Part 1

Special Tools:

ASSEMBLY

NOTE: Soak all friction clutch plates in clean Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON equivalent. Prior to installation, lightly lubricate all 0-ring seals with clean Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON equivalent. Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

1. Mount the (A) case to the (B) Car/Truck Engine Repair Stand.

2. If removed, install the (A) short fluid inlet tube using the (B) Oil Filler Tube Replacer.

3. Install the reverse clutch piston in the case until it is fully seated in the case.

CAUTION: Use care not to misalign the reverse clutch piston in the case bore.

NOTE: Coat the reverse clutch piston seals with petroleum jelly.

4. Install the (A) reverse clutch return spring assembly and the (B) low/reverse one-way clutch inner race with the (C) lubrication hole on the face in the 5 o'clock position.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

5. Install two 5/16-24 x 3 inch bolts with nuts in to the low/reverse one way clutch inner race.
1 Hold the nut.
2 Turn the bolt to compress the low/reverse piston return spring.

6. Install three of the one way clutch inner race bolts and remove the two 5/16-24 x 3 bolts.

7. Install the remaining bolts retaining the low/reverse one-way clutch inner race to the case.

NOTE: Alternate tightening bolts from one side to the other (not in a circle).

8. Install the (A) cushion spring; the (B) reverse clutch pack, starting with an external spline steel plate and alternating with internal splined friction plates; the (C) reverse clutch pressure plate; and the (D) reverse clutch pressure plate retainer snap ring, with the (E) ring opening between the 12 o'clock and 3 o'clock positions.

CAUTION: The number of plates is model-dependent.

NOTE: No stack-up clearance measurement is required. Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

9. Install the No. 13 parking gear thrust washer.
^ Make sure the (A) bronze side of washer is facing outward.
^ Make sure the washer is seated against the (B) tab.

NOTE: Lubricate the steel side of the thrust washer with petroleum jelly.

10. Slide the (A) park gear onto the (B) output shaft with the thrust surface forward.

11. Install the output shaft.

12. Install the (A) reverse clutch hub and the (B) low one-way clutch assembly over the (C) low/reverse one-way clutch inner race by pressing the hub inward and rotating it clockwise to seat fully.

NOTE: When the reverse clutch and the low one-way clutch are installed, the reverse clutch should rotate clockwise. The one-way clutch will hold and not let the clutch hub rotate counterclockwise.

13. Install the (A) No. 12 thrust bearing onto the (B) rear surface of hub assembly.

NOTE: Lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

14. Install the output shaft ring gear assembly.

15. Install the new output shaft retaining ring onto the output shaft.

WARNING: DO NOT OVEREXTEND THE OUTPUT SHAFT RETAINING RING WHEN INSTALLING. MAKE SURE THE OUTPUT SHAFT RETAINING RING IS SECURELY SEATED IN THE GROOVE.

16. Install the (A) reverse planet assembly with the (B) No. 10B and the (C) No. 11 reverse planet thrust washers.

17. Install the reverse planet retaining ring into the reverse clutch hub, making sure the retaining ring is fully seated.

18. Verify the No. 8A intermediate brake drum thrust washer is installed.

NOTE: Tabs on the thrust washer must engage the slots on the intermediate brake drum. Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.

19. Verify the No. 8B forward clutch needle bearing is installed.

NOTE: The large outer diameter radius of the needle bearing must be installed facing inward. Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.

20. Install the (A) forward clutch cylinder assembly onto the (B) intermediate brake drum by rotating it until fully seated.

21. Verify the No. 9A forward clutch thrust bearing is installed (black side facing up).

NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

22. Place the (A) No. 8C forward clutch hub thrust washer onto the (B) forward hub and ring gear assembly.

NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.

23. Place the (A) forward hub and ring gear assembly into the (B) intermediate brake drum and forward clutch cylinder assemblies.

24. Verify the No. 10A forward planet assembly thrust bearing is installed.

NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

25. Place the (A) forward planet assembly into the (B) forward hub and ring gear assembly.

26. Verify the No. 9B forward clutch thrust bearing is installed.

NOTE: The thrust bearing notched inner race must face outward and the large outer diameter radius must face inward.

27. Align the (A) notch with the (B) lug and position the (C) input shell onto the (D) intermediate brake drum. Rotate the input shell until fully seated.

28. Using the (A) Clutch Remover/Replacer, lower the (C) direct clutch, forward clutch and (B) input shell as an assembly into the case. Remove the Clutch Remover/Replacer.

WARNING: WHEN INSTALLING THE (A) CLUTCH REMOVER/REPLACER, THE HOOKS ON THE CROSSBAR MUST ENGAGE THE NOTCHES ON THE (B) INPUT SHELL TO PREVENT INJURY OR DAMAGE.

29. Install the intermediate band with the (A) ear resting on the (B) anchor pin.

30. Gently press the intermediate band servo assembly piston into the case bore.

NOTE: Prior to installation, lightly lubricate the piston seal with clean Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON equivalent.

31. Install the (A) intermediate clutch pressure plate; the (B) intermediate clutch pack, starting with an internal spline plate and alternating with external spline plates; and the (C) intermediate clutch pressure apply plate, with blank area (no teeth) in the 6 o'clock and 12 o'clock positions.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

32. Hold the (A) thrust washer against the (B) center support assembly. Extend the (C) probe of the (D) depth micrometer into the (E) hole until flush with the (F) No. 6 center support thrust washer surface. Record this as (G) reading 1.

NOTE: The following stack-up check measurement indicates not only the amount of space existing between the center support assembly and the intermediate brake drum, it also will indicate if the unit has been properly built to this point.

33. Install the (A) center support assembly with the (B) feed holes aligned.

CAUTION: Do not misalign the center support in the case bore. This can damage the case bore.

NOTE: Make sure the No. 6 center support thrust washer is on the center support prior to installation.

34. Extend the (A) probe of the (B) depth micrometer into the hole in the (C) center support assembly until flush with the (D) No. 6 center support thrust washer. Record this as (E) reading 2.

35. Subtract (A) reading 1 from (B) reading 2. Record this as reading 3. If the final dimension is outside specified limits, this indicates improper assembly.

36. Install the new feedbolts.

CAUTION: Do not tighten bolts at this time. Transmission failure may occur.

37. Install the (A) intermediate clutch return spring with the dished surface inward and one (B) spring leg in the 6 o'clock position.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

38. Install the (A) intermediate/overdrive cylinder assembly with the (B) feed holes aligned.

CAUTION: Do not misalign the intermediate/overdrive cylinder assembly. This can damage the case bore.

39. Position the (A) intermediate/overdrive cylinder retaining ring over the intermediate/overdrive cylinder with the (B) ring opening in the 6 o'clock position to allow proper fluid drainback.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

40. Position the (A) Clutch Spring Fixture Plate, the (B) Clutch Spring Fixture Adapter and the (C) Clutch Spring Compressor Bar onto the (D) intermediate/overdrive cylinder assembly. Install the (E) screws into the threaded holes in the pump face.

NOTE: Refer to the tool chart preceding Step 1 of this procedure for proper tool number identification. Also refer to the illustration for tool installation. No stack-up clearance measurement is required.

41. Tighten the center bolt.

42. Seat the intermediate/overdrive cylinder retaining ring into the case ring groove with the ring opening in the 6 o'clock position.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

43. Install, but do not tighten, new intermediate/overdrive cylinder feedbolt.

CAUTION: Do not tighten bolts at this time. Transmission failure could occur.

44. Loosen the (A) center bolt and remove the (B) Clutch Spring Fixture Assembly.

45. Install the No. 5 overdrive center shaft thrust bearing assembly, overdrive center shaft, overdrive ring gear, overdrive planet assembly, and coast clutch cylinder as an assembly.

46. Install the (A) overdrive clutch pack starting with a steel plate and alternating with friction plates. Install the overdrive clutch pressure plate with the (B) dot facing outward and in the 12 o'clock position.

NOTE: The number of plates in the clutch pack is model-dependent. Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

47. Install the overdrive clutch pressure plate retainer snap ring with the ring opening in the 6 o'clock position.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

48. Check the stack-up clearance.
^ Using a feeler gauge, check the stack-up clearance in 3 places, 120 degrees apart.
^ If the clearance is not to specification, install the correct selective overdrive clutch pressure plate retainer snap ring and recheck the clearance. Refer to the Clutch Plate Usage and Clearance Specification Chart for selective snap ring thicknesses and part numbers.

49. Install the new (A) pump gasket, aligning the (B) gasket and case holes.

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.