Pages 17-20-50 Thru 17-20-53A
17-20-50 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
5. Remove the detent spring and attaching bolt.
6. Remove the valve body-to-case attaching bolts. Remove the valve body. Discard the valve body-to-case gasket.
7. Depress the 2-3 accumulator piston cover. Remove the retaining snap ring, cover and spring.
8. Remove the 2-3 accumulator piston.
9. Remove the seals from the 2-3 accumulator piston and discard.
Installation
1. Clean and inspect the 2-3 accumulator piston. Replace piston if damaged.
2. Clean and inspect the 2-3 accumulator pocket in the case for nicks, burrs or porosity.
3. Install new seals on the 2-3 accumulator piston.
4. Install the 2-3 accumulator piston into the case.
5. Install the return spring and cover.
6. Install the retaining snap ring.
7. Inspect the outer edge of 2-3 accumulator piston pocket for nicks or burrs which might have been raised during the removal or installation of the retaining snap ring.
8. Remove nicks or burrs with a fine honing stone and clean the affected surfaces thoroughly. Failure to do so may cause improper seating of the valve body separator plate to the hydraulic passages in the case and subsequent crossleakage.
9. Clean and inspect the valve body as outlined in this Section.
10. Position a new valve body-to-case gasket to the separator plate.
11. Using Valve Body Guide Pins T80L-77100-A or equivalent, position the valve body to the case, making sure that the inner manual lever and inner TV lever are engaged. Install valve bodyto-case attaching bolts. Tighten to 9-11 N-m (80-100 in.lbs.).
12. Install detent spring and attaching bolt. Tighten to 9-11 N-m (80-100 in.lbs.).
13. Remove the Valve Body Guide Pins T80L- 77100-A or equivalent and install and tighten the two remaining valve body attaching bolts.
14. Position the TV lever torsion spring against the separator plate.
15. Using three filter attaching bolts, install the filter and gasket to the valve body. Tighten attaching bolts to 9-11 N-m (80-1 00 in.lbs.).
16. Clean the transmission oil pan and gasket surfaces thoroughly.
17. Using a new oil pan gasket, secure the pan to the transmission case. It may be necessary to use a 3/8-inch or 1/4-inch drive ratchet with a 10 mm universal socket to install the oil pan bolts. Tighten the attaching bolts to 8-13.5 N-m (6-9 ft.lbs.).
18. Install any exhaust system components that might have been removed.
19. Lower the vehicle and fill the transmission to the proper level with the specified fluid. Start the engine and shift the transmission to all ranges, then check the fluid level. Refer to Transmission Fluid Level Check procedure.
20. Adjust TV linkage rod or cable system as outlined under Linkage Adjustment.
Extension Housing Bushing and Rear Seal
Removal
1. Raise the vehicle on a hoist. Refer to the PreDelivery manual, Section 50-04. Disconnect the driveshaft at the transmission. To maintain driveline balance, mark the rear driveshaft yoke and axle companion flange so the driveshaft can be installed in its original position. Refer to Section 15-60.
2. When only the rear seal needs replacing, carefully remove it with Extension Housing Seal Remover T74P-77248-A or equivalent.
3. Remove the bushing. Use the Extension Housing Bushing Remover T77L-7697-A or equivalent carefully so that the output shaft spline is not damaged.
Installation
1. When installing a new bushing, use Extension Housing Bushing Replacer T80L-77034-A or equivalent.
2. Before installing a new seal, inspect the sealing surface of the universal joint yoke for scores. If scores are found, replace the yoke.
3. Inspect the counterbore of the housing for burrs. Remove burrs with crocus cloth.
4. Install the seal into the housing with Extension Housing Seal Replacer T61L-7657-A or equivalent. The seal should be firmly seated in the bore. Coat the inside diameter of the rubber portion of the seal with Long-Life Lubricant C1AZ-19590-BA or equivalent.
5. Install the driveshaft so that the index marks, made during removal are correctly aligned. Refer to Section 15-60.
NOTE: Lubricate yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent.
17-20-51 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
Extension Housing
Removal
1. Raise the vehicle on a hoist or stands. Refer to Pre-Delivery manual, Section 50-04.
NOTE: Remove any interfering exhaust system components.
2. Disconnect the parking brake cable from the equalizer, if so equipped.
3. Disconnect the driveshaft from the rear axle flange and remove it from the transmission. To maintain driveline balance, mark the rear driveshaft yoke and axle companion flange so the driveshaft can be installed in its original position.
4. Disconnect the speedometer cable from the extension housing.
5. Remove the engine rear support-to-extension housing attaching bolts.
6. Place a jack under the transmission and raise it just enough to remove the weight from the engine rear support.
7. Remove the bolt that secures the engine rear support to the crossmember and remove the support.
8. Place a drain pan under the rear of the transmission case.
9. Lower the transmission and remove the extension housing attaching bolts. Slide the extension housing off the output shaft and allow the fluid to drain. Note location of one bolt for installation.
NOTE: The extension housing bolts have been coated with a sealant. More break torque may be required to remove these bolts.
10. Remove and discard extension housing gasket.
Installation
1. Clean the mounting surface on the transmission and on the extension housing. Remove any sealant from the bolts and the case bolt holes. Position a new gasket on the transmission. Coat the bolts with Ford Threadlock and Sealant E0AZ-19544-A or Ford Pipe Sealant D8AZ-19554-A Teflon Tape or equivalent.
2. Hold the extension housing in place and secure it with the attaching bolts. Tighten to 22-27 N-m (16-20 ft.lbs.)
3. Raise the transmission high enough to position the engine rear support on the crossmember.
4. Secure the support to the crossmember with the attaching bolt and nut. Tighten the bolt to specification. Refer to Group 21 for specifications.
5. Lower the transmission and remove the jack. Install engine rear support-to-extension housing attaching bolts. Tighten the bolts to specification. Refer to Group 21 for specifications.
6. Secure the speedometer cable to the extension housing with the attaching bolt.
7. If so equipped, connect the parking brake cable to the equalizer.
8. Install the driveshaft in the transmission and connect shaft to rear axle flange. Install driveshaft so that index marks, made during removal, are correctly aligned. Refer to Section 15-60.
NOTE: Lubricate yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent.
9. Install any exhaust system components that might have been removed.
10. Lower the vehicle. Fill the transmission to the proper level with the specified fluid. Start the engine and shift the transmission through all ranges, then check the fluid level. Refer to Transmission Fluid Level Check procedure.
Governor
Removal
1. Remove the extension housing as outlined.
NOTE: If the governor body only is to be removed, skip Steps 2 and 3.
2. Remove the governor-to-output shaft retaining snap ring.
3. Using a soft-faced hammer, tap the governor assembly off the output shaft. Remove the governor driveball.
4. Remove the governor-to-counterweight attaching screws. Lift the governor from the counterweight.
Installation
1. Lubricate the governor valve parts with clean transmission fluid. Make certain that the valve moves freely in the valve body bore.
2. Position the governor valve body on the counterweight with the cover facing toward the front of the vehicle. Install the two attaching screws, and tighten to 6-7 N-m (50-60 in.lbs.).
3. Position the governor drive ball into the pocket of the output shaft.
4. Align the keyway in the counterweight to the governor drive ball. Slide governor assembly onto the output shaft. If necessary, gently tap governor into position with a soft-faced hammer.
5. Reinstall the governor-to-output shaft retaining snap ring. Clean the mounting surface on the transmission and on the extension housing. Position a new gasket on the transmission.
6. Install the extension housing as outlined.
17-20-52 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
Shift Linkage, Internal and External
Removal
1. It may be necessary to remove the fan shroud bolts and move the shroud away from the fan on models that require lowering the transmission for access to the manual lever.
2. Raise vehicle on a hoist so that transmission oil pan is accessible. Refer to Pre-Delivery manual, Section 50-04.
3. Remove any interfering exhaust system components.
4. On vehicles that require additional clearance to remove the manual lever, lower the transmission.
5. Apply penetrating oil to the outer throttle lever attaching nut to prevent breaking the inner throttle lever.
6. Grasp the outer throttle lever and hold firmly. Remove the outer throttle lever attaching nut and lockwasher. Swing lever and TV rod or cable assembly out of the way for clearance.
7. Carefully disconnect the manual rod from the transmission manual lever at the transmission using the Shift Linkage Grommet Removal Tool T84P-7341-A or equivalent. For tool usage instructions, refer to Section 17-02.
8. Place a drain pan under the transmission oil pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Remove all of the attaching bolts except two at the front to allow the fluid to further drain. It may be necessary to use a 3/8-inch or 1/4-inch drive ratchet with 10 mm universal socket to remove the oil pan bolts. After all fluid has drained, remove the two remaining bolts and the oil pan and gasket. Discard the gasket. If the same fluid is to be used again, filter the fluid through a 100 mesh screen. Reuse the fluid only if it is in good condition.
9. Remove the transmission oil filter grommet and gasket. Discard the gasket. If the fluid is contaminated, discard the filter. (Do not clean the filter).
10. Remove the manual lever detent spring and roller assembly.
11. Remove the manual lever retaining pin by prying with a narrow sharp screwdriver. Use care when removing the pin.
12. Note assembled position of the TV lever torsion spring, then remove spring.
13. Slide a 5/8-inch box end wrench over the inner manual lever close to the bottom of the lever. Do not allow the wrench to contact the "rooster comb" area. Using a 21 mm wrench, remove the manual lever attaching nut. Securely hold the inner manual lever with the box end wrench while applying break torque to the manual lever attaching nut.
14. Remove the outer manual lever from the case.
15. Remove inner throttle lever and shaft assembly.
16. Remove the inner manual lever and park pawl actuating rod assembly.
17. Disconnect the park pawl actuating rod from the inner manual lever.
18. Remove the manual lever oil seal with a screwdriver or Shift Shaft Seal Remover T58L- 101-B and Slide Hammer T50T-100-A or equivalent. Discard the seal.
Installation
1. Install a new manual lever seal into the case using Shift Shaft Seal Replacer T74P-44598-A or equivalent.
2. Check the manual lever, shaft and threads for damage.
3. With the manual lever attaching nut on the inner throttle lever and shaft assembly, slide the inner throttle lever through the inner manual lever.
4. Slide the outer manual lever in the case. Make sure the lever is properly positioned either up or down depending on application.
5. Allow the inner throttle lever and shaft assembly to slide through the ID bore of the outer manual lever.
6. Snug up the manual lever attaching nut against the inner manual lever making sure that flats are properly aligned. Tighten the nut to remove free play, then tighten the nut to specification. The torque can be approximated by tightening the nut to remove free play, then turning the nut an additional 30 degrees. This is equivalent to rotating one point of the nut one-quarter turn.
7. Position TV lever torsion spring on the inner throttle valve shaft and align into notch.
8. Push manual lever all the way into the case. Make sure inner manual lever pin is engaged in manual valve detent slot and inner throttle lever is acting on the TV valve. Neutral start switch plunger must also be riding on cam surface of inner manual lever.
9. Install new manual lever retaining pin in case. Pin must be flush or slightly below pan surface.
10. Install a new throttle lever seal.
11. Install detent spring. Ensure the detent spring roller is centered on "rooster comb" area. Tighten to 9-11 N-m (80-100 in.lbs.).
12. Install the throttle valve outer lever. Do not push inner throttle valve lever past throttle valve.
13. Install throttle lever lockwasher and attaching nut. Tighten nut to 1 6.5-21.5 N-m (12-16 ft.lbs.).
14. Check PARK function and operation of TV lever and manual lever before further assembly.
17-20-53 Transmission, Automatic-AOD
REMOVAL AND INSTALLATION (Continued)
15. Connect the manual linkage rod to the manual lever at the transmission using the Shift Linkage Grommet Installation Tool T84P-7341-B or equivalent. For tool usage instructions, refer to Section 17-02.
16. Install the oil filter gasket and oil filter. Tighten to 9-11 N-m (80-100 in.lbs.).
17. Install oil pan with a new gasket and tighten bolts to 8-13.5 N-m (6-9 ft.lbs.). It might be necessary to use a 3/8-inch or 1/4-inch drive ratchet with a 10 mm universal socket to install the oil pan bolts. On some vehicles it is easier to install the oil pan after the crossmember is installed.
18. Install exhaust system components and crossmember as appropriate. Install the fan shroud bolts, if removed.
19. Lower vehicle and add three quarts of specified transmission fluid.
20. Check and adjust manual linkage. Refer to Section 17-02.
21. Start vehicle in PARK and with brake pedal applied, cycle gear selector several times. Recheck oil level. Check for leaks.
Neutral Start Switch
Removal
1. Place the selector lever in the manual LOW position.
2. Disconnect battery ground cable.
3. Raise the vehicle on a hoist. Refer to PreDelivery manual, Section 50-04.
4. Disconnect the neutral start switch electrical harness from the neutral start switch by pushing the harness straight up off the switch using a long-blade screwdriver underneath the rubber plug section of the harness.
5. Remove the neutral start switch and O-ring using Neutral Start Switch Socket T74P- 77247-A or equivalent, assembled to a ratchet 24 cm (9-1/2 inches) in length. Once the socket and ratchet are on the switch, sufficient clearance for tool movement can be gained by reaching from the rear of the transmission over the extension housing area while standing on a stool.
NOTE: Use the Neutral Start Switch Socket T74P-77247-A or equivalent for both removing
and installing the switch. Other tools could crush or puncture the walls of the switch.
Installation
1. Install the neutral start switch and O-ring.
CAUTION: Exercise care not to damage the switch terminals. Tighten to 11-15 N-m (8-11 ft.lbs.) using a clicker-type torque wrench, the neutral start switch socket tool and by following the method in Step 4 of the removal procedure for tool clearance.
2. Connect the neutral start switch electrical harness to the neutral start switch.
3. Lower the vehicle from the hoist.
4. Connect battery ground cable.
5. Check the operation of the neutral start switch in each position with the parking brake engaged.
17-20-53A Transmission, Automatic-AOD
DISASSEMBLY AND ASSEMBLY