Part 2 of 2

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






72. CAUTION: Fluid Pump Alignment Set T74P-77103-X must be used to properly align the front pump support and gear to the fluid pump adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Select the gauge that will be the snuggest fit when placed over the fluid pump support and gear.






73. Thread the gauge into Pump Alignment Handle T74P-77103-H (Part of T74P-77103-X, Fluid Pump Alignment Set). Slide the tool over the front pump support and gear until it bottoms out in the pump gear pocket. This centers the pump to the converter housing.






74. Use a Torx 40 socket wrench to tighten the six M8 x 35mm fluid pump support and gear-to-converter housing screws. Tighten the fluid pump support and gear-to-converter housing screws in a star pattern to 22-28 Nm (16-21 lb-ft). Remove the Pump Alignment Handle.











75. NOTE: The overdrive brake drum seal ring gaps must be placed 180 degrees apart. Verify correct seal installation. Be sure seal grooves are clean and free of burrs.

Install the overdrive brake drum seal rings.






76. Install a new fluid pump seal ring.






77. NOTE: Make sure the fluid pump seal ring is installed on the converter housing and pump assembly.

Place a new fluid pump gasket on the fluid pump adapter plate as shown. Use petroleum jelly to hold the fluid pump gasket in place.






78. Install the correct No. 1 fluid pump thrust washer on the fluid pump support and gear. Use petroleum jelly to hold the washer in place.











79. NOTE: Verify correct seal installation. Be sure seal grooves are clean and free of burrs.

Turn the converter housing over and install the front pump support seal ring.






80. Install the input shaft as a guide for the converter housing and fluid pump support and gear assembly. Install the Converter Guide Pins T95L-7902-A as shown.






81. Install the converter housing and fluid pump support and gear assembly (with the fluid pump gasket) and the No. 1 fluid pump thrust washer to the case.






82. NOTE: Lubricate O-rings on converter housing screws.

Remove Converter Guide Pins and use a 17mm socket wrench to install the eight new M10 x 33mm converter housing-to-case screws. Tighten the converter housing-to-case screws in a star pattern to 36-52 Nm (27-39 lb-ft).


83. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Rotate the transmission assembly so the fluid pan rail is facing up.











84. CAUTION: Do not damage the overdrive servo cover to case O-ring during installation. Do not press the overdrive servo cover and O-ring past the relief hole in the case. O-ring damage may occur.

Install the overdrive servo piston spring, servo piston and rod assembly, servo cover to case O-ring with servo cover.


85. NOTE: The J-hook must be in the appropriate hole for the servo being removed, and tool number should be facing up.

Install Servo Cover Compressor T95L-77028-A over the overdrive servo cover at the fluid pan rail. Tighten the screws.






86. Use a 1/2-inch wrench to tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.






87. Carefully install the servo cover retaining ring.

88. CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.

89. Remove Servo Cover Compressor T95L-77028-A.











90. CAUTION: Do not damage the intermediate servo cover to case O-ring during installation. Do not press the intermediate servo cover and seal assembly and O-ring past the relief hole in the case. O-ring damage may occur.

Install the intermediate servo piston spring, servo piston and rod assembly, servo cover to case O-ring with servo cover assembly with O-ring.

91. NOTE: The J-hook must be in the appropriate hole for the servo being removed, and tool number should be facing up.

Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail. Tighten the screws.






92. Use a 1/2-inch wrench to tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.






93. Carefully install the intermediate servo cover retaining ring.

94. CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo piston spring is unloaded.

95. Remove Servo Cover Compressor T95L-77028-A.






96. CAUTION: Install, but do not tighten, a new locknut on the band adjusting screw. Apply petroleum jelly to the locknut seal.

CAUTION: The overdrive servo must be installed prior to band adjustment.

Tighten the overdrive band adjusting screw using Band Adjustment Torque Wrench Set T71P-77370-A. The wrench will click at 14 Nm (10 lb-ft). Back off the band adjusting screw exactly two turns and hold that position. Tighten the overdrive band locknut to 47-61 Nm (35-45 lb-ft) using a 19mm wrench.






97. CAUTION: Install, but do not tighten, a new locknut on the band adjusting screw. Apply petroleum jelly to the locknut seal.

CAUTION: Intermediate servo must be installed prior to band adjustment.

Tighten the band adjusting screw using Band Adjustment Torque Wrench Set T71P-77370-A. The wrench will click at 14 Nm (10 lb-ft). Back off the band adjusting screw exactly two and one-half turns and hold that position. Tighten the intermediate band locknut to 47-61 Nm (35-45 lb-ft) using a 19mm wrench.






98. NOTE: Make sure the tab is in the lock position.

Lubricate and install the 16-pin connector assembly through the case until a click is heard.






99. CAUTION: Do not overstretch the 16-pin connector assembly retaining spring.

Install the 16-pin connector assembly retaining spring.






100. NOTE: Align the slot on the turbine shaft speed (TSS) sensor connector with the slot on the 16-pin connector assembly.

Carefully install the TSS sensor connector into the 16-pin connector assembly.






101. Carefully insert TSS sensor connector wires into the retaining slot on the 16-pin case connector.






102. Install the valve body guide pins into the case in the positions shown.






103. NOTE: Ensure main control assembly gasket is properly aligned.


Install the main control assembly on the case. Align the manual valve with the manual valve inner lever pin as shown.

Main Control Assembly Screws and Locations:

104. Install four M6 x 45mm main control assembly-to-case screws in location A. Fingertighten.

105. Install two M6 x 35mm main control assembly-to-case screws in location B. Fingertighten.

106. Install one M6 x 30mm main control assembly-to-case screw in location C. Fingertighten.

107. Remove both Valve Body Guide pins T95L-70010-B and T95L-70010-C.

108. Install sixteen M6 x 40mm main control assembly-to-case screws in location D. Finger tighten.

Tightening Sequence:

109. Tighten all main control assembly-to-case screws including reverse servo cover sequence (1R, 2R, 3R and 4R), to 8-11 Nm (71-97 lb-in) in sequence shown, using a 10mm socket wrench.






110. Install the manual valve detent spring. Install the manual valve detent spring screw in location A. Tighten the manual valve detent spring screw to 8-11 Nm (71-97 lb-in).

111. NOTE: Perform Steps 105 through 112 only if rear reverse servo piston and rod is to be checked.

Remove the reverse servo piston and rod from the case.

112. NOTE: An A4LD Reverse Servo Return Spring D4ZZ-7D031-A is to be used only as a test spring.

Install the reverse servo piston and rod into the servo bore along with a reverse servo return spring.

113. Install a new reverse servo separator plate cover gasket. Install Servo Rod Selecting Gauge T74P-77190-A and tighten with the three screws.

114. Tighten the servo gauge adjusting screw to 4 Nm (35 lb-in).






115. Install Dial Indicator with Bracketry TOOL-4201-C or equivalent on the transmission case. Position the indicator on the piston pad. Set the dial indicator to zero.

116. NOTE: If the piston travel in this step is 3-5.6mm (0.120-0.220 inch), it is within specification. If the piston travel is greater than 5.6mm (0.220 inch), use the next longer piston and rod. If the piston travel is less than 3mm (0.120 inch), use the next shorter piston and rod.

Back out the servo gauge adjusting screw until it bottoms out on the tool. Record the distance the servo piston traveled.

117. CAUTION: Make sure the test spring is removed after this step.

Use the above procedure to check the piston travel with the newly selected reverse band servo piston and rod (if required) to make sure that the piston travel is 3-5.6mm (0.120-0.220 inch).

Remove the servo gauge and the reverse band servo return spring.

Length - mm Length - Inches I.D.
54/53 2.112/2.085 1 Groove
51/50 2.014/1.986 No Groove
49/48 1.915/1.888 2 Grooves

NOTE: Grooves are located on reverse servo rod.






118. CAUTION: The reverse servo test spring must be removed.

Install the reverse servo cover and the four reverse servo cover-to-case screws. Tighten the reverse servo cover-to-case screws to 9-13 Nm (80-115 lb-in) in the sequence shown.






119. Carefully press down to install the solenoid connectors on the solenoids as shown.






120. CAUTION: Excessive pressure may break the locating pins.

Install the wiring loom protector and guide. Align the pins in the holes of the solenoid clamps and gently push down.






121. CAUTION: Lubricate the fluid filter O-rings with MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid, or they may be damaged.

Install a new fluid filter assembly into the main control assembly. Install one E length M6 x 55 fluid filter assembly-to-main control assembly screw and tighten to 8-11 Nm (71-97 lb-in).











122. Install Rotunda Transmission Tester 007-00085 on the transmission 16-pin case connector.

123. Use Rotunda Transmission Tester 007-00085 and the 4R44E/4R55E Cable/Overlay 007-00106 to perform the solenoid static function check bench testing procedures. Refer to Diagnosis and Testing in this section. This procedure will verify the electrical function of all solenoids prior to installing the fluid pan.






124. Depress the lock tab and remove the transmission tester.






125. Position a new fluid pan gasket on the case fluid pan rail.






126. Install the fluid pan on top of the gasket. Use a 13mm socket wrench to install the eighteen M8 x 16mm fluid pan-to-case screws. Tighten the fluid pan-to-case screws to 11-13 Nm (8-10 lb-ft).






127. NOTE: A transmission heat shield is on all 4.0L applications.

Align transmission heat shield retaining clips over fluid pan rail and install the heat shield on the fluid pan rail.






128. Install the transmission heat shield nut. Tighten the transmission heat shield nut to 8-11 Nm (71-97 lb-in).






129. Remove the transmission from the bench fixture pivot. Place the transmission on a flat surface. Remove the fixture and adapter plate.

130. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup.

NOTE: Use petroleum jelly to hold the gasket in place.

NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.

Install a new extension housing gasket on the case.






131. Install the parking pawl, pawl return spring and pawl shaft into the extension housing.






132. Install the extension housing. Install the five M10 x 30mm extension housing-to-case screws and one stud. Tighten the extension housing-to-case screws and stud to 36-52 Nm (27-39 lb-ft).






133. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.

CAUTION: Tool will bottom when bushing is in the proper position.

NOTE: The lube hole should be located at the 3 o'clock position with view extension from the rear.

NOTE: Install the extension housing bushing only if it was removed in disassembly.

Install the extension housing bushing using Extension Housing Bushing Replacer T77L-7697-F.






134. Install the extension housing seal using Extension Housing Seal Replacer T74P-77052-A.






135. Install the transmission range (TR) sensor on the manual lever. Install the two TR sensor screws and finger tighten. Rotate the manual lever to the neutral position (two detents rearward).






136. Install TR Sensor Alignment Tool (MLPS Alignment Tool) T93P-70010-A into the three slots on the TR sensor. Tighten the TR sensor-to-case screws to 8-11 Nm (71-97 lb-in). Remove the alignment tool.






137. Install the manual control outer lever and manual control outer lever nut. Tighten the manual control outer lever nut to 41-54 Nm (30-40 lb-ft).






138. CAUTION: The splines are not the same on both ends. The shaft end with the shorter splines goes into the front pump support and gear.

Install the input shaft into the front pump support and gear.






139. Insert Front Pump Seal Sizing Tool T95L-70010-G into pump drive gear to make sure the drive gear O-ring is properly seated prior to installing the torque converter. Remove tool.






140. WARNING: THE TORQUE CONVERTER CAN FALL OUT IF THE TRANSMISSION IS TIPPED.

CAUTION: Do not damage the pump drive gear O-ring when installing the torque converter.

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.

NOTE: Lightly lubricate the converter hub with MERCON or MERCON V transmission fluid, meeting FORD specification.






141. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.

Use Torque Converter Handles T81P-7902-C to install the torque converter by pushing and rotating.






142. NOTE: dimension "A" should be 10.23-14.43mm (0.43-0.56 inch).

Check dimension "A."