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Section 348 (Automatic Transaxle/Transmission): Assembly: Transmission: Material

WARNING: This page is about a different car, the 2003 Lincoln Aviator. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Materials
G01635377Courtesy of FORD MOTOR CO.
NOTE: Inspect the transmission case and extension housing for the following:
NOTE: Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
NOTE: Lubricate all seals and the servo bores with clean automatic transmission fluid.
  1. If installing a new transmission case bearing, only carry out the listed steps.
    Fig 2: Component Removal Chart
    G01635378Courtesy of FORD MOTOR CO.
  2. Assemble the components in the order indicated in the following illustration and table.
    Fig 3: Transmission Assembly Procedure (Steps 1-55)
    G01635379Courtesy of FORD MOTOR CO.
    Fig 4: Transmission Assembly Procedure Table (Steps 1-55)
    G01635380Courtesy of FORD MOTOR CO.
  3. Assemble the components in the order indicated in the following illustration and table.
Fig 5: Transmission Assembly Procedure (Steps 56-98)
G01635381Courtesy of FORD MOTOR CO.
Fig 6: Transmission Assembly Procedure Table (Steps 56-98)
G01635382Courtesy of FORD MOTOR CO.

Item 1: Transmission Case Assembly Note 

    WARNING: Make sure the lock pin on the bench-mounted holding fixture is secure. Failure to follow these instructions can result in personal injury.
    Fig 7: Installing Transmission Into Bench With Converter Housing Facing Up
    G01635383Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the transmission into the bench with the converter housing facing up.

Item 2: Case Bearing Disassembly Note 

  1. Inspect case bearing for damage. Install a new component as necessary.
    Fig 8: Inspecting Case Bearing
    G01635384Courtesy of FORD MOTOR CO.
  2. Using the special tool, remove the damaged case bearing.
    • Use an oil stone to remove any nicks or burrs in the bearing case bore.
      Fig 9: Removing Case Bearing
      G01635385Courtesy of FORD MOTOR CO.

Item 2: Case Bearing Assembly Note 

  1. Assemble the special tools.
    Fig 10: Assembling Special Tools
    G01635386Courtesy of FORD MOTOR CO.
    2. CAUTION: Make sure the bearing seal ring is facing the drive handle.
    Fig 11: Installing Case Bearing On Special Tools
    G01635387Courtesy of FORD MOTOR CO.
  2. Install the bearing on the special tools.
  3. Using the special tool, tap the case bearing into the case bearing bore.
    Fig 12: Tapping Case Bearing Into Case Bearing Bore
    G01635388Courtesy of FORD MOTOR CO.

Item 3: Manual Control Lever Seal Assembly Note 

  1. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
    Fig 13: Installing Manual Control Lever Shaft Seal
    G01635389Courtesy of FORD MOTOR CO.

Item 4: Park Pawl Actuating Rod Assembly Note 

  1. Install the parking lever rod.
    Fig 14: Installing Parking Lever Rod
    G01635390Courtesy of FORD MOTOR CO.

Item 5: Manual Control Valve Inner Lever Assembly Note 

  1. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 15: Installing Manual Valve Inner Lever
    G01635391Courtesy of FORD MOTOR CO.

Item 6: Manual Control Lever Shaft Assembly Note 

    CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 16: Installing Manual Control Lever Shaft
    G01635392Courtesy of FORD MOTOR CO.
  1. Install the manual control lever shaft.

Item 7: Manual Control Lever Inner Nut Assembly Note 

  1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
    Fig 17: Installing Manual Valve Inner Lever
    G01635393Courtesy of FORD MOTOR CO.

Item 8: Manual Control Lever Shaft Retaining Pin Assembly Note 

    CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
  1. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
      Fig 18: Tapping Manual Control Lever Shaft Spring Pin Into Case
      G01635394Courtesy of FORD MOTOR CO.

Item 9: Manual Control Lever Inner Nut Assembly Note 

    CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 19: Tightening Nut
    G01635395Courtesy of FORD MOTOR CO.
  1. Tighten the nut.

Item 10: Output Shaft Thrust Washer No. 11 Assembly Note 

    CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
  1. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
      Fig 20: Installing Output Shaft Thrust Washer
      G01635396Courtesy of FORD MOTOR CO.

Item 13: Reverse Band Assembly Note 

    CAUTION: Make sure the band is resting on the two anchor pins in the case.
    Fig 21: Installing Low/Reverse Band
    G01635397Courtesy of FORD MOTOR CO.
  1. Install the low/reverse band over the low/reverse brake drum.

Item 14: Reverse Brake Drum and Clutch Assembly Note 

  1. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
      Fig 22: Installing Low/Reverse Brake Drum
      G01635398Courtesy of FORD MOTOR CO.

Item 15: Reverse Brake Drum Lever Assembly Note 

    NOTE: The reverse band actuating lever must fit into the notches in the band.
    Fig 23: Installing Reverse Band Actuating Lever
    G01635399Courtesy of FORD MOTOR CO.
  1. Install the reverse band actuating lever into the reverse band.

Item 18: Output Shaft Ring Gear Assembly Note 

    CAUTION: Do not damage the seal against the case during assembly.
    Fig 24: Installing Output Shaft Ring Gear
    G01635400Courtesy of FORD MOTOR CO.
  1. Install the output shaft ring gear, hub and seal.

Item 19: Output Shaft Retaining Ring Assembly Note 

    CAUTION: Always install a new output shaft retaining ring.
    Fig 25: Installing Output Shaft Retaining Ring
    G01635401Courtesy of FORD MOTOR CO.
  1. Install a new output shaft retaining ring.

Item 20: Output Shaft Sleeve Assembly Note 

    NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
    Fig 26: Installing Output Shaft Sleeve
    G01635402Courtesy of FORD MOTOR CO.
  1. Install the output shaft sleeve.

Item 23: Reverse Brake Drum Retaining Ring Assembly Note 

    CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 27: Installing Retaining Ring
    G01635403Courtesy of FORD MOTOR CO.
  1. Install the retaining ring.

Item 27: Forward Planet Assembly Note 

    NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
    Fig 28: Installing Forward Planetary Assembly
    G01635404Courtesy of FORD MOTOR CO.
  1. Install the forward planetary assembly.

Item 35: Intermediate Servo Retaining Ring Assembly Note 

  1. Using the special tool, install the retaining ring.
    Fig 29: Installing Retaining Ring
    G01635405Courtesy of FORD MOTOR CO.

Item 37: Intermediate Clutch Drum Bearing No. 4 Assembly Note 

  1. Using the special tool, measure from the top of the gauge bar to the center support ledge in the case at four places, 90 degrees apart.
    • Add the four measurements, divide by four, and record as dimension A.
      Fig 30: Measuring From Top Of Gauge Bar To Center Support Ledge
      G01635406Courtesy of FORD MOTOR CO.
    2. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  2. Install the special tool.
    1. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions.
    2. Tighten the center screw.
      Fig 31: Tightening Center Screw
      G01635407Courtesy of FORD MOTOR CO.
    3. NOTE: Align the disc holes on the special tool with the slot in the gauge bar for correct measurement.
    Fig 32: Measuring Distance From Top Of Gauge Bar To Drum Bearing Surface
    G01635408Courtesy of FORD MOTOR CO.
  3. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
  4. Add dimension B to C, divide by two and record as dimension D.
  5. Subtract A from D, and record as dimension E.
  6. Select the bearing from the following chart, using dimension E.
    Fig 33: Dimension Chart
    G01635409Courtesy of FORD MOTOR CO.
  7. Install the selected No. 4 thrust washer on the direct clutch drum.
    • Coat the thrust washer with petroleum jelly.
      Fig 34: Installing No. 4 Thrust Washer
      G01635410Courtesy of FORD MOTOR CO.

Item 38: Intermediate Brake Band Assembly Note 

    NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
    NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
    NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 35: Installing Intermediate Band
    G01635411Courtesy of FORD MOTOR CO.
  1. Install the intermediate band.

Item 39: Intermediate Brake Band Anchor Strut Assembly Note 

  1. Install the intermediate band anchor strut.
    Fig 36: Installing Intermediate Band Anchor Strut
    G01635412Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 37: Checking Intermediate Band Anchor Strut
    G01635413Courtesy of FORD MOTOR CO.
  2. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 40: Intermediate Brake Band Adjusting Screw Assembly Note 

  1. Loosely install the screw.
    Fig 38: Installing Screw
    G01635414Courtesy of FORD MOTOR CO.

Item 41: Intermediate Brake Band Apply Strut Assembly Note 

  1. Install the intermediate band apply strut.
    Fig 39: Installing Intermediate Band
    G01635415Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 40: Checking Intermediate Band
    G01635416Courtesy of FORD MOTOR CO.
  2. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.

Item 42: Center Support Assembly Note 

    NOTE: Align the center support screw hole with correct case hole.
    Fig 41: Installing Center Support
    G01635417Courtesy of FORD MOTOR CO.
  1. Install the center support.

Item 43: Nut and Cage Assembly Note 

  1. Install the center support locknut and cage.
    Fig 42: Installing Center Support Locknut And Cage
    G01635418Courtesy of FORD MOTOR CO.

Item 44: Center Support Screw Assembly Note 

  1. Loosely install the screw.
    Fig 43: Installing Screw
    G01635419Courtesy of FORD MOTOR CO.

Item 45: Retaining Ring Assembly Note 

    CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
  1. Install the center support retaining ring.
    1. Make sure the center support retaining ring is installed with the tapered side facing up.
    2. Make sure the opening of the center support retaining ring is positioned correctly.
      Fig 44: Installing Center Support Retaining Ring
      G01635420Courtesy of FORD MOTOR CO.

Item 48: Overdrive Servo Retaining Ring Assembly Note 

  1. Using the special tools, install the retaining ring.
    Fig 45: Installing Retaining Ring
    G01635421Courtesy of FORD MOTOR CO.

Item 50: Overdrive Planetary Gear Carrier Assembly Note 

    CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
    Fig 46: Installing Planetary Gear Overdrive Carrier
    G01635422Courtesy of FORD MOTOR CO.
  1. Install the planetary gear overdrive carrier.

Item 52: Overdrive Brake Band Assembly Note 

    NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
    NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
    NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 47: Installing Overdrive Band
    G01635423Courtesy of FORD MOTOR CO.
  1. Install the overdrive band.

Item 53: Overdrive Brake Band Anchor Strut Assembly Note 

  1. Install the overdrive anchor strut.
    Fig 48: Installing Overdrive Anchor Strut
    G01635424Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 49: Checking Overdrive Band Anchor Strut
    G01635425Courtesy of FORD MOTOR CO.
  2. Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 54: Overdrive Brake Band Adjusting Screw Assembly Note 

  1. Loosely install the screw.
    Fig 50: Installing Screw
    G01635426Courtesy of FORD MOTOR CO.

Item 55: Overdrive Brake Band Apply Strut Assembly Note 

  1. Install the overdrive apply strut.
    Fig 51: Installing Overdrive Strut
    G01635427Courtesy of FORD MOTOR CO.
    2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
    Fig 52: Checking Overdrive Band Strut
    G01635428Courtesy of FORD MOTOR CO.
  2. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.

Item 56: Fluid Pump Support Thrust Washer No. 1 Assembly Note 

    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  1. Install the special tool.
    1. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions.
    2. Tighten the center screw.
      Fig 53: Tightening Center Screw
      G01635429Courtesy of FORD MOTOR CO.
    2. NOTE: Align the disc holes on the special tool with the slot in the gauge bar for correct measurement.
    Fig 54: Measuring Distance From Top Of Gauge Bar To Drum Bearing Surface
    G01635430Courtesy of FORD MOTOR CO.
  2. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat measurement 180 degrees opposite side of the special tool and record as dimension B.
  3. Add dimension A to B, divide by two and record as dimension C.
  4. Subtract the thickness of the gauge bar 17.78 mm (0.71 in) from dimension C, and record as dimension D.
  5. Select the No.1 thrust bearing from the following chart using dimension D.
    Fig 55: Dimension Chart (1 Of 2)
    G01635431Courtesy of FORD MOTOR CO.
    Fig 56: Dimension Chart (2 Of 2)
    G01635432Courtesy of FORD MOTOR CO.
  6. Install the selected No. 1 fluid pump input thrust washer.
    • Coat the fluid pump input thrust washer with petroleum jelly.
      Fig 57: Installing No. 1 Fluid Pump Input Thrust Washer
      G01635433Courtesy of FORD MOTOR CO.

Item 57: Fluid Pump Gasket Assembly Note 

  1. Install the special tools into the transmission case.
    Fig 58: Installing Special Tools
    G01635434Courtesy of FORD MOTOR CO.
  2. Install a new pump gasket.
    Fig 59: Installing Pump Gasket
    G01635435Courtesy of FORD MOTOR CO.

Item 58: Fluid Pump Assembly Note 

    CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
    Fig 60: Installing Fluid Pump
    G01635436Courtesy of FORD MOTOR CO.
  1. Install the fluid pump.
    2. CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure, and leakage.
    Fig 61: Aligning Fluid Pump To Adapter Plate
    G01635437Courtesy of FORD MOTOR CO.
  2. Using the special tool, align the fluid pump to the adapter plate.

Item 59: Fluid Pump Screw Assembly Note 

  1. Install screws. Tighten the screws in a star pattern.
    Fig 62: Tightening Screws In A Star Pattern
    G01635438Courtesy of FORD MOTOR CO.
  2. Remove the special tools and install the two remaining screws.
    Fig 63: Installing Two Remaining Screws
    G01635439Courtesy of FORD MOTOR CO.

Item 60: Band Adjusting Locknut Assembly Note 

    CAUTION: Do not allow the overdrive band adjustment screw to back out. The band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 64: Installing Locknut On Band Adjustment Screw
    G01635440Courtesy of FORD MOTOR CO.
  1. Install a new locknut on the band adjustment screw.
    2. CAUTION: The overdrive servo must be installed prior to band adjustment.
    Fig 65: Tightening Overdrive Band Adjustment Screw
    G01635441Courtesy of FORD MOTOR CO.
  2. Using the special tool, tighten the overdrive band adjustment screw. Then, back off the screw exactly (2) turns and hold that position.
  3. Tighten the overdrive band locknut.
    1. Hold the overdrive band adjustment screw stationary.
    2. Tighten the overdrive band locknut.
      Fig 66: Tightening Overdrive Band Locknut
      G01635442Courtesy of FORD MOTOR CO.

Item 61: Band Adjusting Locknut Assembly Note 

    CAUTION: Do not allow the intermediate band adjusting screw to back out. The band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 67: Installing Nut On Band Adjustment Screw
    G01635443Courtesy of FORD MOTOR CO.
  1. Install a new nut on the band adjustment screw.
    2. CAUTION: The intermediate servo must be installed prior to band adjustment.
    Fig 68: Tightening Intermediate Band Adjustment Screw
    G01635444Courtesy of FORD MOTOR CO.
  2. Tighten the intermediate band adjustment screw. Then, back off the screw exactly (2) turns and hold that position.
  3. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
      Fig 69: Tightening Intermediate Band Locknut
      G01635445Courtesy of FORD MOTOR CO.

Item 62: Center Support Bolt Assembly Note 

  1. Tighten the center support bolt.
    Fig 70: Tightening Center Support Bolt
    G01635446Courtesy of FORD MOTOR CO.

Items 63, 64, 65 and 66: Main Control and Screws Assembly Note 

  1. Install the special tools into the transmission case.
    Fig 71: Installing Special Tools Into Transmission Case
    G01635447Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the main control valve body and loosely install the screws.
    1. Install the short screw.
    2. Install the screw with the larger head.
    3. Install the remaining screws.
      Fig 72: Installing Main Control Valve Body
      G01635448Courtesy of FORD MOTOR CO.
  3. Remove the special tools, and loosely install the screw.
    Fig 73: Removing Special Tools
    G01635449Courtesy of FORD MOTOR CO.
  4. Tighten the screws in the sequence shown.
    Fig 74: Main Control Valve Body Screws Tightening Sequence
    G01635450Courtesy of FORD MOTOR CO.

Items 67 and 68: Manual Valve Detent Spring and Screw Assembly Note 

  1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
    Fig 75: Installing Manual Valve Detent Spring
    G01635451Courtesy of FORD MOTOR CO.

Item 69: Solenoid Body O-Ring Seals Assembly Note 

  1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.
    Fig 76: Installing O-Ring Seals On Solenoid Body Connector
    G01635452Courtesy of FORD MOTOR CO.

Items 70, 71 and 72: Solenoid Body and Solenoid Body Screws Assembly Note 

    CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur.
    Fig 77: Installing Solenoid Body
    G01635453Courtesy of FORD MOTOR CO.
  1. Install the solenoid body. Tighten screws in the sequence shown.

Item 74: Reverse Servo Screws Assembly Note 

  1. Install the reverse servo. Tighten the screws in the sequence shown in two stages.
    • Stage 1: Tighten screws to 5 Nm (44 lb-in).
    • Stage 1: Tighten screws to 11 Nm (8 lb-ft).
      Fig 78: Tightening Screws In Sequence
      G01635454Courtesy of FORD MOTOR CO.

Items 75 and 76: Transmission Fluid Filter and Screws Assembly Note 

    CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
    NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
    Fig 79: Installing Seals To Transmission Fluid Filter
    G01635455Courtesy of FORD MOTOR CO.
  1. Lubricate the seals and install the transmission fluid filter.

Item 77: Transmission Fluid Pan Gasket Assembly Note 

    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
  1. Install the transmission fluid pan gasket.

Item 78: Transmission Fluid Pan Assembly Note 

  1. Install the transmission fluid pan and loosely install the screws.
    Fig 80: Installing Transmission Fluid Pan
    G01635456Courtesy of FORD MOTOR CO.

Item 79: Transmission Fluid Pan Screws Assembly Note 

  1. Tighten the 16 screws in a crisscross sequence.
    Fig 81: Tightening Transmission Fluid Pan Screws In A Crisscross Sequence
    G01635457Courtesy of FORD MOTOR CO.

Items 80, 81, 82, and 83: Park Pawl Assembly Note 

    NOTE: The 4x2 vehicle is shown, the 4x4 is similar.
  1. Install the parking pawl assembly and gasket.
    1. Install the parking pawl shaft.
    2. Install the parking pawl return spring.
    3. Install the parking pawl.
    4. Install a new gasket.
      Fig 82: Installing Parking Pawl Shaft
      G01635458Courtesy of FORD MOTOR CO.

Item 86: Extension Housing Seal Assembly Note 

  1. On 4x2 vehicles, use the special tool to install the extension housing seal.
    Fig 83: Installing Extension Housing Seal
    G01635459Courtesy of FORD MOTOR CO.
  2. On 4x4 vehicles, use the special tool to install the extension housing seal.
    Fig 84: Installing Extension Housing Seal (4X4)
    G01635460Courtesy of FORD MOTOR CO.

Items 87 and 88: Transmission Range (TR) Sensor and Screws Assembly Note 

    CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage to the sensor.
    Fig 85: Installing Digital TR Sensor
    G01635461Courtesy of FORD MOTOR CO.
  1. Install the digital TR sensor and loosely install the screws.
    2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
    Fig 86: Installing Special Tool
    G01635462Courtesy of FORD MOTOR CO.
  2. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Item 91: Fluid Pump Assembly Note 

  1. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
    Fig 87: Installing Fluid Pump Gear Seal Ring
    G01635463Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 88: Removing Special Tool
    G01635464Courtesy of FORD MOTOR CO.

Item 92: Front Fluid Pump Seal Assembly Note 

    NOTE: Check and make sure that the garter spring in the seal has not popped off of the converter hub seal.
    Fig 89: Installing Seal Onto Special Tool
    G01635465Courtesy of FORD MOTOR CO.
  1. Install a new seal onto the special tool.
  2. Using the special tool, install a new converter hub seal.
    Fig 90: Installing Converter Hub Seal
    G01635466Courtesy of FORD MOTOR CO.

Item 93: Input Shaft Assembly Note 

    CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
    Fig 91: Installing Input Shaft
    G01635467Courtesy of FORD MOTOR CO.
  1. Install the input shaft.

Item 94: Torque Converter Assembly Note 

    CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotate freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may become damaged.
    Fig 92: Cleaning Converter Hub
    G01635468Courtesy of FORD MOTOR CO.
  1. Lubricate the converter hub with clean automatic transmission fluid.
    2. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.
    Fig 93: Installing Special Tools
    G01635469Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the torque converter by pushing and rotating.
  3. Lubricate the torque converter pilot hub with multipurpose grease.
    Fig 94: Lubricating Torque Converter Pilot Hub
    G01635470Courtesy of FORD MOTOR CO.

Items 95 and 96: Flexplate Adapter Plate and Nuts Assembly Note 

    CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.
    NOTE: Align the identifying mark made on the nut, stud, and adapter plate during disassembly for correct installation.
    Fig 95: Installing Torque Converter Flexplate Adapter Assembly
    G01635471Courtesy of FORD MOTOR CO.
  1. In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.

    If the vehicle is equipped, use the special tool to install the torque converter flexplate adapter assembly and eight nuts.

  2. Install two torque converter flexplate adapter nuts.
    Fig 96: Installing Two Torque Converter Flexplate Adapter Nuts
    G01635472Courtesy of FORD MOTOR CO.

Items 97 and 98: Speed Sensor and Screws Assembly Note 

  1. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.
    Fig 97: Identifying Speed Sensor Holes
    G01635473Courtesy of FORD MOTOR CO.
    2. NOTE: Inspect the speed sensor O-ring seals for damage. If damage to the seals is found, install new seals. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
  2. Install the speed sensors.
  3. Before installing the transmission, make sure that the transmission cooling system (tube and cooler) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler and/or tubes. For additional information, refer to TRANSMISSION FLUID COOLER .
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