Transmission Case Reseal

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-001 (T50T-100-A) Slide Hammer
Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-D020 (D80L-100-R) Collet, 7/8 to 1
Courtesy of FORD MOTOR COMPANY	307-091 Handle, Torque Converter TKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	307-300 Gauge Bar, Shim Selection TKIT-1994-LMH/MH2TKIT-1994-FTKIT-1994-FLM/FM
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR)TKIT-1997-F/FLM/LT
Courtesy of FORD MOTOR COMPANY	307-575 Converter Seal Installer TKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	307-585 Support seal installer TKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	307-758 Installer, Axle Seal -FWD
Courtesy of FORD MOTOR COMPANY	307-773 Bench Mount Fixture
Puller
Caliper Gauge

Materials 

Repair 

1. Remove the transmission. Refer to: Transmission  .
2. For information on component views and base part numbers. Refer to: Transmission Description .
3. Using the special tool, install the transmission onto the bench. Use Special Service Tool: 307-773 Bench Mount Fixture.

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4. Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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5. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.

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

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6. Remove and discard the halfshaft seal from the transmission case.

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7. NOTE: FWD vehicles

   Remove and discard the halfshaft seal from the torque converter housing.

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8. Remove and discard the torque converter hub seal from the torque converter housing. Use the General Equipment: Puller

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9. Remove the studbolts and the main control cover.

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10. Unlock and disconnect the TR sensor.

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11. Unlock and disconnect the OSS sensor electrical connector.

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12. Unlock and disconnect the bulkhead electrical connector.

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13. Remove the transmission wiring harness bolts.

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14. NOTE: Handle the main control with care or damage to the solenoid body may occur.
    NOTE: Note the location of the different length bolts for assembly.

    Remove the bolts and the main control.

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15. Remove the bolt and the OSS sensor.

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16. Remove the bolt and the TSS sensor.

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17. Remove the bolts and the cover assembly.

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18. Remove the secondary fluid filter.

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19. Remove the cover assembly gasket.

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20. Remove the No. 1 thrust bearing.

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21. Remove the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and turbine shaft assembly.

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22. Remove the No. 3 thrust bearing.

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23. Remove the intermediate clutch shell and sun gear assembly.

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24. Remove the C (3, 7) clutch pack assembly.

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25. Remove the No. 4 thrust bearing.

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26. Remove the F (2, 8) clutch sun gear and shell assembly.

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27. Remove the C (3, 7)/F (2, 8) clutch pressure plate.

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28. Remove the reaction/overdrive carrier sun gear.

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29. Remove the No. 5 thrust bearing.

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30. Remove the reaction/overdrive planetary carrier assembly.

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31. Remove the F (2, 8) clutch pack assembly.

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32. Remove the F (2, 8) clutch reaction plate.

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33. Remove the following items.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing

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34. Remove the input sun gear.

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35. Unlock and disconnect the electronic Selectable One-Way Clutch (SOWC) and the Intermediate Speed Sensor (ISS) electrical connector.
    1. Connector lock
    2. Connector release

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36. Remove the electronic Selectable One-Way Clutch (SOWC) snap ring.

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37. Remove the electronic Selectable One-Way Clutch (SOWC) assembly.

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38. Remove the input planetary carrier assembly.

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39. Remove the following items.
    1. No. 9 thrust bearing
    2. No. 10 thrust bearing

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40. Remove the output planetary carrier assembly.

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41. Remove the A (1, 2, 3, 4, 5) clutch snap ring.

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42. Remove the A (1, 2, 3, 4, 5) clutch pressure plate.

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43. Remove the A (1, 2, 3, 4, 5) clutch pack assembly.

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44. Remove the output sun gear and shell assembly.

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45. Remove the No. 12 thrust bearing.

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46. Remove the output planetary carrier hub.

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47. Remove the No. 13 thrust bearing.

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48. NOTE: Note the location of the studbolts for assembly.

    Remove the torque converter housing bolts.

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49. Pry the torque converter housing loose from the transmission case.

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50. Remove the torque converter housing from the transmission case.

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51. Remove and discard the pump-to-case seal.

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52. Remove and discard the transmission fluid auxiliary pump to torque converter housing seal.

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53. Remove and discard the stator support assembly seal.

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54. Remove and discard the input shaft seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 303-D020 (D80L-100-R) Collet, 7/8 to 1.

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55. Install a new input shaft seal on the special tool. Use Special Service Tool: 307-585 Support seal installer.

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56. Using the special tool, install the input shaft seal. Use Special Service Tool: 307-585 Support seal installer.

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57. Install a new stator support assembly seal.

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58. Install a new pump-to-case seal.

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59. 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. Refer to: RTV Sealing Surface Cleaning and Preparation .

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60. NOTE: Make sure the sealing surface of both the transmission case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transmission case.

    Apply a bead of silicone sealant to the machined surface of the transmission case.

    Material

    : Motorcraft® Ultra Silicone Sealant / TA-29

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61. NOTE: Hand tighten the bolts only.

    Install the torque converter housing on top of the transmission case and install the bolts.

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62. NOTE: Install the studbolts in the correct location as noted during disassembly.

    Tighten the bolts in the sequence shown.

    Torque

    : 24 lb.ft (32 Nm)

    Fig 1: Torque Converter Housing Bolts Tightening Sequence

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63. Install a new halfshaft seal on special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-758 Installer, Axle Seal -FWD.

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64. Using the special tool, install the halfshaft seal in the transmission case (1177). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-758 Installer, Axle Seal -FWD.

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65. Install the A (1, 2, 3, 4, 5) clutch pack without the seperator springs.

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66. Install the A (1, 2, 3, 4, 5) clutch pack pressure plate.

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67. Install the A (1, 2, 3, 4, 5) clutch snap ring with the gap at approximately the 5:30 position.

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68. Install the special tool on the transmission case and position plunger on the A (1, 2, 3, 4, 5) clutch pressure plate. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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69. Apply 483 kPa (70 psi) of air pressure to the A (1, 2, 3, 4, 5) clutch piston port while recording the clutch pack clearance on the dial indicator. Measure and record in three places for an average reading. The clearance should be between 0.39 mm (0.015 in) and 1.82 mm (0.071 in). If the clearance is out of range, check the A (1, 2, 3, 4, 5) clutch pack for correct installation. If the A (1, 2, 3, 4, 5) clutch pack is correctly installed, install a new A (1, 2, 3, 4, 5) clutch pack. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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70. Remove the special tool. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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71. Remove the A (1, 2, 3, 4, 5) clutch pressure plate snap ring.

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72. Remove the A (1, 2, 3, 4, 5) clutch pressure plate.

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73. Remove the A (1, 2, 3, 4, 5) clutch pack.

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74. Soak the A (1, 2, 3, 4, 5) clutch assembly in transmission fluid.

    Material

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

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75. Install the A (1, 2, 3, 4, 5) clutch pack without the seperator springs.

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76. Install the A (1, 2, 3, 4, 5) clutch pack pressure plate.

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77. Install the A (1, 2, 3, 4, 5) clutch snap ring with the gap at approximately the 5:30 position.

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78. Install the No. 13 thrust bearing.

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79. Install the output carrier hub.

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80. Install the No. 12 thrust bearing.

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81. Install the output sun gear and shell assembly.

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82. Install the electronic Selectable One-Way Clutch (SOWC).

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83. NOTE: The snap ring gap should be at the 7 o'clock position.

    Install the electronic Selectable One-Way Clutch (SOWC) snap ring.

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84. Connect and lock the electronic Selectable One-Way Clutch (SOWC) and the Intermediate Speed Sensor (ISS) electrical connector.
    1. Connector lock
    2. Connector release

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85. Install the output planetary carrier assembly.

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86. Install the following items.
    1. No. 9 thrust bearing
    2. No. 10 thrust bearing

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87. Install the input planetary carrier assembly.

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88. Install the input sun gear.

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89. Install the following items.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing

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90. Install the reaction planetary carrier assembly.

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91. Install the reaction/overdrive sun gear.

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92. Install the F (2, 8) clutch reaction plate.

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93. NOTE: The F (2, 8) clutch wave plate and separator plate are temporarily reversely installed to measure the F (2, 8) clutch clearance.

    Install the F (2, 8) clutch assembly with the wave plate and the separator plate reversed.

    1. Wave plate
    2. Separator plate

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94. Using the special tool and a depth gauge, measure and record as measurement A, the distance from the transmission case deck surface to the F (2, 8) clutch top plate. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection. Use the General Equipment: Caliper Gauge

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95. Using the special tool and a depth gauge, measure and record as measurement B, the distance from the F (2, 8) clutch piston to the cover assembly deck surface. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection. Use the General Equipment: Caliper Gauge

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96. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the F (2, 8) clutch clearance. The clearance should be between 0.80 mm (0.031 in) and 2.31 mm (0.090 in). If the clearance is out of range, check the F (2, 8) clutch pack for correct installation. If the F (2, 8) clutch pack is correctly installed, install a new F (2, 8) clutch pack.

    Description	Reading
    Measurement A
    Measurement B
    Subtract measurement B from measurement A and add 1.6 mm (0.062 in), check to see if it is within range of 0.80 mm (0.031 in) and 2.31 mm (0.090 in)

97. Remove the F (2, 8) clutch assembly.

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98. Soak the F (2, 8) clutch assembly in transmission fluid.

    Material

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

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99. NOTE: When the F (2, 8) clutch is correctly installed, the wave plate is on top.

    Install the F (2, 8) clutch assembly.

    1. Wave plate
    2. Separator plate

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100. Install the C (3, 7)/F (2, 8) clutch pressure plate.

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101. NOTE: The C (3, 7) clutch wave plate and separator plate are temporarily reversely installed to measure the C (3, 7) clutch clearance.

     Install the C (3, 7) clutch assembly with the wave plate and the separator plate reversed.

     1. Wave plate
     2. Separator plate

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102. Using the special tool and a depth gauge, measure and record as measurement A, the distance from the transmission case deck surface to the C (3, 7) clutch top plate. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection. Use the General Equipment: Caliper Gauge

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103. Using the special tool and a depth gauge, measure and record as measurement B, the distance from the C (3, 7) clutch piston to the cover assembly deck surface. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection. Use the General Equipment: Caliper Gauge

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104. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the C (3, 7) clutch clearance. The clearance should be between 0.70 mm (0.027 in) and 1.90 mm (0.074 in). If the clearance is out of range, check the C (3, 7) clutch pack for correct installation. If the C (3, 7) clutch pack is correctly installed, install a new C (3, 7) clutch pack.

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in), check to see if it is within range of 0.70 mm (0.027 in) and 1.90 mm (0.074 in)

105. Remove the C (3, 7) clutch assembly.

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106. Install the No. 5 thrust bearing.

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107. Install the F (2, 8) clutch sun gear and shell assembly.

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108. Soak the C (3, 7) clutch in transmission fluid.

     Material

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

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109. NOTE: When the C (3, 7) clutch is correctly installed, the wave plate is on top.

     Install the C (3, 7) clutch pack assembly.

     1. Wave plate
     2. Separator plate

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110. Install the No. 4 thrust bearing.

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111. Install the B (4, 6, R)/C (3, 7) clutch hub.

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112. Install the No. 3 thrust bearing.

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113. Material: Petroleum Jelly Using petroleum jelly, install the No. 1 thrust bearing on the B (4, 6, R)/E (5, 6, 7, 8) clutch hub.

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114. Position the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and turbine shaft assembly in the cover assembly, install the dial indicator gauge plunger on the E (5, 6, 7, 8) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the E (5, 6, 7, 8) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.39 mm (0.015 in) and 1.82 mm (0.072 in). If the clearance is out of range, check the E (5, 6, 7, 8) clutch pack for correct installation. If the E (5, 6, 7, 8) clutch pack is correctly installed, install a new E (5, 6, 7, 8) clutch pack.

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115. Position the dial indicator gauge plunger on the B (4, 6, R) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the B (4, 6, R) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the B (4, 6, R) clutch pack for correct installation. If the B (4, 6, R) clutch pack is correctly installed, install a new B (4, 6, R) clutch pack.

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116. Install the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and turbine shaft assembly.

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117. Install the No. 1 thrust bearing.

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118. Inspect the cover assembly gasket for damage and install new if necessary (7B343).

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119. Install the secondary fluid filter (7B301).

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120. NOTE: Install the bolts hand tight.

     Install the cover assembly and bolts.

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121. Tighten the bolts in the sequence shown.

     Torque

     : 124 lb.in (14 Nm)

     Fig 2: Cover Assembly Bolts Tightening Sequence

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122. Material: Petroleum Jelly Lubricate the TSS sensor O-ring with petroleum jelly.

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123. Install the TSS sensor and bolt.

     Torque

     : 80 lb.in (9 Nm)

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124. Install the OSS sensor and bolt.

     Torque

     : 97 lb.in (11 Nm)

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125. NOTE: Note the location of the short and long main control valve body bolts. Install the bolts hand tight.

     Install the main control valve body, the transmission wiring harness and the main control valve body bolts.

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126. Tighten the main control valve body bolts in the sequence shown.

     Torque

     : 89 lb.in (10 Nm)

     Fig 3: Main Control Valve Body Bolts Tightening Sequence

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127. Install the transmission wiring harness bolts.

     Torque

     : 71 lb.in (8 Nm)

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128. Connect and lock the bulkhead electrical connector.

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129. Connect and lock the TR sensor electrical connector.

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130. Connect and lock the OSS sensor electrical connectors.

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131. Inspect the main control cover seal for damage and install new if necessary (7F396).

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132. NOTE: Install the studbolts hand tight.

     Install the main control cover and studbolts.

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133. Tighten the main control cover studbolts in the sequence shown.

     Torque

     : 106 lb.in (12 Nm)

     Fig 4: Main Control Cover Studbolts Tightening Sequence

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134. Install a new toque converter hub seal on the special tool. Use Special Service Tool: 307-575 Converter Seal Installer.

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135. Using the special tool, install the torque converter hub seal in the torque converter housing (7F401). Use Special Service Tool: 307-575 Converter Seal Installer.

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136. Using the special tool, install the RH halfshaft seal in the torque converter housing Use Special Service Tool: 307-758 Installer, Axle Seal -FWD., 205-153 (T80T-4000-W) Handle.

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137. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.

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

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138. Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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139. Remove the transmission from the bench-mounted holding fixture and the special tool. Use Special Service Tool: 307-773 Bench Mount Fixture.

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140. Install the transmission. Refer to: Transmission  .