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Automatic Transmission: Disassembly: Transmission: Disaasembly

    All vehicles 

    WARNING: Do not remove the torque converter from the transmission while still on the jack. Doing so could cause the transmission to fall. Failure to follow these instructions may result in personal injury.
    Fig 1: Placing Transmission On Workbench
    G03975178Courtesy of FORD MOTOR CO.
  1. Place the transmission on a workbench.
  2. Remove the special tool.
    Fig 2: Identifying Converter Holder Special Tool
    G03914881Courtesy of FORD MOTOR CO.
    3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury.
    Fig 3: Removing Torque Converter Using Special Tool
    G03914893Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the torque converter.
    4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
    Fig 4: Removing Input Shaft
    G03914894Courtesy of FORD MOTOR CO.
  4. Remove the input shaft.
  5. Remove the output shaft speed (OSS) sensor.
    1. Remove the OSS screw.
    2. Remove OSS sensor.
      Fig 5: Removing OSS Sensor
      G03914895Courtesy of FORD MOTOR CO.
  6. Remove the intermediate shaft speed sensor.
    1. Remove the intermediate shaft speed screw.
    2. Remove intermediate shaft speed sensor.
      Fig 6: Removing Intermediate Shaft Speed Sensor
      G03914739Courtesy of FORD MOTOR CO.
  7. If equipped, remove the heat shield.
    1. Remove the nut.
    2. Remove the heat shield.
      Fig 7: Removing Heat Shield
      G03914831Courtesy of FORD MOTOR CO.
  8. Remove manual control outer lever nut and manual control outer lever.
    Fig 8: Removing Manual Control Outer Lever Nut And Manual Control Outer Lever
    G03914898Courtesy of FORD MOTOR CO.
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the screws.
    2. Remove the digital TR sensor.
      Fig 9: Removing Digital TR Sensor
      G03914899Courtesy of FORD MOTOR CO.

    10. 4x2 vehicles 

  10. Using the special tools, remove the extension housing seal.
    Fig 10: Removing Extension Housing Seal Using Special Tools
    G03914749Courtesy of FORD MOTOR CO.
    11. NOTE: Remove the extension housing bushing only if service is required.
  11. Using the special tool, remove the extension housing bushing.
    • Inspect the extension housing bushing and driveshaft slip yoke for nicks, gouges, scoring and wear.
      Fig 11: Inspecting Extension Housing Bushing And Driveshaft Slip Yoke
      G03908438Courtesy of FORD MOTOR CO.

    12. All vehicles 

    CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
  12. Remove the screws, studs and the extension housing.
    • Discard the extension housing gasket.
      Fig 12: Discarding Extension Housing Gasket
      G03914902Courtesy of FORD MOTOR CO.
  13. Remove the parking pawl assembly.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
      Fig 13: Removing Parking Pawl Return Spring
      G03914903Courtesy of FORD MOTOR CO.
    14. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
    Fig 14: Installing Special Tool
    G03914904Courtesy of FORD MOTOR CO.
  14. Install the special tool.
  15. Assemble the special tools.
    Fig 15: Assembling Special Tools
    G03914905Courtesy of FORD MOTOR CO.
    16. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 16: Installing Transmission Into Special Tool
    G03914906Courtesy of FORD MOTOR CO.
  16. Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.
    17. CAUTION: Do not reuse the fluid pan gasket.
    Fig 17: Locating Transmission Fluid Pan Bolts
    G03914687Courtesy of FORD MOTOR CO.
  17. Remove the transmission fluid pan screws, pan and transmission pan gasket and then discard the gasket.
  18. Remove the transmission fluid filter and discard.
    1. Remove the screw.
    2. Remove the transmission fluid filter.
      Fig 18: Locating Transmission Fluid Filter Screw
      G03914696Courtesy of FORD MOTOR CO.
  19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
    Fig 19: Identifying Wire Harness Guide And Protector
    G03914729Courtesy of FORD MOTOR CO.
  20. Disconnect the solenoid electrical connectors.
    1. Disconnect the SSA, SSB, SSC and SSD electrical connectors.
    2. Disconnect the torque converter clutch (TCC) solenoid electrical connector.
    3. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
      Fig 20: Identifying Six Solenoid Electrical Connectors
      G03914711Courtesy of FORD MOTOR CO.
  21. Remove the manual control valve detent lever spring.
    1. Remove the screw.
    2. Remove the manual control valve detent lever spring.
      Fig 21: Removing Manual Control Valve Detent Lever Spring
      G03914712Courtesy of FORD MOTOR CO.
  22. Remove the low/reverse band servo cover.
    1. Remove the screws.
    2. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
      • Discard the low/reverse servo separator plate cover gasket.
        Fig 22: Discarding Low/Reverse Servo Separator Plate Cover Gasket
        G03914713Courtesy of FORD MOTOR CO.
  23. Remove the low/reverse band servo piston and rod assembly.
    Fig 23: Removing Low/Reverse Band Servo Piston And Rod Assembly
    G03914725Courtesy of FORD MOTOR CO.
    24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown in Fig 24.
    Fig 24: Identifying Two (Gold Colored) Screws
    G03914715Courtesy of FORD MOTOR CO.
  24. Do not remove the two (gold colored) screws specified.
  25. Remove the twenty-three valve body screws.
    Fig 25: Removing Twenty-Three Valve Body Screws
    G03914915Courtesy of FORD MOTOR CO.
  26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket.
    • Discard gaskets.
      Fig 26: Removing Main Control Valve Body, Valve Body Separator Plate And Main Control To Separator Plate Gasket
      G03914916Courtesy of FORD MOTOR CO.
    27. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 27: Removing Locknuts And Screws
    G03914917Courtesy of FORD MOTOR CO.
  27. Remove the locknuts and the screws.
    28. CAUTION: The servo cover is under spring tension.
    Fig 28: Removing Intermediate Servo Cover Retaining Ring Using Special Tool
    G03914918Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the intermediate servo cover retaining ring.
    29. NOTE: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo, cover and bore.
    Fig 29: Removing Intermediate Band Servo Piston, Spring And Cover Using Special Tool
    G03914919Courtesy of FORD MOTOR CO.
  29. Using the special tool, remove the intermediate band servo piston, spring and cover.
    30. CAUTION: Servo cover is under spring tension.
    Fig 30: Removing Overdrive Servo Retaining Ring And Cover Using Special Tool
    G03914920Courtesy of FORD MOTOR CO.
  30. Using the special tool, remove the overdrive servo retaining ring and cover.
    31. NOTE: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo piston and bore.
    Fig 31: Removing Overdrive Band Servo Piston, Spring And Cover Using Special Tool
    G03914921Courtesy of FORD MOTOR CO.
  31. Using the special tool, remove the overdrive band servo piston, spring and cover.
    32. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  32. Rotate the transmission so the converter housing faces up.
    33. CAUTION: Discard the screws. The screws are not reusable for assembly.
    Fig 32: Removing And Discarding Screws
    G03914922Courtesy of FORD MOTOR CO.
  33. Remove and discard the screws.
  34. Remove the converter housing and fluid pump support.
    • Turn and lift the converter housing and fluid pump support from the case.
      Fig 33: Lifting Converter Housing And Fluid Pump Support From Case
      G03914923Courtesy of FORD MOTOR CO.
  35. Remove the No. 1 fluid pump input thrust washer.
    Fig 34: Removing No. 1 Fluid Pump Input Thrust Washer
    G03914924Courtesy of FORD MOTOR CO.
  36. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
    Fig 35: Compressing Front Band Around Front Brake And Coast Clutch Drum
    G03914925Courtesy of FORD MOTOR CO.
    37. CAUTION: Identify the anchor and apply ends of the front band.
    Fig 36: Removing Front Band
    G03914926Courtesy of FORD MOTOR CO.
  37. Remove the front band.
  38. Remove the front brake and coast clutch drum.
    Fig 37: Removing Front Brake And Coast Clutch Drum
    G03914927Courtesy of FORD MOTOR CO.
  39. Remove the front band apply strut.
    Fig 38: Removing Front Band Apply Strut
    G03914928Courtesy of FORD MOTOR CO.
    40. NOTE: The front band lever shaft is longer than the intermediate band lever shaft.
    Fig 39: Removing Front Band Actuating Lever Shaft
    G03914929Courtesy of FORD MOTOR CO.
  40. Remove the front band actuating lever shaft.
    41. CAUTION: Do not bend trigger wheel.
    NOTE: The No. 2 thrust bearing is in this assembly.
    Fig 40: Removing Planetary Gear Overdrive Carrier
    G03914930Courtesy of FORD MOTOR CO.
  41. Remove the planetary gear overdrive carrier.
    42. NOTE: Tag and identify the front band servo lever. The front band servo lever has a letter stamped on the side.
    Fig 41: Removing Front Band Servo Lever And Front Band Lever To Case Bracket
    G03914931Courtesy of FORD MOTOR CO.
  42. Remove the front band servo lever and front band lever to case bracket.
  43. Remove the No. 2 front planet thrust bearing.
    Fig 42: Removing No. 2 Front Planet Thrust Bearing
    G03914932Courtesy of FORD MOTOR CO.
  44. Remove the front ring gear, front one-way clutch assembly and center shaft as an assembly.
    Fig 43: Removing Front Ring Gear, Front One-Way Clutch Assembly And Center Shaft As Assembly
    G03914933Courtesy of FORD MOTOR CO.
    45. NOTE: Tag and identify the No. 3 center shaft thrust bearing for assembly.
    Fig 44: Removing No. 3 Center Shaft Thrust Bearing
    G03914934Courtesy of FORD MOTOR CO.
  45. Remove the No. 3 center shaft thrust bearing.
    46. CAUTION: The center support locknut can fall into the remaining assembly if not removed.
    Fig 45: Removing Center Support Cap Screw
    G03914935Courtesy of FORD MOTOR CO.
  46. Remove the center support cap screw.
  47. Remove the locknut and cage.
    Fig 46: Removing Locknut And Cage
    G03914936Courtesy of FORD MOTOR CO.
    48. CAUTION: Do not pry on other wires or damage the connector or case surface.
  48. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    1. Remove the TSS sensor electrical connector from the transmission case (16-pin) electrical connector.
    2. Remove the TSS sensor connector wires from wire locator.
      Fig 47: Removing TSS Sensor Connector Wires From Wire Locator
      G03914937Courtesy of FORD MOTOR CO.
    49. CAUTION: Carefully route the TSS connector and wiring into the transmission through the opening in the case.
  49. Remove the TSS sensor.
    1. Remove the screw.
    2. Remove the TSS sensor.
      Fig 48: Removing TSS Sensor
      G03914938Courtesy of FORD MOTOR CO.
    50. CAUTION: Do not overstretch the retaining spring.
    Fig 49: Removing Transmission Case (16-Pin) Electrical Connector Retaining Spring
    G03914842Courtesy of FORD MOTOR CO.
  50. Remove the transmission case (16-pin) electrical connector retaining spring.
    51. CAUTION: Do not damage the connector or harness.
    Fig 50: Pushing Transmission Case (16-Pin) Electrical Connector Out Of Transmission Case
    G03914843Courtesy of FORD MOTOR CO.
  51. Compress the tabs on the transmission case (16-pin) electrical connector.

    Push the transmission case (16-pin) electrical connector out of transmission case.

  52. Remove the center support retaining ring.
    Fig 51: Removing Center Support Retaining Ring
    G03914941Courtesy of FORD MOTOR CO.
    53. NOTE: When removing the center support, pull evenly around the center support web.
    Fig 52: Removing Center Support
    G03914942Courtesy of FORD MOTOR CO.
  53. Remove the center support.
    54. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 53: Removing No. 4 Intermediate Brake Drum Thrust Bearing
    G03914943Courtesy of FORD MOTOR CO.
  54. Remove the No. 4 intermediate brake drum thrust bearing.
  55. Remove the intermediate band anchor strut.
    Fig 54: Removing Intermediate Band Anchor Strut
    G03914944Courtesy of FORD MOTOR CO.
    56. CAUTION: Identify the anchor and apply ends of the intermediate band.
    Fig 55: Removing Intermediate Band
    G03914945Courtesy of FORD MOTOR CO.
  56. Remove the intermediate band.
  57. Remove the intermediate band apply strut.
    Fig 56: Removing Intermediate Band Apply Strut
    G03914946Courtesy of FORD MOTOR CO.
    58. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 57: Removing Intermediate Band Actuating Lever Shaft
    G03914947Courtesy of FORD MOTOR CO.
  58. Remove the intermediate band actuating lever shaft.
    59. NOTE: Tag and identify the intermediate servo band lever. The intermediate servo band lever has a letter stamped into its side.
    Fig 58: Removing Intermediate Servo Actuating Lever
    G03914948Courtesy of FORD MOTOR CO.
  59. Remove the intermediate servo actuating lever.
    60. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
    Fig 59: Removing Intermediate Brake And Direct Clutch Drum
    G03914949Courtesy of FORD MOTOR CO.
  60. Remove the intermediate brake and direct clutch drum.
  61. Remove the No. 5 forward clutch cylinder thrust bearing tag and identify.
    Fig 60: Removing No. 5 Forward Clutch Cylinder Thrust Bearing Tag
    G03914950Courtesy of FORD MOTOR CO.
  62. Remove the forward clutch cylinder.
    Fig 61: Removing Forward Clutch Cylinder
    G03914951Courtesy of FORD MOTOR CO.
  63. Remove the No. 6A forward ring gear hub thrust bearing.
    Fig 62: Removing No. 6A Forward Ring Gear Hub Thrust Bearing
    G03914952Courtesy of FORD MOTOR CO.
  64. Remove the forward ring gear and forward ring gear hub as an assembly.
    Fig 63: Removing Forward Ring Gear And Forward Ring Gear Hub As An Assembly
    G03914953Courtesy of FORD MOTOR CO.
  65. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
    Fig 64: Removing No. 6B Forward Clutch Thrust Washer From Forward Ring Gear Hub
    G03914954Courtesy of FORD MOTOR CO.
    66. NOTE: Check the black oxidized side during removal to make sure of correct placement during reassembly. The black oxidized side must be toward planetary assembly. The uncoated side must face up.
    Fig 65: Removing No. 7 Forward Planet Thrust Bearing
    G03914955Courtesy of FORD MOTOR CO.
  66. Remove the No. 7 forward planet thrust bearing.
  67. Remove the forward planetary assembly.
    Fig 66: Removing Forward Planetary Assembly
    G03914956Courtesy of FORD MOTOR CO.
  68. Remove input shell with the forward sun gear.
    Fig 67: Removing Input Shell With Forward Sun Gear
    G03914957Courtesy of FORD MOTOR CO.
    69. NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
    Fig 68: Removing No. 8 Low/Reverse Planetary Carrier Thrust Bearing
    G03915183Courtesy of FORD MOTOR CO.
  69. Remove the No. 8 low/reverse planetary carrier thrust bearing.
  70. Remove the low/reverse planetary retaining ring.
    Fig 69: Removing Low/Reverse Planetary Retaining Ring
    G03914959Courtesy of FORD MOTOR CO.
  71. Remove low/reverse planetary assembly.
    Fig 70: Removing Low/Reverse Planetary Assembly
    G03914960Courtesy of FORD MOTOR CO.
    72. NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
    Fig 71: Removing No. 9 Low/Reverse Planetary Carrier Thrust Bearing
    G03914961Courtesy of FORD MOTOR CO.
  72. Remove the No. 9 low/reverse planetary carrier thrust bearing.
  73. Remove the output shaft sleeve.
    Fig 72: Removing Output Shaft Sleeve
    G03914962Courtesy of FORD MOTOR CO.
    74. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 73: Removing And Discard Output Shaft Retaining Ring
    G03914963Courtesy of FORD MOTOR CO.
  74. Remove and discard the output shaft retaining ring.
  75. Remove the output shaft ring gear and the output shaft hub.
    Fig 74: Removing Output Shaft Ring Gear And Output Shaft Hub
    G03914964Courtesy of FORD MOTOR CO.
    76. NOTE: Tag and identify the No. 10 output shaft hub thrust bearing.
    Fig 75: Removing No. 10 Output Shaft Thrust Bearing
    G03914965Courtesy of FORD MOTOR CO.
  76. Remove the No. 10 output shaft thrust bearing.
    77. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
    Fig 76: Removing Low/Reverse Brake Drum And One-Way Clutch Assembly
    G03914966Courtesy of FORD MOTOR CO.
  77. Remove the low/reverse brake drum and one-way clutch assembly.
  78. Remove the reverse band.
    Fig 77: Removing Reverse Band
    G03914967Courtesy of FORD MOTOR CO.
  79. Remove the output shaft.
    Fig 78: Removing Output Shaft
    G03914968Courtesy of FORD MOTOR CO.
  80. Remove the park gear.
    Fig 79: Removing Park Gear
    G03915175Courtesy of FORD MOTOR CO.
    81. NOTE: Tag and identify the No. 11 output shaft thrust washer.
    Fig 80: Removing No. 11 Output Shaft Thrust Washer
    G03914970Courtesy of FORD MOTOR CO.
  81. Remove the No. 11 output shaft thrust washer.
    82. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.
    Fig 81: Removing Manual Control Valve Inner Lever Nut
    G03914971Courtesy of FORD MOTOR CO.
  82. Remove the manual control valve inner lever nut.
  83. Remove the manual control valve inner lever and the parking lever actuating rod.
    Fig 82: Removing Manual Control Valve Inner Lever And Parking Lever Actuating Rod
    G03914972Courtesy of FORD MOTOR CO.
    84. CAUTION: Do not damage the case fluid pan rail.
  84. Remove the manual control lever shaft spring pin.
    • Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
    • Pry the spring pin out of its bore.
      Fig 83: Prying Spring Pin Out Of Bore
      G03914973Courtesy of FORD MOTOR CO.
  85. Remove the manual control lever shaft.
    Fig 84: Removing Manual Control Lever Shaft
    G03915170Courtesy of FORD MOTOR CO.
    86. CAUTION: Do not damage the bore.
    Fig 85: Removing Manual Control Lever Seal
    G03914975Courtesy of FORD MOTOR CO.
  86. Remove the manual control lever seal.
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