Disassembled Views

Fig 1: Disassembled View Of Transaxle Components (1 Of 5)

Courtesy of FORD MOTOR CO.

Fig 2: Disassembled View Of Transaxle Components (2 Of 5)

Courtesy of FORD MOTOR CO.

Fig 3: Disassembled View Of Transaxle Components (3 Of 5)

Courtesy of FORD MOTOR CO.

Fig 4: Disassembled View Of Transaxle Components (4 Of 5)

Courtesy of FORD MOTOR CO.

Fig 5: Disassembled View Of Transaxle Components (5 Of 5)

Courtesy of FORD MOTOR CO.

All vehicles 

1. If the transfer shaft fluid dam and bearing race were removed during disassembly, assemble the Handle 205-153 and the Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the Oil Dam Seal Installer with Handle.
   Fig 6: Installing Transfer Shaft Fluid Dam On Special Tool

   Courtesy of FORD MOTOR CO.
2. Using the Handle 205-153 and the Oil Dam Seal Installer 307-583, install the transfer shaft fluid dam in the transaxle case.
   Fig 7: Installing Transfer Shaft Fluid Dam In Transaxle Case

   Courtesy of FORD MOTOR CO.
3. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the transaxle case.
   Fig 8: Locating Transfer Shaft Fluid Dam

   Courtesy of FORD MOTOR CO.
4. Using the Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the transaxle case.
   Fig 9: Pressing Transfer Shaft Bearing Cup In Transaxle Case

   Courtesy of FORD MOTOR CO.
5. If removed, install a new differential bearing race on the Bearing Cup Installer 307-576.
   Fig 10: Installing Differential Bearing Race On Bearing Cup Installer 307-576

   Courtesy of FORD MOTOR CO.
6. Using the Bearing Cup Installer 307-576, Transfer Gear Bearing Installer 307-541 and Drawbar 204-029, press the differential bearing cup in the transaxle case.
   Fig 11: Pressing Differential Bearing Cup In Transaxle Case

   Courtesy of FORD MOTOR CO.
7. Install the park pawl abutment and the pins.
   Fig 12: Installing Park Pawl Abutment And Pins

   Courtesy of FORD MOTOR CO.
8. Install the park pawl and the pin.
   Fig 13: Installing Park Pawl And Pin

   Courtesy of FORD MOTOR CO.
9. Install the park pawl spring.
   Fig 14: Locating Park Pawl Spring

   Courtesy of FORD MOTOR CO.
10. Install the park pawl pin retainer and the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 15: Locating Park Pawl Pin Retainer Bolts

      Courtesy of FORD MOTOR CO.
11. Slide the park pawl over and install the park pawl actuator rod.
    Fig 16: Installing Park Pawl Actuator Rod

    Courtesy of FORD MOTOR CO.
12. Lubricate a new manual shaft seal and the Manual Lever Seal Installer 307-581 with petroleum jelly and install the seal on the Manual Lever Seal Installer 307-581.
    Fig 17: Installing Seal On Manual Lever Seal Installer 307-581

    Courtesy of FORD MOTOR CO.
13. Using the Manual Lever Seal Installer 307-581, install the manual lever shaft seal in the transaxle case.
    Fig 18: Installing Manual Lever Shaft Seal In Transaxle Case

    Courtesy of FORD MOTOR CO.
14. Install the Transmission Range (TR) sensor.
    1. Position the park pawl actuating rod in the TR  sensor detent plate.
    2. Install the TR  sensor in the transaxle case.
       Fig 19: Installing TR Sensor In Transaxle Case

       Courtesy of FORD MOTOR CO.
15. Install a new TR  sensor locking pin in the transaxle case.
    Fig 20: Locating TR Sensor Locking Pin

    Courtesy of FORD MOTOR CO.
16. Using the Manual Lever Retaining Pin Installer 307-592, drive the TR  sensor locking pin into the transaxle case.
    Fig 21: Installing TR Sensor Locking Pin Into Transaxle Case

    Courtesy of FORD MOTOR CO.
17. Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.
    Fig 22: Locating O-Ring Seal

    Courtesy of FORD MOTOR CO.
18. Install the transmission fluid reservoir and the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 23: Locating Transmission Fluid Reservoir Bolts

      Courtesy of FORD MOTOR CO.
19. Install a new pump-to-case seal.
    Fig 24: Locating Pump-To-Case Seal

    Courtesy of FORD MOTOR CO.
20. Install the transfer shaft and gear assembly.
    Fig 25: Identifying Transfer Shaft And Gear Assembly

    Courtesy of FORD MOTOR CO.
21. Tilt the transfer shaft and gear assembly over and install the differential assembly.
    Fig 26: Installing Differential Assembly

    Courtesy of FORD MOTOR CO.
22. Install the differential and transfer shaft bearing cups on the bearings.
    Fig 27: Remove/Install Differential And Transfer Shaft Bearing Cups

    Courtesy of FORD MOTOR CO.
23. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 and 307-591/2) on the differential and transfer shaft bearing cups.
    Fig 28: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1, 307-591/2)

    Courtesy of FORD MOTOR CO.
24. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (studs) in the transaxle case to align the torque converter housing.
    Fig 29: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3 From Transaxle Case

    Courtesy of FORD MOTOR CO.
NOTE: Make sure that the silicone has been cleaned off the machined surface of the transaxle case and the torque converter housing before installing the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) or the preload measurement may be inaccurate.
Fig 30: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3
Courtesy of FORD MOTOR CO.
25. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) on the studs to space the torque converter housing from the transaxle case.
26. Place the torque converter housing on the Differential/Transfer Gear Bearing Shim Gauge 307-591/3.
    Fig 31: Locating Torque Converter Housing

    Courtesy of FORD MOTOR CO.
27. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (remaining 4 spacers, bolts and washers).
    • Tighten to 24 Nm (18 lb-ft).
      Fig 32: Installing Differential/Transfer Gear Bearing Shim Gauge 307-591/3

      Courtesy of FORD MOTOR CO.
28. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts and washers) on the studs.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 33: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3 On Studs

      Courtesy of FORD MOTOR CO.
29. Rotate the transfer shaft and the differential several times to seat the bearings.
    Fig 34: Rotating Transfer Shaft And Differential

    Courtesy of FORD MOTOR CO.
30. Using a feeler gauge, measure and record the smallest and largest preload gap on the Differential/Transfer Gear Bearing Shim Gauge 307-591/1 placed on the differential assembly. Add the 2 measurements and divide by 2. This is the thickness of the differential bearing preload shim. For additional information, refer to SPECIFICATIONS in this service information for the differential bearing preload shim part number.
    Fig 35: Checking Thickness Of Differential Bearing Preload Shim

    Courtesy of FORD MOTOR CO.
31. Using a feeler gauge, measure and record the smallest and largest preload gap on Differential/Transfer Gear Bearing Shim Gauge 307-591/2 placed on the transfer shaft assembly. Add the 2 measurements and divide by 2. This is the thickness of the transfer shaft bearing preload shim. For additional information, refer to SPECIFICATIONS in this service information for the transfer gear bearing preload shim part number.
    Fig 36: Checking Thickness Of Transfer Shaft Bearing Preload Shim

    Courtesy of FORD MOTOR CO.
32. Remove the torque converter housing and the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.
    Fig 37: Removing Torque Converter Housing And Differential/Transfer Gear Bearing Shim Gauge 307-591/3

    Courtesy of FORD MOTOR CO.
33. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) from the transaxle case.
    Fig 38: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3

    Courtesy of FORD MOTOR CO.
34. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 studs) from the transaxle case.
    Fig 39: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3 From Transaxle Case

    Courtesy of FORD MOTOR CO.
35. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/1 and 307-591/2 from the differential and transfer shaft assemblies.
    Fig 40: Remove/Install Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1, 307-591/2)

    Courtesy of FORD MOTOR CO.
36. Remove the differential and transfer shaft bearing cups.
    Fig 41: Remove/Install Differential And Transfer Shaft Bearing Cups

    Courtesy of FORD MOTOR CO.
37. Install a new torque converter hub seal on the Converter Seal Installer 307-575.
    Fig 42: Installing Torque Converter Hub Seal On Converter Seal Installer 307-575

    Courtesy of FORD MOTOR CO.
NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Fig 43: Installing Torque Converter Hub Seal In Torque Converter Housing
Courtesy of FORD MOTOR CO.
38. Using the Converter Seal Installer 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.

    Front Wheel Drive (FWD) vehicles 

39. Assemble the Handle 205-153 on the Cover Axle Seal Installer 307-582A and install a new RH halfshaft seal on Cover Axle Seal Installer 307-582A.
    Fig 44: Installing RH Halfshaft Seal On Cover Axle Seal Installer 307-582A

    Courtesy of FORD MOTOR CO.
NOTE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.
Fig 45: Installing RH Halfshaft Seal In Torque Converter Housing
Courtesy of FORD MOTOR CO.
40. Use the Handle 205-153 and the Cover Axle Seal Installer 307-582A. Install the RH halfshaft seal in the torque converter housing.

    All vehicles 

41. Assemble the Handle 205-153 and the Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the Oil Dam Seal Installer 307-583.
    Fig 46: Installing Transfer Shaft Fluid Dam On Oil Dam Seal Installer 307-583

    Courtesy of FORD MOTOR CO.
NOTE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.
Fig 47: Installing Fluid Dam In Torque Converter Housing
Courtesy of FORD MOTOR CO.
42. Using the Handle 205-153 and the Oil Dam Seal Installer 307-583, install the fluid dam in the torque converter housing.
43. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the torque converter housing.
    Fig 48: Locating Transfer Shaft Fluid Dam

    Courtesy of FORD MOTOR CO.
44. Install the transfer shaft preload shim in the torque converter housing.
    Fig 49: Remove/Install Preload Shim

    Courtesy of FORD MOTOR CO.
45. Using the Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the torque converter housing.
    Fig 50: Pressing Transfer Shaft Bearing Cup In Torque Converter Housing

    Courtesy of FORD MOTOR CO.
46. Install the differential bearing preload shim in the torque converter housing.
    Fig 51: Remove/Install Differential Bearing Preload Shim

    Courtesy of FORD MOTOR CO.
47. Install a new differential bearing race on the Bearing Cup Installer 307-576.
    Fig 52: Installing Differential Bearing Race On Bearing Cup Installer 307-576

    Courtesy of FORD MOTOR CO.
48. Using the Bearing Cup Installer 307-576, Transfer Gear Bearing Installer 307-541 and the Drawbar 204-029, press the differential bearing cup in the torque converter housing.
    Fig 53: Pressing Differential Bearing Cup In Torque Converter Housing

    Courtesy of FORD MOTOR CO.
49. Install the pump drive sprocket and driven sprocket thrust washers.
    Fig 54: View Of Pump Drive Sprocket And Driven Sprocket Thrust Washers

    Courtesy of FORD MOTOR CO.
NOTE: The dot on the pump sprocket is installed facing upward.
Fig 55: Locating Pump Sprocket And Chain Assembly
Courtesy of FORD MOTOR CO.
50. Install the pump sprocket and chain assembly.
51. Position the pump and filter assembly in place and install the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 56: Locating Pump And Filter Assembly Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Fig 57: View Of Stator Support Assembly
Courtesy of FORD MOTOR CO.
52. Position the stator support assembly in place on the torque converter housing.
53. Install the stator support bolts. Tighten in the sequence shown in illustration.
    • Tighten to 41 Nm (30 lb-ft).
      Fig 58: Identifying Stator Support Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
54. Position the differential carrier baffle in place and install the bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 59: Locating Bolt And Fluid Baffle Of Torque Converter Housing

      Courtesy of FORD MOTOR CO.
55. Lubricate the ends of the transaxle fluid tube with petroleum jelly and install it in the transaxle.
    Fig 60: Locating Transaxle Lube Tube

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the sealing surface of both the transaxle case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transaxle case.
Fig 61: Applying Sealant To Machined Surface Of Transaxle Case
Courtesy of FORD MOTOR CO.
56. Apply a bead of silicone sealant to the machined surface of the transaxle case.
NOTE: Install the 2 studbolts in the correct location as noted during disassembly.
Fig 62: Locating Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
57. Install the torque converter housing on top of the transaxle case and install the bolts.
NOTE: The studbolts are 1 and 16 in the tightening sequence.
58. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 63: Identifying Torque Converter Housing Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
59. Assemble the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install a new halfshaft seal on Cover Axle Seal Installer 307-582A.
    Fig 64: Installing Halfshaft Seal On Cover Axle Seal Installer 307-582A

    Courtesy of FORD MOTOR CO.
60. Using the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install the halfshaft seal in the transaxle case.
    Fig 65: Installing Halfshaft Seal In Transaxle Case

    Courtesy of FORD MOTOR CO.
61. Lubricate the forward clutch piston seals with petroleum jelly.
    Fig 66: Locating Forward Clutch Piston Seals

    Courtesy of FORD MOTOR CO.
62. Position the forward clutch piston in place in the transaxle case.
    Fig 67: Identifying Forward Clutch Piston Position

    Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Intermediate Spring Compressor 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.
Fig 68: Pushing Forward Clutch Piston Down Into Bore
Courtesy of FORD MOTOR CO.
63. Using the Forward/Intermediate Spring Compressor 307-584/1, push the forward clutch piston down into the bore.
64. Install the forward clutch piston return spring with the tabs facing downward.
    Fig 69: Locating Forward Clutch Piston Return Spring

    Courtesy of FORD MOTOR CO.
NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.
NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
Fig 70: View Of Forward Clutch Spring Compressor And Forward/Intermediate Spring Compressor
Courtesy of FORD MOTOR CO.
65. Install the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and compress the forward clutch piston return spring.
NOTE: Forward Clutch Spring Compressor and the Forward/Overdrive Spring Compressor not shown in illustration for clarity.
66. Install the forward clutch piston return spring snap ring.
    • Install the snap ring.
    • The snap ring gap should be at the top of the transaxle case.
      Fig 71: Locating Forward Clutch Piston Return Spring Snap Ring

      Courtesy of FORD MOTOR CO.
67. Remove the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).
    Fig 72: View Of Forward Clutch Spring Compressor And Forward/Intermediate Spring Compressor

    Courtesy of FORD MOTOR CO.
68. Install the forward clutch wave spring.
    Fig 73: Installing Forward Clutch Wave Spring

    Courtesy of FORD MOTOR CO.
69. Lubricate the forward clutch pack in clean transmission fluid.
    Fig 74: Identifying Forward Clutch Pack

    Courtesy of FORD MOTOR CO.
70. Install the forward clutch pack assembly.
    1. Position the forward clutch pack assembly in the case.
    2. Make sure the alignment tab on the clutch pack is positioned in the correct location.
       Fig 75: Identifying Forward Clutch Pack Assembly And Alignment Tab

       Courtesy of FORD MOTOR CO.
71. Install the low OWC  .
    Fig 76: Installing Low OWC

    Courtesy of FORD MOTOR CO.
NOTE: The low OWC  snap ring gap must be positioned as shown in illustration so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.
Fig 77: Locating Low OWC Snap Ring
Courtesy of FORD MOTOR CO.
72. Install the low OWC  snap ring.
73. Compare the position of the low OWC  snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
    Fig 78: Locating Low/Reverse Clutch Pressure Plate Tab

    Courtesy of FORD MOTOR CO.
74. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transaxle case and position the plunger on a top friction disc tab.
    Fig 79: Installing Dial Indicator Gauge With Holding Fixture 100-002 On Transaxle Case

    Courtesy of FORD MOTOR CO.
75. Install a new forward clutch feed seal.
    Fig 80: Installing Forward Clutch Feed Seal

    Courtesy of FORD MOTOR CO.
76. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low OWC  for correct installation. If the forward clutch pack and low OWC  is correctly installed, install a new forward clutch pack.
    Fig 81: Recording Clutch Pack Clearance

    Courtesy of FORD MOTOR CO.
77. Remove the Dial Indicator Gauge with Holding Fixture 100-002 from the transaxle case.
78. Install the No. 11 stator support thrust bearing.
    Fig 82: Remove/Install No. 11 Support Assembly Thrust Bearing

    Courtesy of FORD MOTOR CO.
79. Install the front planetary carrier hub.
    Fig 83: Locating Front Planetary Carrier Hub Assembly

    Courtesy of FORD MOTOR CO.
80. Install the No. 10 front sun gear thrust bearing.
    Fig 84: Remove/Install No. 10 Front Sun Gear Thrust Bearing

    Courtesy of FORD MOTOR CO.
81. Install the front sun gear and shell assembly.
    Fig 85: Remove/Install Front Planetary Sun Gear And Shell Assembly

    Courtesy of FORD MOTOR CO.
82. Install the front carrier and rear ring gear assembly.
    Fig 86: Remove/Install Front Planetary Carrier And Rear Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
83. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
    Fig 87: Installing No. 8 Front/Center Planetary Gear Assembly And No. 7 Center Sun Gear Thrust Bearings

    Courtesy of FORD MOTOR CO.
84. Install the center planetary carrier and front ring gear assembly.
    Fig 88: Remove/Install Center Planetary Carrier And Front Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The groove on the center sun gear is installed facing up.
Fig 89: Remove/Install Center Planetary Sun Gear
Courtesy of FORD MOTOR CO.
85. Install the center planetary sun gear.
86. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
    Fig 90: Installing No. 6 Center Sun Gear And No. 5 Center/Rear Planetary Thrust Bearings

    Courtesy of FORD MOTOR CO.
87. Install the rear planetary gear carrier assembly.
    Fig 91: Remove/Install Rear Planetary Carrier Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low One-Way Clutch (OWC) snap ring may result in damage to the transaxle.
88. Install the low/reverse clutch pressure plate.
    1. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC  snap ring.
    2. Install the low/reverse clutch pressure plate.
       Fig 92: Installing Low/Reverse Clutch Pressure Plate

       Courtesy of FORD MOTOR CO.
89. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC  snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
    Fig 93: Measuring Depth Of Low/Reverse Clutch Pressure Plate

    Courtesy of FORD MOTOR CO.
90. Lubricate the low/reverse clutch pack with clean transmission fluid.
    Fig 94: Identifying Low/Reverse Clutch Pack

    Courtesy of FORD MOTOR CO.
91. Install the low/reverse clutch pack.
    Fig 95: Locating Low/Reverse Clutch Pack

    Courtesy of FORD MOTOR CO.
92. Install the low/reverse pressure plate.
    Fig 96: Installing Low/Reverse Pressure Plate

    Courtesy of FORD MOTOR CO.
93. Using a suitable straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to the low/reverse pressure plate.
    Fig 97: Measuring Distance From Transaxle Case Deck Surface To Low/Reverse Pressure Plate

    Courtesy of FORD MOTOR CO.
94. Using the same straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.
    Fig 98: Measuring Distance From Low/Reverse Clutch Piston To Cover Assembly Deck Surface

    Courtesy of FORD MOTOR CO.
95. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 1.01 mm (0.039 in) and 2.47 mm (0.097 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack.
    READING DESCRIPTION CHART
    
    

    Description	Reading
    Measurement A
    Measurement B
    Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the low/reverse clutch clearance.

96. Install the intermediate clutch pressure plate.
    Fig 99: Installing Intermediate Clutch Pressure Plate

    Courtesy of FORD MOTOR CO.
97. Lubricate the intermediate clutch pack assembly in clean transmission fluid.
    Fig 100: Identifying Intermediate Clutch Pack Assembly

    Courtesy of FORD MOTOR CO.
98. Install the intermediate clutch pack assembly.
    Fig 101: Locating Intermediate Clutch Pack Assembly

    Courtesy of FORD MOTOR CO.
99. Install the intermediate clutch pack wave spring.
    Fig 102: Installing Intermediate Clutch Pack Wave Spring

    Courtesy of FORD MOTOR CO.
100. Using a suitable straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to a low point on the intermediate clutch wave spring.
     Fig 103: Measuring Distance From Transaxle Case Deck Surface To Low Point On Intermediate Clutch Wave Spring

     Courtesy of FORD MOTOR CO.
101. Using the straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.
     Fig 104: Measuring Distance From Intermediate Clutch Piston To Cover Assembly Deck Surface

     Courtesy of FORD MOTOR CO.
102. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.99 mm (0.038 in) and 2.56 mm (0.1 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
     READING DESCRIPTION CHART
     
     

     Description	Reading
     Measurement A
     Measurement B
     Subtract measurement B from measurement A and add 1.6 mm (0.062 in) to get the intermediate clutch clearance.

103. Install the rear sun gear and shell assembly.
     Fig 105: Installing Rear Sun Gear And Shell Assembly

     Courtesy of FORD MOTOR CO.
104. Install the No. 3 rear sun gear thrust bearing.
     Fig 106: Remove/Install No. 3 Rear Sun Gear Thrust Bearing

     Courtesy of FORD MOTOR CO.
105. Install the overdrive/direct clutch hub and turbine shaft assembly.
     Fig 107: Remove/Install Overdrive/Direct Clutch Hub And Turbine Shaft Assembly

     Courtesy of FORD MOTOR CO.
106. Install the No. 1 cover assembly thrust bearing.
     Fig 108: Remove/Install No. 1 Cover Assembly Thrust Bearing

     Courtesy of FORD MOTOR CO.
107. Install the cover assembly gasket.
     Fig 109: View Of Cover Assembly Gasket

     Courtesy of FORD MOTOR CO.
108. Route the Turbine Shaft Speed (TSS) sensor harness through the transaxle case to the valve body area and install the cover assembly.
     Fig 110: Remove/Install Cover Assembly

     Courtesy of FORD MOTOR CO.
109. Install the cover assembly bolts and tighten the bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
       Fig 111: Identifying Cover Assembly Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
110. Install the Output Shaft Speed (OSS) sensor and the bolt.
     • Tighten to 12 Nm (106 lb-in).
       Fig 112: Identifying Output Shaft Speed (OSS) Sensor

       Courtesy of FORD MOTOR CO.
NOTE: Be careful not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.
NOTE: Make sure that the manual pin (part of the TR  sensor) is correctly installed in the manual valve.
111. Position the TSS  , OSS  and TR  sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.
     1. Manual pin
     2. Manual valve
        Fig 113: Identifying Manual Pin And Valve

        Courtesy of FORD MOTOR CO.
112. Install the main control valve body bolts. Tighten the bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
       Fig 114: Identifying Main Control Valve Body Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: Make sure not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
NOTE: Install the different length bolts in the locations noted during disassembly.
113. Install the solenoid body bolts hand-tight.
     1. 42 mm (1.653 in) bolt
     2. 63 mm (2.48 in) bolts
     3. 80 mm (3.149 in) bolts
     4. 95 mm (3.74 in) bolts
        Fig 115: Identifying Solenoid Body Bolts Tightening Sequence

        Courtesy of FORD MOTOR CO.
114. Tighten the solenoid body bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
       Fig 116: Identifying Solenoid Body Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
115. Route the OSS  sensor wiring harness into the retainer.
     Fig 117: Locating OSS Sensor Wiring Harness

     Courtesy of FORD MOTOR CO.
116. Connect the TSS  and OSS  sensor electrical connectors.
     Fig 118: Locating TSS And OSS Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
117. Connect the TR  sensor electrical connector and slide the lock tab to the LOCK position.
     Fig 119: Connecting TR Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
118. Inspect the transaxle main control cover seal for damage and install new if necessary.
     Fig 120: Locating Transaxle Main Control Cover Seal

     Courtesy of FORD MOTOR CO.
NOTE: Install the studbolts in the locations noted during disassembly.
119. Install the transaxle main control cover and install the bolts.
     1. Bolt location
     2. Studbolt location
        Fig 121: Identifying Transaxle Main Control Cover Bolts

        Courtesy of FORD MOTOR CO.
120. Tighten the main control cover bolts in the sequence shown in illustration.
     • Tighten to 12 Nm (106 lb-in).
       Fig 122: Identifying Main Control Cover Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
121. Install the manual control lever and the nut.
     • Tighten to 18 Nm (159 lb-in).
       Fig 123: Remove/Install Manual Lever And Nut

       Courtesy of FORD MOTOR CO.
NOTE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
Fig 124: Remove/Install Torque Converter From Transaxle
Courtesy of FORD MOTOR CO.
122. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transaxle.
123. Remove the bolts from the torque converter.
     Fig 125: View Of Torque Converter Bolts

     Courtesy of FORD MOTOR CO.