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Transaxle Reassembly

NOTE: For thrust washer and thrust bearing locations, see Fig 8 . For gasket, piston and seal locations, see Fig 9 . For snap ring and retaining ring locations, see Fig 10 .
NOTE: Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean ATF. Use petroleum jelly on gaskets and thrust washers to hold them in place. Soak all friction discs in ATF for 15 minutes. Use all NEW gaskets and seals, and tighten bolts to specification.
  1. Install final drive input gear bearing. Install Special Tool (205-005) and press final drive input gear bearing in place. Install a NEW collapsible spacer. See Figure . Using Special Tool (205-024), position final drive input gear. While holding final drive input gear bearing, rotate transaxle on stand 180 degrees. Using Special Tools (205-024 and 307-256), install final drive input gear bearing.
  2. Rotate transaxle on stand 180 degrees. Using Special Tool (307-413), lock final drive input gear in place. Rotate transaxle on stand 180 degrees. Using Special Tools (307-414 and SR-017233), tighten bearing retainer nut to achieve preload specification. See TORQUE SPECIFICATIONS  . Ensure bearing preload is within specification and measure rotating torque with special tools. If bearing preload is not within specification, a NEW collapsible spacer must be installed.
  3. Rotate transaxle on stand 180 degrees. Position transfer shaft gears in transaxle case. Install parking pawl return spring, parking pawl abutment, lever and pin. Reconnect spring and install parking pawl assembly cover and bolts, and tighten bolts to specification. See TORQUE SPECIFICATIONS  . Install differential assembly and position bearing races.
  4. Position Shim Selection Set (308-164) and Bearing Shim Gauge (307-417). Position converter housing and install long bolts to seat case cover flat. Install short bolts. See Fig 1 . Tighten all bolts to 44 INCH lbs. (5.0 Nm). Remove bolts and remove converter housing.
    Fig 1: Using Shim Selection Tools
    G00022531Courtesy of FORD MOTOR CO.
  5. Remove special tools. Measure depth of plunger on bearing shim gauges and select the correct differential and transfer shaft shim. See SHIM SELECTION  table. Install correct differential and transfer shaft shim and bearing races in converter housing. Apply a bead .39" (1.0 mm) thick of Ultra Silicone Sealant (or equivalent) around transaxle case. Position converter housing on transaxle case and install bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  6. Install intermediate/overdrive band servo piston return spring, servo piston and "O" ring. See Fig 9 . Install intermediate/overdrive band servo piston cover and tighten bolts evenly to compress spring evenly. Install shift lever assembly and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Install NEW "O" rings on manual lever shaft and install manual lever shaft and secure with roll pin. Install TR sensor.
  7. Install thinner, longer accumulator springs in neutral drive accumulator bore with neutral drive accumulator piston. Install accumulator springs in 1-2 accumulator bore with 1-2 accumulator piston. Install transaxle internal wire harness connector. Ensure manual valve is in manual control valve shift lever and install valve body assembly. Connect solenoid wire connectors and install ground wire and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Install ATF filter, TFT sensor and transaxle pan.
    8. NOTE: Clutch pack clearance measurement procedure is not available.
    Fig 2: Installing Low/Reverse Clutch Bevel Ring
    G00022530Courtesy of FORD MOTOR CO.
  8. Install low/reverse clutch piston, return spring and bevel ring. See Fig 2 . Install low one-way clutch inner race and retaining ring. Install low/reverse clutch plates, pressure plate and clutch plate retaining ring. See Fig 5 . Clutch pack clearance should be .087-.098" (2.00-2.50 mm). If clearance is not as specified, replace selective snap ring. Snap rings are available in thicknesses from .069-.073" (1.75-1.85 mm) to .116-.120" (2.95-3.05 mm), in increments of .004" (.10 mm). Install planet gear assembly ensuring edge of planet gear assembly fits flush with transaxle case. Ensure planet gear assembly rotates clockwise only after installation.
  9. Install intermediate/overdrive brake drum assembly and brake band. See Fig 6 . Install direct clutch cylinder thrust bearing with rollers facing up. Install NEW end cover-to-case seals and end cover seals. Reinstall direct clutch hub shim and an additional shim to increase total shim thickness to a minimum of .080" (2.03 mm). Position transaxle end cover on transaxle assembly.
  10. To select correct direct clutch hub shim to obtain transaxle end play clearance specification, measure and record gap between transaxle end cover and transaxle case. Remove transaxle end cover. Subtract transaxle end cover gap measurement from total of shim thickness used in step  9 to obtain required shim thickness. Add or subtract required amount of shim thickness to obtain transaxle end play clearance of .010-.020" (.25-.50 mm). Shims are available in thicknesses from .070-.072" (1.78-1.83 mm) to .101-.103" (2.57-2.62 mm) in increments of .008" (.20 mm).
  11. Install correct direct clutch hub shim. Apply bead .039" (1.0 mm) thick of Ultra Silicon Sealant (or equivalent) to transaxle end cover. Install transaxle end cover and bolts, and tighten bolts to specification. See TORQUE SPECIFICATIONS  . Using Band Anchor Bolt Tool (307-415 and 307-416), tighten intermediate/overdrive band to 44 INCH lbs. (5.0 N.m), then back out bolt 3 1/2 turns. Holding bolt tool, lightly seat nut against transaxle case. Remove bolt tool without changing nut position. Using bolt tool, select an intermediate/overdrive band anchor bolt that measures from end of bolt to face of nut. See Fig 3 . Install correct intermediate/overdrive band anchor bolt.
    Fig 3: Selecting Correct Band Anchor Bolt
    G00022529Courtesy of FORD MOTOR CO.
  12. Install forward clutch assembly and thrust washer. Lubricate and install NEW oil pump seals and install oil pump. DO NOT force oil pump down at this time. Install oil pump bolts and tighten in a crisscross pattern to specification. Install OSS sensor and TSS sensor. Align and tighten TR sensor and manual control lever. Install torque converter.
SHIM SELECTION

Gauge Reading - In. (mm) Shim Thickness - In. (mm)
Transfer Shaft Shim
.013-.015 (.33-.38) .019-.020 (.48-.52)
.015-.017 (.38-.43) .021-.022 (.53-.57)
.017-.019 (.43-.48) .023-.024 (.58-.62)
.019-.021 (.48-.53) .025-.026 (.63-.67)
.021-.023 (.53-.58) .027-.028 (.68-.72)
.023-.025 (.58-.63) .029-.030 (.73-.77)
.025-.027 (.63-.68) .031-.032 (.78-.82)
.027-.029 (.68-.73) .033-.034 (.83-.87)
.029-.031 (.73-.78) .035-.036 (.88-.92)
.031-.033 (.78-.83) .037-.038 (.93-.97)
.033-.035 (.83-.88) .039-.040 (.98-1.02)
.035-.037 (.88-.93) .041-.042 (1.03-1.07)
.037-.039 (.93-.98) .043-.044 (1.08-1.13)
.039-.041 (.98-1.03) .044-.046 (1.13-1.17)
.041-.043 (1.03-1.08) .046-.048 (1.17-1.23)
.043-.045 (1.08-1.13) .048-.050 (1.23-1.27)
.045-.047 (1.13-1.18) .050-.052 (1.27-1.32)
Differential Shaft Shim
.011-.013 (.28-.33) .019-.020 (.48-.52)
.013-.015 (.33-.38) .021-.022 (.53-.57)
.015-.017 (.38-.43) .023-.024 (.58-.62)
.017-.019 (.43-.48) .025-.026 (.63-.67)
.019-.021 (.48-.53) .027-.028 (.68-.72)
.021-.023 (.53-.58) .029-.030 (.73-.77)
.023-.025 (.58-.63) .031-.032 (.78-.82)
.025-.027 (.63-.68) .033-.034 (.83-.87)
.027-.029 (.68-.73) .035-.036 (.88-.92)
.029-.031 (.73-.78) .037-.038 (.93-.97)
.031-.033 (.78-.83) .039-.040 (.98-1.02)
.033-.035 (.83-.88) .041-042 (1.03-1.07)
.035-.037 (.88-.93) .043-.044 (1.08-1.13)
.037-.039 (.93-.98) .044-.046 (1.13-1.17)
.039-.041 (.98-1.03) .046-.048 (1.17-1.23)
.041-.043 (1.03-1.08) .048-.050 (1.23-1.27)
.043-.045 (1.08-1.13) .050-.052 (1.27-1.32)
.045-.047 (1.13-1.18) .052-.054 (1.32-1.37)
.047-.049 (1.18-1.23) .054-.056 (1.37-1.43)
.049-.051 (1.23-1.28) .056-.058 (1.43-1.47)
.051-.053 (1.28-1.33) .058-.060 (1.47-1.52)
.053-.055 (1.33-1.38) .060-.062 (1.52-1.57)
Fig 4: Exploded View Of Torque Converter Housing Components
G00026708Courtesy of FORD MOTOR CO.
Fig 5: Exploded View Of Low/Reverse Clutch & Planet Gear Assemblies
G00026709Courtesy of FORD MOTOR CO.
Fig 6: Exploded View Of Direct & Reverse Clutches & Brake Band
G00026712Courtesy of FORD MOTOR CO.
Fig 7: Exploded View Of Differential Assembly, Transfer Shaft & Final Drive Input Components
G00026713Courtesy of FORD MOTOR CO.
Fig 8: Identifying Bearing, Thrust Bearing & Thrust Washer Locations
G00026710Courtesy of FORD MOTOR CO.
Fig 9: Identifying Gasket, Piston & Seal Locations
G00026714Courtesy of FORD MOTOR CO.
Fig 10: Identifying Snap Ring & Retaining Ring Locations
G00026711Courtesy of FORD MOTOR CO.
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