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Home >> Ford Truck >> 2012 >> Explorer AWD V6-3.5L >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Automatic Transmission - 6F35 >> Transmission - Overhaul >> Part 2

Part 2




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)






50. Remove the center planetary carrier/front ring gear assembly.





51. 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






52. Remove the center planetary sun gear.





53. Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as necessary.

- Sun gear teeth
- Spline teeth






54. Remove the No. 5 and No. 6 thrust bearings.

1. No. 5 thrust bearing
2. No. 6 thrust bearing






55. Remove the center support assembly.





56. Remove the rear planetary carrier/center ring gear assembly.





57. 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






58. Remove the low/reverse wave spring, clutch pack and pressure plate.

- Inspect the low/reverse clutch pack and pressure plate surface for damage or excessive wear and install new, if necessary.






59. Remove the low OWC (One-Way Clutch).





60. NOTICE: Do not clean in water or with water-based solvents. Damage to the component may occur.

NOTE: The low OWC (One-Way Clutch) should not be disassembled.
Clean and inspect the low OWC (One-Way Clutch) 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 OWC (One-Way Clutch).





61. Inspect the intermediate (2, 6) clutch surface for damage. If the surface is burned or worn excessively, install a new OWC (One-Way Clutch).





62. 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.

- Inspect the intermediate (2, 6) clutch surface for damage or excessive wear and install new, if necessary.






63. 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






64. Remove the pressure plate and the wave spring.

- Inspect the pressure plate surface for damage or excessive wear and install new, if necessary.






65. Remove the No. 3 thrust bearing.





66. Remove the overdrive/direct clutch assembly.





67. 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.





68. Remove the intermediate (2, 6) clutch apply ring.





69. Remove the 3 clutch support tower bolts and the clutch support tower.





70. NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.





71. NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.





72. NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston.





73. Remove and discard the 5 clutch feed seals.





74. Remove the nut and the manual control lever from the manual control shaft.





75. NOTICE: 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 211-061 (T78P-3504-N1) , pull the manual control shaft pin out of the manual control shaft.





76. Remove the manual control shaft.





77. Remove the TR (Transmission Range) sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR (Transmission Range) sensor.





78. Remove and discard the manual control shaft seal.





79. Remove and discard the LH (Left Hand) halfshaft seal.





80. NOTICE: If the LH (Left Hand) transmission case bushing or the LH (Left Hand) halfshaft bushing surface shows signs of excessive wear or damage, a new LH (Left Hand) transmission case bushing and a new LH (Left Hand) halfshaft must be installed, or excessive noise or transmission failure can occur.

Clean and inspect the LH (Left Hand) transmission case bushing and the bushing surface on the LH (Left Hand) halfshaft for damage or excessive wear. If the LH (Left Hand) transmission case bushing or the LH (Left Hand) halfshaft shows signs of excessive wear or damage, install new components. REFER to Transmission Case . Clean the silicone from the transmission case-to-torque converter housing sealing surface and the main control cover sealing surface.






81. Remove the 2 bolts and the differential transmission fluid baffle from the torque converter housing.





82. Remove the 8 pump-to-torque converter housing bolts and the pump and filter assembly.





83. Remove and discard the RH (Right Hand) halfshaft seal.





84. Clean and 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 . Clean the silicone from the torque converter housing-to-transmission case sealing surface.

- Differential ring gear teeth






85. NOTE: Note the orientation of the transmission fluid filter to the pump assembly.
Pump and Filter Assembly - Remove the transmission fluid filter from the pump assembly.

1. Rotate the transmission fluid filter 90° clockwise.

2. Pull the transmission fluid filter out of the pump assembly.






86. Remove the magnet from the transmission fluid filter.





87. Assemble 100-001 (T50T-100-A) and 303-D019 (D80L-100-Q) and remove and discard the input shaft seal.





88. Remove the pump assembly-to-torque converter housing O-ring seal.





89. If equipped, remove the torque converter hub seal snap ring.





90. Using a dent puller, remove the torque converter hub seal.





91. Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.





92. Loosen the 23 pump bolts.





93. Remove the 2 pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.





94. Remove the 23 pump bolts and separate the pump assembly halves.





95. NOTE: The dot on the inner pump gear faces up.
Remove the pump gears.





96. Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a magnet.





97. Install a M4 bolt in the valve and remove the main pressure regulator valve assembly.





98. Compress the TCC (Torque Converter Clutch) control valve spring with a screwdriver and remove the retainer with a magnet.





99. Remove the TCC (Torque Converter Clutch) control valve assembly.




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