ports that the feed seals are removed from. Failure to install the feed seals in the ports they were removed from can result in pressure loss and transmission failure.
Remove and discard the clutch feed seals.
- Vehicle with slip yoke transmission
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- Remove the TSS sensor.
- Remove the OSS sensor.
Vehicles equipped with a fixed flange transmission
- Remove the bolt, washer and the output shaft flange.
Vehicles equipped with a slip yoke transmission
- Remove and discard the output shaft flange seal. Use Special Service Tool: 307-309 Remover, Torque Converter Seal., 100-001 (T50T-100-A) Slide Hammer.
- Remove the extension housing bolts and the extension housing.
- Remove and discard the O-ring seal from the extension housing.
- Remove and discard the rubber grommet from the output shaft.
- Remove and discard the rear bushing fluid feed seal.
All vehicles
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NOTE: The output shaft nut is coated with Loctite®. Failure to loosen the Loctite® by applying heat to the output shaft nut can cause damage to the Output Shaft Nut Socket.NOTE: Make sure to clean any debris from the Loctite® that may have fallen into the transmission case when removing the output shaft nut. Failure to clean the debris can result in transmission fluid or filter contamination or damage to the transmission.
Apply heat to the output shaft nut to soften the Loctite®. Using the special tool, remove the output shaft nut. Use Special Service Tool: 307-649 Socket, Output Shaft Nut.
- Remove the park pawl abutment plate bolts and remove the park pawl abutment plate and the park pawl spring.
- Remove the manual control lever nut and the manual control lever.
- Remove and discard the selector shaft seal.
- Compress the tabs and push the wiring harness bulkhead through the transmission case and remove the transmission wiring harness.
- Remove and discard the torque converter hub seal. Use Special Service Tool: 307-309 Remover, Torque Converter Seal., 100-001 (T50T-100-A) Slide Hammer.
- Remove the pump bolts.
- Install the special tool on the pump. Install the pin in the top hole. Install Special Service Tool: 307-651 Bracket, Pump Remover/Installer.
- Using the special tools lift the pump out of the transmission case. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Install the special tool on the forward/overdrive clutch assembly. Install the pin in the center hole. Install Special Service Tool: 307-651 Bracket, Pump Remover/Installer.
- Using the special tools lift the forward/ overdrive clutch assembly out of the transmission case. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- If the direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing is in the transmission, remove the clutch thrust bearing.
- Pry through the transmission case on the ends of the center support beveled retaining ring to unseat the beveled retaining ring from the groove.
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WARNING: The beveled retaining ring has a strong spring force and could cause injury if not released carefully. Use the tool indicated in the procedure. Release the retaining ring tension only while it is contained within the transmission housing to restrain any unintended movement. Failure to follow this instruction may result in personal injury.
Using the special tool, remove the beveled retaining ring. Release the tension on the beveled retaining ring when the snap ring is in the torque converter housing area. Use Special Service Tool: 307-654 Pliers, Snap Ring.
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- Remove the center support assembly.
- Remove the anti-fretting ring.
- Inspect the center support alignment lugs to be sure they are installed securely in the center support.
- Remove the anti-clunk clip.
- Remove the rear selective shim, No. 2 sun gear thrust bearing and the No. 2 sun gear.
- Rear selective shim
- No. 2 sun gear thrust bearing
- No. 2 sun gear
- Inspect the No. 2 sun gear teeth, splines and the No. 2 thrust washer for damage.
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NOTE: The No. 2 thrust washer may be stuck to the rear planetary gearset.
If necessary, remove the No. 2 thrust washer.
- No. 2 thrust washer to thrust bearing surface
- No. 2 sun gear splines
- No. 2 sun gear teeth
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- Remove the rear planetary gearset.
- Remove the No. 3 sun gear thrust bearing and the No. 3 sun gear.
- No. 3 sun gear
- No. 3 sun gear thrust bearing
- Inspect the No. 3 sun gear teeth, splines and thrust bearing for damage. Be sure the thrust bearing spins freely.
- No. 3 sun gear teeth
- No. 3 sun gear splines
- No. 3 sun gear thrust bearing
- Inspect the rear planetary gearset for damage.
- Inspect the bearing surfaces for damage.
- Inspect the pinion gear teeth for damage. Make sure that there is not any excessive end play and the pinion gears spin freely.
- Inspect the low/reverse (1, R) clutch pressure plate surface for damage or burnt surfaces.
- The one-way clutch should lock clockwise.
- The one-way clutch should rotate counterclockwise.
- Remove the low/reverse (1, R) clutch plates and the low/reverse (1, R) clutch steel plates.
- Low/reverse (1, R) clutch plates
- Low/reverse (1, R) clutch steel plates
- Remove the low/reverse (1, R) clutch apply plate and the low/reverse (1, R) wave spring.
- Low/reverse (1, R) clutch apply plate
- Low/reverse (1, R) wave spring
- Remove the rear planetary gearset thrust bearing.
- Remove the output shaft.
- Remove the output shaft thrust bearing.
- Remove the low/reverse clutch piston assembly bolt.
- Remove the low/reverse clutch piston assembly.
Vehicles equipped with a fixed flange or 4WD
- Using the special tools, remove and discard the output shaft seal. Use Special Service Tool: 307-309 Remover, Torque Converter Seal., 100-001 (T50T-100-A) Slide Hammer.
All vehicles
- Remove the output shaft thrust bearing and washer.
- Remove the vent tube.
- Inspect the vent tube to be sure it is not restricted. Install a new vent tube if necessary.
- Clean and inspect the transmission case for damage. Inspect the output shaft bearing and the manual control linkage for damage and install new components as necessary. Refer to: Transmission Case .
- If the forward/overdrive clutch assembly thrust bearing is stuck to the bottom of the forward/overdrive clutch assembly, remove the thrust bearing.
- Assemble special tools and install the forward/overdrive clutch assembly. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
- Remove the direct (3, 5, R) clutch snap ring.
- Remove the direct (3, 5, R) clutch hub and the direct (3, 5, R) clutch plates as an assembly from the forward/overdrive clutch assembly. Remove the direct (3, 5, R) clutch plates from the direct (3, 5, R) clutch hub.
- Remove the direct (3, 5, R) clutch hub thrust bearing.
- Remove the forward (1, 2, 3, 4) clutch hub.
- Remove the forward (1, 2, 3, 4) clutch hub thrust bearing.
- Remove the overdrive (4, 5, 6) clutch hub and center shaft assembly.
- Remove the thrust bearing from the overdrive (4, 5, 6) clutch/input shaft assembly.
- Remove the overdrive (4, 5, 6) clutch/input shaft assembly.
- Remove the front planetary carrier thrust bearing.
- Remove the direct (3, 5, R) clutch apply ring.
- Remove the forward (1, 2, 3, 4) clutch snap ring.
- Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
- Forward (1, 2, 3, 4) clutch pressure plate
- Forward (1, 2, 3, 4) clutch assembly
- Forward (1, 2, 3, 4) wave spring Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
- Remove the front planetary snap ring and the front planetary carrier from the forward (1, 2, 3, 4) clutch cylinder.
- Remove the front planetary sun gear selective shim and the front planetary sun gear.
- Front planetary sun gear selective shim
- Front planetary sun gear
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- Install the special tool and compress the forward (1, 2, 3, 4) clutch return spring. Install Special Service Tool: 307-525 Compressor, Clutch Spring.
- Remove the snap ring.
- Remove the forward (1, 2, 3, 4) clutch balance piston from the forward (1, 2, 3, 4) cylinder.
- Remove and discard the O-ring seal and the "D" cut seal from the forward (1, 2, 3, 4) clutch balance piston.
- Remove the forward (1, 2, 3, 4) clutch return spring.
- Gently tap the forward (1, 2, 3, 4) clutch piston cylinder upside down on a bench to remove the forward (1, 2, 3, 4) clutch piston from the forward (1, 2, 3, 4) clutch cylinder.
- Remove and discard the "D" cut seal (7F227) from the forward (1, 2, 3, 4) clutch piston.
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- Install the special tool on the direct (3, 5, R) clutch balance piston. Apply slight pressure to the balance piston by tightening the clutch spring compressor by hand. Install Special Service Tool: 307-525 Compressor, Clutch Spring.
- Compress the retaining ring by pushing the retaining ring inward to remove the direct (3, 5, R) clutch balance piston. Adjust tension on the clutch spring compressor by hand while compressing the retaining ring as needed.
View a video version of this procedure below.
multimedia:A supplement to the article is available. - Remove the direct (3, 5, R) clutch balance piston.
- Remove and discard the direct (3, 5, R) clutch balance piston seal.
- Remove the direct (3, 5, R) clutch return spring.
- Gently tap the forward (1, 2, 3, 4) clutch piston cylinder upside down on a bench to remove the direct (3, 5, R) clutch piston from the forward (1, 2, 3, 4) clutch cylinder.
- Remove and discard the direct (3, 5, R) clutch piston seal from the direct (3, 5, R) clutch piston.
- Remove and discard the "D" cut seals and the O-ring seal from the forward (1, 2, 3, 4) clutch cylinder.
- Forward (1, 2, 3, 4) clutch piston inner "D" cut seal
- Direct (3, 5, R) clutch balance piston inner O-Ring seal
- Direct (3, 5, R) clutch piston inner "D" cut seal
- Clean and inspect the forward (1, 2, 3, 4) clutch cylinder for damage.
- Inspect the piston sealing surfaces for damage.
- Inspect the TSS sensor tone wheel for damage.
- Inspect the bushing and Teflon® sealing surfaces for damage.
- Install the new seals and the O-ring on the forward (1, 2, 3, 4) clutch cylinder and lubricate them with clean transmission fluid.
- Forward (1, 2, 3, 4) clutch piston inner "D" cut seal (88.5 mm ID)
- Direct (3, 5, R) clutch balance piston inner O-ring seal (107.5 mm ID)
- Direct (3, 5, R) clutch piston inner "D" cut seal (119 mm ID)
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install a new direct (3, 5, R) clutch piston "D" cut seal (186 mm ID) on the direct (3, 5, R) clutch piston and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the direct (3, 5, R) clutch piston in the forward (1, 2, 3, 4) clutch cylinder.
- Install the direct (3, 5, R) clutch return spring.
- Install a new direct (3, 5, R) clutch balance piston "D" cut seal (186 mm ID) on the direct (3, 5, R) clutch balance piston and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
- Position the direct (3, 5, R) clutch balance piston on the direct (3, 5, R) clutch return spring.
- Install the special tool and compress the direct (3, 5, R) clutch piston return spring until the snap ring retains the direct (3, 5, R) clutch balance piston. Install Special Service Tool: 307-525 Compressor, Clutch Spring.
- Install a new "D" cut seal (166 mm ID) on the forward (1, 2, 3, 4) clutch piston and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the forward (1, 2, 3, 4) clutch piston in the forward (1, 2, 3, 4) cylinder.
- Install the forward (1, 2, 3, 4) clutch piston return spring on the forward (1, 2, 3, 4) clutch piston.
- Install a new O-ring seal (120 mm ID) and a new "D" cut seal (173 mm ID) on the forward (1, 2, 3, 4) clutch balance piston and lubricate them with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
- Position the forward (1, 2, 3, 4) clutch balance piston on the forward (1, 2, 3, 4) clutch piston return spring.
- Install the special tool and compress the forward (1, 2, 3, 4) clutch return spring and install the forward (1, 2, 3, 4) clutch piston snap ring. Install Special Service Tool: 307-525 Compressor, Clutch Spring.
- Inspect the front planetary gearset for damage.
- Inspect the sun gear for damage. Inspect the gear face and the splines for damage.
- Inspect the planetary carrier.
- Make sure the gears spin freely.
-
NOTE: Be sure the sun gear is installed correctly in the planetary carrier or the selective shim cannot be installed in the sun gear and damage to the front planetary gearset will occur.
Install the front planetary sun gear in the front planetary carrier with the selective shim surface facing up.
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- Install the front planetary carrier into the forward (1, 2, 3, 4) clutch cylinder.
- Install the snap ring.
- Lubricate the forward (1, 2, 3, 4) clutch wave spring, clutch assembly and pressure plate with clean transmission fluid.
- Pressure plate
- Wave spring
- Steel clutch plates
- Clutches
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
NOTE: Align the tabs on the steel clutch plates and the pressure plate with the wave spring when installing the forward (1, 2, 3, 4) clutch assembly or the direct (3, 5, R) clutch apply ring will not fit on the direct (3, 5, R) clutch piston.
Install the forward (1, 2, 3, 4) clutch wave spring, the forward (1, 2, 3, 4) clutch assembly with all steel clutch plate tabs aligned with the wave spring and the forward (1, 2, 3, 4) clutch pressure plate with the tabs aligned with the steel clutch plates.
- Forward (1, 2, 3, 4) clutch wave spring
- Forward (1, 2, 3, 4) clutch assembly
- Forward (1, 2, 3, 4) clutch pressure plate
- Install the forward (1, 2, 3, 4) clutch snap ring.
- Install the Dial Indicator Gauge with Holding Fixture. Position the plunger of the dial indicator on the forward (1, 2, 3, 4) clutch pressure plate. Zero the dial indicator. Install Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.
- Average the 3 recorded clutch clearance measurements and compare it to the forward (1, 2, 3, 4) clutch clearance specification, refer to specifications. If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new forward (1, 2, 3, 4) clutch snap ring to adjust the clutch clearance. Refer to: Specifications .
- Install the direct (3, 5, R) clutch apply ring.
- Lubricate the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate with clean transmission fluid.
- Pressure plate
- Clutches
- Steel clutch plates
- Wave spring
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate in the forward (1, 2, 3, 4) clutch cylinder.
- Direct (3, 5, R) clutch wave spring
- Direct (3, 5, R) clutch assembly
- Direct (3, 5, R) pressure plate
- Install the direct (3, 5, R) clutch snap ring.
- Install the special tools. Position the plunger of the dial indicator on the direct (3, 5, R) clutch pressure plate. Zero the dial indicator. Install Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Pull up on the pressure plate and measure and record the clutch clearance in 3 different places.
- Average the 3 recorded clutch clearance measurements and compare it to the direct (3, 5, R) clutch clearance specification, refer to specifications. If the clutch clearance is not within specification, remove the snap ring and measure it. Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new direct (3, 5, R) clutch snap ring to adjust the clutch clearance. Refer to: Specifications .
- Remove the direct (3, 5, R) clutch snap ring.
- Remove the direct (3, 5, R) pressure plate, clutch wave spring, clutch assembly.
- Direct (3, 5, R) pressure plate
- Direct (3, 5, R) clutch assembly
- Direct (3, 5, R) clutch wave spring
- Install the overdrive (4, 5, 6) clutch cylinder on the special tools. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
- Remove the overdrive (4, 5, 6) clutch snap ring.
- Remove the overdrive (4, 5, 6) pressure plate and clutch assembly.
- Overdrive (4, 5, 6) pressure plate
- Overdrive (4, 5, 6) clutch assembly
- Using the special tool and a press, compress the overdrive (4, 5, 6) clutch balance piston and remove the snap ring. Remove and discard the overdrive (4, 5, 6) clutch balance piston. Use Special Service Tool: 307-525 Compressor, Clutch Spring. Use the General Equipment: Hydraulic Press
- Remove the overdrive (4, 5, 6) return spring.
- Remove and discard the overdrive (4, 5, 6) clutch piston.
- Reposition the overdrive (4, 5, 6) clutch cylinder and input shaft assembly in the special tool. Remove and discard the input shaft Teflon® seals and TCC Teflon® seal.
- Inspect the overdrive (4, 5, 6) clutch cylinder and input shaft assembly for damage. Inspect the bearing surfaces, Teflon® seal surfaces, ring gear and bushing surfaces for excessive wear or damage. If damage or excessive wear is found, install new components as necessary.
- Bearing/bushing surfaces
- Ring gear
- Teflon® seal surfaces
- Install the special tool 307-653/1 on the input shaft and adjust it so the bottom edge is lined up just above the top edge of the bottom Teflon® seal groove. Lubricate the special tool 307-653/1 with clean transmission fluid and install a new Teflon® seal by sliding it down the special tool 307-653/1 into the groove. Adjust the special tool 307- 653/1 and install the remaining 3 input shaft Teflon® seals into the grooves. Lubricate the special tool 307-653/3 with clean transmission fluid and install it over the Teflon® seals to size the seals. Install Special Service Tool: 307-653 Sizer, Input Shaft Teflon Seal.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the special tool 307-653/2 on the end of the input shaft. Lubricate the special tool 307-653/2 with clean transmission fluid and install a new Teflon® seal into the groove. Lubricate the special tool 307-653/3 with clean transmission fluid and install it over the Teflon® seal to size the seal. Install Special Service Tool: 307-653 Sizer, Input Shaft Teflon Seal.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Position the overdrive (4, 5, 6) clutch cylinder and input shaft assembly in the special tool with the input shaft facing down. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
- Lubricate the sealing surfaces of a new overdrive (4, 5, 6) clutch piston with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the new overdrive (4, 5, 6) clutch piston in the overdrive (4, 5, 6) clutch cylinder and input shaft assembly.
- Install the overdrive (4, 5, 6) clutch piston return spring with the circles facing up.
- Lubricate the sealing surfaces of a new overdrive (4, 5, 6) clutch balance piston with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Position the clutch balance piston on top of the clutch piston return spring.
- Using the special tool and a press, compress the overdrive (4, 5, 6) clutch piston return spring and install the snap ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring. Use the General Equipment: Hydraulic Press
- Lubricate the overdrive (4, 5, 6) clutch assembly and pressure plate with clean transmission fluid.
- Pressure plate
- Clutches
- Steel clutch plates
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the overdrive (4, 5, 6) clutch assembly and pressure plate in the overdrive (4, 5, 6) clutch cylinder and input shaft assembly.
- Overdrive (4, 5, 6) clutch assembly
- Overdrive (4, 5, 6) pressure plate
- Install the overdrive (4, 5, 6) clutch snap ring.
- Install the special tool. Position the plunger of the dial indicator on the overdrive (4, 5, 6) clutch pressure plate. Zero the dial indicator. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Pull up on the pressure plate and measure and record the clutch clearance in 3 different places. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
-
- Average the 3 recorded clutch clearance measurements and compare it to the overdrive (4, 5, 6) clutch clearance specifications. Refer to: Specifications .
- If the clutch clearance is not within specification, remove the snap ring and measure it.
- Compare the dimension to the overdrive (4, 5, 6) clutch selective snap ring chart in specifications and install a new direct (3, 5, R) clutch snap ring to adjust the clutch clearance Refer to: Specifications .
- Inspect the overdrive (4, 5, 6) clutch hub/center shaft assembly, direct (3, 5, R) clutch hub and forward (1, 2, 3, 4) clutch hub for damage or excessive wear. Inspect the bushing, bearing and splined surfaces. Install new components as necessary.
- Bearing surfaces
- Splined surfaces
- Clutch splined surfaces
- Bushing surfaces
- Position the forward (1, 2, 3, 4) clutch assembly in the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission., 307-662 Gauge, Clutch Pack Endplay.
- Install the front planetary carrier thrust bearing.
- Install the overdrive (4, 5, 6) clutch/input shaft assembly in the forward (1, 2, 3, 4) clutch.
- Install the thrust bearing on the overdrive (4, 5, 6) clutch/input shaft assembly.
- Install the overdrive (4, 5, 6) clutch hub and center shaft assembly in the overdrive (4, 5, 6) clutch.
- Install the forward (1, 2, 3, 4) clutch hub thrust bearing.
- Install the forward (1, 2, 3, 4) clutch hub.
- Install the direct (3, 5, R) clutch hub thrust bearing.
- Install the low/reverse clutch piston assembly on the special tool.
- Using the special tool, compress the low/reverse (1, R) return spring and remove the snap ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring.
- Remove the low/reverse (1, R) piston return spring.
- Using compressed air, remove the low/reverse (1, R) piston from the low/reverse cylinder.
- Remove and discard the "D" Cut seal from the low/reverse (1, R) cylinder.
- Remove and discard the "D" cut seals from the low/reverse (1, R) piston.
-
NOTE: Inspect the air bleed orifice and make sure it is not blocked by any debris.
Clean and inspect the lip seal sealing surfaces on both the low/reverse (1, R) piston and cylinder for damage and install new components as necessary.
- Install new "D" cut seals (156.5 mm ID, 202 mm ID) on the low/reverse (1, R) piston and lubricate with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install a new "D" cut seal (95 mm ID) on the low/reverse (1, R) cylinder and lubricate with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
NOTE: Be sure to align the alignment marks on the low/reverse (1, R) cylinder and piston when installing the piston in the cylinder.
Align the marks and install the low/reverse (1, R) piston in the cylinder.
- Install the low/reverse (1, R) piston return spring.
- Using the special tool compress the low/reverse (1, R) return spring and install the snap ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring.
- Remove the intermediate (2, 6) clutch pack snap ring.
- Remove the intermediate (2, 6) clutch pressure plate, clutch assembly and wave spring from the intermediate (2, 6) clutch center support.
- Intermediate (2, 6) clutch pressure plate
- Intermediate (2, 6) clutch assembly
- Intermediate (2, 6) clutch wave spring
- Using the special tools, compress the intermediate (2, 6) clutch return spring and remove the intermediate (2, 6) clutch 2-piece retaining ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring., 307-655 Installer, Center Support Bearing., 307-658 Compressor, C Clutch Return Spring.
- Remove the intermediate (2, 6) clutch return spring.
- Using compressed air, remove the intermediate (2, 6) clutch piston.
- Remove and discard the intermediate (2, 6) clutch inner and outer piston seals from the intermediate (2, 6) clutch piston.
- Clean and inspect the intermediate (2, 6) clutch piston sealing surfaces for damage. If damage is found, install a new center support.
- Lubricate new intermediate (2, 6) clutch inner and outer piston seals (169 mm ID, 202 mm ID) with clean transmission fluid and install on the intermediate (2, 6) clutch piston.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the intermediate (2, 6) clutch piston.
- Install the intermediate (2, 6) clutch return spring.
- Using the special tools, compress the intermediate (2, 6) clutch return spring and install the 2-piece retaining ring. Use Special Service Tool: 307-525 Compressor, Clutch Spring., 307-655 Installer, Center Support Bearing., 307-658 Compressor, C Clutch Return Spring.
- Lubricate the intermediate (2, 6) clutch assembly with clean transmission fluid.
- Pressure plate
- Friction plates
- Steel plates
- Wave spring
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
NOTE: The intermediate (2, 6) clutch pressure plate is installed with the step facing up.
Install the intermediate (2, 6) clutch wave spring, clutch assembly and pressure plate.
- Intermediate (2, 6) clutch wave spring
- Intermediate (2, 6) clutch assembly
- Intermediate (2, 6) clutch pressure plate
- Install the intermediate (2, 6) clutch pack snap ring.
- Install the intermediate (2, 6) clutch assembly on the special tool. Position the plunger of the dial indicator on the intermediate (2, 6) clutch pressure plate and zero the dial indicator. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 307-662 Gauge, Clutch Pack Endplay.
- Pull up on the intermediate (2, 6) clutch pressure plate and measure and record the clutch clearance in 3 different places.
-
- Average the 3 recorded clutch clearance measurements and compare it to the intermediate (2, 6) clutch clearance specification, refer to specifications. Refer to: Specifications .
- If the clutch clearance is not within specification, remove the snap ring and measure it.
- Compare the dimension to the forward (1, 2, 3, 4), direct (3, 5, R), intermediate (2, 6) clutch selective snap ring chart in specifications and install a new intermediate (2, 6) clutch snap ring to adjust the clutch clearance. Refer to: Specifications .
- Remove and discard the pump housing square cut O-ring seal.
- Remove and discard the Teflon® seals.
-
NOTE: Note the location of the different pump bolt lengths for assembly.
Remove the pump bolts and separate the stator support from the pump housing and body.
- Remove the plate assembly.
-
NOTE: PTO pump shown, non PTO similar.
Remove the pump body from the pump housing.
- Thread of the long bolts in the pump body by hand.
- Position the pump housing on 2 blocks of wood.
- Tap the bolts with a rubber mallet to separate the pump housing from the pump body. Remove the bolts and remove the pump body from the pump housing. Use the General Equipment: Rubber Mallet
-
NOTE: Observe the position of the locating dots on the pump gears. Dots must be facing up.
Remove the pump gears from the pump body.
- Remove and discard the pump body O-ring seal from the pump body.
- Remove the anti-drain back valve.
Vehicles with PTO
- Remove the thrust bearing from the PTO drive gear.
- Remove the PTO drive gear from the pump housing.
- Remove the PTO drive gear thrust washer from the pump housing.
- Remove and discard the O-ring seal and the Teflon® seals from the stator support.
- O-ring seal
- Teflon® seals
Vehicles without PTO
- Remove and discard the O-ring seal and the Teflon® seal from the stator support.
- O-ring seal
- Teflon® seal
All vehicles
- Clean and inspect the pump housing and stator support for damage. Inspect the pump gear surfaces for scoring or damage. Inspect the sealing surfaces for damage. Install a new pump if necessary.
- Pump housing
- Gear surfaces
- Stator support
- Sealing surfaces
-
NOTE: The pump gears must be installed in the pump body with the locating dots facing up or damage may occur.
Inspect the pump body and pump gears for damage. Inspect the torque converter hub bearing to be sure it spins freely and does not have excessive wear. Inspect the pump gears for scoring or excessive wear. Install a new pump if necessary.
- Pump body
- Torque converter hub bearing
- Pump gears
Vehicles without PTO
- Install a new O-ring seal (61 mm ID) on the stator support and lubricate it with clean transmission fluid. Use Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Lubricate the special tool with clean transmission fluid and install it on the stator support. Install a new Teflon® seal (54 mm ID) on the special tool and slide it down into the groove. Use Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the special tool to size the Teflon® seal.
Vehicles with PTO
- Inspect the PTO drive gear for damage. Inspect the gear teeth for damage and inspect the thrust washer and bearing surface for excessive wear. If damage is found, install a new pump.
- Teeth
- Thrust bearing surface
- Thrust washer surface
- Install a new O-ring seal (47 mm ID) on the PTO drive gear and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the special tool on the PTO drive gear and lubricate it with clean transmission fluid. Adjust the special tool such that the bottom edge is just above the particular groove. Install new Teflon® seals (65 mm ID) on the special tool and slide it down into the grooves. Install Special Service Tool: 307-659 Installer/Sizer, Pump Seal PTO.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the special tool to size the Teflon® seals. Install Special Service Tool: 307-659 Installer/Sizer, Pump Seal PTO.
- Install the PTO drive gear thrust washer in the pump housing.
- Remove the special tool above the Teflon® seals. Remove Special Service Tool: 307-659 Installer/Sizer, Pump Seal PTO.
- Install the PTO drive gear in the pump housing.
- Install the thrust bearing on the PTO drive gear.
All vehicles
- Install a new pump body seal (183 mm ID) and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Lubricate the pump gears with clean transmission fluid and install the pump gears in the pump body with the dots facing up.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install and lubricate the anti-drain back valve.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Position the pump housing on the pump body with the alignment pin lined up with the alignment hole and push the pump housing until it is seated on the pump body.
- Install the plate assembly.
Vehicles without PTO
- Remove the special tool from the stator support. Remove Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO.
All vehicles
-
NOTE: Install the bolts in the locations noted during disassembly.
Position the stator support in the pump housing and body and install the pump bolts.
- Tighten the bolts in a crisscross pattern.
Torque:
18 lb.ft (25 Nm)
- Tighten the bolts in a crisscross pattern.
- Install the special tools on the stator support and adjust them so the innermost Teflon® seal can be installed. Lubricate the special tools with clean transmission fluid. Position a new Teflon® seal on the special tool and gently slide it down to the bottom groove. Using the special tools install the 2 new Teflon® seals (77 mm ID) in the remaining grooves. Install Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO., 307-659 Installer/Sizer, Pump Seal PTO.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Using the special tool size the 3 Teflon® seals. Use Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install a new pump housing seal (248 mm ID) and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Using the special tool install a new hub seal. Use Special Service Tool: 307-660 Installer, Front Pump Seal.
- Install the vent tube.
- Rotate the transmission upright and install the low/reverse clutch piston assembly in the transmission case.
- Install the low/reverse cylinder alignment bolt.
- Install the longest clutch feed tube in the low/reverse feed tube port to align the low/reverse piston assembly.
- Install the low/reverse cylinder alignment bolt.
Torque:
97 lb.in (11 Nm)
- Remove the feed tube.
- Install the output shaft thrust bearing.
- Install the output shaft.
- Rotate the transmission to access the output shaft and install the thrust washer.
- Install the thrust bearing.
- Loosely install the output shaft nut.
- Install the rear planetary gearset thrust bearing.
- Position the center support up side down on 2 blocks of wood. Install the anti-fretting ring and the rear planetary carrier onto the center support.
- Center support Use the General Equipment: Wooden Block
- Anti-fretting ring
- Rear planetary carrier
- Install the low/reverse (1, R) clutch assembly onto the rear planetary carrier so that it rests on the one way clutch. Install the low/reverse (1, R) wave spring and the Low/reverse (1, R) clutch apply plate.
- Low/reverse (1, R) clutch assembly
- Low/reverse (1, R) wave spring
- Low/reverse (1, R) clutch apply plate
-
NOTE: The low/reverse clutch measurement in specifications is a measurement of the clutch height and is NOT the clutch clearance.
Using a depth gauge, measure the distance from the piston contact surface of the apply ring to the center support surface in 3 different places. Average the 3 measurements and record as the low/ reverse clutch measurement. Use the General Equipment: Depth Gauge
- Compare the low/reverse (1, R) clutch measurement to the low/reverse (1, R) clutch measurement specification, refer to specifications. If the low/reverse (1, R) clearance is out of specification, install a new low/reverse (1, R) clutch assembly. Refer to: Specifications .
- Lubricate the low/reverse (1, R) clutch in clean transmission fluid.
- Apply plate
- Clutch plates
- Steel plates
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Position the transmission in the upright position and install the low/reverse (1, R) wave spring and the low/reverse (1, R) clutch apply plate.
- Low/reverse (1, R) wave spring
- Low/reverse (1, R) clutch apply plate
- Install the low/reverse (1, R) clutch plates and the low/reverse (1, R) clutch steel plates.
- Low/reverse (1, R) clutch plates
- Low/reverse (1, R) clutch steel plates
-
NOTE: The anti-clunk clip is NOT installed in this step.NOTE: Make sure the outer one way clutch splines are aligned as shown or the anti-clunk clip will not fit into the transmission case.
Install the rear planetary gearset with the outer one way clutch splines aligned so the anti-clunk clip can be installed correctly. Inspect the one way clutch to be sure it is aligned correctly for installation of the anti-clunk spring. The anti-clunk spring should rest against both a spline of the one way clutch and an inner spline of the transmission case.
- One way clutch spline
- Transmission case spline
- Install the No. 3 sun gear with the beveled end facing down and install the No. 3 sun gear thrust bearing.
- No. 3 sun gear
- No. 3 sun gear beveled end
- No. 3 sun gear thrust bearing
- Install the thrust washer on the No. 2 sun gear. Use petroleum jelly if needed to hold the thrust washer to the sun gear and install the No. 2 sun gear in the rear planetary gearset with the thrust washer facing down.
- No. 2 sun gear thrust washer
- No. 2 sun gear
- Install the No. 2 sun gear thrust bearing on top of the No. 2 sun gear.
- Install the special tool on the transmission case. Install Special Service Tool: 307-661 Gauge, End Play.
-
NOTE: Make sure to zero the dial indicator on the transmission case and not the rear planetary gearset or inaccurate measurements can be recorded causing damage to the transmission.
Position a depth dial indicator on the special tool with the plunger positioned on the top of the transmission case step that the center support rests on. Zero the dial indicator. Use Special Service Tool: 307-661 Gauge, End Play. Use the General Equipment: Depth Gauge
- Gently lift the plunger of the dial indicator off the transmission case step, slide the dial indicator over and drop the plunger onto the No. 2 sun gear thrust bearing. Record this distance as measurement A. Use Special Service Tool: 307-661 Gauge, End Play. Use the General Equipment: Depth Gauge
- With measurement A recorded, calculate the selective shim thickness and find the part number.
- Zero
- Measurement A
-
NOTE: The distance on the center support from the transmission case surface to the No. 2 sun gear thrust bearing surface equals 8.55 mm (0.336 in). 8.55 mm (0.336 in) is subtracted from measurement A to compensate for the offset of the center support.
Subtract 8.55 mm (0.336 in) from measurement A to get the clearance for the rear shim. Compare the clearance of the rear shim to the Rear Selective Shim Part Number Chart in Specifications to get the correct selective shim dimension and part number. The target clearance with the correct rear shim installed should be between 0.8-1.1 mm (0.031-0.043 in). Refer to: Specifications .
- Install the rear selective shim on top of the thrust bearing.
-
NOTE: When installing the center support, make sure the alignment lugs are lined up with the slots in the transmission case and the feed hole is facing down.NOTE: Inspect the alignment lugs to be sure they are installed in the center support and are not loose. If the alignment lugs are loose, use petroleum jelly to hold them in place when installing the center support.
Install the anti-fretting ring and the center support assembly.
- Anti-fretting ring
- Center support assembly
-
WARNING: The beveled retaining ring has a strong spring force and could cause injury if not released carefully. Use the tool indicated in the procedure. Release the retaining ring tension only while it is contained within the transmission housing to restrain any unintended movement. Failure to follow this instruction may result in personal injury.NOTE: Be sure the beveled retaining ring is installed with the beveled end facing up or the beveled retaining ring can come loose and damage to the transmission can occur.
Place the beveled retaining ring in the torque converter housing. Using the special tool, compress the beveled retaining ring in the torque converter housing and install the beveled retaining ring with the beveled retaining ring gap in the 12 o'clock position and the beveled side facing up. Use Special Service Tool: 307-654 Pliers, Snap Ring.
- Tap on the center support snap ring to make sure it is seated in the groove. Use the General Equipment: Rubber Mallet
- Install direct (3, 5, R)/intermediate (2, 6) clutch thrust bearing.
- Install the direct (3, 5, R)/intermediate (2, 6) clutch hub in the intermediate (2, 6) clutch.
- Install the intermediate clutch feed tube.
-
NOTE: Be sure to turn the shop air supply down to 276 kPa (40 psi) or damage to the clutch seals can occur.
Install the special tool and apply 276 kPa (40 psi) of shop air to the special tool. Install Special Service Tool: 307-652 Plate, C-Clutch Air.
- Remove the direct (3, 5, R)/intermediate (2, 6) clutch hub.
- Using the special tools, install the direct (3, 5, R)/intermediate (2, 6) clutch hub in the forward/overdrive clutch assembly. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission., 307-662 Gauge, Clutch Pack Endplay.
- Install the direct (3, 5, R) clutch wave spring, clutch assembly and pressure plate in the forward/overdrive clutch assembly. Install the direct (3, 5, R) clutch snap ring.
- Direct (3, 5, R) clutch wave spring
- Clutch assembly
- Pressure plate
- Snap ring
- Install the special tool on the forward/overdrive clutch assembly with the pin installed in the center hole and support it with the special tool. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Using the special tools, gently install the forward/overdrive clutch assembly in the transmission case. Make sure the forward/overdrive clutch assembly is seated all the way by making sure it rests slightly above the rib of the transmission case as shown.
- Remove the special tool. Remove Special Service Tool: 307-652 Plate, C-Clutch Air.
- Install the anti-clunk clip.
- Position the pump assembly on 2 blocks of wood and remove the special tool. Remove Special Service Tool: 307-657 Installer, Pump Seal - Non-PTO. Use the General Equipment: Wooden Block
- Position the special tool on the pump with it centered to the center of the stator support. Using a depth gauge, measure the distance from the top of the special tool to the front shim surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement A. Use Special Service Tool: 307-661 Gauge, End Play. Use the General Equipment: Depth Gauge
-
NOTE: Apply pressure to the special tool to hold it flush against the stator support when measuring to the deck surface.
Using a depth gauge, measure the distance from the top of the special tool to the deck surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement B. Use Special Service Tool: 307-661 Gauge, End Play. Use the General Equipment: Depth Gauge
- Subtract measurement A from measurement B and record as measurement C.
- Position the special tool on the transmission case pump deck surface. Using a depth gauge, measure the distance from the top of the special tool to the selective shim surface on the No. 1 sun gear. Subtract the height of the special tool 12.7 mm (0.5 in) from the measurement and record as measurement D. Remove the special tool. Use Special Service Tool: 307-661 Gauge, End Play. Use the General Equipment: Depth Gauge
- Subtract measurement C from measurement D and record that distance as the front selective shim clearance. Look up the clearance on the Front Selective Shim Part Number Chart in Specifications to get the correct front selective shim part number. The target clearance with the correct front shim installed should be between 0.15-0.45 mm (0.006-0.018 in). Refer to: Specifications .
- Install the selective shim on top of the No. 1 sun gear. Make sure the selective shim is positioned correctly in the No. 1 sun gear groove.
- Install the special tool on the pump with the pin in the top hole. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Using the special tools, gently position the pump in the transmission case with the feed tube surface facing the bottom of the transmission. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Align the bolt holes and loosely install 2 bolts. Gently tap the pump until it is seated on the deck surface of the transmission case.
- Install the rest of the bolts and tighten in a crisscross pattern.
Torque:
18 lb.ft (25 Nm)
- If reusing the original torque converter, use an emery cloth to clean the torque converter hub seal material off of the torque converter hub.
- Install the special tool on the torque converter with the pin in the bottom hole. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Using the special tools install the torque converter. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 307-651 Bracket, Pump Remover/Installer.
- Install the special tool. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
-
NOTE: Note the ports where the feed seals are removed from. Failure to install the feed seals in the ports they were removed from can result in pressure loss and transmission failure.
Rotate the transmission to access the main control area. Install the clutch feed seals.
- Vehicle with slip yoke transmission
-
NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.
Pressure check both low/reverse (1, R) clutch feed ports using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the low/reverse piston assembly and inspect the clutch piston seals and sealing surfaces for damage.
-
NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.
Pressure check the intermediate (2, 6) clutch feed port using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the center support and inspect the clutch piston seals and sealing surfaces for damage.
-
NOTE: Make sure to turn the shop air supply down to 276 kPa (40 psi) or damage can occur to the clutch seals.
Pressure check the forward, overdrive, and direct clutch feed ports using 276 kPa (40 psi) of shop air. If clutch application is not observed, disassemble the transmission and the forward/overdrive clutch assembly and inspect the forward (1, 2, 3, 4), overdrive (4, 5, 6) and direct (3, 5, R) clutch piston seals and sealing surfaces for damage.
- Forward (1, 2, 3, 4) clutch port
- Overdrive (4, 5, 6) clutch port
- Direct (3, 5, R) clutch port
- Inspect the wiring harness bulkhead O-ring for damage and install a new O-ring if necessary. Lubricate the wiring harness O-ring with clean transmission fluid and install the wiring harness bulkhead in the transmission case. Make sure the 2 tabs lock the bulkhead in the transmission case.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the park pawl spring on the park pawl and position the park pawl abutment plate in place and install the bolts.
Torque:
97 lb.in (11 Nm)
- Lubricate and install the new selector shaft seal.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the manual control lever and the nut.
Torque:
18 lb.ft (24 Nm)
-
NOTE: Fixed flange/4WD shown, slip yoke similar.
Remove the output shaft nut.
Vehicles equipped with a fixed flange or 4WD
- Using the special tools install the output shaft seal. Use Special Service Tool: 205-440 Remover/Installer, Drive Pinion Oil Seal., 307-650 Installer, Output Shaft Seal.
All vehicles
-
NOTE: Fixed flange/4WD shown, slip yoke similar.
Place the manual control lever in PARK and install the output shaft nut using the special tool. Use Special Service Tool: 307-649 Socket, Output Shaft Nut.
Torque:
148 lb.ft (200 Nm)
Vehicles equipped with a slip yoke transmission
- Install a new feed seal and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install a new O-ring seal on the extension housing and lubricate it with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the extension housing and the bolts.
Torque:
30 lb.ft (40 Nm)
- Position a new output shaft seal on the special tool. Use Special Service Tool: 205-440 Remover/Installer, Drive Pinion Oil Seal., 307-650 Installer, Output Shaft Seal.
- Using the special tool, install a new output shaft seal. Use Special Service Tool: 205-440 Remover/Installer, Drive Pinion Oil Seal., 307-650 Installer, Output Shaft Seal.
All vehicles
-
- Install the TSS sensor.
Torque:
97 lb.in (11 Nm)
- Install the OSS sensor.
Torque:
97 lb.in (11 Nm)
- Install the TSS sensor.
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NOTE: Do not push seals all the way down into main control valve body. Seals will be seated when main control valve body is installed to the transmission.
Install the seals.
-
NOTE: Slip yoke shown, fixed flange/4WD similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.
Clean and inspect the fluid supply feed tubes.
- Install new O-rings on the fluid supply feed tubes and lubricate the O-rings with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
- Install the intermediate (2, 6) clutch fluid supply feed tube.
-
NOTE: Slip yoke shown, fixed flange/4WD similar. Slip yoke transmissions have 3 tubes, fixed flange/4WD transmissions have 2 tubes.
Install the fluid supply feed tube assembly.
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NOTE: The 3 long bolts hold the valve body in and the 3 short bolts hold the feed tubes in.
Position the main control in place and install the bolts.
Torque:
97 lb.in (11 Nm)
-
NOTE: Do not bend the manual valve rod clip when installing the manual valve rod. If the manual valve rod clip is bent back to install the manual valve rod instead of sliding it off, the manual valve rod clip will become permanently distorted causing total loss of transmission control or transmission failure. If the manual valve rod clip is bent, install a new manual valve rod clip.
Install the manual valve rod into the manual valve and the TR sensor. Slide the manual valve rod clip over the manual valve rod until the manual valve rod clip tab goes through the TR sensor to hold the manual valve rod in place.
- Manual valve rod
- Manual valve
- TR sensor
- Manual valve rod clip
- Manual valve rod clip tab
- Position the wiring harness in place and connect the electrical connectors.
- Solenoids
- TFT sensor
- TR sensor
- OSS sensor
- TSS sensor
- Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean transmission fluid.
Material
Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
-
NOTE: The long bolt is installed in the back of the filter.
Install the transmission fluid filter and the bolts.
Torque:
97 lb.in (11 Nm)
- Clean and inspect the transmission fluid pan and magnet.
-
NOTE: The transmission fluid pan gasket is a reusable gasket.
Clean the transmission gasket. Inspect the transmission fluid pan gasket for damage and install a new transmission fluid pan gasket if necessary.
- Install the transmission fluid pan and the bolts. Tighten the bolts in a crisscross pattern.
Torque:
80 lb.in (9 Nm)
Vehicles equipped with fixed flange transmission
- Install the output shaft flange and the washer (7D498) and the bolt.
Torque:
98 lb.ft (133 Nm)
All vehicles
- If the Overdrive clutch was replaced, add the contents of the two syringes in the 6R ATF additive kit to the transmission fluid.
Material
Motorcraft® 6R ATF Additive F / XL-16