Part 2

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.







50. Install the (A) input shaft with long splined end first. Install the (B) aligning pin.





51. Verify the (A) No. 1 pump thrust washer and the (B) No. 2A overdrive sun gear thrust bearing are installed.

NOTE: Lightly lubricate the thrust washer and bearing with petroleum jelly to hold it in place during assembly.





52. Install the (A) front pump assembly with the (B) filter inlet tube bore in the 6 o'clock position. Fully seat the front pump assembly using hand pressure only. When the pump is fully seated, remove the (C) aligning pin.

CAUTION: Fully seat the front pump assembly using hand pressure only. Do not use bolts to draw the front pump assembly into the case. Tighten the bolts alternately to avoid possible damage.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.





53. Install the bolts with new rubber-coated washers. Tighten the bolts alternately in a crisscross pattern.

CAUTION: Discard the old washers.





54. Remove the input shaft.

CAUTION: Remove the input shaft prior to rotating the transmission.





55. Using the (A) Shift Lever Seal Replacer, install the (B) manual control lever seal.





56. Install the manual control lever shaft assembly.
1 Install the manual control lever shaft assembly.
2 Install and seat the manual lever shaft retaining pin below the case surface.
3 Install the (A) parking pawl actuating rod, the (B) inner manual valve detent lever and the (C) nut onto the manual control lever shaft assembly.

NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when installing the inner manual valve detent lever nut.

4 Install the (F) manual control valve detent lever spring and the (G) bolt.

NOTE: The manual control valve detent lever spring must be on the inner manual valve detent lever and the detent lever pin must align with the manual shift valve.





57. Install the (A) parking pawl shaft, the (B) parking pawl and the (C) parking pawl return spring with the spring end resting on the inside of the case.





58. If removed, install the parking pawl abutment with a new Torx head screw.

CAUTION: The Torx head screw has a thread-locking compound. If the screw is removed, it must be discarded and a new one installed.





59. Install the (A) parking rod guide plate with the (B) bolts.

NOTE: Make sure the dimple on the parking guide support plate is facing inward and the parking pawl actuating rod is in the parking rod support plate slot.





60. Place the new extension housing gasket on the extension housing.

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.





61. Install the (A) extension housing, the 8 (B) bolts, and the (C) stud.





62. Using the (A) Extension Housing Seal Replacer, install a new (B) extension housing seal.





63. Tighten the center support assembly, and the intermediate/overdrive cylinder assembly feedbolts.
1 Tighten bolts.
2 Tighten bolts.





64. Install the (A) spring and the (B) steel Electronic Pressure Control (EPC) check ball.

NOTE: The steel EPC check ball has a 0.25-inch diameter and is smaller than the other check balls.





65. Install the 8 rubber check balls.

CAUTION: Use care not to damage the rubber check balls.





66. Install a new separating plate-to-case gasket on the separating plate.





67. Install the valve body separator plate.

NOTE: Check the placement of the steel EPC check ball under separator plate.





68. Install the (A) separating plate reinforcing plate, with the stamped word UP visible, and install the (B) bolts.





69. Install a new main control-to-separating plate gasket.





70. Install the solenoid screen assembly by pushing it in and rotating it to lock.





71. Install the (A) solenoid body assembly with the (B) nut and the (C) Torx head bolts finger-tight.

NOTE: Prior to installing the solenoid body assembly, coat the case connector bore with petroleum jelly or equivalent.





72. Install the (A) main control valve body, aligning the (B) manual shift valve with the (C) inner manual valve detent lever. Install the (D) nuts and the (E) bolts finger-tight.





73. Install the (A) accumulator body with the (B) nuts and the (C) bolts finger-tight.





74. Tighten all accumulator body, upper and lower control body and solenoid body nuts and bolts.





75. Select the appropriate filter assembly and transmission pan.

CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage.





76. Install a new filter and seal assembly by pressing it into place.

CAUTION: Do not reuse the old filter and seal assembly.

NOTE: Prior to installation, lightly lubricate the fluid filter seal with clean Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification.





77. Place the transmission pan magnet on the dimple in the bottom of the transmission fluid pan.





78. Install the (A) gasket, the (B) transmission fluid pan and the 20 (C) bolts.

CAUTION: Do not discard the gasket. Clean, inspect and reuse unless damaged. This is a reusable gasket.





79. With the transmission in NEUTRAL, install and adjust the digital Transmission Range (TR) sensor.
1 Install the digital TR sensor.
2 Loosely install the bolts.





80. Install the Digital TR Sensor Alignment Tool.





81. Tighten the bolts.
82. If not done previously, apply sealer to case inlet and outlet fitting threads.
^ Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5.

CAUTION: Make sure the Cooler Bypass Valve (CBV) has been cleaned and flushed; refer to CBV Assembly. Make sure the four rubber-coated sealing washers are placed properly on the CBV fittings.





83. Install the (A) CBV with the (B) front (inlet) and the (C) rear (outlet) cooler line case fitting.

CAUTION: Do not over-tighten.





84. With the fluid pan facing down, install the input shaft with the long splined end first.





85. Using the (A) Torque Converter Handles, install the torque converter by lifting up slightly and holding onto the (B) pilot to center the converter in the housing. Then, push and rotate the converter onto the front pump assembly until it bottoms out.

CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.

NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal. Carry the torque converter with the handles held in the 6 o'clock and 12 o'clock positions.





86. Check the seating of the torque converter.
1 Place the (A) straightedge across the (B) converter housing.
2 Make sure there is a gap between the converter pilot face and the straightedge.
3 Remove the Torque Converter Handles.