Part 1

1. Prepare for transaxle assembly by proceeding with the following steps:
a. Clean all parts (except friction plates, seals and intermediate/overdrive band) in solvent.
b. Dry all parts with compressed air (do not use shop towels).
c. Lubricate all internal parts (including friction plates) with Motorcraft MERCON(r) Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON(r) specification.
d. Order the required service parts.
e. Make sure that the complete assortment of selective thickness parts are on hand for adjustments during assembly:
^ drive sprocket thrust washers
^ driven sprocket thrust bearing shims
^ differential case thrust bearing shims
^ low/reverse clutch pressure plates
f. During assembly, use petroleum jelly to hold the parts in place (do not use grease).
g. When tightening fasteners, use an accurate torque wrench.
h. Lightly coat bolt and nut threads with automatic transmission fluid for installation torque specifications.





2. Slide the intermediate and overdrive band assembly into the transaxle case.





3. Apply a thin coat of petroleum jelly to the pump support seals and the pump bore in the transaxle case, install the two Pump Removal Bolts T94P-77000-G to the pump assembly and lower the pump assembly into the transaxle case.





4. Install the nine pump assembly bolts. Use an 8 mm socket to tighten the pump assembly bolts in the sequence shown to 12-14 Nm (107-123 inch lbs.).





5. Lubricate seals and piston bore with clean Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON(r) equivalent and install the low/reverse clutch piston into Low/Reverse Clutch Piston Outer Seal Protector T94P-77000-D1 and Low/Reverse Clutch Piston Inner Seal Protector T94P-77000-D5 (part of Clutch Piston Seal Protector/Sizer Set T94P-77000-D). Install the low/reverse clutch piston. Remove the seal protectors. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





6. Install the low/reverse clutch return spring assembly.





7. Use a screwdriver to install the low/reverse clutch return spring retaining ring.





8. Install the low/reverse clutch wave spring

CAUTION: The low/reverse clutch wave spring is installed in this position for measurement purposes only.

Low/Reverse Clutch Plates:

9. Install the low/reverse clutch plates, and the low/reverse clutch pressure plate.





10. Install the low one-way clutch thrust Late.

CAUTION: The low one-way clutch thrust plate is installed in this position for measurement purposes only.





11. Use a feeler gauge to measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate. Make a second measurement on the opposite side. Average the two measurements to obtain the clearance.
12. The standard clearance is 0.54 to 1.17 mm (0.02 to 0.05 inch). If the clearance is not within specification, select the proper thickness pressure plate to obtain the standard clearance.
Pressure Plate Thickness mm (inch)
2.57-2.47 (0.100 to 0.097)
2.36-2.26 (0.092 to 0.088)
2.16-2.06 (0.085 to 0.081)

Part 1 Of 2:

Part 2 Of 2:

13. Remove the low one-way clutch thrust plate, low/reverse clutch pressure plate, low/reverse clutch external spline clutch plate (steel), low/reverse clutch internal spline clutch plates (friction), and the low/reverse clutch wave spring.

NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.





14. Install the No. 1 pump support thrust bearing assembly.
15. Remove the seal sizer from the forward/coast/direct clutch cylinder assembly.





16. Install the assembly of forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.





17. Install the turbine shaft assembly.





18. Install the No. 4 turbine shaft thrust bearing assembly.





19. Install the forward one-way clutch and low-intermediate sun gear assembly.





20. Install the No. 5 low-intermediate sun gear thrust bearing assembly.





21. Install the low-intermediate carrier assembly.





22. Install the No. 6 low-intermediate carrier thrust bearing assembly.





23. Install the low-intermediate ring gear assembly.





24. Install the No. 7 reverse/overdrive sun gear thrust bearing assembly.





25. Install the reverse/overdrive sun gear and shell assembly.





26. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.





27. Install the low/reverse clutch plates.





28. Install the low/reverse clutch pressure plate





29. Install the low/reverse clutch wave spring.





30. Install the low one-way clutch assembly with the I.D. ring on the inner ring facing UP.





31. Install the low one-way clutch thrust plate.





32. Install the low one-way clutch retaining ring.

NOTE: Make sure to position the low one-way clutch retaining ring as shown.





33. Snap the socket end of the manual valve detent lever actuating rod on the parking cam actuator lever.





34. Snap the opposite socket end of the manual valve detent lever actuating rod assembly on the manual valve detent lever assembly.





35. Install Preload Tool T94P-77000-R1, Preload Tool Adapter T94P-77000-R2, Preload Tool Aligner T94P-77000-R3, and Preload Aligner Adapter T94P-77000-R4 (all are part of Preload Tool Adapter/Aligner Set T94P-77000-R), on the reverse/overdrive carrier assembly as shown. Install and tighten the four bolts to 13 Nm (120 inch lbs.).





36. Install Gauge Bar T94P-77000-Q with short spacers across the transaxle case.





37. Measure the distance from the top of the gauge bar to the No. 12 driven sprocket bearing assembly surface area of the transaxle case. This is dimension A.





38. Use a depth micrometer to measure the distance from the top of the gauge bar to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft. Repeat this measurement on the other side of the turbine shaft 180° from the first measurement. The average of these two dimensions is dimension B.
39. Subtract dimension B from dimension A to get dimension C.
40. Use dimension C to select the proper No. 11 driven sprocket shim from the following chart.
Dimension C: Shim Thickness
14.34-14.17 mm (0.565-0.558 in): 2.20-2.10 mm (0.087-0.083 in)
14.16-14.00 mm (0.557-0.551 in): 2.02-1.92 mm (0.080-0.076 in)
13.99-13.83 mm (0.550-0.544 in): 1.85-1.75 mm (0.073-0.069 in)
13.82-13.66 mm (0.543-0.538 in): 1.67-1.57 mm (0.066-0.062 in)
13.65-13.49 mm (0.537-0.531 in): 1.50-1.40 mm (0.059-0.055 in)
13.48-13.32 mm (0.530-0.524 in): 1.32-1.22 mm (0.052-0.048 in)
41. Remove the gauge bar and preload tool.
42. Install the selected No. 11 driven sprocket shim on the case.





43. Install the No. 12 driven sprocket bearing assembly.
44. Lubricate the needles and seals in the No.18 driven sprocket bearing assembly.





45. Install the No.9 reverse/overdrive ring gear thrust bearing assembly.





46. Install the reverse/overdrive ring gear assembly, for gauging only.

NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.





47. Install Preload Tool Aligner T94P-77000-R3 (part of Preload Tool Adapter/Aligner Set T94P-77000-R) on the shaft. Install and tighten the four bolts to 13 Nm (120 inch lbs.). Install Preload Tool T94P-77000-R1 (part of Preload Tool Adapter/Aligner Set T94P-77000-R) on the reverse/overdrive ring gear assembly.





48. Install Gauge Bar T94P-77000-Q with short spacers on the transaxle case.





49. Use a depth micrometer to measure the distance from the top of the Gauge Bar to the face of the reverse/overdrive ring gear assembly on one side of the turbine shaft. Repeat this measurement on the other side of the turbine shaft 180° from the first measurement. The average of these two dimensions is dimension A.
50. Use combined thickness 25.4 mm (1.00 inch) of Gauge Bar T94P-77000-Q and short spacers as distance B.
51. Subtract dimension A from dimension B to get dimension C.
52. Use dimension C to select the proper No.10 drive sprocket thrust washer from the following chart.
Dimension C: No. 10 Thickness
1.12-0.86 mm (0.044-0.034 in.)
1.51-1.41 mm (0.059-0.056 in.)
0.85-0.60 mm (0.033-0.024 in.)
1.77-1.67 mm (0.070-0.066 in.)
0.59-0.34 mm (0.023-0.013 in.)
2.03-1.93 mm (0.080-0.076 in.)
0.33-0.08 mm (0.013-0.003 in.)
2.29-2.19 mm (0.090-0.086 in.)
53. Remove the gauge bar and preload tool.





54. Apply petroleum jelly to the selected No. 10 drive sprocket thrust washer and install on the converter housing.





55. Remove the reverse/overdrive ring gear assembly.





56. Install new fluid filter and seal assembly.





57. Temporarily install one alignment pin in filter eyelet and transaxle case hole.





58. Use Shift Lever Seal Replacer TOOL-77288 or equivalent to install the filter recirculating regulator exhaust seal.

NOTE: Lubricate the filter recirculating regulator exhaust seal prior to installation.

59. Remove the alignment pin.





60. Install the rear chain cover in the case.





61. Assemble the drive chain assembly on the driven sprocket assembly, and the reverse/overdrive ring gear assembly with the copper color link facing upward.





62. Lower the drive chain assembly, driven sprocket assembly, and the reverse/overdrive ring assembly together in the case. Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.

WARNING: WEAR GLOVES AS PERSONAL PROTECTION FROM SHARP CHAIN AND SPROCKET TEETH.





63. Install the front chain cover by snapping it into place.





64. Install the No. 13 driven sprocket thrust bearing assembly.





65. Install the final drive carrier and differential assembly.





66. Install Gauge Bar T94P-77000-Q with Gauge Bar Spacer Set T94P-77000-T on the case and secure bolts.

NOTE: Plastic washers should be placed between bolt heads and gauge bar.





67. Use a depth micrometer to measure the distance from the top of the gauge bar to the shim surface area of the final drive carrier and differential assembly. Make two measurements and average. This is dimension A.