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 - 6F50 and 6F55 >> Transmission - Overhaul >> Part 5

Part 5




Transmission - Overhaul

Special Tool(s)










Material(s)






Exploded View










































200. Install a new O-ring seal on the transmission fluid reservoir. Lubricate the seal with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





201. Install the transmission fluid reservoir and the 2 bolts.
- Tighten to 12 Nm (106 lb-in).





202. Install a new pump-to-case seal.





203. Install the transfer shaft and gear assembly.





204. Tilt the transfer shaft and gear assembly over and install the differential assembly.





205. Install a new torque converter hub seal on 307-575.





206. NOTICE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

Using 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.





207. NOTICE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.

NOTE:Front Wheel Drive (FWD) Only.

Assemble 205-153 (T80T-4000-W) on 307-582A and install a new RH (Right Hand) halfshaft seal on 307-582A. Using 205-153 (T80T-4000-W) and 307-582A install the RH (Right Hand) halfshaft seal in the torque converter housing.





208. Install the pump drive sprocket and driven sprocket thrust washers.





209. NOTE: The dot on the pump sprocket is installed facing upward.
Install the pump sprocket and chain assembly.





210. Flush the pump with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.





211. NOTE: Lubricate the seal with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.

Install the fluid filter seal in the fluid pump.





212. NOTE: Install the filter in the correct orientation as noted in removal.

Install the fluid filter in the fluid pump.





213. Position the pump and filter assembly in place and install the 3 bolts.
- Tighten to 12 Nm (106 lb-in).





214. NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Position the stator support assembly in place on the torque converter housing.





215. Install the stator support bolts. Tighten in the sequence shown.
- Tighten to 41 Nm (30 lb-ft).





216. Position the transmission fluid baffle in place and install the bolt.
- Tighten to 12 Nm (106 lb-in).





217. Lubricate the ends of the transmission fluid tube with petroleum jelly and install it in the transmission.





218. NOTICE: Make sure the sealing surface of both the transmission case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transmission case.

Apply a bead of Ultra Silicone Sealant to the machined surface of the transmission case.





219. NOTE: Install the 2 studbolts in the correct location as noted during disassembly.
Install the torque converter housing on top of the transmission case and install the bolts.





220. NOTE: The studbolts are 1 and 16 in the tightening sequence.
Tighten the bolts in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).





221. Assemble 205-153 (T80T-4000-W) and 307-582A , install a new halfshaft seal on 307-582A.





222. Using 205-153 (T80T-4000-W) and 307-582A , install the halfshaft seal in the transmission case.





223. Forward Clutch Installation - Lubricate the forward clutch piston seals with petroleum jelly.





224. Position the forward clutch piston in place in the transmission case.





225. NOTE: Install 307-584 /1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.
Using 307-584 /1, push the forward clutch piston down into the bore.





226. Install the forward clutch piston return spring with the tabs facing downward.





227. NOTE: Install 307-584 /1 with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
Install 307-584 /1, 307-584 /2, 307-574 /1 and 307-574 /2 and compress the forward clutch piston return spring.





228. NOTE: 307-574 and 307-584 not shown for clarity.
Install the forward clutch piston return spring snap ring.

- Install the snap ring.
- The snap ring gap should be at the top of the transmission case.






229. Remove 307-584 /1, 307-584 /2, 307-574 /1 and 307-574 /2.





230. Install the forward clutch wave spring.





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





232. Install the forward clutch pack assembly.

1. Position the forward clutch pack assembly in the case.

2. Make sure the alignment tab on the clutch pack is positioned in the correct location.






233. Install the low OWC (One-Way Clutch).





234. NOTE: The low OWC (One-Way Clutch) snap ring gap must be positioned as shown so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.
Install the low OWC (One-Way Clutch) snap ring.





235. Compare the position of the low OWC (One-Way Clutch) snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.





236. Install 100-002 (TOOL-4201-C) on the transmission case and position the plunger on a top friction disc tab.





237. Install a new forward clutch feed seal.





238. Apply 483 kPa (70.05 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on 100-002 (TOOL-4201-C). The clearance should be between 0.85 mm (0.0335 in) and 2.41 mm (0.0949 in). If the clearance is out of range, check the forward clutch pack and low OWC (One-Way Clutch) for correct installation. If the forward clutch pack and low OWC (One-Way Clutch) is correctly installed, install a new forward clutch pack.





239. Remove 100-002 (TOOL-4201-C) from the transmission case.

240. Install the No. 11 stator support thrust bearing.





241. Install the front planetary carrier hub.





242. Install the No. 10 front sun gear thrust bearing.





243. Install the front sun gear and shell assembly.





244. Install the front carrier and rear ring gear assembly.





245. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.





246. Install the center planetary carrier and front ring gear assembly.





247. NOTE: The groove on the center sun gear is installed facing up.
Install the center planetary sun gear.





248. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.





249. Install the rear planetary gear carrier assembly.




pro multis Credits:Operation CHARM About Operation CHARM