Part 3

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)






100. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump assembly for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the pump assembly as an assembly.

101. NOTE: TCC (Torque Converter Clutch) control valve retainer shown assembled in the pump body, main pressure regulator valve retainer similar.

Assemble the TCC (Torque Converter Clutch) control valve and main pressure regulator valve and install the valves in the pump. Compress the valve springs with a screwdriver and install the retainers.





102. NOTE: The dot on the inner pump gear faces up.
Install the pump gears.





103. Position the stator support on the pump housing and install the 23 pump bolts hand-tight.





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





105. Tighten the 23 pump bolts.
- Torque: 10 Nm (89 lb-in).





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





107. Install a new torque converter hub seal on 307-627.





108. Using 307-627 , install a new torque converter hub seal.





109. If equipped, install the torque converter hub seal snap ring.





110. Install a new pump assembly-to-torque converter housing O-ring seal.





111. Install a new input shaft seal on 307-634.





112. Using 307-634 , install the input shaft seal.





113. Install a new O-ring on a new transmission fluid filter and lubricate it with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





114. Install the magnet on the transmission fluid filter.





115. Install the transmission fluid filter.

1. Position the transmission fluid filter in the pump assembly.

2. Rotate the transmission fluid filter counterclockwise 90°.






116. NOTICE: 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.
Center Support - Using 307-630 and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer.





117. Remove the low/reverse clutch return spring.





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 307-630 and a press, compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer.





120. Remove the return spring from the forward (1, 2, 3, 4) clutch piston.





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.





122. Clean and inspect the center support for damage. Install a new center support if necessary.

123. NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Install 307-628 /2 and 307-629 on the forward clutch piston side of the center support.





124. Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly.





125. Position the forward (1, 2, 3, 4) clutch piston on 307-628 /2 and 307-629 and push it down into the center support.





126. NOTICE: 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 307-630 and a press, compress the forward (1, 2, 3, 4) clutch return spring and install the snap ring retainer and the snap ring.





128. Inspect the snap ring to be sure it is seated in the groove on the center support.





129. Turn the center support over and install 307-628 /1 and 307-628 /2 on the low/reverse piston side of the center support.





130. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly.





131. Position the low/reverse clutch piston on 307-628 /1 and 307-628 /2 and push it down into the center support.





132. Install the low/reverse piston return spring.





133. Using 307-630 and a press, compress the low/reverse clutch return spring and install the snap ring retainer and the snap ring.





134. Inspect the snap ring to be sure it is seated in the groove on the center support.





135. Remove and discard the 4 Teflon(R) seals.





136. Clean and inspect the clutch support tower for damage. Install a new clutch support tower if damaged.





137. Install 307-578 /3 on the clutch support tower and adjust 307-578 /3 to align the bottom edge of the tool with the top edge of the bottom Teflon(R) seal groove.





138. Install a new Teflon(R) seal on 307-578 /3.





139. Install 307-578 /2 over 307-578 /3. Using 307-578 /2, slide the Teflon(R) seal over the clutch support tower and into the groove.





140. Remove 307-578 /2 and 307-578 /3.

- Repeat Steps 137 through 140 for the other 3 Teflon(R) seals.






141. Install 307-578 /1 on the clutch support tower to size the 4 Teflon(R) seals.





142. Overdrive/Direct Clutch Assembly - Remove the input shaft snap ring.





143. Remove the input shaft.





144. Remove the overdrive (4, 5, 6) clutch hub.





145. Remove the overdrive (4, 5, 6) clutch hub, No. 2 thrust bearing.





146. Remove the overdrive (4, 5, 6) clutch snap ring.





147. Remove the overdrive (4, 5, 6) clutch pressure plate and clutch assembly.





148. Install 307-589 /1 and 307-584 /2 on the balance piston.





149. Using 307-589 /1 and 307-584 /2 and a press, compress the overdrive (4, 5, 6) clutch return spring and remove the snap ring.