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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: Locating Output Shaft Speed (OSS) Sensor
      G04652816Courtesy of FORD MOTOR CO.
  3. Remove the turbine shaft speed (TSS) sensor.
    Fig 2: Locating Turbine Shaft Speed (TSS) Sensor
    G04652817Courtesy of FORD MOTOR CO.
    CAUTION: Do not use air tools.
  4. While holding the lever, remove the manual control lever.
    Fig 3: Locating Manual Control Lever
    G04652818Courtesy of FORD MOTOR CO.
  5. Remove the transmission range (TR) sensor.
    Fig 4: Locating Transmission Range (TR) Sensor
    G04652819Courtesy of FORD MOTOR CO.
  6. Remove the special tool.
    Fig 5: Identifying Special Tool (307-346)
    G04652820Courtesy of FORD MOTOR CO.
  7. Remove the rubber vent cap.
    Fig 6: Locating Rubber Vent Cap
    G04652821Courtesy of FORD MOTOR CO.
    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.
  8. Using the special tool, remove the torque converter.
    Fig 7: Identifying Special Tool (307-091)
    G04652822Courtesy of FORD MOTOR CO.
  9. Remove the differential opening cover.
    Fig 8: Locating Differential Opening Cover
    G04652823Courtesy of FORD MOTOR CO.
  10. Remove the LH and RH axle seals.
  11. Using the special tool, mount the transaxle to a bench.
    Fig 9: Identifying Special Tool (307-410) On Transaxle To Bench
    G04652824Courtesy of FORD MOTOR CO.
  12. Remove the bolts.
    Fig 10: Locating Torque Converter Bolts
    G04652825Courtesy of FORD MOTOR CO.
  13. Using the two 10-mm bolts, remove the fluid pump.
    Fig 11: Locating Fluid Pump Bolts
    G04652826Courtesy of FORD MOTOR CO.
  14. Remove the fluid pump seals.
    Fig 12: Locating Fluid Pump Seals
    G04652827Courtesy of FORD MOTOR CO.
  15. Remove the forward clutch thrust washer.
    Fig 13: Locating Clutch Thrust Washer
    G04652828Courtesy of FORD MOTOR CO.
  16. Remove the forward clutch assembly.
    Fig 14: Locating Clutch Assembly
    G04652829Courtesy of FORD MOTOR CO.
    NOTE: Small levers will aid in the removal of the forward clutch hub.
  17. Remove the forward clutch hub.
    Fig 15: Locating Clutch Hub
    G04652830Courtesy of FORD MOTOR CO.
  18. Rotate the transaxle 180 degrees.
  19. Remove the end cover.
    Fig 16: Locating Transaxle Cover Bolts
    G04652831Courtesy of FORD MOTOR CO.
  20. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
  21. Remove the direct clutch hub bearing shim.
    Fig 17: Locating Clutch Hub Bearing Shim
    G04652832Courtesy of FORD MOTOR CO.
  22. Remove the end cover seals.
    Fig 18: Locating Cover Seals
    G04652833Courtesy of FORD MOTOR CO.
  23. Remove the end cover-to-case seals.
    Fig 19: Locating Cover-To-Case Seals
    G04652834Courtesy of FORD MOTOR CO.
  24. Remove the direct clutch cylinder thrust bearing.
    Fig 20: Locating Clutch Cylinder Thrust Bearing
    G04652835Courtesy of FORD MOTOR CO.
  25. Remove the intermediate/overdrive band anchor bolt.
    Fig 21: Locating Intermediate/Overdrive Band Anchor Bolt
    G04652836Courtesy of FORD MOTOR CO.
  26. Remove the intermediate/overdrive band.
    Fig 22: Locating Intermediate/Overdrive Band
    G04652837Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/overdrive drum assembly.
    Fig 23: Locating Intermediate/Overdrive Drum Assembly
    G04652838Courtesy of FORD MOTOR CO.
  28. Remove the planet gear assembly.
    Fig 24: Locating Planet Gear Assembly
    G04652839Courtesy of FORD MOTOR CO.
  29. Remove the low/reverse clutch plate retaining ring.
    Fig 25: Locating Low/Reverse Clutch Plate Retaining Ring
    G04652840Courtesy of FORD MOTOR CO.
  30. Remove the low/reverse clutch plates, pressure plate and wave spring.
    Fig 26: Locating Low/Reverse Clutch Plates, Pressure Plate And Wave Spring
    G04652841Courtesy of FORD MOTOR CO.
  31. Remove the low one-way clutch retaining ring.
    Fig 27: Locating Low One-Way Clutch Retaining Ring
    G04652842Courtesy of FORD MOTOR CO.
  32. Remove the low one-way clutch inner race.
    Fig 28: Locating Low One-Way Clutch Inner Race
    G04652843Courtesy of FORD MOTOR CO.
  33. Remove the low/reverse clutch return spring.
    Fig 29: Locating Low/Reverse Clutch Return Spring
    G04652844Courtesy of FORD MOTOR CO.
  34. Remove the low/reverse clutch piston.
    Fig 30: Locating Low/Reverse Clutch Piston
    G04652845Courtesy of FORD MOTOR CO.
  35. Using the special tool, remove the transmission fluid pan.
    • Remove the bolts.
    • Using a suitable tool, remove the transmission fluid pan.
      Fig 31: Locating Transmission Fluid Pan Bolts
      G04652846Courtesy of FORD MOTOR CO.
  36. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
  37. Disconnect the transmission fluid temperature (TFT) sensor.
    Fig 32: Locating Transmission Fluid Temperature (TFT) Sensor
    G04652847Courtesy of FORD MOTOR CO.
  38. Remove the fluid filter.
    Fig 33: Locating Fluid Filter
    G04652848Courtesy of FORD MOTOR CO.
    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.
  39. 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 PCA; Color B (Black).
    5. Solenoid SSA; Color N (Neutral).
    6. Solenoid SSB; Color B (Black).
      Fig 34: Locating Ground Wire Bolt
      G04652849Courtesy of FORD MOTOR CO.
    NOTE: Note the locations of the longer bolts.
  40. Remove the 13 main control valve body bolts.
    Fig 35: Locating Main Control Valve Body Bolts
    G04652850Courtesy of FORD MOTOR CO.
    NOTE: Squeeze the tabs on the side of the electrical connector.
  41. Remove the transaxle internal harness electrical connector.
    Fig 36: Locating Transaxle Internal Harness Electrical Connector
    G04652851Courtesy of FORD MOTOR CO.
    NOTE: Each accumulator has 2 springs. All 4 springs are different sizes.
    NOTE: Note the size and location of the accumulator springs to aid assembly.
    NOTE: Accumulator bore and pistons are a match as to depth, some piston may have steps. Install new pistons in the same bore as removed.
  42. Remove the accumulator pistons and springs.
    Fig 37: Locating Accumulator Pistons And Springs
    G04652852Courtesy of FORD MOTOR CO.
  43. Remove the manual lever shaft roll pin.
    Fig 38: Locating Manual Lever Shaft Roll Pin
    G04652853Courtesy of FORD MOTOR CO.
  44. Remove the manual lever shaft.
    Fig 39: Locating Manual Lever Shaft
    G04652854Courtesy of FORD MOTOR CO.
  45. Remove the O-ring seals from the manual lever shaft.
    Fig 40: Locating O-Ring Seals
    G04652855Courtesy of FORD MOTOR CO.
  46. Remove the control lever assembly.
    Fig 41: Locating Control Lever Assembly Bolts
    G04652856Courtesy of FORD MOTOR CO.
    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.
  47. Remove the 3 intermediate/overdrive piston servo cover bolts and the servo cover.
    Fig 42: Locating Intermediate/Overdrive Piston Servo Cover Bolts
    G04652857Courtesy of FORD MOTOR CO.
  48. Remove the O-ring seal.
    Fig 43: Locating O-Ring Seal
    G04652858Courtesy of FORD MOTOR CO.
  49. Remove the intermediate/overdrive servo piston.
    Fig 44: Locating Intermediate/Overdrive Servo Piston
    G04652859Courtesy of FORD MOTOR CO.
  50. Remove the intermediate/overdrive servo piston return spring.
    Fig 45: Locating Intermediate/Overdrive Servo Piston Return Spring
    G04652860Courtesy of FORD MOTOR CO.
  51. Rotate the transaxle 180 degrees.
  52. Remove the bolts and separate the converter housing from the transaxle case.
    Fig 46: Locating Converter Housing Bolts
    G04652861Courtesy of FORD MOTOR CO.
  53. Remove the differential assembly.
    Fig 47: Locating Differential Assembly Gear
    G04652862Courtesy of FORD MOTOR CO.
  54. Remove the parking pawl assembly cover.
    • Remove the bolts and the parking pawl assembly cover.
      Fig 48: Locating Parking Pawl Assembly Cover Bolts
      G04652863Courtesy of FORD MOTOR CO.
  55. Remove the parking pawl abutment.
    1. Unclip the spring.
    2. Remove the pin.
    3. Remove the lever.
    4. Remove the parking pawl abutment.
      Fig 49: Locating Parking Pawl Abutment
      G04652864Courtesy of FORD MOTOR CO.
  56. Remove the spring.
    Fig 50: Locating Spring
    G04652865Courtesy of FORD MOTOR CO.
  57. Remove the transfer shaft gears.
    Fig 51: Locating Transfer Shaft Gears
    G04652866Courtesy of FORD MOTOR CO.
  58. Using the special tool, lock the final drive input gear.
    Fig 52: Identifying Special Tool (307-413)
    G04652867Courtesy of FORD MOTOR CO.
  59. Rotate the transaxle 180 degrees.
    NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
  60. Using the special tools, remove the final drive input gear bearing retainer nut.
    Fig 53: Identifying Special Tools (307-414, 307-420)
    G04652868Courtesy of FORD MOTOR CO.
  61. Remove the special tools.
  62. Rotate the transaxle 180 degrees.
  63. Remove the special tool.
    Fig 54: Identifying Special Tools (307-413)
    G04652869Courtesy of FORD MOTOR CO.
    CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.
  64. Rotate the transaxle 180 degrees.
  65. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
    Fig 55: Locating Final Drive Input Gear
    G04652870Courtesy of FORD MOTOR CO.
  66. Remove and discard the collapsible spacer.
    Fig 56: Locating Collapsible Spacer
    G04652871Courtesy of FORD MOTOR CO.
    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.
  67. Using a suitable chisel, remove the final drive input gear bearing.
    Fig 57: Locating Final Drive Input Gear Bearing
    G04652872Courtesy of FORD MOTOR CO.
  68. Using the special tools, remove the final drive input gear bearing inner race.
    Fig 58: Identifying Special Tools (204-069, 205-D015, 205-D064) Into Final Drive Input Gear Bearing Inner Race
    G04652873Courtesy of FORD MOTOR CO.
  69. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.
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