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Final Reassembly

  1. Install reverse clutch on forward clutch. See Figure . Ensure No. 2 needle bearing is in position in reverse clutch. Install No. 3 needle bearing and forward clutch hub in forward clutch. Position No. 4 needle bearing on forward clutch hub.
  2. Install drive shell over clutch assemblies. Install No. 5 needle bearing and forward sun gear on drive shell. Install complete assembly into case, rotating output shaft to aid in engaging sun gear with planetary gears. See Fig 1 .
  3. Install overdrive band into case and around drive shell assembly. Ensure band anchor is properly positioned on anchor pin. Using a screwdriver to hold overdrive band in position, lubricate and install overdrive servo.
  4. With overdrive servo installed, inspect band and apply pin for proper position and engagement. If band anchor and apply pin are not properly engaged, remove servo and re-position band as necessary.
  5. Install intermediate clutch pack pressure plate, clutch pack (starting with a friction plate and alternating steel and friction plates) and selective steel plate in this order. Measure intermediate clutch clearance.
  6. Intermediate clutch clearance is measured using a depth micrometer and End Play Checking Bar (T80L-77003-A). Set end play tool across pump case mounting surface. Locate micrometer end play bar and read depth. See Fig 2 .
    NOTE: A downward pressure must be applied to clutch pack while measuring intermediate clutch clearance.
    Fig 1: Installing Drive Shell & Clutch Assemblies
    G92D14632Courtesy of FORD MOTOR CO.
    Fig 2: Measuring Intermediate Clutch Clearance
    G92E14633Courtesy of FORD MOTOR CO.
  7. Check depth again with micrometer 180 degrees opposite from previous measurement. Ensure depth at intermediate clutch selective steel plate is 1.634-1.646" (41.504-41.808 mm). Ensure average of the 2 measurements is within this range.
  8. If intermediate clutch clearance (depth) is not within tolerance, see INTERMEDIATE CLUTCH SELECTIVE STEEL PLATES  . Install correct size plate and recheck clearance.
    INTERMEDIATE CLUTCH PLATE USAGE

    Application Steel Plates Friction Plates
    All 3 3
    INTERMEDIATE CLUTCH SELECTIVE STEEL PLATES

    Part No. (1) Thickness
    E0AP7F220-A1A .069 (1.75 mm)
    E0AP7F220-A2A .079 (2.01 mm)
    E0AP7F220-A3A .089 (2.26 mm)
    E0AP7F220-A4A .099 (2.51 mm)
    (1) Snap ring thicknesses have .002" (.05 mm) tolerance.
  9. Check transmission end play by locating depth micrometer on End Play Checking Bar (T80L-77003-A). Ensure depth is measured at reverse clutch drum thrust face. See Fig 3 . Standard end play is .004-.044" (.101-1.11 mm).
  10. Check end play 180 degrees opposite end of reverse clutch drum thrust face to determine average depth. Thrust washer controlling transmission end play is located on stator support which is attached to back of pump housing.
  11. Transmission end play can be adjusted using one of selective thrust washers available for service. After measuring depth, select required thrust washer. See END PLAY THRUST WASHER SELECTION  .
    Fig 3: Measuring Transmission End Play
    G92F14634Courtesy of FORD MOTOR CO.
    END PLAY THRUST WASHER SELECTION

    Measured Depth In. (mm) Washer Thickness In. (mm) Color Code
    1.483-1.500 (37.67-38.10) .050-.054 (1.27-1.37) Green
    1.501-1.517 (38.13-38.53) .068-.072 (1.73-1.83) Yellow
    1.518-1.534 (38.56-38.96) .085-.089 (2.16-2.26) Natural
    1.535-1.551 (38.99-39.40) .102-.106 (2.59-2.69) Red
    1.552-1.568 (39.42-39.83) .119-.123 (3.02-3.12) Blue
  12. Install selected transmission end play thrust washer on stator support. Use petroleum jelly to hold it in place. Install pump alignment dowel, made by cutting the head from a M8 x 1.25 bolt, into pump mounting bolt hole at 6 o'clock position.
  13. Install new pump gasket into case. Install pump assembly into case using 2 slide hammers to lower pump into position. Remove alignment dowel. Coat all pump-to-case bolts with Loctite and install in case.
  14. Alternately tighten bolts a few turns at a time to draw pump into case. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Install 2-3 accumulator assembly. Install 2 valve body Alignment Pins (T8OL-77100-A) into valve body.
  15. Install valve body gasket and valve body assembly over pins. Ensure manual and throttle levers are properly positioned before installing valve body retaining bolts.
    NOTE: Two different length valve body retaining bolts are used. Longer bolts are used at 4 front, 1 center and 3 rear locations.
  16. Loosely install valve body retaining bolts. Starting at center and working outward, tighten bolts. Remove alignment pins and install bolts. Install detent spring and roller assembly and tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  17. Position T.V. lever torsion spring against separator plate "V" notch. This spring pushes the throttle lever in direction of wide open throttle.
  18. Install filter grommet, new filter gasket, and filter on valve body. Install filter attaching bolts and tighten. Position new pan gasket on case and install oil pan. Clean mating surface on transmission and extension housing. Position new gasket on transmission. Slide extension housing into place.
  19. Clean bolts and case holes for 2 bottom bolts and lower right hand corner bolt (as viewed from rear of extension housing). Coat bolts with Teflon tape and install. Install remaining bolts and tighten to specification.
  20. Slide direct drive shaft into turbine input shaft. Install torque converter. Ensure pump is fully seated.
Fig 4: Locating Needle & Thrust Bearings
G92G14635Courtesy of FORD MOTOR CO.
Fig 5: Exploded View of AOD Transmission
G92H14636Courtesy of FORD MOTOR CO.
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