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

Part 6




Transmission - Overhaul

Special Tool(s)










Material(s)






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250. NOTICE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low OWC (One-Way Clutch) snap ring may result in damage to the transmission.

Install the low/reverse clutch pressure plate.

1. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC (One-Way Clutch) snap ring.

2. Install the low/reverse clutch pressure plate.






251. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC (One-Way Clutch) snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.





252. Lubricate the low/reverse clutch pack with clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





253. Install the low/reverse clutch pack.





254. Install the low/reverse pressure plate.





255. Low/Reverse Clutch Measurement - Using a straightedge and 303-D075 (D92P-4201-A) , measure and record as measurement A, the distance from the transmission case deck surface to the low/reverse pressure plate.





256. Using the same straightedge and 303-D075 (D92P-4201-A) , measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.





257. Subtract measurement B from measurement A and add 1.6 mm (0.063 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 1.01 mm (0.0398 in) and 2.47 mm (0.0972 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 low/reverse clutch pack.





258. Install the intermediate clutch pressure plate.





259. Lubricate the intermediate clutch pack assembly in clean Motorcraft(R) MERCON(R) LV Automatic Transmission Fluid.





260. Install the intermediate clutch pack assembly.





261. Install the intermediate clutch pack wave spring.





262. Intermediate Clutch Measurement - Using a straightedge and 303-D075 (D92P-4201-A) , measure and record as measurement A, the distance from the transmission case deck surface to a low point on the intermediate clutch wave spring.





263. Using the same straightedge and 303-D075 (D92P-4201-A) , measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.





264. Subtract measurement B from measurement A and add 1.6 mm (0.063 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.0390 in) and 2.56 mm (0.1008 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.





265. Install the rear sun gear and shell assembly.





266. Install the No. 3 rear sun gear thrust bearing.





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






268. Position the overdrive/direct clutch assembly in the cover assembly, install 100-002 (TOOL-4201-C) or a dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70.05 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 1.13 mm (0.0445 in) and 2.28 mm (0.0898 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.





269. Position 100-002 (TOOL-4201-C) on the direct clutch pressure plate. Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.98 mm (0.0386 in) and 2.34 mm (0.0921 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.





270. Install the overdrive/direct clutch hub and turbine shaft assembly.





271. Install the No. 1 cover assembly thrust bearing.





272. Install the cover assembly gasket.





273. Route the TSS (Turbine Shaft Speed) sensor harness through the transmission case to the valve body area and install the cover assembly.





274. Install the cover assembly bolts and tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).





275. Install the OSS (Output Shaft Speed) sensor and the bolt.
- Tighten to 12 Nm (106 lb-in).





276. NOTICE: Be careful not to pinch the TSS (Turbine Shaft Speed), OSS (Output Shaft Speed) or TR (Transmission Range) sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.

NOTE: Make sure that the pin (part of the TR (Transmission Range) sensor) is correctly installed in the manual valve.
Position the TSS (Turbine Shaft Speed), OSS (Output Shaft Speed) and TR (Transmission Range) sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.

1. Pin (part of the TR (Transmission Range) sensor)

2. Manual valve






277. Install the main control valve body bolts. Tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).





278. NOTICE: Make sure not to pinch the TSS (Turbine Shaft Speed), OSS (Output Shaft Speed) or TR (Transmission Range) sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.

NOTE: Install the different length bolts in the locations noted during disassembly.
Install the solenoid body bolts hand-tight.

1. 42 mm (1.6535 in) bolt

2. 63 mm (2.4803 in) bolts

3. 80 mm (3.1496 in) bolts

4. 95 mm (3.7402 in) bolts






279. Tighten the solenoid body bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).





280. Route the OSS (Output Shaft Speed) sensor wiring harness into the retainer.





281. Connect the TSS (Turbine Shaft Speed) and OSS (Output Shaft Speed) sensor electrical connectors.





282. Connect the TR (Transmission Range) sensor electrical connector and slide the lock tab to the LOCK position.





283. Inspect the transmission main control cover seal for damage and install new if necessary.





284. NOTE: Install the studbolts in the locations noted during disassembly.
Install the transmission main control cover and install the bolts.

1. Bolt location

2. Studbolt location






285. Tighten the main control cover bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).





286. NOTICE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.4724 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.

Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transmission.





287. Remove the bolts from the torque converter.





288. Install 307-346 (T97T-7902-A).




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