Assembly

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.

Assembly






1. If rear case bushing was removed, position replacement rear case bushing on Extension Housing Seal Replacer T61L-7657-A and install in bushing bore through the front of the case.






2. Thread Impact Slide Hammer T50T-100-A into Extension Housing Seal Replacer T61L-7657-A through the back of the case. Install the rear case bushing.






3. With transmission in the vertical position, coat No. 9 case rear bearing with petroleum jelly and install the No. 9 case rear bearing on the transmission case boss.






4. Install output shaft, output shaft ring gear and direct clutch as an assembly.






5. Install retaining ring that supports reverse clutch band.






6. Install the reverse clutch band. Ensure reverse clutch band is seated on anchor pins.

7. NOTE: 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. Top of planetary gear support should be below snap ring groove.

Install planetary assembly and planetary gear support as a unit.

8. Align notch in planetary gear support with overdrive band anchor pin.






9. Rotate the output shaft, if necessary, to align the planetary assembly splines with the direct clutch hub splines.






10. Install the case to planet support spring using a screwdriver to position.






11. Install center support retaining ring. Reference retaining ring end tab to anchor pin location.






12. Install forward clutch sun gear, No. 5 forward clutch sun gear bearing, reverse sun gear and No. 4 forward clutch hub bearing.






13. Install intermediate stub shaft.






14. Install forward clutch hub and No. 3 forward clutch hub front bearing.






15. Install forward clutch assembly.






16. NOTE: Wiggle the input shaft while engaging the reverse clutch splines. Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.

Install reverse clutch cylinder assembly and No. 2 forward clutch bearing.











17. Install overdrive band over reverse clutch assembly and position the pocket of the overdrive band against overdrive band anchor pin. Install overdrive servo piston return spring and overdrive servo piston assembly. Verify tip of piston assembly engages the pocket of overdrive band. Using Servo Piston Remover/Replacer T92P-70023-A, install piston assembly into the case and compress overdrive servo piston return spring.






18. Make sure overdrive band anchor pin and tip of the overdrive servo piston assembly are properly positioned against band pockets. Tighten tool until piston is below retaining ring groove and install retaining ring, then remove tool.






19. Install intermediate clutch as follows:

a. Intermediate clutch pressure plate is the thickest. Install this first with chamfer side down.
b. Clutch plates.
c. Perform intermediate clutch selective steel plate procedure.






20. With proper intermediate plates selected and installed, perform end clearance check for No. 1 front pump support thrust washer using the same tools.

21. NOTE: Maintain downward pressure on clutch pack while measuring depth.

Measure the intermediate clutch clearance using Depth Micrometer D80P- 4201-A or equivalent and Gauge Bar T80L-77003-A.

22. Set the gauge bar across the pump case mounting surfaces. The depth at the intermediate clutch separator plate is:

- 42.0-42.4mm (1.643-1.677 inch)

Check the clearance again 180 degrees opposite to ensure the average depth is within tolerance.

If the depth is not within tolerance, the following size selective steel plates are available:

Selective Steel Plates
1.80-1.7mm (0.071-0.067 Inch)
2.05-1.95mm (0.081-0.077 Inch)
2.31-2.20mm (0.091-0.087 Inch)
2.56-2.46mm (0.101-0.097 Inch)

Install correct plate and check clearance.






23. Position the Depth Micrometer D80P-4201-A or equivalent on Gauge Bar T80L-77003-A so that the depth is measured at the reverse clutch drum thrust face. Check the end play 180 degrees opposite to determine the average depth.











24. Install No. 1 front pump support thrust washer on pump body. Use petroleum jelly to hold in place.

25. Install oil pump gasket. Make sure oil pump gasket is positioned and case passages are covered.






26. To maintain pump to case alignment, use a fabricated M8-1.25mm bolt (head removed) as a guide. Install in the 12 o'clock position using petroleum jelly on pump to case seal surfaces to aid pump installation.






27. To aid assembly, grasp input shaft and wiggle shaft while pressing down on pump.






28. Remove alignment bolt and install pump to case bolts. Alternate bolt tightening to draw the pump fully into the case. Tighten to 20-26 Nm (15-19 lb-ft).






29. Place transmission in the horizontal position. Install parking pawl and parking pawl return spring. Slide parking pawl shaft into case through parking pawl.






30. Install output shaft speed sensor (OSS). Tighten bolt to 7-10 Nm (5-7 lb-ft).






31. Install manual control lever oil seal using Shift Lever Seal Replacer T74P-77498-A.






32. Install EPC solenoid.

33. Install new extension housing gasket and extension housing. Tighten bolts to 25-30 Nm (18-22 lb-ft).






34. Install extension housing seal.






35. Position manual valve detent lever and parking lever actuating rod into case. Parking lever actuating rod must be positioned over parking pawl.

36. Slide manual control lever shaft into case and position through detent. Install inner nut and tighten to 26-37 Nm (20-27 lb-ft).

37. Install manual lever shaft retaining pin.






38. Install screen into case (either end first).

39. NOTE: This is not an ordinary installation procedure and does not compensate for band wear.

Install reverse band servo spring and reverse band servo piston and rod. When piston and rod assembly replacement becomes necessary or when reverse band has been replaced, determine the correct length of the reverse servo piston and rod, and proceed as follows:

a. Use MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid to lubricate the reverse piston seal to facilitate assembly and to prevent damage to the seal.
b. Install the reverse servo piston and return spring. Do not install the piston cover or retaining ring.






c. Install Servo Piston Selection Tool T80L-77030-A. Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A to 5.6 Nm (50 lb-in).






d. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent and position the indicator stem on the flat portion of the piston. Zero the dial indicator.
e. Thread the bolt out of the selector tool until the piston stops against the bottom of the tool.
f. Read the amount of piston travel on the dial indicator.
- If the travel is 2.845-6.020mm (0.112-0.237 inch), the piston length is within specification.
- If the travel is not within specification, selective pistons are available in the following lengths:
ID
74.56mm (2.936 inch) 1 groove
75.92mm (2.989 inch) 2 grooves
77.29mm (3.043 inch) 3 grooves
Length of rod measured from piston surface to end of rod.
Select the proper rod to bring the servo piston travel within specification.
g. Use MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid to lubricate the cover seal to facilitate assembly and to prevent damage to the seal.
h. Remove the servo selection tool and dial indicator.






40. Tighten screw on Servo Piston Remover/Replacer T92P-70023-A to allow enough clearance to install retaining ring.






41. NOTE: Retainer is secured by main control.

Install the following components for 2-3 accumulator:

- 2-3 accumulator piston upper seal
- 2-3 shift accumulator piston
- 2-3 accumulator piston lower seal
- 2-3 shift accumulator piston spring
- 2-3 shift accumulator spring retainer












42. Install the following components for 1-2 accumulator:

- 1-2 shift spring
- 1-2 shift accumulator piston seal
- 1-2 shift accumulator piston
- 1-2 shift accumulator lower seal
- 1-2 shift spring
- 1-2 accumulator cover and seal assembly
- Internal retaining ring






43. NOTE: Tab on connector is secured by main control.

Align and install wiring connector into case. Inspect O-ring and replace if required.

44. Position main control valve body using the two alignment bolts as a guide. Ensure coasting booster valve shuttle balls are in the correct locations.






45. Install the solenoid retainer. Loosely install one long 6mm bolt.

46. Loosely install 11 long and 12 short bolts.






47. Install manual valve detent spring and one bolt.






48. Tighten main control valve body bolts to 9-11 Nm (80-100 lb-in).






49. Connect wiring connectors to transmission fluid temperature sensor, shift solenoids, EPC solenoid and TCC solenoid.






50. Install transmission fluid filter.






51. Install transmission range (TR) sensor on manual control lever shaft and loosely install screws.






52. NOTE: PARK is the last detent when the manual control lever is full forward. Return two detents toward output shaft for NEUTRAL.

Position manual control lever in NEUTRAL. Insert Transmission Range (TR) Sensor Alignment Tool (MLPS Alignment Tool) T93P-70010-A into slots. Align all three slots on TR sensor with three tabs on tool.

53. Tighten TR sensor screws to 12-15 Nm (9-11 lb-ft).

54. Install the manual control lever on the manual control lever shaft and install the outer nut. Tighten the outer nut to 26-37 Nm (20-27 lb-ft).






55. Install new oil pan to case gasket and transmission fluid pan. Tighten all transmission pan screws to 12-15 Nm (9-11 lb-ft).