Part 3

Transmission - Overhaul

Special Tool(s)










Material(s)






Exploded View










































100. Remove and discard the overdrive clutch piston outer seals from the piston.





101. 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 clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Remove the snap ring.





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





103. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly.






104. Remove the direct clutch cylinder. Position the overdrive/direct clutch assembly in the cover assembly. Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port to remove the direct clutch cylinder from the overdrive/direct clutch assembly. Remove the overdrive/direct clutch assembly from the rear cover and remove the direct clutch cylinder.





105. Remove the rear direct clutch cylinder seal.





106. Remove and discard the direct clutch piston.





107. Remove the direct clutch piston return spring.





108. Remove and discard the direct clutch piston seals.





109. Remove the direct clutch snap ring.





110. Remove the direct clutch pressure plate, clutch assembly and wave spring.





111. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.

112. Install the direct clutch wave spring.





113. Lubricate the direct clutch pack in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





114. Install the direct clutch assembly and pressure plate.





115. Install the direct clutch snap ring.





116. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.





117. Install the direct clutch piston return spring.





118. Lubricate a new direct clutch piston with petroleum jelly and install the piston.





119. Install a new rear direct clutch cylinder seal and lubricate it with petroleum jelly.





120. Install the direct clutch cylinder.





121. NOTICE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the direct clutch cylinder is pressed too far, the direct clutch cylinder alignment tab may be broken off. The tab is used to align the TSS (Turbine Shaft Speed) sensor tone wheel (part of the direct clutch cylinder). If the tab is broken, erratic shifts and transmission damage can occur.

NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.

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

1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.

2. Install the snap ring.






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





123. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.





124. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.





125. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using 307-589 /1.





126. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.

Install the overdrive clutch piston return spring.





127. Lubricate the seals on a new balance piston with petroleum jelly.





128. Install the new balance piston and install 307-589 /1 and 307-584 /2.





129. Using a press, compress the overdrive clutch piston return spring and install the snap ring.





130. Remove 307-589 /1 and 307-584 /2 from the balance piston.





131. Install the No. 2 rear sun gear thrust bearing.





132. Install the overdrive clutch hub.





133. Lubricate the overdrive clutch pack in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





134. Install the overdrive clutch pack assembly and the pressure plate.





135. Install the overdrive clutch pack snap ring.





136. Cover - Remove the bolt and the TSS (Turbine Shaft Speed) sensor.





137. Using 307-584 /1 and 307-584 /2, compress the intermediate clutch return spring, using a press and remove the snap ring.





138. Remove 307-584 /1 and 307-584 /2.





139. Remove the intermediate clutch return spring.





140. Remove and discard the intermediate clutch piston.





141. Install 307-584 /2 and 307-588 /3, using a press, compress the low/reverse clutch return spring and remove the snap ring.





142. Remove 307-584 /2 and 307-588 /3.





143. Remove the low/reverse clutch return spring.





144. Remove and discard the low/reverse clutch piston.





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





146. Clean and inspect the cover for damage. Install a new cover, if damaged.

147. Install 307-578 /3 on the cover and adjust 307-578 /3 to align the bottom edge of 307-578 /3 with the top edge of the bottom Teflon(R) seal groove.





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





149. Install 307-578 /2 over 307-578 /3. Using 307-578 /2, slide the Teflon(R) seal over the cover and into the groove.