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Air Pressure Check

  1. Disconnect negative battery cable. Remove air cleaner assembly. Disconnect transaxle harness connector. Compress tabs on transaxle electrical harness receptacle and push into case. Raise and support vehicle.
  2. Remove drain plug and drain fluid. Remove left front fender splash shield. Secure cooler lines away from main control cover assembly (side cover). Remove cover and gasket. Remove 12 valve body bolts. Slightly lift valve body and remove "Z" link.
  3. Remove valve body with wiring harness. Remove thermostatic oil level control valve bracket. Pull valve straight out of transaxle case.
    CAUTION: DO NOT  air check coast clutch unless air pressure is maintained in forward clutch circuit, or piston may be forced out of forward clutch piston.
  4. Install Transmission Test Plate (T94P-77000-S). Air check clutch hydraulic circuits for function and leakage. See Fig 1. If leakage is detected, disassemble transaxle and inspect. Remove test plate.
  5. Install thermostatic oil level control valve in transaxle case. Install bracket. Tighten bolt to specification. See TORQUE SPECIFICATIONS . Install new "O" ring on valve body harness connector receptacle. Install receptacle in transaxle case.
  6. Insert "Z" link into end of manual valve. Place valve body in position on transaxle case and install 12 valve body bolts. Tighten bolts in sequence. See Fig 2. Tighten bolts to specification.
  7. 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. See Fig 3. Move manual valve detent lever assembly to "D" position.
  8. 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.
  9. 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 main control cover (side cover) with new gasket. Tighten bolts in sequence. See Fig 4. Tighten bolts to specification.
  10. To complete installation, reverse removal procedures. Tighten drain plug to specification. Add six qts. of Mercon ATF. Start and run vehicle. Add fluid as necessary.
Fig 1: Air Checking Transaxle Assembly
G94G36612Courtesy of FORD MOTOR CO.
Fig 2: Valve Body Bolt Tightening Sequence
G94H36613Courtesy of FORD MOTOR CO.
Fig 3: Installing Shifter Shaft Alignment Tool
G94I36614Courtesy of FORD MOTOR CO.
Fig 4: Cover Bolt Tightening Sequence
G94J36615Courtesy of FORD MOTOR CO.
CAUTION: Perform line pressure test before performing stall speed test. If line pressure is low at stall, DO NOT  perform stall speed test or transaxle damage will occur. DO NOT  maintain Wide Open Throttle (WOT) in any gear for more than 5 seconds.
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