Assembly
ASSEMBLEThrust Washer Identification, (1988 Mustang And 1988-1989 Bronco II And Ranger):
Thrust Washer Identification, (1988 Thunderbird And 1988-1989 Aerostar):
Thrust Washer Identification, (1989-1991 Mustang):
Thrust Washer Identification, (1990 Bronco II And 1990-1991 Aerostar And Ranger, Except 4.0L Engines):
Thrust Washer Identification, (1990-1991 Aerostar And Ranger And 1991 Explorer W/4.0L Engine):
CAUTION: Some of the thrust washers used are very similar and could be improperly installed during installation, refer to the Thrust Washer Identification images for thrust washer and ring identification.
1. Prior to beginning assembly of transmission, high clutch seal sizing procedure must be performed as follows:
a. Install new high clutch seals on support hub.
NOTE: Seal grooves have a dovetail contour with straight side walls on pressure sealing sides.
b. Apply a liberal amount of petroleum jelly to center support hub and seals.
c. Using overdrive brake drum as a sizing tool, carefully rotate center support while inserting into overdrive brake drum.
d. Observe seals as they enter cavity to ensure that they do not roll over or become cut.
e. Ensure center support is fully seated into overdrive brake drum to stand for several minutes so that seals seat in grooves, then set aside until required for reassembly.
2. Place thrust washer No. 12 on 1987-1989 models or No. 11 on 1990-1992 models, into back of case.
3. Install collector body in rear of case, then the output shaft.
NOTE: If a new output shaft is being installed, 4.0L models do not have a lubricant hole.
4. Install governor on collector body and torque attaching bolts.
5. Place thrust washer No. 11 on 1987-1989 models or No. 10 on 1990-1991 models, into case from front, then install low/reverse drum using overrunning clutch replacement guide T74P-77193-A or equivalent.
NOTE: 4.0L models use a sprag-type overrunning ring clutch and guide tool is not required.
6. Install output shaft ring gear and snap ring onto output shaft, using a new snap ring.
7. On models with 4.0L engines, install output shaft sleeve (lubricant guide).
8. On all models, install thrust washer No. 10 on 1987-1989 models or No. 9 on 1990-1991 models, reverse planet assembly and thrust washer No. 9 on 1987-1989 models or No. 8 on 1990-1991 models, using petroleum jelly to hold thrust washers in position on planet assembly.
9. Install snap ring in drum to hold planet assembly in place, then install low reverse band.
NOTE: 4.0L models do not have a snap ring at this location.
10. Replace servo piston or O-ring, if necessary, then install low-reverse servo piston to hold band in position.
11. Install intermediate a overdrive servo springs, pistons, covers, and snap rings, replacing pistons or O-rings as necessary.
NOTE: Ensure covers are installed in proper location.
Identification Of Intermediate And Overdrive Shafts And Levers:
12. Locate and identify intermediate servo apply lever and shaft. Intermediate lever has a boss on shaft hole and is shorter than overdrive shaft.
13. Install intermediate servo apply lever and shaft into case.
14. Install complete forward clutch and reverse/high clutch assembly.
15. Turn transmission so that output shaft points downward, then install intermediate band and apply strut.
16. Temporarily install intermediate band anchor strut and input shaft as an alignment guide, then check rear endplay as follows:
Fabricating Depth Gauge Fixture:
a. Fabricate a depth gauge fixture from a spare overdrive center support by drilling a 1/8 inch hole through thrust washer surface of center support, as shown in the Fabricating Depth Gauge Fixture image, to allow access of a depth micrometer to area between thrust surfaces of center support and intermediate brake drum.
b. Remove rubber seats from spare center support to allow easy access of depth micrometer.
c. Place depth micrometer D80P-4201-A or equivalent over drilled hole in fabricated depth gauge fixture.
Obtaining Reading A:
d. Extend probe until it is flush with thrust washer surface of fixture, as shown in the Obtaining Reading A image, and record micrometer reading (A).
e. Install fabricated depth gauge fixture into intermediate brake drum and fully seat it in transmission case. Gently wiggle input shaft to allow fixture to slide into intermediate brake drum from its own weight. Fixture will axially locate drum in its proper position.
Installing Fabricated Depth Gauge In Intermediate Brake Drum:
f. Place depth micrometer over drilled hole in fixture, as shown in the Installing Fabricated Depth Gauge In Intermediate Brake Drum image.
g. Continue extending probe until it contacts thrust washer surface of intermediate brake drum and record reading (B). appearing on micrometer.
Determining Reading B And Dimension A:
h. Subtract reading A from reading B to determine dimension a, as shown in the Determining Reading B And Dimension A image.
i. Remove and rotate fixture 180 degrees and repeat steps 15c through 15h.
Thrust Washer Identification Chart:
j. Average two dimensions A, then select proper thrust washer from the Thrust Washer Identification Chart, required to obtain specified endplay of 0.O12-0.O22 inch.
NOTE: If specified endplay cannot be obtained transmission is improperly assembled or parts are missing or out of specification. Disassemble transmission to locate part(s) that has caused problem.
k. Remove micrometer and depth gauge fixture.
17. Remove center support from overdrive drum, then coat correct selective thrust washer No. 4 with petroleum jelly to hold in place and position on center support.
18. Insert input shaft, short splines down, through center support and into splines in forward clutch cylinder.
19. Carefully place center support into case without starting it into intermediate brake drum, ensuring it is square with case and 5 mm Allen bolt retainer nut is aligned with bolt hole in case.
20. Without applying any pressure to center support, gently wiggle input shaft, allowing center support to slide into intermediate brake drum using its own weight until support is fully seated, then remove input shaft.
21. Position No. 3 thrust washer on top of center support.
22. Install large snap ring to retain center support in position with snap ring taper toward front of transmission, ensuring ends of snap ring are positioned in wide shallow cavity located at 5 o'clock position.
Center Support Snap Ring Identification:
NOTE: Two types of snap rings are used, they should be positioned as shown in the Center Support Snap Ring Identification image.
23. Install 5 mm Allen head bolt that retains center support to case.
24. Install sun gear and overdrive clutch adapter into overdrive planet assembly and one-way clutch, centering needle bearing race inside of planetary. Ensure it remains centered, positioned with extruded lip in upward position (toward sun gear).
25. Assemble overdrive planet and one-way or over running (sprag) clutch assembly as follows:
Exploded View Of Planet And One-Way Or Over Running Clutch Assembly:
a. One-way or over running (sprag) clutch assembly must be installed into overdrive center shaft so that flanges of inner and outer cages are toward overdrive planet assembly, which is toward front of transmission, as shown in the Exploded View Of Planet And One-Way Or Over Running Clutch Assembly image.
b. Overdrive clutch washer that is positioned between overdrive planet carrier and center shaft must be installed so that the recessed inside diameter faces forward (not against over running or one-way clutch assembly).
Exploded View Of Planet And One-Way Or Over Running Clutch Assembly Proper Build Up Check:
c. Perform proper assembly buildup check by holding planet assembly and ensuring center shaft turns clockwise, as shown in the Exploded View Of Planet And One-Way Or Over Running Clutch Assembly Proper Build Up Check image.
26. Install overdrive planet assembly and one-way clutch into case.
27. Install overdrive drum assembly, then the overdrive bracket, apply lever, and shaft.
28. Install overdrive band and apply strut, then the anchor strut.
NOTE: Ensure correct band is installed.
29. Ensure needle bearing race in overdrive planetary is centered and that overdrive clutch is fully seated.
30. Place No. 1 selective washer on top of overdrive clutch drum and temporarily install pump assembly into case, ensuring it is fully seated so that pump body is below level of case gasket surface.
CAUTION: Check for damaged or missing front pump support seal, replacing if necessary. There is a rough casting portion of the crescent, this is not a flaw and pump should not be replaced.
Checking Endplay:
31. Mount dial indicator block on pump plunger resting on transmission housing, as shown in the Checking Endplay image, and zero dial indicator.
32. Swing indicator around so that plunger contacts pump and record dial reading.
NOTE: This reading is amount of end play and should be noted for later use.
33. Move dial indicator block to opposite side of pump 180° and repeat steps 31 and 32.
34. If average of readings obtained in steps 32 and 33 is not 0.001-0.025 inch on 1987-1990 models or 0.007-0.025 on 1991 models, change No. 1 selective washer. No. 1 selective washers are available in thicknesses of 0.053-0.055, 0.060-0.062, 0.068-0.070, 0.076-0.078, 0.084-0.086, and 0.092-0.094 inch on 1987-1989 models and 0.047, 0.055, 0.063, 0.067, 0.071, 0.075, 0.079, 0.083, 0.087, 0.094, 0.102, and 0.110 inch on 1990 models.
35. Remove pump and selective washer.
36. Install a new pump oil seal using front pump alignment set T74P-77103-X and front pump seal replacer T87L-77248-AH or their equivalents, then stake seal in place using T87L-77248-BH or equivalent in two places between existing stakes.
37. Position separator plate on converter housing.
Oil Pump Gear Identification:
38. Position two pump gears into pump housing. The inside edge of the small gear has a chamfer on one side, as shown in the Oil Pump Gear Identification image. This chamfer must be positioned toward front of transmission. The larger gear has a dimple on one side which must be positioned toward rear of transmission.
39. Position pump assembly onto separator plate and converter housing and Install attaching bolts finger tight.
NOTE: Note that pump assembly stator end face has a depression. This is completely interchangeable with flat stator end face.
40. Using front pump alignment set T74P-77103-X or equivalent, align pump in converter housing as follows:
a. Select arbor with smallest inside diameter that will fit completely over pump shaft.
b. Assemble common handle to selected arbor and slide tool down over shaft until it bottoms against pump, allowing the outside diameter of the tool arbor to automatically center pump in converter housing.
c. Torque five 10 mm bolts on 1987-88 models or five new 6 mm bolts on 1989-1991 models, then remove alignment tool.
41. Insert input shaft into pump, then install converter into pump gears. Rotate converter to ensure free movement, then remove converter and input shaft.
42. Coat converter gasket with petroleum jelly and position on converter housing.
43. Using petroleum jelly, position No. 1 selective thrust washer on rear of pump.
44. Align converter housing and pump to transmission and install eight 17 mm bolts, with new aluminum washers on 1987-88 models or new O-rings on 1989-1991 models, then torque bolts.
45. Using band adjusting torque wrench T71P-77370-A or equivalent, adjust overdrive band as follows:
Adjusting Overdrive Band:
a. Install new locknut on adjusting screw, but do not tighten at this time, then tighten adjusting screw until wrench clicks, as shown in the Adjusting Overdrive Band image.
b. Back off adjusting screw exactly two turns on models with 2.3L, 2.9L, and 3.0L engine or exactly 3-1/2 turns on models with 4.0L engine.
c. Hold adjusting screw from turning and torque locknut.
46. Using tool T71P-77370-A or equivalent, adjust intermediate band as follows:
Adjusting Intermediate Band:
a. Install new locknut on adjusting screw, then tighten adjusting screw until handle clicks, as shown in the Adjusting Intermediate Band image.
b. Back off adjusting screw exactly two turns.
c. Hold adjusting screw from turning and torque locknut.
47. Using shift lever oil seal installer T74P-77498-A or equivalent, install shift lever oil seal.
48. Install internal shift linkage and centering pin, then torque 7/8 inch nut.
49. Install O-ring, kickdown lever, and 13 mm nut and torque nut.
50. Install neutral start switch using neutral start switch socket T74P-77247-A or equivalent, and torque.
51. Install converter clutch solenoid electrical connector.
52. Install throttle valve, rod, vacuum diaphragm, retaining clip, and bolt, ensuring throttle valve moves freely in its bore.
53. Using tapered punches, align valve body to separator plate and gasket.
54. Install two separator plate attaching bolts and torque.
55. Remove transmission from holding fixture and place on bench, bottom up.
56. Attach and lock selector lever connecting rod (Z-link) to manual valve and ease control valve body into case.
CAUTION: Use caution not to bend connecting rod (Z-link).
Valve Body Attaching Bolt Locations:
57. Insert correct length bolts into holes A and B, as shown in the Valve Body Attaching Bolt Locations image, to position control valve body in case.
58. Position 3-4 shift solenoid retainer and insert all remaining bolts, except filter screen bolt.
NOTE: 3-4 shift solenoid retainer tabs must be on outside of metal inner retainer.
59. Torque control valve body bolts, starting in center and working toward outer edges.
60. Remove bolt from hole A and install detent lever spring to bolt, torque bolt, then connect two converter clutch solenoid wires.
61. Check reverse servo piston travel as follows:
a. Install reverse servo piston assembly into servo bore together with reverse servo check spring D4ZZ-70031-A or equivalent.
Checking Travel Of Reverse Servo Piston:
b. Install new servo cover gasket and tool T74P-77190-A or equivalent, securing with three attaching bolts, as shown in the Checking Travel Of Reverse Servo Piston image.
c. Torque servo tool adjusting screw to 36 in lbs.
d. Install dial indicator with bracketry TOOL-4201-C or equivalent, on transmission case, position indicator on piston pad and zero dial indicator.
e. Back out servo tool adjusting screw until piston bottoms out on tool and record distance of servo piston travel.
Reverse Servo Piston Selection Chart:
f. If piston travel is not within 0.120-0.220 inch, select replacement piston and rod, as shown in the Reverse Servo Piston Selection Chart, using next longest piston and rod if piston travel exceeds specification, or next shortest piston and rod if piston travel was less than specification.
g. Repeat procedure using new piston and rod to ensure piston travel is within specifications.
h. Remove servo adjusting tool and the reverse servo piston checking spring.
62. Install servo piston assembly, accumulator spring, gasket, and cover.
63. Install four 10 mm servo retaining bolts and torque.
64. Install filter screen using new O-rings and torque attaching bolt.
65. Remove any trace of old gasket on case and oil pan, position oil pan gasket on case and install oil pan, then torque attaching bolts.
66. Remove any trace of old gasket on case and extension housing, then install parking pawl and return spring in housing and preload.
67. Position new gasket on case and install extension housing, being sure to correctly seat operating park rod in extension guide cup. Torque attaching bolts.
68. Replace extension housing seal and bushing.
69. Install torque converter.
CAUTION: Some torque converter installations may result in the converter impeller hubs not being fully engaged in the oil pump drive gears, resulting in broken oil pump gears and damaged converter impeller hub.
NOTE: Proper installation of converter requires full engagement of the converter hub in the pump gear. To accomplish this, the converter must be pushed and at the same time rotated through what feels like two notches or bumps. When fully installed, a rotation of the converter will usually result in a clicking noise being heard, caused by the converter surface touching the housing to case bolts. This clicking noise is normal.
Determining Torque Converter Installation Depth:
NOTE: A properly installed converter will have a dimension A, as shown in the Determining Torque Converter Installation Depth image, converter pilot nose front face to converter housing outer face, of 7/16 to 9/16 inch.