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Section 1376 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0003426Courtesy of FORD MOTOR CO.
 Air Test Plate, Transmission 307-246 (T92P-7006-A)
GF0000909Courtesy of FORD MOTOR CO.
 Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)
GF0000024Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0003433Courtesy of FORD MOTOR CO.
 Gauge, Transmission Solenoid Connectors 307-426
GF0000942Courtesy of FORD MOTOR CO.
 Handle, Torque Converter 307-091 (T81P-7902-C)
GF0003518Courtesy of FORD MOTOR CO.
 Installer, Servo Piston 307-073 (T80L-77030-A)
GF0000968Courtesy of FORD MOTOR CO.
 Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)
GF0000966Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Fluid Seal 308-002 (T61L-7657-A)
GF0003517Courtesy of FORD MOTOR CO.
 Remover/Installer, Servo Piston 307-251 (T92P-70023-A)
GF0003689Courtesy of FORD MOTOR CO.
 Remover/Installer, Transmission Extension Housing 307-077 (T80L-77110-A)
GF0000918Courtesy of FORD MOTOR CO.
 Rubber Tip Air Nozzle 100-D009 (D93L-7000-A)
GF0003688Courtesy of FORD MOTOR CO.
 Shim Selection Gauge 307-072 (T80L-77003-A)
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0003690Courtesy of FORD MOTOR CO.
 Test Plate Screw Set, Transmission 307-126 (T82P-7006-C)
Material

Item Specification
MERCON® LV Automatic Transmission Fluid
XT-10-QLV		 MERCON® LV
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
Fig 1: Exploded View Of Automatic Transmission (1 Of 3)
GF0003691Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Automatic Transmission (2 Of 3)
GF0003692Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Automatic Transmission (3 Of 3)
GF0003693Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7902 Converter assembly (model dependent)
2 7A103 Pump and piston assembly - transmission fluid
3 7A248 Seal assembly - pump
4 7A248 Seal - pump
5 7B258 Bushing - pump
6 N605789-S101 Bolt - M8-1.25 x 35 hex head (7 required, attaches 7A103 to 7005)
7 7A106 Body assembly - pump (part of 7A103)
8 7A136 Gasket - front pump
9 7H169 Gear - pump inner gerotor (part of 7A103)
10 7H169 Gear - pump outer gerotor (part of 7A103)
11 7A108 Support assembly - front pump
12 N605787-S1000 Bolt - M8-1.25 x 25 hex flange head (5 required, attaches 7A108 to 7A103)
13 7D020 Seals - reverse clutch cylinder (2 required)
14 7D019 Seals - forward clutch cylinder (2 required)
15 7E005 Piston and valve assembly - intermediate clutch
16 7D014 Washer - front pump support thrust - select fit No. 1
17 7F222 Spring and retainer - intermediate clutch piston return
18 7A609 Anti-rattle clip - intermediate clutch (model dependent)
19 7B442 Plates - intermediate clutch external spline (select fit) (steel)
20 7B164 Plate assembly - intermediate clutch internal spline (friction)
21 7B066 Plate - intermediate clutch pressure
22 7F196 Band assembly - overdrive
23 391267-S Ring - 3-21/64 retains type SU external (retains 7F262 to 7F215)
24 7A089 Clutch assembly - intermediate one-way clutch
25 7D044 Drum assembly - reverse clutch
26 7D403 Seal - reverse clutch piston outer
27 7D402 Piston assembly - reverse clutch
28 7D404 Seal reverse clutch piston inner
29 7D256 Ring - reverse clutch piston pressure
30 7B070 Spring - reverse clutch piston return
31 7A577 Retainer - reverse clutch piston spring
32 7B066 Plate - reverse clutch front pressure
33 7B164 Plates - reverse clutch internal spline (friction)
34 7B442 Plates - reverse clutch external spline (steel)
35 7B066 Plate - reverse clutch rear pressure
36 7B497 Seals - input shaft (2 required)
37 7D483 Retainer - reverse clutch pressure plate - select fit
38 7A166 Bearing and race assembly - forward clutch No. 2
39 7F207 Cylinder and input shaft assembly - forward clutch
40 7A548 Seal - forward clutch piston outer
41 7C099 Seal - forward clutch piston inner
42 7A262 Piston - forward clutch
43 7A480 Spring - forward clutch piston return
44 7A527 Retainer return spring - forward clutch
45 388099-S Snap ring - retaining - 1-59/64 (retains 7A529 in 7F207)
46 7E085 Spring - rear clutch pressure plate (model dependent)
47 7B442 Plates - forward clutch external spline (steel)
48 7B164 Plates - forward clutch internal spline (friction)
49 7B066 Plate - forward clutch pressure
50 7D483 Snap ring - retaining (select fit)
51 7F231 Bearing and race assembly - forward clutch front No. 3
52 7B067 Hub - forward clutch
53 7F351 Shaft - intermediate stub
54 7C096 Bearing and race assembly - forward clutch hub No. 4
55 7A019 Gear assembly - reverse clutch sun
56 7D234 Bearing and race assembly - forward clutch sun gear No. 5
57 7D235 Retaining ring - center support - 7-7/32
58 7A399 Gear assembly - forward clutch sun
59 7F277 Spring - case to planet support
60 7A130 Support assembly - planetary gear
61 7A089 One-way clutch (OWC) cage spring and roller assembly - planetary
62 7A398 Planetary assembly (model dependent)
63 7D095 Band assembly - reverse
64 392004-S300 Retaining ring - 0.58 thick (locates reverse band during assembly)
65 7F236 Hub - direct clutch
66 7F243 Bearing and race assembly - direct clutch inner No. 7
67 7F237 Support - direct clutch inner bearing
68 7D483 Retaining ring - direct clutch pressure plate (select fit)
69 7B066 Plate - direct clutch pressure
70 7B164 Plates - direct clutch internal spline (friction)
71 7B442 Plates - direct clutch external spline (steel)
72 388104-S Retainer ring - 1-19/32 (retains 7F235 to 7F283)
73 7F235 Retainer and spring assembly - direct clutch
74 7A262 Piston assembly - direct clutch
75 7C099 Seal - direct clutch piston inner
76 7A548 Seal - direct clutch piston outer
77 7F283 Cylinder assembly - direct clutch
78 7F274 Seals - output shaft small - direct clutch (2 required)
79 7F240 Bearing and race assembly - direct clutch outer No. 8
80 7060 Shaft assembly - output (model dependent)
81 7F273 Seals - output to case shaft large (3 required)
82 87054-S94 Seal - O-ring (piloted output shaft only) (model dependent)
83 7A233 Gear - output shaft ring
84 7D164 Hub - output shaft
85 97713-S Snap ring - 1-13/16 retaining (retains 7D164 to 7060)
86 7C122 Snap ring - retaining (retains 7D164 to 7A153)
87 7025 Bushing - rear case
88 7F242 Bearing and race assembly - case rear No. 9
89 7005 Case assembly
90 7086 Gasket - extension (model dependent)
91 N803747-S102 Bolt - M8-1.25 x 30 (6 required, attaches 7A039 to 7005) (model dependent)
92 7A039 Extension housing assembly (model dependent)
93 7A034 Bushing - extension housing (part of 7A039)
94 7052 Seal assembly - extension housing (model dependent)
95 7H183 Extension housing plug (includes O-ring 87036-S94)
96 57621-S2 Extension housing plug bolt and washer
97 390318-S100 Pipe plugs - 1/8-27 Dryseal tapered (5 required)
98 7F295 Pin - overdrive band anchor
99 388142-S Pins - reverse band anchor (part of 7005)
100 7A246 Vent assembly - case
101 7H398 Plug - non TSS applications
102 W700005-S309 Bolt - M6-1.0 x 25 hex flange HD (attaches TSS sensor to case)
103 7M101 Sensor assembly - transmission turbine shaft speed sensor
104 N605771-S427 Bolt - M6-1.0 x 14 hex head (attaches output shaft speed sensor to case)
105 7H103 Sensor assembly - transmission output shaft speed
106 N811757-S100 Seal - 14.0 x 1.78 O-ring
107 W500015-S309 Bolt and washer assembly - M6-1.0 x 25 mm (1 in) (2 required, attaches 7F293 to 7005) (model dependent)
108 7F293 Sensor - transmission range
109 7A256 Lever assembly - manual control (model dependent)
110 7H296 Link assembly - manual control (model dependent)
111 7C493 Shaft - transmission manual control lever (model dependent)
112 N808737-S427 Nut - M10-1.5 (attaches 7A256 to 7C493)
113 7B498 Seal assembly - manual control lever
114 373907-S2 Nut - 1/4 spring (retains identification tag to 7000)
115 7B148 Tag - identification (part of 7005)
116 7D273 Connector assembly - transmission fluid cooler tube case fittings (2 required)
117 7N171 Plug - converter housing access
118 7B210 Pin - manual lever shaft retainer
119 391131 Seal - 0.426 x 0.070 O-ring
120 N805862-S Seal - 14.0 x 1.78 O-ring
121 7G383 Solenoid valve - transmission pressure control
122 7A441 Pawl - parking pawl
123 7D071 Shaft - parking pawl
124 7D419 Cup - park rod guide (part of 7A039)
125 7D070 Spring - parking pawl return
126 7A232 Rod assembly - park pawl actuating
127 7A115 Lever assembly - manual valve detent lever
128 N800287-S536 Nut - M14 x 1.5 hex intermediate detent lever (attaches 7A115 to 7A256)
129 7H188 Piston assembly - overdrive servo
130 7F201 Spring - overdrive servo piston
131 7F203 Rod - overdrive servo actuating
132 7H179 Washer - backup overdrive servo Belleville
133 7G277 Spring - Belleville overdrive cushion spring
134 7F200 Piston assembly - overdrive servo
135 97411-S Ring - retaining
136 391377-S Ring - 2.85 retaining type TVP "H" internal (retains 7H188 to 7005)
137 7D031 Spring - reverse band servo piston
138 7D189 Piston assembly - reverse band servo
139 7D036 Cover assembly - reverse band servo piston
140 388215-S100 Retaining ring internal - 3-13/16
141 7H292 Piston and seal assembly - 2-3 accumulator (bonded seals)
142 7F285 Ring - 2-3 shift accumulator piston (model dependent)
143 7B264 Retainer - 2-3 shift accumulator spring
144 7F284 Spring - 1-2 shift accumulator (model dependent)
145 7F251 Piston assembly - 1-2 shift accumulator (bonded seals)
146 7F284 Spring - 1-2 shift accumulator
147 7F284 Nested spring - 1-2 (inner spring) (vehicle dependent)
148 7F247 Cover and seal assembly - 1-2 accumulator
149 7384 Ring - 2-1/16 retaining type HU internal (retains 7H300 to 7005)
150 N807178-S1000 Bolts - M6-1.0 x 18 hex head (12 required attaches reinforcing plate to valve body)
151 7F282 Plates - valve body reinforcing (part of 7A100)
152 7C155 Gasket - valve body separator upper
153 7A008 Plate - control valve body separator (part of 7A100)
154 7D100 Gasket - valve body separator lower
155 7D174 Valve - converter drainback
156 7A091 Body assembly - main control
157 7H173 Gasket - valve body cover plate
158 7C034 Plate - valve body cover (part of 7A100)
159 N807178-S1000 Bolt - M6-1.0 x 18 hex head (11 required, attaches 7C034 to 7A100 (part of 7A100)
160 7A100 Control assembly - main (model dependent)
161 7A098 Filter and seal assembly - transmission fluid
162 7A191 Gasket - transmission fluid pan
163 7A194 Pan - transmission fluid
164 N605785-S1036 Bolt - M8-1.25 x 18 hex flange head (14 required, attaches 7A194 to 7005)
165 7L027 Magnet - ceramic case (part of 7A194)
166 N808947-S1300 Bolt - M8-1.25 x 46 hex shoulder pilot (2 required attaches 7C034 to 7A100)
167 N807179-S1000 Bolt - M6-1.0 x 52 hex flange head (12 required, attaches 7A100 to 7005)
168 7H111 Retainer - solenoid
169 7E195 Ball - 1/4 diameter coast booster valve shuttle (8 required)
170 7H187 Screen - solenoid pressure supply
171 N800670-S1000 Bolt - M6-1.0 x 40 hex flange head (13 required, attaches 7A100 to 7005)
172 7E332 Spring assembly - manual valve detent
173 7Z276 Seal - 0.864 x 0.070 O-ring (2 required)
174 7G276 Bulkhead assembly - wiring connector
175 7G276 Bulkhead assembly - connector (molded lead frame)
176 7Z484 Seals - 6.07 x 1.70 O-ring (2 required)
177 7G484 Solenoid valve - transmission shift
178 7G136 Solenoid valve - transmission torque converter clutch
179 N807178-S1000 Bolt - M6-1.0 x 16 hex head (retains 7D136 and 7G484 to 7A100)
180 7Z136 Seal - 0.489 x 0.070 O-ring
181 7Z484 Seal - 0.176 x 0.070 O-ring
182 - Intermediate clutch assembly
183 - Intermediate OWC
184 - Reverse clutch assembly
185 - Forward clutch assembly
186 - Direct clutch assembly
CAUTION: Before beginning assembly, carry out and inspect the following:
  • When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.
  • All fasteners must be tightened to the torque specification indicated. In addition to appearing in the section, the necessary torques can be found in the TORQUE SPECIFICATIONS  table.
  • When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.
  • Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.
  • Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.
  1. Use the special tools to install the rear case bushing if removed.
    1. Position the rear case bushing and the special tool inside the case.
    2. Assemble the special tools through the back of the case.
    2. Fig 4: Positioning Rear Case Bushing Using Special Tool
    GF0003694Courtesy of FORD MOTOR CO.
  2. Place the transmission in the vertical position.
  3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
    4. Fig 5: Coating No. 9 Case Rear Bearing With Petroleum Jelly
    GF0003596Courtesy of FORD MOTOR CO.
    CAUTION: Be sure the No. 7 and No. 8 needle bearings and direct clutch hub are installed as shown under DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES . Internal damage and shift problems may occur to the transmission.
  4. Install the output shaft and output shaft ring gear.
    5. Fig 6: Installing Output Shaft And Output Shaft Ring Gear
    GF0003695Courtesy of FORD MOTOR CO.
  5. Install the No. 8 bearing.
    6. Fig 7: Locating No. 8 Bearing
    G03888748Courtesy of FORD MOTOR CO.
  6. Install the direct clutch.
    7. Fig 8: Identifying Direct Clutch Pack
    G03888747Courtesy of FORD MOTOR CO.
    NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
  7. Install the reverse band support retaining ring.
    8. Fig 9: Locating Reverse Band Support Retaining Ring
    GF0003696Courtesy of FORD MOTOR CO.
    NOTE: Make sure the band is seated on the anchor pins.
  8. Install the reverse band.
    9. Fig 10: Locating Reverse Band
    GF0003697Courtesy of FORD MOTOR CO.
    NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
    NOTE: The top of the planetary gear support must be below the snap ring groove.
  9. Install the planetary assembly and planetary gear support as a unit.
    • Rotate the output shaft to fully seat the planetary assembly.
    10. Fig 11: Locating Planetary Assembly And Planetary Gear Support
    GF0003698Courtesy of FORD MOTOR CO.
    NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly, both ends of the spring will be visible.
  10. Install the case to the planet support spring located at the 1 o'clock position.
    11. Fig 12: Installing Case To Planet Support Spring
    GF0003699Courtesy of FORD MOTOR CO.
    NOTE: When installing the center support retaining ring the opening of the center support retaining ring should be toward the hole in the case where the turbine shaft speed (TSS) sensor would go.
  11. Install the center support retaining ring.
    12. Fig 13: Locating Center Support Retaining Ring
    GF0003590Courtesy of FORD MOTOR CO.
  12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear 2 piece bearing and the reverse sun gear.
    13. Fig 14: Locating Forward Clutch Sun Gear, No. 5 Forward Clutch Sun Gear Bearing Reverse Sun Gear
    GF0003700Courtesy of FORD MOTOR CO.
  13. Install the No. 4 forward clutch hub bearing.
    14. Fig 15: Locating No. 4 Forward Clutch Hub Bearing
    GF0003701Courtesy of FORD MOTOR CO.
  14. Install the intermediate stub shaft.
    15. Fig 16: Locating Intermediate Stub Shaft
    GF0003702Courtesy of FORD MOTOR CO.
  15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
    16. Fig 17: Installing Forward Clutch Hub And No. 3 Forward Clutch Hub Front Bearing
    GF0003703Courtesy of FORD MOTOR CO.
  16. Install the forward clutch assembly.
    17. Fig 18: Locating Forward Clutch Assembly
    GF0003704Courtesy of FORD MOTOR CO.
    NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
  17. Install the reverse clutch cylinder assembly.
    1. Install the reverse clutch cylinder.
    2. Install the No. 2 forward clutch bearing.
    18. Fig 19: Identifying Reverse Clutch Cylinder Assembly
    GF0003705Courtesy of FORD MOTOR CO.
  18. Install the overdrive band.
    • Position the overdrive band pocket onto the anchor pin.
    19. Fig 20: Locating Overdrive Band
    GF0003706Courtesy of FORD MOTOR CO.
  19. Install the overdrive servo spring.
    1. Install the overdrive servo piston return spring.
    2. Install the overdrive servo piston.
    20. Fig 21: Installing Overdrive Servo Spring
    GF0003707Courtesy of FORD MOTOR CO.
  20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
    21. Fig 22: Verifying Tip Of Piston Assembly Engages Pocket Of Overdrive Band
    GF0003708Courtesy of FORD MOTOR CO.
  21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
    22. Fig 23: Compressing Overdrive Servo Assembly Using Special Tool
    GF0003709Courtesy of FORD MOTOR CO.
  22. Install the intermediate clutch pressure plate.
    23. Fig 24: Locating Intermediate Clutch Pressure Plate
    GF0003710Courtesy of FORD MOTOR CO.
    NOTE: Before assembly, soak the new clutch discs in clean transmission fluid.
  23. Install the intermediate clutch pack and selective steel plate.
    24. Fig 25: Locating Intermediate Clutch Pack And Selective Steel Plate
    GF0003711Courtesy of FORD MOTOR CO.
  24. Using the special tool, check the intermediate clutch clearance.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.

      If the intermediate clutch is not within specification, install a correct selective plate.

      SELECTIVE STEEL PLATES

      Specification
      1.80-1.70 mm (0.071-0.067 in)
      2.05-1.95 mm (0.081-0.077 in)
      2.31-2.20 mm (0.091-0.087 in)
      2.56-2.46 mm (0.101-0.097 in)
    25. Fig 26: Checking Intermediate Clutch Clearance Using Special Tool (307-072)
    GF0040987Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
    1. Position the special tool on the pump case mounting surface.
    2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.

      Use the No. 1 thrust washer chart to select the correct washer.

      NO. 1 THRUST WASHER CHART

      Depth Thickness Color Code
      37.706-38.184 mm (1.485-1.503 in) 1.270-1.372 mm (0.050-0.054 in) Green
      38.185-38.641 mm (1.504-1.521 in) 1.727-1.829 mm (0.068-0.072 in) Yellow
      38.642-39.073 mm (1.522-1.538 in) 2.159-2.261 mm (0.085-0.089 in) Natural
      39.074-39.505 mm (1.539-1.555 in) 2.591-2.692 mm (0.102-0.106 in) Red
      39.506-40.165 mm (1.556-1.581 in) 3.023-3.124 mm (0.119-0.123 in) Blue
    26. Fig 27: Measuring Clearance For No.1 Front Pump Thrust Washer Using Special Tool
    GF0003713Courtesy of FORD MOTOR CO.
  26. Install the intermediate anti-rattle clip, if equipped.
    27. Fig 28: Identifying Intermediate Clutch Anti-Rattle Clip
    G03888735Courtesy of FORD MOTOR CO.
    NOTE: Align the intermediate clutch return spring pack indent with the pump check ball.
  27. Install the intermediate clutch return spring pack.
    28. Fig 29: Locating Intermediate Clutch Piston Return Spring Pack
    GF0003583Courtesy of FORD MOTOR CO.
  28. Install the No. 1 front pump support thrust washer.
    • Use petroleum jelly to hold the washer in place.
    29. Fig 30: Locating No. 1 Front Pump Support Thrust Washer
    GF0003714Courtesy of FORD MOTOR CO.
    NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.
  29. Install an alignment pin at the top of the case.
    30. Fig 31: Locating Alignment Pin
    GF0003715Courtesy of FORD MOTOR CO.
    NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
  30. Install the pump gasket.
    31. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
  31. Install the pump assembly.
    32. Fig 32: Identifying Pump Assembly
    GF0003716Courtesy of FORD MOTOR CO.
  32. Remove the alignment pin and install the front pump bolts.
    • Alternate bolt tightening to set the pump.
      • Tighten to 27 Nm (20 lb-ft).
    33. Fig 33: Removing Alignment Pin And Front Pump Bolts
    GF0003717Courtesy of FORD MOTOR CO.
  33. Rotate the transmission to the horizontal position.
  34. Install the parking pawl.
    1. Position the parking pawl return spring.
    2. Position the parking pawl.
    3. Install the parking pawl shaft.
    35. Fig 34: Identifying Parking Pawl Shaft
    GF0003718Courtesy of FORD MOTOR CO.
  35. Install a new extension housing gasket and the extension housing.
    1. Position the extension housing.
    2. Install the 4 bolts and 2 nuts.
      • Tighten to 28 Nm (21 lb-ft).
    36. Fig 35: Extension Housing & Bolts
    GF0003501Courtesy of FORD MOTOR CO.
    NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock position.
  36. Using the special tool, install a new extension housing seal.
    37. Fig 36: Installing Extension Housing Seal
    GF0003506Courtesy of FORD MOTOR CO.
  37. Install the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
    1. Install the TSS speed sensor and the bolt.
      • Tighten to 11 Nm (8 lb-ft).
    2. Install the OSS speed sensor and the bolt.
      • Tighten to 12 Nm (9 lb-ft).
    38. Fig 37: TSS Speed Sensor, OSS Speed Sensor & Bolt
    GF0014096Courtesy of FORD MOTOR CO.
  38. Using the special tool, install the manual control lever seal.
    39. Fig 38: Installing Manual Control Lever Seal Using Special Tool
    GF0003720Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean transmission fluid.
  39. Lubricate the EPC solenoid and install it into the case.
    40. Fig 39: Installing EPC Solenoid Into Case
    GF0003721Courtesy of FORD MOTOR CO.
  40. Install the manual control valve detent lever and parking lever actuating rod.
    41. Fig 40: Locating Manual Valve Detent Lever And Parking Lever Actuating Rod
    GF0003722Courtesy of FORD MOTOR CO.
  41. Install the manual control lever shaft.
    1. Slide the manual control lever shaft into the case.
    2. Install the manual control lever shaft inner nut.
      • Tighten to 32 Nm (24 lb-ft).
    3. Install the manual control lever shaft retaining pin.
    42. Fig 41: Installing Manual Control Lever Shaft
    GF0003723Courtesy of FORD MOTOR CO.
  42. Install the 1-2 accumulator piston assembly.
    1. Install the 1-2 accumulator upper spring.
    2. Install the 1-2 accumulator.
    3. Install the inner and outer 1-2 lower accumulator spring.
    4. Install the 1-2 accumulator cover and seal.
    43. Fig 42: Identifying 1-2 Accumulator Cover And Seal
    GF0003724Courtesy of FORD MOTOR CO.
  43. Install the 1-2 accumulator retaining ring.
    44. Fig 43: Locating Accumulator Piston Retaining Ring
    G03888654Courtesy of FORD MOTOR CO.
    NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
    NOTE: Lubricate the reverse piston seal with clean transmission fluid to facilitate assembly and prevent damage to the seal.
    NOTE: Do not install the reverse servo piston cover and seal at this time.
  44. Install the reverse servo piston and rod assembly.
    45. Fig 44: Locating Reverse Servo Piston And Return Spring
    GF0003725Courtesy of FORD MOTOR CO.
  45. Install the special tool.
    46. Fig 45: Identifying Special Tool
    GF0003726Courtesy of FORD MOTOR CO.
  46. Install the special tool.
    • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
    47. Fig 46: Identifying Special Tools
    GF0003727Courtesy of FORD MOTOR CO.
  47. Loosen the bolt until the piston stops against the tool.
    48. Fig 47: Loosening Bolt Until Piston Stops Against Tool
    GF0003728Courtesy of FORD MOTOR CO.
  48. Verify that the amount of piston travel on the dial indicator is within specification.
    49. Fig 48: Verifying Amount Of Piston Travel On Dial Indicator
    GF0003729Courtesy of FORD MOTOR CO.
  49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
    1. One groove
    2. Two grooves
    3. Three grooves
    50. Fig 49: Identifying Servo Piston Travel Specification
    GF0003526Courtesy of FORD MOTOR CO.
  50. Remove the special tools.
    51. Fig 50: Identifying Special Tools
    GF0003730Courtesy of FORD MOTOR CO.
  51. Install the reverse servo assembly.
    1. Install the rod.
    2. Install the piston assembly.
    3. Install the reverse servo piston cover and seal.
    52. Fig 51: Identifying Reverse Servo Assembly
    GF0003731Courtesy of FORD MOTOR CO.
  52. Using the special tool, install the reverse servo retaining ring.
    1. Compress the reverse band servo.
    2. Install the reverse band servo retaining ring.
    53. Fig 52: Compressing Reverse Band Servo Using Special Tool
    GF0003732Courtesy of FORD MOTOR CO.
  53. Install the 2-3 accumulator assembly.
    1. Install the accumulator piston.
    2. Install the accumulator piston spring.
    3. Install the accumulator spring retainer.
    54. Fig 53: Identifying 2-3 Accumulator Assembly
    GF0003733Courtesy of FORD MOTOR CO.
  54. Using the special tools, apply regulated air pressure to the test ports. Verify that the components are applied and released.
    55. Fig 54: Applying Air Pressure To Test Ports Using Special Tools With Pressure Specification
    GF0003734Courtesy of FORD MOTOR CO.
    NOTE: The tab on the electrical connector is secured by main control valve body.
  55. Install the electrical connector into the case.
    56. Fig 55: Installing Electrical Connector Into Case
    GF0003735Courtesy of FORD MOTOR CO.
    NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
  56. Align the main control valve body alignment bolts and position the main control valve body.
    57. Fig 56: Positioning Main Control Valve Body Gasket And Main Control Valve Body
    GF0003494Courtesy of FORD MOTOR CO.
    NOTE: The main control valve body bolts will be tightened in later steps.
  57. Loosely install the 11 long main control valve body bolts.
    58. Fig 57: Locating Long Main Control Valve Body Bolts
    G04584287Courtesy of FORD MOTOR CO.
  58. Install the EPC solenoid bracket and loosely install the bolt.
    59. Fig 58: EPC Solenoid Bracket And Bolt
    G03888951Courtesy of FORD MOTOR CO.
    NOTE: The main control valve body bolts will be tightened in later steps.
  59. Loosely install the 12 short main control valve body bolts.
    60. Fig 59: Locating 12 Short Main Control Valve Body Bolts
    G03882434Courtesy of FORD MOTOR CO.
  60. Install the manual control valve detent lever spring and loosely install the bolt.
    61. Fig 60: Identifying Manual Control Valve Detent Lever Spring Bolts
    G04584504Courtesy of FORD MOTOR CO.
  61. Tighten the bolts in the sequence shown in the illustration.
    • Tighten to 10 Nm (89 lb-in).
    62. Fig 61: Main Control Valve Body Bolt Torque Sequence
    GF0003496Courtesy of FORD MOTOR CO.
  62. Inspect the molded lead frame for damage.
    • Using the special tool, check all the molded lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
    • If the special tool passes through any molded lead frame connector pins or does not feel like it makes a good contact, install a new molded lead frame.
    63. Fig 62: Locating Lead Frame Connector Pins
    G04584207Courtesy of FORD MOTOR CO.
  63. Connect the molded lead frame to the solenoids.
    • Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place.
    • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
    64. Fig 63: Connecting Molded Lead Frame To Solenoids
    GF0003497Courtesy of FORD MOTOR CO.
  64. Install the transmission fluid filter and seal assembly.
    65. Fig 64: Locating Fluid Filter And Seal Assembly
    GF0003736Courtesy of FORD MOTOR CO.
  65. Position the pan magnet into the transmission fluid pan.
    66. Fig 65: Locating Pan Magnet In Transmission Fluid Pan
    G03888537Courtesy of FORD MOTOR CO.
    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused.
  66. Install the transmission fluid pan and gasket.
    1. Position the transmission fluid pan and transmission fluid pan gasket in place.
    2. Install the transmission fluid pan bolts.
      • Tighten to 14 Nm (10 lb-ft).
    67. Fig 66: Transmission Fluid Pan & Bolts
    GF0014097Courtesy of FORD MOTOR CO.
  67. Loosely install the digital transmission range (TR) sensor and bolts.
    68. Fig 67: Identifying Digital TR Sensor And Bolts
    G04584370Courtesy of FORD MOTOR CO.
    NOTE: The tool is designed to fit snugly.
    NOTE: The manual control lever must be in the NEUTRAL position.
  68. Using the special tool, align the digital TR sensor slots.
    69. Fig 68: Aligning Digital TR Sensor Slots Using Special Tool (307-351)
    G04584268Courtesy of FORD MOTOR CO.
    CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
  69. Tighten the bolts in an alternating sequence.
    • Tighten to 9 Nm (80 lb-in).
    70. Fig 69: Aligning Digital TR Sensor Slots With Special Tool
    G04584269Courtesy of FORD MOTOR CO.
  70. Lightly lubricate the converter hub with clean transmission fluid.
    71. Fig 70: Lubricating Converter Hub
    GF0003737Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
  71. Using the special tools, install the torque converter.
    72. Fig 71: Removing/Installing Torque Converter
    GF0003560Courtesy of FORD MOTOR CO.
  72. Lubricate the torque converter pilot hub with multi-purpose grease.
    73. Fig 72: Lubricating Converter Pilot Hub
    GF0003738Courtesy of FORD MOTOR CO.
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