Steps 101 - 144

101. NOTE: The screws will be tightened in later steps.

Loosely install the four M6 x 45 mm screws.





102. NOTE: The screws will be tightened in later steps.

Loosely install the two M6 x 35 mm screws.





103. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the M6 x 35 mm screws.





104. Remove the valve body guide pins.





105. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the sixteen m6 x 40mm screws.





106. Tighten the screws in the sequence shown.





107. Install the main control valve detent lever spring.
1 Position the main control valve body detent lever spring on the valve body.
2 Install the screw.





108. NOTE: Perform the following steps only if low/reverse band servo piston and rod is to be checked.

Remove the low/reverse band servo piston and rod from the case.





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

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





110. Install Servo Rod Selecting Gauge.
1 Install a new low/reverse servo separator plate cover gasket.
2 Tighten the screws.





111. Tighten the servo gauge adjusting screw.





112. Install Dial Indicator with Bracketry on the transmission case.
1 Position the indicator on the piston pad.
2 Set the dial indicator to zero.





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

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





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

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





- Grooves are located on low/reverse servo rod. Install select servo and rod assembly.





115. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
1 Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
2 Loosely install the screws.





116. Tighten the screws in the sequence shown.





117. Connect the solenoid electrical connectors.
1 Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
2 Connect the TCC electrical connector.
3 Connect the Electronic Pressure Control (EPC) solenoid electrical connector.





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

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





119. CAUTION: Make sure that both fluid pan filter O-rings are properly installed on the fluid pan filter prior to installation.

Install the fluid pan filter O-rings.
- Coat the fluid pan filter O-rings with MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification.





120. Install the fluid pan filter.
1 Position fluid pan filter on the main control valve body.
2 Install screw.





121. Install the transmission fluid pan and transmission fluid pan gasket.
- Loosely install the screws.





122. Tighten the screws.





123. Remove the transmission from the Bench Mounted Holding Fixture and place on a flat surface.





124. Remove the fixture arm of the Bench Mounted Holding Fixture and the A4LD Holding Fixture Adapter.





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

Install a new extension housing gasket.





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

Install the parking pawl assembly.
1 Install the parking pawl shaft into the extension housing.
2 Install the parking pawl.
3 Install the parking pawl return spring.





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

Install the extension housing.
1 Install the extension housing and the gasket.
2 Install the screws.
3 Install the stud.





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

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

NOTE: Remove any burrs from the extension housing counterbore.

Align lube hole with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear.





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

Using Extension Housing Bushing Replacer, install the extension housing bushing.
1 Position Extension Housing Bushing Replacer.
2 Install the extension housing bushing.





130. Position new extension housing seal with drain hole in the 6 o'clock position.





131. Using Align Extension Housing Seal Replacer, install a new extension housing seal.
1 Align Extension Housing Seal Replacer.
2 Install the extension housing seal.





132. Install the digital Transmission Range (TR) sensor.
1 Position the digital TR sensor on the transmission.
2 Loosely install the screws.
3 Rotate manual lever to neutral position (two detents rearward).





133. Adjust the digital TR sensor using the Digital TR Sensor Alignment Tool.
1 Install alignment tool. The tool is designed to fit snugly.
2 Tighten the screws and remove the tool.





134. Install the manual control lever.
1 Install the lever.
2 Install the nut.





135. Install the transmission servo heat shield and nut.





136. NOTE: Inspect O-ring for damage. Replace if damaged.

Install the Output Shaft Speed (OSS) sensor.
1 Install the OSS sensor.
2 Install the screw.





137. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.

Install the input shaft.





138. Check that the fluid pump gear seal ring is seated.
Insert Front Pump Seal Sizing Tool into the fluid pump drive gear.





139. CAUTION: Do not damage the fluid pump 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.

Lubricate the converter hub with MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification.





140. WARNING: The torque converter can fall out if the transmission is tipped.

Use the Torque Converter Handles to install the by pushing and rotating.





141. NOTE: Dimension "A" should tee 10.23 - 14.43 mm (0.43 - 0.56 inch).

Make sure the torque converter is installed to specification.





142. Lubricate the torque converter pilot hub with Ford Multipurpose Grease DOAZ-19584-AA meeting specification ESB-MIC93-B.
143. Before installing the transmission, make sure that the transmission cooling system (line and cooler[s]) have been thoroughly flushed. If contamination cannot be removed or proper flow cannot be obtained, replace cooler(s) and/or lines.





144. Install the Torque Converter Holding Tool on case.