Section 1142 (Automatic Transmission - 5R110W (TORQSHIFT(R))): Disassembly: Transmission: Disassembly

All vehicles 

1. Remove the special tool.
Fig 1: Holding Torque Converter Using Special Tool
Courtesy of FORD MOTOR CO.
WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.
NOTE: Transmission fluid loss will occur when removing the torque converter.
2. Using the special tools, remove the torque converter.
Fig 2: Installing Torque Converter Using Special Tools
Courtesy of FORD MOTOR CO.
3. Remove the turbine shaft speed (TSS) and intermediate shaft speed combination sensor.
   1. Remove the bolt.
   2. Remove the sensor.
Fig 3: Identifying TSS And Intermediate Shaft Combination Speed Sensor
Courtesy of FORD MOTOR CO.
4. Remove the output shaft speed (OSS) sensor.
   1. Remove the bolt.
   2. Remove the OSS.
Fig 4: Identifying Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.
5. Mount the transmission onto a suitable stand.
6. Remove the input shaft.
Fig 5: Input Shaft And Stator Support Seal
Courtesy of FORD MOTOR CO.
7. Install a new transmission fluid drain plug and seal assembly if there is evidence of leaking.
Fig 6: Locating Transmission Fluid Pan Drain Plug
Courtesy of FORD MOTOR CO.
NOTE: Do not discard the transmission fluid pan gasket unless damaged. This is a reusable transmission fluid pan gasket.
8. Remove the transmission fluid pan and the gasket. Check and clean the magnet if foreign material is evident.
Fig 7: Locating Transmission Fluid Pan & Gasket
Courtesy of FORD MOTOR CO.
NOTE: After removal, discard the transmission fluid filter and seal assembly.
9. Remove the transmission fluid filter and seal assembly by carefully pulling and rotating the transmission fluid filter as necessary.
Fig 8: Locating Transmission Fluid Filter & Seal Assembly
Courtesy of FORD MOTOR CO.
NOTE: There is no retainer on the manual valve. Hold the manual valve in place while removing the solenoid assembly from the transmission to avoid dropping the valve.
10. Remove the solenoid body.
    1. Disconnect the transmission range (TR) position sensor.
    2. Remove the solenoid body bolts.
    3. Remove the solenoid body.
Fig 9: Identifying Solenoid Body Bolts
Courtesy of FORD MOTOR CO.
11. Remove and discard the solenoid body gasket.
Fig 10: Locating Solenoid Body Gasket
Courtesy of FORD MOTOR CO.
12. Remove the feed bolts.
Fig 11: Locating Feed Bolts
Courtesy of FORD MOTOR CO.
13. Remove and discard the front pump bolts.
Fig 12: Locating Front Pump Bolts
Courtesy of FORD MOTOR CO.
14. Using the special tools, remove the front pump.
Fig 13: Identifying Front Pump
Courtesy of FORD MOTOR CO.
NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.
15. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
Fig 14: Pump Thrust Washer, Overdrive Sun Gear Thrust Bearing, And Pump Gasket
Courtesy of FORD MOTOR CO.
16. Remove the overdrive separator plates, clutch plates and overdrive pressure plate.
Fig 15: Overdrive Separator Plates, Clutch Plates, And Overdrive Pressure Plate
Courtesy of FORD MOTOR CO.
17. Remove the overdrive clutch retaining ring.
Fig 16: Overdrive Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
18. Install the special tool.
Fig 17: Identifying Special Tool (307-S383)
Courtesy of FORD MOTOR CO.
NOTE: The No. 3 overdrive carrier thrust bearing and race assembly may come out with the coast clutch cylinder assembly or it may stay in the transmission.
19. Using the special tool, remove the coast clutch cylinder assembly.
Fig 18: Special Tool And Coast Clutch Cylinder Assembly
Courtesy of FORD MOTOR CO.
20. Remove the No. 4 thrust bearing.
Fig 19: Locating Thrust Bearing
Courtesy of FORD MOTOR CO.
21. Remove the overdrive ring gear and center shaft.
Fig 20: Locating Center Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
22. Remove the No. 5 sun gear thrust bearing.
Fig 21: Locating Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
23. Using the special tool, remove the center support retaining ring.
Fig 22: Center Support Snap Ring And Special Tool
Courtesy of FORD MOTOR CO.
24. Install the special tools into the center support assembly.
Fig 23: Identifying Center Support Assembly
Courtesy of FORD MOTOR CO.
25. Using the special tools, remove the center support, direct clutch and forward clutch cylinder assembly.
Fig 24: Special Tools, Center Support, Direct Clutch, And Forward Clutch Cylinder Assembly
Courtesy of FORD MOTOR CO.
26. Remove the forward clutch hub and the No. 9 thrust washer.
Fig 25: Locating Thrust Washer
Courtesy of FORD MOTOR CO.
27. Remove the forward ring gear and hub assembly.
Fig 26: Locating Forward Ring Gear And Hub
Courtesy of FORD MOTOR CO.
28. Remove the forward carrier race and the No. 11 bearing assembly.
Fig 27: Identifying Carrier Race And No. 11 Bearing Assembly
Courtesy of FORD MOTOR CO.
29. Remove the forward carrier.
Fig 28: Identifying Carrier
Courtesy of FORD MOTOR CO.
30. Remove the sun gear and the No. 12 thrust bearing.
Fig 29: Sun Gear And No. 12 Thrust Bearing
Courtesy of FORD MOTOR CO.
31. Remove the low reverse sun gear and shell assembly.
Fig 30: Low/Reverse Sun Gear And Shell Assembly
Courtesy of FORD MOTOR CO.

Early build vehicles 

32. Remove and discard the low/reverse clutch retaining ring.
Fig 31: Low/Reverse Clutch Wavy Retaining Ring
Courtesy of FORD MOTOR CO.
33. Remove the low/reverse one-way clutch (OWC), clutch pack and carrier and hub assembly.
Fig 32: Low/Reverse One-Way Clutch, Clutch Pack, Carrier, And Hub Assembly
Courtesy of FORD MOTOR CO.

Late build vehicles 

34. Remove and discard the low/reverse clutch retaining ring.
Fig 33: Locating Low/Reverse Clutch Retaining Ring
Courtesy of FORD MOTOR CO.
NOTE: The output hub and ring gear assembly may stick to the low/reverse rocker clutch, clutch pack and carrier and hub assembly.
35. Remove the rocker clutch, low/reverse clutch pack and carrier and hub assembly.
Fig 34: Locating Rocker Clutch, Low/Reverse Clutch Pack & Carrier & Hub Assembly
Courtesy of FORD MOTOR CO.

All vehicles 

36. Remove the No. 15 thrust bearing.
Fig 35: Identifying No. 15 Thrust Bearing
Courtesy of FORD MOTOR CO.
37. Place the transmission manual control lever in PARK to lock the output shaft from rotating.
38. Remove the output hub and ring gear.
Fig 36: Removing The Output Hub And Ring Gear
Courtesy of FORD MOTOR CO.
39. Remove the low reverse No. 16 thrust bearing.
Fig 37: Locating Low Reverse Thrust Bearing
Courtesy of FORD MOTOR CO.
40. If equipped, remove the output shaft flange.
    1. Remove and discard the bolt.
    2. Remove the output shaft flange.
Fig 38: Identifying Output Shaft Flange And Bolt
Courtesy of FORD MOTOR CO.
41. If equipped, use the special tool to remove and discard the output shaft retaining nut.
Fig 39: Identifying Output Shaft With Special Tool
Courtesy of FORD MOTOR CO.
42. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
Fig 40: Identifying Output Shaft Seal
Courtesy of FORD MOTOR CO.
43. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
Fig 41: Identifying Extension Housing Seal
Courtesy of FORD MOTOR CO.
44. Remove the 9 bolts and the extension housing.
Fig 42: Locating Transmission Extension Housing Bolts
Courtesy of FORD MOTOR CO.
45. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.
Fig 43: Locating Extension Housing Ball Bearing
Courtesy of FORD MOTOR CO.
46. Remove and discard the extension housing gasket.
Fig 44: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
47. Remove the output shaft.
Fig 45: Identifying Output Shaft
Courtesy of FORD MOTOR CO.
48. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer.
Fig 46: Locating No. 17 Park Gear Thrust Washer
Courtesy of FORD MOTOR CO.
49. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing.
Fig 47: Identifying Park Gear Thrust Washer
Courtesy of FORD MOTOR CO.
NOTE: Do not fully compress the return spring or damage to the spring may occur.
50. Using the special tools, remove and discard the reverse clutch return spring retaining ring.
Fig 48: Identifying Reverse Clutch Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
51. Remove the return spring.
Fig 49: Locating Return Spring
Courtesy of FORD MOTOR CO.
52. While applying air to the extension housing side of the case, remove and discard the reverse piston.
Fig 50: Locating Reverse Clutch Piston Seals
Courtesy of FORD MOTOR CO.
53. Remove the parking rod guide plate bolts and plate.
Fig 51: Locating Parking Rod Guide Plate And Bolts
Courtesy of FORD MOTOR CO.
54. Remove the plastic orifice lube plug from the rear of the case and discard.
Fig 52: Plastic Orifice Lube Plug
Courtesy of FORD MOTOR CO.
55. Remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
Fig 53: Parking Pawl, Return Spring, And Shaft
Courtesy of FORD MOTOR CO.
NOTE: The Torx head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new bolt installed.
56. Remove the parking pawl abutment.
Fig 54: Identifying Parking Pawl Abutment
Courtesy of FORD MOTOR CO.
NOTE: The pin should be driven down into the case.
57. Using a suitable tool, remove and discard the manual control lever shaft retaining pin.
Fig 55: Identifying Manual Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
58. Using the special tool, remove the manual control lever shaft retaining pin.
Fig 56: Identifying Manual Lever Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
59. Remove the manual control lever shaft.
Fig 57: View Of Manual Control Lever
Courtesy of FORD MOTOR CO.
60. Remove the TR position sensor, manual control lever and park rod as an assembly.
Fig 58: Identifying Manual Control Lever And Park Rod Assembly
Courtesy of FORD MOTOR CO.
61. Using the special tool, remove and discard the manual control lever seal.
Fig 59: Identifying Manual Control Lever Seal With Special Tools
Courtesy of FORD MOTOR CO.
NOTE: The short transmission fluid inlet tube should be removed only if it is loose or damaged.
62. If required, remove the short transmission fluid inlet tube.
Fig 60: Short Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
NOTE: The top portion seal groove will work the best when removing the seal pack.
63. Inspect the rear case Teflon® seal retainer for damage. If damage is evident, use the special tool to remove the seal retainer.
Fig 61: Identifying Seal Retainer
Courtesy of FORD MOTOR CO.
64. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly and all transmission fluid passages for obstructions.
65. Inspect the rear case snubber bushing. If damage is found, install a new transmission case.
Fig 62: Inspecting Rear Case Snubber Bushing
Courtesy of FORD MOTOR CO.
66. Check all parking linkage parts for wear or damage.
67. Inspect the reverse clutch case vent for blockage. The vent is located in the case at the 12 o'clock position. If evidence of blockage is found, use low air pressure to clear out the blockage. Apply air pressure to the extension housing side of the vent.
68. If the low/reverse clutch-to-case snap ring has rotated in the case snap ring groove, or is partially dislodged, the case snap ring groove has been damaged. To avoid repeat repairs, use a new case for the overhaul.
69. If installing a new case, remove the transmission fluid cooler tube fittings.