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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 thrust 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 thrust washers, see Figure .
  1. Place transaxle case in horizontal position. Install drive sprocket support bearing, if necessary. Install drive sprocket support. Drive sprocket support bolt holes are offset. See Fig 1 . 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 output shaft seal using seal driver. After installation, ensure garter springs are present on seals.
  3. Install End Play Tool (T87P-70014-AH) and Step Plate Adapter (D80L-630-3) over right output shaft seal. See Fig 2 . End play tool will be used to select thrust washers.
  4. Position transaxle case in vertical position. Install thrust bearing No. 19 over case boss with flat side facing up and outer lip facing down. Install final drive ring gear with external splines up. Lightly tap ring gear to fully seat in case splines.
  5. Using petroleum jelly, install No. 18 thrust washer to end of differential assembly. See Fig 3 . Lower final drive assembly into case. Gently tap into place using a brass hammer. Install snap ring and align end of snap ring with low-intermediate band anchor pin.
  6. Check end play at output shaft to select thrust washer No. 18. 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 end play tool screw to 35-44 INCH lbs. (4-5 N.m). Observe dial indicator. End play should be .004-.016" (.10-.40 mm). See Fig 4 .
  7. If end play is not within specification, replace No. 18 selective thrust washer. See THRUST WASHER NO. 18 SELECTION  table.
    THRUST WASHER NO. 18 SELECTION

    Thickness In. (mm) Color Code
    .046-.050 (1.18-1.28) Red
    .050-.054 (1.28-1.38) Green
    .054-.058 (1.38-1.48) Blue
    .058-.062 (1.48-1.58) Black
    .062-.066 (1.58-1.68) White
    .066-.070 (1.68-1.78) Brown
    .070-.074 (1.78-1.88) Gold
  8. After installing correct thrust washer, recheck end play . If end play is within specifications, back off screw on tool and leave in position to ensure correct selective thrust washer No. 5 and 8 are installed.
    Fig 1: Identifying Driven Sprocket Support Offset Holes
    G98G07047Courtesy of FORD MOTOR CO.
    Fig 2: Installing End Play Tool
    G92E12850Courtesy of FORD MOTOR CO.
    Fig 3: Assembling Final Drive Components
    G92F12851Courtesy of FORD MOTOR CO.
    Fig 4: Checking Output Shaft End Play
    G92H12853Courtesy of FORD MOTOR CO.
  9. Install low-intermediate band and align anchor pin pocket with anchor pin. Install No. 15 thrust bearing. Install rear sun gear and drum assembly.
  10. Reassemble ring gear and shell assembly, rear planetary, thrust bearing No. 13, 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 reverse clutch cylinder anchor bolt with case hole.
  12. Start reverse clutch anchor pin bolt, but do not tighten. See Figure . Install sun gear shell assembly into transaxle case. Using Front Clutch Loading Tool (T86P-70389-A), lower sun gear shell assembly into case. See Figure . Align sun gear shell into front planetary and intermediate clutch hub onto forward planetary splines. Ensure sun gear shell assembly is fully seated before removing tool.
  13. Tighten screw on End Play Tool (T87P-7001-AH) to 35-44 INCH lbs. (4-5 N.m). Install overdrive band into case. Install plastic retainer with crosshairs facing up. Install direct clutch hub thrust bearing No. 9 over output shaft with outer lip facing up. Install Gauge Tube (T94P-77001-MH) over output shaft and seat against direct clutch hub thrust bearing No. 9.
  14. Place Gauge Bar (T94P-77000-Q) with round legs across chain cover gasket surface. Using depth micrometer, measure distance between gauge bar and gauge tube. See Fig 5 . Take 2 readings 180 degrees apart and note average as specification "A". Use specification "A" to select No. 8 thrust washer. See THRUST WASHER NO. 8 SELECTION  table.
    THRUST WASHER NO. 8 SELECTION

    Specification "A" Inch (mm) Washer Thickness Inch (mm) Washer Color
    1.688-1.697 (42.88-43.10) .056-.060 (1.43-1.53) Natural
    1.697-1.706 (43.11-43.34) .066-.070 (1.68-1.78) Dk. Green
    1.707-1.716 (43.35-43.59) .076-.080 (1.92-2.02) Lt. Blue
    1.717-1.723 (43.60-43.77) .085-.089 (2.17-2.27) Red
    1.724-1.731 (43.78-43.98) .093-.096 (2.35-2.45) Black
  15. Remove Gauge Tube and take a measurement from gauge bar to No. 5 thrust washer mating surface. Take 2 readings 180 degrees apart and note average as specification "B". See Fig 6 . Remove gauge bar and depth micrometer.
  16. To find appropriate thrust washer No. 5, subtract specification "A" from specification "B" and to that subtotal add the mid range thickness of thrust washer No. 8 (example: .077"/1.97 mm for Lt. Blue washer), this total is specification "C". Use the following formula: "C"= ("B" - "A") + No. 8 Thrust Washer Thickness  . From specification "C" selection of No. 5 thrust washer can be calculated. See NO. 5 THRUST WASHER SELECTION  table.
    NO. 5 THRUST WASHER SELECTION

    Specification "C" In. (mm) Washer Thickness In. (mm) Washer Color
    1.027-1.038 (26.08-26.37) .086-.090 (2.18-2.28) Green
    1.039-1.048 (26.38-26.61) .096-.100 (2.43-2.53) Black
    1.048-1.057 (26.62-26.86) .105-.109 (2.67-2.77) Natural
    1.058-1.069 (26.87-27.15) .115-.119 (2.92-3.02) Red
    1.069-1.083 (27.16-27.50) .128-.132 (3.26-3.36) Blue
    Fig 5: Measuring Dimension "A"
    G98I07048Courtesy of FORD MOTOR CO.
    Fig 6: Measuring Dimension "B"
    G98A07049Courtesy of FORD MOTOR CO.
  17. Apply petroleum jelly to newly selected No. 5 thrust washer and install on driven sprocket support. Install newly selected No. 8 thrust washer on end of driven sprocket support. Remove direct clutch hub thrust bearing No. 9 from transaxle and install on top of No. 8 thrust washer.
  18. Use petroleum jelly to hold thrust bearing and thrust washer in place on driven sprocket support. Apply petroleum jelly to angle cut seals and install onto driven sprocket support. Install driven sprocket support. Remove end play tool from bottom of case.
  19. Install parking pawl, return spring, parking pawl shaft and locator pin. Ensure parking pawl engages parking gear and returns freely. Install park rod actuating lever and park rod in case. Install park rod bracket and start bracket bolts. Push in parking pawl and locate rod between pawl and bracket.
  20. Tighten park rod bracket bolts, reverse clutch anchor pin bolt and lock nut to specification. Clean and apply appropriate threadlock around tube-to-case surface and lightly tap NEW transfer tubes into position until fully seated. See Figure . Install tube retaining brackets.
  21. 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. See Figure . Install NEW lock pin through case hole, aligning with groove in shaft. Install NEW roll pins.
  22. Align tabs of No. 2 and No. 4 thrust washers and install on drive and driven sprocket supports. See Figure . 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.
  23. Install No. 1 (plastic) and No. 3 (metal) thrust washers on chain cover, aligning tabs with slots in chain cover. Use petroleum jelly to hold thrust washer in place. Install NEW chain cover gasket. Install marked accumulator springs to correct position.
  24. Carefully align chain cover input shaft bore with input shaft. Ensure chain cover alignment pins are in case. 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.
  25. Install remaining chain cover bolts and tighten to specification in sequence. See Fig 7 . Ensure chain cover bolts accessed through bellhousing are installed. 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 7: Chain Cover Tightening Sequence
    G92J12855Courtesy of FORD MOTOR CO.
  26. Install input shaft "O" ring. Install turbine shaft speed sensor. Tighten reverse clutch anchor pin bolt to 89-106 INCH lbs. (10-12 N.m) and 19 mm lock nut to 26-35 ft. lbs. (35-47 N.m). See Figure .
  27. Install seal and oil filter into case. Install reverse apply tube/oil filter bracket and bolt. Install oil pan magnet. Install oil pan with NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  28. Install output shaft seal and circlip. Perform air pressure test. See AIR PRESSURE TESTS  under PERFORMANCE TESTS. Install NEW Teflon seals on pump drive shaft. Install shaft and connect manual valve link to detent lever.
  29. 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 Figure .
  30. Install bulkhead connector and electrical connectors. Ensure connectors "click" to lock position as they are installed. Install self-adhesive gasket to valve body side cover. Install side cover to chain cover and tighten bolts to specification.
  31. Move transaxle to horizontal position. Place gear selector in Neutral position. Install Transmission Range (TR) sensor and lightly tighten bolts. Align slots of TR sensor using Manual Lever Position Sensor Alignment Tool (T97L-70010-A). See Figure . Tighten TR sensor bolts to 80-106 INCH lbs. (9-12 N.m).
  32. Install chain cover bolts in bellhousing and tighten to specification. Proceed to SERVO PISTON TRAVEL CHECK  for selection of appropriate length servo rods and installation of overdrive and low-intermediate servos.
  33. 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  . Install dipstick tube grommet and dipstick tube in case. Ensure input shaft "O" ring has been installed prior to installing torque converter. Install torque converter.
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