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Automatic Transmission: Disassembly: Transaxle: Disassembly

    CAUTION: If, during repair work, abrasive particles are found in the transaxle fluid (particles from the clutch or metal chips or foreign material), the transaxle must be disassembled completely and thoroughly cleaned. Also, clean the fluid pipes, fluid cooler and torque converter carefully. In the case of extreme soiling of the fluid pipes, install a new fluid cooler and torque converter.
    NOTE: In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid.
  1. Inspect the transaxle during disassembly.
  2. Remove the output shaft speed (OSS) sensor.
    1. Remove the bolt.
    2. Remove the OSS.
      Fig 1: Removing Output Shaft Speed (OSS) Sensor
      G03433290Courtesy of FORD MOTOR CO.
  3. Remove the turbine shaft speed (TSS) sensor.
    Fig 2: Removing Turbine Shaft Speed (TSS) Sensor
    G03433291Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not use air tools.
    Fig 3: Removing Manual Control Lever
    G03433292Courtesy of FORD MOTOR CO.
  4. While holding the lever remove the manual control lever.
  5. Remove the transmission range (TR) sensor.
    Fig 4: Removing Transmission Range (TR) Sensor
    G03433293Courtesy of FORD MOTOR CO.
  6. Remove the special tool.
    Fig 5: Removing Special Tool
    G03433294Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not tilt the torque converter when removing it, to prevent damaging the torque converter hub.
    NOTE: The torque converter is filled with fluid. Drain into a suitable container.
    Fig 6: Removing Torque Converter
    G03433295Courtesy of FORD MOTOR CO.
  7. Using the special tool, remove the torque converter.
  8. Using the special tool, mount the transaxle to a bench.
    Fig 7: Using Special Tool And Mounting Transaxle To Bench
    G03433296Courtesy of FORD MOTOR CO.
  9. Remove the bolts.
    Fig 8: Removing Torque Converter Bolts
    G03433297Courtesy of FORD MOTOR CO.
  10. Using the two 10 mm bolts, remove the fluid pump.
    Fig 9: Using Two 10 Mm Bolts And Removing Fluid Pump
    G03433298Courtesy of FORD MOTOR CO.
  11. Remove the fluid pump seals.
    Fig 10: Removing Fluid Pump Seals
    G03433299Courtesy of FORD MOTOR CO.
  12. Remove the forward clutch thrust washer.
    Fig 11: Removing Forward Clutch Thrust Washer
    G03433300Courtesy of FORD MOTOR CO.
  13. Remove the forward clutch assembly.
    Fig 12: Removing Forward Clutch Assembly
    G03433301Courtesy of FORD MOTOR CO.
    14. NOTE: Small levers will aid in the removal of the forward clutch hub.
    Fig 13: Removing Forward Clutch Hub
    G03433302Courtesy of FORD MOTOR CO.
  14. Remove the forward clutch hub.
  15. Rotate the transaxle 180 degrees.
  16. Remove the end cover.
    Fig 14: Removing End Cover
    G03433303Courtesy of FORD MOTOR CO.
  17. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
  18. Remove the direct clutch hub bearing shim.
    Fig 15: Removing Direct Clutch Hub Bearing Shim
    G03433304Courtesy of FORD MOTOR CO.
  19. Remove the end cover seals.
    Fig 16: Removing End Cover Seals
    G03433305Courtesy of FORD MOTOR CO.
  20. Remove the end cover to case seals.
    Fig 17: Removing End Cover Case Seals
    G03433306Courtesy of FORD MOTOR CO.
  21. Remove the direct clutch cylinder thrust bearing.
    Fig 18: Removing Direct Clutch Cylinder Thrust Bearing
    G03433307Courtesy of FORD MOTOR CO.
  22. Remove the intermediate/overdrive band anchor bolt.
    Fig 19: Removing Intermediate/Overdrive Band Anchor Bolt
    G03433308Courtesy of FORD MOTOR CO.
  23. Remove the intermediate/overdrive band.
    Fig 20: Removing Intermediate/Overdrive Band
    G03433309Courtesy of FORD MOTOR CO.
  24. Remove the intermediate/overdrive drum assembly.
    Fig 21: Removing Intermediate/Overdrive Drum Assembly
    G03433310Courtesy of FORD MOTOR CO.
  25. Remove the planet gear assembly.
    Fig 22: Removing Planet Gear Assembly
    G03433311Courtesy of FORD MOTOR CO.
  26. Remove the low/reverse clutch plate retaining ring.
    Fig 23: Removing Low/Reverse Clutch Plate Retaining Ring
    G03433312Courtesy of FORD MOTOR CO.
  27. Remove the low/reverse clutch plates, pressure plate and bevel ring.
    Fig 24: Removing Low/Reverse Clutch Plates, Pressure Plate And Bevel Ring
    G03433313Courtesy of FORD MOTOR CO.
  28. Remove the low one-way clutch retaining ring.
    Fig 25: Removing Low One-Way Clutch Retaining Ring
    G03433314Courtesy of FORD MOTOR CO.
  29. Remove the low one-way clutch inner race.
    Fig 26: Removing Low One-Way Clutch Inner Race
    G03433315Courtesy of FORD MOTOR CO.
  30. Remove the low/reverse clutch return spring.
    Fig 27: Removing Low/Reverse Clutch Return Spring
    G03433316Courtesy of FORD MOTOR CO.
  31. Remove the low/reverse clutch piston.
    Fig 28: Removing Low/Reverse Clutch Piston
    G03433317Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the transaxle fluid pan.
    Fig 29: Removing Transaxle Fluid Pan
    G03433318Courtesy of FORD MOTOR CO.
  33. Clean the silicone from the transaxle fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
  34. Disconnect the transmission fluid temperature (TFT) sensor.
    Fig 30: Disconnecting Transmission Fluid Temperature (TFT) Sensor
    G03433319Courtesy of FORD MOTOR CO.
  35. Remove the fluid filter.
    Fig 31: Removing Fluid Filter
    G03433320Courtesy of FORD MOTOR CO.
    36. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.
  36. Remove the ground wire bolt, disconnect the electrical connectors and remove the wire harness.
    1. Solenoid SSC; Color N (Neutral).
    2. Solenoid SSE; Color G (Green).
    3. Solenoid SSD; Color L (Blue).
    4. Solenoid EPC; Color B (Black).
    5. Solenoid SSA; Color N (Neutral).
    6. Solenoid SSB; Color B (Black).
      Fig 32: Disconnecting Electrical Connectors And Removing Wire Harness
      G03433321Courtesy of FORD MOTOR CO.
    37. NOTE: Note the locations of the longer bolts.
    Fig 33: Removing 13 Main Control Valve Body Bolts
    G03433322Courtesy of FORD MOTOR CO.
  37. Remove the 13 main control valve body bolts.
    38. NOTE: Squeeze the tabs on the side of the electrical connector.
    Fig 34: Removing Transaxle Internal Harness Electrical Connector
    G03433323Courtesy of FORD MOTOR CO.
  38. Remove the transaxle internal harness electrical connector.
    39. NOTE: Each accumulator has two springs. All four springs are different sizes.
    NOTE: Note the size and location of the accumulator springs to aid assembly.
    Fig 35: Removing Accumulator Pistons And Springs
    G03433324Courtesy of FORD MOTOR CO.
  39. Remove the accumulator pistons and springs.
  40. Remove the manual lever shaft roll pin.
    Fig 36: Removing Manual Lever Shaft Roll Pin
    G03433325Courtesy of FORD MOTOR CO.
  41. Remove the manual lever shaft.
    Fig 37: Removing Manual Lever Shaft
    G03433326Courtesy of FORD MOTOR CO.
  42. Remove the O-ring seals from the manual lever shaft.
    Fig 38: Removing O-Ring Seals From Manual Lever Shaft
    G03433327Courtesy of FORD MOTOR CO.
  43. Remove the control lever assembly.
    Fig 39: Removing Control Lever Assembly
    G03433328Courtesy of FORD MOTOR CO.
    44. CAUTION: The intermediate/ overdrive band servo cover plate is spring loaded. The bolts should be removed evenly until plate is unloaded, then remove the bolts.
  44. Remove the intermediate/overdrive piston servo cover.
    1. Remove the bolts.
    2. Remove the intermediate/overdrive piston servo cover.
      Fig 40: Removing Intermediate/Overdrive Piston Servo Cover
      G03433329Courtesy of FORD MOTOR CO.
  45. Remove the O-ring seal.
    Fig 41: Removing O-Ring Seal
    G03433330Courtesy of FORD MOTOR CO.
  46. Remove the intermediate/overdrive servo piston.
    Fig 42: Removing Intermediate/Overdrive Servo Piston
    G03433331Courtesy of FORD MOTOR CO.
  47. Remove the intermediate/overdrive servo piston return spring.
    Fig 43: Removing Intermediate/Overdrive Servo Piston Return Spring
    G03433332Courtesy of FORD MOTOR CO.
  48. Rotate the transaxle 180 degrees.
  49. Remove the bolts and separate the converter housing from the transaxle case.
    Fig 44: Removing Bolts And Separating Converter Housing From Transaxle Case
    G03433333Courtesy of FORD MOTOR CO.
  50. Remove the differential assembly.
    Fig 45: Removing Differential Assembly
    G03433334Courtesy of FORD MOTOR CO.
  51. Remove the parking pawl assembly cover.
    1. Remove the bolts.
    2. Remove the parking pawl assembly cover.
      Fig 46: Removing Parking Pawl Assembly Cover Bolts
      G03433335Courtesy of FORD MOTOR CO.
  52. Remove the parking pawl abutment.
    1. Unclip the spring.
    2. Remove the pin.
    3. Remove the lever.
    4. Remove the parking pawl abutment.
      Fig 47: Removing Parking Pawl Abutment
      G03433336Courtesy of FORD MOTOR CO.
  53. Remove the spring.
    Fig 48: Removing Spring
    G03433337Courtesy of FORD MOTOR CO.
  54. Remove the transfer shaft gears.
    Fig 49: Removing Transfer Shaft Gears
    G03433338Courtesy of FORD MOTOR CO.
  55. Using the special tool, lock the final drive input gear.
    Fig 50: Using Special Tool And Locking Final Drive Input Gear
    G03433339Courtesy of FORD MOTOR CO.
  56. Rotate the transaxle 180 degrees.
    57. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
    Fig 51: Removing Final Drive Input Gear Bearing Retainer Nut
    G03433340Courtesy of FORD MOTOR CO.
  57. Using the special tools, remove the final drive input gear bearing retainer nut.
  58. Remove the special tools.
  59. Rotate the transaxle 180 degrees.
  60. Remove the special tool.
    Fig 52: Removing Special Tools
    G03433341Courtesy of FORD MOTOR CO.
    61. CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.
  61. Rotate the transaxle 180 degrees.
  62. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
    Fig 53: Removing Final Drive Input Gear Bearing
    G03433342Courtesy of FORD MOTOR CO.
  63. Remove and discard the collapsible spacer.
    Fig 54: Removing Collapsible Spacer
    G03433343Courtesy of FORD MOTOR CO.
    64. WARNING: Wear eye protection when working with the chisel as the cutting operation may produce splinters. Failure to follow this instruction may result in personal injury.
    Fig 55: Removing Final Drive Input Gear Bearing
    G03433344Courtesy of FORD MOTOR CO.
  64. Using a suitable chisel, remove the final drive input gear bearing.
  65. Using the special tools, remove the final drive input gear bearing inner race.
    Fig 56: Removing Final Drive Input Gear Bearing Inner Race
    G03433345Courtesy of FORD MOTOR CO.
  66. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.
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