A/T - A4LD Premature Clutch Wear

89ford06

Article No. 89-9-17

TRANSMISSION - A4LD - CLUTCH WEAR - VEHICLES BUILT BEFORE 4/01/89

LIGHT TRUCK: 1986-89 AEROSTAR


ISSUE: Clutch wear can be caused by improper positioning of the transmission manual valve in the reverse, overdrive or drive positions. Friction in the transmission shift cable assembly and/or the shift selector bezel can result in improper positioning of the detent plate and manual valve. This causes incomplete clutch application.

ACTION: Install a new design A4LD transmission shift cable and shift detent bezel. Refer to following procedure for service details.

FIGURE 1:

SHIFT CABLE AND SHIFT BEZEL DETENT INSTALLATION

1. Remove the shift lever floor carpet retainer.

2. Remove the old shift detent bezel from the shift lever assembly.

3. Install the new shift detent bezel, (E99Z-7D443-B) in the shift lever assembly.

4. Reinstall the shift lever floor carpet retainer.

5. From under the vehicle, disconnect the shift cable from the shift lever assembly, Figure 1.

6. Remove the clip holding the shift cable to the shift lever assembly.

7. Loosen the adjusting screw on the shift cable and remove the cable end fitting from the manual lever ball stud, Figure 1.

8. Remove the clip holding the shift cable to the cable bracket, Figure 1.

9. Position the new shift cable, (E99Z-7E395-A) next to the manual lever ball stud.

NOTE: DO NOT CONNECT OR TIGHTEN THE SHIFT CABLE AT THIS TIME. THE SHIFT

CABLE WILL BE CONNECTED AND TIGHTENED IN PLACE DURING THE MANUAL LINKAGE ADJUSTMENT.

10. Reinstall the clip that holds the shift cable to the cable bracket.

11. Connect the other end of the new shift cable to the shift lever assembly, 12. Reinstall the clip that holds the shift cable to the shift lever assembly.

MANUAL LINKAGE ADJUSTMENT

1. From inside the vehicle, place the shift lever in the overdrive position.

2. Have a second person hold the shift lever against the rear of the overdrive stop.

3. From under the vehicle, place the manual lever in the overdrive position by moving the manual lever all the way rearward, and then moving it three (3) detents forward.

4. Connect the shift cable end fitting on the manual lever.

5. Tighten the adjustment screw to 40-60 in.lbs. (5-7 N-m).

6. Check for proper operation.

PART NUMBER PART NAME CLASS

E99Z-7E395-A Shift Cable B
E99Z-7D443-B Shift Bezel Detent B

OTHER APPLICABLE ARTICLES: 87-2-15
WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage

OPERATION DESCRIPTION TIME
890917A Install Cable & Bezel 0.8 Hr.
(includes adjust linkage)

DEALER CODING
BASIC PART NO. CONDITION CODE
7340 36
OASIS CODES: 5100, 5101, 5102, 5104, 5200, 5300, 5550