Pages 17-20-42 Thru 17-20-45
1989
17-20-42 Transmission, Automatic-AOD
ADJUSTMENTS (Continued)
15. Check TV pressure. Refer to Steps 3 through 6.
16. Repeat Steps 10 through 14, if necessary.
NOTE: For best transmission function, the TV pressure should be set as close as possible to 227 kPa (33 psi) in NEUTRAL with gauge tool installed. Since the TV pressure goes up approximately 14 kPa (2 psi) when the shift lever is moved from NEUTRAL to a forward gear ((D) or D), this will result in a TV pressure setting near the desirable 241 kPa (35 psi) in forward gear. Do not attempt to check TV pressure with the transmission in gear. When the gauge tool is removed, the TV pressure should drop to less than 34 kPa (5 psi). If the TV pressure does not drop to less than 34 kPa (5 psi), reset the TV pressure to a value less than 227 kPa (33 psi) with gauge tool installed but no less than 207 kPa (30 psi). Verify that the TV pressure is less than 34 kPa (5 psi) with gauge tool removed.
REMOVAL AND INSTALLATION
Transmission Fluid Drain and Refill Normal maintenance and lubrication requirements do not necessitate periodic automatic transmission fluid changes. If major service, such as a clutch band, bearing, etc., is required in the transmission, it will have to be removed for service. At this time, the converter, transmission cooler and cooler lines must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions (police or taxi), the transmission and torque converter should be drained and refilled with fluid as specified. On the Automatic Overdrive transmission (AOD) (Code T), use MERCON fluid or an equivalent fluid that meets Ford Specification ESP-M2C-185-C.
CAUTION: Use of a fluid other than specified above could result in transmission malfunction and/or failure. Refer to Vehicle Certification Label affixed to LH front door lock face panel or door pillar for transmission code. When filling a dry transmission and converter, refer to Specifications for capacity. Check the fluid level following the room temperature checking procedures. Procedures for partial drain and refill, due to in-vehicle service operation, are as follows.
1. Raise vehicle on a hoist. Refer to the PreDelivery manual Section 50-04.
2. Place a drain pan under the transmission.
3. Loosen the pan attaching bolts and drain the fluid from the transmission.
4. When fluid has drained to the level of the pan flange, remove the rest of the pan bolts, working from the rear, to allow it to drop and drain slowly.
5. When all the fluid has been drained from the transmission, remove and thoroughly clean the pan. Discard the oil pan gasket.
6. Remove and discard the oil filter assembly and the oil filter assembly-to-valve body gasket. DO NOT reuse or clean the filter assembly. The filter element material will contaminate the transmission.
7. Install new pan filter assembly and gasket. DO NOT reuse the old gasket.
8. Place a new gasket on the pan, and install the pan on the transmission. Tighten the oil pan-tocase attaching bolt to specification. Refer to the appropriate transmission section.
9. Add 2.8 liters (3 quarts) of fluid to the transmission through the filler tube.
10. Check the fluid level following the checking procedures. If it is necessary to perform a complete drain and refill, remove the residual fluid from the torque converter and the cooler lines.
17-20-43 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
To drain the torque converter:
1. Remove the lower converter access cover.
2. Rotate the torque converter until the drain plug comes into view.
3. Remove the drain plug and allow the transmission fluid to drain.
NOTE: It is recommended that this procedure be performed prior to other operations to allow sufficient time for the converter to drain properly.
4. Flush the cooler lines completely.
Fluid Cooler Lines
Tube Fittings
When fluid leakage is found at the oil cooler, the cooler must be replaced. Refer to Group 27 for coolant replacement procedure.
When one or more of the fluid cooler steel tubes must be replaced, each replacement tube must be fabricated from the same size steel tubing as the original line.
Using the old tube as a guide, bend the new tube as required. Add the necessary fittings, and install the tube.
After the fittings have been tightened to specification, add fluid as needed and check for fluid.
Transmission
NOTE: If the transmission is being removed for a major overhaul, it is important to completely clean all transmission components, including converter, cooler, cooler lines, main control valve body, governor, all clutches, and all check balls after any transmission servicing that generates contamination. These contaminants are a major cause for recurring transmission troubles and must be removed from the system before the transmission is put back into service.
The cleaning of debris from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission.
Cleaning and flushing procedures for transmission components, including the direct clutch check ball, can be found in this Section listed under Cleaning and Inspection.
Removal
1. Raise vehicle on a hoist. Refer to Pre-Delivery manual Section 50-04.
2. Place the drain pan under the transmission fluid pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Finally remove all of the pan attaching bolts except two at the front, to allow the fluid to further drain. With fluid drained, install two bolts on the rear side of the pan to temporarily hold it in place.
3. Remove the converter drain plug access cover from the lower end of the converter housing.
4. Remove the converter-to-flywheel attaching nuts. Place a wrench on the crankshaft pulley attaching bolt to turn the converter to gain access to the nuts.
5. Place a drain pan under the converter. With the wrench on the crankshaft pulley attaching bolt, turn the converter to gain access to the converter drain plug and remove the plug. After the fluid has been drained, install the plug.
6. Remove catalytic converter assembly.
7. Remove body reinforcement.
8. Remove exhaust pipe and muffler assembly.
9. To maintain driveshaft balance, mark the rear driveshaft yoke and the companion flange so the driveshaft can be installed in its original position.
10. Remove four bolts retaining driveshaft to companion flange.
17-20-44 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
11. Loosen axle assembly rear mounting to crossmember nuts approximately 6.4 mm (0.25 inch).
12. Position axle stand under front of axle housing and remove forward mounting nuts and bushings. Pull vent tube from hole in sub-frame.
13. Lower front of axle housing with axle stand and slide driveshaft out of transmission above axle housing. Let driveshaft rest on front driveshaft support and axle assembly.
CAUTION: Use care when positioning driveshaft so not to nick, burr or contaminate driveshaft yoke or companion flange.
14. Disconnect the cable from the terminal on the starter motor. Remove the three attaching bolts and remove the starter motor. Disconnect the neutral start switch wires at the plug connector.
15. Remove the rear mount-to-crossmember attaching bolts and the two crossmember-toframe attaching bolts.
16. Remove the two engine rear support-toextension housing attaching bolts.
17. Disconnect TV linkage rod or cable from transmission TV lever ball stud. Disconnect cable from bellcrank lever stud and remove self-tapping bolt from bell housing bracketry.
18. Carefully disconnect manual cable from transmission manual lever at transmission. Remove cable mounting bracket from case.
19. Remove the two bolts securing the bellcrank bracket to the converter housing.
20. Raise the transmission with a transmission jack to provide clearance to remove the crossmember. Remove the rear mount from the crossmember and remove the crossmember from the side supports.
NOTE: Disconnect and remove any interfering exhaust system hardware.
21. Lower the transmission to gain access to the oil cooler lines.
22. Disconnect oil cooler line from the fittings on the transmission using Cooler Line Disconnect Tool T86P-77265-AH or equivalent.
23. Disconnect the speedometer cable from the extension housing.
24. Remove the bolt that secures the transmission fluid filler tube to the cylinder block. Lift the filler tube and the dipstick from the transmission.
25. Secure the transmission to the jack with a chain.
26. Remove the converter housing-to-cylinder block attaching bolts.
27. Carefully move the transmission and converter assembly away from the engine and, at the same time, lower the jack to clear the underside of the vehicle.
28. Remove the converter and mount the transmission in Bench Mounted Holding Fixture T57L-500-B or equivalent.
Installation
1. Tighten converter drain plug to 11-38 N-m (8-28 ft.lbs.).
2. Position the converter on the transmission, ensuring the converter drive flats are fully engaged in the pump gear by rotating the converter.
IMPORTANT: Lubricate pilot with chassis grease.
3. With the converter properly installed, place the transmission on the jack. Secure the transmission to the jack with a chain.
4. Rotate the converter until the studs and drain plug are in alignment with the holes in the flywheel.
5. Align the orange balancing marks on converter stud and flywheel bolt hole if balancing marks are present.
17-20-45 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
6. Move the converter and transmission assembly forward into position, using care not to damage the flywheel and the converter pilot. The converter face must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.
NOTE: Before installing the torque converter to the flywheel attaching nut, a check should be made to ensure that the converter is properly seated. The converter should move freely with respect to the flywheel. Grasp the stud. Movement back and forth should result in a metallic clank noise if the converter is properly seated. If the converter will not move, the transmission must be removed and the converter repositioned so that the impeller hub is properly engaged in the pump gear.
7. Install transmission housing-to-engine attaching bolts. Tighten to 55-68 N-m (40-50 ft.lbs.).
8. Remove the safety chain from around the transmission.
9. Install a new O-ring on the lower end of the transmission filler tube. Insert the tube in the transmission case and secure the tube to the engine with the attaching bolt.
10. Connect the speedometer cable to the extension housing.
11. Connect the oil cooler lines to the RH side of transmission case. Tighten lines to 24-31 N-m (18-23 ft.lbs.).
12. Position the crossmember on the side supports. Position the rear mount on the crossmember and install the attaching bolt and nut.
13. Secure the engine rear support to the extension housing and tighten the bolts to specification. Refer to Group 21 for Specifications.
14. Lower the transmission and remove the jack.
15. Secure the crossmember to the side supports with the attaching bolts and tighten to 95-136 N-m (70-100 ft.lbs.).
16. Connect the TV linkage rod to the transmission TV lever. Connect the manual linkage rod to the manual lever at the transmission.
17. Connect TV linkage rod or cable to transmission TV lever ball stud. Attach cable to bell housing bracketry by installing self-tapping bolt. Also, connect cable to bellcrank lever stud.
18. Connect manual linkage rod to manual lever at transmission using the Shift Linkage Grommet Installation Tool T84P-7341-B or equivalent. For tool usage instructions, refer to Section 17-02.
19. Install converter-to-flywheel attaching nuts. Tighten to 27-46 N-m (20-34 ft.lbs.).
20. Install the converter housing access cover and secure it with the attaching bolts. Tighten to 16-22 N-m (12-16 ft.lbs.).
21. Secure the starter motor in place with the attaching bolts. Connect the cable to the terminal on the starter. Connect the neutral start switch harness at the transmission.
22. Slide driveshaft slip yoke into transmission.
NOTE: Lubricate the yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent.
23. Raise axle housing with axle stand and install bushings and retaining nuts. Tighten to 92-136 N-m (68-100 ft.lbs.). Remove axle stand.