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Section 1533 (Automatic Transmission - 6-Speed POWERSHIFT Transmission - DPS6 6DCT250): Assembly: Transmission

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Special Tool(s) / General Equipment 

GFD267737Courtesy of FORD MOTOR COMPANY
 204-594
Forcing screw
GFD267738Courtesy of FORD MOTOR COMPANY
 205-118 (T77F-4222-A)
Differential bearing cap installer
GFD264157Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W)
Handle
GFD267770Courtesy of FORD MOTOR COMPANY
 205-425
Installer, Differential Carrier Seal LH
TKIT-1999-F/FLM/LT
GFD267696Courtesy of FORD MOTOR COMPANY
 307-580
Holding Fixture
TKIT-2006UF-FLM
TKIT-2006UF-ROW
GFD267577Courtesy of FORD MOTOR COMPANY
 307-670
Remover/Installer, Shift Lever Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267520Courtesy of FORD MOTOR COMPANY
 307-671
Installer, Axle Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267771Courtesy of FORD MOTOR COMPANY
 307-672
Installer, Input Guide and Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267542Courtesy of FORD MOTOR COMPANY
 307-674
Installer, Outer Input Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267698Courtesy of FORD MOTOR COMPANY
 307-680
Table, Assembly (DPS6)
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267772Courtesy of FORD MOTOR COMPANY
 307-681
Differential Bearing Preload Tool
TKIT-2010D-FLM
TKIT-2010D-ROW
GFD267773Courtesy of FORD MOTOR COMPANY
 308-164 (T88C-77000-JF)
Shim Selection Set
Feeler Gauge
Hot Air Gun
Punch

Materials 

Name Specification
Motorcraft® Gasket Maker
TA-16		 WSK-M2G348-A5
  1. Refer to the video.
    multimedia:A supplement to the article is available.
  2. Install the hollow input shaft on the inner input shaft.
    GFD267774Courtesy of FORD MOTOR COMPANY
  3. NOTE: Make sure that the synchronizers are in the neutral position.

    Install the output shaft assembly in the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).

    GFD267733Courtesy of FORD MOTOR COMPANY
  4. Install the input shaft assembly in the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
    GFD267775Courtesy of FORD MOTOR COMPANY
  5. Install the output shaft assembly in the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).
    GFD267776Courtesy of FORD MOTOR COMPANY
  6. NOTE: After installing the assembly table place the gear assembly in the upright position.

    Install the input and output shaft assemblies in the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).

    GFD267730Courtesy of FORD MOTOR COMPANY
  7. Remove Special Service Tool: 307-680 Table, Assembly (DPS6).
    GFD267777Courtesy of FORD MOTOR COMPANY
  8. Install the 4th/reverse gear shift fork.
    GFD267778Courtesy of FORD MOTOR COMPANY
  9. Install the 2nd/6th gear shift fork and linkage.
    GFD267779Courtesy of FORD MOTOR COMPANY
  10. NOTE: Make sure the shift drums are in the neutral position.

    Install shift drum 2.

    GFD267780Courtesy of FORD MOTOR COMPANY
  11. NOTE: Make sure the shift drums are in the neutral position.

    Install shift drum 1 and the 3rd gear linkage.

    GFD267781Courtesy of FORD MOTOR COMPANY
  12. Install the 1st/5th gear shift fork.
    GFD267782Courtesy of FORD MOTOR COMPANY
  13. Install the 3rd gear shift fork.
    GFD267783Courtesy of FORD MOTOR COMPANY
  14. Install the shift fork rods.
    GFD267784Courtesy of FORD MOTOR COMPANY
  15. NOTE: This step only applies to transmissions built before April-2013.

    Install the oil spout.

    GFD267725Courtesy of FORD MOTOR COMPANY
  16. NOTE: Make sure that the bearing retainers are correctly located.

    Install the special tool. Use Special Service Tool: 307-680 Table, Assembly (DPS6).

    GFD267785Courtesy of FORD MOTOR COMPANY
  17. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.

    GFD267786Courtesy of FORD MOTOR COMPANY
  18. Align the special tools with the bolt holes in the transmission case and install the transmission case.
    GFD267787Courtesy of FORD MOTOR COMPANY
  19. Install new bearing retainer bolts.

    Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 24 lb.ft (32 Nm)

    GFD267788Courtesy of FORD MOTOR COMPANY
  20. Install the special tool. Use Special Service Tool: 307-580 Holding Fixture.
    GFD267720Courtesy of FORD MOTOR COMPANY
  21. Remove Special Service Tool: 307-680 Table, Assembly (DPS6).
    GFD267789Courtesy of FORD MOTOR COMPANY
  22. Install the magnet.
    GFD267718Courtesy of FORD MOTOR COMPANY
  23. Install the small clock gears.
    GFD267790Courtesy of FORD MOTOR COMPANY
  24. Install the large clock gears.
    GFD267791Courtesy of FORD MOTOR COMPANY
  25. Install the park pawl.
    GFD267714Courtesy of FORD MOTOR COMPANY
  26. NOTE: Make sure that the pawl pin is aligned to the actuation shaft guide.

    Install the park pawl actuator shaft assembly.

    GFD267713Courtesy of FORD MOTOR COMPANY
  27. Install the differential.
    GFD267717Courtesy of FORD MOTOR COMPANY
  28. NOTE: The following 8 steps are only required when replacing the differential housing bearings.

    Install the differential bearing cup on the bearing.

    GFD267792Courtesy of FORD MOTOR COMPANY
  29. Install the special tools on the transmission case. Use Special Service Tool: 307-681 Differential Bearing Preload Tool, 308-164 (T88C-77000-JF) Shim Selection Set.
    GFD267793Courtesy of FORD MOTOR COMPANY
  30. Install the clutch housing on the special tool. Use Special Service Tool: 307-681 Differential Bearing Preload Tool.

    Torque: 159 lb.in (18 Nm)

    GFD267794Courtesy of FORD MOTOR COMPANY
  31. Rotate the special tool to seat the bearing cup. Use Special Service Tool: 307-681 Differential Bearing Preload Tool.
    GFD267795Courtesy of FORD MOTOR COMPANY
  32. Tighten the bolt on the special tool. Use Special Service Tool: 307-681 Differential Bearing Preload Tool.
    GFD267796Courtesy of FORD MOTOR COMPANY
  33. Using a feeler gauge, measure record the clearance at the 3 locations shown. Average the 3 measurements. Use the General Equipment: Feeler Gauge
    GFD267797Courtesy of FORD MOTOR COMPANY
  34. Remove the special tools.
  35. NOTE: The shim size is the average of the 3 measurements.
    NOTE: Using the average of the recorded measurements, select the appropriate shim from the shim selection chart in Specifications .

    Use the Differential Shim Selection Chart in specifications to select the correct shim. Install the selected shim into the clutch housing. Refer to: Specifications .

    GFD267798Courtesy of FORD MOTOR COMPANY
  36. Using the special tools install the differential bearing cup in the clutch housing. Use Special Service Tool: 204-594 Forcing screw, 205-118 (T77F-4222-A) Differential bearing cap installer, 307-671 Installer, Axle Seal.
    GFD267799Courtesy of FORD MOTOR COMPANY
  37. Apply a 1 mm bead of silicone to the transmission case.

    Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    GFD267800Courtesy of FORD MOTOR COMPANY
  38. NOTE: Make sure that a new component is installed.

    Install a new input shaft bearing. Use Special Service Tool: 204-594 Forcing screw, 205-118 (T77F-4222-A) Differential bearing cap installer, 205-425 Installer, Differential Carrier Seal LH.

    GFD267801Courtesy of FORD MOTOR COMPANY
  39. Install the input shaft bearing retainer and new bolts.

    Torque: 97 lb.in (11 Nm)

    GFD267802Courtesy of FORD MOTOR COMPANY
  40. NOTE: Take extra care not to overheat the bearing.

    Using a heat gun, heat the input shaft inner bearing race. Use the General Equipment: Hot Air Gun

    GFD267803Courtesy of FORD MOTOR COMPANY
  41. NOTE: Be sure that the park pawl detent is NOT already installed when installing the clutch housing on the transmission case. If the transmission was disassembled for a repair that did not require complete transmission disassembly, the park pawl detent must be removed before installing the clutch housing or damage to the park pawl actuator shaft will occur.

    Install the clutch housing on the transmission case.

    GFD267804Courtesy of FORD MOTOR COMPANY
  42. Tap the clutch housing down onto the transmission case. Use Special Service Tool: 307-672 Installer, Input Guide and Seal.
    GFD267805Courtesy of FORD MOTOR COMPANY
  43. NOTE: Fastener quantity varies with application.

    Install the transmission case bolts.

    Torque: 20 lb.ft (27 Nm)

    GFD267706Courtesy of FORD MOTOR COMPANY
  44. NOTE: Fastener quantity varies with application.

    Install the transmission case bolts.

    Torque: 20 lb.ft (27 Nm)

    GFD267705Courtesy of FORD MOTOR COMPANY
  45. Using a brass punch, gently tap in the park plunger into the transmission case. Install the park plunger plug. Use the General Equipment: Punch

    Torque: 32 lb.ft (43 Nm)

    GFD267806Courtesy of FORD MOTOR COMPANY
  46. NOTE: Make sure that the component is clean and free of foreign material.

    Using the special tool, install a new shift lever seal. Install Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal.

    Torque: 133 lb.in (15 Nm)

    GFD267582Courtesy of FORD MOTOR COMPANY
  47. NOTE: Make sure that a new component is installed.

    Install a new manual lever and install a new bolt.

    Torque: 19 lb.ft (26 Nm)

    GFD267807Courtesy of FORD MOTOR COMPANY
  48. Using a punch, install a new clutch housing plug. Install the plug so it is level with the chamfer of the outer diameter of the plug hole.
    GFD267808Courtesy of FORD MOTOR COMPANY
  49. NOTE: Make sure that a new component is installed.

    Install a new input shaft snap ring.

    GFD267809Courtesy of FORD MOTOR COMPANY
  50. Using the special tools, install a new input shaft case seal. Use Special Service Tool: 307-672 Installer, Input Guide and Seal.
    GFD267810Courtesy of FORD MOTOR COMPANY
  51. Using the special tools, install a new hollow input shaft seal. Use Special Service Tool: 307-674 Installer, Outer Input Seal.
    GFD267811Courtesy of FORD MOTOR COMPANY
  52. NOTE: Make sure that the bolt heads are not protruding above the housing surface.

    Install the guide tube and the bolts.

    Torque: 71 lb.in (8 Nm)

    GFD267812Courtesy of FORD MOTOR COMPANY
  53. Install the following items:

    1. Install the clutch actuator. Refer to: Clutch Actuator .
    2. Install the clutch and damper unit. Refer to: Clutch and Damper Unit .
    3. Install the clutch actuator motor. Refer to: Clutch Actuator Motor .
    4. Install the ISS sensor. Refer to: Input Shaft Speed (ISS) Sensor .
    5. Install the OSS sensor. Refer to: Output Shaft Speed (OSS) Sensor .
    6. Install the TR sensor. Refer to: Transmission Range (TR) Sensor .
    7. Install the TCM. Refer to: Transmission Control Module (TCM) .

  54. Install the transmission wiring harness.
    GFD267699Courtesy of FORD MOTOR COMPANY
  55. Inspect the LH halfshaft seal surface for damage or debris.
    GFD267525Courtesy of FORD MOTOR COMPANY
  56. Using the special tools, install a new LH halfshaft seal. Install Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-671 Installer, Axle Seal.
    GFD267526Courtesy of FORD MOTOR COMPANY
  57. Inspect the RH halfshaft seal surface for damage or debris.
    GFD267535Courtesy of FORD MOTOR COMPANY
  58. Using the special tools, install a new RH halfshaft seal. Install Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-671 Installer, Axle Seal.
GFD267536Courtesy of FORD MOTOR COMPANY
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