Installation

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.


NOTE:
- To service the 1-2 or 2-3 accumulators or the overdrive or reverse servo assemblies use the following procedure:
- This is not an ordinary installation procedure and does not compensate for band wear.

1. Install reverse band servo spring, reverse band servo piston and rod. When piston and rod assembly replacement becomes necessary, or when the reverse band has been replaced, determine the correct length of the reverse servo piston and rod, proceed as follows:
a. Lubricate the reverse piston seal to facilitate assembly and to prevent damage to the seal.
b. Install the reverse servo piston and return spring. Do not install the piston cover or retaining ring.





c. Install Servo Piston Selection Tool T80L-77030-A. Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A to 5.6 Nm (49 in. lbs.).





d. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent and position the indicator stem on the flat portion of the piston. Zero the dial indicator.
e. Thread the bolt out of the selector tool until the piston stops against the bottom of the tool.
f. Read the amount of piston travel on the dial indicator.
- If the travel is 2.845-6.020 mm (0.112-0.237 inch), the piston length is within specification.
- If the travel is not within specification selective pistons are available in the following lengths:
74.56 mm (2.936 inch) 1 groove
75.92 mm (2.989 inch) 2 groove
77.29 mm (3.043 inch) 3 groove

NOTE: Length of rod measured from piston surface to end of rod.

- Select the proper rod to bring the servo piston travel within specification.

g. Lubricate the cover seal to facilitate assembly and to prevent damage to the seal.
h. Remove the servo selection tool and dial indicator.
2. Install Servo Piston Remover/Replacer T92P-70023-A to transmission case.
3. Tighten screw on Servo Piston Remover/Replacer T92P-70023-A to allow enough clearance to install retaining ring.





4. Install reverse servo retaining ring and remove tool.

CAUTION: Make sure reverse servo retaining ring is completely seated before removing tool.








5. Install overdrive servo piston return spring and overdrive servo piston assembly. Verify tip of piston assembly engages the pocket of overdrive band. Using Servo Piston Remover/Replacer T92P-70023-A, install piston assembly into the case and compress overdrive servo piston return spring.
6. Tighten tool until piston is below retaining ring groove and install retaining ring, remove tool.





7. Install the components for 2-3 accumulator in the following order:
- upper accumulator seal
- accumulator piston
- lower accumulator seal
- accumulator piston spring
- rear band servo spring retainer

NOTE: Retainer is secured by main control.





8. Assemble the components for 1-2 accumulator in the following order:
- 1-2 accumulator spring
- accumulator piston seal
- accumulator piston
- lower accumulator seal
- 1-2 accumulator spring
- cover and seal assembly
- accumulator piston retaining ring





9. Install the 1-2 accumulator assembly and spring to case. Install cover and seal assembly. Install retaining ring.
10. Install main control valve body.





11. Install fluid filter and grommet.





12. Clean, inspect and install pan-to-case gasket and transmission pan. Tighten all bolts to 12-15 Nm (9-11 ft. lbs.).

NOTE: Transmission pan-to-case gasket is reuseable if not damaged.

13. Install transmission shift linkage to manual control lever
14. Pour 4.7 liters (5 quarts) of Motorcraft MERCON or MERCON V (ATF) Transmission Fluid or equivalent FORD approved fluid into fluid filler tube.
15. Reconnect battery ground cable.
16. Start the engine and add specified fluid as required to achieve the proper fluid level.
17. Check the transmission for leaks.