Part 2

Install the front band anchor strut.





62. Install the front band adjusting screw.





63. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

CAUTION: The tabs on the washer go into the pump face.

Perform front end play check procedure as follows:
^ Coat the fluid pump inlet thrust washer (No. 1) with petroleum jelly.
^ Install the fluid pump inlet thrust washer (No. 1) on the rear of the fluid pump and place pump into position in case.





64. CAUTION: The special tool must rest on the gasket surface.

Measure the front end play clearance.
1. Place special tool across the case.
2. Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
^ Read the measurement and subtract special tool thickness -17.78 mm (0.700 inch). This is dimension A.
^ Repeat the measurement at the opposite side of the transmission case. This is dimension B.
^ Add dimensions A and B together and divide by two. This is front end clearance dimension C.

65. CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.

NOTE: The front end play specification is 0.18 - 0.70 mm (0.007 - 0.028 inch).

Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).





Front End Play Selective Thrust Washer No. 1





66. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

CAUTION: The tabs on the washer go into the pump face.

Remove pump and install No. 1 thrust washer onto pump. After installing selected front pump thrust washer No. 1, repeat front end play check. Make sure correct end play, then remove pump for assembly.





67. Install a new O-ring in fluid pump drive gear.





68. CAUTION: Lubricate the special tool with Ford Multi-Purpose Grease DOAZ-19584-A meeting Ford specification ESA-M1C45-A.

Install the fluid pump drive gear on special tool to seat O-ring. Remove the tool.





69. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.

Install the pump gears into the fluid pump housing. Apply Ford Multi-Purpose Grease DOAZ-19584-A meeting Ford specification ESA-MC193-B to pump gear to prevent scoring at start-up.





70. CAUTION: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.





71. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.

NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.

Install the fluid pump on the converter housing.
^ Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.





72. Loosely install the fluid pump screws.





73. CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.





74. Thread the gauge into special tool and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.





75. Tighten the fluid pump bolts in a star pattern and remove the pump alignment handle.





76. Install a new fluid pump seal ring.
^ Coat the fluid pump seal ring with petroleum jelly.





77. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.

Install a new fluid pump gasket.
^ Hold the fluid pump gasket in place with petroleum jelly.





78. CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.

Install the front pump support seal.





79. Install the selected No. 1 fluid pump thrust washer.
^ Coat the fluid pump thrust washer with petroleum jelly.





80. Install the special tools into the transmission case.





81. CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.

Install the input shaft.





82. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1) selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring remain in the correct position throughout this step.

Install the fluid pump and converter housing onto the case.





83. NOTE: Lubricate O-rings on converter housing screws.

Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.





84. Remove the input shaft.

85. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.

Rotate the transmission assembly so the fluid pan all are facing up.





86. Assemble the front servo assembly.
1. Install the front servo cover O-ring on front servo cover. Coat the front servo cover O-ring with petroleum jelly.
2. Install front servo piston into the front servo cover.
3. Install the front servo piston spring on the front servo piston.





87. CAUTION: Do not damage the front servo to case O-ring during installation.

CAUTION: Do not press the front servo cover and O-ring past the relief hole in the case or O-ring damage may occur.

Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.





88. Assemble the intermediate servo assembly.
1. Install the intermediate servo cover O-ring on intermediate servo cover. Coat the intermediate servo cover O-ring with petroleum jelly.
2. Install intermediate servo piston into the intermediate servo cover.
3. Install the intermediate servo piston spring on the intermediate servo piston.





89. CAUTION: Do not damage servo cover to case O-ring during installation.

CAUTION: Do not press the intermediate servo cover and O-ring past the relief hole in the case or O-ring damage may occur.

Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.





90. CAUTION: Do not allow front band adjustment screw to back out. Band strut can fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install new locknut on the band adjustment screw.





91. CAUTION: The front servo must be installed prior to band adjustment.

NOTE: The wrench will click at the specified torque.

Tighten front band adjustment screw using the special tool and back off front band adjustment screw exactly two (2) turns and hold that position.





92. Tighten the front band locknut.
1. Hold the front band adjustment screw stationary.
2. Tighten the front band locknut.





93. CAUTION: Do not allow intermediate band adjusting screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install new nut on the band adjustment screw.





94. CAUTION: The intermediate servo must be installed prior to band adjustment.

NOTE: The wrench will click at the specified torque.

Tighten intermediate band adjusting screw using the special tool and back off intermediate band adjusting screw exactly two (2) turns and hold that position.





95. Tighten the intermediate band locknut.
1. Hold the intermediate band adjustment screw stationary.
2. Tighten the intermediate band locknut.





96. CAUTION: Install new O-rings on the 16-pin electrical connector. Coat the O-rings with petroleum jelly.

NOTE: Make sure that the tab is in the lock position.

Position the transmission case (16-pin) electrical connector into the case bore.
^ Press the transmission case (16-pin) electrical connector through the case until a click is heard.





97. CAUTION: Do not overstretch the retaining spring.

Install the 16-pin electrical connector retaining spring.





98. CAUTION: Align the slot on the turbine shaft speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.

Install the TSS sensor electrical connector into the transmission case (16-pin) electrical connector.
1. Connect the TSS sensor electrical connector.
2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.





99. Install the special tools into the transmission case.