Section 596 (Automatic Transmission - 6R80): Assembly: Transmission
WARNING: This page is about a different car, the 2017 Lincoln Navigator and 2017 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
Special Tool (s)
| Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) | |
| Drawbar (Heavy Duty Threaded) 204-029 (T77F-1176) | |
| End Play Gauge, Transmission 307-534 | |
| Handle, Torque Converter 307-091 (T81P-7902-C) | |
| Installer, Fluid Pump Seal 307-556 | |
| Installer, Front Wheel Hub Oil Seal 205-276 (T88T-1175-AH) | |
| Installer, Needle Bearing 307-714 | |
| Installer, Output Seal (4X2) 307-715 | |
| Installer, 6R80 Rear Seal 4X4 307-637 | |
| Installer, Roller Bearing 307-713 | |
| Installer, Shifter Fluid Seal 307-559 | |
| Installer, Spindle/Axle Shaft 205-199 (T83T-3132-A1) | |
| Remover, Transmission Fluid Pump 307-553 | |
| Retaining Ring Pliers 307-343 (T95P-77001-AHR) |
Material
| Item | Specification |
| Motorcraft ® MERCON ® LV Automatic Transmission Fluid XT-10-QLVC (US); CXT-10-LV12 (Canada) | MERCON ® LV |
| Motorcraft ® 6R ATF Additive Kit XL-16 | - |
Disassembled Views
| Item | Part Number | Description |
|---|---|---|
| 1 | N800750-S437-S437 | Flexplate-to-torque converter nut (4 required) |
| 2 | 7902 | Torque converter |
| 3 | 7A103 | Pump assembly |
| 4 | 7A248 | Front pump oil seal |
| 5 | - | Pump body (part of 7A103) |
| 6 | 7A248 | Front pump inner oil seal |
| 7 | 7N134 | Front pump-to-case bolt (13 required) |
| 8 | 7A103 | Front pump assembly |
| 9 | W707871-S300-S300 | Bolt - attaches pump to pump adapter assembly (11 required) |
| 10 | 7A248 | Front pump outer oil seal |
| 11 | 7D019 | Clutch support fluid seal |
| 12 | 7L323 | Front pump support seal |
| 13 | - | Forward (A) clutch assembly |
| 14 | 7D014 | Front pump selective washer |
| 15 | 7A360 | Forward (A) clutch cylinder and hub assembly |
| 16 | 7A548 | Forward (A) clutch inner piston seal |
| 17 | 7A548 | Forward (A) clutch outer piston seal |
| 18 | 7A262 | Forward (A) clutch piston |
| 19 | 7A480 | Forward (A) clutch piston retaining spring |
| 20 | 7H360 | Forward (A) clutch balance piston assembly |
| 21 | 7A548 | Forward (A) clutch balance piston outer seal |
| 22 | 7H365 | Forward (A) clutch balance piston snap ring |
| 23 | 7E085 | Forward (A) clutch cushion spring |
| 24 | 7E314 | Forward (A) clutch steel plates (externally splined) (quantity model dependent) |
| 25 | 7B164 | Forward (A) clutch friction plates (internally splined) (quantity model dependent) |
| 26 | 7B066 | Forward (A) clutch pressure plate |
| 27 | 7D483 | Pressure plate retaining snap ring |
| 28 | 7D063 | Front planetary sun gear (No. 1) |
| 29 | 7H375 | Bearing (T1) |
| 30 | - | Front planetary carrier assembly snap ring (part of 7A398) |
| 31 | 7A398 | Front planetary carrier assembly |
| 32 | 7L339 | Plate transmission fluid collector |
| 33 | 7L495 | Bearing (T2) |
| 34 | - | Overdrive (E) clutch assembly |
| 35 | 7G091 | Turbine shaft seals (3 required) |
| 36 | 7F207 | Input shaft |
| 37 | 7A548 | Overdrive (E) clutch piston outer seal |
| 38 | 7A548 | Overdrive (E) clutch piston inner seal |
| 39 | 7A262 | Overdrive (E) clutch piston |
| 40 | 7B070 | Overdrive clutch piston spring |
| 41 | 7A548 | Balance piston outer seal |
| 42 | 7H360 | Overdrive (E) balance piston |
| 43 | 7C122 | Balance piston snap ring |
| 44 | 7B442 | Overdrive (E) clutch steel plates (externally splined) |
| 45 | 7B164 | Overdrive (E) clutch friction plates (internally splined) |
| 46 | 7B066 | Overdrive (E) pressure plate |
| 47 | 7D483 | Overdrive (E) clutch retaining ring |
| 48 | 7C096 | Bearing (T3) |
| 49 | 7F351 | Intermediate (C) clutch shaft |
| 50 | 7H375 | Bearing (T4) |
| 51 | 7B067 | Sun gear hub and shaft assembly |
| 52 | 7F236 | Direct (B) clutch hub |
| 53 | 7C122 | Direct (B) clutch cylinder retaining ring |
| 54 | 7D483 | Direct (B) clutch pressure plate retaining ring |
| 55 | - | Direct (B) clutch assembly (clutch B) |
| 56 | 7B066 | Direct (B) clutch pressure plate |
| 57 | 7B164 | Direct (B) clutch friction plates (internally splined) (quantity model dependent) |
| 58 | 7B442 | Direct (B) clutch steel plates (externally splined) (quantity model dependent) |
| 59 | 7E085 | Direct (B) clutch cushion plate |
| 60 | 7C096 | Roller bearing (T5) |
| 61 | 7A577 | Direct (B) clutch piston retaining ring |
| 62 | 7A262 | Direct (B) clutch balance piston |
| 63 | 7A548 | Direct (B) clutch balance seal |
| 64 | 7B488 | Direct (B) clutch piston return spring |
| 65 | - | Direct (B) clutch piston |
| 66 | 7A548 | Direct (B) clutch piston outer seal |
| 67 | 7C099 | Direct (B) clutch piston inner seal |
| 68 | 7F283 | Direct (B) clutch cylinder |
| 69 | 7D020 | Shell cylinder seals (2 required) |
| 70 | 7D483 | Center support retaining ring |
| 71 | - | Intermediate (C) clutch assembly |
| 72 | 7D483 | Intermediate (C) clutch pressure plate retaining ring |
| 73 | 7B066 | Intermediate (C) clutch pressure plate |
| 74 | 7B442 | Intermediate (C) clutch steel plates (externally splined) (quantity model dependent) |
| 75 | 7B164 | Intermediate (C) clutch friction plates (internally splined) (quantity model dependent) |
| 76 | 7E085 | Intermediate (C) clutch pressure plate spring |
| 77 | 7A577 | Intermediate (C) clutch retaining ring |
| 78 | 7B043 | Intermediate (C) clutch ring |
| 79 | 7A480 | Intermediate (C) clutch piston spring |
| 80 | 7E005 | Intermediate (C) clutch piston |
| 81 | 7F225 | Intermediate (C) clutch piston inner seal |
| 82 | 7F224 | Intermediate (C) clutch piston outer seal |
| 83 | 7F373 | Bearing (T6) |
| 84 | 7B220 | Center support keys (2 required) |
| 85 | 7G199 | Center support feed tube seal (black) |
| 86 | 7G087 | Center support feed tube seal (green or orange) |
| 87 | 7G084 | Center support feed tube seal (blue) |
| 88 | 7G033 | Center support assembly |
| 89 | 7D404 | Low/reverse clutch piston center seal |
| 90 | 7D403 | Low/reverse clutch piston outer seal |
| 91 | 7A262 | Low/reverse clutch piston |
| 92 | 7B070 | Low/reverse clutch piston return spring |
| 93 | 7H318 | Low/reverse clutch piston retainer |
| 94 | 7D483 | Retainer transmission-snap ring |
| 95 | 7E085 | Clutch disc cushion plate |
| 96 | 7B442 | Low/reverse clutch steel plates (externally splined) |
| 97 | 7B164 | Low/reverse clutch friction plates (internally splined) |
| 98 | 7B066 | Low/reverse clutch pressure plate (select fit) |
| 99 | 7A089 | OWC |
| 100 | 7F405 | Thrust gear shim (select fit) |
| 101 | 7C041 | Thrust bearing (T7) |
| 102 | 7D063 | Sun gear No. 2 |
| 103 | 7D235 | Thrust bearing outer race |
| 104 | 7D234 | Roller bearing (T8) |
| 105 | 7D063 | Sun gear No. 3 |
| 106 | 7D234 | Roller bearing (T9) |
| 107 | - | Roller bearing race (T9) |
| 108 | 7D006 | Rear planetary carrier assembly |
| 109 | - | Fluid collar rear planetary plate (part of 7D006) |
| 110 | 7A153 | Output shaft ring gear assembly |
| 111 | 7G178 | Thrust Bearing (T10) |
| 112 | 7060 | Output shaft park gear assembly |
| 113 | 7N194 | Output shaft retaining ring |
| 114 | 7B368 | Bearing (T11) |
| 115 | 7005 | Transmission case assembly (model dependent) |
| 116 | 7A010 | Transmission case fluid fill plug assembly |
| 117 | 7H398 | Transmission case fluid fill plug |
| 118 | 7A010 | Transmission case fluid fill seal |
| 119 | 7A010 | Transmission oil level indicator |
| 120 | 7034 | Transmission case vent assembly (model dependent) |
| 121 | 7A415 | Output shaft bearing assembly (all models) |
| 122 | 7030 | Output shaft bearing snap ring (all models) |
| 123 | 7052 | Output shaft seal (4WD) |
| 124 | 7R205 | Output shaft ball bearing (RWD) |
| 125 | 7030 | Output shaft ball bearing snap ring (RWD) |
| 126 | 7N135 | Slip plane washer (RWD) |
| 127 | 7052 | Output shaft seal (RWD) |
| 128 | 7A021 | Output shaft flange (RWD) |
| 129 | 7052 | Output shaft flange seal (RWD) |
| 130 | 7045 | Output shaft flange retaining nut (RWD) |
| 131 | 7E332 | Manual valve detent spring |
| 132 | W711235-S300-S300 | Manual valve detent spring retaining screw and washer |
| 133 | 7A232 | Park pawl actuator rod |
| 134 | 7A441 | Park pawl |
| 135 | 7D070 | Park pawl return spring |
| 136 | 7D071 | Park pawl shaft |
| 137 | 7H398 | Plug assembly transmission case housing |
| 138 | 7G101 | Park rod actuating plate |
| 139 | W711235-S300-S300 | Park pawl abutment retaining screw and washer |
| 140 | W708455-S441-S441 | Manual control lever nut |
| 141 | 7A256 | Manual control lever |
| 142 | 7B498 | Manual control lever shaft seal |
| 143 | 7C493 | Manual control lever shaft |
| 144 | 7A209 | Manual control lever shaft spacer |
| 145 | 7A115 | Manual valve detent lever assembly |
| 146 | 7G100 | Manual valve detent lever retaining pin |
| 147 | 7F277 | OWC bias spring |
| 148 | 7H322 | Thermal bypass valve |
| 149 | 7F401 | Front pump adapter seal |
| 150 | 7A100 | Main control assembly |
| 151 | - | Main control valve body assembly (part of 7A100) |
| 152 | 7Z490 | Main control valve body separator plate |
| 153 | - | Lower main control valve body (part of 7A100) |
| 154 | 7G276 | Molded leadframe |
| 155 | 7G276 | Bulkhead connector sleeve |
| 156 | 7A248 | Bulkhead connector sleeve seals |
| 157 | - | Transmission fluid filter seal (part of 7A098) |
| 158 | 7A098 | Transmission fluid filter |
| 159 | - | Transmission fluid pan magnet |
| 160 | 7A191 | Transmission fluid pan gasket |
| 161 | 7A194 | Transmission fluid pan |
| 162 | W500214-S437-S437 | Transmission fluid pan bolt |
NOTE:
Clutch plate quantity is model dependent based on engine displacement. Refer to Clutch Plate Quantity chart in the Specifications .
All vehicles
- 2.
Position the park pawl and spring into the case and install the park pawl pin.- 1.
Park pawl
- 2.
Park pawl return spring
- 3.
Park pawl pin
- 1.
- 7.
Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.
- 8.
Position the manual control lever spacer in place and slide the manual control lever shaft into the case and the manual lever detent plate.- 1.
Manual control lever spacer
- 2.
Manual control lever shaft
- 3.
Manual control lever detent plate
- 1.
- 9.
Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual control lever shaft and install a new roll pin.
- 11.
If removed, position a new bearing on the Needle Bearing Installer. Install the bearing with the flat bearing surface facing down and the rounded bearing surface facing up so that when installed, the flat surface is on the snap ring side and the rounded surface is on the transmission case side.- 1.
Rounded bearing surface facing up
- 2.
Flat bearing surface facing down
- 1.
- 12.NOTE: RWD case shown, 4WD case similar.
Assemble the Front Wheel Hub Oil Seal Installer and the Needle Bearing Installer on the Drawbar and install the bearing in the transmission case.
Rear Wheel Drive (RWD) vehicles
- 15.
Assemble the Front Wheel Hub Oil Seal Installer and the Roller Bearing Installer on the Drawbar and install the bearing in the transmission case.
All vehicles
- 22.NOTE: When installing the sun gear, make sure that the TAPERED EDGE is facing UP toward the torque converter housing.
Install the sun gear into the planetary assembly.
- 23.NOTE: Be sure the bearing race is installed in the sun gear.
Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing down.
- 1.
Low/reverse sun gear
- 2.
Bearing race
- 1.
- 24.NOTE: Place the manual control lever in PARK when installing the rear planetary gearset to hold the rear ring gear stationary.
Install the planetary carrier.
- 25.NOTE: Friction and steel plate quantity are model dependent and vary based on engine displacement. For additional information, refer to the Clutch Plate Quantity Chart in the Specifications .
Soak the low/reverse clutch plates in clean automatic transmission fluid.
- 26.
Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates and ending with the wave spring plate on the top.
- 27.NOTE: Inspect the T7 thrust bearing and selective shim for damage or scoring.
Install the T7 thrust bearing and the selective shim.
- 28.NOTE: Align the OWC in the transmission case so the bias spring fits into the transmission case.
Install the OWC as shown so the bias spring can be installed as shown.
- 30.NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.
Install the center support into the case.
- 31.NOTE: Install the snap ring with the beveled surface facing up and the snap ring gap in the 3 o'clock or the 9 o'clock position.NOTE: Rotate the case to a horizontal position.
Using the Retaining Ring Pliers, install the center support snap ring. Make sure the snap ring is fully seated.
Four-Wheel Drive (4WD) vehicles
- 33.
Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the output shaft seal protector.
Rear Wheel Drive (RWD) vehicles
- 36.
Position a new output shaft seal on the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer.
- 37.
Using the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer, install the output shaft seal.
Rear Wheel Drive (RWD) vehicles
- 40.
Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.
- 41.NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.
Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading. The reading should be within 0.6-0.9 mm (0.024-0.035 in).
- If the reading is not within specification, install a different (either thinner or thicker) selective shim.
- 43.
After installing the new output shaft flange retaining nut, stake the slots to prevent it from coming loose.
Four-Wheel Drive (4WD) vehicles
- 44.
Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft.
- 45.
Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).- If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
All vehicles
- 46.
Rotate the transmission in the vertical position with the torque converter housing facing up and install the T6 bearing.
- 51.
If the front pump was not disassembled and assembled, install a new front pump O-ring seal and lubricate it with petroleum jelly.
- 55.
Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover, position the pump assembly in the case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into the case.
- 56.NOTE: Failure to replace the fasteners will result in transmission fluid leakage.
Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.
- Tighten pump fasteners with washers to 10 Nm (89 lb-in).
- Tighten fasteners without washers to 10 Nm (89 lb-in).
- 57.
Install the Transmission End Play Gauge on the input shaft to measure the end play.- Tighten the wing nut.
- 58.
Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.- Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.
- Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump shim.
- Measure the original shim, install a thinner or a thicker shim to achieve the correct measurement.
- 59.
Rotate the transmission in the horizontal position with the main control area facing up and install 3 new center support feed tube seals.- 1.
Center support feed tube seal (7G199 Black)
- 2.
Center support feed tube seal (7G087 Green or Orange)
- 3.
Center support feed tube seal (7G084 Blue)
- 1.
- 60.NOTE: Make sure the transmission fluid filter seal has been removed. If it has not, use a pick and remove the seal.NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.
Install the front pump adapter seal and prime the fluid pump.
- 62.
Align the guide pins in the alignment holes in the transmission case and position the main control assembly in place.- 1.
Alignment holes
- 2.
Guide pins
- 1.
- 63.NOTE: The main control assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the main control assembly down.
Slightly lift the main control assembly and align the manual valve in the manual valve linkage and position the main control in place.
- 64.
Install the 11 main control assembly bolts and tighten in the sequence shown.- Tighten to 8 Nm (71 lb-in).
- 66.
With the release tab up and unlocked, push the outer shell of the bulkhead connector sleeve into the transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
- 67.
Press down on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure the locking tab is securely locked.
- 69.NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
- 70.
Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.- Tighten to 9 Nm (80 lb-in).
- 73.NOTE: Only 9-10 ml of the 6R ATF Additive Kit XL-16 kit should be used after all of the fluid has been replaced in the transmission or if the overdrive frictions are replaced. Too much additive in the fluid can result in converter clutch slip issues.NOTE: The 6R ATF Additive Kit XL-16 kit contains two syringes. The syringe with additive "F" is to be used after all of the fluid has been replaced in the transmission or if the overdrive frictions are replaced. The syringe with additive "T" is a tracer that is part of the kit and is not used.
If the Overdrive clutch FRICTIONS were replaced, add 9-10 ml of Motorcraft ® 6R ATF Additive Kit XL-16 syringe with additive "F" to the transmission.