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Section 231 (Automatic Transaxle/Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2003 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Removing Vent Tube
G01564877Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools
G01564878Courtesy of FORD MOTOR CO.
  1. Using the special tools, remove torque converter.
    Fig 3: Removing Torque Converter
    G01564879Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transmission to the bench.
    Fig 4: Mounting Transmission Over Bench
    G01564880Courtesy of FORD MOTOR CO.
    3. NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
  3. Remove the transmission fluid pan and transmission fluid pan gasket.
    1. Remove the bolts.
    2. Remove the transmission fluid pan and transmission fluid pan to case gasket.
      Fig 5: Removing Transmission Fluid Pan And Gasket
      G01564881Courtesy of FORD MOTOR CO.
  4. Clean the transmission fluid pan and pan magnet.
    Fig 6: Identifying Transmission Fluid Pan And Pan Magnet
    G01564882Courtesy of FORD MOTOR CO.
    5. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
    Fig 7: Removing Fluid Filter And Grommet
    G01564883Courtesy of FORD MOTOR CO.
  5. Remove the fluid filter and grommet.
    6. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
  6. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead inter-connector.
      Fig 8: Disconnecting Molded Lead Frame From The Solenoids
      G01564884Courtesy of FORD MOTOR CO.
  7. Remove the output shaft speed (OSS) sensor.
    1. Remove the bolt.
    2. Remove the OSS sensor.
      Fig 9: Removing Output Shaft Speed Sensor
      G01564885Courtesy of FORD MOTOR CO.
    8. CAUTION: Discard the manual lever shaft outer nut. Do not reuse.
  8. Remove the outer manual control lever.
    1. Remove the manual lever shaft outer nut.
    2. Remove the outer manual control lever.
      Fig 10: Removing Outer Manual Control Lever
      G01564886Courtesy of FORD MOTOR CO.
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
      Fig 11: Removing Digital Transmission Range Sensor
      G01564887Courtesy of FORD MOTOR CO.
  10. Remove the manual control valve detent lever spring.
    1. Remove the bolt.
    2. Remove the manual control valve detent lever spring.
      Fig 12: Removing Manual Control Valve Detent Lever Spring
      G01564888Courtesy of FORD MOTOR CO.
  11. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 13: Removing Control Valve Body Bolts
    G01564889Courtesy of FORD MOTOR CO.
  12. Remove and discard the pump outlet screen.
    Fig 14: Removing And Discarding The Pump Outlet Screen
    G01564890Courtesy of FORD MOTOR CO.
    13. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 15: Removing Manual Lever Shaft Retaining Pin
    G01564891Courtesy of FORD MOTOR CO.
  13. Remove the manual lever shaft retaining pin.
  14. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
      Fig 16: Removing Manual Lever Shaft Inner Nut
      G01564892Courtesy of FORD MOTOR CO.
  15. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
      Fig 17: Removing Parking Lever Actuating Rod
      G01564893Courtesy of FORD MOTOR CO.
    16. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged the new seal may leak.
    Fig 18: Removing Manual Control Lever Shaft Seal
    G01564894Courtesy of FORD MOTOR CO.
  16. Remove the manual control lever shaft seal.
  17. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
      Fig 19: Removing EPC Solenoid
      G01564895Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator spring retainer.
    Fig 20: Removing 2-3 Accumulator Spring Retainer
    G01564896Courtesy of FORD MOTOR CO.
  19. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
      Fig 21: Removing 2-3 Accumulator Piston
      G01564897Courtesy of FORD MOTOR CO.
  20. Using the special tool, remove the reverse band servo retaining ring.
    Fig 22: Removing Reverse Band Servo Retaining Ring
    G01564898Courtesy of FORD MOTOR CO.
  21. Remove the reverse band servo.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod assembly.
    3. Remove the reverse band servo spring.
      Fig 23: Removing Reverse Band Servo
      G01564899Courtesy of FORD MOTOR CO.
    22. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
    Fig 24: Removing Overdrive Servo Piston Retainer
    G01564900Courtesy of FORD MOTOR CO.
  22. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  23. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
      Fig 25: Removing Overdrive Servo Piston
      G01564901Courtesy of FORD MOTOR CO.
  24. Compress the 1-2 accumulator cover and remove the 1-2 accumulator piston retaining ring.
    Fig 26: Removing 1-2 Accumulator Piston Retaining Ring
    G01564902Courtesy of FORD MOTOR CO.
  25. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the inner and outer 1-2 accumulator springs.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
      Fig 27: Removing 1-2 Accumulator Upper Spring
      G01564903Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the extension housing seal.
    Fig 28: Removing Extension Housing Seal
    G01564904Courtesy of FORD MOTOR CO.
    27. NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
  27. Remove the extension housing.
    1. Remove the four bolts and two nuts.
    2. Remove the extension housing and the extension housing gasket.
      Fig 29: Removing Extension Housing And The Extension Housing Gasket
      G01564905Courtesy of FORD MOTOR CO.
  28. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
      Fig 30: Removing Parking Pawl
      G01564906Courtesy of FORD MOTOR CO.
  29. Rotate the transmission to the vertical position with the output shaft towards the floor.
    30. CAUTION: Extreme care must be taken during transmission connector removal. Do not pull on wires, or use a hammer on the connector body.
    Fig 31: Placing Screwdriver On The Flat Portion Of The Connector And Pushing Connector
    G01564907Courtesy of FORD MOTOR CO.
  30. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  31. Using the special tools remove the front pump seal.
    Fig 32: Removing Front Pump Seal
    G01564908Courtesy of FORD MOTOR CO.
    32. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 33: Removing Front Bolts
    G01564909Courtesy of FORD MOTOR CO.
  32. Remove the front bolts.
  33. Using the special tools, remove the front pump support.
    Fig 34: Removing Front Pump Support
    G01564910Courtesy of FORD MOTOR CO.
  34. Remove and discard the pump gasket.
  35. If equipped, remove the intermediate clutch anti-ratle clip.
    Fig 35: Removing Intermediate Clutch Anti-Ratle Clip
    G01564911Courtesy of FORD MOTOR CO.
    36. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
  36. Remove the following components as an assembly:
    • intermediate clutch pack.
    • intermediate one-way clutch.
    • reverse clutch.
    • forward clutch assembly.
      Fig 36: Intermediate Clutch Pack, One-Way Clutch, Reverse Clutch And Forward Clutch Assembly
      G01564912Courtesy of FORD MOTOR CO.
  37. Disengage and remove the overdrive band.
    Fig 37: Removing Overdrive Band
    G01564913Courtesy of FORD MOTOR CO.
  38. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 38: Removing Forward Clutch Hub And The No. 3 Forward Clutch Hub Front Bearing
    G01564914Courtesy of FORD MOTOR CO.
  39. Remove the intermediate stub shaft.
    Fig 39: Removing Intermediate Stub Shaft
    G01564915Courtesy of FORD MOTOR CO.
  40. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 40: Aligning Reverse Sun Shell With The Overdrive Band Anchor Pin
    G01564916Courtesy of FORD MOTOR CO.
  41. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
      Fig 41: Removing Forward Clutch Sun Gear, Bearing And No. 4 Forward Clutch Hub Bearing
      G01564917Courtesy of FORD MOTOR CO.
  42. Remove the center support retaining ring and note location for assembly.
    Fig 42: Removing Center Support Retaining Ring
    G01564918Courtesy of FORD MOTOR CO.
  43. Remove the case to planet support spring.
    Fig 43: Removing Case To Planet Support Spring
    G01564919Courtesy of FORD MOTOR CO.
  44. Remove the planetary gear support and planetary as an assembly.
    Fig 44: Removing Planetary Gear Support And Planetary
    G01564920Courtesy of FORD MOTOR CO.
  45. Remove the reverse clutch band.
    Fig 45: Removing Reverse Clutch Band
    G01564921Courtesy of FORD MOTOR CO.
  46. Remove the retaining ring.
    Fig 46: Removing Retaining Ring
    G01564922Courtesy of FORD MOTOR CO.
  47. Remove the direct clutch pack.
    Fig 47: Removing Direct Clutch Pack
    G01564923Courtesy of FORD MOTOR CO.
  48. Remove the No. 8 bearing.
    Fig 48: Removing No. 8 Bearing
    G01564924Courtesy of FORD MOTOR CO.
  49. Remove the output shaft, output shaft ring gear assembly and direct clutch.
    Fig 49: Removing Output Shaft, Output Shaft Ring Gear Assembly And Direct Clutch
    G01564925Courtesy of FORD MOTOR CO.
  50. Remove the No. 9 case rear bearing.
    Fig 50: Removing No. 9 Case Rear Bearing
    G01564926Courtesy of FORD MOTOR CO.
  51. Inspect and if necessary, using the special tools, remove the rear case bushing.
    Fig 51: Removing Rear Case Bushing
    G01564927Courtesy of FORD MOTOR CO.
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