Automatic Transmission: Assembly: Transaxle

Special Tools

Illustration	Tool Name	Tool Number
	Dial Indicator Gauge With Holding Fixture	100-002 (TOOL-4201-C)
	Step Plate	205-D014 (D80L-630-3)
	Installer, Steering Gear Pinion Bearing	211-161 (T90C-3504-DH)
	Depth Micrometer	303-D075 (D92P-4201-A)
	Retaining Ring Pliers	307-343 (T95P-77001-AHR)
	Handle, Torque Converter	307-091 (T81P-7902-C)
	Test Plate Screw Set, Transmission	307-126 (T82P-7006-C)
	Air Test Plate, Transmission	307-312 (T94P-77001-EH)
	Gasket, Transmission Air Test Plate	307-313 (T94P-77001-EH1)
	Installer, Halfshaft Output Fluid Seal	307-157 (T86P-1177-B)
	Gauge, Servo Rod	307-162 (T86P-70023-B)
	Holding Fixture Transmission	307-003 (T57L-500-B)
	Lifting Fixture, Clutch Pack	307-171 (T86P-70389-A)
	Installer, Torque Converter Fluid Seal	307-186 (T87L-77837-AH)
	End Play Gauge	307-187 (T87P-70014-AH)
	Remover/Installer, Servo Piston	307-251 (T92P-70023-A)
	Shim Selection Gauge Bar	307-300 (T94P-77000-Q)
	Remover, Reverse Clutch/Planet	307-314 (T94P-77001-FH)
	Aligner, Output Shaft Fluid Seal	307-317 (T94P-77001-JH)
	Shim Selection Gauge	307-320 (T94P-77001-MH)
	Shim Depth Gauge	307-321 (T94P-77001-NH)
	Alignment Gauge, TR Sensor	307-351 (T97L-70010-A)
	Remover/Installer Bearing Tube	308-025 (T75L-7025-C)
	Remover, Bearing Collet Sleeve	308-049 (T77F-7025-C)

Fig 1: Exploded View Of Transaxle Components (1 Of 4)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Transaxle Components (2 Of 4)

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Transaxle Components (3 Of 4)

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Transaxle Components (4 Of 4)

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	N811125-S	Pushpin
2	N605890-S1036	Bolt - M6-1.0 x 16.5 hex flange head (2 required) (attaches dust cover to case)
3	7966	Cover - lower converter housing
4	7966	Cover - lower converter housing
5	7902	Converter assembly
6	7F401	Seal assembly - converter impeller hub
7	1177	Seal assembly - differential (2 required)
8	N806944-S1036	Stud - M10 - 1.5 x 60.5 pilot
9	7005	Case assembly
10	7G112	Bearing and race assembly - differential carrier thrust No. 19
11	7G103	Washer - differential carrier thrust No. 18
12	7F343	Gear - final drive ring
13	7C144	Rear support spacer
14	7F465	Gear and differential case assembly
15	W803200-S	Ring - 27 mm (1.08 in) retaining external (retains output shaft in differential case assembly)
16	706051-S	Ring - 77.3 mm (3.09 in) retaining external (retains pinion shaft in differential case)
17	4230	Washers - rear axle differential pinion thrust (2 required)
18	4215	Pinions - front wheel drive differentials (2 required)
19	4228	Washer - differential side gear thrust (2 required)
20	4236	Gear - differential sides (2 required)
21	67847-S	Pin - coiled spring (retains differential pinion shaft)
22	4211	Shaft - differential pinion
23	7060	Shaft - differential output
24	N804139-S	Circle clip - output shaft retaining
25	7F342	Gear and deflector assembly - final drive sun
26	7A233	Gear - parking
27	7F405	Bearing and race assembly - final drive gear thrust No. 16
28	7F451	Race - Final drive gear thrust - front No. 16 (select fit)
29	7A130	Support assembly - rear planetary
30	7G085	Seal assembly - fluid transfer tube (2 required)
31	7H290	Piston and seal assembly - low/intermediate clutch
32	7H266	Washer - support and spring assembly - low/intermediate clutch (bonded)
33	7D483	Ring - 56.3 mm (2.25 in) retainer type SU external
34	7G178	Bearing and race assembly - sun gear thrust No. 15
35	7D483	Ring - 170 mm (6.8 in) 14.5 degree bevel (retains rear support in case) (select fit)
36	7D171	Race - Low/intermediate one-way clutch - outer
37	7A089	Low/intermediate one-way clutch - race and roller assembly
38	7E085	Spring - low/intermediate clutch cushion
39	7B164	Plate assembly - low/intermediate clutch - internal (5 required) (friction)
40	7B442	Plate - low/intermediate clutch - external (5 required) steel
41	7B066	Plate - low/intermediate clutch - pressure
42	7D483	Retainer - low/intermediate clutch (select fit)
43	7A162	Band assembly - coast
44	7A626	Gear/drum/race assembly - rear sun
45	7A153	Gear - rear ring
46	7D006	Gear assembly - rear planetary
47	7G177	Bearing and race assembly - planetary thrust center No. 13
48	7A398	Gear assembly - front planetary
49	7D483	Ring - front planetary retaining
50	7D483	Ring - 153.9 mm (6.15 in) internal retaining (select fit)
51	7B066	Plate - reverse clutch - pressure
52	7B164	Plate assembly - reverse clutch - internal (4 required) (friction)
53	7B442	Plate - reverse clutch - external (4 required) (steel)
54	7E085	Spring - reverse clutch piston
55	N803048-S	Ring - 67.0 mm (2.68 in) retaining type SU - eternal (retains support and spring assembly in reverse clutch cylinder)
56	7G335	Support and spring assembly - reverse clutch
57	7D402	Piston - reverse clutch
58	7D403	Seal - reverse clutch piston - outer
59	7D404	Seal - reverse clutch piston - inner
60	7F341	Cylinder - reverse clutch
61	7D064	Gear and shell assembly - front sun
62	7C096	Bearing and race assembly - forward sun gear thrust No. 10 and 11
63	7B067	Hub - intermediate clutch
64	7D483	Ring - 152.26 mm (6.09 in) retainer style - internal (select fit)
65	7B066	Plate - intermediate clutch - pressure
66	7B164	Plate assembly - intermediate/direct clutch - internal (friction)
67	7B442	Plate - intermediate/direct clutch - external (steel)
68	7E085	Intermediate clutch cushion spring
69	7C122	Ring - 72.0 mm (2.88 in) retaining style SU - external
70	7H185	Piston assembly - intermediate clutch balance
71	7F222	Support and spring assembly - intermediate clutch
72	7E005	Piston assembly - intermediate clutch
73	7F225	Seal - intermediate clutch piston - inner
74	7G120	Cylinder and hub assembly - direct/intermediate clutch
75	7G102	Seal - intermediate/direct clutch hub (2 required)
76	7F225	Seal - direct clutch piston - inner
77	7A262	Piston assembly - direct clutch
78	7G448	Ring - direct clutch apply
79	7F235	Support and spring assembly - direct clutch
80	7C122	Ring - 77.0 mm (3.08 in) retaining style SU - external (retains direct clutch support and spring assembly to cylinder)
81	7B066	Plate - direct clutch - pressure
82	7F369	Washer - direct one-way clutch thrust No. 7
83	7D171	Race - direct one-way clutch outer
84	7A089	Clutch assembly - direct one-way
85	7G156	Race and bushing assembly - direct one-way clutch inner
86	7A360	Cylinder and valve assembly - forward clutch
87	7A548	Seal - forward clutch piston - inner
88	7A262	Piston assembly - forward clutch
89	7G299	Support and spring assembly - forward clutch
90	N803053-S	Ring - 85.0 mm (3.4 in) retaining type style SU - external (retains forward clutch support and spring assembly in cylinder)
91	7B164	Plate assembly - forward clutch - internal (4 required) (friction)
92	7B442	Plate - forward clutch - external (4 required) (steel)
93	7B066	Plate - forward clutch - pressure
94	7A166	Washer - forward clutch thrust No. 6
95	7D171	Race - low one-way clutch - outer
96	7A089	Clutch assembly - low one-way
97	7L669	Drum assembly - overdrive
98	7F240	Bearing and race assembly - direct clutch hub No. 9
99	7G273	Washer - driven sprocket support thrust No. 8 (select fit)
100	7F196	Band assembly - overdrive
101	7D430	Retainer - overdrive band
102	7D019	Seal - forward clutch cylinder (5 required)
103	7D014	Washer - support thrust front No. 5 (select fit)
104	7G166	Support assembly - driven sprocket
105	7G247	Bearing assembly - driven sprocket
106	7G115	Washer - driven sprocket thrust No. 4
107	7G132	Sprocket and race assembly - driven
108	7H150	Wheel - driven sprocket speed sensor
109	7A108	Support assembly - stator (part of 7N825 support assembly)
110	7G233	Bearing assembly - drive sprocket
111	6749	Seal - turbine shaft O-ring
112	7G091	Seal - turbine shaft - rear
113	7F213	Shaft - turbine
114	7G099	Washer - drive sprocket thrust No. 1 and 2
115	7G129	Sprocket assembly - drive
116	N803178-S	Ring - 26.36 mm (1.05 in) retaining style SU - external (retains turbine shaft to drive sprocket)
117	7G090	Seals - turbine shaft - front
118	7G093	Seal - pump shaft - rear (2 required)
119	7B328	Shaft assembly - pump drive
120	7G092	Seals - front pump shaft (2 required)
121	7G089	Collars - fluid level thermostatic retaining (2 required)
122	7G191	Element - fluid level thermostatic
123	7G190	Plate - fluid level thermostatic valve
124	N804184-S	Pins - 4 mm (0.16 in) x 22 coiled (3 required) (retains fluid level thermostatic valve plate and fluid)
125	7G249	Chain assembly - drive
126	7G096	Washer - chain cover thrust No. 3
127	N605890-S1000	Bolt - M6-1.0 x 16.5 hex flange head (attaches detent spring assembly to chain cover)
128	7E332	Spring assembly - manual valve detent
129	7G276	Bulkhead assembly - wiring connector
130	7G303	Gasket - chain cover
131	7G188	Cover assembly - chain
132	7035	Vent assembly - case
133	7L282	Vent cap
134	7Z465	Retainer - clip transaxle cooler tube (2 required)
135	7D273	Connector assembly - cooler 3/8 (2 required)
136	390685-S100	Plugs - 1/8-27 mm hex head special pilot (2 required) (pressure tap plugs for chain cover)
137	N807737-S	Screws - M6-1.0 x 17 pan head pilot (attaches separator plate to valve body)
138	7G308	Screen assembly - bypass clutch solenoid (2 required)
139	N807739-S	Pin - 6 mm (0.24 in) x 20 spring coiled (part of 7A100)
140	7A100	Control assembly - main
141	7A136	Gasket - pump assembly to valve body
142	7A142	Plate - pump body separator
143	7G331	Gasket - pump body to separator plate
144	7A104	Body, bearing and seal assembly - pump
145	7Z144	Seal - 12.42 x 1.78 O-ring - outer (small)
146	7Z144	Seal - 25.12 x 1.78 O-ring - inner (large)
147	7G383	Solenoid assembly - electronic pressure control (EPC)
148	N803727-S	Bolt - M6-1.0 x 30 hex head (3-attaches pump assembly to main control)
149	7Z484	Seal - 6.07 x 1.78 O-ring - outer (small) (1 on solenoid assembly (EPC) - 1 on solenoid assembly (TCC) - 3 on solenoid assembly - shift)
150	7Z484	Seal - 15.6 x 1.78 O-ring - inner (large) (1 on solenoid assembly (EPC) - 1 on solenoid assembly (TCC) - 3 on solenoid assembly - shift)
151	7G136	Solenoid assembly - torque converter clutch (TCC)
152	N605772-S	Bolt - M6-1.0 x 16 large hex flange head (attaches torque converter solenoid and pressure control solenoid to pump body)
153	7G285	Spring - pump bore ring
154	N803499-S	Pin - 8 mm (0.32 in) x 37.7 straight hardened
155	7G287	Rings - pump valve support (2 required)
156	7A146	Rotor - pump
157	7R194	Ring - pump body
158	7G282	Support - pump bore ring side gear
159	7G281	Seal - pump bore ring side
160	7G187	Cover and sleeve assembly - pump
161	N807073-S1100	Bolt - M6-1.0 x 88.5 hex flange head pilot (4-attaches pump cover, pump body, valve body to chain cover)
162	N605892-S21	Bolt - M6-1.0 x 22.5 hex head (2-attaches pump cover to pump body)
163	7G286	Vane - pump (7 required)
164	7G283	Seal - pump bore ring radial
165	7G284	Support - pump bore ring radial seal
166	7H141	Sensor assembly - transmission fluid temperature (TFT)
167	7F396	Gasket - main control cover
168	N811076-S437	Bolt - M6-1.0 x 16.5 hex flange pilot (19-attaches bottom pan to case)
169	N605893-S1427	Bolt - M6-1.0 x 27.5 hex flange pilot (4-attaches main control cover to chain cover)
170	N605908-S437	Bolt - M8-1.25 x 38 hex flange pilot (11-attaches main control cover to chain cover
171	7G004	Cover - main control
172	7G484	Solenoid valve - shift (3 required)
173	N606026-S1000	Bolt - M6-1.0 x 60 hex flange head (15 - attaches pump body and main control to chain cover
174	N606022-S1000	Bolt - M6-1.0 x 40 hex flange head (4-attaches valve body to chain cover)
175	7Z490	Plate assembly - control valve body separator (bonded)
176	7A100	Pump and control assembly
177	N807738-S	Pin - 5 mm (0.2 in) x 14 spring coiled
178	N805551-S101	Stud - M8 x 1.25-1.25 x 81.8 hex head shoulder (attaches chain cover assembly to case assembly)
179	N606024-S36	Bolt - M6-1.0 x 50 hex flange head (attaches chain cover to case)
180	N605771-S36	Bolt - M6-1.0 x 14 hex flange head (attaches turbine shaft speed sensor to chain cover assembly)
181	N803807-S1000	Bolt - M10-1.50 x 43 hex (attaches chain cover to driven sprocket and support assembly)
182	N606042-S2	Bolt - M8-1.25 x 45 hex flange head (2- attaches chain cover to driven sprocket support assembly)
183	N811757-S100	Seal - 15.0x1.5 O-ring
184	7M101	Sensor - turbine shaft speed (TSS)
185	N605789-S1036	Bolt - M8-1.25 x 35 hex flange head (15-attaches chain cover to case)
186	7A020	Indicator assembly - fluid level
187	N605892-S1036	Bolts - M6-1.0 x 22.5 hex flange head (1-attaches filler tube to case and 3-attaches O.D. servo cover to case)
188	7A228	Tube assembly - filler upper
189	7H003	Tube assembly - filler lower
190	7N243	Grommet - filler tube
191	7D027	Cover - overdrive servo piston
192	7D024	Seal - overdrive servo cover
193	7H188	Piston assembly - overdrive servo
194	7F201	Spring - overdrive servo piston return
195	373907-S2	Nut - 1/4 spring (attaches I.D. tag to case)
196	7B148	Tag - service identification
197	N605789-S101	Bolt - M8-1.25 x 35 hex flange head (2-attaches case to chain cover)
198	N808161-S36	Screw - M6-1.0 x 28 pan head (5 required) (5-attaches case to chain cover)
199	N802996-S1000	Screw - M6-1.0 x 20 pan head (6-attaches stator support to converter housing)
200	N605775-S103	Bolt - M6-1.0 x 30 hex flange head (2-attaches transmission range sensor to case)
201	7F293	Sensor assembly - transmission range (TR)
202	7C493	Shaft - manual control lever
203	7H103	Sensor assembly - transmission output shaft sensor (OSS)
204	N605890-S36	Bolts - M6-1.0 x 16.5 hex flange head (attaches the OSS sensor)
205	7A434	Heat shield - OSS
206	7F337	Seal assembly - manual control shaft
207	N802998-S	Pin - 12.76 mm (0.51 in) x 25 dowel harden (2 required)
208	7N049	Rod - manual control valve actuating
209	7G100	Pins - shaft retainer (1 used as park pawl shaft retainer, 3 used as manual control shaft pin)
210	7A115	Lever assembly - manual valve detent (inner)
211	7F251	Pistons - 1-2, 2-3 shift accumulator
212	7G095	Seals - 1-2, 2-3 and N-D shift accumulator piston
213	7G267	Springs - 1-2 shift accumulator
214	7F284	Springs - accumulator 1-2 and 2-3 assist
215	7G094	Shaft - shift accumulator piston (4 required)
216	7G257	Spring - 2-3 shift accumulator
217	7F246	Pistons - reverse shift accumulator
218	7F248	Seals - reverse shift accumulator piston
219	7G266	Spring - reverse shift accumulator
220	7G266	Spring - 3-4 shift accumulator
221	7H276	Shaft - drive shift accumulator
222	7G274	Piston - drive shift accumulator
223	7G300	Spring - drive shift accumulator (outer)
224	7G301	Spring - drive shift accumulator (inner)
225	7H277	Seal - drive shift accumulator cover
226	7H275	Cover - drive shift accumulator
227	N807757	Bolt - M6-1.0 x 60 hex flange head (attaches drive shift accumulator cover to case)
228	N804647-S	Screw - M12 x 1.75 x 45 set hex socket (reverse clutch assembly locator bolt)
229	N620015-S	Nut - M12 x 1.75 hex (reverse clutch assembly locator nut)
230	7A256	Lever assembly - manual control
231	7H291	Spring - coast servo return
232	7H281	Piston and rod assembly - coast servo
233	7H284	Cover and seal assembly - coast servo
234	7H285	Ring - coast servo cover retainer
235	7A232	Rod assembly - parking pawl actuator
236	7G101	Abutment - parking pawl actuator
237	N605787-S1000	Bolts - M8 x 1.25 x 25 hex flange head (2-attaches abutment to case)
238	7D070	Spring - parking pawl return
239	7D071	Shaft - parking pawl
240	7A441	Pawl - parking brake
241	N802947-S	Plug - 13.9 mm cup
242	7G199	Tube - reverse fluid supply transfer
243	7G087	Tube - servo apply fluid transfer
244	7G463	Tube - low/intermediate clutch apply fluid transfer
245	7G084	Tube - rear lube fluid transfer
246	N808020-S100	Seal - O-ring (used on rear lube fluid tube)
247	N808021-S100	Seal - O-ring (used on reverse fluid supply tube)
248	N808022-S100	Seals - O-ring (used on servo apply tube - reverse supply tube and low/intermediate clutch apply tube)
249	N808023-S100	Seal - O-ring (used on servo apply tube)
250	7G353	Bracket assembly - tube support main
251	7G353	Bracket assembly - tube support (reverse clutch and servo apply)
252	7G353	Bracket assembly - tube support (rear lube and low/intermediate clutch)
253	7Z302	Seal - fluid filter
254	7A089	Filter assembly - fluid
255	7L027	Magnet - ceramic case
256	7A191	Gasket - transaxle pan
257	7A194	Pan - transaxle
258	-	Low/intermediate one-way clutch
259	-	Low/intermediate clutch
260	-	Reverse clutch
261	-	Intermediate clutch
262	-	Direct clutch
263	-	Forward clutch
264	-	Direct one-way clutch

Install the parking pawl assembly.
1. Install the parking pawl and return spring.
2. Install the parking pawl shaft.

Fig 5: Identifying Parking Pawl, Return Spring And Parking Pawl Shaft

Courtesy of FORD MOTOR CO.

Install the park pawl roll pin.

Fig 6: Installing Park Pawl Roll Pin

Courtesy of FORD MOTOR CO.

Using the special tool, install the cup plug.

Fig 7: Installing Cup Plug

Courtesy of FORD MOTOR CO.

NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.

Install the stator support.

Fig 8: Stator Support

Courtesy of FORD MOTOR CO.

Install the stator support bolts.
- Tighten to 13 Nm (10 lb-ft).

Fig 9: Bolts

Courtesy of FORD MOTOR CO.

Using the special tool, install the converter impeller hub seal.

Fig 10: Installing Converter Impeller Hub Seal

Courtesy of FORD MOTOR CO.

Install the differential carrier thrust bearing.
1. Install the differential carrier thrust washer.
2. Install the differential carrier thrust bearing and race (tabs down).

Fig 11: Identifying Differential Carrier Thrust Bearing & Race

Courtesy of FORD MOTOR CO.

Install the final drive ring gear.

Fig 12: Locating Final Drive Ring Gear

Courtesy of FORD MOTOR CO.

Install the rear planet support spacer.

Fig 13: Rear Planet Support Spacer

Courtesy of FORD MOTOR CO.

Install the final drive differential assembly.

Fig 14: Identifying Final Drive Differential & Rear Planet Support Assembly

Courtesy of FORD MOTOR CO.

Align the rear lube tube holes in the case window.

Fig 15: Aligning Rear Lube Tube Holes In Case Window

Courtesy of FORD MOTOR CO.

NOTE: The retaining ring must be correctly installed.

Using the special tool, install the beveled retaining ring.

Fig 16: Using Special Tool (307--343) To Install Beveled Retaining Ring

Courtesy of FORD MOTOR CO.

Fig 17: Identifying Proper Bevel Installation

Courtesy of FORD MOTOR CO.

CAUTION: If the support is not visible on the inside diameter of the retaining ring, the low/intermediate piston could be damaged.

Make sure that the beveled retaining ring seats correctly in the case groove with the bevel down. The final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall.

Fig 18: Final Drive Support

Courtesy of FORD MOTOR CO.

Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove.

Fig 19: Prying To Ensure Ring Is Seated

Courtesy of FORD MOTOR CO.

Install the special tools.

Fig 20: Identifying Special Tool (307-187) And (205-D014)

Courtesy of FORD MOTOR CO.

Remove the No. 15 needle bearing.

Fig 21: No. 15 Needle Bearing

Courtesy of FORD MOTOR CO.

NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.

Install the special tools.

Fig 22: Identifying Special Tool (307-300) And (307-321)

Courtesy of FORD MOTOR CO.

Install the special tool and zero the dial indicator.

Fig 23: Identifying Special Tool (307-300), (100-002) And (307-321)

Courtesy of FORD MOTOR CO.

Tighten the bolt.
- Tighten to 1.5 Nm (12 lb-in).

Fig 24: Tightening Special Tool Bolt

Courtesy of FORD MOTOR CO.

Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification, the next larger beveled ring retainer will need to be used.

Fig 25: Identifying Special Tool (307-300), (100-002) And (307-321)

Courtesy of FORD MOTOR CO.

Select the correct beveled retaining ring.

Item	Part Number	Thickness	Style
1	F5DZ-TD483-E	1.48-1.63 mm (0.058-0.064 inch)	Style 5
2	F5DZ-TD483-D	1.54-1.68 mm (0.061-0.067 inch)	Style 4
3	F5DZ-TD483-C	1.60-1.75 mm (0.063-0.069 inch)	Style 3
4	F5DZ-TD483-B	1.66-1.81 mm (0.065-0.071 inch)	Style 2
5	F5DZ-TD483-A	1.72-1.87 mm (0.068-0.074 inch)	Style 1

Fig 26: Identifying Beveled Retaining Ring Styles

Courtesy of FORD MOTOR CO.

NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer.

Install the No. 15 thrust bearing.

Fig 27: No. 15 Needle Bearing

Courtesy of FORD MOTOR CO.

Check the clearance for the No. 16 thrust washer. Mount the Dial Indicator with the stylus on the end of the output shaft. Zero the dial indicator.

Fig 28: Identifying Clearance For Thrust Washer Using Special Tool (100--102)

Courtesy of FORD MOTOR CO.

Tighten the bolt. Read and record the dial indicator reading.
- Tighten to 1.5 Nm (12 lb-in).

Fig 29: Tightening Special Tool Bolt

Courtesy of FORD MOTOR CO.

NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.

If the clearance is not within specification a thicker or thinner washer will need to be added.

NO. 16 THRUST RACE (WASHER)

Thickness	ID
2.25-2.15 mm	Green (No. 1)
2.37-2.27 mm	Blue (No. 2)
2.49-2.39 mm	Black (No. 3)
2.61-2.51 mm	White (No. 4)
2.73-2.63 mm	Brown (No. 5)
2.85-2.75 mm	Gold (No. 6)

Fig 30: Checking No. 16 Thrust Washer Clearance (With Specifications)

Courtesy of FORD MOTOR CO.

Install the low/intermediate one-way clutch assembly.

Fig 31: Low/Intermediate One-Way Clutch Assembly

Courtesy of FORD MOTOR CO.

NOTE: The friction plate internal splines will center the one-way clutch.

Install the low/intermediate clutch pressure plate.
1. Install the low/intermediate clutch wave spring.
2. Install the low/intermediate clutch pack.
3. Install the low/intermediate clutch pressure plate.

Fig 32: Identifying Low/Intermediate Clutch Pressure Plate Components

Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the retaining ring is seated in the case groove.

Install the low/intermediate clutch retaining ring.

Fig 33: Low/Intermediate Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

WARNING: To prevent injury, wear eye protection when using pressurized air.

NOTE: Be sure the pressurized air is dry and regulated at 276 kPa (40 psi).

Apply regulated air pressure to the low/intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal.

Fig 34: Applying Air Pressure To Low/Intermediate Apply Port

Courtesy of FORD MOTOR CO.

Measure the clearance between the clutch pressure plate and the low/intermediate clutch retainer. If the clearance is not within specification a thicker or thinner retainer may be needed.

SELECTIVE RETAINING RINGS

Thickness
1.54-1.64 mm (0.061-0.065 inch)
2.08-2.18 mm (0.082-0.086 inch)
2.62-2.72 mm (0.103-0.107 inch)
3.16-3.26 mm (0.125-0.128 inch)
3.68-3.78 mm (0.145-0.149 inch)

Fig 35: Checking Clutch Pressure Plate To Low/Intermediate Clutch Retainer Clearance (With Specifications)

Courtesy of FORD MOTOR CO.

Install the coast band.
1. Install the coast band.
2. Align the anchor pin pocket with the anchor pin in the case.

Fig 36: Identifying Coast Band

Courtesy of FORD MOTOR CO.

Install the low/intermediate drum. Rotate the low/intermediate drum and sun gear into the low/intermediate one-way clutch.

Fig 37: Installing Low/Intermediate Drum

Courtesy of FORD MOTOR CO.

Install the park rod abutment and make sure that the park pawl moves freely.
- Tighten to 28 Nm (21 lb-ft).

Fig 38: Locating Park Pawl Abutment Bolts

Courtesy of FORD MOTOR CO.

Install the coast band piston cover.
1. Install the coast band servo piston spring.
2. Install the coast band servo piston.
3. Install the coast band servo piston cover.

Fig 39: Identifying Coast Band Piston Cover

Courtesy of FORD MOTOR CO.

Using the special tool, install the coast servo cover retaining ring.

Fig 40: Installing Coast Servo Cover Retaining Ring Using Special Tool (307-251)

Courtesy of FORD MOTOR CO.

Using the special tools, install the front planetary/reverse clutch assembly.

Fig 41: Installing Front Planetary/Reverse Clutch Assembly Using Special Tool (307-025), (307-314) And (308-049)

Courtesy of FORD MOTOR CO.

Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.

Fig 42: Aligning Reverse Clutch Cylinder Apply Tube Hole With Case Hole

Courtesy of FORD MOTOR CO.

Loosely install the reverse clutch anchor pin.

Fig 43: Reverse Clutch Anchor Pin

Courtesy of FORD MOTOR CO.

Using the special tool, install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.

Fig 44: Installing Forward/Intermediate Clutch Assembly Using Special Tool (307--171)

Courtesy of FORD MOTOR CO.

Install the overdrive band.

Fig 45: Overdrive Band

Courtesy of FORD MOTOR CO.

NOTE: The foot of the overdrive retainer fits against the band.

Install the overdrive band anchor strut with the cross hairs facing upward.

Fig 46: Overdrive Band Anchor Strut

Courtesy of FORD MOTOR CO.

Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
1. Remove the No. 9 bearing and race.
2. Remove the No. 8 sprocket support.

Fig 47: No. 9 Bearing & Race, & No. 8 Sprocket Support

Courtesy of FORD MOTOR CO.

Install only the No. 9 needle bearing with the outer lip upward.

Fig 48: No. 9 Needle Bearing

Courtesy of FORD MOTOR CO.

Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.

Fig 49: Installing Special Tool (307--320) Over Output Shaft

Courtesy of FORD MOTOR CO.

Install the special tool to make the measurements.

Fig 50: Identifying Special Tools (303--D075), (307--300), And (307--320)

Courtesy of FORD MOTOR CO.

When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by 2 to obtain reading A.

Fig 51: Taking Measurements Using Special Tool (307-300), (303-D075) And (307-320)

Courtesy of FORD MOTOR CO.

NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.

Use reading A to select the correct No. 8 thrust washer from the chart.

NO. 8 THRUST WASHER SELECTION CHART

Reading A	Washer Thickness	Dimension C	Color/ID
42.88-43.10 mm (1.688-1.696 inch)	1.43-1.53 mm (0.056-0.060 inch)	1.48 mm (0.058 inch)	Natural (No. 1)
43.11-43.34 mm (1.697-1.706 inch)	1.68-1.78 mm (0.066-0.070 inch)	1.73 mm (0.068 inch)	Dark Green (No. 2)
43.35-43.59 mm (1.707-1.716 inch)	1.92-2.02 mm (0.075-0.080 inch)	1.97 mm (0.077 inch)	Light Blue (No. 3)
43.60-43.77 mm (1.717-1.723 inch)	2.17-2.27 mm (0.085-0.089 inch)	2.22 mm (0.087 inch)	Red (No. 4)
43.78-43.98 mm (1.724-1.731 inch)	2.35-2.45 mm (0.093-0.096 inch)	2.40 mm (0.094)	Black (No. 5)

Remove the special tools.

Fig 52: Identifying Special Tools (303--D075), (307--300), And (307--320)

Courtesy of FORD MOTOR CO.

Install the special tools to take the measurements.

Fig 53: Identifying Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

Measure down to the No. 5 thrust washer mating surface of the overdrive drum. Take another reading on the other side of the drum 180 degrees from the first one. Add both readings and divide by 2 to obtain reading B.

Fig 54: Taking Measurements Using Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

Remove the special tools.

Fig 55: Identifying Special Tool (307-300) And (303-D075)

Courtesy of FORD MOTOR CO.

NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.

Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D.


Reading B:
- Reading A:
Difference:
+Dimension C:
Reading D:

Use Reading D to select the correct No. 5 thrust washer.

NO. 5 SUPPORT THRUST WASHER CHART

Reading D	Washer Thickness	Color/ID
26.08-26.37 mm (1.027-1.038 inch)	2.18-2.28 mm (0.086-0.090 inch)	Green (No. 1)
26.38-26.61 mm (1.039-1.047 inch)	2.43-2.53 mm (0.096-0.100 inch)	Black (No. 2)
26.62-26.86 mm (1.048-1.057 inch)	2.67-2.77 mm (0.105-0.109 inch)	Natural (No. 3)
26.87-27.15 mm (1.058-1.068 inch)	2.92-3.02 mm (0.115-0.119 inch)	Red (No. 4)
27.16-27.50 mm (1.069-1.083 inch)	3.26-3.36 mm (0.128-0.132 inch)	Blue (No. 5)

NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.

Install the No. 5 front support thrust washer.

Fig 56: No. 5 Front Support Thrust Washer

Courtesy of FORD MOTOR CO.

CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure. Use petroleum jelly to hold bearing and washer in place.

Install the correct bearing.
1. Install the correct No. 8 driven sprocket support thrust washer.
2. Install the No. 9 direct clutch needle bearing.

Fig 57: No. 8 Driven Sprocket Support Thrust Washer & No. 9 Direct Clutch Needle Bearing

Courtesy of FORD MOTOR CO.

Install the driven sprocket support assembly.

Fig 58: Driven Sprocket Support Assembly

Courtesy of FORD MOTOR CO.

Install the neutral/drive accumulator cover.
1. Install the neutral/drive accumulator piston.
2. Install the neutral/drive accumulator spring.
  - The outer spring is yellow in color.
  - The inner spring is grey in color.
3. Install the neutral/drive accumulator cover.

Fig 59: Neutral/Drive Accumulator Piston, Spring & Cover

Courtesy of FORD MOTOR CO.

Install the bolt.
- Tighten to 11 Nm (8 lb-ft).

Fig 60: Identifying Bolt

Courtesy of FORD MOTOR CO.

NOTE: All the fluid supply tubes must have new O-rings installed.

Install the fluid supply tubes.

Fig 61: Fluid Supply Tubes

Courtesy of FORD MOTOR CO.

Install the brackets and bolts.
- Tighten to 11 Nm (8 lb-ft).

Fig 62: Fluid Supply Tube Brackets

Courtesy of FORD MOTOR CO.

Using the special tool, install the manual control lever shaft seal.

Fig 63: Installing Manual Control Lever Shaft Seal Using Special Tool (211-161)

Courtesy of FORD MOTOR CO.

Install the parking lever actuating rod.
- Push in on the park pawl.
- Slide the parking lever actuating rod down to fit in the park pawl.

Fig 64: Parking Lever Actuating Rod

Courtesy of FORD MOTOR CO.

NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.

Install the manual control lever shaft.

Fig 65: Locating Manual Control Lever Shaft

Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.

Install the roll pins.

Fig 66: Locating Roll Pins

Courtesy of FORD MOTOR CO.

NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.

Install the thrust washers.
1. Install the No. 2 drive sprocket thrust washer.
2. Install the No. 4 driven sprocket thrust washer.

Fig 67: Identifying No. 2 Thrust Washer & No. 4 Thrust Washer

Courtesy of FORD MOTOR CO.

CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent.

NOTE: Lower the assembly into the sprocket supports simultaneously.

Install the drive chain and sprockets.

Fig 68: Drive Chain & Sprockets Assembly

Courtesy of FORD MOTOR CO.

Install the shift accumulator springs.
1. Install the 1-2 shift accumulator piston spring (no color or brown).
2. Install the 2-3 shift accumulator piston spring (no color or brown).
3. Install the reverse shift accumulator piston spring (pink).
4. Install the 3-4 shift accumulator piston spring (pink).

Fig 69: Identifying Shift Accumulator Springs

Courtesy of FORD MOTOR CO.

NOTE: Make sure that the alignment pins are installed in the case.

Install the new chain cover gasket.

Fig 70: Locating Chain Cover Gasket

Courtesy of FORD MOTOR CO.

CAUTION: Be extremely careful not to damage the cast iron sealing ring.

Use petroleum jelly to hold thrust washers in place during assembly.
1. Install the No. 1 thrust washer.
2. Install the No. 2 thrust washer.
3. Install the chain cover.

Fig 71: Thrust Washers & Chain Cover

Courtesy of FORD MOTOR CO.

NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.

Start the 2 bolts.

Fig 72: 2 Cover Bolts

Courtesy of FORD MOTOR CO.

Install the remaining bolts.
- Tighten No. 1 to 30 Nm (22 lb-ft).
- Tighten No. 2 to 41 Nm (30 lb-ft).
- Tighten No. 3 to 28 Nm (21 lb-ft).
- Tighten No. 4 to 13 Nm (10 lb-ft).

Fig 73: Cover Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

Install the bolts.
- Tighten No. 1 to 30 Nm (22 lb-ft).
- Tighten No. 2 to 13 Nm (10 lb-ft).

Fig 74: Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

CAUTION: The test spring from the overdrive servo rod tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.

Inspect the spring height.
1. Test spring.
2. Original spring.

Fig 75: Identifying Test Spring & Original Spring

Courtesy of FORD MOTOR CO.

Check overdrive servo travel. Install the overdrive servo piston.
1. Install the test spring.
2. Install the overdrive servo piston.

Fig 76: Test Spring & Overdrive Servo Piston

Courtesy of FORD MOTOR CO.

Install the special tools.
- Tighten to 10 Nm (89 lb-in).

Fig 77: Identifying Special Tool (307-162) And (100-002)

Courtesy of FORD MOTOR CO.

Using the special tools, tighten the center screw and zero out the dial indicator.
- Tighten to 1.13 Nm (10 lb-in).

Fig 78: Identifying Special Tool (307-162) And (100-002)

Courtesy of FORD MOTOR CO.

Using the special tools, back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, see the overdrive specification chart and determine which overdrive servo rod to use.

Fig 79: Checking Piston Movement (With Specifications)

Courtesy of FORD MOTOR CO.

If the overdrive servo travel was incorrect, install a new overdrive servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.

OVERDRIVE PISTON ROD SELECTION CHART

Overdrive Servo Rod Length		No. of Grooves^a
mm	Inch	No. of Grooves^a
99.33	3.91	0
98.05	3.86	1
96.78	3.81	2

^a Grooves are at the tip.

CAUTION: Do not assemble the transaxle using the test spring.

Install the overdrive servo.
1. Install the overdrive servo spring.
2. Install the overdrive servo.
3. Install the overdrive servo cover and bolts.
  - Tighten to 13 Nm (10 lb-ft).

Fig 80: Identifying Overdrive Servo Cover & Bolts

Courtesy of FORD MOTOR CO.

Install the transmission test plate.

Fig 81: Identifying Special Tool (307-313), (307-312) And (307-126)

Courtesy of FORD MOTOR CO.

WARNING: Wear safety glasses while carrying out this procedure to prevent personal injury.

NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies.

NOTE: Plugging the vent hole during the test will provide an inaccurate result.

Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate clutch ports.

Item	Part Number	Description
1	-	1-2 accumulator test passage
2	-	Overdrive servo test passage
3	-	Direct clutch test passage
4	-	Low/intermediate clutch and accumulator test passage
5	-	Coast band test passage
6	-	Reverse clutch test passage
7	-	3-4 accumulator test passage
8	-	Neutral/reverse accumulator test passage
9	-	Vent hole
10	-	Forward clutch test passage
11	-	Intermediate clutch test passage
12	-	2-3 accumulator test passage

Fig 82: Identifying Air Pressure Test Passages

Courtesy of FORD MOTOR CO.

CAUTION: The seals must be lapped correctly or internal leakage will occur.

Install the new Teflon® seals on the pump shaft.

Fig 83: Properly Aligned Seal Ends

Courtesy of FORD MOTOR CO.

Install the pump shaft.

Fig 84: Pump Shaft

Courtesy of FORD MOTOR CO.

Install the manual valve detent lever.

Fig 85: Manual Valve Detent Lever

Courtesy of FORD MOTOR CO.

Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.

Fig 86: Main Pump Assembly & Main Control Valve Body

Courtesy of FORD MOTOR CO.

CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.

Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolts and tighten in sequence.
- Tighten to 13 Nm (10 lb-ft).

Fig 87: Identifying Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Connect the connectors.

Fig 88: Electrical Connectors

Courtesy of FORD MOTOR CO.

NOTE: The transaxle side cover gasket is reusable if not torn or ripped.

Remove the gasket. Clean and inspect the gasket, and reinstall into the pan.

Fig 89: Locating Transaxle Side Cover Gasket

Courtesy of FORD MOTOR CO.

Install the M6 x 1.00 pan bolts.
- Tighten to 12 Nm (9 lb-ft).

Fig 90: Locating M6 Bolts

Courtesy of FORD MOTOR CO.

Install the M8 x 1.25 pan bolts.
- Tighten to 29 Nm (21 lb-ft).

Fig 91: Locating M8 Bolts

Courtesy of FORD MOTOR CO.

Install the mounting bracket and bolts.
- Tighten to 62 Nm (46 lb-ft).

Fig 92: Locating Rear Transaxle Support Insulator Bracket

Courtesy of FORD MOTOR CO.

Tighten the reverse clutch anchor bolt.
1. Tighten the anchor bolt.
  - Tighten to 11 Nm (8 lb-ft).
2. Tighten the locknut.
  - Tighten to 54 Nm (40 lb-ft).