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Transaxle Reassembly

NOTE: Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean ATF. Use petroleum jelly on gaskets, thrust washers and needle bearings to retain in place. Use all new gaskets and seals. Tighten bolts evenly.
  1. Using a plastic hammer, tap output and idler gear into converter housing. Install bearing housing, and tighten to 14-19 ft. lbs. (19-26 N.m). Align groove on idle shaft with mark on bearing housing, and tap in roll pin.
  2. Install 2-3 accumulator, and tighten retaining bolts to 69-95 INCH lbs. (8-11 N.m). Install parking pawl and shaft. Install spring and retaining ring. Move shaft to check for proper parking pawl operation. Install parking assist lever and retaining ring. Install actuator support, and tighten retaining bolts to 95-120 INCH lbs. (11-14 N.m).
  3. Install manual shaft, spacer, manual plate, washer and nut, and tighten to 30-41 ft. lbs. (41-55 N.m). Install bracket and retaining bolt. Tighten bolt to 69-95 INCH lbs. (8-11 N.m). Install detent ball, spring, washer and plug. Tighten plug to 9-13 ft. lbs. (12-18 N.m).
  4. Using Seal Protector (T88C-77000-GH), carefully install low and reverse clutch piston by pushing evenly around circumference. DO NOT  damage outer seal. Remove protector.
  5. Install return spring and retainer. Compress return spring and retainer using Spring Compressor (T88C-77000-AH) and Plate (T87C-77000-B). See Fig 1 . Install snap ring. Remove spring compressor.
    Fig 1: Installing Return Spring
    G92F15425Courtesy of FORD MOTOR CO.
  6. Submerge reverse clutch piston in transaxle fluid. Apply maximum of 57 psi (392 kPa) compressed air for no more than 3 seconds through fluid passage. No bubbles should appear between piston and seals. Install output shell to output gear and 2.83" (72.0 mm) thrust washer on output shell.
  7. Apply thin coat of silicone sealant to contact surfaces of converter housing and transaxle case. Install new "O" rings. Install case to converter housing, and tighten retaining bolts to specification.
  8. Install Transaxle Plugs (T88C-7025-AH) to differential side gears. Failure to install plugs may allow differential side gears to become mispositioned.
  9. With thrust washer and needle bearing correctly positioned, install 3-4 clutch and turbine shaft assembly into case. See Fig 2 . Install internal gear and snap ring.
    Fig 2: Locating Thrust Washers & Needle Bearings
    G92E15424Courtesy of FORD MOTOR CO.
  10. With thrust washer and needle bearing correctly positioned, install carrier hub assembly.
  11. Install low and reverse clutch pack, retaining plate and snap ring. Using a feeler gauge, check clearance between retaining ring and retaining plate. If clearance is not .083-.094" (2.10-2.40 mm), install a different retaining plate. Retaining plates are available in following thicknesses: .268" (6.80 mm), .276" (7.00 mm), .283" (7.20 mm), .291" (7.40 mm), .299" (7.60 mm) and .307" (7.80 mm).
    NOTE: 2.2L EFI engine uses 4 drive plates and 4 driven plates. All other models use 5 of each plate.
  12. Install wave washer. Turn carrier hub assembly counterclockwise, and carefully install one-way clutch. Install snap ring.
  13. Install servo spring and servo. Compress servo using a "C" clamp and install retaining ring. Remove "C" clamp. Install piston stem.
  14. Install anchor strut. Install 2-4 band in case fully expanded. Interlock 2-4 band and anchor strut. With thrust washer and needle bearing correctly positioned, install small sun gear and one-way clutch by rotating.
  15. Pull 2-4 band using pliers, and install piston stem in correct position. Loosely tighten piston stem by hand. Ensure needle bearing is correctly positioned.
  16. Install clutch assembly by rotating. Measure height difference between reverse and forward drum and case. Height difference should be .032" (.80 mm) for 1.6L and 2.2L EFI models, .035" (.90 mm) for 1.8L & 1.9L models and .151" (3.80 mm) for 2.2L turbo and 3.0L EFI models. See Fig 3 .
    Fig 3: Measuring Height Difference Of Case & Clutch
    G92G15426Courtesy of FORD MOTOR CO.
  17. Place needle bearing on clutch assembly. To adjust total end play, remove previous thrust washer and gasket from oil pump. Place a .087" (2.20 mm) thrust washer on oil pump. Set oil pump on clutch assembly.
  18. Using a feeler gauge, measure clearance between transaxle case and oil pump. See Fig 4 . Select correct end play thrust washer to install. See END PLAY THRUST WASHER SELECTION CHART  .
    END PLAY THRUST WASHER SELECTION CHART

    Measured Clearance: In. (mm) Thrust Washer Thickness: In. (mm) Part Number
    .000-.004 (0.00-0.11) .087 (2.20) E92Z-7D014-D
    .004-.011 (0.11-0.30) .078 (2.00) E92Z-70D14-C
    .012-.019 (0.31-0.50) .071 (1.80) E92Z-7D014-B
    .020-.027 (0.51-0.70) .063 (1.60) E92Z-7D014-A
    .028-.035 (0.71-0.90) .055 (1.40) E92Z-7D014-F
    .036-.043 (0.91-1.10) .047 (1.20) E92Z-7D014-E
    Fig 4: Measuring Oil Pump-To-Case Clearance
    G92H15427Courtesy of FORD MOTOR CO.
  19. Remove oil pump. Place selected thrust washer and new gasket on oil pump. Install oil pump on clutch assembly, and tighten retaining bolts to 14-19 ft. lbs. (19-26 N.m) Loosen lock nut, and tighten piston stem to 78-95 INCH lbs (9-11 N.m). Loosen piston stem 2 turns. Tighten lock nut to 18-29 ft. lbs. (25-39 N.m).
  20. Install oil strainer using new "O" ring. Tighten retaining bolts to 69-95 INCH lbs. (8-11 N.m). Ensure magnets are correctly positioned in oil pan. Install oil pan and new gasket. Tighten retaining bolts to 69-95 INCH lbs. (8-11 N.m).
  21. Align manual valve with pin on manual plate, and install valve into case. Tighten retaining bolts to 95-130 INCH lbs. (11-15 N.m). Install solenoid connector using a new "O" ring in case.
  22. Install new "O" ring on kickdown cable bracket. Feed cable through case, and connect cable to throttle cam. Install kickdown cable attaching bolt and bracket. Tighten attaching bolt to 69-95 INCH lbs. (8-11 N.m) and bracket bolt to 14-19 ft. lbs. (19-26 N.m).
  23. Install valve body cover using a new gasket. Tighten to 69-95 INCH lbs. (8-11 N.m). Install oil pipes, oil hoses and switch box as an assembly. Tighten switch box retaining bolts to 12-17 ft. lbs. (16-24 N.m). Install ball, spring, new washers and plug. Install harness clip, and tighten to 69-95 INCH lbs. (8-11 N.m). Tighten plug to 23-35 ft. lbs. (31-47 N.m).
  24. Install solenoid connector. Install pulse generator and fluid temperature switch. Tighten pulse generator bolts to 69-95 INCH lbs. (8-11 N.m) and tighten fluid temperature switch bolts to 22-29 ft. lbs. (29-39 N.m).
  25. Install dipstick tube using a new "O" ring. Tighten retaining bolts to 61-87 INCH lbs. (7-10 N.m).
  26. Turn manual shaft to neutral position. Install neutral safety switch to loosely tighten retaining bolts. Remove screw, and insert a .079" (2.00 mm) pin. Move neutral safety switch until pin engages switch alignment hole.
  27. Tighten switch retaining bolts to 69-95 INCH lbs. (8-11 N.m). Remove pin, and install screw. Install harness using remaining clip, and tighten to 69-95 INCH lbs. (8-11 N.m).
  28. Remove transaxle from holding fixture. Using Converter Seal Replacer (T88C-77000-BH), install converter seal.
  29. Install new "O" ring on turbine shaft. Install oil pump shaft.
  30. Fill torque converter with specified transaxle fluid. Carefully install torque converter in converter housing while rotating to align splines.
  31. Measure distance between torque converter and end of converter housing. Distance should be .98" (25.0 mm). See Fig 5 .
  32. Install right transaxle mount, and tighten retaining bolts to 43-49 ft. lbs. (58-67 N.m). Using Differential Seal Replacer (T87C-77000-H), install differential oil seals. To complete reassembly of transaxle, reverse disassembly procedure.
Fig 5: Measuring Converter Housing Clearance
G92I15428Courtesy of FORD MOTOR CO.
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