Automatic Transmission - 6F35: Overhaul: Transmission
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 | |
| 211-061 (T78P-3504-N1) Remover, Roll Pin | |
| 303-D011 (D80L-100-G) Actuator Pin (Dia 3/16) | |
| 303-D019 (D80L-100-Q) Collet, 3/4 to 7/8 | |
| 307-003 (T57L-500-B) Holding Fixture, Transmission | |
| 307-091 Handle, Torque Converter TKIT-2009TC-F | |
| 307-300 Gauge Bar, Shim Selection TKIT-1994-F TKIT-1994-FLM/FM TKIT-1994-LMH/MH2 | |
| 307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW | |
| 307-574 Forward Clutch Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings) TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 307-581 Manual lever seal installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 307-5842-6 Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 307-589 Overdrive clutch and balance piston service set TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 307-625 Fixture, Bench Mounting TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-626 Installer, Differential Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-627 Installer, Converter Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-628 Protector, Low Reverse Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-629 Protector, Low Reverse / 1-2-3-4 Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-630 Center Support Piston Spring Tool TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-632 Protector, 2-6 Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-6332-6 Piston return spring Comp TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-635 Protector, Turbine Shaft Seal TKIT-2008ET-FLM TKIT-2008ET-ROW | |
| 307-718 Installer, Axle Seal TKIT-2013B-FL TKIT-2013B-ROW | |
| 307-723 Installer, Turbine Seal TKIT-2014A-FL | |
| Flat Headed Screw Driver | |
| Magnetic Socket | |
| Hydraulic Press | |
| Long Nose Pliers | |
| Puller | |
| Punch |
Materials
| Name | Specification |
|---|---|
| Ultra Silicone Sealant TA-29 | - |
| Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) XT-10-QLVC (U.S.) | MERCON ® LVWSS-M2C938-A |
- 1.
For information on component views and base part numbers. Refer to: Transmission Description .
- 2.NOTE: Use M10 x 1.5 x 25mm bolts to attach the special tool to the transmission case.
Install the special tool. Use Special Service Tool: 307-625 Fixture, Bench Mounting.
- 3.
Mount the transmission to the bench-mounted holding fixture. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission, 307-625 Fixture, Bench Mounting.
- 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 from the transmission. Use Special Service Tool: 307-091 Handle, Torque Converter.
- 6.
- 1.
Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
- 2.
A new or remanufactured torque converter must be installed if one or more of the following statements are true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes:
-
- Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
- 3.
If none of the above conditions are present, continue with the following fluid inspection.
- 4.
Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
- 5.
Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
- 1.
- 7.NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.
- 1.
Drain the remaining fluid from the torque converter. Apply the specified amount of fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- Agitate by hand.
- Thoroughly drain the fluid.
- 1.
- 8.NOTE: Note the location of the stud bolts for assembly.
Remove the main control cover bolts and the main control cover.
- 12.NOTE: If the transmission internal wiring harness frame has melted due to overheat condition the transmission and cooler must be replaced.NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.
Remove the main control nut and the main control-to-transmission case bolts and remove the main control assembly.
- 13.
Inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it. Refer to: Main Control Valve Body .
- 15.
Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transmission case seals.
- 19.NOTE: Note the location of the stud bolts for assembly.
Remove the torque converter housing bolts.
- 24.
Check that the bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear. Install new components, if necessary. Refer to: Differential .
- 27.NOTE: If the transmission plastic baffle has melted due to overheat condition the transmission and cooler must be replaced.
Remove the differential transmission fluid baffle.
- 31.
Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.- Check for stretching or tightness of the chain links.
- Check that the chain moves freely.
- 32.
Inspect the driven sprocket for damage or excessive wear and install new, if necessary.- Chain teeth
- Spline teeth
- Thrust bearing surfaces
- Bearing
- 33.
Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
- 34.
Inspect the drive sprocket for damage or excessive wear and install new, if necessary.- Chain teeth
- Spline teeth
- Thrust washer surface
- 35.
Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if necessary.- Park gear teeth
- Spline teeth
- Thrust washer surface
- Thrust bearing surface
- Bearing surfaces
- Needle bearing
- 36.
Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
- 38.
- 1.
Remove the No. 12 driven sprocket thrust bearing.
- 2.
Remove the No. 10 front sun gear and shell assembly thrust bearing.
- 1.
- 43.NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
Remove the forward (1, 2, 3, 4) clutch snap ring.
- 47.
Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, as necessary.- Gear teeth
- Shell-to-clutch pack surfaces
- Thrust bearing surfaces
- 49.
Clean and inspect the front planetary carrier/rear ring gear assembly for damage or excessive wear and install new, as necessary.- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Spline teeth
- Thrust bearing
- Thrust bearing surfaces
- Ring gear teeth
- 52.
Clean and inspect the center planetary carrier/front ring gear assembly for damage or excessive wear and install new, as necessary.- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Spline teeth
- Thrust bearing surfaces
- Ring gear teeth
- 54.
Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as necessary.- Sun gear teeth
- Spline teeth
- 58.
Clean and inspect the rear planetary carrier/center ring gear assembly for damage or excessive wear and install new, as necessary.- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Spline teeth
- Thrust bearing surfaces
- Thrust bearing
- 60.
Inspect the low/reverse clutch pack and pressure plate surface for damage or excessive wear and install new, if necessary.
- 62.NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.NOTE: The low One-Way Clutch (OWC) should not be disassembled.
Clean and inspect the low One-Way Clutch (OWC) for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new low One-Way Clutch (OWC).
- 63.
Inspect the intermediate (2, 6) clutch surface for damage. If the surface is burned or worn excessively, install a new low One-Way Clutch (OWC).
- 64.NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
- 65.
Inspect the intermediate (2, 6) clutch surface for damage or excessive wear and install new, if necessary.
- 66.
Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, if necessary.- Sun gear teeth
- Shell-to-clutch pack surfaces
- Bearing surfaces
- 71.NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
Remove the No. 1 thrust bearing.
- 74.NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.
- 75.NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.
- 76.NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston. Use the General Equipment: Long Nose Pliers
- 79.NOTE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transmission case causing damage to the transmission case.
Using the special tool, pull the manual control shaft pin out of the manual control shaft. Use Special Service Tool: 211-061 (T78P-3504-N1) Remover, Roll Pin.
- 81.
Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.
- 82.
Remove and discard the manual control shaft seal. Use the General Equipment: Flat Headed Screw Driver
- 84.
- Clean and inspect the LH transmission case bushing and the bushing surface on the LH halfshaft for damage or excessive wear. If the LH transmission case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components. Refer to: Transmission Case .
NOTE: If the LH transmission case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transmission case bushing and a new LH halfshaft must be installed, or excessive noise or transmission failure can occur.- Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
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.
- 87.
- Inspect the torque converter housing and the differential ring gear for damage or excessive wear. If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear. Refer to: Transmission Case .
- Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
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.
- 88.NOTE: Note the orientation of the transmission fluid filter to the fluid pump assembly.
Rotate the transmission fluid filter 90 degrees clockwise and pull the transmission fluid filter out of the pump assembly. Discard the transmission fluid filter.
- 89.
Assemble the special tools and remove and discard the input shaft seal. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer, 303-D011 (D80L-100-G) Actuator Pin (Dia 3/16), 303-D019 (D80L-100-Q) Collet, 3/4 to 7/8.
- 93.
Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
- 95.
Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
- 98.
Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a magnet. Use the General Equipment: Flat Headed Screw Driver. Use the General Equipment: Magnetic Socket
- 100.
Compress the TCC control valve spring with a screw driver and remove the retainer with a magnet. Use the General Equipment: Flat Headed Screw Driver. Use the General Equipment: Magnetic Socket
- 103.NOTE: The TCC control valve retainer is shown assembled in the pump body, the main pressure regulator valve retainer is similar.
Assemble the TCC control valve assembly and main pressure regulator valve assembly and install the valves in the pump. Compress the valve springs with a screw driver and install the retainers.
- 106.
Install the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
- 108.
Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
- 109.
Install a new torque converter hub seal on the special tool. Use Special Service Tool: 307-627 Installer, Converter Seal.
- 110.
Using the special tool, install a new torque converter hub seal. Use Special Service Tool: 307-627 Installer, Converter Seal.
- 113.
Install a new input shaft seal on the special tool. Use Special Service Tool: 307-723 Installer, Turbine Seal.
- 114.
Using the special tool, install the input shaft seal. Use Special Service Tool: 307-723 Installer, Turbine Seal.
- 115.
Install the new transmission fluid filter.- 1.
Position the transmission fluid filter in the pump assembly.
- 2.
Rotate the transmission fluid filter counterclockwise 90 degrees.
- 1.
- 116.NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.
Using the special tool and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer. Use Special Service Tool: 307-630 Center Support Piston Spring Tool. Use the General Equipment: Hydraulic Press
- 118.
Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the low/reverse clutch piston.
- 119.NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Using the special tool and a press, compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer. Use Special Service Tool: 307-630 Center Support Piston Spring Tool. Use the General Equipment: Hydraulic Press
- 121.
Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the forward (1, 2, 3, 4) clutch piston.
- 123.NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Install the special tools on the forward clutch piston side of the center support. Use Special Service Tool:307-628 Protector, Low Reverse Piston Seal., 307-629 Protector, Low Reverse / 1-2-3-4 Piston Seal.
- 125.
Position the forward (1, 2, 3, 4) clutch piston on the special tools and push it down into the center support. Use Special Service Tool: 307-628 Protector, Low Reverse Piston Seal., 307-629 Protector, Low Reverse / 1-2-3-4 Piston Seal.
- 126.NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
Install the forward (1, 2, 3, 4) clutch piston return spring.
- 127.
Using the special tools and a press, compress the forward (1, 2, 3, 4) clutch return spring and install the snap ring retainer and the snap ring. Use Special Service Tool: 307-630 Center Support Piston Spring Tool. Use the General Equipment: Hydraulic Press
- 128.
Inspect the snap ring to be sure it is seated in the groove on the center support. Use the General Equipment: Flat Headed Screw Driver
- 129.
Turn the center support over and install the special tools on the low/reverse piston side of the center support. Use Special Service Tool: 307-628 Protector, Low Reverse Piston Seal.
- 131.
Position the low/reverse clutch piston on the special tools and push it down into the center support. Use Special Service Tool: 307-628 Protector, Low Reverse Piston Seal.
- 133.
Using the special tools and a press, compress the low/reverse clutch return spring and install the snap ring retainer and the snap ring. Use Special Service Tool: 307-630 Center Support Piston Spring Tool. Use the General Equipment: Hydraulic Press
- 134.
Inspect the snap ring to be sure it is seated in the groove on the center support. Use the General Equipment: Flat Headed Screw Driver
- 136.
Clean and inspect the clutch support tower for damage. Install a new clutch support tower if damaged.
- 137.
Install the special tool on the clutch support tower and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon ® seal groove. Use Special Service Tool: 307-578Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 138.
Install a new Teflon ® seal on the special tool. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 139.
Install the special tool 307-578/2 over 307-578/3. Using the special 307-578/2, slide the Teflon ® seal over the clutch support tower and into the groove. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 140.
Remove tools and repeat steps for the other 3 Teflon ® seals. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 141.
Install the special tool on the clutch support tower to size the 4 Teflon ® seals. Use Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 149.
Install the special tools on the balance piston. Use Special Service Tool: 307-5842-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- 150.
Using a press, compress the overdrive (4, 5, 6) clutch return spring and remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set. Use the General Equipment: Hydraulic Press
- 153.
Install the clutch support tower in the transmission case and install the clutch support tower bolts.Torque: 106 lb.in (12 Nm)
- 154.
Remove the special tool. Remove Special Service Tool: 307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings).
- 157.
Apply compressed air to the overdrive (4, 5, 6) clutch piston port and remove the overdrive (4, 5, 6) clutch piston.
- 159.
Remove and discard the overdrive (4, 5, 6) clutch piston seal from the overdrive/direct clutch assembly.
- 161.NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
- 1.
Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
- 2.
Remove the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set. Use the General Equipment: Hydraulic Press
- 1.
- 164.NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.
- 165.
Remove the direct (3, 5, R) clutch snap ring.- 1.
Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
- 2.
Using a tool, compress the snap ring.
- 3.
Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
- 4.
Remove the snap ring.
- 1.
- 169.
Clean and inspect the overdrive/direct clutch assembly for damage or excessive wear and install new components as necessary.
- 172.
Soak the direct (3, 5, R) clutch pack in transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 174.
Install the direct (3, 5, R) clutch snap ring.- 1.
Compress the snap ring.
- 2.
Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
- 3.
Release the tension on the snap ring.
- 1.
- 175.NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
Install the direct (3, 5, R) clutch piston return spring.
- 178.NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
- 1.
Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
- 2.
Install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set. Use the General Equipment: Hydraulic Press
- 1.
- 179.
Install new seals on the overdrive (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
- 180.
Install a new overdrive (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
- 182.
Using the special tools, install the overdrive (4, 5, 6) clutch piston into the overdrive/direct clutch assembly by hand. Use Special Service Tool: 307-589 Overdrive clutch and balance piston service set.
- 183.NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.
Install the overdrive (4, 5, 6) clutch piston return spring.
- 185.
Install the special tools on the balance piston. Use Special Service Tool: 307-584 2-6 Spring Compressor., 307-589 Overdrive clutch and balance piston service set.
- 186.
Using a press, compress the overdrive (4, 5, 6) clutch return spring and install the snap ring. Use Special Service Tool: 307-584 2-6 Spring Compressor.,307-589 Overdrive clutch and balance piston service set. Use the General Equipment: Hydraulic Press
- 189.
Soak the overdrive (4, 5, 6) clutch pack in transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 195.
Position the overdrive/direct clutch assembly in the transmission case, install the special tool or a dial indicator and position the plunger on the overdrive (4, 5, 6) clutch pressure plate. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 196.NOTE: The dial indicator plunger is positioned on the overdrive (4, 5, 6) clutch pressure plate.
Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 197.
Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator. The clearance should be between 1.71 mm (0.067 in) and 3.61 mm (0.142 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 198.
Remove the special tool, overdrive/direct clutch assembly and the No. 1 overdrive/direct clutch assembly thrust bearing. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 199.
Assemble the special tools. Install a new LH halfshaft seal on the special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.
- 200.
Using the special tools, install the new LH halfshaft seal in the transmission case. Use Special Service Tool: 205-153 (T80T-4000-W)Handle., 307-626 Installer, Differential Seal.
- 201.
Install a new manual control shaft seal on the special tool. Use Special Service Tool: 307-581 Manual lever seal installer.
- 202.
Using the special tool, install the new manual control shaft seal in the transmission case. Use Special Service Tool: 307-581 Manual lever seal installer.
- 204.
Lubricate the seals on the intermediate (2, 6) clutch piston with transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 205.NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transmission case.
- 206.
Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transmission case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.- 1.
Inner double tabs
- 2.
Bleed hole
- 3.
Outer tabs
- 1.
- 208.
Install the special tool on the intermediate (2, 6) clutch piston. Push the intermediate (2, 6) clutch piston into the clutch cylinder by hand. Use Special Service Tool: 307-584 2-6 Spring Compressor.
- 209.NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transmission can occur.
Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
- 1.
Inner double tabs
- 2.
Bleed hole
- 3.
Outer tabs
- 1.
- 210.NOTE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
Position the snap ring in place. Align the gap of the snap ring to face the front of the transmission.
- 1.
Snap ring
- 2.
Snap ring gap
- 3.
Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transmission case)
- 1.
- 211.
Install the special tool on the transmission case to center the intermediate (2, 6) clutch return spring. Use Special Service Tool: 307-633 2-6 Piston return spring Comp.
- 212.
Install the special tool on the snap ring. Use Special Service Tool: 307-633 2-6 Piston return spring Comp.
- 213.
Install the special tool on the transmission case. Use Special Service Tool: 307-574 Forward Clutch Spring Compressor.
- 214.NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.
Using the special tools, install the intermediate (2, 6) clutch snap ring in the groove. Use Special Service Tool: 307-574 Forward Clutch Spring Compressor., 307-633 2-6 Piston return spring Comp.
- 216.NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.
Install the No. 1 thrust bearing with the flat side facing up.
- 218.NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.
Install the No. 3 thrust bearing with the flat side facing down.
- 221.
Soak the intermediate (2, 6) clutch assembly in transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 222.
Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.- 1.
Steel plate
- 2.
Friction plate
- 1.
- 223.
Install the special tool on the transmission case. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 224.
Using a depth gauge, measure and record as measurement A, the distance from the special tool to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 225.
Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the transmission case step above the intermediate (2, 6) clutch. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 226.
Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.Description Reading Measurement A Measurement B Subtract measurement B from measurement A and check to see if it is within range of 0.240mm (0.009 in) and 2.60 mm (0.102 in)
- 227.NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transmission case.
- 1.
Friction plate
- 2.
Steel plate
- 1.
- 230.NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the One-Way Clutch (OWC).
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the One-Way Clutch (OWC) and install the low/reverse pressure plate.
- 231.
Soak the low/reverse clutch in transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 232.
Align the low/reverse clutch pack with the pressure plate and install it in the transmission case temporarily reversing the wave spring and top steel plate.- 1.
Steel plate.
- 2.
Wave spring.
- 1.
- 233.
Install the special tool on the side of the center support with the long support legs. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 234.
Using a depth gauge, measure and record as measurement A, the distance from the top of the special tool to the contact surface of the low/reverse clutch piston. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 235.
Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the leg surface of the center support. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 236.
Subtract measurement B from measurement A and record as measurement C.Description Reading Measurement A Measurement B Subtract measurement B from measurement A and record as measurement C
- 237.
Install the special tool on the transmission case. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 238.
Using a depth micrometer, measure and record as measurement D, the distance from the special tool to the top of the One-Way Clutch (OWC). Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 239.
Using a depth gauge, measure and record as measurement E, the distance from the top of special tool to the top of the low/reverse clutch at 3 different points and average the 3 distances. Use Special Service Tool: 307-300 Gauge Bar, Shim Selection.
- 240.
Subtract measurement E from measurement D and record as measurement F.Description Reading Measurement D Measurement E Subtract measurement E from measurement D and record as measurement F
- 241.
Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.Description Reading Measurement C Measurement F Subtract measurement F from measurement C and check to see if it is within range of 0.406mm (0.015 in) and 2.000 mm (0.078 in)
- 242.NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transmission case.
- Wave spring
- Steel plate
- 243.NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transmission.
Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transmission case.
- 1.
Long center support legs face down
- 2.
Feed holes face the front of the transmission case
- 1.
- 250.
Soak the forward (1, 2, 3, 4) clutch pack in transmission fluid.Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid (U.S.) / XT-10-QLVC (U.S.) (MERCON ® LV) (WSS-M2C938-A)
- 253.NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transmission.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.
- 255.
Install the special tool or a dial indicator on the transmission case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 256.
Install the new low/reverse and forward (1, 2, 3, 4) clutch main control-to-transmission case seals.
- 257.
Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transmission for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 258.NOTE: Make sure the front planetary sun gear and shell assembly is fully engaged into both forward clutch friction plates.
Install the front planetary sun gear and shell assembly.
- 261.
Install the park pawl actuator rod in the TR sensor. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transmission case.
- 264.NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the manual control lever nut.
Torque: 18 lb.ft (24 Nm)
- 266.
Position the transmission fluid baffle in place and install the transmission fluid baffle bolts.Torque: 106 lb.in (12 Nm)
- 267.
Position the fluid reservoir in place and install the fluid reservoir bolts.Torque: 106 lb.in (12 Nm)
- 269.
- 1.
Simultaneously install the drive/driven sprocket and chain assembly.
- 2.
Lightly tap on the driven sprocket to be sure it is fully seated in the case.
- 1.
- 275.
Install the special tool on the input shaft. Use Special Service Tool: 307-635 Protector, Turbine Shaft Seal.
- 276.NOTE: FWD Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-718 Installer, Axle Seal.
- 277.NOTE: FWD Vehicles.
Using the special tools, install the new RH halfshaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-718 Installer, Axle Seal.
- 278.NOTE: AWD Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-718 Installer, Axle Seal.
- 279.NOTE: AWD Vehicles.
Using the special tools, install the new RH halfshaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-718 Installer, Axle Seal.
- 280.
Install the pump and filter assembly in the torque converter housing and install the pump-to-torque converter housing bolts.Torque: 26 lb.ft (35 Nm)
- 281.NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.
Apply silicone to the sealing surface of the transmission case.
Material: Ultra Silicone Sealant / TA-29
- 283.NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing bolts and the torque converter housing stud bolt.
Torque: 18 lb.ft (24 Nm)
- 287.
Install the new main control-to-transmission case separator plate and align it on the stud and the guide pin.
- 288.NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR sensor.
- 292.
Tighten the main control-to-transmission case bolts and the main control nut in a crisscross pattern.Torque: 89 lb.in (10 Nm)
- 293.
Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the TR sensor detent spring bolt.Torque: 115 lb.in (13 Nm)
- 294.NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
Install the main control-to-cover seal.
- 297.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 .
- 298.
Apply silicone to the main control sealing surface of the transmission case.Material: Ultra Silicone Sealant / TA-29
- 299.NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover and the main control cover bolts and stud bolts.
Torque: 106 lb.in (12 Nm)
- 300.NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tools, install the torque converter. Use Special Service Tool: 307-091Handle, Torque Converter.
- 302.
Remove the transmission from the bench-mounted holding fixture. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission., 307-625 Fixture, Bench Mounting.