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Section 1376 (Automatic Transmission): Disassembly: Transmission

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G04584487
 Slide Hammer
100-001 (T50T-100-A)
G04584488
 Holding Fixture, Transmission
307-003 (T57L-500-B)
G04584489
 Slide Hammer
307-005 (T59L-100-B)
G04584490
 Remover, Transmission Fluid Seal
307-048 (T74P-77248-A)
G04584491
 Handle, Torque Converter
307-091 (T81P-7902-C)
G04584492
 Remover, Transmission Fluid Pump
307-221 (T89T-70010-A)
G04584493
 Remover/Installer, Servo Piston
307-251 (T92P-70023-A)
G04584494
 Remover, Torque Converter Fluid Seal
307-309 (T94P-77001-BH)
G04584495
 Remover, Bearing Cup
308-047 (T77F-1102-A)
  1. Using the special tools, remove torque converter.
    Fig 1: Removing Torque Converter
    G04584496Courtesy of FORD MOTOR CO.
  2. Using the special tool, mount the transmission to the bench.
    Fig 2: Mounting Transmission To Bench
    G04584497Courtesy of FORD MOTOR CO.
    3. NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
    Fig 3: Removing Bolts, Transmission Fluid Pan And Transmission Fluid Pan-To-Case Gasket
    G04584498Courtesy of FORD MOTOR CO.
  3. Remove the bolts, transmission fluid pan and transmission fluid pan-to-case gasket.
  4. Clean the transmission fluid pan and pan magnet.
    Fig 4: Locating Pan Magnet In Transmission Fluid Pan
    G03888537Courtesy of FORD MOTOR CO.
    5. CAUTION: If installing a new filter and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
    NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
    Fig 5: Removing Fluid Filter And Grommet
    G04584500Courtesy of FORD MOTOR CO.
  5. Remove the fluid filter and grommet.
    6. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
  6. Disconnect the molded lead frame from the solenoids.
    1. Disconnect the shift solenoid SSA and SSB.
    2. Disconnect the torque converter clutch (TCC).
    3. Disconnect the electronic pressure control (EPC) solenoid.
    4. Disconnect the bulkhead interconnector.
      Fig 6: Identifying Molded Lead Frame And Solenoids
      G04584282Courtesy of FORD MOTOR CO.
  7. Remove the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
    1. Remove the OSS sensor bolt.
    2. Remove the OSS sensor.
    3. Remove the TSS sensor bolt.
    4. Remove the TSS sensor.
      Fig 7: Removing TSS Sensor
      G04584502Courtesy of FORD MOTOR CO.
  8. Remove the digital transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
      Fig 8: Removing Digital TR Sensor
      G04584503Courtesy of FORD MOTOR CO.
  9. Remove the manual control valve detent lever spring.
    • Remove the bolt.
      Fig 9: Removing Manual Control Valve Detent Lever Spring Bolts
      G04584504Courtesy of FORD MOTOR CO.
  10. Remove the 23 main control valve body bolts and the main control valve body.
    Fig 10: Locating Main Control Valve Body Bolts
    G03882633Courtesy of FORD MOTOR CO.
  11. Remove and discard the pump outlet screen.
    Fig 11: Identifying Pump Outlet Screen
    G03888559Courtesy of FORD MOTOR CO.
    12. NOTE: Use a shop cloth to protect the transmission case surface.
    Fig 12: Removing Manual Lever Shaft Retaining Pin
    G04584507Courtesy of FORD MOTOR CO.
  12. Remove the manual lever shaft retaining pin.
  13. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
      Fig 13: Removing Manual Lever Shaft Inner Nut
      G04584508Courtesy of FORD MOTOR CO.
  14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
      Fig 14: Removing Parking Lever Actuating Rod
      G04584509Courtesy of FORD MOTOR CO.
    15. CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged, the new seal may leak.
    Fig 15: Removing Manual Control Lever Shaft Seal
    G04584510Courtesy of FORD MOTOR CO.
  15. Remove the manual control lever shaft seal.
  16. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
      Fig 16: Removing Bolt And EPC Solenoid Bracket
      G04584511Courtesy of FORD MOTOR CO.
  17. Remove the 2-3 accumulator spring retainer.
    Fig 17: Removing 2-3 Accumulator Spring Retainer
    G04584512Courtesy of FORD MOTOR CO.
  18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
      Fig 18: Removing 2-3 Accumulator Piston
      G04584513Courtesy of FORD MOTOR CO.
  19. Using the special tool, remove the reverse band servo retaining ring.
    Fig 19: Removing Reverse Band Servo Retaining Ring
    G04584514Courtesy of FORD MOTOR CO.
  20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
      Fig 20: Removing Reverse Band Servo Spring
      G04584515Courtesy of FORD MOTOR CO.
    21. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
    Fig 21: Removing Overdrive Servo Piston Retainer
    G04584516Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
  22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
      Fig 22: Removing Overdrive Servo Piston Return Spring
      G04584517Courtesy of FORD MOTOR CO.
  23. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 23: Locating Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
  24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the inner and outer lower 1-2 accumulator spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
      Fig 24: Removing 1-2 Accumulator Upper Spring
      G04584519Courtesy of FORD MOTOR CO.
  25. Using the special tools, remove the extension housing seal.
    Fig 25: Removing Extension Housing Seal
    G04584520Courtesy of FORD MOTOR CO.
    26. NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
  26. Remove the extension housing.
    1. Remove the 4 bolts and 2 nuts.
    2. Remove the extension housing and the extension housing gasket.
      Fig 26: Removing Extension Housing And Extension Housing Gasket
      G04584521Courtesy of FORD MOTOR CO.
  27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
      Fig 27: Removing Parking Pawl Return Spring
      G04584522Courtesy of FORD MOTOR CO.
  28. Rotate the transmission to the vertical position with the output shaft toward the floor.
    29. CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
    Fig 28: Pushing Connector Out Through Bottom Of Case
    G04584523Courtesy of FORD MOTOR CO.
  29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
  30. Using the special tools, remove the front pump seal.
    Fig 29: Removing Front Pump Seal
    G04584524Courtesy of FORD MOTOR CO.
    31. NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
    Fig 30: Removing Bolts
    G04584525Courtesy of FORD MOTOR CO.
  31. Remove the bolts.
  32. Using the special tools, remove the front pump support.
    Fig 31: Removing Front Pump Support
    G04584526Courtesy of FORD MOTOR CO.
  33. Remove and discard the pump gasket.
    • Remove the intermediate clutch piston return spring.
    • Remove the intermediate clutch piston return spring support.
  34. Remove the intermediate anti-rattle clip, if equipped.
    Fig 32: Identifying Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
    35. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
  35. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
      Fig 33: Removing Intermediate Clutch Pack
      G04584528Courtesy of FORD MOTOR CO.
  36. Disengage and remove the overdrive band.
    Fig 34: Removing Overdrive Band
    G04584529Courtesy of FORD MOTOR CO.
  37. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 35: Removing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    G04584530Courtesy of FORD MOTOR CO.
  38. Remove the intermediate stub shaft.
    Fig 36: Removing Intermediate Stub Shaft
    G04584531Courtesy of FORD MOTOR CO.
  39. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 37: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin
    G04584532Courtesy of FORD MOTOR CO.
  40. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
      Fig 38: Removing No. 4 Forward Clutch Hub Bearing
      G04584533Courtesy of FORD MOTOR CO.
  41. Remove the center support retaining ring and note location for assembly.
    Fig 39: Removing Center Support Retaining Ring
    G04584534Courtesy of FORD MOTOR CO.
  42. Remove the case-to-planet support spring.
    Fig 40: Removing Case-To-Planet Support Spring
    G04584535Courtesy of FORD MOTOR CO.
  43. Remove the planetary gear support and planetary as an assembly.
    Fig 41: Removing Planetary Gear Support And Planetary
    G04584536Courtesy of FORD MOTOR CO.
  44. Remove the reverse clutch band.
    Fig 42: Removing Reverse Clutch Band
    G04584537Courtesy of FORD MOTOR CO.
  45. Remove the retaining ring.
    Fig 43: Removing Retaining Ring
    G04584538Courtesy of FORD MOTOR CO.
  46. Remove the direct clutch pack.
    Fig 44: Identifying Direct Clutch Pack
    G03888747Courtesy of FORD MOTOR CO.
  47. Remove the No. 8 bearing.
    Fig 45: Locating No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  48. Remove the output shaft and output shaft ring gear assembly.
    Fig 46: Removing Output Shaft And Output Shaft Ring Gear Assembly
    G04584541Courtesy of FORD MOTOR CO.
  49. Remove the No. 9 case rear bearing.
    Fig 47: Locating No. 9 Case Rear Bearing
    G03888750Courtesy of FORD MOTOR CO.
  50. Inspect and, if necessary, use the special tools to remove the rear case bushing.
    Fig 48: Removing Rear Case Bushing
    G04584543Courtesy of FORD MOTOR CO.
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