Section 5 (Automatic Transmission - 8-Speed Automatic Transmission - 8F57 (2 Of 2)): Overhaul: Transmission
WARNING: This page is about a different variant/trim than selected.
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A) Slide Hammer | |
|---|---|
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
| 205-153 (T80T-4000-W) Handle | |
| 303-D020 (D80L-100-R) Collet, 7/8 to 1 | |
| 307-091 Handle, Torque Converter TKIT-2009TC-F | |
| 307-300 Gauge Bar, Shim Selection TKIT-1994-LMH/MH2TKIT-1994-FTKIT-1994-FLM/FM | |
| 307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR)TKIT-1997-F/FLM/LT | |
| 307-575 Converter Seal Installer TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings) TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-579 Support Solid seal installer (single seal) TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-581 Manual lever seal installer TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-582 A Cover Axle Seal Installer TKIT-2008AS-FLM | |
| 307-5842-6 Spring Compressor TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-585 Support seal installer TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-588 Reverse clutch piston and retaining ring set TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-589 Overdrive clutch and balance piston service set TKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 307-589-01Adapter for 307-589/1 | |
| 307-691 Tester, Torque Convertor Leak | |
| 307-732 Tool Kit, Torque Converter Flusher | |
| 307-753 Tester, Electric One Way Clutch | |
| 307-758 Installer, Axle Seal -FWD | |
| 307-773 Bench Mount Fixture | |
| Flat Headed Screw Driver | |
| Hydraulic Press | |
| Puller | |
| Wooden Block | |
| Caliper Gauge |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Ultra Silicone SealantTA-29 | - |
| Motorcraft® MERCON® ULV Automatic Transmission FluidXT-12-QULV | WSS-M2C949-A, MERCON® ULV |
| Petroleum Jelly | - |
All vehicles
- Using the special tool, install the transmission onto the bench. Use Special Service Tool: 307-773 Bench Mount Fixture.
- Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
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NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tool, remove the torque converter from the transmission. Use Special Service Tool: 307-091 Handle, Torque Converter.
- A new or remanufactured torque converter must be installed if one or more of the following statements are true:
- The sealing surface has a groove worn from the seal.
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, threaded pads, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of water or antifreeze contamination.
Flush The Torque Converter With The Transmission Cooling System Heated Flusher
-
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
- Check and top off the transmission fluid level of the transmission cooling system heated flusher with transmission fluid.
- Turn on the heater and allow the transmission fluid in the transmission cooling system heated flusher 15-30 minutes to heat up to 60 deg.C (140 deg.F) before using.
- Place the torque converter in an arbor press. Support the torque converter on the mounting pads.
- Using the special tools, assemble the correct turbine shaft simulator to the torque converter flush main hub and place it on the torque converter hub. Use Special Service Tool: 307-732 Tool Kit, Torque Converter Flusher.
- Using the special tool, install the slotted cap. Use Special Service Tool: 307-691 Tester, Torque Convertor Leak.
- Apply enough force from the press to seal the torque converter flush main hub to the torque converter hub.
- Connect the flush machine to the main hub.
- Red hose on top.
- Blue hose on bottom.
- Follow the equipment instructions to purge transmission fluid from the torque converter prior to starting the flushing procedure.
-
WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.NOTE: Maintain visual contact with torque converter during the entire flush procedure. Immediately stop the flush machine if a leak develops. Repeat set up steps to reseal the tool to the converter hub and continue flushing.
Forward flush the converter for 15 minutes.
- Monitor GPM flow meter periodically during the flush procedure. Flow rate above 2.0 gallons per minute is required to break up and dislodge any contamination trapped behind the TCC plate. Service flush machine filter(s) if flow rate drops below 2 GPM.
- Follow the equipment instructions to purge the torque converter.
-
WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.
Allow torque converter and equipment to cool for 30 minutes before handling.
- Disconnect the hoses and remove the special tools.
All vehicles
- Remove the studbolts and the main control cover.
- Unlock and disconnect the TR sensor.
- Unlock and disconnect the OSS sensor electrical connector.
- Unlock and disconnect the bulkhead electrical connector.
- Remove the transmission wiring harness bolts.
-
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.
- Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. Refer to: Main Control Valve Body .
- Remove the bolt and the OSS sensor.
- Remove the bolt and the TSS sensor.
- Remove the bolts and cover assembly.
- Remove and discard the secondary fluid filter.
- Remove the cover assembly gasket.
- Remove the No. 1 thrust bearing.
- Remove the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and turbine shaft assembly.
- Remove the No. 3 thrust bearing.
- Remove the B (4, 6, R)/ C (3, 7) clutch hub.
- Clean and inspect the B (4, 6, R)/ C (3, 7) clutch hub assembly for damage or wear, install new if necessary (7A019).
- Gear teeth
- Shell-to-clutch pack surfaces
- Thrust bearing surfaces
- Remove the C (3, 7) clutch pack assembly.
- Inspect the C (3, 7) clutch pack assembly for damage or excessive wear, install new if necessary (7F220) (7F219).
- Remove the No. 4 thrust bearing.
- Remove the F (2, 8) clutch sun gear and shell assembly.
- Inspect the F (2, 8) clutch sun gear and shell assembly for damage or excessive wear, install new if necessary (7D062).
- Remove the C (3, 7)/F (2, 8) clutch pressure plate.
- Inspect the C (3, 7)/F (2, 8) clutch pressure plate for damage or excessive wear, install new if necessary (7B437).
- Remove the reaction/overdrive carrier sun gear.
- Inspect the reaction/overdrive sun gear for damage or excessive wear, install new if necessary (7D063).
- Remove the No. 5 thrust bearing.
- Remove the reaction/overdrive planetary carrier assembly.
- Clean and inspect the reaction/overdrive planetary carrier assembly for damage or excessive wear, install new as necessary (7G224).
- Remove the F (2, 8) clutch pack assembly.
- Inspect the F (2, 8) clutch pack assembly for damage or excessive wear, install new if necessary (7G474) (7E313).
- Remove the F (2, 8) clutch reaction plate.
- Inspect the F (2, 8) clutch reaction plate for damage or excessive wear, install new if necessary (7A450).
- Remove the following items.
- No. 7 thrust bearing
- No. 8 thrust bearing
- Remove the input sun gear.
- Inspect the input sun gear for damage or excessive wear, install new if necessary (7G231).
- Unlock and disconnect the electronic Selectable One-Way Clutch (SOWC) solenoid and the Intermediate Shaft Speed (ISS) sensor electrical connector.
- Connector lock
- Connector release
- Remove the electronic Selectable One-Way Clutch (SOWC) snap ring.
- Remove the electronic Selectable One-Way Clutch (SOWC) assembly.
- Clean and inspect the electronic Selectable One-Way Clutch (SOWC) assembly for damage or excessive wear, install new as necessary (7P030).
- Remove the input planetary carrier assembly.
- Clean and inspect the input planetary carrier assembly for damage or excessive wear, install new as necessary (7L192).
- Remove the following items.
- No. 9 thrust bearing.
- No. 10 thrust bearing.
- Remove the output planetary carrier assembly.
- Clean and inspect the output planetary carrier assembly for damage or excessive wear, install new as necessary (7N473).
- Remove the A (1, 2, 3, 4, 5) clutch snap ring.
- Remove the A (1, 2, 3, 4, 5) clutch pressure plate.
- Inspect the A (1, 2, 3, 4, 5) clutch pressure plate for damage or excessive wear, install new if necessary (7J406).
- Remove the A (1, 2, 3, 4, 5) clutch pack.
- Inspect the A (1, 2, 3, 4, 5) clutch pack assembly for damage or excessive wear, install new if necessary (7E314) (7E311).
- Remove the A (1, 2, 3, 4, 5) clutch piston snap ring.
- Remove the A (1, 2, 3, 4, 5) clutch piston return spring.
- Remove the A (1, 2, 3, 4, 5) clutch piston.
- Remove the output sun gear and shell assembly.
- Inspect the output sun gear and shell assembly for damage or excessive wear, install new if necessary (7G304).
- Remove the No. 12 thrust bearing.
- Remove the output planetary carrier hub.
- Remove the No. 13 thrust bearing.
-
NOTE: Note the location of the stud bolts for assembly.
Remove the torque converter housing bolts and stud bolts.
- Pry the torque converter housing loose from the transmission case.
- Remove the torque converter housing from the transmission case.
- Remove the differential and ring gear assembly.
- Remove the transfer shaft and gear assembly.
-
NOTE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.
- Install new bearings or a ring gear on the differential if damage or excessive wear is found. Refer to: Differential .
- If the differential bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to: Torque Converter Housing .
- If the differential ring gear is replaced, the transfer shaft must also be replaced. Refer to: Transfer Shaft .
-
NOTE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
- Bearings
- Transfer shaft input gear
- Transfer shaft
- Park pawl wheel
- If the transfer shaft bearings are replaced the bearing races in the transmission case and the torque converter housing must also be replaced. Refer to: Transmission Case .
- If the transfer shaft is replaced, the differential ring gear must also be replaced. Refer to: Differential .
- Remove and discard the pump-to-case seal.
- Remove the bolts and the transmission fluid reservoir.
- Remove and discard the reservoir O-ring seal.
- Disconnect the park-by-wire return spring from the support bracket.
- Remove the bolt and the park-by-wire support bracket.
- Remove and discard the TR sensor roll pin.
- Remove the manual control shaft and lever.
- Rotate the TR sensor detent plate clockwise, remove the park pawl actuating rod from the TR sensor and remove the TR sensor.
- Remove the park pawl actuating rod.
- Disconnect the transmission fluid auxiliary pump electrical connector.
- Release and remove the transmission wiring harness.
- Remove and discard the transmission fluid auxiliary pump to torque converter housing seal.
- Remove the bolts and the transmission fluid auxiliary pump.
- Inspect the transmission fluid auxiliary pump to transmission case O-ring for damage, install new if necessary
- Remove and discard the manual lever shaft seal.
-
NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
If the transmission case side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to: Transmission Case .
- Remove and discard the halfshaft seal from the transmission case.
- Remove the bolt and the fluid baffle from the torque converter housing.
- Remove the bolts and the stator support assembly.
- Remove the bolts and the fluid pump and filter assembly.
-
NOTE: Note the orientation of the fluid filter to the fluid pump.
Remove and discard the fluid filter.
- Pull the filter out of the bore of the fluid pump.
- If the filter seal did not come off with the filter, remove and discard the seal from the pump.
- Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.
- Remove the fluid pump sprocket and chain assembly.
- Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
- Check the drive chain for wear, damage, stretching or tightness of the chain links.
- Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.
- Remove the fluid pump drive sprocket and driven sprocket thrust washers.
-
NOTE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.
If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. Refer to: Transmission Case .
-
NOTE: FWD vehicles
Remove and discard the halfshaft seal from the torque converter housing.
-
NOTE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.
If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. Refer to: Torque Converter Housing .
- Remove and discard the torque converter hub seal. Use the General Equipment: Puller
- Remove the E (5, 6, 7, 8) clutch snap ring.
- Remove the E (5, 6, 7, 8) clutch hub and clutch assembly.
- Remove the bottom clutch steel plate.
- Remove the No. 2 thrust bearing.
- Using the special tool, compress the E (5, 6, 7, 8) piston return spring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589-01 Adapter for 307-589/1. Use the General Equipment: Hydraulic Press
- With the E (5, 6, 7, 8) piston return spring compressed, remove the balance piston snap ring.
- Remove and discard the balance piston.
- Remove the E (5, 6, 7, 8) piston return spring.
- Using petroleum jelly, install the No. 1 thrust bearing on the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly.
- Install the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly in the rear cover.
- Apply air pressure to the E (5, 6, 7, 8) clutch piston port on the rear cover and remove the E (5, 6, 7, 8) clutch piston.
- Remove and discard the E (5, 6, 7, 8) clutch piston inner seal.
- Remove and discard the E (5, 6, 7, 8) clutch piston outer seals from the piston.
-
NOTE: Only compress the B (4, 6, R) clutch piston return spring far enough to take the tension from the B (4, 6, R) clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Using the special tools and a press, compress the B (4, 6, R) clutch piston return spring, and remove the snap ring.
- Do not contact the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and shaft assembly with the B (4, 6, R) clutch cylinder. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- Remove the snap ring.
- Using petroleum jelly, install the No. 1 thrust bearing on the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly.
Material
: Petroleum Jelly
- Position the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly in the cover assembly.
- Apply 483 kPa (70.05 psi) of air pressure to the B (4, 6, R) clutch piston port to remove the B (4, 6, R) clutch cylinder from the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly. Remove the B (4, 6, R)/E (5, 6, 7, 8) clutch assembly from the rear cover and remove the B (4, 6, R) clutch cylinder.
- Remove and discard the rear B (4, 6, R) clutch piston seal.
- Remove and discard the B (4, 6, R) clutch piston.
- Remove the B (4, 6, R) clutch piston return spring.
- Remove and discard the B (4, 6, R) clutch piston seals.
- Remove the B (4, 6, R) clutch snap ring.
- Remove the B (4, 6, R) clutch pressure plate, clutch assembly and wave spring.
- Clean and inspect the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and shaft assembly for damage, install new if necessary.
- Install the B (4, 6, R) clutch wave spring.
- Soak the B (4, 6, R) clutch assembly in transmission fluid.
Material
: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)
- Install the B (4, 6, R) clutch assembly and pressure plate.
- Install the B (4, 6, R) clutch snap ring.
- Install new B (4, 6, R) clutch piston seals and lubricate the seals with petroleum jelly (7C000).
Material
: Petroleum Jelly
- Install the B (4, 6, R) clutch piston return spring.
Material
: Petroleum Jelly
- Lubricate a new B (4, 6, R) clutch piston with petroleum jelly and install the piston (7F254).
- Install a new rear B (4, 6, R) clutch piston seal and lubricate it with petroleum jelly (7E056).
Material
: Petroleum Jelly
- Install the B (4, 6, R) clutch cylinder.
-
NOTE: Only compress the B (4, 6, R) clutch piston return spring far enough to install the B (4, 6, R) clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.NOTE: Align the tab on the B (4, 6, R) clutch cylinder with the slot on the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and shaft assembly.
Install the E (5, 6, 7, 8) Clutch.
- Do not contact the clutch hub and B (4, 6, R)/E (5, 6, 7, 8) clutch shaft assembly with the B (4, 6, R) clutch cylinder. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- Install the snap ring.
- Install new seals on the E (5, 6, 7, 8) clutch piston and lubricate the seals with petroleum jelly (7A548).
Material
: Petroleum Jelly
- Install a new E (5, 6, 7, 8) clutch piston inner seal and lubricate the seal with petroleum jelly (7J007).
Material
: Petroleum Jelly
- Using the special tool, push the E (5, 6, 7, 8) clutch piston in the cylinder by hand. Use Special Service Tool: 307-589-01 Adapter for 307-589/1.
-
NOTE: Install the E (5, 6, 7, 8) clutch piston return spring so that the holes are facing upward.
Install the E (5, 6, 7, 8) clutch piston return spring.
- Lubricate the seals on a new balance piston with petroleum jelly (7J029).
Material
: Petroleum Jelly
- Using the special tool, compress the E (5, 6, 7, 8) clutch piston return spring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589-01 Adapter for 307-589/1.
- Using a press, compress the E (5, 6, 7, 8) clutch piston return spring and install the snap ring.
- Install the No. 2 thrust bearing.
- Install the E (5, 6, 7, 8) clutch hub.
- Soak the E (5, 6, 7, 8) clutch assembly in transmission fluid.
Material
: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)
- Install the E (5, 6, 7, 8) clutch pack assembly and the pressure plate.
- Install the E (5, 6, 7, 8) clutch pack snap ring.
- Using the special tools, compress the C (3, 7) clutch return spring, using a press and remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor. Use the General Equipment: Hydraulic Press
- Remove the C (3, 7) clutch return spring.
- Remove and discard the C (3, 7) clutch piston.
- Using the special tools, compress the F (2, 8) clutch return spring and remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-588 Reverse clutch piston and retaining ring set. Use the General Equipment: Hydraulic Press
- Remove the F (2, 8) clutch return spring.
- Remove and discard the F (2, 8) clutch piston.
- Remove and discard the 4 Teflon® seals.
- Using the special tool, install the input shaft support seals (7C565). Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Using the special tool, size all 4 Teflon® seals. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Install the special tools. Use Special Service Tool: 307-588 Reverse clutch piston and retaining ring set.
- Align the piston bleed hole with the indentation in the cover. Using the special tools, lubricate and install the F (2, 8) clutch piston (7D402). Use Special Service Tool: 307-588 Reverse clutch piston and retaining ring set.
Material
: Petroleum Jelly
- Install the F (2, 8) clutch piston return spring with the tabs facing down.
-
NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Using the special tools, compress the F (2, 8) clutch piston return spring and install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-588 Reverse clutch piston and retaining ring set. Use the General Equipment: Hydraulic Press
- Lubricate the sealing surfaces on the C (3, 7) clutch piston with petroleum jelly.
Material
: Petroleum Jelly
- Install the C (3, 7) clutch piston (7F472).
- Install the C (3, 7) clutch piston return spring.
-
NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Using the special tool, compress the C (3, 7) clutch piston return spring, install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor. Use the General Equipment: Hydraulic Press
- Remove the special tool. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- Remove and discard the stator support assembly seal.
- 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.
- Remove the drive sprocket thrust washer.
- Remove and discard the stator support-to-torque converter seal.
-
NOTE: Note the location of the Torx® head and the hex head bolts for assembly.
Remove the bolts and the stator support feed tube.
- Remove and discard the gasket for the feed tube assembly.
- Clean and inspect the stator support assembly for damage and install new, if necessary.
- Install the drive sprocket thrust washer.
- Using the special tool, slide the seal in to the groove on the stator support assembly (7J475). Use Special Service Tool: 307-579 Support Solid seal installer (single seal).
- Using the special tool, size the seal. Use Special Service Tool: 307-579 Support Solid seal installer (single seal).
- Install a new gasket on the stator support assembly (7J246).
-
NOTE: Install the Torx® and the hex bolts in the correct locations as noted during disassembly.
Position the stator support feed tube assembly in place and install the bolts hand-tight.
- Tighten the stator support feed tube Torx® head bolts.
Torque
: 62 lb.in (7 Nm)
- Tighten the stator support feed tube hex-head bolts.
Torque
: 106 lb.in (12 Nm)
- Install a new input shaft seal on the special tool. Use Special Service Tool: 307-585 Support seal installer.
- Using the special tool, install the input shaft seal (7048). Use Special Service Tool: 307-585 Support seal installer.
- Install a new stator support assembly seal (7J246).
- Inspect the main control assembly for damage. If damage is found install a new main control assembly (7A100). If the main control assembly is not damaged, disassemble and clean it. Refer to: Main Control Valve Body
.
- Install a new manual control shaft seal on the special tool. Use Special Service Tool: 307-581 Manual lever seal installer.
- Lubricate a new manual shaft seal and the special tool with petroleum jelly and install the seal (7F337). Use Special Service Tool: 307-581 Manual lever seal installer.
Material
: Petroleum Jelly
- Install a new transmission fluid auxiliary pump to torque converter housing seal (7J135).
- Lubricate the transmission fluid auxiliary pump to transmission case O-ring.
Material
: Petroleum Jelly
- Install the transmission fluid auxiliary pump and bolts.
Torque
: 97 lb.in (11 Nm)
- Install the transmission wiring harness.
- Connect the transmission fluid auxiliary pump electrical connector.
- Slide the park pawl over and install the park pawl actuator rod.
-
- Position the park pawl actuating rod in the TR sensor.
- Position the TR sensor in the transmission case.
- Install the manual control shaft and lever.
- Install the TR sensor roll pin (7G100).
- Install the park-by-wire support bracket and bolt.
Torque
: 97 lb.in (11 Nm)
- Connect the park-by-wire return spring to the support bracket.
- Install a new O-ring, lubricate (7N142).
Material
: Petroleum Jelly
- Install the transmission fluid reservoir and the bolt.
Torque
: 106 lb.in (12 Nm)
- Install a new pump-to-case seal (7J246).
- Install the transfer shaft and gear assembly.
- Tilt the transfer shaft and gear assembly over and install the differential assembly.
- Install a new torque converter hub seal on the special tool. Use Special Service Tool: 307-575 Converter Seal Installer.
-
NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
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. Use the General Equipment: Wooden Block
-
NOTE: FWD vehicles
Install a new RH halfshaft seal on the special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
-
NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Using the special tool, install the RH halfshaft seal in the torque converter housing (1177). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-758 Installer, Axle Seal -FWD. Use the General Equipment: Wooden Block
- Install the pump drive sprocket and driven sprocket thrust washers.
-
NOTE: The dot on the pump sprocket is installed facing upward.
Install the pump sprocket and chain assembly.
- Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
Material
: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)
- Install a new fluid filter seal, lubricate (7A103).
Material
: Petroleum Jelly
-
NOTE: Install the filter in the correct orientation as noted in removal.
Install the new fluid filter in the fluid pump (7K172).
- Position the pump and filter assembly in place and install the bolts.
Torque
: 97 lb.in (11 Nm)
- Remove the special tool. Remove Special Service Tool: 307-579 Support Solid seal installer (single seal).
-
NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Position the stator support assembly in place on the torque converter housing and install the stator support bolts. Tighten in the sequence shown.
Torque
: 159 lb.in (18 Nm)
- Position the differential carrier baffle in place and install the bolt.
Torque
: 106 lb.in (12 Nm)
-
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 .
-
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
-
NOTE: Install the studbolts in the correct location as noted during disassembly. Install the bolts hand tight.
Install the torque converter housing on top of the transmission case and install the bolts.
- Tighten the torque converter bolts and in the sequence shown.
Torque
: 24 lb.ft (32 Nm)
- Install a new halfshaft seal on special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-758 Installer, Axle Seal -FWD.
- 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.
- Lubricate the A (1, 2, 3, 4, 5) clutch piston seals with petroleum jelly (7A262).
Material
: Petroleum Jelly
- Install the A (1, 2, 3, 4, 5) clutch piston in the transmission case.
- Install the A (1, 2, 3, 4, 5) clutch piston return spring with the tabs facing downward.
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NOTE: The snap ring gap should be at the 12 o'clock position.
Using a flat headed screw driver, install the A (1, 2, 3, 4, 5) clutch piston return spring snap ring. Use the General Equipment: Flat Headed Screw Driver
- Install the A (1, 2, 3, 4, 5) clutch pack without the seperator springs.
- Install the A (1, 2, 3, 4, 5) clutch pack pressure plate.
- Install the A (1, 2, 3, 4, 5) clutch snap ring with the gap at approximately the 5:30 position.
- Install the special tool on the transmission case and position the 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.
- 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.
- Remove the special tool. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Remove the A (1, 2, 3, 4, 5) clutch pressure plate snap ring.
- Remove the A (1, 2, 3, 4, 5) clutch pressure plate.
- Remove the A (1, 2, 3, 4, 5) clutch pack.
- 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)
- Install the A (1, 2, 3, 4, 5) clutch assembly with the seperator springs.
- Install the A (1, 2, 3, 4, 5) clutch pressure plate.
- Install the A (1, 2, 3, 4, 5) clutch snap ring with the gap at approximately the 5:30 position.
- Install the No. 13 thrust bearing.
- Install the output carrier hub.
- Install the No. 12 thrust bearing.
- Install the output sun gear and shell assembly.
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NOTE: Be sure to use the correct cable for proper solenoid operation.
Using the special tool with the blue adapter cable, test the electronic Selectable One-Way Clutch (SOWC) solenoid and strut. Verify the movement of the strut that locks the electronic Selectable One-Way (SOWC) in the counter-clockwise direction. Use Special Service Tool: 307-753 Tester, Electric One Way Clutch.
- Install the electronic Selectable One-Way Clutch (SOWC).
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NOTE: The snap ring gap should be at the 7 o'clock position.
Install the electronic Selectable One-Way Clutch (SOWC) snap ring.
- Connect and lock the electronic Selectable One-Way Clutch (SOWC) solenoid and the Intermediate Shaft Speed (ISS) sensor connector.
- Connector lock
- Connector release
- Install the output planetary carrier assembly.
- Install the following items.
- No. 9 thrust bearing.
- No. 10 thrust bearing.
- Install the input planetary carrier assembly.
- Install the input sun gear.
- Install the following items.
- No. 7 thrust bearing
- No. 8 thrust bearing
- Install the reaction planetary carrier assembly.
- Install the reaction/overdrive sun gear.
- Install the F (2, 8) clutch reaction plate.
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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.
- Wave plate
- Separator plate
- 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
- 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
- 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) - Remove the F (2, 8) clutch assembly.
- Soak the F (2, 8) clutch assembly in transmission fluid.
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NOTE: When the F (2, 8) clutch is correctly installed, the wave plate is on top.
Install the F (2, 8) clutch assembly.
- Wave plate
- Separator plate
- Install the C (3, 7)/F (2, 8) clutch pressure plate.
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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.
- Wave plate
- Separator plate
- 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
- 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
- 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) - Remove the C (3, 7) clutch assembly.
- Install the No. 5 thrust bearing.
- Install the F (2, 8) clutch sun gear and shell assembly.
- 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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NOTE: When the C (3, 7) clutch is installed correctly, the wave plate is on top.
Install the C (3, 7) clutch pack assembly.
- Wave plate
- Separator plate
- Install the No. 4 thrust bearing.
- Install the B (4, 6, R)/C (3, 7) clutch hub.
- Install the No. 3 thrust bearing.
- Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.
- 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.
- 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.
- Install the B (4, 6, R)/E (5, 6, 7, 8) clutch hub and turbine shaft assembly.
- Install the No. 1 thrust bearing.
- Inspect the cover assembly gasket for damage and install new if necessary (7B343).
- Install the secondary fluid filter (7B301).
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NOTE: Install the bolts hand tight.
Install the cover assembly and bolts
- Tighten the cover bolts in the sequence shown.
Torque
:Stage 1: 89 lb.in (10 Nm) Stage 2: 60 deg.
- Lubricate the TSS sensor O-ring with petroleum jelly.
Material
: Petroleum Jelly
- Install the TSS sensor and bolt.
Torque
: 80 lb.in (9 Nm)
- Install the OSS sensor and bolt.
Torque
: 97 lb.in (11 Nm)
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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.
- Tighten the main control bolts in the sequence shown.
Torque
: 89 lb.in (10 Nm)
- Install the transmission wiring harness bolts.
Torque
: 71 lb.in (8 Nm)
- Connect and lock the bulkhead electrical connector.
- Connect and lock the TR sensor electrical connector.
- Connect and lock the OSS sensor electrical connectors.
- Inspect the main control cover seal for damage and install new if necessary (7F396).
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NOTE: Install the bolts hand tight.
Install the main control cover and the stud bolts.
- Tighten the main control cover studbolts in the sequence shown.
Torque
: 106 lb.in (12 Nm)
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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.
- Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
- Remove the transmission from the bench-mounted holding fixture and the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.