LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 1993 >> Taurus SHO, 3.2 P, AXODE >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - Ax4S/AXOD-E >> Transaxle Reassembly >> Notes

Transaxle Reassembly: Notes

NOTE: Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean ATF. Use petroleum jelly on gaskets, thrust washers and needle bearings to retain them in place. Use all new gaskets and seals, and tighten bolts evenly.
NOTE: For identification and position of thrust bearings and washers, see Figure .
  1. Place case in horizontal position. Install drive sprocket support bearing, if necessary. Install drive sprocket support. Drive sprocket support bolt holes are offset. Sprocket support can only be aligned one way. Install and tighten 6 Torx (T-30) bolts to specification. See TORQUE SPECIFICATIONS.
  2. Install converter oil seal using appropriate seal driver. Install right-hand output shaft seal using seal driver. After installation, ensure garter springs are present on seals.
  3. Install AXOD End Play Tool (T87P-70014-AH) and Step Plate Adapter (D80L-630-3) over right-hand output shaft opening. See Fig 1 . This tool will be used to select thrust washers.
  4. Position transaxle case in vertical position. Install No. 19 needle bearing over case boss with flat side facing up and outer lip facing down. Install final drive ring with external splines up. Lightly tap ring gear to fully seat in case splines.
  5. Install speedometer drive gear, differential assembly, final drive sun gear, parking gear, No. 16 needle bearing, rear planet support, No. 15 needle bearing and No. 18 thrust washer. See Fig 2 .
  6. Lower final drive assembly into case. Install snap ring and align end of snap ring with low-intermediate band anchor pin. Check end clearance at output shaft to select No. 18 thrust washer. Mount a dial indicator to end of output shaft. Back out screw on tool installed in step 3), until it no longer touches shaft. Zero dial indicator. Tighten screw to 35-44 INCH lbs. (4-5 N.m). Observe dial indicator. End clearance should be .004-.025" (.10-.63 mm). See Fig 3 .
  7. If not within specification, replace No. 18 selective thrust washer. See NO. 18 THRUST WASHER SELECTION table.
    NO. 18 THRUST WASHER SELECTION

    Thickness/In. (mm) Color Code
    .048-.052 (1.20-1.28) Red
    .052-.054 (1.30-1.38) Green
    .056-.058 (1.40-1.48) Blue
    .060-.062 (1.50-1.58) Black
    .064-.066 (1.60-1.68) White
    .068-.070 (1.70-1.78) Brown
    .072-.074 (1.80-1.88) Gold
  8. After installing correct thrust washer, recheck clearance. If end clearance is within specifications, back off screw on tool and leave in position for No. 5 and No. 8 selective thrust washer clearance check.
    Fig 1: Installing End Play Tool
    G92E12850Courtesy of FORD MOTOR CO.
    Fig 2: Assembling Final Drive Components
    G92F12851Courtesy of FORD MOTOR CO.
    Fig 3: Checking Output Shaft End Play
    G92H12853Courtesy of FORD MOTOR CO.
  9. Install low-intermediate band and align anchor pin pocket with anchor pin. Install low-intermediate drum and sun gear assembly.
  10. Reassemble ring gear and shell assembly, rear planetary, No. 13 needle bearing, front planetary and snap ring. See Figure . Carefully slide planetary assembly over output shaft.
  11. Lower reverse clutch into case and ensure clutch plates engage (intermediate clutch hub may be used as a tool to turn splines, if necessary). Align clutch cylinder anchor pin pocket with anchor pin case hole.
  12. Start reverse anchor pin bolt, but do not tighten. Reassemble forward, direct and intermediate clutch assembly. Using Front Clutch Loading Tool (T86P-70389-A), lower assembly into case. Align shell and sun gear splines into forward planetary. Ensure assembly is fully seated before removing tool.
  13. Install overdrive band into case. Install plastic retainer with crosshairs facing up. Check end clearance for No. 5 and No. 8 thrust washer.
  14. Tighten screw on End Play Tool (T87P-7001-AH) to 35-44 INCH lbs. (4-5 N.m). Ensure all 5 Teflon seals and No. 5 thrust washer are removed from driven sprocket support. Install No. 9 needle bearing over output shaft, with outer lip facing up. Install No. 8 selective thrust washer. Install driven sprocket support and driven sprocket. Remove No. 5 thrust washer from sprocket support, if attached.
  15. To measure No. 8 thrust washer clearance, it must first be determined if machined bolt hole surfaces on driven sprocket support are ABOVE or BELOW case machined surface. See Fig 4 .
  16. If bolt hole surfaces are ABOVE the case machined surface, place depth micrometer on machined bolt hole surface and measure distance to case machined surface. Check both bolt hole surfaces and determine average of both readings. If measurement exceeds .008" (.21 mm), measure existing No. 8 thrust washer and select a washer that will ensure a measurement of .000-.008" (.00-.21 mm). See NO. 8 THRUST WASHER SELECTION  table. Select washer and repeat measurement procedure; record reading of this measurement for use in a later step.
  17. If machined bolt hole surfaces are BELOW case machined surface, place depth micrometer on case machined surface and measure distance to machined bolt hole surface. See Fig 4 . Measure both bolt hole surfaces and determine average of both readings. If average reading exceeds .018" (.46 mm), measure existing No. 8 thrust washer and select a washer that will bring measurement to less than .018" (.46 mm). See NO. 8 THRUST WASHER SELECTION  table. Recheck measurement and record reading.
    NO. 8 THRUST WASHER SELECTION

    Thickness/Inch (mm) Color
    .056-.060 (1.43-1.53) Natural
    .066-.070 (1.68-1.78) Dark Green
    .075-.079 (1.92-2.02) Light Blue
    .085-.089 (2.17-2.27) Red
  18. With correct No. 8 thrust washer selected, check end play and No. 5 thrust washer installation. Remove driven sprocket support, No. 8 thrust washer and No. 9 needle bearing. Apply petroleum jelly to No. 5 thrust washer and install on driven sprocket support. Align washer tab with mating slot in support. Install driven sprocket support. DO NOT install No. 8 thrust washer or No. 9 needle bearing at this time.
  19. Determine if machined bolt hole surfaces of sprocket support are now ABOVE or BELOW machined case surface. If machined bolt hole surfaces are ABOVE case surface, add the distance of the final measurement taken in step 17) to the distance above the case. This distance should be .000-.033" (.00-.85 mm). If measurement exceeds specification, replace No. 5 thrust washer and recheck. See NO. 5 THRUST WASHER SELECTION  table.
    Fig 4: Measuring Thrust Washer Clearance
    G92I12854Courtesy of FORD MOTOR CO.
  20. If machined bolt hole surfaces are BELOW the case surface, record this measurement and the final measurement from step 17). Subtract the thickness of No. 8 thrust washer from No. 5 thrust washer. Result must be .000-.033" (.00-.84 mm). If measurement is not within specification, replace No. 5 thrust washer and recheck. See NO. 5 THRUST WASHER SELECTION  table.
    NO. 5 THRUST WASHER SELECTION

    Thickness Color
    .086-.090" (2.18-2.28 mm) Green
    .095-.099" (2.43-2.53 mm) Black
    .105-.109" (2.67-2.77 mm) Natural
    .115-.118" (2.92-3.02 mm) Red
  21. Remove tool from bottom of case. Remove dial indicator set-up. Remove driven sprocket support and install No. 9 needle bearing and correct No. 8 thrust washer. Install 5 Teflon seals on driven sprocket support. Install correct No. 5 thrust washer. Install driven sprocket support.
  22. If manual shaft components have not been installed, tap manual shaft seal into case. Start manual shaft through seal, and slide manual detent lever onto shaft. Slide shaft through park rod actuating lever and tap into case hole. Install new lock pin through case hole, aligning with groove in shaft. Install new roll pins.
  23. Install parking pawl, return spring, parking pawl shaft and locator pin. Ensure parking pawl engages park gear and returns freely. Install park rod actuating lever and park rod in case. Install park rod abutment and start abutment bolts. Push in parking pawl and locate rod between pawl and abutment.
  24. Tighten reverse drum Allen head (6 mm) bolts to 89-106 INCH lbs. (10-12 N.m) and 19 mm lock nut to 26-35 ft. lbs. (35-47 N.m). Tighten park rod abutment bolts, reverse anchor pin bolt and lock nut to specification. Clean and lightly tap oil tubes into position until fully seated. Apply Threadlock (262) around tube-to-case surface. Install tube retaining brackets.
  25. Install seal and oil filter into case. Install reverse apply tube/oil filter bracket and bolt. Install oil pan with new gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Position transaxle with input shaft and overdrive band facing up.
  26. Align tabs of No. 2 and No. 4 thrust washers and install on drive and driven sprocket supports. Lubricate and install cast iron sealing ring on input shaft. Install chain on drive and driven sprockets. Lower assembly into sprocket supports, rotating to ensure components are fully seated.
  27. Install No. 1 (plastic) and No. 3 (metal) thrust washers on chain cover, aligning tabs with slots in chain cover. Install new chain cover gasket. Install marked accumulator springs to correct position. Carefully align chain cover input shaft bore with input shaft. Ensure cast iron sealing ring is not damaged. Gently apply downward pressure, to overcome accumulator spring pressure, and start 2 chain cover bolts 180 degrees apart.
  28. Install remaining chain cover bolts and tighten to specification in sequence. See Fig 5 . Input shaft should have end play and rotate freely. If it does not rotate freely, remove chain cover and check for damaged cast iron seal.
    Fig 5: Chain Cover Tightening Sequence
    G92J12855Courtesy of FORD MOTOR CO.
  29. Install turbine speed sensor. Install output shaft seal and circlip. Perform air pressure test. See AIR PRESSURE TEST  under PERFORMANCE TESTS. Install new Teflon seals on pump driveshaft. Install shaft and connect manual valve link to detent lever.
  30. Start oil pump and valve body assembly over pump shaft and connect manual valve link to manual valve. Push valve body down until seated. Install valve body bolts and tighten in sequence to 80-106 INCH lbs. (9-12 N.m). Ensure 3 short bolts are located in correct position. See Fig 6 .
  31. Install bulkhead connector and electrical connectors. Ensure connectors "click" to lock position as they are installed. Place gear selector in Neutral position. Install Manual Lever Position Sensor (MLPS) and lightly tighten bolts. Align slots of MLPS using Gear Position Sensor Adjuster (T91P-70010-A). Tighten bolts to 80-106 INCH lbs. (9-12 N.m).
  32. Install valve body cover with new self-adhesive gasket. Tighten bolts to specification. Install dipstick tube grommet and dipstick tube in case. Install speedometer driven gear and drive gear shaft. Install thrust bearing and race with black side of race facing upward. Install speedometer cover with new seal. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Place transaxle in horizontal position. Install remaining chain cover bolts in bellhousing. Proceed to SERVO PISTON TRAVEL CHECK  if any of the following components are being replaced:
    • Transaxle Case Assembly
    • Band Assembly
    • Drum/Sun Gear Assembly
    • Servo Piston Rod
    • Servo Piston
Fig 6: Identifying Valve Body Tightening Sequence
G92A12856Courtesy of FORD MOTOR CO.
NOTE: Servo piston travel check of both the overdrive and low-intermediate servos should only be performed if either the transaxle case, band assembly, drum and sun gear assembly, servo piston rod or servo piston were replaced.
NOTE: If test springs from servo tool kits are used in test procedure, ensure they are not interchanged with operational springs. Test springs are weaker and may be shorter or have smaller wire diameter. Spring color may be identical.
scientia non olet · About LEMON Manuals