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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 5

Part 5




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)






200. Assemble 205-153 (T80T-4000-W) and 307-626. Install a new LH (Left Hand) halfshaft seal on 307-626.





201. Using 307-626 and 205-153 (T80T-4000-W) , install the new LH (Left Hand) halfshaft seal in the transmission case.





202. Install a new manual control shaft seal on 307-581.





203. Using 307-581 , install the new manual control shaft seal in the transmission case.





204. Intermediate Clutch Installation - Install 307-632.





205. Lubricate the seals on the intermediate (2, 6) clutch piston with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





206. NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.

Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transmission case.





207. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transmission case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.

1. Outer tabs

2. Open area at the bottom of the transmission case

3. Bleed hole

4. Inner double tabs






208. Remove the intermediate (2, 6) clutch piston return spring.





209. Install 307-584 /1 on the intermediate (2, 6) clutch piston.





210. Using 307-584 /1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.





211. Remove 307-584 /1 and 307-632.





212. NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transmission can occur.

Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.

1. Outer tabs

2. Bleed hole

3. Inner double tabs






213. NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.

Position the snap ring in place. Align the gap of the snap ring to face the front of the transmission.

1. Snap ring

2. Snap ring gap

3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transmission case)






214. Install 307-633 /2 on the transmission case to center the intermediate (2, 6) clutch return spring.





215. Install 307-633 /1 on the snap ring.





216. Install 307-574 /1 on the transmission case.





217. NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.

Using 307-574 /1 and 307-633 , install the intermediate (2, 6) clutch snap ring in the groove.





218. Remove 307-574 /1 and 307-633.





219. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place.





220. NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.

Install the No. 1 thrust bearing with the flat side facing up.





221. Install the overdrive/direct clutch assembly.





222. NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.

Install the No. 3 thrust bearing with the flat side facing down.





223. Install the direct/intermediate clutch hub and rear sun gear assembly.





224. Install the intermediate (2, 6) wave spring assembly.





225. Soak the intermediate (2, 6) clutch assembly in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





226. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.





227. Intermediate Clutch Measurement - Install 307-300 (T94P-77000-Q) on the transmission case.





228. Using a depth gauge, measure and record as measurement A, the distance from 307-300 (T94P-77000-Q) to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.





229. Using a depth gauge, measure and record as measurement B, the distance from 307-300 (T94P-77000-Q) to the transmission case step above the intermediate (2, 6) clutch.





230. Subtract measurement B from measurement A. The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.





231. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transmission case.





232. Install the OWC (One-Way Clutch) assembly.





233. Install the rear planetary carrier/center ring gear assembly.





234. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC (One-Way Clutch).
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC (One-Way Clutch) and install the low/reverse pressure plate.





235. Soak the low/reverse clutch in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





236. Align the low/reverse clutch pack with the pressure plate and install it in the transmission case temporarily reversing the wave spring and top steel plate.





237. Low/Reverse Clutch Measurement - Install 307-300 (T94P-77000-Q) on the side of the center support with the long support legs.





238. Using a depth gauge, measure and record as measurement A, the distance from the top of 307-300 (T94P-77000-Q) to the contact surface of the low/reverse clutch piston.





239. Using a depth gauge, measure and record as measurement B, the distance from the top of 307-300 (T94P-77000-Q) to the leg surface of the center support.





240. Subtract measurement B from measurement A and record as measurement C.





241. Install 307-300 (T94P-77000-Q) on the transmission case.





242. Using a depth micrometer, measure and record as measurement D, the distance from 307-300 (T94P-77000-Q) to the top of the OWC (One-Way Clutch).





243. Using a depth gauge, measure and record as measurement E, the distance from the top of 307-300 (T94P-77000-Q) to the top of the low/reverse clutch at 3 different points and average the 3 distances.





244. Subtract measurement E from measurement D and record as measurement F.





245. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.016 in) and 2.00 mm (0.079 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.





246. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transmission case.





247. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transmission.
Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transmission case.

1. Long center support legs face down

2. Feed holes face the front of the transmission case





248. Install the No. 5 and No. 6 thrust bearings.

1. No. 5 thrust bearing

2. No. 6 thrust bearing






249. Install the center sun gear.




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