Steps 1 - 45

Special Tools:

Note:
- Soak all friction clutch plates in clean MERCON V(R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V(R).
- Prior to installation, lightly lubricate all O-ring seals with clean MERCON V(R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V(R).
- Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

1. Mount the (A) case to the (B) Car/Truck Engine Repair Stand.

2. If removed, install the (A) short fluid inlet tube using the (B) Oil Filler Tube Replacer.

3. CAUTION: If equipped, use care not to misalign the 7D402 in the case bore.

Note: Coat the reverse clutch piston seals with petroleum jelly.

Install the reverse clutch piston in the case until it is fully seated in the case.

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

Install the (A) reverse clutch return spring assembly and the (B) low/reverse one-way clutch inner race with the (C) lubrication hole on the face in the 5 o'clock position.

5. Install two 5/16-24 x 3inch bolts with nuts in to the low/reverse one way clutch inner race.
1. Hold the nut.
2. Turn the bolt to compress the low/reverse piston return spring.

6. Install three of the one-way clutch inner race bolts and remove the two 5/16-24 x 3 bolts.

7. Note: alternate tightening bolts from one side to the other (not in a circle).

Install the remaining bolts retaining the low/reverse one-way clutch inner race to the case.

8. Note: When the reverse clutch and the low one-way clutch are installed, the reverse clutch should rotate clockwise. The one-way clutch will hold and not let the clutch hub rotate counterclockwise.

Install the reverse clutch hub and the low one-way clutch assembly over the low/reverse one-way clutch inner race by pressing the hub inward and rotating it clockwise to seat fully.

9. CAUTION: The number of plates is model-dependent.

Note:
- No stack-up clearance measurement is required.
- Clock position is viewed looking into the converter housing with the top of the case in the 12 o'clock position.

Install the (A) cushion spring; the (B) reverse clutch pack, starting with an external spline steel plate and alternating with internal splined friction plates; the (C) reverse clutch pressure plate; and the (D) reverse clutch pressure plate retainer snap ring, with the (E) ring opening between the 12 o'clock and 3 o'clock positions.

10. Note: Apply petroleum jelly to the No. 13 parking gear bearing to hold it in place.

Install the No. 13 parking gear bearing.

11. CAUTION: If equipped, use care not to damage the output shaft drive sprocket speed sensor wheel. This will cause incorrect reading of the output shaft speed sensor (OSS) which will cause a repeat repair.

Note: The output shaft and drive sprocket speed sensor wheel are model-dependent.

Install the output shaft.

12. Note: Lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Install the (A) No. 12 thrust bearing onto the (B) rear surface of the hub assembly.

13. Install the output shaft ring gear assembly.

14. WARNING: Do not overextend the output shaft retaining ring during installation. Make sure the output shaft retaining ring is securely seated in the groove.

Install the new output shaft retaining ring onto the output shaft.

15. Install the reverse planet assembly.
1. Install the No. 11 thrust washer.
2. Install the reverse planet.
3. Install the No. 10 B thrust washer.

16. Install the reverse planet retaining ring into the reverse clutch hub, making sure the retaining ring is fully seated.

17. Note:
- Tabs on the thrust washer must engage the slots on the intermediate brake drum.
- Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.

Verify the No. 8A intermediate brake drum thrust washer is installed.

18. Note:
- The large outer diameter radius of the needle bearing must be installed facing inward.
- Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 8B forward clutch needle bearing is installed.

19. Install the (A) forward clutch cylinder assembly onto the (B) intermediate brake drum by rotating it until fully seated.

20. Note: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 9A forward clutch thrust bearing is installed (black side facing up).

21. Note: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.

Place the (A) No. 8C forward clutch hub thrust washer onto the (B) forward hub and ring gear assembly.

22. Place the (A) forward hub and ring gear assembly into the (B) intermediate brake drum and forward clutch cylinder assemblies.

23. Note: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 10A forward planet assembly thrust bearing is installed.

24. Place the (A) forward planet assembly into the (B) forward hub and ring gear assembly.

25. Note: The thrust bearing notched inner race must face outward and the large outer diameter radius must face inward.

Verify the No. 9B forward clutch thrust bearing is installed.

26. Align the (A) notch with the (B) lug and position the (C) input shell onto the (D) intermediate brake drum. Rotate the input shell until fully seated.

27. WARNING: When installing the (A) Clutch Assembly Loading Tool, the hooks on the crossbar must engage the notches on the (B) input shell to prevent injury or damage.

Using the (A) Clutch Assembly Loading Tool, lower the (C) direct clutch, forward clutch and (B) input shell as an assembly into the case. Remove the Clutch Assembly Loading Tool.

28. Install the intermediate band with the (A) ear resting on the (B) anchor pin.

29. Note: Prior to installation, lightly lubricate the piston seal with clean MERCON V(R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V(R).

Gently press the intermediate band servo assembly piston into the case bore.

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

Install the (A) intermediate clutch pressure plate; the (B) intermediate clutch pack, starting with an internal spline plate and alternating with external spline plates; and the (C) intermediate clutch pressure apply plate, with blank area (no teeth) in the 6 o'clock and 12 o'clock positions.

31. Note: The following stack-up check measurement indicates not only the amount of space existing between the center support assembly and the intermediate brake drum, it also will indicate if the unit has been properly built to this point.

Hold the (A) thrust washer against the (B) center support assembly. Extend the (C) probe of the (D) Depth Micrometer into the (OD hole until flush with the (F) No. 6 center support thrust washer surface. Record this as (G) reading 1.

32. CAUTION: Do not misalign the center support in the case bore. This can damage the case bore.

Note: Make sure the No. 6 center support thrust washer is on the center, support prior to installation.

Install the (A) center support assembly with the (B) feed holes aligned.

33. Extend the (A) probe of the (B) Depth Micrometer into the hole in the (C) center support assembly until flush with the (D) No. 6 center support thrust washer. Record this as (E) reading 2.

34. Subtract (A) reading 1from (B) reading 2 Record this as reading 3. If the final dimension is outside specified limits, this indicates improper assembly.

35. CAUTION: Do not tighten the bolts at this time. This could cause transmission failure.

Install the new feed bolts.

36. Note: Clock position is viewed looking into the converter housing with the top of the case in the 12 o'clock position.

Install the (A) intermediate clutch return spring with the dished surface inward and one (B) spring leg in the 6 o'clock position.

37. CAUTION: Do riot misalign the intermediate/overdrive cylinder assembly. This can damage the case bore.

Install the (A) intermediate/overdrive cylinder assembly with the (B) feed holes aligned.

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

Position the (A) intermediate/overdrive cylinder retaining ring over the intermediate/overdrive cylinder with the (B) ring opening in the 6 o'clock position to allow proper fluid drainback.

39. Install the Clutch Spring Fixture.
1. Install the Clutch Spring Fixture.
2. Rotate the tool clockwise to lock in place.
3. Tighten the handle.

40. CAUTION: Make sure the snap ring is fully seated into the case. Transmission failure could occur.

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

Seat the intermediate/overdrive cylinder retaining ring into the case ring groove with the ring opening in the 6 o'clock position.

41. CAUTION: Do not tighten the bolts at this time. Transmission failure could occur.

Install new intermediate/overdrive cylinder feed bolt.

42. Loosen the center bolt and remove the Clutch Spring Fixture.

43. Note:
- On coast clutch assemblies having PTO ring gear, the overdrive clutch plates must be installed prior to coast clutch assembly.
- The number of plates in the clutch pack is model-dependent.
- Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the (A) overdrive clutch pack starting with a steel plate and alternating with friction plates. Install the overdrive clutch pressure plate with the (B) dot facing outward and in the 12 o'clock position.

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

Install the overdrive clutch pressure plate retainer snap ring with the ring opening in the 6 o'clock position.

45. Check the stack- up clearance.
- Using a feeler gauge, check the stack-up clearance in 3places, 120 degrees apart.
- If the clearance is not to specification, install the correct selective overdrive clutch pressure plate retainer snap ring and recheck the clearance.