Part 2

Transmission















Disassembled Views

Transmission Disassembled View (Part 1):

Transmission Disassembled View (Part 2):

Transmission Disassembled View (Part 3):

NOTE: Clutch plate quantity is model dependant based on engine displacement:
- 4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)
- Four friction plates
- Five steel plates

- 5.4L engine (Expedition, Navigator, F-150)
- Five friction plates
- Six steel plates


All vehicles

45. Install the T6 thrust bearing.





46. Install the direct clutch drum.





47. Install the T5 bearing on the direct clutch assembly.





48. Install the forward and overdrive clutch assembly.





49. Install the selective pump washer.





50. If the front pump assembly was not disassembled and assembled, install a new front pump outer diameter O-ring seal and lubricate it with petroleum jelly.





51. Install a new front pump seal on the Fluid Pump Seal Installer 307-556.





52. Using the Fluid Pump Seal Installer 307-556, install the front pump seal.





53. Install the Transmission Fluid Pump Remover 307-553 on the front pump.





54. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover 307-553, position the pump assembly in the case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into the case.





55. Remove the Transmission Fluid Pump Remover 307-553.





56. Install new front pump bolts with new washers. Tighten the bolts in a crisscross pattern.
- Tighten to 10 Nm (89 lb-in).





57. Install the Transmission End Play Gauge 307-534 on the input shaft to measure the end play.
- Tighten the wing nut.





58. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the Transmission End Play Gauge 307-534.
- Push down on the Transmission End Play Gauge 307-534 and zero out the Dial Indicator Gauge.

- Lift up on the Transmission End Play Gauge 307-534 and record the measurement on the Dial Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump washer.

- Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.





59. Remove the Dial Indicator Gauge with Holding Fixture 100-002 and the Transmission End Play Gauge 307-534.





60. Install the 4 rubber feed tubes for the center support.

1. Black feed tubes

2. Green feed tube

3. Blue feed tube





61. NOTE: Make sure that the fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.

NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.

Install the rubber adapter and prime the fluid pump.





62. Install the thermal bypass valve into the case.





63. Align the mechatronic assembly guide pins in the alignment holes in the transmission case and position the mechatronic assembly in place.

1. Alignment holes

2. Guide pins





64. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the mechatronic assembly down.

Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and position the mechatronic assembly in place.





65. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the Transmission Control Module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.

Install the mechatronic assembly bolts and tighten the bolts in the sequence shown.

- Tighten to 8 Nm (71 lb-in).





66. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the Transmission Control Module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.

With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.





67. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.





68. Install a new transmission fluid filter.





69. NOTE: The fluid pan gasket can be reused if not damaged.

Install a new transmission fluid pan gasket if required.





70. Install the fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).





71. Using the Torque Converter Handle 307-091, install the torque converter. Remove the Torque Converter Handle 307-091.