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Disassembled Views

Fig 1: Disassembled View Of Transaxle (1 Of 3)
G08023813Courtesy of FORD MOTOR CO.
Fig 2: Disassembled View Of Transaxle (2 Of 3)
G08023814Courtesy of FORD MOTOR CO.
Fig 3: Disassembled View Of Transaxle (3 Of 3)
G08023815Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7005 Transaxle case
2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal
15 7C099 Direct (3, 5, R) clutch piston inner (front) seal
16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/Overdrive (O/D) (4, 5, 6) clutch cylinder and hub assembly
19 7A548 O/D (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
21 7D234 No. 2 thrust bearing
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 O/D (4, 5, 6) clutch piston outer (rear) seal
28 7A548 O/D (4, 5, 6) clutch piston outer (front) seal
29 7A262 O/D (4, 5, 6) clutch piston
30 7F222 O/D (4, 5, 6) clutch piston return spring
31 7H360 O/D (4, 5, 6) clutch balance piston
32 7C122 O/D (4, 5, 6) clutch piston snap ring
33 7B164 O/D (4, 5, 6) clutch friction plates (5 required)
34 7B442 O/D (4, 5, 6) clutch steel plates (5 required)
35 7B066 O/D (4, 5, 6) clutch pressure plate
36 7D483 O/D (4, 5, 6) clutch snap ring
37 7H351 O/D (4, 5, 6) clutch hub
38 7D234 No. 3 thrust bearing
39 7A019 Rear planetary sun gear and shell assembly
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2 required)
42 7B442 Intermediate (2, 6) clutch steel plates (2 required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
45 7C096 No. 6 thrust bearing
46 7G177 No. 5 thrust bearing
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7H318 Low/reverse clutch piston snap ring retainer
53 7B070 Low/reverse clutch piston return spring
54 7D402 Low/reverse clutch piston
55 7L328 Center support
56 7A262 Forward (1, 2, 3, 4) clutch piston
57 7B070 Forward (1, 2, 3, 4) clutch piston return spring
58 7D041 Forward (1, 2, 3, 4) clutch piston snap ring retainer
59 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
60 7D491 Center planetary carrier/front ring gear
61 7D063 Center planetary sun gear
62 7C096 No. 7 thrust bearing
63 7C096 No. 8 thrust bearing
64 7D491 Front planetary carrier/rear ring gear
65 7A019 Front planetary sun gear and shell assembly
66 7D234 No. 10 thrust bearing
67 7B070 Forward (1, 2, 3, 4) clutch wave spring
68 7B164 Forward (1, 2, 3, 4) clutch friction plates (2 required)
69 7B442 Forward (1, 2, 3, 4) clutch steel plates (2 required)
70 7B066 Forward (1, 2, 3, 4) clutch pressure plate
71 7D483 Forward (1, 2, 3, 4) clutch snap ring
72 7978 Transmission fluid baffle
73 W500214 Transmission fluid baffle bolt (2 required)
74 7060 Park gear
75 7G132 Drive chain drive sprocket
76 7C122 Drive sprocket snap ring
77 7G099 No. 13 thrust washer
78 7G249 Drive chain
79 7D234 No. 11 thrust washer
80 7048 Input shaft seal
81 7A098 Transmission fluid filter
82 7L027 Magnet
83 W302860 Pump-to-torque converter housing bolt (8 required)
84 7A103 Pump assembly
85 7A248 Pump assembly-to-torque converter housing O-ring seal
86 7A248 Torque converter hub seal
87 7P113 Torque converter hub seal retainer
88 7F343 Different ring gear
89 7C122 Differential ring gear snap ring
90 7H245 Differential transmission fluid baffle
91 W500214 Differential transmission fluid baffle bolt (2 required)
92 7975 Torque converter housing
93 W701606 Torque converter housing stud bolt
94 7A443 Torque converter housing bolt (16 required)
95 7902 Torque converter
96 1177 RH halfshaft seal
97 391308-S Transaxle filler tube O-ring
98 7A228 Transaxle filler tube
99 W520101 Transaxle filler tube nut
100 7A020 Transmission fluid level indicator
101 7G355 No. 12 thrust bearing
102 7G132 Drive chain driven sprocket
103 7F342 Differential sun gear
104 7F465 Differential assembly
105 7G112 No. 15 thrust bearing
106 7B362 Torque converter housing-to-transaxle case guide pins
107 7D070 Park pawl spring
108 7A441 Park pawl
109 7D071 Park pawl pin
110 7F337 Manual control shaft seal
111 7A232 Park pawl actuator rod
112 7H557 Transmission Range (TR) sensor
113 7C493 Manual control shaft
114 7G100 Manual control shaft pin
115 7A256 Manual control lever
116 W708455 Manual control lever nut
117 7E332 Manual valve detent spring
118 W711235 Manual valve detent spring bolt
119 7J387 Lubrication funnel
120 7A248 Torque converter housing-to-transaxle case seal (large)
121 7A248 Torque converter housing-to-transaxle case seal (small) (4 required)
122 7B431 Main control alignment pin
123 7C207 Main control stud
124 7G199 Main control-to-center support seal (2 required)
125 7H322 Thermal bypass valve and sleeve
126 - Thermal bypass valve spring (part of 7H322)
127 W713644 Output Shaft Speed (OSS) sensor bolt
128 7H103 OSS sensor
129 7Z490 Main control-to-transaxle case separator plate
130 7A100 Main control valve body
131 N605770 Separator plate-to-soledoid body bolt (2 required)
132 7Z490 Main control valve body-to-solenoid body separator plate
133 7G391 Solenoid body
134 W500303 Solenoid body-to-valve body bolt (2 required)
135 W302863 Main control-to-transaxle case bolt (long) (10 required)
136 W302862 Main control-to-transaxle case bolt (short) (12 required)
137 W520412 Main control nut
138 7G276 Main control leadframe
139 W505513 Main control leadframe screw (5 required)
140 7B329 Main control-to-cover seal
141 7G004 Main control cover
142 W714629 Main control cover stud bolt (5 required)
143 W500214 Main control cover bolt (8 required)
144 7010 Drain plug
145 7H398 Line pressure tap
146 7D273 Transmission fluid cooler tube fittings (2 required)
147 1177 LH halfshaft seal
148 7025 LH halfshaft bushing
149 7M101 Turbine Shaft Speed (TSS) sensor
150 W500214 TSS bolt
151 7A246 Vent tube
152 W500214 Lubrication funnel bolts
153 7G342 Solenoid body strategy tag
154 7B148 Transaxle service identification tag
155 - Direct clutch (3, 5, R)
156 - Intermediate clutch (2, 6)
157 - O/D clutch (4, 5, 6)
158 - Forward clutch (1, 2, 3, 4)
159 - Low/reverse clutch

All vehicles 

  1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.
    Fig 4: Locating Transaxle Case-To-Torque Converter Housing Sealing Surface And Main Control Cover Sealing Surface
    G08023816Courtesy of FORD MOTOR CO.
  2. Assemble the Handle 205-153 and the Bushing Installer 307-664 and install a new bushing on the Bushing Installer.
    Fig 5: Locating Bushing On Bushing Installer
    G08023817Courtesy of FORD MOTOR CO.
  3. Using the Handle 205-153 and the Bushing Installer 307-664, install the new bushing in the transaxle case.
    Fig 6: Installing Bushing In Transaxle Case Using Handle 205-153 And Bushing Installer 307-664
    G08023818Courtesy of FORD MOTOR CO.
  4. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the Differential Seal Installer 307-626.
    Fig 7: Locating LH Halfshaft Seal On Differential Seal Installer 307-626
    G08023819Courtesy of FORD MOTOR CO.
  5. Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in the transaxle case.
    Fig 8: Installing LH Halfshaft Seal In Transaxle Case
    G08023820Courtesy of FORD MOTOR CO.
  6. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.
    Fig 9: Locating Manual Control Shaft Seal On Manual Lever Seal Installer 307-581
    G08023821Courtesy of FORD MOTOR CO.
  7. Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the transaxle case.
    Fig 10: Installing Manual Control Shaft Seal In Transaxle Case
    G08023822Courtesy of FORD MOTOR CO.
  8. If not previously installed, install the clutch support tower and the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 11: Locating Clutch Support Tower
      G08023823Courtesy of FORD MOTOR CO.
  9. Remove Input Shaft Support Seal Installer 307-578/1.
    Fig 12: Identifying Input Shaft Support Seal Installer 307-578/1
    G08023824Courtesy of FORD MOTOR CO.
  10. Install 2-6 Piston Seal Protector 307-632.
    Fig 13: Identifying 2-6 Piston Seal Protector 307-632
    G08023825Courtesy of FORD MOTOR CO.
  11. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.
    Fig 14: Locating Intermediate (2, 6) Clutch Piston
    G08023826Courtesy of FORD MOTOR CO.
    12. NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.
    Fig 15: Locating Intermediate (2, 6) Clutch Piston
    G08023827Courtesy of FORD MOTOR CO.
  12. Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.
  13. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Open area at the bottom of the transaxle case
    3. Bleed hole
    4. Inner double tabs
      Fig 16: Positioning Intermediate (2, 6) Clutch Piston Return Spring On Piston
      G08023828Courtesy of FORD MOTOR CO.
  14. Remove the intermediate (2, 6) clutch piston return spring.
    Fig 17: Locating Intermediate (2, 6) Clutch Piston Return Spring
    G08023829Courtesy of FORD MOTOR CO.
  15. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.
    Fig 18: Identifying Forward/Intermediate Spring Compressor 307-584/1 On Intermediate (2, 6) Clutch Piston
    G08023830Courtesy of FORD MOTOR CO.
  16. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
    Fig 19: Pushing Intermediate (2, 6) Clutch Piston Into Clutch Cylinder
    G08023831Courtesy of FORD MOTOR CO.
  17. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector 307-632.
    Fig 20: Identifying Forward/Intermediate Spring Compressor 307-584/1 And Clutch Piston Seal Protector 307-632
    G08023832Courtesy of FORD MOTOR CO.
    18. NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.
  18. Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
    1. Outer tabs
    2. Bleed hole
    3. Inner double tabs
      Fig 21: Identifying Intermediate (2, 6) Clutch Piston Return Spring Outer Tabs, Bleed Hole And Inner Double Tabs
      G08023833Courtesy of FORD MOTOR CO.
    19. NOTE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
  19. Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
    1. Snap ring
    2. Snap ring gap
    3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)
      Fig 22: Identifying Low/Reverse And Forward (1, 2, 3, 4) Clutch Hydraulic Ports And Snap Ring
      G08023834Courtesy of FORD MOTOR CO.
  20. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the intermediate (2, 6) clutch return spring.
    Fig 23: Identifying 2-6 Piston Return Spring Compressor 307-633/2
    G08023835Courtesy of FORD MOTOR CO.
  21. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.
    Fig 24: Identifying 2-6 Piston Return Spring Compressor 307-633/1
    G08023836Courtesy of FORD MOTOR CO.
  22. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.
    Fig 25: Identifying Forward Clutch Spring Compressor 307-574/1 On Transaxle Case
    G08023837Courtesy of FORD MOTOR CO.
    23. NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.
    Fig 26: Installing Intermediate (2, 6) Clutch Snap Ring In Groove
    G08023838Courtesy of FORD MOTOR CO.
  23. Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.
  24. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633.
    Fig 27: Identifying Forward Clutch Spring Compressor 307-574/1 And 2-6 Piston Return Spring Compressor 307-633
    G08023839Courtesy of FORD MOTOR CO.
  25. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.
    Fig 28: Locating Intermediate (2, 6) Clutch Apply Ring
    G08023840Courtesy of FORD MOTOR CO.
    26. NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.
    Fig 29: Locating No. 1 Thrust Bearing
    G08023841Courtesy of FORD MOTOR CO.
  26. Install the No. 1 thrust bearing with the flat side facing up.
  27. Install the overdrive/direct clutch assembly.
    Fig 30: Locating Overdrive/Direct Clutch Assembly
    G08023842Courtesy of FORD MOTOR CO.
    28. NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.
    Fig 31: Locating No. 3 Thrust Bearing
    G08023843Courtesy of FORD MOTOR CO.
  28. Install the No. 3 thrust bearing with the flat side facing down.
  29. Install the direct/intermediate clutch hub and rear sun gear assembly.
    Fig 32: Locating Direct/Intermediate Clutch Hub And Rear Sun Gear Assembly
    G08023844Courtesy of FORD MOTOR CO.
  30. Install the intermediate (2, 6) wave spring assembly.
    Fig 33: Locating Intermediate (2, 6) Wave Spring Assembly
    G08023845Courtesy of FORD MOTOR CO.
  31. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.
    Fig 34: Identifying Intermediate (2, 6) Clutch Assembly
    G08023846Courtesy of FORD MOTOR CO.
  32. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
    Fig 35: Locating Intermediate (2, 6) Clutch Assembly
    G08023847Courtesy of FORD MOTOR CO.
  33. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 36: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G08023848Courtesy of FORD MOTOR CO.
  34. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
    Fig 37: Measuring Distance From Shim Selection Gauge 307-300 To Top Of Intermediate (2, 6) Clutch Pack (Measurement A)
    G08023849Courtesy of FORD MOTOR CO.
  35. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
    Fig 38: Measuring Distance From Top Of Shim Selection Gauge 307-300 To Transaxle Case Step (Measurement B)
    G08023850Courtesy of FORD MOTOR CO.
  36. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in)  
    37. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
    Fig 39: Removing Top Intermediate (2, 6) Clutch Friction And Steel Plate
    G08023851Courtesy of FORD MOTOR CO.
  37. Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.
  38. Install the One-Way Clutch (OWC) assembly.
    Fig 40: Locating Low One-Way Clutch (OWC)
    G08023852Courtesy of FORD MOTOR CO.
  39. Install the rear planetary carrier/center ring gear assembly.
    Fig 41: Locating Rear Planetary Carrier/Center Ring Gear Assembly
    G08023853Courtesy of FORD MOTOR CO.
    40. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.
    Fig 42: Locating Low/Reverse Pressure Plate
    G08023854Courtesy of FORD MOTOR CO.
  40. Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.
  41. Soak the low/reverse clutch in clean automatic transmission fluid.
    Fig 43: Identifying Low/Reverse Clutch
    G08023855Courtesy of FORD MOTOR CO.
  42. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.
    Fig 44: Locating Low/Reverse Clutch Pack
    G08023856Courtesy of FORD MOTOR CO.
  43. Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs.
    Fig 45: Identifying Shim Selection Gauge 307-300
    G08023857Courtesy of FORD MOTOR CO.
  44. Using a suitable depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
    Fig 46: Measuring Distance From Top Of Shim Selection Gauge 307-300 To Contact Surface Of Low/Reverse Clutch Piston (Measurement A)
    G08023858Courtesy of FORD MOTOR CO.
  45. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.
    Fig 47: Measuring Distance From Top Of Shim Selection Gauge 307-300 To Leg Surface Of Center Support (Measurement B)
    G08023859Courtesy of FORD MOTOR CO.
  46. Subtract measurement B from measurement A and record as measurement C.
    Description Reading
    Measurement A  
    Measurement B  
    Subtract measurement B from measurement A and record as measurement C.  
  47. Install the Shim Selection Gauge 307-300 on the transaxle case.
    Fig 48: Identifying Shim Selection Gauge 307-300 On Transaxle Case
    G08023860Courtesy of FORD MOTOR CO.
  48. Using a suitable depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge 307-300 to the top of the OWC.
    Fig 49: Measuring Distance From Shim Selection Gauge 307-300 To Top Of OWC Using Depth Micrometer
    G08023861Courtesy of FORD MOTOR CO.
  49. Using a suitable depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average the 3 distances.
    Fig 50: Measuring Distance From Top Of Shim Selection Gauge 307-300 To Top Of Low/Reverse Clutch
    G08023862Courtesy of FORD MOTOR CO.
  50. Subtract measurement E from measurement D and record as measurement F.
    Description Reading
    Measurement D  
    Measurement E  
    Subtract measurement E from measurement D and record as measurement F  
  51. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 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 clutch pack.
    Description Reading
    Measurement C  
    Measurement F  
    Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in)  
    52. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
    Fig 51: Removing Top Low/Reverse Clutch Steel Plate And Wave Spring
    G08023863Courtesy of FORD MOTOR CO.
  52. Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.
    53. NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.
  53. Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
    1. Long center support legs face down
    2. Feed holes face the front of the transaxle case
      Fig 52: Installing Center Support With Long Legs Facing Down
      G08023864Courtesy of FORD MOTOR CO.
  54. Install the No. 5 and No. 6 thrust bearings.
    1. No. 5 thrust bearing
    2. No. 6 thrust bearing
      Fig 53: Identifying No. 5 And No. 6 Thrust Bearings
      G08023865Courtesy of FORD MOTOR CO.
  55. Install the center sun gear.
    Fig 54: Locating Center Sun Gear
    G08023866Courtesy of FORD MOTOR CO.
  56. Install the center carrier/front ring gear assembly.
    Fig 55: Locating Center Carrier/Front Ring Gear Assembly
    G08023867Courtesy of FORD MOTOR CO.
  57. Install the No. 7 and No. 8 thrust bearings.
    1. No. 7 thrust bearing
    2. No. 8 thrust bearing
      Fig 56: Identifying No. 7 And No. 8 Thrust Bearings
      G08023868Courtesy of FORD MOTOR CO.
  58. Install the front planetary/rear ring gear assembly.
    Fig 57: Locating Front Planetary Carrier/Rear Ring Gear Assembly
    G06097382Courtesy of FORD MOTOR CO.
  59. Install the forward (1, 2, 3, 4) clutch wave spring.
    Fig 58: Locating Forward (1, 2, 3, 4) Clutch Wave Spring
    G06097678Courtesy of FORD MOTOR CO.
  60. Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid.
    Fig 59: Identifying Forward (1, 2, 3, 4) Clutch Pack
    G06097679Courtesy of FORD MOTOR CO.
  61. Install the forward (1, 2, 3, 4) clutch pack.
    Fig 60: Locating Forward (1, 2, 3, 4) Clutch Pack
    G06097680Courtesy of FORD MOTOR CO.
  62. Install the forward (1, 2, 3, 4) clutch pressure plate.
    Fig 61: Locating Forward (1, 2, 3, 4) Clutch Pressure Plate
    G06097681Courtesy of FORD MOTOR CO.
    63. NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
  63. Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
    1. Forward (1, 2, 3, 4) clutch snap ring
    2. Forward (1, 2, 3, 4) clutch snap ring gap
      Fig 62: Identifying Forward (1, 2, 3, 4) Clutch Snap Ring And Gap
      G06097682Courtesy of FORD MOTOR CO.
  64. Using a suitable tool, seat the snap ring in the snap ring groove.
    Fig 63: Seating Snap Ring In Snap Ring Groove
    G06097683Courtesy of FORD MOTOR CO.
  65. Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
    Fig 64: Positioning Plunger On Top Forward (1, 2, 3, 4) Clutch Friction Plate
    G06097684Courtesy of FORD MOTOR CO.
  66. Install the new low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.
    Fig 65: Locating Low/Reverse And Forward (1, 2, 3, 4) Clutch Feed Seals In Transaxle Case
    G06097685Courtesy of FORD MOTOR CO.
  67. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
    Fig 66: Applying Air Pressure To Forward (1, 2, 3, 4) Clutch Piston Port
    G06097686Courtesy of FORD MOTOR CO.
  68. Install the front planetary sun gear and shell assembly.
    Fig 67: Locating Front Planetary Sun Gear And Shell Assembly
    G06097687Courtesy of FORD MOTOR CO.
  69. Install the No. 10 thrust bearing.
    Fig 68: Locating No. 10 Thrust Bearing
    G06097688Courtesy of FORD MOTOR CO.
  70. Install the park pawl.
    Fig 69: Locating Park Pawl
    G06097689Courtesy of FORD MOTOR CO.
  71. Install the park pawl pin and spring.
    Fig 70: Locating Park Pawl Pin And Spring
    G06097690Courtesy of FORD MOTOR CO.
  72. Install the park pawl actuator rod in the Transmission Range (TR) sensor.
    Fig 71: Locating Park Pawl Actuator Rod
    G06097691Courtesy of FORD MOTOR CO.
  73. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transaxle case.
    Fig 72: Positioning Park Pawl Actuator Rod And TR Sensor In Transaxle Case
    G06097692Courtesy of FORD MOTOR CO.
  74. Install the manual control shaft and align the roll pin holes.
    Fig 73: Installing Manual Control Shaft
    G06097693Courtesy of FORD MOTOR CO.
  75. Install the manual control shaft roll pin.
    Fig 74: Installing Manual Control Shaft Roll Pin
    G06097694Courtesy of FORD MOTOR CO.
    76. 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.
  76. Install the manual control lever and the nut.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 75: Locating Manual Control Lever And Nut
      G06097402Courtesy of FORD MOTOR CO.
  77. Install the 5 new clutch feed seals.
    Fig 76: Locating Clutch Feed Seals
    G06097696Courtesy of FORD MOTOR CO.
  78. Position the transmission fluid baffle in place and install the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 77: Locating Bolts And Transmission Fluid Baffle
      G08023568Courtesy of FORD MOTOR CO.
  79. Position the lube funnel in place and install the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 78: Locating Bolts And Transmission Fluid Reservoir
      G08023567Courtesy of FORD MOTOR CO.
  80. Install the No. 12 thrust bearing.
    Fig 79: Locating No. 12 Driven Sprocket Thrust Bearing
    G08023565Courtesy of FORD MOTOR CO.
  81. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
    Fig 80: Installing Drive/Driven Sprocket And Chain Assembly
    G08023892Courtesy of FORD MOTOR CO.
  82. Install the No. 11 thrust bearing.
    Fig 81: Locating No. 11 Drive Sprocket Thrust Bearing
    G08023563Courtesy of FORD MOTOR CO.
  83. Install the No. 13 thrust washer.
    Fig 82: Locating No. 13 Thrust Washer
    G08023562Courtesy of FORD MOTOR CO.
  84. Install the final drive sun gear.
    Fig 83: Locating Differential Planetary Sun Gear
    G08023561Courtesy of FORD MOTOR CO.
  85. Install the differential assembly.
    Fig 84: Locating Differential Assembly
    G06097705Courtesy of FORD MOTOR CO.
  86. Install the No. 15 thrust bearing.
    Fig 85: Locating No. 15 Thrust Bearing
    G06097706Courtesy of FORD MOTOR CO.
  87. Install the Turbine Shaft Seal Protector 307-635 on the input shaft.
    Fig 86: Identifying Turbine Shaft Seal Protector 307-635 On Input Shaft
    G08023898Courtesy of FORD MOTOR CO.
  88. Clean the torque converter housing sealing surface.
    Fig 87: Locating Torque Converter Housing Sealing Surface
    G06377407Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  89. Assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the Seal Installer 307-626.
    Fig 88: Locating RH Seal On Seal Installer 307-626
    G06097709Courtesy of FORD MOTOR CO.
  90. Using the Handle 205-153 and Differential Seal Installer 307-626, install the new RH halfshaft seal.
    Fig 89: Installing RH Halfshaft Seal Using Handle 205-153 And Differential Seal Installer 307-626
    G06097710Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  91. Install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428.
    Fig 90: Locating RH Seal On RH Halfshaft Fluid Seal Installer 307-428
    G06097711Courtesy of FORD MOTOR CO.
  92. Using the RH Halfshaft Fluid Seal Installer 307-428, install the new RH halfshaft seal.
    Fig 91: Installing RH Halfshaft Seal Using RH Halfshaft Fluid Seal Installer 307-428
    G06097712Courtesy of FORD MOTOR CO.

    All vehicles 

  93. Install the differential ring gear in the torque converter housing.
    Fig 92: Installing Differential Ring Gear
    G06097411Courtesy of FORD MOTOR CO.
    94. NOTE: Be sure the flat side of the beveled snap ring is facing down or the ring can come loose, causing damage to the transaxle.
    Fig 93: Installing Differential Ring Gear Snap Ring
    G06097410Courtesy of FORD MOTOR CO.
  94. Install the beveled differential ring gear snap ring with the flat side facing down.
  95. Seat the snap ring using a suitable tool.
    Fig 94: Seating Snap Ring Using Tool
    G06097715Courtesy of FORD MOTOR CO.
  96. Install the pump and filter assembly in the torque converter housing and install the 8 pump bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 95: Locating Bolts, Pump And Filter Assembly
      G07444260Courtesy of FORD MOTOR CO.
  97. Install the transmission fluid baffle and the 2 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 96: Locating Bolts And Oil Baffle
      G06097408Courtesy of FORD MOTOR CO.
    98. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
    Fig 97: Identifying Transaxle Case Sealing Surface
    G08023909Courtesy of FORD MOTOR CO.
  98. Apply silicone to the sealing surface of the transaxle case.
    99. NOTE: Be sure the stud bolt is in the correct location as noted during disassembly.
  99. Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque converter housing bolts.
    1. Tighten to 24 Nm (18 lb-ft).
    2. Stud bolt location.
      Fig 98: Locating Transaxle Case-To-Torque Converter Housing Bolts And Stud Bolt Location
      G06097719Courtesy of FORD MOTOR CO.
  100. Remove the Turbine Shaft Seal Protector 307-635.
    Fig 99: Identifying Turbine Shaft Seal Protector 307-635
    G06097720Courtesy of FORD MOTOR CO.
  101. Install the Turbine Shaft Speed (TSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 100: Locating Turbine Shaft Speed (TSS) Sensor Bolt
      G06097721Courtesy of FORD MOTOR CO.
  102. Install the Output Shaft Speed (OSS) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 101: Locating OSS Sensor Bolt
      G06097362Courtesy of FORD MOTOR CO.
  103. Assemble the bypass valve in the sleeve and install the assembly in the case.
    1. Bypass valve
    2. Bypass valve sleeve
      Fig 102: Installing Bypass Valve Assembly In Case
      G06097723Courtesy of FORD MOTOR CO.
  104. Install the bypass valve spring.
    Fig 103: Installing Bypass Valve Spring
    G06097724Courtesy of FORD MOTOR CO.
  105. Install the new main control-to-transaxle case separator plate and align it on the stud and the guide pin.
    Fig 104: Aligning Main Control-To-Transaxle Case Separator Plate On Stud And Guide Pin
    G06097725Courtesy of FORD MOTOR CO.
    106. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
    Fig 105: Aligning Manual Valve On TR Sensor
    G06097726Courtesy of FORD MOTOR CO.
  106. Position the main control assembly in place and align the manual valve on the TR sensor.
  107. Install the nut hand-tight.
    Fig 106: Locating Main Control Assembly Nut
    G06097727Courtesy of FORD MOTOR CO.
  108. Install the short bolts hand-tight.
    Fig 107: Locating Main Control Assembly Short Bolts
    G06097728Courtesy of FORD MOTOR CO.
  109. Install the long bolts hand-tight.
    Fig 108: Locating Main Control Assembly Long Bolts
    G06097729Courtesy of FORD MOTOR CO.
  110. Tighten the main control bolts and the nut in a crisscross pattern.
    • Tighten to 10 Nm (89 lb-in).
      Fig 109: Locating Main Control Bolts And Nut
      G06097730Courtesy of FORD MOTOR CO.
  111. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 110: Locating TR Sensor Detent Spring And Bolt
      G06097731Courtesy of FORD MOTOR CO.
    112. NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
    Fig 111: Locating Solenoid Body-To-Main Control Cover Grommet
    G06097355Courtesy of FORD MOTOR CO.
  112. Install the solenoid body-to-main control cover seal.
  113. Connect the TR sensor electrical connector.
    Fig 112: Locating TR Sensor Electrical Connector
    G06097354Courtesy of FORD MOTOR CO.
  114. Connect the OSS sensor electrical connector.
    Fig 113: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G06097353Courtesy of FORD MOTOR CO.
  115. Clean the main control cover sealing surface.
    Fig 114: Locating Main Control Cover Sealing Surface
    G06097735Courtesy of FORD MOTOR CO.
  116. Apply silicone to the main control sealing surface of the transaxle case.
    Fig 115: Locating Main Control Sealing Surface Of Transaxle Case
    G06097736Courtesy of FORD MOTOR CO.
  117. Position the main control cover in place.
    Fig 116: Locating Main Control Cover
    G06097737Courtesy of FORD MOTOR CO.
    118. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
  118. Install the main control cover bolts.
    1. Bolt location
    2. Stud bolt location
    3. Tighten to 12 Nm (106 lb-in).
      Fig 117: Identifying Main Control Cover Bolts
      G06097738Courtesy of FORD MOTOR CO.
    119. NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 118: Installing Torque Converter In Transaxle Using Torque Converter Handle 307-091
    G06097351Courtesy of FORD MOTOR CO.
  119. Using the Torque Converter Handle 307-091, install the torque converter.
  120. Remove the Torque Converter Handle 307-091.
    Fig 119: Identifying Torque Converter Handle 307-091
    G06097350Courtesy of FORD MOTOR CO.
  121. Install the Torque Converter Retainer 307-566.
    Fig 120: Identifying Torque Converter Retainer 307-566
    G06097349Courtesy of FORD MOTOR CO.
  122. Remove the transaxle from the bench-mounted holding fixture.
    Fig 121: Identifying Transaxle On Bench-Mounted Holding Fixture
    G06097742Courtesy of FORD MOTOR CO.
  123. Remove the Holding Fixture 307-625.
    Fig 122: Identifying Holding Fixture 307-625
    G06097347Courtesy of FORD MOTOR CO.
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