Special Tool(s) / General Equipment
100-001
(T50T-100-A)
Slide Hammer |
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100-002
(TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge |
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205-153
(T80T-4000-W)
Handle |
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211-061
(T78P-3504-N1)
Remover, Roll Pin |
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303-D011
(D80L-100-G)
Actuator Pin (Dia 3/16) |
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303-D019
(D80L-100-Q)
Collet, 3/4 to 7/8 |
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307-003
(T57L-500-B)
Holding Fixture, Transmission |
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307-091 Handle, Torque Converter TKIT-2009TC-F |
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307-300 Gauge Bar, Shim Selection TKIT-1994-LMH/MH2 TKIT-1994-F TKIT-1994-FLM/FM |
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307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW |
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307-574 Forward Clutch Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW |
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307-578 Input Shaft Support Seal Installer (Back Plate, Multiple rings) TKIT-2006UF-FLM TKIT-2006UF-ROW |
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307-581 Manual lever seal installer TKIT-2006UF-FLM TKIT-2006UF-ROW |
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307-584 2-6 Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW |
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307-589 Overdrive clutch and balance piston service set TKIT-2006UF-FLM TKIT-2006UF-ROW |
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307-625 Fixture, Bench Mounting TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-626 Installer, Differential Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-627 Installer, Converter Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-628 Protector, Low Reverse Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-629 Protector, Low Reverse / 1-2-3-4 Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-630 Center Support Piston Spring Tool TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-632 Protector, 2-6 Piston Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-633 2-6 Piston return spring Comp TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-635 Protector, Turbine Shaft Seal TKIT-2008ET-FLM TKIT-2008ET-ROW |
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307-691 Tester, Torque Convertor Leak |
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307-718 Installer, Axle Seal TKIT-2013B-FL TKIT-2013B-ROW |
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307-723 Installer, Turbine Seal TKIT-2014A-FL |
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307-732 Tool Kit, Torque Converter Flusher |
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Flat Headed Screw Driver | |
Magnetic Socket | |
Hydraulic Press | |
Long Nose Pliers | |
Puller | |
Punch |
Materials
Name | Specification |
---|---|
Motorcraft® Ultra Silicone Sealant TA-29 |
WSS-M4G323-A8 |
Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC |
WSS-M2C938-A MERCON® LV, |
All vehicles
NOTE: Use M10 x 1.5 x 25mm bolts to attach the special tool to the transmission case.
Install the special tool.NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tools, remove the torque converter from the transmission.Flush The Torque Converter With The Transmission Cooling System Heated Flusher
NOTE: Use transmission fluid specified for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail, which will affect the operation of the transmission.
The torque converter must be flushed every time the transmission is overhauled. It is mandatory that proper equipment and procedures be followed when flushing the torque converter. The flushing equipment used MUST:WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.
NOTE: Maintain visual contact with torque converter during the entire flush procedure. Immediately stop the flush machine if a leak develops. Repeat set up steps to reseal the tool to the converter hub and continue flushing.
Forward flush the converter for 15 minutes.WARNING: The torque converter, adaptor 307-732, and the hoses will be hot.
Allow torque converter and equipment to cool for 30 minutes before handling.Flush The Torque Converter By Hand
NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.
NOTE: Only flush the torque converter by hand when the transmission cooling system heated flusher is not available.
Auto-Start-Stop
NOTE: On some vehicles the transmission fluid auxiliary pump is removed during the transmission removal.
NOTICE: Do not use power tools to remove the transmission fluid auxiliary pump bolts or damage can occur.
All vehicles
NOTE: Note the location of the stud bolts for assembly.
Remove the main control cover bolts and the main control cover.NOTICE: If the transmission internal wiring harness frame has melted due to overheat condition the transmission and cooler must be replaced.
NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.
Remove the main control nut and the main control-to-transmission case bolts and remove the main control assembly.NOTE: Note the location of the stud bolts for assembly.
Remove the torque converter housing bolts.NOTE: If the transmission plastic baffle has melted due to overheat condition the transmission and cooler must be replaced.
Remove the differential transmission fluid baffle.NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).
NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
Remove the forward (1, 2, 3, 4) clutch snap ring.NOTICE: Do not clean in water or with water-based solvents. Damage to the component may occur.
NOTE: The low One-Way Clutch (OWC) should not be disassembled.
Clean and inspect the low One-Way Clutch (OWC) for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new low One-Way Clutch (OWC).NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
Remove the No. 1 thrust bearing.NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston.NOTICE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transmission case causing damage to the transmission case.
Using the special tool, pull the manual control shaft pin out of the manual control shaft.NOTICE: If the LH transmission case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transmission case bushing and a new LH halfshaft must be installed, or excessive noise or transmission failure can occur.
Clean and inspect the LH transmission case bushing and the bushing surface on the LH halfshaft for damage or excessive wear. If the LH transmission case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components.NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.NOTE: Note the orientation of the transmission fluid filter to the fluid pump assembly.
Rotate the transmission fluid filter 90 degrees clockwise and pull the transmission fluid filter out of the pump assembly.NOTE: The dot on the inner pump gear faces up.
Remove the pump gears.NOTE: Make sure the valves and the pump housing are clean and dry.
Install the TCC control valve and the main pressure regulator valve in the pump housing. Verify each valve moves freely in the pump housing bore and falls out under its own weight.NOTE: The TCC control valve retainer is shown assembled in the pump body, the main pressure regulator valve retainer is similar.
Assemble the TCC control valve assembly and main pressure regulator valve assembly and install the valves in the pump. Compress the valve springs with a screw driver and install the retainers.NOTE: The dot on the inner pump gear faces up.
Install the pump gears.NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.
Using the special tool and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer.NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Using the special tool and a press, compress the forward (1,2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer.NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Install the special tools on the forward clutch piston side of the center support.NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
Install the forward (1, 2, 3, 4) clutch piston return spring.NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
Install the direct (3, 5, R) clutch piston return spring.NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.
Install the overdrive (4, 5, 6) clutch piston return spring.NOTE: The dial indicator plunger is positioned on the overdrive (4, 5, 6) clutch pressure plate.
Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transmission case.NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transmission can occur.
NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3,4) clutch hydraulic ports are located.
NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.
Using the special tools, install the intermediate (2, 6) clutch snap ring in the groove.NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.
Install the No. 1 thrust bearing with the flat side facing up.NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.
Install the No. 3 thrust bearing with the flat side facing down.Description | Reading |
Measurement A | |
Measurement B | |
Subtract measurement B from measurement A and check to see if it is within range of 0.240mm (0.009 in) and 2.60 mm (0.102 in) |
NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the One-Way Clutch (OWC).
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the One-Way Clutch (OWC) and install the low/reverse pressure plate.Description | Reading |
Measurement A | |
Measurement B | |
Subtract measurement B from measurement A and record as measurement C |
Description | Reading |
Measurement D | |
Measurement E | |
Subtract measurement E from measurement D and record as measurement F |
Description | Reading |
Measurement C | |
Measurement F | |
Subtract measurement F from measurement C and check to see if it is within range of 0.406mm (0.015 in) and 2.000 mm (0.078 in) |
NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transmission.
NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transmission.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.NOTE: Make sure the front planetary sun gear and shell assembly is fully engaged into both forward clutch friction plates.
Install the front planetary sun gear and shell assembly.NOTICE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the manual control lever nut.NOTE: FWD Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool.NOTE: FWD Vehicles.
Using the special tools, install the new RH halfshaft seal.NOTE: AWD Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool.NOTE: AWD Vehicles.
Using the special tools, install the new RH halfshaft seal.NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.
Apply silicone to the sealing surface of the transmission case.NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing bolts and the torque converter housing stud bolt.NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR sensor.NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
Install the main control-to-cover seal.NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover and the main control cover bolts and stud bolts.Auto-Start-Stop
All vehicles
NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tools, install the torque converter.Note: Depending on your vehicle option package, the controls may look different from what you see here.