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Section 671 (Automatic Transmission - 10-Speed Automatic Transmission - 10R80 MHT (Diagnosis & Testing - Installation)): Overhaul: Transmission

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Special Tool(s) / General Equipment 

GFD559112Courtesy of FORD MOTOR COMPANY
100-001 (T50T-100-A)Slide Hammer
GFD559113Courtesy of FORD MOTOR COMPANY
100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge
GFD559704Courtesy of FORD MOTOR COMPANY
205-1018Installation Tube
GFD559705Courtesy of FORD MOTOR COMPANY
205-199 (T83T-3132-A1)Installer, Spindle/Axle ShaftT83-4000-ATKIT-1983-FTKIT-1983-FLMTKIT-1983-FX
GFD559706Courtesy of FORD MOTOR COMPANY
307-003 (T57L-500-B)Holding Fixture, Transmission
GFD559117Courtesy of FORD MOTOR COMPANY
307-309Remover, Torque Converter SealTKIT-1994-FMH/FLMHTKIT-1994-LMH/MHTKIT-1994-FH
GFD559707Courtesy of FORD MOTOR COMPANY
307-549Installer, Shift Shaft Fluid SealTKIT-2005D1-F1
GFD559120Courtesy of FORD MOTOR COMPANY
307-5842-6 Spring CompressorTKIT-2006UF-FLMTKIT-2006UF-ROW
GFD559121Courtesy of FORD MOTOR COMPANY
307-589Overdrive clutch and balance piston service setTKIT-2006UF-FLMTKIT-2006UF-ROW
GFD559122Courtesy of FORD MOTOR COMPANY
307-651Bracket, Pump Remover/Installer
GFD559123Courtesy of FORD MOTOR COMPANY
307-651-01Adapter for 307-651 (Super Sub Assembly Lifting)
GFD559516Courtesy of FORD MOTOR COMPANY
307-651-03Lift Fixture Adapter (MHT)
GFD559124Courtesy of FORD MOTOR COMPANY
307-653Sizer, Input Shaft Teflon Seal
GFD559126Courtesy of FORD MOTOR COMPANY
307-661Gauge, End PlayTKIT-2009C-FTKIT-2009C-ROW
GFD559127Courtesy of FORD MOTOR COMPANY
307-661-01Spacers/Plate, Clearance Gage
GFD559517Courtesy of FORD MOTOR COMPANY
307-661-02Adapter for 307-661
GFD559128Courtesy of FORD MOTOR COMPANY
307-662Gauge, Clutch Pack EndplayTKIT-2009C-FTKIT-2009C-ROW
GFD559129Courtesy of FORD MOTOR COMPANY
307-691Tester, Torque Convertor Leak
GFD559130Courtesy of FORD MOTOR COMPANY
307-732Tool Kit, Torque Converter Flusher
GFD559131Courtesy of FORD MOTOR COMPANY
307-732-01Adapter for 307-732 (Converter Flusher (10R80)
GFD559132Courtesy of FORD MOTOR COMPANY
307-733Compressor, Clutch Piston
GFD559708Courtesy of FORD MOTOR COMPANY
307-734Tool, OWC Alignment
GFD558983Courtesy of FORD MOTOR COMPANY
307-736Installer, Pump Drive Gear Bearing
GFD558984Courtesy of FORD MOTOR COMPANY
307-737Press Tool, Oil Pump Drive Idler Gear
GFD559134Courtesy of FORD MOTOR COMPANY
307-741Spring Compressor, F Clutch
GFD558985Courtesy of FORD MOTOR COMPANY
307-743Remover, Pump Drive Gear
GFD559028Courtesy of FORD MOTOR COMPANY
307-746Remover, Transmission Wiring Harness Connector
GFD559135Courtesy of FORD MOTOR COMPANY
307-747Installer/ Sizer, Input Shaft Solid Sealing Rings; Large
GFD559136Courtesy of FORD MOTOR COMPANY
307-748Installer/Sizer, Input Shaft Solid Sealing Rings; Small
GFD559709Courtesy of FORD MOTOR COMPANY
307-749Installer/Sizer, R2-S3 Shaft Solid Seal
GFD559579Courtesy of FORD MOTOR COMPANY
307-782Installer, Output Shaft Seal
GFD559710Courtesy of FORD MOTOR COMPANY
307-783Installer, Roll Pin
GFD559141Courtesy of FORD MOTOR COMPANY
307-790Endplay Check Gauge
GFD559142Courtesy of FORD MOTOR COMPANY
307-797Installer, Alignment Studs (3) and Alignment Pin (All 10R)
GFD559711Courtesy of FORD MOTOR COMPANY
307-802Installer, Input Shaft
Feeler Gauge
Rubber Mallet
Floor Crane
Mounting Stand
Hydraulic Press
Adjustable Mounting Arm
Punch
Wooden Block
Magnet

Materials 

Name Specification
Motorcraft® MERCON® ULV Automatic Transmission FluidXT-12-QULV WSS-M2C949-A, MERCON® ULV

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 .
    1. Using a floor crane, mount the transmission to a mounting stand. Use the General Equipment: Mounting StandUse the General Equipment: Adjustable Mounting ArmUse the General Equipment: Floor Crane
    2. Rotate the transmission to the upright position.
    GFD559518Courtesy of FORD MOTOR COMPANY
  3. Remove the transmission fluid level indicator and plug assembly.
    GFD558991Courtesy of FORD MOTOR COMPANY
  4. Using the special tools, remove and discard the input shaft seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 307-309 Remover, Torque Converter Seal.
    GFD559712Courtesy of FORD MOTOR COMPANY
  5. Remove the rear hybrid unit bolts.
    GFD559519Courtesy of FORD MOTOR COMPANY
  6. Remove the short hybrid drive unit bolt.
    GFD559520Courtesy of FORD MOTOR COMPANY
  7. Remove the hybrid drive unit bolts.
    GFD559521Courtesy of FORD MOTOR COMPANY
  8. Install the special tools on the hybrid drive unit. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer., 307-651-03 Lift Fixture Adapter (MHT).
    GFD559522Courtesy of FORD MOTOR COMPANY
  9. Using a floor crane and the special tools, remove the hybrid drive unit. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer., 307-651-03 Lift Fixture Adapter (MHT).Use the General Equipment: Floor Crane
    GFD559523Courtesy of FORD MOTOR COMPANY
  10. Position the hybrid drive unit on 2 blocks of wood.

    1. Correct Use the General Equipment: Wooden Block
    2. Correct Use the General Equipment: Wooden Block
    3. NOTE: Do not place the hybrid drive unit with the torque converter facing up with out using blocks or damage to the input shaft snap ring can occur.

      Incorrect

    GFD559524Courtesy of FORD MOTOR COMPANY
  11. NOTE: The hybrid drive unit gasket can be reused if not damaged.

    Remove the hybrid drive unit gasket. Replace if necessary.

    GFD559525Courtesy of FORD MOTOR COMPANY
  12. Remove the transmission fluid spray nozel.
    GFD559526Courtesy of FORD MOTOR COMPANY
  13. Clean and inspect the transmission fluid spray nozel.
    GFD559527Courtesy of FORD MOTOR COMPANY
  14. 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

  15. Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.

    Material

    : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

  16. 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.
  17. Place the hybrid drive unit on a press. Support the drive unit on mounting pads.
    GFD559713Courtesy of FORD MOTOR COMPANY
    1. Assemble the special tools. Use Special Service Tool: 307-732 Tool Kit, Torque Converter Flusher., 307-732-01 Adapter for 307-732 (Converter Flusher (10R80).
    2. Install the special tools on the torque converter hub.
    GFD559714Courtesy of FORD MOTOR COMPANY
  18. Using the special tool, install the slotted cap. Use Special Service Tool: 307-691 Tester, Torque Convertor Leak.
    GFD559715Courtesy of FORD MOTOR COMPANY
  19. Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.
    GFD559716Courtesy of FORD MOTOR COMPANY
  20. Connect the flush machine to the main hub.

    1. Red hose on top.
    2. Blue hose on bottom.

    GFD559717Courtesy of FORD MOTOR COMPANY
  21. Follow the equipment instructions to purge transmission fluid from the torque converter prior to starting the flushing procedure.
  22. 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.

  23. 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.
  24. Follow the equipment instructions to purge the torque converter.
  25. 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.

  26. Disconnect the hoses and remove the special tools.
  27. NOTE: Note the location of the bolts and studbolts for assembly.

    Remove the bolts and studbolts and the transmission fluid pan.

    1. Studbolts
    2. Bolts

    GFD559528Courtesy of FORD MOTOR COMPANY
  28. Remove and discard the hybrid drive unit feed tube seals.
    GFD559529Courtesy of FORD MOTOR COMPANY
  29. NOTE: The transmission fluid pan gasket can be reused if not damaged.

    Clean and inspect the pan, magnet, the gasket and seals.

    1. Transmission fluid pan gasket
    2. Transmission fluid pan to transmission case seals
    3. Magnet

    GFD559530Courtesy of FORD MOTOR COMPANY
  30. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
    NOTE: Use a 10ep Torx Plus® socket to remove the bolts

    Remove the bolts and the transmission fluid filter.

    1. 73 mm bolt
    2. 25 mm bolt

    GFD559531Courtesy of FORD MOTOR COMPANY
  31. NOTE: The transmission fluid filter seal will either come off with the transmission fluid filter or it will be stuck in the pump.

    Remove the transmission fluid filter seal.

    GFD559155Courtesy of FORD MOTOR COMPANY
  32. Remove and discard the transmission fluid auxiliary pump filter seal.
    GFD559532Courtesy of FORD MOTOR COMPANY
  33. Disconnect the transmission fluid auxiliary pump electrical connectors.

    • Slide the plastic locks to the unlock position. While pressing the plastic tabs, disconnect the electrical connectors.

    GFD559533Courtesy of FORD MOTOR COMPANY
  34. Remove the bolts and the transmission fluid auxiliary pump.
    GFD559534Courtesy of FORD MOTOR COMPANY
  35. Disconnect the main control main electrical connector.
    GFD559535Courtesy of FORD MOTOR COMPANY
  36. NOTE: Use a 8 x 1.25 mm bolt to hold the park override lever into position.

    Rotate the park override lever to the park override position and loosely install the bolt.

    GFD558998Courtesy of FORD MOTOR COMPANY
    1. Remove the 68 mm bolts and the main control assembly.
    2. Check to see if the main control-to-transmission fluid pump seal is attached to the main control.
    GFD559536Courtesy of FORD MOTOR COMPANY
  37. Clean and inspect the main control for damage. Refer to: Main Control Valve Body .
  38. Unlock and disconnect the speed sensors.

    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor

    GFD559537Courtesy of FORD MOTOR COMPANY
  39. Remove the speed sensors.

    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor

    GFD559538Courtesy of FORD MOTOR COMPANY
  40. Disconnect the TR sensor electrical connector.
    GFD559157Courtesy of FORD MOTOR COMPANY
  41. Using the special tool, disconnect the transmission internal wiring harness connector from the transmission case.

    1. Slide the special tool over the connector flush with the transmission case. Use Special Service Tool: 307-746 Remover, Transmission Wiring Harness Connector.
    2. Use the special tool to push the connector through the case.

    GFD559158Courtesy of FORD MOTOR COMPANY
  42. Remove the bolts, release the retainers and the transmission internal wiring harness.
    GFD559688Courtesy of FORD MOTOR COMPANY
  43. Remove the bolts and the transmission fluid pump.
    GFD558978Courtesy of FORD MOTOR COMPANY
    1. Remove the transmission fluid pump driven gear outer cover.
    2. Clean and inspect the transmission fluid pump driven gear.
    3. If replacing the transmission fluid pump driven gear or transmission fluid pump driven gear inner cover, remove the retaining ring and the transmission fluid pump driven gear.
    GFD559160Courtesy of FORD MOTOR COMPANY
  44. If necessary, remove the bolts and the transmission fluid pump driven gear inner cover.
    GFD559161Courtesy of FORD MOTOR COMPANY
  45. Remove the bolt and allow the park override lever to return to the normal operating position.
    GFD559162Courtesy of FORD MOTOR COMPANY

    Rear Wheel Drive (RWD) vehicles 

  46. Remove the stakes from the output shaft flange retaining nut. Use the General Equipment: Punch
    GFD559718Courtesy of FORD MOTOR COMPANY
  47. Remove and discard the output shaft flange nut.
    GFD559719Courtesy of FORD MOTOR COMPANY
    1. Index mark the output shaft to the flange.
    2. Remove the output shaft flange.
    GFD559720Courtesy of FORD MOTOR COMPANY

    All vehicles 

  48. Using a punch, remove and discard the manual shaft-to-TR sensor roll pin. Use the General Equipment: Punch
    GFD559166Courtesy of FORD MOTOR COMPANY
  49. Release the tension from the park return spring.

    • Slide the end of the park return spring off the transmission case.

    GFD559167Courtesy of FORD MOTOR COMPANY
  50. Remove the manual shaft and park override lever, the TR sensor and the park pawl actuator rod.
    GFD559168Courtesy of FORD MOTOR COMPANY
  51. Remove and discard the manual control shaft seal.
    GFD559169Courtesy of FORD MOTOR COMPANY
  52. Remove the bolt and the TR sensor detent spring.
    GFD559170Courtesy of FORD MOTOR COMPANY
  53. Rotate the transmission to a vertical position. Remove the bolts and the front support assembly.
    GFD559539Courtesy of FORD MOTOR COMPANY
  54. Using the special tools and a floor crane, remove the clutch and planetary assembly. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer., 307-651-01 Adapter for 307-651 (Super Sub Assembly Lifting).Use the General Equipment: Floor Crane
    GFD559540Courtesy of FORD MOTOR COMPANY
  55. Remove the (T9) thrust bearing.
    GFD559174Courtesy of FORD MOTOR COMPANY
  56. Remove the output shaft and planetary carrier No. 4 assembly.
    GFD559175Courtesy of FORD MOTOR COMPANY
  57. Remove the (T10) thrust bearing.
    GFD559176Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the output shaft seals.
    2. Clean and inspect the output shaft and planetary carrier No. 4 assembly.
    GFD559177Courtesy of FORD MOTOR COMPANY
  58. Using the special tools, remove and discard the output shaft seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 307-309 Remover, Torque Converter Seal.
    GFD559721Courtesy of FORD MOTOR COMPANY

    Rear Wheel Drive (RWD) vehicles 

  59. Remove the anti-ting washer.
    GFD559722Courtesy of FORD MOTOR COMPANY

    All vehicles 

  60. NOTE: Rear Wheel Drive (RWD) transmission case ball bearings cannot be serviced separately. They can only be serviced as a case and bearing assembly.

    Clean and inspect the transmission case and bearings. Check for leaks from plugs and park pawl actuator rod sleeve. Repair or replace as necessary. Refer to: Transmission Case .

    GFD559723Courtesy of FORD MOTOR COMPANY
  61. NOTE: If replacing A clutch separating springs, all separating springs must be replaced as a matching set or damage can occur.

    Remove the A clutch 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.

    GFD559181Courtesy of FORD MOTOR COMPANY
  62. Using a magnet, remove the selective shim and the (T3) thrust bearing. Use the General Equipment: Magnet
    GFD559182Courtesy of FORD MOTOR COMPANY
  63. Remove and discard the input shaft front Teflon® seals.
    GFD559183Courtesy of FORD MOTOR COMPANY
  64. Remove one side of the No. 1 planetary carrier snap ring.
    GFD559184Courtesy of FORD MOTOR COMPANY
  65. Flip the clutch and planetary assembly over with the input shaft through a hole in the bench. Remove the No. 1 planetary carrier snap ring and remove the clutch and planetary container cylinder.
    GFD559185Courtesy of FORD MOTOR COMPANY
    1. Inspect the No. 4 ring gear.
    2. NOTE: Remove the ring gear when replacement is necessary.

      If necessary, remove the ring gear snap ring.

    3. If necessary, remove the ring gear fron the inside of the clutch and planetary container cylinder.
    GFD559186Courtesy of FORD MOTOR COMPANY
  66. Remove the (T8) thrust bearing.
    GFD559187Courtesy of FORD MOTOR COMPANY
  67. Remove the E clutch and input shaft assembly.
    GFD559188Courtesy of FORD MOTOR COMPANY
  68. Remove the No. 3 planetary carrier and the No. 3 sun gear.
    GFD559189Courtesy of FORD MOTOR COMPANY
  69. Inspect the No. 3 planetary carrier and the No. 3 sun gear.
    GFD559190Courtesy of FORD MOTOR COMPANY
  70. Remove the CDF clutch assembly from the planetary carrier assembly.
    GFD559191Courtesy of FORD MOTOR COMPANY
  71. Remove the No. 3 sun gear shaft and No. 2 ring gear assembly.
    GFD559192Courtesy of FORD MOTOR COMPANY
  72. Inspect the No. 3 sun gear shaft and No. 2 ring gear assembly.
    GFD559193Courtesy of FORD MOTOR COMPANY
  73. Remove the (T5) thrust bearing.
    GFD559194Courtesy of FORD MOTOR COMPANY
  74. Remove the No. 2 planetary carrier.
    GFD559195Courtesy of FORD MOTOR COMPANY
  75. NOTE: It is not nessary to remove the fluid collector from the No. 2 planetary carrier.

    Inspect the No. 2 planetary carrier and the fluid collector.

    1. If the fluid collector is broken remove and discard.

    GFD559196Courtesy of FORD MOTOR COMPANY
  76. If necessary, install the new the fluid collector.
    GFD559197Courtesy of FORD MOTOR COMPANY
  77. Remove the No. 2 sun gear.
    GFD559198Courtesy of FORD MOTOR COMPANY
  78. Remove the No. 1 sun gear.
    GFD559199Courtesy of FORD MOTOR COMPANY
  79. Inspect the No. 1 and No. 2 sun gears.
    GFD559200Courtesy of FORD MOTOR COMPANY
  80. Gently pry up on the clips and remove the No. 1 bearing support locking ring.
    GFD559201Courtesy of FORD MOTOR COMPANY
  81. Rotate the No. 1 bearing support clockwise and remove the bearing support.
    GFD559202Courtesy of FORD MOTOR COMPANY
  82. Remove the No. 1 ring gear bearing.
    GFD559203Courtesy of FORD MOTOR COMPANY
  83. Remove the No. 1 ring gear.
    GFD559204Courtesy of FORD MOTOR COMPANY
  84. Remove the ring gear No 1 bearing.
    GFD559205Courtesy of FORD MOTOR COMPANY
  85. Remove the ring gear No 1 snap ring.
    GFD559207Courtesy of FORD MOTOR COMPANY
  86. Inspect the A clutch hub, No. 1 ring gear and the No. 1 planetary carrier.
    GFD559208Courtesy of FORD MOTOR COMPANY
  87. Install the ring gear No 1 snap ring.
    GFD559207Courtesy of FORD MOTOR COMPANY
  88. Install the ring gear No. 1 bearing.
    GFD559205Courtesy of FORD MOTOR COMPANY
  89. Install the No. 1 ring gear.
    GFD559204Courtesy of FORD MOTOR COMPANY
  90. Install the No. 1 ring gear bearing.
    GFD559203Courtesy of FORD MOTOR COMPANY
  91. Install the ring gear No. 1 bearing support and rotate it counter clockwise to lock it.
    GFD559209Courtesy of FORD MOTOR COMPANY
  92. Align the tabs with the slots and install the No. 1 bearing support locking ring.
    GFD559210Courtesy of FORD MOTOR COMPANY
  93. Remove and discard the sun gear No. 3 shaft Teflon® seals.
    GFD559211Courtesy of FORD MOTOR COMPANY
  94. 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: 307-749 Installer/Sizer, R2-S3 Shaft Solid Seal.
    GFD559212Courtesy of FORD MOTOR COMPANY
  95. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-749 Installer/Sizer, R2-S3 Shaft Solid Seal.
    GFD559213Courtesy of FORD MOTOR COMPANY
  96. 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 3 Teflon® seals. Use Special Service Tool: 307-749 Installer/Sizer, R2-S3 Shaft Solid Seal.
    GFD559214Courtesy of FORD MOTOR COMPANY
  97. Install the special tool to size the 4 Teflon® seals. Allow the special tool to stay on the No 3 sun gear shaft for 5 minutes prior to final assembly. Use Special Service Tool: 307-749 Installer/Sizer, R2-S3 Shaft Solid Seal.
    GFD559215Courtesy of FORD MOTOR COMPANY
  98. Remove the snap ring and the C clutch 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.
    GFD559216Courtesy of FORD MOTOR COMPANY
  99. Using the special tools and a press, remove the C clutch balance dam retainer. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.Use the General Equipment: Hydraulic Press
    GFD559217Courtesy of FORD MOTOR COMPANY
  100. Remove the C clutch balance dam.
    GFD559218Courtesy of FORD MOTOR COMPANY
  101. Remove the C clutch piston return spring.
    GFD559219Courtesy of FORD MOTOR COMPANY
  102. Remove and discard the C clutch balance dam inner and outer seals.
    GFD559220Courtesy of FORD MOTOR COMPANY
  103. Remove the C clutch piston. Use compressed air into one oil passage hole while plugging the hole on the opposite side.
    GFD559221Courtesy of FORD MOTOR COMPANY
  104. Remove and discard the C clutch piston inner and outer seals.
    GFD559222Courtesy of FORD MOTOR COMPANY
  105. Remove the snap ring and the D clutch 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.
    GFD559223Courtesy of FORD MOTOR COMPANY
  106. Remove the D clutch apply ring.
    GFD559224Courtesy of FORD MOTOR COMPANY
  107. Using the special tools and a press, remove the D clutch balance dam retainer. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.Use the General Equipment: Hydraulic Press
    GFD559225Courtesy of FORD MOTOR COMPANY
  108. Remove and discard the balance dam.
    GFD559226Courtesy of FORD MOTOR COMPANY
  109. Remove the D clutch piston return spring.
    GFD559227Courtesy of FORD MOTOR COMPANY
  110. Remove the D clutch piston. Use compressed air into one oil passage hole while plugging the hole on the opposite side.
    GFD559228Courtesy of FORD MOTOR COMPANY
  111. Remove and discard the D clutch piston inner and outer seals.
    GFD559229Courtesy of FORD MOTOR COMPANY
  112. Remove the F clutch keeper snap ring, F clutch snap ring keeper and the F clutch snap ring.

    1. F clutch keeper snap ring
    2. F clutch snap ring keeper
    3. F clutch snap ring

    GFD559230Courtesy of FORD MOTOR COMPANY
  113. Remove the F clutch 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.
    GFD559231Courtesy of FORD MOTOR COMPANY
  114. Remove the F clutch apply ring.
    GFD559232Courtesy of FORD MOTOR COMPANY
  115. Using the special tools and a press, compress the F clutch balance dam and remove the retainer. Remove the F clutch balance dam. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press
    GFD559233Courtesy of FORD MOTOR COMPANY
  116. Remove and discard the F clutch balance dam outer seal.
    GFD559234Courtesy of FORD MOTOR COMPANY
  117. Remove the F clutch piston return spring.
    GFD559235Courtesy of FORD MOTOR COMPANY
  118. Remove and discard the F clutch balance dam inner seal.
    GFD559236Courtesy of FORD MOTOR COMPANY
  119. Remove the F clutch piston.
    GFD559237Courtesy of FORD MOTOR COMPANY
  120. Remove and discard the F clutch piston seals.
    GFD559238Courtesy of FORD MOTOR COMPANY
  121. Clean and inspect the CDF clutch cylinder.
    GFD559239Courtesy of FORD MOTOR COMPANY
  122. Install the new F clutch piston seals. Lubricate the seals with petroleum jelly.
    GFD559240Courtesy of FORD MOTOR COMPANY
  123. Install the F clutch piston.
    GFD559237Courtesy of FORD MOTOR COMPANY
  124. Install the new F clutch balance dam inner seal. Lubricate the seal with petroleum jelly.
    GFD559241Courtesy of FORD MOTOR COMPANY
  125. Install the F clutch piston return spring.
    GFD559235Courtesy of FORD MOTOR COMPANY
  126. Install the new F clutch balance dam outer seal. Lubricate the seal with petroleum jelly.
    GFD559242Courtesy of FORD MOTOR COMPANY
  127. NOTE: The F clutch balance dam retainer will not be in the groove at this time.

    Install the F clutch balance dam and retainer on the CDF clutch cylinder.

    GFD559243Courtesy of FORD MOTOR COMPANY
  128. Using the special tools and a press, compress the F clutch balance dam and install the retainer into the groove. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press
    GFD559233Courtesy of FORD MOTOR COMPANY
    1. Position the F clutch apply ring onto the F clutch piston.
    2. Position the F clutch pressure plate upside-down onto the apply ring. Using the special tools and a press, press the apply ring onto the F clutch piston. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press
    GFD559244Courtesy of FORD MOTOR COMPANY
  129. NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the F clutch plates in clean transmission fluid. Install the F clutch assembly.

    1. Steel plates
    2. Friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. Pressure plate

    GFD559245Courtesy of FORD MOTOR COMPANY
  130. Install the F clutch snap ring, F clutch snap ring keeper and the F clutch keeper snap ring.

    1. F clutch snap ring
    2. F clutch snap ring keeper
    3. F clutch keeper snap ring

    GFD559246Courtesy of FORD MOTOR COMPANY
  131. Assemble the special tools and position the CDF clutch cylinder with the F clutch facing up. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD559247Courtesy of FORD MOTOR COMPANY
  132. Using the special tool, measure the F clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Zero the dial indicator. 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 the measurement to the clutch clearance chart in specifications to determine the correct size snap ring. Install the correct F clutch snap ring. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD559248Courtesy of FORD MOTOR COMPANY
  133. Install the new D clutch piston inner and outer seals. Lubricate the seals with petroleum jelly.
    GFD559249Courtesy of FORD MOTOR COMPANY
  134. Install the D clutch piston.
    GFD559250Courtesy of FORD MOTOR COMPANY
  135. Install the D clutch piston return spring.
    GFD559227Courtesy of FORD MOTOR COMPANY
  136. Lubricate the new D clutch balance dam seals with petroleum jelly.
    GFD559251Courtesy of FORD MOTOR COMPANY
  137. Using the special tools and a press, Install the D clutch balance dam and install the retainer. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.Use the General Equipment: Hydraulic Press
    GFD559225Courtesy of FORD MOTOR COMPANY
  138. Install the D clutch apply ring.
    GFD559224Courtesy of FORD MOTOR COMPANY
  139. NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the D clutch plates in clean transmission fluid. Install the D clutch assembly.

    1. Steel plates
    2. Friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. Pressure plate

    GFD559252Courtesy of FORD MOTOR COMPANY
  140. Install the D clutch snap ring.
    GFD559253Courtesy of FORD MOTOR COMPANY
  141. Assemble the special tools and position the CDF clutch cylinder with the D clutch facing up. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD559254Courtesy of FORD MOTOR COMPANY
  142. Using the special tool, measure the D clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Zero the dial indicator. 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 the measurement to the clutch clearance chart in specifications to determine the correct size snap ring. Install the correct D clutch snap ring. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD559255Courtesy of FORD MOTOR COMPANY
  143. Install the new C clutch piston inner and outer seals. Lubricate the seals with petroleum jelly.
    GFD559256Courtesy of FORD MOTOR COMPANY
  144. Install the C clutch piston.
    GFD559257Courtesy of FORD MOTOR COMPANY
  145. Install the new C clutch balance dam seals. Lubricate the seals with petroleum jelly.
    GFD559258Courtesy of FORD MOTOR COMPANY
  146. Install the C clutch piston return spring.
    GFD559219Courtesy of FORD MOTOR COMPANY
  147. Install the C clutch balance dam.
    GFD559218Courtesy of FORD MOTOR COMPANY
  148. Using the special tools and a press, compress the C clutch balance dam and install the retainer. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.Use the General Equipment: Hydraulic Press
    GFD559217Courtesy of FORD MOTOR COMPANY
  149. NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the C clutch plates in clean transmission fluid. Install the C clutch assembly.

    1. Steel plates
    2. Friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. Pressure plate

    GFD559259Courtesy of FORD MOTOR COMPANY
  150. Install the C clutch snap ring.
    GFD559260Courtesy of FORD MOTOR COMPANY
  151. Assemble the special tools and position the CDF clutch cylinder with the C clutch facing up. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD559261Courtesy of FORD MOTOR COMPANY
  152. Using the special tool, measure the C clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Zero the dial indicator. 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 the measurement to the clutch clearance chart in specifications to determine the correct size snap ring. Install the correct C clutch snap ring. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD559262Courtesy of FORD MOTOR COMPANY
  153. NOTE: Pry up from the 2 tabs to prevent the bearing from separating.

    Remove the (T6) thrust bearing.

    GFD559263Courtesy of FORD MOTOR COMPANY
  154. Remove the snap ring and the No. 3 ring gear.
    GFD559264Courtesy of FORD MOTOR COMPANY
  155. Remove the rear No. 3 ring gear snap ring.
    GFD559265Courtesy of FORD MOTOR COMPANY
  156. Inspect the No. 3 ring gear.
    GFD559266Courtesy of FORD MOTOR COMPANY
  157. Remove the input shaft and the E clutch from No. 4 shell and sun gear.
    GFD559267Courtesy of FORD MOTOR COMPANY
  158. Inspect the No. 4 shell and sun gear.
    GFD559268Courtesy of FORD MOTOR COMPANY
  159. NOTE: Pry up from the 2 tabs to prevent the bearing from separating.

    Remove the (T7) thrust bearing.

    GFD559269Courtesy of FORD MOTOR COMPANY
  160. Remove the snap ring and remove the input shaft from the E clutch assembly.
    GFD559270Courtesy of FORD MOTOR COMPANY
  161. Remove and discard the input shaft-to-sun gear No. 3 shaft Teflon® seals.
    GFD559271Courtesy of FORD MOTOR COMPANY
  162. NOTE: The input shaft may contain D-ring or O-ring E clutch seals, depending on the production level of the transmission.

    Remove and discard the input shaft D-ring or O-ring seals.

    GFD559272Courtesy of FORD MOTOR COMPANY
  163. Remove and discard the input shaft Teflon® seal.
    GFD559273Courtesy of FORD MOTOR COMPANY
  164. Clean and inspect the input shaft.
    GFD559274Courtesy of FORD MOTOR COMPANY
  165. NOTE: Do not compress the balance dam to far or damage to the E clutch hub can occur. Only compress the E clutch hub far enough to remove the retainer.

    Using the special tool and a press, compress the E clutch balance dam and remove the retainer. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press

    GFD559275Courtesy of FORD MOTOR COMPANY
  166. Pry the E clutch piston and balance dam upward and remove the piston and balance dam from the E clutch hub.
    GFD559276Courtesy of FORD MOTOR COMPANY
  167. Remove the E clutch balance dam and discard the E clutch piston.

    1. E clutch balance dam
    2. E clutch piston

    GFD559277Courtesy of FORD MOTOR COMPANY
  168. Remove and discard the E clutch balance dam outer seal.
    GFD559278Courtesy of FORD MOTOR COMPANY
  169. Remove the E clutch piston return spring.
    GFD559279Courtesy of FORD MOTOR COMPANY
  170. Remove the E clutch 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.
    GFD559280Courtesy of FORD MOTOR COMPANY
  171. Remove and discard the E clutch piston and balance dam inner seals.
    GFD559281Courtesy of FORD MOTOR COMPANY
  172. Clean and inspect the E clutch hub.
    GFD559282Courtesy of FORD MOTOR COMPANY
  173. Install the new E clutch piston and balance dam inner seals. Lubricate the seals with petroleum jelly.
    GFD559283Courtesy of FORD MOTOR COMPANY
  174. NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the E clutch plates in clean transmission fluid. Install the E clutch assembly.

    1. Pressure plate (select fit)
    2. Friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. NOTE: Align the inner splines of the steel plates with the pressure plate internal splines.

      Steel plates

    4. Apply plate (2.9-3.0)

    GFD559284Courtesy of FORD MOTOR COMPANY
  175. Install the E clutch piston return spring.
    GFD559279Courtesy of FORD MOTOR COMPANY
  176. Install a new E clutch balance dam outer seal. Lubricate the seal with petroleum jelly.
    GFD559285Courtesy of FORD MOTOR COMPANY
  177. Install the E clutch balance dam in the new E clutch piston.

    1. E clutch balance dam
    2. E clutch piston

    GFD559286Courtesy of FORD MOTOR COMPANY
  178. Lubricate the new E clutch piston seal with petroleum jelly.
    GFD559724Courtesy of FORD MOTOR COMPANY
  179. Install the new E clutch piston and balance dam in the E clutch hub.
    GFD559288Courtesy of FORD MOTOR COMPANY
  180. NOTE: Do not compress the balance dam too far or damage to the E clutch hub can occur. Only compress the E clutch hub far enough to install the retainer.

    Using the special tool and a press, compress the E clutch balance dam and install the retainer. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press

    GFD559275Courtesy of FORD MOTOR COMPANY
  181. Assemble the special tools and position the E clutch assembly on the special tool. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD559289Courtesy of FORD MOTOR COMPANY
  182. Using the special tool, measure the E clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Zero the dial indicator. 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 the measurement to the clutch clearance chart in specifications to determine the correct size pressure plate. Install the correct E clutch pressure plate. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD559290Courtesy of FORD MOTOR COMPANY
  183. NOTE: The E clutch seals have been updated to O-ring seals. The new seal kit may contain D-ring seals or O-ring seals, either can be used.

    Install the new input shaft E clutch seals.

    GFD559291Courtesy of FORD MOTOR COMPANY
  184. Install the input shaft in the E clutch and install the snap ring.
    GFD559270Courtesy of FORD MOTOR COMPANY
  185. Install the (T7) thrust bearing onto the E clutch with the tab locators up. Snap the bearing into place.
    GFD559292Courtesy of FORD MOTOR COMPANY
  186. NOTE: Align the outer splines on the friction plates.

    Install the input shaft and the E clutch into the No. 4 shell and sun gear.

    GFD559267Courtesy of FORD MOTOR COMPANY
  187. Install the lower rear No. 3 ring gear snap ring.
    GFD559265Courtesy of FORD MOTOR COMPANY
  188. Install the No. 3 ring gear and the snap ring. Align the snap ring gap 180 deg. from the bottom snap ring gap.
    GFD559264Courtesy of FORD MOTOR COMPANY
  189. Install the (T6) thrust bearing onto the E clutch with the tab locators down. Snap the bearing into place.
    GFD559293Courtesy of FORD MOTOR COMPANY
  190. 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: 307-747 Installer/ Sizer, Input Shaft Solid Sealing Rings; Large.
    GFD559725Courtesy of FORD MOTOR COMPANY
  191. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-747 Installer/ Sizer, Input Shaft Solid Sealing Rings; Large.
    GFD559295Courtesy of FORD MOTOR COMPANY
  192. 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 4 Teflon® seals. Use Special Service Tool: 307-747 Installer/ Sizer, Input Shaft Solid Sealing Rings; Large.
    GFD559726Courtesy of FORD MOTOR COMPANY
  193. Install the special tool to size the 5 Teflon® seals. Allow the special tool to stay on the input shaft for 5 minutes prior to final assembly. Use Special Service Tool: 307-747 Installer/ Sizer, Input Shaft Solid Sealing Rings; Large.
    GFD559297Courtesy of FORD MOTOR COMPANY
  194. Install the No. 1 sun gear in the No. 1 planetary carrier.
    GFD559199Courtesy of FORD MOTOR COMPANY
  195. Install the No. 2 sun gear.
    GFD559198Courtesy of FORD MOTOR COMPANY
  196. Install the No. 2 planetary carrier.
    GFD559195Courtesy of FORD MOTOR COMPANY
  197. Install the (T5) bearing.
    GFD559194Courtesy of FORD MOTOR COMPANY
  198. Remove Special Service Tool: 307-749 Installer/Sizer, R2-S3 Shaft Solid Seal.
    GFD559215Courtesy of FORD MOTOR COMPANY
  199. Install the No. 3 sun gear shaft into the CDF clutch assembly.

    1. Position the CDF clutch assembly on 2 blocks of wood. Use the General Equipment: Wooden Block
    2. Rotate the No. 3 sun gear shaft back and forth to install.
    3. NOTE: When the No. 3 sun gear shaft is correctly installed the clearance between CDF clutch assembly and the special tool is approximately 1 mm.

      Using the special tool and a feeler gauge, check the clearance between the CDF clutch assembly and the special tool. Use Special Service Tool: 307-661 Gauge, End Play.Use the General Equipment: Feeler Gauge

    GFD559298Courtesy of FORD MOTOR COMPANY
  200. While holding the sun gear No. 3 shaft, flip the CDF clutch assembly over and install it on to the No. 2 planetary carrier.
    GFD559191Courtesy of FORD MOTOR COMPANY
  201. Install the No. 3 planetary carrier.
    GFD559299Courtesy of FORD MOTOR COMPANY
  202. Install the No. 3 sun gear.

    1. NOTE: The No. 3 sun gear shaft splines will be flush with the No. 3 sun gear splines when correctly installed.

      Check the No. 3 sun gear shaft for correct installation.

    GFD559300Courtesy of FORD MOTOR COMPANY
  203. Remove Special Service Tool: 307-747 Installer/ Sizer, Input Shaft Solid Sealing Rings; Large.
    GFD559297Courtesy of FORD MOTOR COMPANY
  204. Install the E clutch and input shaft assembly.
    GFD559188Courtesy of FORD MOTOR COMPANY
  205. Install the (T8) thrust bearing.
    GFD559187Courtesy of FORD MOTOR COMPANY
    1. NOTE: Some early build transmissions are not equipped with lazer applied ink marks.

      If the No. 4 ring gear was removed, inspect the ring gear and the clutch and planetary container cylinder for lazer applied ink marks.

    2. NOTE: If ink marks are present the marks must be aligned or a transmission vibration can occur.

      If ink marks are present align the marks and install the No. 4 ring gear on the clutch and planetary container cylinder.

    3. Install the No. 4 ring gear snap ring.
    GFD559301Courtesy of FORD MOTOR COMPANY
    1. NOTE: Some early build transmissions are not equipped with lazer applied ink marks.

      Inspect the No. 1 planetary carrier and the clutch and planetary container cylinder for lazer applied ink marks.

    2. NOTE: If ink marks are present the marks must be aligned or a transmission vibration can occur.

      If ink marks are present align the marks and install the clutch and planetary container cylinder onto the No. 1 planetary carrier and install the snap ring. Make sure the snap ring is seated.

    3. Install the No. 1 planetary carrier snap ring. Make sure the snap ring is seated.
    GFD559302Courtesy of FORD MOTOR COMPANY
  206. Using the special tool, install a new Teflon® seal in the groove on the input shaft. Use Special Service Tool: 307-653 Sizer, Input Shaft Teflon Seal.
    GFD559303Courtesy of FORD MOTOR COMPANY
  207. Using the special tool, size the Teflon® seal. Allow the special tool to stay on the input shaft for 5 minutes prior to final assembly. Use Special Service Tool: 307-653 Sizer, Input Shaft Teflon Seal.
    GFD559304Courtesy of FORD MOTOR COMPANY
  208. 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: 307-748 Installer/Sizer, Input Shaft Solid Sealing Rings; Small.
    GFD559305Courtesy of FORD MOTOR COMPANY
  209. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-748 Installer/Sizer, Input Shaft Solid Sealing Rings; Small.
    GFD559306Courtesy of FORD MOTOR COMPANY
  210. 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 4 Teflon® seals. Use Special Service Tool: 307-748 Installer/Sizer, Input Shaft Solid Sealing Rings; Small.
    GFD559307Courtesy of FORD MOTOR COMPANY
  211. Install the special tool to size the 5 Teflon® seals. Allow the special tool to stay on the input shaft for 5 minutes prior to final assembly. Use Special Service Tool: 307-748 Installer/Sizer, Input Shaft Solid Sealing Rings; Small.
    GFD559308Courtesy of FORD MOTOR COMPANY
  212. Install the TR sensor detent spring and loosely install the bolt.
    GFD559170Courtesy of FORD MOTOR COMPANY
  213. Using the special tool install the new manual shaft seal in the transmission case. Use Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.
    GFD559309Courtesy of FORD MOTOR COMPANY
  214. Slide the manual shaft and park override lever into the TR sensor.
    GFD559310Courtesy of FORD MOTOR COMPANY
  215. Using the dimpled end of the special tool, install the new manual shaft-to-TR sensor roll pin flush with the shaft.

    1. New roll pin
    2. Dimpled end of special tool Use Special Service Tool: 307-783 Installer, Roll Pin.Use the General Equipment: Rubber Mallet

    GFD559311Courtesy of FORD MOTOR COMPANY
  216. Slide the end of the park return spring onto the transmission case.
    GFD559312Courtesy of FORD MOTOR COMPANY
    1. Align the detent spring in the center of the TR sensor.
    2. Torq: 97 lb.in (11 Nm)ue
    GFD559313Courtesy of FORD MOTOR COMPANY
  217. Install new seals on the output shaft.
    GFD559316Courtesy of FORD MOTOR COMPANY
  218. Install the (T10) thrust bearing on the output shaft.
    GFD559176Courtesy of FORD MOTOR COMPANY
  219. NOTE: Use a 8 x 1.25 mm bolt to hold the park override lever into position.

    Rotate the park override lever to the park override position and loosley install the bolt.

    GFD558998Courtesy of FORD MOTOR COMPANY
  220. Install the output shaft and planetary carrier assembly No. 4.
    GFD559175Courtesy of FORD MOTOR COMPANY
  221. Remove the bolt and allow the park override lever to return to the normal operating position.
    GFD559162Courtesy of FORD MOTOR COMPANY
  222. Install the (T9) thrust bearing.
    GFD559174Courtesy of FORD MOTOR COMPANY
  223. Lubricate the output shaft bushing with petroleum jelly.
    GFD559321Courtesy of FORD MOTOR COMPANY
  224. Remove Special Service Tool: 307-748 Installer/Sizer, Input Shaft Solid Sealing Rings; Small.
    GFD559308Courtesy of FORD MOTOR COMPANY
  225. Remove Special Service Tool: 307-653 Sizer, Input Shaft Teflon Seal.
    GFD559304Courtesy of FORD MOTOR COMPANY
  226. Using the special tools and a floor crane, install the clutch and planetary assembly. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer., 307-651-01 Adapter for 307-651 (Super Sub Assembly Lifting).Use the General Equipment: Floor Crane
    GFD559540Courtesy of FORD MOTOR COMPANY
  227. Using the special tool, remove the B clutch snap ring.

    1. NOTE: The B clutch snap ring ends are positioned in the opening of the B clutch pressure plate with a raised notch.

      Note the position of the B clutch snap ring ends for assembly.

    2. Using the special tools and a press, compress the B clutch assembly. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press
    3. Remove the B clutch snap ring.

    GFD559323Courtesy of FORD MOTOR COMPANY
  228. NOTE: Remove the One-Way Clutch (OWC) and B clutch assembly gently, as the One-Way Clutch (OWC) rollers and springs could become dislodged.

    Gently remove the One-Way Clutch (OWC) and B clutch assembly.

    GFD559324Courtesy of FORD MOTOR COMPANY
  229. NOTE: If replacing B clutch separating springs, all separating springs must be replaced as a matching set or damage can occur.

    Remove the B clutch assembly from the One-Way Clutch (OWC). 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.

    GFD559325Courtesy of FORD MOTOR COMPANY
  230. Remove the B clutch apply plate and the one remaining B clutch separating spring.

    1. B clutch separating spring
    2. B clutch apply plate

    GFD559326Courtesy of FORD MOTOR COMPANY
    1. Use compressed air into the oil passage hole.
    2. Remove and discard the B clutch piston.
    GFD559327Courtesy of FORD MOTOR COMPANY
    1. Using the special tools and a press, compress the A clutch piston return spring. Use Special Service Tool: 307-741 Spring Compressor, F Clutch., 307-733 Compressor, Clutch Piston.Use the General Equipment: Hydraulic Press
    2. Remove the A clutch piston return spring snap ring.
    GFD559328Courtesy of FORD MOTOR COMPANY
  231. Remove the A clutch piston return spring.
    GFD559329Courtesy of FORD MOTOR COMPANY
  232. Use compressed air into the oil passage hole and remove the A clutch piston.
    GFD559330Courtesy of FORD MOTOR COMPANY
  233. Remove and discard the A clutch piston outer seal and the A clutch piston inner seal.
    GFD559331Courtesy of FORD MOTOR COMPANY
  234. Remove the front support cover bolt and the front support cover snap ring.
    GFD559334Courtesy of FORD MOTOR COMPANY
    1. NOTE: Do not pry on the transmission fluid pump drive gear to remove the front support cover or damage to the transmission fluid pump drive gear can occur.
    2. Push up on the back of the front support cover and remove the front support cover from the front support.
    GFD559335Courtesy of FORD MOTOR COMPANY
  235. Remove the transmission fluid pump drive gear.
    GFD559336Courtesy of FORD MOTOR COMPANY
    1. Inspect the transmission fluid pump idler gear for damage.
    2. Make sure the transmission fluid pump idler gear bearing spins freely and has no excessive end play.
    GFD559337Courtesy of FORD MOTOR COMPANY
  236. NOTE: Tighten the special tools evenly to remove the transmission fluid pump idler gear.

    If necessary, use the special tools, to remove the transmission fluid pump idler gear and bearing. Use Special Service Tool: 307-743 Remover, Pump Drive Gear.

    GFD559338Courtesy of FORD MOTOR COMPANY
  237. Using a press, to remove and discard the transmission fluid pump idler gear bearing. Use the General Equipment: Hydraulic Press
    GFD559339Courtesy of FORD MOTOR COMPANY
  238. Remove and discard the stator support seal.
    GFD559340Courtesy of FORD MOTOR COMPANY
  239. Clean and inspect the components for damage or excessive ware, replace as necessary.

    1. One-Way Clutch (OWC) inner race
    2. One-Way Clutch (OWC) rollers
    3. Gear splines

    GFD559341Courtesy of FORD MOTOR COMPANY
  240. Install the new stator support seal on the front support. Lubricate the stator support seal with petroleum jelly.
    GFD559727Courtesy of FORD MOTOR COMPANY
  241. If removed, using the special tool and a press, install the new transmission fluid pump idler gear bearing. Use Special Service Tool: 307-736 Installer, Pump Drive Gear Bearing.Use the General Equipment: Hydraulic Press
    GFD559009Courtesy of FORD MOTOR COMPANY
    1. Position the special tool on the front support. Use Special Service Tool: 307-737 Press Tool, Oil Pump Drive Idler Gear.
    2. NOTE: Install the transmission fluid pump idler gear with the grooved side up.
    3. Using the special tools and a press, install the transmission fluid pump idler gear and bearing. Use the General Equipment: Hydraulic Press
    GFD559728Courtesy of FORD MOTOR COMPANY
  242. Install the transmission fluid pump drive gear with the flat side down.
    GFD559344Courtesy of FORD MOTOR COMPANY
  243. Install the front support cover by pressing down evenly by hand.
    GFD559345Courtesy of FORD MOTOR COMPANY
  244. NOTE: The front support cover snap ring ends are located in the cover alignment features.

    Install the front support cover bolt and the front support cover snap ring.

    Torque: 62 lb.in (7 Nm)

    GFD559334Courtesy of FORD MOTOR COMPANY
  245. Install the new A clutch piston outer seal and the new A clutch piston inner seal. Lubricate the A clutch piston seals with petroleum jelly.
    GFD559350Courtesy of FORD MOTOR COMPANY
  246. Install the A clutch piston by pushing down on the piston until an audible click is heard.
    GFD559351Courtesy of FORD MOTOR COMPANY
  247. Install the A clutch piston return spring with the retaining tabs facing upward.
    GFD559352Courtesy of FORD MOTOR COMPANY
    1. Using the special tools and a press, compress the A clutch piston return spring. Use Special Service Tool: 307-741 Spring Compressor, F Clutch., 307-733 Compressor, Clutch Piston.Use the General Equipment: Hydraulic Press
    2. NOTE: Be sure snap ring ends are not located on the A clutch piston return spring retaining tabs.

      Install the A clutch piston return spring snap ring ends in the center of the return spring retaining tabs.

    GFD559353Courtesy of FORD MOTOR COMPANY
    1. Lubricate the B clutch piston seals with petroleum jelly.
    2. Install the new B clutch piston.
    GFD559354Courtesy of FORD MOTOR COMPANY
  248. Install the B clutch apply plate.
    GFD559355Courtesy of FORD MOTOR COMPANY
  249. NOTE: The B clutch separating springs are not installed when measuring the B clutch clearance.

    Temporarily install the B clutch friction plates, B clutch steel plates and the B clutch pressure plate to measure the B clutch clearance.

    GFD559356Courtesy of FORD MOTOR COMPANY
  250. Install the B clutch snap ring with the grooved side down.

    1. B clutch snap ring grooved side

    GFD559357Courtesy of FORD MOTOR COMPANY
  251. Assemble the special tools and position the front support assembly on the special tool. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay., 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD559358Courtesy of FORD MOTOR COMPANY
  252. Using the special tool, measure the B clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Gently push down on the pressure plate to zero the dial indicator. 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 the measurement to the clutch clearance chart in specifications to determine the correct size snap ring. Install the correct B clutch snap ring. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD559359Courtesy of FORD MOTOR COMPANY
  253. Remove the B clutch snap ring.
    GFD559360Courtesy of FORD MOTOR COMPANY
  254. Remove the B clutch assembly.
    GFD559356Courtesy of FORD MOTOR COMPANY
  255. Verify that all the One-Way Clutch (OWC) rollers and springs are seated.

    1. Springs
    2. Rollers

    GFD559361Courtesy of FORD MOTOR COMPANY
  256. NOTE: The One-Way Clutch (OWC) hub should rotate counter-clockwise freely when installed correctly.

    1. Position the special tool on the front support. Use Special Service Tool: 307-734 Tool, OWC Alignment.
    2. With a counter-clockwise rotation gently install the One-Way Clutch (OWC) onto the front support.

    GFD559362Courtesy of FORD MOTOR COMPANY
  257. NOTE: If replacing B clutch separating springs, all separating springs must be replaced as a matching set or damage can occur.
    NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the B clutch plates in clean transmission fluid. With the B clutch apply plate installed, correctly install the B clutch plates and springs.

    1. B clutch friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    2. B clutch separating springs
    3. B clutch steel plates
    4. B clutch pressure plate

    GFD559363Courtesy of FORD MOTOR COMPANY
  258. NOTE: Be sure to align the top B clutch friction to the One-Way Clutch (OWC) hub or damage can occur.

    Use the special tools to compress the B clutch assembly. Use Special Service Tool: 307-741 Spring Compressor, F Clutch.Use the General Equipment: Hydraulic Press

    GFD559364Courtesy of FORD MOTOR COMPANY
  259. Install the B clutch snap ring in the correct location with the grooved side down.

    1. B clutch snap ring grooved side

    GFD559365Courtesy of FORD MOTOR COMPANY
  260. Install the (T3) thrust bearing.
    GFD559544Courtesy of FORD MOTOR COMPANY
  261. Install the special tool. Use Special Service Tool: 307-790 Endplay Check Gauge.
    GFD559545Courtesy of FORD MOTOR COMPANY
  262. Using the special tools and a depth gauge, measure the distance from the top of the special tool 307-661 to top of the special tool 307-790 in 2 different places. Average the measurements. Record this as measurement A. Use Special Service Tool: 307-661 Gauge, End Play., 307-661-01 Spacers/Plate, Clearance Gage., 307-661-02 Adapter for 307-661., 307-790 Endplay Check Gauge.
    GFD559546Courtesy of FORD MOTOR COMPANY
  263. Using the special tools and a depth gauge, measure the distance from the top of the special tool to front support mating surface in 2 different places. Average the measurements. Record this as measurement B. Use Special Service Tool: 307-661 Gauge, End Play., 307-661-01 Spacers/Plate, Clearance Gage., 307-661-02 Adapter for 307-661.
    GFD559547Courtesy of FORD MOTOR COMPANY
  264. Subtract measurement B from measurement A and record this as measurement C. Add 63.5 mm to measurement C.

    1. Subtract it
    2. Add it

    GFD559548Courtesy of FORD MOTOR COMPANY
  265. Using the special tool and a depth gauge, measure the distance from the top of the special tool to the transmission deck mating surface in 2 different places. Average the measurements. Record this measurement as measurement D. Use Special Service Tool: 307-661 Gauge, End Play.
    GFD559729Courtesy of FORD MOTOR COMPANY
  266. Using the special tool and a depth gauge, measure the distance from the top of the special tool to (T3) thrust bearing surface in 2 different places. Average the measurements. Record this as measurement E. Use Special Service Tool: 307-661 Gauge, End Play.
    GFD559370Courtesy of FORD MOTOR COMPANY
  267. Calculate the correct shim thickness. Subtract measurement E from measurement D and record this as measurement F. Subtract measurement F from measurement C to get the clearance between the front support and the (T3) thrust bearing. Using the Selective Fit Shim Charts in specifications, select the correct shim. Refer to: Specifications .
    GFD559550Courtesy of FORD MOTOR COMPANY
  268. Install the selective shim.
    GFD559372Courtesy of FORD MOTOR COMPANY
  269. NOTE: The A clutch separating springs are not installed when measuring the A clutch clearance.

    Temporarily install the A clutch into the transmission out of order to measure the A clutch clearance.

    1. Install the pressure plate.
    2. Install the friction plates.
    3. Install the steel plates.
    4. Install the wave spring.
    5. Install the apply plate.

    GFD559730Courtesy of FORD MOTOR COMPANY
  270. Using the special tools and a depth gauge, measure the distance from the top of the special tool to the top of the A clutch apply plate in 2 different places. Average the measurements. Record this as measurement A. Use Special Service Tool: 307-661 Gauge, End Play., 307-661-01 Spacers/Plate, Clearance Gage., 307-661-02 Adapter for 307-661.
    GFD559731Courtesy of FORD MOTOR COMPANY
  271. Using the special tools and a depth gauge, measure the distance from the top of the special tool to front support mating surface in 2 different places. Average the measurements. Record this as measurement B. Use Special Service Tool: 307-661 Gauge, End Play., 307-661-01 Spacers/Plate, Clearance Gage., 307-661-02 Adapter for 307-661.
    GFD559547Courtesy of FORD MOTOR COMPANY
  272. Using the special tool and a depth gauge, measure the distance from the top of the special tool to the transmission deck mating surface in 2 different places. Average the measurements. Record this as measurement D. Use Special Service Tool: 307-661 Gauge, End Play.
    GFD559729Courtesy of FORD MOTOR COMPANY
  273. Using the special tool and a depth gauge, measure the distance from the top of the special tool to the A clutch piston surface in 2 different places. Average the measurements. Record this as measurement E. Use Special Service Tool: 307-661 Gauge, End Play.
    GFD559376Courtesy of FORD MOTOR COMPANY
  274. Subtract measurement B from measurement A and record this as measurement C. Subtract measurement E from measurement D and record this as measurement F. Subtract measurement F from measurement C to get the A clutch clearance. Compare the A clutch clearance to the clutch specifications chart. If the A clutch clearance is not with in the specification range select the correct A clutch apply plate. Refer to: Specifications .
    GFD559377Courtesy of FORD MOTOR COMPANY
  275. NOTE: If replacing A clutch separating springs, all separating springs must be replaced as a matching set or damage can occur.
    NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the A clutch plates in clean transmission fluid. Install the A clutch assembly.

    1. Pressure plate
    2. Friction plates

      Material

      : Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. Separator springs
    4. Steel plates
    5. Apply plate (select fit)
    6. Wave spring

    GFD559551Courtesy of FORD MOTOR COMPANY
  276. Lubricate the Teflon seals with petroleum jelly.
    GFD559552Courtesy of FORD MOTOR COMPANY
  277. Install the special tool in the location shown. Use Special Service Tool: 307-797 Installer, Alignment Studs (3) and Alignment Pin (All 10R).
    GFD559553Courtesy of FORD MOTOR COMPANY
  278. Install the front support into the transmission case. Align the pump gear to the pump drive gear pocket area. Rotate the input to align the one-way clutch splines with the No. 1 sun gear.
    GFD559554Courtesy of FORD MOTOR COMPANY
    1. Install the special tool studs, washers and nuts in the location shown. Use Special Service Tool: 307-797 Installer, Alignment Studs (3) and Alignment Pin (All 10R).
    2. Tighten the special tool nuts evenly to seat the front support assembly to the transmission case.
    GFD559555Courtesy of FORD MOTOR COMPANY
    1. With the special tools installed, hand tight the front support bolts in a crisscross pattern.
    2. Remove the special tools and install the front support bolts hand tight.
    GFD559556Courtesy of FORD MOTOR COMPANY
  279. Tighten the front support bolts in a crisscross pattern.

    Torque: 26 lb.ft (35 Nm)

    GFD559557Courtesy of FORD MOTOR COMPANY
  280. Install the transmission fluid spray nozel.
    GFD559526Courtesy of FORD MOTOR COMPANY
  281. Install the hybrid drive unit gasket.
    GFD559525Courtesy of FORD MOTOR COMPANY
  282. If installing a new hybrid drive unit, position the dowl pins flush with the housing.
    GFD559558Courtesy of FORD MOTOR COMPANY
  283. Using a floor crane and the special tools, install the hybrid drive unit. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer., 307-651-03 Lift Fixture Adapter (MHT).Use the General Equipment: Floor Crane
    GFD559523Courtesy of FORD MOTOR COMPANY
  284. Install the long hybrid drive unit bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD559521Courtesy of FORD MOTOR COMPANY
  285. Install the short hybrid drive unit bolt.

    Torque: 18 lb.ft (25 Nm)

    GFD559520Courtesy of FORD MOTOR COMPANY
  286. Install the rear hybrid drive unit bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD559519Courtesy of FORD MOTOR COMPANY
  287. Position the new input shaft seal on the input shaft.
    GFD559732Courtesy of FORD MOTOR COMPANY
  288. Using the special tools, install the input shaft seal. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft., 307-802 Installer, Input Shaft.
    GFD559733Courtesy of FORD MOTOR COMPANY
  289. Position a new output shaft seal on the special tools. Use Special Service Tool: 205-1018 Installation Tube., 307-782 Installer, Output Shaft Seal.
    GFD559584Courtesy of FORD MOTOR COMPANY
  290. Using the special tools, install the new output shaft seal. Use Special Service Tool: 205-1018 Installation Tube., 307-782 Installer, Output Shaft Seal.
    GFD559734Courtesy of FORD MOTOR COMPANY

    Rear Wheel Drive (RWD) vehicles 

  291. Install the anti-ting washer.
    GFD559735Courtesy of FORD MOTOR COMPANY
  292. NOTE: If the output shaft or output shaft flange are replaced with new parts, align lazer applied ink marks.

    Align the index marks marks made during removal.

    GFD559736Courtesy of FORD MOTOR COMPANY
  293. Install the new output shaft flange retaining nut.

    Torque: 59 lb.ft (80 Nm)

    GFD559737Courtesy of FORD MOTOR COMPANY
  294. After installing the new output shaft flange retaining nut, stake the slots to prevent it from coming loose. Use the General Equipment: Punch
    GFD559718Courtesy of FORD MOTOR COMPANY

    All vehicles 

  295. Install the wiring harness. Lubricate the O-ring seals with petroleum jelly. Align the tab on the electrical connector with the indention in the transmission case and install the main electrical connector in the transmission case. Align the wiring harness and install the bolts.

    1. Torq: 97 lb.in (11 Nm)ue
    2. Torq: 106 lb.in (12 Nm)ue

    GFD559689Courtesy of FORD MOTOR COMPANY
  296. Support the opposite side of the TR sensor and connect the electrical connector.
    GFD559157Courtesy of FORD MOTOR COMPANY
  297. Install the speed sensors.

    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor

    • Torq: 62 lb.in (7 Nm)ue

    GFD559538Courtesy of FORD MOTOR COMPANY
  298. Connect and lock the speed sensors.

    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor

    GFD559559Courtesy of FORD MOTOR COMPANY
  299. If removed, install the transmission fluid pump driven gear inner cover and the bolts.

    Torque: 115 lb.in (13 Nm)

    GFD559161Courtesy of FORD MOTOR COMPANY
    1. If removed, install the transmission fluid pump driven gear and the retaining ring.
    2. Install the transmission fluid pump driven gear outer cover.
    GFD559017Courtesy of FORD MOTOR COMPANY
  300. Install the transmission fluid pump and the bolts.

    Torque: 71 lb.in (8 Nm)

    GFD558978Courtesy of FORD MOTOR COMPANY
  301. NOTE: Use a 8 x 1.25 mm bolt to hold the park override lever into position.

    Rotate the park override lever to the park override position and loosely install the bolt.

    GFD558998Courtesy of FORD MOTOR COMPANY
  302. NOTE: Only install 68 mm length bolts or the transmission clutch and planetary container can be damaged and result in transmission failure.

    Loosely install the main control valve body.

    1. NOTE: Be sure the main control-to-case seal is attached to the main control.
    2. Align the guide pins on the main control valve body with the alignment holes in the transmission case.
    3. Align the TR sensor with the park pawl lock valve.
    4. Loosely install the 68 mm length main control-to-transmission case bolts.

    GFD559560Courtesy of FORD MOTOR COMPANY
  303. Tighten the bolts in the sequence shown.

    Torque: 89 lb.in (10 Nm)

    GFD559561Courtesy of FORD MOTOR COMPANY
  304. Connect the main control main electrical connector.
    GFD559535Courtesy of FORD MOTOR COMPANY
  305. Install the transmission fluid auxiliary pump and the bolts.

    Torque: 97 lb.in (11 Nm)

    GFD559534Courtesy of FORD MOTOR COMPANY
  306. Connect the transmission fluid auxiliary pump electrical connectors.

    • Connect the electrical connectors. Slide the plastic locks to the locked position.

    GFD559562Courtesy of FORD MOTOR COMPANY
  307. NOTE: If a new auxiliary pump was installed, the barcode must be recorded, prior to installation of the transmission fluid pan, gasket and filter.

    Scan the 2D barcode on the new auxiliary pump using a QR or 2D barcode reader app and record the last 22 digits of the barcode.

    GFD559738Courtesy of FORD MOTOR COMPANY
  308. Install the new transmission fluid auxiliary pump filter seal.
    GFD559563Courtesy of FORD MOTOR COMPANY
  309. Install the filter seal in the pump.
    GFD559021Courtesy of FORD MOTOR COMPANY
  310. NOTE: If the bolts are installed in the wrong locations, transmission damage will occur.
    NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
    NOTE: Use a 10ep Torx Plus® socket to install the bolts.

    Install the filter and the bolts in the correct locations.

    1. 73 mm bolt
    2. 25 mm bolt

    • Torq: 97 lb.in (11 Nm)ue

    GFD559531Courtesy of FORD MOTOR COMPANY
  311. Install the new hybrid drive unit feed tube seals.
    GFD559564Courtesy of FORD MOTOR COMPANY
  312. NOTE: The transmission fluid pan gasket can be reused if not damaged.

    Install the fluid pan gasket and seals.

    1. Transmission fluid pan gasket
    2. Transmission fluid pan to transmission case seals

    GFD559565Courtesy of FORD MOTOR COMPANY
  313. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.

    1. Studbolts

      Torque: 106 lb.in (12 Nm)

    2. Bolts

      Torque: 89 lb.in (10 Nm)

    GFD559528Courtesy of FORD MOTOR COMPANY
  314. Install the transmission fluid level indicator.
    GFD558991Courtesy of FORD MOTOR COMPANY
  315. Remove the bolt and allow the park override lever to return to the normal operating position.
GFD559162Courtesy of FORD MOTOR COMPANY