FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
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 6

Part 6




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)







250. Install the center carrier/front ring gear assembly.





251. Install the No. 7 and No. 8 thrust bearings.

1. No. 7 thrust bearing

2. No. 8 thrust bearing






252. Install the front planetary/rear ring gear assembly.





253. Install the forward (1, 2, 3, 4) clutch wave spring.





254. Soak the forward (1, 2, 3, 4) clutch pack in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





255. Install the forward (1, 2, 3, 4) clutch pack.





256. Install the forward (1, 2, 3, 4) clutch pressure plate.





257. NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transmission.

Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.

1. Forward (1, 2, 3, 4) clutch snap ring

2. Forward (1, 2, 3, 4) clutch snap ring gap






258. Seat the snap ring in the snap ring groove.





259. Forward Clutch Measurement - Install 100-002 (TOOL-4201-C) or a dial indicator on the transmission case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.





260. Install the new low/reverse and forward (1, 2, 3, 4) clutch main control-to-transmission case seals.





261. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.003 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transmission for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.





262. Install the front planetary sun gear and shell assembly.





263. Install the No. 10 thrust bearing.





264. Install the park pawl.





265. Install the park pawl pin and spring.





266. Install the park pawl actuator rod in the TR (Transmission Range) sensor.





267. Position the park pawl aside and position the park pawl actuator rod and the TR (Transmission Range) sensor in the transmission case.





268. Install the manual control shaft and align the manual control shaft pin holes.





269. Install the manual control shaft pin.





270. NOTICE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.

Install the manual control lever and the nut.
- Torque: 24 Nm (18 lb-ft).





271. Install the 5 new clutch feed seals.





272. Position the transmission fluid baffle in place and install the 2 bolts.
- Torque: 12 Nm (106 lb-in).





273. Position the fluid reservoir in place and install the 2 fluid reservoir bolts.
- Torque: 12 Nm (106 lb-in).





274. Install the No. 12 thrust bearing.





275. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.





276. Install the No. 11 thrust bearing.





277. Install the No. 13 thrust washer.





278. Install the differential sun gear.





279. Install the differential assembly.





280. Install the No. 15 thrust bearing.





281. Install 307-635 on the input shaft.





282. Assemble 205-153 (T80T-4000-W) and 307-626. Install a new RH (Right Hand) seal on 307-626.





283. Using 205-153 (T80T-4000-W) and 307-626 , install the new RH (Right Hand) halfshaft seal.





284. Install the pump and filter assembly in the torque converter housing and install the 8 pump-to-torque converter housing bolts.
- Torque: 35 Nm (26 lb-ft).





285. Install the differential transmission fluid baffle and the 2 bolts.
- Torque: 12 Nm (106 lb-in).





286. NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying Ultra Silicone Sealant.

Apply Ultra Silicone Sealant to the sealing surface of the transmission case.





287. NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing on the transmission case and install the 16 torque converter housing bolts and the torque converter housing stud bolt.

1. Torque converter housing bolt location.

2. Torque converter housing stud bolt location.
- Torque: 24 Nm (18 lb-ft).






288. Remove 307-635.





289. Install the TSS (Turbine Shaft Speed) sensor and the TSS (Turbine Shaft Speed) sensor bolt.
- Torque: 10 Nm (89 lb-in).





290. Install the OSS (Output Shaft Speed) sensor and the OSS (Output Shaft Speed) sensor bolt.
- Torque: 10 Nm (89 lb-in).





291. Install the new main control-to-transmission case separator plate and align it on the stud and the guide pin.





292. NOTE: Be sure that the manual pin (part of the TR (Transmission Range) sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR (Transmission Range) sensor.





293. Install the main control nut hand-tight.





294. Install the short main control-to-transmission case bolts hand-tight.





295. Install the long main control-to-transmission case bolts hand-tight.





296. Tighten the main control-to-transmission case bolts and the main control nut in a crisscross pattern.
- Torque: 10 Nm (89 lb-in).





297. Position the TR (Transmission Range) sensor detent spring in place with the alignment tab in the alignment hole and install the TR (Transmission Range) sensor detent spring bolt.
- Torque: 13 Nm (115 lb-in).





298. NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
Install the main control-to-cover seal.





299. Connect the TR (Transmission Range) sensor electrical connector.





300. Connect the OSS (Output Shaft Speed) sensor electrical connector.





301. Clean the main control cover sealing surface.





302. Apply Ultra Silicone Sealant to the main control sealing surface of the transmission case.





303. Position the main control cover in place.





304. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover bolts.

1. Bolt location

2. Stud bolt location

- Torque: 12 Nm (106 lb-in).





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

Using 307-091 (T81P-7902-C) , install the torque converter.





306. Remove 307-091 (T81P-7902-C).





307. Install 307-566.





308. Remove the transmission from the bench-mounted holding fixture.





309. Remove 307-625.




pro multis Credits:Operation CHARM About Operation CHARM