Transmission Disassembly

1. Remove the transmission from the vehicle.

Refer to Section 307-01B of the 2004 F-SD/Excursion Workshop Manual or 307-01C of the 2004 E-Series Workshop Manual for repair instructions.





2. Remove Special Tool Torque Converter Retainer 307-346. See Figure 1.

3. WARNING: Use the special tools when removing the torque converter because it is very heavy. Failure to follow this instruction may result in personal injury.

NOTE:
Fluid loss will occur when removing the torque converter.





Using Special Tools Torque Converter Handles 307-091 remove the torque converter. See Figure 2.





4. Remove the intermediate shaft and turbine shaft speed combination sensor. See Figure 3.

1) Remove the bolt.

2) Remove the sensor.

5. Mount the transmission onto a suitable stand.





6. Remove the input shaft. See Figure 4.

7. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.





Remove the transmission fluid pan and the gasket. Check and clean the magnet if foreign material is evident. See Figure 5.





8. NOTE: After removal, discard the filter and seal assembly.

Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. See Figure 6.

9. CAUTION: There is no retainer on the manual valve. To avoid dropping the manual valve, hold the valve while removing the solenoid assembly from the transmission.





Remove the solenoid body. See Figure 7.

1) Disconnect the transmission range sensor.

2) Remove the solenoid body bolts.

3) Remove the solenoid body.





10. Remove and discard the solenoid body gasket. See Figure 8.





11. Remove the forward clutch orifice. See Figure 9.





12. Remove and retain the feed bolts. See Figure 10.





13. Remove and discard the front pump bolts. Nine (9) new bolts are required to complete this repair. See Figure 11.





14. Using Special Tools Transmission Fluid Pump Remover 307-221 and Slide Hammer 100-001, remove the front pump. See Figure 12.

15. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.

Remove the No. 1 pump thrust washer.





See Figure 13.

1) Remove the No. 1 pump thrust washer.

2) Remove the No. 2A overdrive sun gear thrust bearing.

3) Remove the pump gasket and discard.











16. Remove the overdrive separator plates, clutch plates and overdrive pressure plate. See Figure 14.





17. Remove the overdrive clutch retaining ring. See Figure 15.





18. Install Special Tool Clutch Loading Fixture 307-S383. See Figure 16.





19. Remove the coast clutch cylinder assembly.
See Figure 17. [NEW]





20. Remove the No. 4 thrust bearing. See Figure 18.





21. Remove the overdrive ring gear and center shaft. See Figure 19.





22. Remove the No.5 sun gear thrust bearing. See Figure 20.





23. Using Special Tool Retaining Ring Pliers 307-343, remove the center support retaining ring. See Figure 21.





24. Install Special Tools Coast Clutch Fixture Body 307-385 and Coast Clutch Fixture Handle 307-384 as shown in the following illustration. See Figure 22.





25. Remove the center support, direct clutch and the forward clutch cylinder assembly. See Figure 23.





26. Remove the forward clutch hub thrust washer No.9. See Figure 24.





27. Remove the forward ring gear and hub assembly. See Figure 25.





28. Remove the forward carrier race and No.11 bearing assembly. See Figure 26.





29. Remove the forward carrier. See Figure 27.





30. Remove the No. 12 thrust bearing. See Figure 28.





31. Remove the low reverse sun gear and shell assembly. See Figure 29.





32. Remove and discard the low/reverse clutch retaining ring. See Figure 30.





33. Remove the low/reverse one-way clutch, clutch pack, carrier and hub assembly. See Figure 31.