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Home >> Ford Truck >> 2012 >> Explorer FWD L4-2.0L Turbo >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Automatic Transmission - 6F35 >> Transmission - Overhaul >> Part 4

Part 4




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)






150. Remove 307-589 /1 and 307-584 /2.





151. Remove and discard the balance piston.





152. Remove the overdrive (4, 5, 6) piston return spring.





153. Install the clutch support tower in the transmission case and install the 3 clutch support tower bolts.
- Torque: 12 Nm (106 lb-in).





154. Remove 307-578 /1 (sizer).





155. Install the No. 1 overdrive/direct clutch assembly thrust bearing.





156. Position the overdrive/direct clutch assembly in the transmission case.





157. Apply compressed air to the overdrive (4, 5, 6) clutch piston port and remove the overdrive (4, 5, 6) clutch piston.





158. Remove the overdrive/direct clutch assembly from the transmission case.





159. Remove the overdrive (4, 5, 6) clutch piston seal from the overdrive/direct clutch assembly.





160. Remove the 2 seals from the overdrive (4, 5, 6) clutch piston.





161. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

Install 307-589 /2 and 307-584 /2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.

1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.

2. Remove the snap ring.






162. Remove 307-589 /2 and 307-584 /2.





163. Remove the direct (3, 5, R) clutch cylinder.





164. Remove and discard the direct (3, 5, R) clutch piston.





165. NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.





166. Remove the direct (3, 5, R) clutch snap ring.

1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.

2. Compress the snap ring.

3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.

4. Remove the snap ring.






167. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.





168. Remove and discard the 3 direct (3, 5, R) clutch piston seals.





169. Clean and inspect the overdrive/direct clutch assembly for damage or excessive wear and install new components as necessary.

170. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.





171. Install the direct (3, 5, R) clutch wave spring.





172. Soak the direct (3, 5, R) clutch pack in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





173. Install the direct (3, 5, R) clutch assembly and pressure plate.





174. Install the direct (3, 5, R) clutch snap ring.

1. Compress the snap ring.

2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.

3. Release the tension on the snap ring.






175. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
Install the direct (3, 5, R) clutch piston return spring.





176. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.





177. Install the direct (3, 5, R) clutch cylinder.





178. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

Install 307-589 /2 and 307-584 /2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.

1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.

2. Install the snap ring.






179. Remove 307-589 /2 and 307-584 /2.





180. Install 2 new seals on the overdrive (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.





181. Install a new overdrive (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.





182. Position the overdrive (4, 5, 6) clutch piston in place.





183. Using 307-589 /1, install the overdrive (4, 5, 6) clutch piston into the overdrive/direct clutch assembly by hand.





184. NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.
Install the overdrive (4, 5, 6) clutch piston return spring.





185. Lubricate the seals on a new balance piston and position the piston in place.





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





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





188. Remove 307-589 /1 and 307-584 /2.





189. Install the No. 2 thrust bearing.





190. Install the overdrive (4, 5, 6) clutch hub.





191. Soak the overdrive (4, 5, 6) clutch pack in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





192. Install the overdrive (4, 5, 6) clutch pack.





193. Install the overdrive (4, 5, 6) clutch pressure plate.





194. Install the overdrive (4, 5, 6) clutch snap ring.





195. Install the input shaft.





196. While holding the input shaft in place, install the snap ring.





197. Position the overdrive/direct clutch assembly in the transmission case, install 100-002 (TOOL-4201-C) or a dial indicator and position the plunger on the overdrive (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.070 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.





198. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on 100-002 (TOOL-4201-C). The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.





199. Remove 100-002 (TOOL-4201-C) , overdrive/direct clutch assembly and the No. 1 overdrive/direct clutch assembly thrust bearing.




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