Section 1227 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) CHART

	Adjustment Set, Transmission Band 307-S022 (T71P-77370-A)
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Depth Micrometer 303-D026 (D80P-4201-A) or equivalent
	Dial Indicator with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
	Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)
	Installer, Transmission Extension Housing Oil Seal (4x2) 308-002 (T61L-7657-A)
	Sizer, Piston Seal 307-338 (T95L-70010-G)
	Alignment Set, Fluid Pump 307-S039 (T74P-77103-X)
	Aligner, Fluid Pump Handle 307-431
	Aligner, Fluid Pump Pilot 307-432
	Gauge Bar 307-400
	Compressor, Servo Cover 307-402
	Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)
	Handle, Torque Converter 307-091 (T81P-7902-C)
	Compressor, Cushion Spring 307-401
	Aligner, Valve Body 307-334 (T95L-70010-C)
	Alignment Pins, Transmission Pump 307-399
	Aligner, Flex Plate 307-403
	Installer, Transmission Extension Housing Fluid Seal (4x4) 307-435
	Air Test Plate 307-0433/01, 307-433/02, 307-433/03

MATERIAL ITEM SPECIFICATION

Item	Specification
MERCON® V Automatic Transmission Fluid XT-5-QM	MERCON® V
Multi-Purpose Grease XG-4	ESR-M1C159-A

Fig 1: Disassembled Views Transmission (1 Of 6)

Courtesy of FORD MOTOR CO.

Fig 2: Disassembled Views Transmission (2 Of 6)

Courtesy of FORD MOTOR CO.

Fig 3: Disassembled Views Transmission (3 Of 6)

Courtesy of FORD MOTOR CO.

Fig 4: Disassembled Views Transmission (4 Of 6)

Courtesy of FORD MOTOR CO.

Fig 5: Disassembled Views Transmission (5 Of 6)

Courtesy of FORD MOTOR CO.

Fig 6: Disassembled Views Transmission (6 Of 6)

Courtesy of FORD MOTOR CO.

All vehicles

Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
Inspect the transmission case for the following:
- Stripped bolt hole threads.
- Gasket and mating surfaces for burrs or nicks.
- Obstructions to vent and fluid passages.
- Cracks or warpage.
  
  Fig 7: Inspecting Transmission Case
  Courtesy of FORD MOTOR CO.

4x2 vehicles

Inspect the extension housing for cracks, burrs or warpage.

Fig 8: Inspecting Extension Housing For Cracks
Courtesy of FORD MOTOR CO.

4x4 vehicles

Inspect the extension housing for cracks, burrs or warpage.

Fig 9: Inspecting Extension Housing For Cracks
Courtesy of FORD MOTOR CO.

All vehicles

Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.

Fig 10: Identifying Case Bearing
Courtesy of FORD MOTOR CO.

WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.

Fig 11: Installing Transmission Into Bench With Converter Housing Facing Up

Courtesy of FORD MOTOR CO.

Using the special tool, install the transmission into the bench with the converter housing facing up.
Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.

Fig 12: Installing Manual Control Lever Shaft Seal And Lubricate It With Petroleum Jelly
Courtesy of FORD MOTOR CO.
Install the parking lever rod.

Fig 13: Identifying Parking Lever Actuating Rod
Courtesy of FORD MOTOR CO.
Install the manual control lever.

Fig 14: Identifying Manual Control Valve Inner Lever
Courtesy of FORD MOTOR CO.
Assemble the manual valve inner lever and parking lever actuating rod as shown in Fig 15.

Fig 15: Locating Manual Valve Inner Lever At Parking Lever Actuating Rod
Courtesy of FORD MOTOR CO.

CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Fig 16: Installing Manual Control Lever Shaft

Courtesy of FORD MOTOR CO.

Install the manual control lever shaft.
Install the manual valve inner lever onto the manual shaft and loosely install the nut.

Fig 17: Installing Manual Valve Inner Lever Onto Manual Shaft
Courtesy of FORD MOTOR CO.

CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.

NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.

Install the manual control lever shaft spring pin.
- Tap the manual control lever shaft spring pin into the transmission case.
  
  Fig 18: Taping Manual Control Lever Shaft Spring Pin Into Transmission Case
  Courtesy of FORD MOTOR CO.

CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.

Tighten the nut.
- Tighten to 48 Nm (35 lb-ft)
  
  Fig 19: Tightening Nut
  Courtesy of FORD MOTOR CO.

CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.

Install the output shaft thrust washer (No. 11).
- Coat the output shaft thrust washer with petroleum jelly.
  
  Fig 20: Coating Output Shaft Thrust Washer With Petroleum Jelly
  Courtesy of FORD MOTOR CO.
Install the park gear on the output shaft.

Fig 21: Identifying Park Gear On Output Shaft
Courtesy of FORD MOTOR CO.
Install the output shaft and park gear.

Fig 22: Installing Output Shaft And Park Gear
Courtesy of FORD MOTOR CO.
Install the low/reverse brake drum.
- Rotate the low/reverse brake drum clockwise to install.
  
  Fig 23: Identifying Low/Reverse Brake Drum
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure band is resting on the 2 anchor pins in the case.

Fig 24: Identifying Low/Reverse Band

Courtesy of FORD MOTOR CO.

Install the low/reverse band over the reverse drum.

NOTE: The reverse band actuating lever must fit into the notches in the band.

Fig 25: Identifying Reverse Band Actuating Lever

Courtesy of FORD MOTOR CO.

Install the reverse band actuating lever into the reverse band.
Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.

Fig 26: Installing Reverse Band Actuating Lever Shaft Into Case And Into Reverse Band Actuating Lever
Courtesy of FORD MOTOR CO.
Install the No. 10 needle bearing into the case.

Fig 27: Identifying Low Intermediate Sun Gear Bearing
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the seal against the case during assembly.

Fig 28: Identifying Output Shaft Ring Gear

Courtesy of FORD MOTOR CO.

Install the output shaft ring gear, hub and seal.

CAUTION: Always install a new output shaft retaining ring.

Fig 29: Identifying Output Shaft Retaining Ring

Courtesy of FORD MOTOR CO.

Install a new output shaft retaining ring.

NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.

Fig 30: Identifying Output Shaft Sleeve

Courtesy of FORD MOTOR CO.

Install the output shaft sleeve.
Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.

Fig 31: Identifying Thrust Bearing
Courtesy of FORD MOTOR CO.

CAUTION: Make sure the needle bearings stay in place.

Fig 32: Identifying Low/Reverse Planetary Assembly

Courtesy of FORD MOTOR CO.

Install the low/reverse planetary assembly.

CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.

Fig 33: Identifying Retaining Ring

Courtesy of FORD MOTOR CO.

Install the retaining ring.
Install the No. 8 thrust bearing.

Fig 34: Identifying Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the spacer on the input shell, using petroleum jelly to hold it in place.

Fig 35: Installing Spacer On Input Shell Using Petroleum Jelly To Hold It In Place
Courtesy of FORD MOTOR CO.
Install the input shell and sun gear assembly.

Fig 36: Identifying Input Shell And Sun Gear Assembly
Courtesy of FORD MOTOR CO.

NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.

Fig 37: Identifying Forward Planetary Assembly

Courtesy of FORD MOTOR CO.

Install the forward planetary assembly.
Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.

Fig 38: Identifying Forward Planet Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.

Fig 39: Identifying Forward Clutch Thrust Washer
Courtesy of FORD MOTOR CO.
Install the forward ring gear and hub as an assembly.

Fig 40: Identifying Forward Ring Gear And Hub
Courtesy of FORD MOTOR CO.
Install the No. 6A forward ring gear hub thrust bearing into the forward ring gear and hub.

Fig 41: Installing Forward Ring Gear Hub Thrust Bearing Into Forward Ring Gear And Hub
Courtesy of FORD MOTOR CO.
Install the forward clutch cylinder.

Fig 42: Identifying Forward Clutch Cylinder
Courtesy of FORD MOTOR CO.
Install the No. 5 thrust bearing.

Fig 43: Identifying Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the intermediate servo piston and spring.
- Lubricate the servo bore with clean automatic transmission fluid.
  
  Fig 44: Identifying Intermediate Servo Piston And Spring
  Courtesy of FORD MOTOR CO.
Using the special tool, install the retaining ring.

Fig 45: Installing Retaining Ring
Courtesy of FORD MOTOR CO.
Install the direct clutch drum.

Fig 46: Identifying Direct Clutch Drum
Courtesy of FORD MOTOR CO.
Using a depth micrometer with an 8-inch extension, measure from the top of the gauge bar to center support ledge in case at 4 places 90 degrees apart.
- Add the 4 measurements, divide by 4 and record as dimension A.
  
  Fig 47: Measuring From Top Of Gauge Bar To Center Support Ledge In Case
  Courtesy of FORD MOTOR CO.

CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

Install the special tool.
1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
  - Tighten to 15 Nm (11 lb-ft).
2. Tighten the center screw.
  - Tighten to 1 Nm (10 lb-in).
    
    Fig 48: Installing Special Tool
    Courtesy of FORD MOTOR CO.

NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.

Fig 49: Measuring Distance From Top Of Gauge Bar To Drum Bearing

Courtesy of FORD MOTOR CO.

Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
Add dimension B to C, divide by 2 and record as dimension D.
Subtract A from D and record as dimension E.

Select bearing from the following chart, using dimension E.

BEARING PART NUMBER THICKNESS REFERENCE

Dimension E	Service Part Number (7D014)	Bearing Thickness	Identification (Notches)
1.69-1.87 mm (0.066-0.074 in)	XW4Z-CA	2.65-2.80 mm (0.104-0.110 in)	None
1.88-2.04 mm (0.073-0.080 in)	XW4X-DA	2.83-2.98 mm (0.111-0.116 in)	One
2.05-2.22 mm (0.081- 0.088 in)	XW4Z-EA	3.01-3.16 mm (0.118-0.124 in)	2
2.23-2.43 mm (0.088-0.096 in)	XW4Z-FA	3.21-3.36 mm (0.126-0.132 in)	3

NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.

NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.

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 50: Identifying Intermediate Band

Courtesy of FORD MOTOR CO.

Install the intermediate band.

CAUTION: To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.

Install the intermediate band anchor strut.
1. Small "U" notch.
2. Large "U" notch.
  
  Fig 51: Installing Intermediate Band Anchor Strut
  Courtesy of FORD MOTOR CO.
  
  Fig 52: Identifying Intermediate Band Anchor Strut
  Courtesy of FORD MOTOR CO.

CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Fig 53: Checking Make Sure Intermediate Band Anchor Strut

Courtesy of FORD MOTOR CO.

Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
Loosely install the screw.

Fig 54: Locating Screw
Courtesy of FORD MOTOR CO.
Install the intermediate band apply strut.

Fig 55: Installing Intermediate Band Apply Strut
Courtesy of FORD MOTOR CO.

CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Fig 56: Checking Intermediate Band

Courtesy of FORD MOTOR CO.

Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
Install the selected No. 4 thrust washer on the direct clutch drum.
- Coat the thrust washer with petroleum jelly.
  
  Fig 57: Identifying Intermediate Brake Drum Thrust Washer
  Courtesy of FORD MOTOR CO.

NOTE: Align the center support screw hole with correct case hole.

Fig 58: Installing Center Support

Courtesy of FORD MOTOR CO.

Install the center support.
Install the center support locknut and cage.

Fig 59: Locating Center Support Locknut And Cage
Courtesy of FORD MOTOR CO.
Loosely install the screw.

Fig 60: Installing Screw
Courtesy of FORD MOTOR CO.

CAUTION: Install the center support retaining ring with the tapered side facing up.

CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.

Install the center support retaining ring.
1. Make sure the center support retaining ring is installed with the tapered side facing up.
2. Make sure the opening of the center support retaining ring is positioned correctly.
  
  Fig 61: Installing Center Support Retaining Ring
  Courtesy of FORD MOTOR CO.
Install the center shaft thrust bearing (No. 3).

Fig 62: Identifying Center Shaft Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.

Fig 63: Identifying Overdrive Ring Gear
Courtesy of FORD MOTOR CO.

CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.

Fig 64: Identifying Planetary Gear Overdrive Carrier

Courtesy of FORD MOTOR CO.

Install the planetary gear overdrive carrier.
Install the overdrive brake drum and coast clutch drum assembly.

Fig 65: Identifying Overdrive Brake And Coast Clutch Drum
Courtesy of FORD MOTOR CO.
Install the overdrive band servo piston and spring.
- Lubricate the servo bore with clean automatic transmission fluid.
  
  Fig 66: Identifying Overdrive Band Servo Piston
  Courtesy of FORD MOTOR CO.
Using the special tools, install the retaining ring.

Fig 67: Installing Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.

NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.

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 68: Identifying Overdrive Band

Courtesy of FORD MOTOR CO.

Install the overdrive band.

Install the overdrive anchor strut.
1. Small "U" notch.
2. Large "U" notch.
  
  Fig 69: Installing Overdrive Anchor Strut (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 70: Identifying Overdrive Anchor Strut
  Courtesy of FORD MOTOR CO.

CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Fig 71: Checking Overdrive Band Anchor Strut

Courtesy of FORD MOTOR CO.

Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.
Loosely install the screw.

Fig 72: Locating Screw
Courtesy of FORD MOTOR CO.
Install the overdrive apply strut.

Fig 73: Identifying Overdrive Apply Strut
Courtesy of FORD MOTOR CO.

CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Fig 74: Checking Overdrive Band

Courtesy of FORD MOTOR CO.

Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.

CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

Install the special tool.
1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
  - Tighten to 15 Nm (11 lb-ft).
2. Tighten the center screw.
  - Tighten to 1 Nm (10 lb-in).
    
    Fig 75: Installing Special Tool
    Courtesy of FORD MOTOR CO.

NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.

Fig 76: Aligning Disc Holes On Special Tool

Courtesy of FORD MOTOR CO.

Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat measurement 180 degrees opposite side of the special tool and record as dimension B.
Add dimension A to B, divide by 2 and record as dimension C.
Subtract the thickness of the gauge bar 17.78 mm (0.70 in) from dimension C and record as dimension D.

Select the No. 1 thrust bearing from the following chart using dimension D.

NO.1 THRUST BEARING SERVICE PART NUMBER

Dimension D	Service Part Number (7D014)	Bearing Thickness	Identification (Color/ID)
38.05-38.13 mm (1.50 in)	F7TZ-TA	1.55-1.60 mm (0.061-0.063 in)	White
38.14-38.28 mm (1.50-1.51 in)	F7TZ-MA	1.75-1.80 mm (0.069-0.071 in)	Green
38.29-38.42 mm (1.51 in)	F7TZ-NA	1.85-1.90 mm (0.073-0.075 in)	Red
38.43-38.61 mm (1.51-1.52 in)	F7TZ-RA	2.05-2.10 mm (0.081-0.083 in)	Black
38.63-38.74 mm (1.52-1.53 in)	F7TZ-SA	2.15-2.20 mm (0.095-0.097 in)	Yellow

Install the selected No. 1 fluid pump input thrust washer.
- Coat the fluid pump input thrust washer with petroleum jelly.
  
  Fig 77: Coating Fluid Pump Input Thrust Washer With Petroleum Jelly
  Courtesy of FORD MOTOR CO.
Install the special tools into the transmission case.

Fig 78: Installing Special Tools Into Transmission Case
Courtesy of FORD MOTOR CO.
Install the pump gasket.

Fig 79: Locating Pump Gasket
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.

Fig 80: Installing Fluid Pump

Courtesy of FORD MOTOR CO.

Install the fluid pump.

CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage.

Fig 81: Aligning Fluid Pump To Adapter Plate

Courtesy of FORD MOTOR CO.

Using the special tool, align the fluid pump to the adapter plate.
Install 6 screws. Tighten the screws in a star pattern.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 82: Tightening Screws In Star Pattern
  Courtesy of FORD MOTOR CO.
Remove the special tools and install the 2 remaining screws.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 83: Installing Remaining Screws
  Courtesy of FORD MOTOR CO.

CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Fig 84: Identifying Locknut On Band Adjustment Screw

Courtesy of FORD MOTOR CO.

Install a new locknut on the band adjustment screw.

CAUTION: The overdrive servo must be installed prior to band adjustment.

Using the special tool, tighten the overdrive band adjustment screw. Then back off the screw exactly (2) turns and hold that position.
- Tighten to 14 Nm (10 lb-ft).
  
  Fig 85: Tightening Overdrive Band Adjustment Screw
  Courtesy of FORD MOTOR CO.
Tighten the overdrive band locknut.
1. Hold the overdrive band adjustment screw stationary.
2. Tighten the overdrive band locknut.
  - Tighten to 54 Nm (40 lb-ft).
    
    Fig 86: Tightening Overdrive Band Locknut
    Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Fig 87: Identifying Locknut On Band Adjustment Screw

Courtesy of FORD MOTOR CO.

Install new nut on the band adjustment screw.

CAUTION: The intermediate servo must be installed prior to band adjustment.

Tighten the intermediate band adjustment screw. Then back off the screw exactly (2) turns and hold that position.
- Tighten to 14 Nm (10 lb-ft).
  
  Fig 88: Tightening Intermediate Band Adjustment Screw
  Courtesy of FORD MOTOR CO.
Tighten the intermediate band locknut.
1. Hold the intermediate band adjustment screw stationary.
2. Tighten the intermediate band locknut.
  - Tighten to 54 Nm (40 lb-ft).
    
    Fig 89: Tightening Intermediate Band Locknut
    Courtesy of FORD MOTOR CO.
Tighten the center support screw.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 90: Tightening Center Support Screw
  Courtesy of FORD MOTOR CO.
Using the special tools, carry out the air pressure test procedure. For additional information, refer to SPECIAL TESTING PROCEDURES .

Fig 91: Carrying Out Air Pressure Test
Courtesy of FORD MOTOR CO.
Install the special tools into the transmission case.

Fig 92: Installing Special Tools Into Transmission Case
Courtesy of FORD MOTOR CO.
Using the special tools, install the main control valve body and loosely install the screws.
1. Install the short screw.
2. Install the screw with the larger head.
3. Install the remaining screws.
  
  Fig 93: Installing Screw With Larger Head
  Courtesy of FORD MOTOR CO.
Remove the special tools and loosely install the screw.

Fig 94: Removing Special Tools And Loosely Install Screw
Courtesy of FORD MOTOR CO.
Tighten the screws in the sequence shown in Fig 95.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 95: Tightening Screws In Sequence
  Courtesy of FORD MOTOR CO.
With the manual lever in the NEUTRAL position, install the manual valve detent spring.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 96: Installing Manual Valve Detent Spring
  Courtesy of FORD MOTOR CO.
Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Fig 97: Identifying O-Ring Seals
Courtesy of FORD MOTOR CO.

CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.

Install the solenoid body. Tighten bolts in the sequence shown in Fig 98.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 98: Identifying Screw Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten bolts to 5 Nm (44 lb-in).
- Stage 2: Tighten bolts to 11 Nm (8 lb-ft).
  
  Fig 99: Installing Reverse Servo
  Courtesy of FORD MOTOR CO.

CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.

NOTE: Make sure that the fluid filter seals are correctly seated on the filter.

Lubricate the seals and install the transmission fluid filter.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 100: Installing Transmission Fluid Filter
  Courtesy of FORD MOTOR CO.

NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Fig 101: Identifying Transmission Fluid Pan And Gasket

Courtesy of FORD MOTOR CO.

Install the transmission fluid pan and gasket and loosely install the screws.
Tighten the 16 screws in a crisscross sequence.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 102: Identifying Transmission Fluid Pan And Gasket
  Courtesy of FORD MOTOR CO.

NOTE: 4x2 shown, 4x4 similar.

Install the parking pawl assembly and gasket.
1. Install the parking pawl shaft.
2. Install the parking pawl return spring.
3. Install the parking pawl.
4. Install a new gasket.
  
  Fig 103: Installing Parking Pawl Return Spring
  Courtesy of FORD MOTOR CO.
4x2 vehicles
Install the extension housing.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 104: Installing Extension Housing
  Courtesy of FORD MOTOR CO.
Using the special tool, install the extension housing seal.

Fig 105: Installing Extension Housing Seal
Courtesy of FORD MOTOR CO.

4x4 vehicles
Install the extension housing.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 106: Installing Extension Housing Seal
  Courtesy of FORD MOTOR CO.
Using the special tool, install the extension housing seal.

Fig 107: Installing Extension Housing Seal
Courtesy of FORD MOTOR CO.

All vehicles

CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.

Fig 108: Installing Digital Transmission Range (TR) Sensor

Courtesy of FORD MOTOR CO.

Install the digital transmission range (TR) sensor and loosely install the screws.

CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.

NOTE: The manual lever must be in the NEUTRAL position.

Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 109: Aligning Digital TR Sensor
  Courtesy of FORD MOTOR CO.
Install the outer manual lever.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 110: Installing Outer Manual Lever
  Courtesy of FORD MOTOR CO.

CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.

Fig 111: Installing Input Shaft

Courtesy of FORD MOTOR CO.

Install the input shaft.
Using the special tool, make sure that the fluid pump gear seal ring is fully seated.

Fig 112: Ensuring Fluid Pump Gear Seal Ring Is Fully Seated
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 113: Ensuring Fluid Pump Gear Seal Ring Is Fully Seated
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.

CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Fig 114: Ensuring Fluid Pump Gear Seal Ring Is Fully Seated

Courtesy of FORD MOTOR CO.

Lubricate the converter hub with clean automatic transmission fluid.

WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.

Fig 115: Installing Torque Converter By Pushing And Rotating

Courtesy of FORD MOTOR CO.

Using the special tools, install the torque converter by pushing and rotating.
Lubricate the torque converter pilot hub with multi-purpose grease.

Fig 116: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
Courtesy of FORD MOTOR CO.

CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.
In order to correctly install the special service tool, it must be installed using 1 round and 1 oblong hole. Using 2 oblong holes will cause damage to the transmission.

NOTE: Position the adapter plate on the torque converter and identify the position of the orange or green paint daub on the converter face.

If the vehicle is equipped, use the special tool to install the torque converter flex plate adapter assembly and 8 nuts.
- Tighten to 44 Nm (33 lb-ft).
  
  Fig 117: Positioning Adapter Plate On Torque Converter
  Courtesy of FORD MOTOR CO.
Install 2 torque converter flex plate adapter nuts.

Fig 118: Installing Torque Converter Flex Plate Adapter Nuts
Courtesy of FORD MOTOR CO.
Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.

Fig 119: Filling Transmission Fluid
Courtesy of FORD MOTOR CO.

NOTE: Inspect O-ring seals for damage. Install new seals if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.

Install the sensors.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 120: Inspecting O-Ring Seals
  Courtesy of FORD MOTOR CO.