Part 1

Transmission - Overhaul

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)














Material(s)






Overhaul

REFER to Pump and Filter Assembly.

REFER to Center Support.

REFER to Overdrive/Direct Clutch Assembly.

REFER to Intermediate Clutch Installation.

REFER to Intermediate Clutch Measurement.

REFER to Low/Reverse Clutch Measurement.

REFER to Forward Clutch Measurement.

1. Install 307-625.





2. Using 307-625 , install the transmission on a bench-mounted holding fixture.





3. Remove 307-566.





4. Install 307-091 (T81P-7902-C).





5. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.

Using 307-091 (T81P-7902-C) , remove the torque converter from the transmission.





6. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid designated for the transmission and torque converter being serviced.

Clean and inspect the torque converter for damage.

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 is 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 torque converter failure modes.
- Major metallic failure
- Multiple clutch plate 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.

6. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur.

If the fluid passed inspection:

- drain the remaining fluid from the torque converter.
- using only Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid, add 1.89 L (2 qt) of clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid into the torque converter and agitate by hand.
- thoroughly drain the Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.

7. NOTE: Note the location of the stud bolts for assembly.
Remove the 13 bolts and the main control cover.





8. Disconnect the OSS (Output Shaft Speed) sensor electrical connector.





9. Disconnect the TR (Transmission Range) sensor electrical connector.





10. Remove the main control-to-cover seal.





11. NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.
Remove the main control nut and the 22 main control-to-transmission case bolts and remove the main control assembly.





12. Clean and 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 - Overhaul .

13. Remove and discard the main control-to-transmission case separator plate.





14. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transmission case seals.

1. Forward (1, 2, 3, 4) clutch main control-to-transmission case seal.
2. Low/reverse clutch main control-to-transmission case seal.






15. Remove the TSS (Turbine Shaft Speed) sensor bolt and the TSS (Turbine Shaft Speed) sensor.





16. Remove the TR (Transmission Range) sensor detent spring bolt and the TR (Transmission Range) sensor detent spring.





17. Remove the OSS (Output Shaft Speed) sensor bolt and the OSS (Output Shaft Speed) sensor.





18. NOTE: Note the location of the stud bolts for assembly.
Remove the 17 torque converter housing bolts.





19. Pry the torque converter housing loose from the transmission case.





20. Remove the torque converter housing from the transmission case.





21. Remove the No. 15 differential thrust bearing.





22. Remove the differential assembly.





23. Clean and inspect the differential assembly for damage or excessive wear and install new components, if necessary. REFER to Differential Gear Assembly .

- Thrust bearing surfaces
- Spider gear and side gear teeth
- Differential planetary gear teeth
- Differential planetary gear teeth to be sure they spin freely and do not move back and forth or side to side excessively

24. Remove the differential sun gear.





25. Clean and inspect the differential sun gear for damage or wear and install new, as necessary.





- Sun gear teeth
- Spline teeth

26. Remove the No. 13 thrust washer.





27. Remove the No. 11 drive sprocket thrust bearing.





28. Simultaneously remove the drive and driven sprockets and the chain.





29. Remove the drive chain from the drive and driven sprockets.





30. Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.

- Check the drive chain for wear, stretching or tightness of the chain links.
- Check that the chain moves freely.






31. Inspect the driven sprocket for damage or excessive wear and install new, if necessary.

- Chain teeth
- Spline teeth
- Thrust bearing surfaces
- Bearing






32. Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.





33. Inspect the drive sprocket for damage or excessive wear and install new, if necessary.

- Chain teeth
- Spline teeth
- Thrust washer surface






34. 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






35. Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.





36. Install the drive chain on the drive and driven sprockets.





37. Remove the No. 12 driven sprocket thrust bearing.





38. Remove the No. 10 front sun gear and shell assembly thrust bearing.





39. Remove the 2 bolts and the fluid reservoir.





40. Remove the 2 bolts and the transmission fluid baffle.





41. Remove the park pawl pin and spring.





42. Remove the park pawl.





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.





44. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.

- Inspect the forward (1, 2, 3, 4) clutch pressure plate and clutch assembly surface for damage or excessive wear and install new, if necessary.






45. Remove the front planetary sun gear and shell assembly.





46. 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






47. Remove the front planetary carrier/rear ring gear assembly.





48. 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






49. Remove the No. 7 and No. 8 thrust bearings.

1. No. 7 thrust bearing
2. No. 8 thrust bearing