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Automatic Transmission: Disassembly: Transaxle

Fig 1: Identifying Special Tool(s) (1 Of 3)
G01361728Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tool(s) (2 Of 3)
G01361729Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tool(s) (3 Of 3)
G01361730Courtesy of FORD MOTOR CO.
    CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 4: Removing Torque Converter Using Special Tools
    G01361731Courtesy of FORD MOTOR CO.
  1. Using the special tools, remove the torque converter.
  2. Using the special tool, install the transaxle into the bench.
    Fig 5: Installing Transaxle Into Bench Using Special Tool
    G01361732Courtesy of FORD MOTOR CO.
    3. NOTE: During a case replacement the identification tag will need to be transferred to the new case, use caution not to damage the tag.
    Fig 6: Removing Identification Tag
    G01361733Courtesy of FORD MOTOR CO.
  3. Remove the identification tag.
  4. Place a drain pan under the transaxle, rotate the transaxle to a vertical position and allow the fluid to drain. Once the fluid has drained, rotate the transaxle to a horizontal position.
    Fig 7: Placing A Drain Pan Under Transaxle To Allow Fluid To Drain
    G01361734Courtesy of FORD MOTOR CO.
  5. Remove the filler tube.
    Fig 8: Removing Filler Tube
    G01361735Courtesy of FORD MOTOR CO.
    6. CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.
  6. Remove the overdrive servo piston and rod.
    • Remove the bolts.
    • Remove the cover.
    • Remove the piston and rod.
      Fig 9: Removing Overdrive Servo Piston And Rod
      G01361736Courtesy of FORD MOTOR CO.
  7. Remove the output shaft speed (OSS) sensor cover.
    Fig 10: Removing Output Shaft Speed (OSS) Sensor Cover
    G01361737Courtesy of FORD MOTOR CO.
  8. Remove the output shaft speed (OSS) sensor.
    • Unclip the harness.
    • Remove the output shaft speed (OSS) sensor.
      Fig 11: Removing Output Shaft Speed (OSS) Sensor
      G01361738Courtesy of FORD MOTOR CO.
  9. Remove the digital TR sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
      Fig 12: Removing Digital TR Sensor
      G01361739Courtesy of FORD MOTOR CO.
  10. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
      Fig 13: Removing TSS Sensor
      G01361740Courtesy of FORD MOTOR CO.
    11. NOTE: The differential seal is a two-piece constructed seal.
    Fig 14: Removing LH Differential Seal Using Special Tools
    G01361741Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the LH differential seal.
  12. Using the special tools, remove the LH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector from the LH differential seal and remove the protector from the tool.
      Fig 15: Removing Metal Protector From LH Differential Seal Metal Protector Using Special Tools
      G01361742Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the rubber portion of LH differential seal.
    1. Install the special tool into the LH differential seal and rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
      Fig 16: Removing Rubber Portion Of Seal Of LH Differential Seal Using Special Tools
      G01361743Courtesy of FORD MOTOR CO.
  14. Install the special tool into the RH differential seal.
    Fig 17: Installing Special Tool Into RH Differential Seal
    G01361744Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
      Fig 18: Removing Metal Protector Of Seal Metal Protector Using Special Tools
      G01361745Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the rubber portion of the seal.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
      Fig 19: Removing Rubber Portion Of Seal Using Special Tools
      G01361746Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the converter hub seal.
    Fig 20: Removing Converter Hub Seal Using special tools
    G01361747Courtesy of FORD MOTOR CO.
  18. Remove the bolts.
    Fig 21: Removing Bolts
    G01361748Courtesy of FORD MOTOR CO.
  19. Rotate the transaxle to a horizontal position.
  20. Remove the mount bracket.
    Fig 22: Removing Mount Bracket
    G01361749Courtesy of FORD MOTOR CO.
    21. NOTE: The main control cover gasket is reusable if not torn or damaged.
    Fig 23: Removing Pan
    G01361750Courtesy of FORD MOTOR CO.
  21. Remove the pan.
    22. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
    Fig 24: Lifting Locking Tab And Disconnecting Electrical Connectors
    G01361751Courtesy of FORD MOTOR CO.
  22. Lift the locking tab and disconnect the electrical connectors.
    23. NOTE: The manual valve should be inserted completely.
    Fig 25: Rotating Manual Control Lever To Low Detent
    G01361752Courtesy of FORD MOTOR CO.
  23. Using a 9 mm wrench rotate the manual control lever to the low detent.
    24. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body.
    CAUTION: Only 4 of the 6 pump cover bolts need to be removed.
    Fig 26: Removing Bolts
    G01361753Courtesy of FORD MOTOR CO.
  24. Remove the bolts.
  25. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
      Fig 27: Rotating Main Control Valve Body While Lifting Off
      G01361754Courtesy of FORD MOTOR CO.
  26. Disconnect the manual control valve actuating rod.
    Fig 28: Disconnecting Manual Control Valve Actuating Rod
    G01361755Courtesy of FORD MOTOR CO.
  27. Remove the pump shaft.
    Fig 29: Removing Pump Shaft
    G01361756Courtesy of FORD MOTOR CO.
    28. NOTE: The transaxle pan gasket is reusable if not torn or damaged.
    Fig 30: Removing Bolts, Transmission Fluid Pan And Gasket
    G01361757Courtesy of FORD MOTOR CO.
  28. Remove the bolts, transmission fluid pan and gasket.
  29. Remove, clean and inspect the magnet.
    Fig 31: Removing, Cleaning And Inspecting Magnet
    G01361758Courtesy of FORD MOTOR CO.
  30. Remove the filter.
    Fig 32: Removing Filter
    G01361759Courtesy of FORD MOTOR CO.
    31. NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
    Fig 33: Removing Fluid Filter Seal
    G01361760Courtesy of FORD MOTOR CO.
  31. Remove the fluid filter seal.
  32. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 34: Loosening Nut And Removing Reverse Clutch Anchor Pin
    G01361761Courtesy of FORD MOTOR CO.
    33. CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.
    NOTE: Mark bolt size and location for assembly.
    Fig 35: Removing Bolts
    G01361762Courtesy of FORD MOTOR CO.
  33. Remove the bolts.
    34. NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.
    Fig 36: Removing Chain Cover And Gasket
    G01361763Courtesy of FORD MOTOR CO.
  34. Remove the chain cover and gasket.
  35. Remove the shift accumulator springs.
    1. Remove the 1-2 shift accumulator piston inner assist springs.
    2. Remove the 1-2 shift accumulator piston outer springs (blue).
    3. Remove the 2-3 shift accumulator piston inner assist spring.
    4. Remove the 2-3 shift accumulator piston outer spring (blue).
    5. Remove the reverse shift accumulator piston spring (pink).
    6. Remove the 3-4 shift accumulator piston spring (pink).
      Fig 37: Removing Shift Accumulator Springs
      G01361764Courtesy of FORD MOTOR CO.
    36. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
    Fig 38: Removing Drive Sprocket, Driven Sprocket And Drive Chain As An Assembly
    G01361765Courtesy of FORD MOTOR CO.
  36. Remove the drive sprocket, driven sprocket, and drive chain as an assembly.
    37. NOTE: The thrust washers may remain on the sprockets.
  37. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
      Fig 39: Removing Thrust Washers
      G01361766Courtesy of FORD MOTOR CO.
    38. CAUTION: Use care not to damage the machined surface of the case.
    NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
    Fig 40: Removing Roll Pins
    G01361767Courtesy of FORD MOTOR CO.
  38. Remove the roll pins.
    39. NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
    Fig 41: Removing Manual Control Lever Shaft
    G01361768Courtesy of FORD MOTOR CO.
  39. Remove the manual control lever shaft.
  40. Remove the parking lever actuating rod.
    Fig 42: Removing Parking Lever Actuating Rod
    G01361769Courtesy of FORD MOTOR CO.
  41. Remove the manual control lever shaft seal.
    Fig 43: Removing Manual Control Lever Shaft Seal
    G01361770Courtesy of FORD MOTOR CO.
    42. NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
    Fig 44: Removing Bolts And Brackets
    G01361771Courtesy of FORD MOTOR CO.
  42. Remove the bolts and brackets.
  43. Using the special tools, remove the fluid lube tubes.
    Fig 45: Removing Fluid Lube Tubes Using Special Tools
    G01361772Courtesy of FORD MOTOR CO.
  44. Remove the bolts and the park pawl abutment.
    Fig 46: Removing Bolts And Park Pawl Abutment
    G01361773Courtesy of FORD MOTOR CO.
  45. Remove the neutral/drive accumulator bolt.
    Fig 47: Removing Neutral/Drive Accumulator Bolt
    G01361774Courtesy of FORD MOTOR CO.
  46. Remove the neutral/drive accumulator.
    1. Remove the cover.
    2. Remove the springs.
    3. Remove the piston and shaft.
      Fig 48: Removing Neutral/Drive Accumulator
      G01361775Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston, and rod as an assembly.
      Fig 49: Removing Coast Band Servo Using Special Tool
      G01361776Courtesy of FORD MOTOR CO.
    48. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
    Fig 50: Removing Drive Sprocket Support And No. 5 Thrust Washer
    G01361777Courtesy of FORD MOTOR CO.
  48. Remove the drive sprocket support and the No. 5 thrust washer.
    49. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
    Fig 51: Removing No. 8 Driven Sprocket Support Selective Fit Rear Thrust Washer And No. 9 Needle Bearing Using Special Tool
    G01361778Courtesy of FORD MOTOR CO.
  49. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
  50. Remove the plastic overdrive band retainer.
    Fig 52: Removing Plastic Overdrive Band Retainer
    G01361779Courtesy of FORD MOTOR CO.
  51. Remove the overdrive band.
    Fig 53: Removing Overdrive Band
    G01361780Courtesy of FORD MOTOR CO.
    52. NOTE: Do not over-tighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
    Fig 54: Installing Hook End Of Special Tool Into One Of The Lube Holes In The Front Sun Shell
    G01361781Courtesy of FORD MOTOR CO.
  52. Position the special tool into the case and install the hook end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
  53. Using the special tool, remove the front clutch assembly.
    Fig 55: Removing Front Clutch Assembly Using Special Tool
    G01361782Courtesy of FORD MOTOR CO.
  54. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 56: Removing Reverse Clutch And Planet Assembly Using Special Tools
    G01361783Courtesy of FORD MOTOR CO.
  55. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 57: Removing Low/Intermediate Drum, Sun Gear And One-Way Clutch Assembly
    G01361784Courtesy of FORD MOTOR CO.
  56. Remove the coast band.
    Fig 58: Removing Coast Band
    G01361785Courtesy of FORD MOTOR CO.
    57. CAUTION: Use care not to damage any machined surfaces.
    Fig 59: Removing Low/Intermediate Clutch Retaining Ring
    G01361786Courtesy of FORD MOTOR CO.
  57. Remove the low/intermediate clutch retaining ring.
  58. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
      Fig 60: Removing Low/Intermediate Clutch Pack
      G01361787Courtesy of FORD MOTOR CO.
    59. WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
    CAUTION: Use care not to damage final drive support assembly, transaxle case, or retaining ring during removal.
    Fig 61: Removing Beveled Retaining Ring Using Special Tool
    G01361788Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
  60. Remove the final drive differential and rear planet support assembly.
    Fig 62: Removing Final Drive Differential And Rear Planet Support Assembly
    G01361789Courtesy of FORD MOTOR CO.
    61. NOTE: The differential carrier thrust washer may remain on the differential assembly.
  61. Remove the differential carrier thrust washer.
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
      Fig 63: Removing Differential Carrier Thrust Washer
      G01361790Courtesy of FORD MOTOR CO.
  62. Remove the rear planet support spacer.
    Fig 64: Removing Rear Planet Support Spacer
    G01361791Courtesy of FORD MOTOR CO.
  63. Remove the final drive ring gear.
    Fig 65: Removing Final Drive Ring Gear
    G01361792Courtesy of FORD MOTOR CO.
  64. Remove the stator support bolts.
    Fig 66: Removing Stator Support Bolts
    G01361793Courtesy of FORD MOTOR CO.
    65. NOTE: Inspect the bearing, bushing and the surface of the stator support. If any damage is indicated, install a new stator support.
  65. Remove and inspect the stator support.
    1. Remove the stator support.
    2. Inspect the bearing for damage.
    3. Inspect the bushing for damage.
    4. Inspect the surface for damage.
      Fig 67: Removing And Inspecting Stator Support
      G01361794Courtesy of FORD MOTOR CO.
    66. NOTE: The following procedures are done only if a case replacement is necessary.
    Fig 68: Removing Park Pawl Shaft Retaining Pin
    G01361795Courtesy of FORD MOTOR CO.
  66. Remove the park pawl shaft retaining pin.
  67. Using the special tools, remove the cup plug.
    Fig 69: Removing Cup Plug Using Special Tools
    G01361796Courtesy of FORD MOTOR CO.
  68. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
      Fig 70: Removing Parking Pawl
      G01361797Courtesy of FORD MOTOR CO.
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