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Section 1273 (Automatic Transaxle/Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
TRANSMISSION DISASSEMBLY SPECIAL TOOLS

G03948850
 Remover, Input Shaft Oil Seal 308-375
G03985217
 Remover, Transmission Fluid Pump 307-397
G03912866
 Holding Fixture, Transmission 307-003 (T57L-500-B)
G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03922675
 Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH)
G03997617
 Compressor, Servo Cover 307-402
G03914889
 Handle, Torque Converter 307-091 (T81P-7902-C)
G03997382
 Remover, Output Shaft Flange 307-523
Fig 1: Exploded View Of Transmission (1 Of 6)
G03985224Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transmission (2 Of 6)
G03997384Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transmission (3 Of 6)
G03985226Courtesy of FORD MOTOR CO.
Fig 4: Exploded View Of Transmission (4 Of 6)
G03997386Courtesy of FORD MOTOR CO.
Fig 5: Exploded View Of Transmission (5 Of 6)
G03997387Courtesy of FORD MOTOR CO.
Fig 6: Exploded View Of Transmission (6 Of 6)
G03997388Courtesy of FORD MOTOR CO.
CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If not damaged, the gasket should be reused.
NOTE: Tag and identify all parts for reassembly.
    WARNING: The torque converter is heavy, especially when full of fluid.
    NOTE: If not installing a new torque converter, leave the adapter plate screwed to the torque converter.
    Fig 7: Removing Torque Converter And Adapter Plate
    G03948860Courtesy of FORD MOTOR CO.
  1. Using the special tools, remove the torque converter and adapter plate as an assembly.
  2. If the vehicle is equipped, and installation of a new or remanufactured torque converter is necessary, remove the torque converter adapter plate.
    Fig 8: Removing Torque Converter Adapter Plate
    G03948858Courtesy of FORD MOTOR CO.
  3. If the adapter plate has been removed, use the special tools to remove the torque converter.
    Fig 9: Removing Torque Converter
    G03948859Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
    Fig 10: Removing Input Shaft
    G03948861Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the transmission into the bench with the torque converter housing facing up.
    Fig 11: Installing Transmission Into The Bench With The Torque Converter Housing Facing Up
    G03949105Courtesy of FORD MOTOR CO.
  6. Remove the transmission sensors.
    Fig 12: Removing Transmission Sensors
    G03948862Courtesy of FORD MOTOR CO.
  7. Remove the transmission range senor.
    Fig 13: Locating Transmission Range Sensor
    G03985236Courtesy of FORD MOTOR CO.
  8. Remove and discard the nut.
    Fig 14: Removing Driveshaft Nut
    G03985155Courtesy of FORD MOTOR CO.
  9. Using the special tool, remove the output shaft flange.
    Fig 15: Removing Output Shaft Flange
    G03985151Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the extension housing seal.
    Fig 16: Removing Extension Housing Seal
    G03948865Courtesy of FORD MOTOR CO.
    11. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 17: Identifying Extension Housing And Mounting Screws
    G03985165Courtesy of FORD MOTOR CO.
  11. Remove the extension housing.
  12. Remove the parking pawl assembly and discard the gasket.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    4. Remove and discard the gasket.
    Fig 18: Removing Parking Pawl Assembly
    G03948869Courtesy of FORD MOTOR CO.
    13. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If the gasket is not damaged, the gasket should be reused.
    Fig 19: Identifying Transmission Fluid Pan And Gasket
    G03948629Courtesy of FORD MOTOR CO.
  13. Remove the transmission fluid pan and gasket.
  14. Remove the transmission fluid filter and discard.
    Fig 20: Identifying Transmission Fluid Filter Mounting Screws
    G03948630Courtesy of FORD MOTOR CO.
  15. Remove the manual control valve detent spring
    Fig 21: Identifying Manual Control Valve Detent Spring
    G03985127Courtesy of FORD MOTOR CO.
    16. WARNING: The upper and lower servo covers are under spring tension. Use care when removing the piston and cover assembly. Failure to follow these instructions may result in personal injury.
    Fig 22: Removing Reverse Servo Assembly
    G03948644Courtesy of FORD MOTOR CO.
  16. Remove the reverse servo assembly.
    17. CAUTION: Do not damage solenoid body connector pins.
    Fig 23: Locating Solenoid Body Mounting Screws
    G03948643Courtesy of FORD MOTOR CO.
  17. Remove the solenoid body assembly by lifting on the body and pushing the connector from the other side of the case.
  18. Remove the main control valve body, separator plate and gasket.
    Fig 24: Removing Main Control Valve Body
    G03948646Courtesy of FORD MOTOR CO.
  19. Using the special tools, remove the converts hub seal.
    Fig 25: Removing Converts Hub Seal
    G03948876Courtesy of FORD MOTOR CO.
    20. CAUTION: Failure to loosen the OD band adjusting screw prior to pump removal may cause damage to the pump and OD band.
    CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 26: Locating Locknuts
    G03948877Courtesy of FORD MOTOR CO.
  20. Remove the locknuts, and loosen the OD band adjusting screw.
  21. Remove and tag part for assembly.
    Fig 27: Removing And Tagging Part For Assembly
    G03948878Courtesy of FORD MOTOR CO.
    22. CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.
    Fig 28: Locating Transmission Housing Screws
    G03948879Courtesy of FORD MOTOR CO.
  22. Remove and discard the screws.
  23. Install the special tool.
    Fig 29: Installing Special Tool Into Transmission Housing
    G03948880Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the pump.
    Fig 30: Removing Pump
    G03948881Courtesy of FORD MOTOR CO.
    25. CAUTION: Servo cover is under spring tension.
    Fig 31: Removing Intermediate Servo Cover Retaining Ring
    G03948882Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the intermediate servo cover retaining ring.
  26. Remove the intermediate band servo piston and spring.
    Fig 32: Locating Intermediate Band Servo Piston And Spring
    G03948883Courtesy of FORD MOTOR CO.
    27. CAUTION: Servo cover is under spring tension.
    Fig 33: Removing Overdrive Servo Cover Retaining Ring
    G03948884Courtesy of FORD MOTOR CO.
  27. Using the special tool, remove the overdrive servo cover retaining ring and cover.
  28. Remove the front band servo piston and spring.
    Fig 34: Locating Front Band Servo Piston And Spring
    G03948885Courtesy of FORD MOTOR CO.
  29. Remove the screw.
    Fig 35: Locating Screw
    G03948886Courtesy of FORD MOTOR CO.
    30. NOTE: Tag and identify parts for reassembly.
    Fig 36: Identifying Apply Strut
    G03948887Courtesy of FORD MOTOR CO.
  30. Compress the overdrive band and remove the apply strut.
    31. CAUTION: Identify the anchor and apply ends of the overdrive band.
    NOTE: The new overdrive band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 37: Identifying Overdrive Band
    G03948888Courtesy of FORD MOTOR CO.
  31. Remove and inspect the overdrive band. Check the following conditions for installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
  32. Remove the overdrive brake and coast clutch drum.
    Fig 38: Identifying Overdrive Brake And Coast Clutch Drum
    G03948889Courtesy of FORD MOTOR CO.
    33. CAUTION: Do not bend the trigger wheel.
    NOTE: The No. 12 thrust bearing is in this assembly.
    Fig 39: Identifying Planetary Gear Overdrive Carrier
    G03948890Courtesy of FORD MOTOR CO.
  33. Remove the planetary gear overdrive carrier.
  34. Remove the No. 2 overdrive planet thrust bearing.
    Fig 40: Identifying Overdrive Planet Thrust Bearing
    G03948891Courtesy of FORD MOTOR CO.
  35. Remove the overdrive ring gear, overdrive one-way clutch assembly and center shaft as an assembly.
    Fig 41: Identifying Overdrive Ring Gear
    G03948892Courtesy of FORD MOTOR CO.
    36. NOTE: Tag and identify the center shaft thrust bearing No. 3 for reassembly.
    Fig 42: Identifying Center Shaft Thrust Bearing
    G03948893Courtesy of FORD MOTOR CO.
  36. Remove the No. 3 center shaft thrust bearing.
    37. CAUTION: The center support locknut could fall into the remaining assembly if not removed.
    Fig 43: Locating Center Support Locknut Bolt
    G03948894Courtesy of FORD MOTOR CO.
  37. Remove the bolt.
  38. Remove the locknut and cage.
    Fig 44: Locating Center Support Locknut And Cage
    G03948895Courtesy of FORD MOTOR CO.
  39. Remove the center support retaining ring.
    Fig 45: Identifying Center Support Retaining Ring
    G03948896Courtesy of FORD MOTOR CO.
    40. NOTE: The center support is repaired as an assembly. Any damage requires installing a new component.
    NOTE: When removing the center support, pull evenly around the center support web.
    Fig 46: Removing Center Support
    G03948897Courtesy of FORD MOTOR CO.
  40. Remove the center support.
  41. Inspect the center support assembly for wear or damage.
    1. Inspect the thrust surfaces for wear or damage.
    2. Inspect the center support sealing surface.
    3. Inspect the fluid passage for blockage or damage.
    Fig 47: Inspecting Center Support Assembly
    G03948898Courtesy of FORD MOTOR CO.
  42. Inspect the seal rings for damage.
    Fig 48: Identifying Seal Rings
    G03948899Courtesy of FORD MOTOR CO.
  43. Inspect the bearing for missing rollers or damage.
    Fig 49: Inspecting Bearing For Missing Rollers Or Damage
    G03948900Courtesy of FORD MOTOR CO.
  44. Inspect the direct clutch feed hole for blockage or damage.
    1. Rotate the center support bearing to locate the direct clutch feed hole.
    2. Inspect the direct clutch feed hole for blockage or damage.
    Fig 50: Inspecting Direct Clutch Feed Hole
    G03948901Courtesy of FORD MOTOR CO.
    45. NOTE: Tag and identify the No. 4 intermediate clutch drum thrust bearing.
    Fig 51: Identifying Intermediate Brake Drum Thrust Washer
    G03948902Courtesy of FORD MOTOR CO.
  45. Remove the intermediate brake drum thrust bearing (No. 4).
  46. Remove, tag and identify the band anchor strut for assembly.
    Fig 52: Identifying Intermediate Band Anchor Strut
    G03948903Courtesy of FORD MOTOR CO.
    47. CAUTION: Identify the anchor and apply ends of the intermediate band.
    NOTE: The new intermediate band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
    Fig 53: Identifying Intermediate Band
    G03948904Courtesy of FORD MOTOR CO.
  47. Remove and inspect the intermediate band. Check the following conditions when installing a new band:
    • Inspect for glazing.
    • Inspect for missing friction material.
    • Inspect for material flaking.
    • Inspect for damage to the anchor pins.
  48. Remove, tag and identify the band apply strut.
    Fig 54: Installing Intermediate Band Apply Strut
    G03948905Courtesy of FORD MOTOR CO.
  49. Remove the screw.
    Fig 55: Locating Screw
    G03949148Courtesy of FORD MOTOR CO.
    50. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
    Fig 56: Identifying Direct Clutch Drum
    G03948907Courtesy of FORD MOTOR CO.
  50. Remove the direct clutch drum.
  51. Remove the No. 5 forward clutch cylinder thrust bearing, tag and identify.
    Fig 57: Identifying Thrust Bearing
    G03948908Courtesy of FORD MOTOR CO.
    52. NOTE: The No. 6A thrust bearing may come out with the cylinder. Tag and identify for reassembly.
    Fig 58: Identifying Forward Clutch Cylinder
    G03948909Courtesy of FORD MOTOR CO.
  52. Remove the forward clutch cylinder.
    53. NOTE: The No. 6A forward ring gear hub thrust bearing may have come out with the forward clutch cylinder.
    Fig 59: Identifying Forward Ring Gear Hub Thrust Bearing
    G03948910Courtesy of FORD MOTOR CO.
  53. Remove the No. 6A forward ring gear hub thrust bearing.
    54. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
    Fig 60: Identifying Forward Ring Gear And Hub
    G03948911Courtesy of FORD MOTOR CO.
  54. Remove the forward ring gear and hub as an assembly.
  55. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
    Fig 61: Identifying Forward Clutch Thrust Washer
    G03948912Courtesy of FORD MOTOR CO.
    56. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
    Fig 62: Identifying Forward Planet Thrust Bearing
    G03948913Courtesy of FORD MOTOR CO.
  56. Remove the No. 7 forward planet thrust bearing.
  57. Remove the forward planetary assembly.
    Fig 63: Identifying Forward Planetary Assembly
    G03948914Courtesy of FORD MOTOR CO.
  58. Remove the input shell and sun gear assembly.
    Fig 64: Identifying Input Shell And Sun Gear Assembly
    G03948915Courtesy of FORD MOTOR CO.
  59. Remove the spacer.
    Fig 65: Removing Spacer
    G03948916Courtesy of FORD MOTOR CO.
    60. NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
    Fig 66: Identifying Thrust Bearing
    G03948917Courtesy of FORD MOTOR CO.
  60. Remove the thrust bearing.
  61. Remove the retaining ring.
    Fig 67: Identifying Retaining Ring
    G03949127Courtesy of FORD MOTOR CO.
  62. Remove the low/reverse planetary assembly.
    Fig 68: Identifying Low/Reverse Planetary Assembly
    G03948919Courtesy of FORD MOTOR CO.
    63. NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
    Fig 69: Identifying Thrust Bearing
    G03948920Courtesy of FORD MOTOR CO.
  63. Remove the thrust bearing.
    64. NOTE: Use slots located around the outside of the sleeve.
    Fig 70: Identifying Output Shaft Sleeve
    G03949124Courtesy of FORD MOTOR CO.
  64. Using a small pick, remove the output shaft sleeve.
    65. WARNING: The output shaft may fall out after removing the snap ring. Failure to follow these instructions may result in personal injury.
    CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 71: Identifying Output Shaft Retaining Ring
    G03948922Courtesy of FORD MOTOR CO.
  65. While holding the output shaft, remove and discard the output shaft retaining ring.
  66. Remove the output shaft ring gear and hub.
    Fig 72: Identifying Output Shaft Ring Gear
    G03948923Courtesy of FORD MOTOR CO.
  67. Remove the No. 10 low intermediate sun gear bearing.
    Fig 73: Identifying Low Intermediate Sun Gear Bearing
    G03948924Courtesy of FORD MOTOR CO.
    68. CAUTION: Do not pry on the outer edge of the case. Damage to the gasket sealing surface could occur.
    NOTE: It may be necessary to grind flat spots on the edges of the reverse band actuating lever shaft in order to remove it.
    Fig 74: Identifying Reverse Band Actuating Lever Shaft
    G03985297Courtesy of FORD MOTOR CO.
  68. Using a pair of vice grips, hold the flat spots on the reverse band actuating lever shaft, wiggle it back and forth and remove the reverse band actuating lever shaft.
  69. Remove the reverse band actuating lever assembly.
    Fig 75: Identifying Reverse Band Actuating Lever
    G03948926Courtesy of FORD MOTOR CO.
    70. NOTE: The inner race of the rear one-way clutch is not removable. It is repaired in the case.
    Fig 76: Identifying Low/Reverse Brake Drum
    G03948927Courtesy of FORD MOTOR CO.
  70. Remove the low/reverse brake drum and one-way clutch assembly by rotating it clockwise.
    71. NOTE: The reverse one-way clutch is part of the reverse brake drum assembly. Install a new reverse brake drum as an assembly only.
    Fig 77: Inspecting Reverse Brake Drum Assembly
    G03948928Courtesy of FORD MOTOR CO.
  71. Inspect the reverse brake drum assembly and install a new reverse brake drum assembly if damaged.
    1. Inspect the reverse brake drum sprags.
    2. Inspect the reverse brake drum rollers.
    3. Inspect the reverse brake drum.
  72. Remove the reverse band.
    Fig 78: Identifying Low/Reverse Band
    G03948929Courtesy of FORD MOTOR CO.
  73. Remove the output shaft and park gear.
    Fig 79: Identifying Output Shaft And Park Gear
    G03985302Courtesy of FORD MOTOR CO.
    74. NOTE: Tag and identify the No. 11 output shaft thrust washer.
    Fig 80: Removing Output Shaft Thrust Washer
    G03985303Courtesy of FORD MOTOR CO.
  74. Remove the output shaft thrust washer.
    75. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.
    Fig 81: Locating Nut
    G03985304Courtesy of FORD MOTOR CO.
  75. Remove the nut.
  76. Remove the manual shaft retaining pin.
    Fig 82: Locating Manual Shaft Retaining Pin
    G03985305Courtesy of FORD MOTOR CO.
  77. Remove the manual control lever shaft.
    Fig 83: Removing Manual Control Lever Shaft
    G03985306Courtesy of FORD MOTOR CO.
  78. Disconnect the manual valve inner lever from the parking lever actuating rod.
    Fig 84: Locating Manual Valve Inner Lever At Parking Lever Actuating Rod
    G03948935Courtesy of FORD MOTOR CO.
  79. Remove the manual valve inner lever.
    Fig 85: Identifying Manual Control Valve Inner Lever
    G03948936Courtesy of FORD MOTOR CO.
  80. Remove the parking lever actuating rod.
    Fig 86: Identifying Parking Lever Actuating Rod
    G03948937Courtesy of FORD MOTOR CO.
    81. CAUTION: Do not damage the bore.
    Fig 87: Locating Manual Control Lever Seal
    G03948938Courtesy of FORD MOTOR CO.
  81. Remove the manual control lever seal.
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