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Automatic Transmission: Disassembly: Transaxle: Disassembly

    CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 1: Identifying Torque Converter
    G03956961Courtesy 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 2: Installing Transaxle Into Bench Mount
    G03956962Courtesy of FORD MOTOR CO.
    3. NOTE: When installing a new case, the identification tag must be transferred to the new case, use caution to prevent damage to the tag.
    Fig 3: Removing Identification Tag
    G03956963Courtesy of FORD MOTOR CO.
  3. Remove the identification tag.
  4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
    Fig 4: Placing Drain Pan Under Transaxle
    G03956964Courtesy of FORD MOTOR CO.
  5. Remove the filler tube.
    Fig 5: Locating Filler Tube Mounting Bolt
    G03956965Courtesy of FORD MOTOR CO.
    6. CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components can be ejected from the case.
    Fig 6: Locating Overdrive Servo Piston
    G03956966Courtesy of FORD MOTOR CO.
  6. Remove the overdrive servo piston and rod.
    • Remove the bolts.
    • Remove the cover.
    • Remove the piston and rod.
  7. Remove the output shaft speed (OSS) sensor cover.
    Fig 7: Locating Output Shaft Speed (OSS) Sensor Cover
    G03956967Courtesy of FORD MOTOR CO.
  8. Remove the OSS sensor.
    • Unclip the harness.
    • Remove the OSS sensor.
    Fig 8: Locating OSS Sensor
    G03956968Courtesy of FORD MOTOR CO.
  9. Remove the digital TR sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 9: Removing Digital TR Sensor
    G03956969Courtesy of FORD MOTOR CO.
  10. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
    Fig 10: Removing TSS Sensor
    G03956970Courtesy of FORD MOTOR CO.
    11. NOTE: The differential seal is a two-piece constructed seal.
    Fig 11: Removing LH Differential Seal
    G03956828Courtesy 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 Front Crankshaft Oil Seal Remover.
    2. Rotate the forcing screw while holding the Front Crankshaft Oil Seal Remover.
    3. Remove the metal protector from the LH differential seal and remove the protector from the tool.
    Fig 12: Removing Differential Seal
    G03956829Courtesy 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.
    2. Rotate the forcing screw while holding the Front Crankshaft Oil Seal Remover.
    3. Remove the rubber portion of the seal.
    Fig 13: Removing Rubber Portion Of Seal
    G03956830Courtesy of FORD MOTOR CO.
  14. Install the special tool into the RH differential seal.
    Fig 14: Identifying Differential Seal Installation Special Tools
    G03956831Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the Front Crankshaft Oil Seal Remover.
    2. Rotate the forcing screw while holding the Front Crankshaft Oil Seal Remover.
    3. Remove the metal protector of the seal.
    Fig 15: Removing Metal Protector Of Seal
    G03956832Courtesy of FORD MOTOR CO.
  16. Using the special tool, remove the rubber portion of the seal.
    1. Rotate the Front Crankshaft Oil Seal Remover.
    2. Rotate the forcing screw while holding the Front Crankshaft Oil Seal Remover.
    3. Remove the rubber portion of the seal.
    Fig 16: Removing Rubber Portion Of Seal
    G03956833Courtesy of FORD MOTOR CO.
    17. CAUTION: Use special tool 307-309 to remove the converter hub seal. Stator support surface will be damaged if any other type tool is used. Stator support surface damage will cause a P0741 code to be set after repairs.
    Fig 17: Removing Converter Hub Seal
    G03956977Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the converter hub seal.
  18. Remove the bolts.
    Fig 18: Locating Bolts
    G03956978Courtesy of FORD MOTOR CO.
  19. Rotate the transaxle to a horizontal position.
  20. Remove the mount bracket.
    Fig 19: Removing Mount Bracket
    G04004863Courtesy of FORD MOTOR CO.
    21. NOTE: The main control cover gasket is reusable if not torn or damaged.
    Fig 20: Removing Pan
    G03956767Courtesy of FORD MOTOR CO.
  21. Remove the pan.
    22. CAUTION: Do not pull on the wires or pry the connectors. Damage to the connector will result.
    Fig 21: Disconnecting Electrical Connectors
    G03956775Courtesy of FORD MOTOR CO.
  22. Lift the locking tab and disconnect the electrical connectors.
    23. NOTE: The manual valve should be inserted completely.
    Fig 22: Rotating Manual Control Lever To Low Detent
    G03956982Courtesy 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 must be removed.
    Fig 23: Removing Pump Cover Bolts
    G03956776Courtesy 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 24: Removing Main Control Valve Body
    G03956777Courtesy of FORD MOTOR CO.
  26. Disconnect the manual control valve actuating rod.
    Fig 25: Disconnecting Manual Control Valve Actuating Rod
    G03956985Courtesy of FORD MOTOR CO.
  27. Remove the pump shaft.
    Fig 26: Removing Pump Shaft
    G03956986Courtesy of FORD MOTOR CO.
    28. NOTE: The transaxle pan gasket is reusable if not torn or damaged.
    Fig 27: Removing Bolts, Transmission Fluid Pan And Gasket
    G03956987Courtesy of FORD MOTOR CO.
  28. Remove the bolts, transmission fluid pan and gasket.
  29. Remove, clean and inspect the magnet.
    Fig 28: Inspecting Magnet
    G03956988Courtesy of FORD MOTOR CO.
  30. Remove the filter.
    Fig 29: Removing Filter
    G03956989Courtesy 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 30: Removing Fluid Filter Seal
    G03956990Courtesy of FORD MOTOR CO.
  31. Remove the fluid filter seal.
  32. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 31: Removing Reverse Clutch Anchor Pin
    G03956991Courtesy 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 32: Removing Chain Cover Bolts
    G03956992Courtesy of FORD MOTOR CO.
  33. Remove the bolts.
    34. NOTE: Plastic thrust washers No. 1 and No. 3 may stick to the cover or to the sprockets.
    Fig 33: Removing Chain Cover And Gasket
    G03956993Courtesy 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 spring.
    2. Remove the 2-3 shift accumulator piston spring.
    3. Remove the reverse shift accumulator piston spring.
    4. Remove the 3-4 shift accumulator piston spring.
    Fig 34: Removing Shift Accumulator Springs
    G03956994Courtesy 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 35: Removing Drive Sprocket, Driven Sprocket And Drive Chain
    G03956995Courtesy 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.
    Fig 36: Removing Thrust Washers
    G04005265Courtesy of FORD MOTOR CO.
  37. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
    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 37: Removing Roll Pins
    G04005264Courtesy 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 38: Removing Manual Control Lever Shaft
    G04005263Courtesy of FORD MOTOR CO.
  39. Remove the manual control lever shaft.
  40. Remove the parking lever actuating rod.
    Fig 39: Removing Parking Lever Actuating Rod
    G03956999Courtesy of FORD MOTOR CO.
  41. Remove the manual control lever shaft seal.
    Fig 40: Removing Manual Control Lever Shaft Seal
    G03957000Courtesy of FORD MOTOR CO.
    42. NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
    Fig 41: Removing Bolts And Brackets
    G04005260Courtesy of FORD MOTOR CO.
  42. Remove the bolts and brackets.
  43. Using the special tools, remove the fluid lube tubes.
    Fig 42: Removing Fluid Lube Tubes
    G03957002Courtesy of FORD MOTOR CO.
  44. Remove the bolts and the park pawl abutment.
    Fig 43: Removing Bolts And Park Pawl Abutment
    G03957003Courtesy of FORD MOTOR CO.
  45. Remove the neutral/drive accumulator bolt.
    Fig 44: Removing Neutral/Drive Accumulator Bolt
    G03957004Courtesy 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 45: Removing Neutral/Drive Accumulator
    G03957005Courtesy 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 46: Removing Coast Band Servo
    G03957006Courtesy of FORD MOTOR CO.
    48. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
    Fig 47: Removing Drive Sprocket Support And No. 5 Thrust Washer
    G03957007Courtesy 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 48: Removing Driven Sprocket Support Selective Fit Rear Thrust Washer & No. 9 Needle Bearing
    G03957008Courtesy 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 49: Removing Plastic Overdrive Band Retainer
    G03957009Courtesy of FORD MOTOR CO.
  51. Remove the overdrive band.
    Fig 50: Removing Overdrive Band
    G03957010Courtesy of FORD MOTOR CO.
    52. NOTE: Do not overtighten the handle of the tool. Place two 3/8-inch washers between the handle and the notched block.
    Fig 51: Positioning Special Tool Into Case
    G03957011Courtesy 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 52: Removing Front Clutch Assembly
    G03957012Courtesy of FORD MOTOR CO.
  54. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 53: Removing Reverse Clutch And Planet Assembly
    G03957013Courtesy of FORD MOTOR CO.
  55. Remove the low/intermediate drum, sun gear and one-way clutch assembly.
    Fig 54: Removing Low/Intermediate Drum, Sun Gear And One-Way Clutch Assembly
    G03957014Courtesy of FORD MOTOR CO.
  56. Remove the coast band.
    Fig 55: Removing Coast Band
    G03957015Courtesy of FORD MOTOR CO.
    57. CAUTION: Use care not to damage any machined surfaces.
    Fig 56: Removing Low/Intermediate Clutch Retaining Ring
    G04005231Courtesy 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 57: Removing Low/Intermediate Clutch Pack
    G03957017Courtesy 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 58: Removing Beveled Retaining Ring
    G03957018Courtesy 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 59: Identifying Final Drive Differential And Rear Planet Support Assembly
    G03957019Courtesy of FORD MOTOR CO.
    61. NOTE: The differential carrier thrust washer may remain on the differential assembly.
    Fig 60: Removing Differential Carrier Thrust Washer
    G03957020Courtesy of FORD MOTOR CO.
  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.
  62. Remove the rear planet support spacer.
    Fig 61: Removing Rear Planet Support Spacer
    G04005211Courtesy of FORD MOTOR CO.
  63. Remove the final drive ring gear.
    Fig 62: Removing Final Drive Ring Gear
    G04005210Courtesy of FORD MOTOR CO.
  64. Inspect the bearing in the stator support for damage. If damage is indicated, install a new stator support.
    Fig 63: Inspecting Bearing In Stator Support For Damage
    G03957023Courtesy of FORD MOTOR CO.
  65. Remove the bolts.
    Fig 64: Removing Stator Support Bolts
    G03957024Courtesy of FORD MOTOR CO.
  66. Remove the stator support assembly.
    Fig 65: Removing Stator Support Assembly
    G03957025Courtesy of FORD MOTOR CO.
    67. NOTE: The following procedures are done only if a case replacement is necessary.
    Fig 66: Removing Park Pawl Shaft Retaining Pin
    G03957026Courtesy of FORD MOTOR CO.
  67. Remove the park pawl shaft retaining pin.
  68. Using the special tools remove the cup plug.
    Fig 67: Removing Cup Plug
    G03957027Courtesy of FORD MOTOR CO.
  69. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
    Fig 68: Locating Parking Pawl And Return Spring
    G03957028Courtesy of FORD MOTOR CO.
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