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Home >> Ford Truck >> 2010 >> F 150 2WD V8-5.4L Flex Fuel >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> 6R80 >> Assembly >> Steps 1-40

Steps 1-40




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. Refer to Clutch Plate Quantity chart in the Specifications.

NOTE: For vehicles equipped with a 4.6L or 5.4L engine, the Transmission Control Module (TCM) is part of the molded leadframe.

NOTE: For vehicles equipped with a 6.2L engine, the PCM replaces the TCM.

All vehicles

1. Install the detent spring and the 2 bolts.
- Tighten to 12 Nm (106 lb-in).





2. Position the park pawl and spring into the case and install the park pawl pin.

1. Park pawl

2. Park pawl spring

3. Park pawl pin





3. Install the park pawl pin bolt.
- Tighten to 23 Nm (17 lb-ft).





4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer 307-559.





5. Using the Shifter Fluid Seal Installer 307-559, install the manual control lever shaft seal.





6. Assemble the manual valve detent lever assembly and park pawl actuator rod.





7. Position the detent lever and park pawl actuator rod in the transmission case.





8. Position the manual control lever spacer in place and slide the manual control lever shaft in the case and into the manual lever detent plate.

1. Manual control lever spacer

2. Manual control lever shaft

3. Manual control lever detent plate





9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual control lever shaft and install a new roll pin using a suitable tool.





10. Install the park rod actuating plate and the 4 bolts.
- Tighten to 12 Nm (106 lb-in).





Four-Wheel Drive (4WD) vehicles

11. If removed, position a new bearing on Needle Bearing Installer 307-639. Install the bearing with the flat bearing surface facing down and the rounded bearing surface facing up so that when installed, the flat surface is on the snap ring side and the rounded surface is on the transmission case side.

1. Rounded bearing surface facing up

2. Flat bearing surface facing down





12. Using the Needle Bearing Installer 307-639, the Drawbar 204-029 and the Front Wheel Hub Oil Seal Installer 205-276, install the bearing in the transmission case.





13. Install the snap ring.





Rear Wheel Drive (RWD) vehicles

14. Install the bearing on the Rear Bearing Remover/Installer 307-647.





15. Assemble the Front Wheel Hub Oil Seal Installer 205-276 and the Rear Bearing Remover/Installer 307-647 on the Drawbar 204-029 and install the bearing in the transmission case.





16. Remove the Front Wheel Hub Oil Seal Installer 205-276, the Rear Bearing Remover/Installer 307-647 and the Drawbar 204-029.





17. Position the thrust bearing spacer in place.





18. Using the Needle Bearing Installer 307-639 and a press, press the thrust bearing spacer in place.





19. Install the T12 thrust bearing.





20. Install the slip plane washer.





All vehicles

21. Place the transmission in the vertical position.

22. Install the T11 bearing, planet carrier hub and output shaft assembly.





4WD vehicles

23. Position a new output shaft seal in place.





24. Using the Rear Seal 4X4 Installer 307-637, install the output shaft seal.





RWD vehicles

25. Position a new output shaft seal on the Rear Seal Installer 4X2 307-638.





26. Using the Rear Seal Installer 4X2 307-638, install the output shaft seal.





27. Install the output shaft flange and the extension housing flange seal.





28. Loosely install a new output shaft flange nut.





All vehicles

29. Install the T10 bearing and silver shim (caged bearing) on the planet carrier hub and output shaft assembly.





30. Install the T9 roller bearing race in the bottom of the carrier.





31. Install the top T8 and the bottom T9 roller bearings onto the sun gear.





32. NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque converter housing.

Install the sun gear into the planet assembly.





33. Install the low/reverse sun gear and race in the planet carrier.





34. Install the planet carrier.





35. NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional information, refer to the Clutch Plate Quantity Chart in the Specifications.

Soak the new low/reverse clutch plates in clean automatic transmission fluid.





36. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates and ending with the wave spring plate on the top.





37. NOTE: Inspect and install a new thrust bearing as required.

Install the low/reverse thrust bearing T7 and the select fit thrust gear shim.





38. NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.

Install the center support into the case.





39. NOTE: Rotate the case to a horizontal position.

Using the Retaining Ring Pliers 307-343, install the center support snap ring. Using a suitable tool, be sure the snap ring is fully seated.





RWD vehicles

40. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transmission case and position the plunger on the output shaft flange.




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