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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 them in place. Use all new gaskets and seals, and tighten bolts evenly.
NOTE: For identification and position of thrust bearings and washers, see Fig 7 .
  1. Slide intermediate/overdrive band assembly into transaxle case. Install oil pump assembly in transaxle case. Tighten bolts to specification in crisscross pattern. See TORQUE SPECIFICATIONS  .
  2. Install low/reverse clutch piston into Low/Reverse Clutch Piston Outer Seal Protector (T94P-77000-D1). Install Low/Reverse Clutch Piston Inner Seal Protector (T94P-77000-D1) into piston. Install piston and remove protectors. See Fig 1 .
  3. Install low/reverse clutch return spring assembly. Install snap ring. Install low/reverse clutch wave spring (measuring purposes only). Install low/reverse clutch plates, and pressure plate. See Figure and Fig 2 . Install low one-way clutch thrust plate (measuring purposes only).
  4. Measure in 2 locations, clearance between low/reverse clutch pressure plate and thrust plate. Average measurements. Clearance should be .021-.046" (.54-1.17 mm). If clearance is not within specification, select proper thickness pressure plate. Pressure plates are available in the following thicknesses: .097-.101 (2.47-2.57), .089-.093 (2.26-2.36) and .081-.085 (2.06-2.16).
    Fig 1: Installing Low/Reverse Clutch Piston
    G94I36630Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of Low/Reverse Clutch Assembly
    G94J36631Courtesy of FORD MOTOR CO.
  5. Remove low/reverse pressure plate, clutch discs and wave spring. Install No. 1 pump support thrust bearing. Remove seal sizer from forward/coast/direct cylinder assembly and install. Install turbine shaft assembly.
  6. Install No. 4 turbine shaft thrust bearing. Install forward one-way clutch and low-intermediate sun gear assembly. Install No. 5 low-intermediate sun gear thrust bearing. Install low-intermediate planetary carrier assembly. Install No. 6 low-intermediate planetary thrust bearing. Install low-intermediate ring gear.
  7. Install No. 7 reverse/overdrive sun gear thrust bearing. Install reverse/overdrive sun gear and shell assembly. Install reverse/overdrive planetary carrier assembly with No. 8 thrust bearing. Install low/reverse clutch plates.
  8. Install low/reverse clutch pressure plate previously selected. Install low/reverse clutch wave spring. Install low one-way clutch assembly with I.D. ring on inner ring, facing upward. Install low one-way clutch thrust plate. Install low one-way clutch snap ring.
  9. Install manual valve detent lever actuating rod. Install Preload Tool Adapter/Aligner Set (T94P-77000-R), on reverse/overdrive planetary carrier assembly. See Fig 3 . Tighten mounting bolts to 119 INCH lbs. (13.5 N.m).
  10. Install Gauge Bar (T94P-77000-Q), with short spacers across transaxle case. Measure distance from top of gauge bar to No. 12 driven sprocket bearing assembly (Dimension "A"). See Fig 3 .
  11. Measure the distance from the top of gauge bar to the bearing surface on the reverse/overdrive planetary carrier assembly (Dimension "B"). See Fig 4 . Dimension "B" - Dimension "A" = Dimension "C". Use Dimension "C" to select correct No. 11 driven sprocket shim. See the DRIVEN SPROCKET SHIM SELECTION CHART  .
    DRIVEN SPROCKET SHIM SELECTION CHART

    Dimension "C" In. (mm) Shim Thickness In. (mm)
    .558-.565 (14.17-14.34) .083-.087 (2.10-2.20)
    .551-.557 (14.00-14.16) .076-.080 (1.92-2.02)
    .544-.550 (13.83-13.99) .069-.073 (1.75-1.85)
    .538-.543 (13.66-13.82) .062-.066 (1.57-1.67)
    .531-.537 (13.49-13.65) .055-.059 (1.40-1.50)
    .524-.530 (13.32-13.48) .048-.052 (1.22-1.32)
  12. Install selected No. 11 shim. Remove gauge bar and preload tool. Install No. 12 driven sprocket bearing assembly. Ensure No. 18 needle bearing is lubricated. Install No. 9 reverse/overdrive ring gear thrust bearing. Install reverse/overdrive ring gear assembly (measuring purposes only).
  13. Install Preload Tool Adapter/Aligner Set (T94P-77000-R) on reverse/overdrive ring gear. Tighten mounting bolts to 119 INCH lbs. (13.5 N.m). Install Gauge Bar (T94P-77000-Q), with short spacers across transaxle case. See Fig 3 .
  14. Measure distance between top of gauge bar to face of reverse/overdrive ring gear assembly (Dimension "D"). Combined thickness of gauge bar and short spacers (1.00" (25.4 mm) is Dimension "E". Dimension "D" - Dimension "E" = Dimension "F". Use Dimension "F" to select correct No. 10 drive sprocket thrust washer. Refer to DRIVE SPROCKET THRUST WASHER SELECTION CHART  .
    DRIVE SPROCKET THRUST WASHER SELECTION CHART

    Dimension "E" In. (mm) Washer Thickness In. (mm)
    .034-.044 (.86-1.12) .056-.059 (1.41-1.51)
    .024-.033 (.60-.85) .066-.070 (1.67-1.77)
    .013-.023 (.34-.59) .076-.080 (1.93-2.03)
    .003-.013 (.08-.33) .086-.090 (2.19-2.29)
    Fig 3: Determining Transaxle Thrust Washer & Shim Thickness
    G94A36632Courtesy of FORD MOTOR CO.
    Fig 4: Transaxle Thrust Washer & Shim Thickness (Dimension "A")
    G94B36633Courtesy of FORD MOTOR CO.
    Fig 5: Transaxle Thrust Washer & Shim Thickness (Dimension "B")
    G94C36634Courtesy of FORD MOTOR CO.
    Fig 6: Measuring Reverse/Overdrive Ring Gear Height
    G94C38242Courtesy of FORD MOTOR CO.
  15. Remove gauge bar and preload tool. Apply petroleum jelly to selected No. 10 drive sprocket thrust washer and install on converter housing. Remove reverse/overdrive ring gear assembly. Install oil filter and seal assembly. Temporarily install appropriate guide pin through filter eyelet into transaxle case hole.
  16. Install oil filter recirculating regulator exhaust seal. Remove guide pin. Install rear chain cover in transaxle case. Assembly drive chain assembly on driven sprocket assembly, and reverse/ overdrive ring gear assembly. Install and fully seat chain and sprocket/ring gear assembly.
  17. Install front chain cover. Install No. 13 driven sprocket thrust bearing assembly. Install final drive planetary/differential assembly. Install Gauge Bar (T94P-77000-Q) with Spacer Set (T94P-77000-T) on transaxle case. Tighten mounting bolts to 119 INCH lbs. (13.5 N.m). See Fig 7 .
  18. Measure distance from top of gauge bar to shim surface area of final drive assembly. Measure in 2 places and average measurements (Dimension "G"). Combined thickness of gauge bar with long spacers (7.00" (177.8 mm) is Dimension "H".
  19. Dimension "G" - Dimension "H" = Dimension "I". Use Dimension "I" to select correct No. 14 differential bearing shim. See DIFFERENTIAL BEARING SHIM SELECTION CHART  .
    DIFFERENTIAL BEARING SHIM SELECTION CHART

    Dimension "I" In. (mm) Washer Thickness In. (mm)
    5.136-5.148 (130.46-130.76) .039-.043 (.98-1.08)
    5.124-5.136 (130.16-130.45) .050-.054 (1.28-1.38)
    5.113-5.123 (129.87-130.15) .062-.066 (1.57-1.67)
    5.101-5.123 (129.87-130.15) .074-.078 (1.87-1.97)
    5.089-5.101 (129.27-129.56) .085-.089 (2.17-2.27)
    Fig 7: Determining Final Drive Shim Thickness
    G94D36635Courtesy of FORD MOTOR CO.
  20. Remove gauge bar and spacers. Install and fully seat speedometer drive gear with tabs facing downward. Install selected No. 14 differential bearing shim. Install No. 15 differential bearing. Install converter housing with gasket.
  21. Install housing bolts (20) and tighten to specification in crisscross pattern. See TORQUE SPECIFICATIONS  . Lubricate and install intermediate and overdrive servo piston and return spring assembly in transaxle case bore. Note number of grooves of servo apply rod. Install Servo Piston Rod Selector (T94P-77000-M) on piston.
  22. Loosely assembly legs and bar of selector. See Fig 8 . Tighten selector assembly legs. Tighten center bolt to 36 INCH lbs. (4.1 N.m). Measure and record distance between top of center bolt and selector tool bar (Dimension "J"). See Fig 9 . Unscrew center bolt until piston movement stops. Measure distance between center bolt and bar (Dimension "K"). Dimension "J" - Dimension "K" = Dimension "L" (rod travel).
  23. Verify that rod travel (Dimension "L") is within specification. See SERVO ROD TRAVEL SPECIFICATION CHART  . If distance is not within specification, replace servo piston and recheck.
    SERVO ROD TRAVEL SPECIFICATION CHART

    Number Of Rod Grooves Travel Specification In. (mm) Rod Length In. (mm)
    0 .096-.194 (2.43-4.93) 4.26 (108.1)
    1 .093-.190 (2.35-4.82) 4.22 (107.1)
    2 .096-.194 (2.43-4.93) 4.16 (105.7)
  24. Remove servo piston selection tool. Install NEW servo cover cap. Using Servo Cover Remover/Replacer (T94P-77000-L), compress servo cover assembly. Install retaining ring. Release servo cover pressure. Remove tool.
    CAUTION: DO NOT  air check coast clutch since piston may be forced out of forward clutch piston.
  25. Install Transmission Test Plate (T94P-77000-S). Air check clutch hydraulic circuits for function and leakage. See Figure . If leakage is detected, disassemble transaxle and inspect. Remove test plate.
  26. Install thermostatic oil level control valve. Tighten bracket bolt to specification. See TORQUE SPECIFICATIONS  . Install new "O" ring on valve body harness connector receptacle. Install receptacle in transaxle case.
  27. Insert "Z" link into end of manual valve. Place valve body in position on transaxle case and install 12 bolts. Tighten bolts in sequence. See Figure . Tighten bolts to specification. Refer to TORQUE SPECIFICATIONS  .
  28. Remove manual control lever bolt and lever assembly. Using Shifter Shaft Alignment Tool (T94P-77000-H), move manual control lever shaft to "D" position. Install pin to hold tool in position. Move manual valve detent lever assembly to "D" position. See Figure .
  29. Loosen nut on ball stud of manual valve detent lever actuating rod assembly. Snug nut on ball stud. Remove shifter pin. Rotate Shifter Shaft Alignment tool until socket can be installed on nut. Tighten bolt to specification. See TORQUE SPECIFICATIONS  .
  30. Rotate lever back to "D" position and recheck adjustment. Remove pin and alignment tool. Install manual control lever assembly. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Install manual lever position sensor. Install main control cover (side cover) with new gasket. Tighten bolts in sequence. See Figure . Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  31. Install vehicle speed sensor. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Install dipstick tube with new grommet. Install dipstick. Install transmission speed sensor. Install differential seals and converter seal. Install drain plug. Install oil pump drive shaft. Install torque converter. Remove transaxle from mount.
Fig 8: Measuring Servo Rod Travel (1 of 2)
G94F36637Courtesy of FORD MOTOR CO.
Fig 9: Measuring Servo Rod Travel (2 of 2)
G94G36638Courtesy of FORD MOTOR CO.
Fig 10: Identifying Thrust Bearing, Shims & Washers
G94H36639Courtesy of FORD MOTOR CO.
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