Steps 1 - 68

Special Tools:

1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.

2. Inspect the transmission case for the following:
- stripped bolt hole threads
- gasket and mating surfaces for burrs or nicks
- obstructions to vent and fluid passages
- cracks or warpage

3. inspect the extension housing for cocks, burrs or warpage.

4. Inspect case bearing for damage. Install a new component as necessary. Follow Steps 5-8 if replacing the case bearing. If not replacing the case bearing, proceed to Step 9.

5. Using the special tool, remove the case bearing.
- Use an oil stone to remove any nicks or burrs in the bearing case bore.

6. Assemble the special tools.

7. CAUTION: Make sure bearing seal ring is facing the drive handle.

Install the bearing on the special tools.

8. Using the special tool, tap case bearing into case bearing bore.

9. WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.

Using the special tool, install the transmission into the bench with the converter housing facing up.

10. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.

11. Install the intermediate servo piston and spring.
- Lubricate the servo bore with MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.

12. Using the special tool, install the retaining ring.

13. Install the overdrive band servo piston and spring.
- Lubricate the servo bore with MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.

14. Using the special tools, install the retaining ring.

15. Install the parking lever rod.

16. Install the manual control lever.

17. Assemble the manual valve inner lever and parking lever actuating rod as shown.

18. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Install the manual control lever shaft.

19. Install the manual valve inner lever onto the manual shaft and loosely install the nut.

20. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.

Note: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.

Install the manual control lever shaft spring pin.
- Tap the manual control lever shaft spring pin into the transmission case.

21. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.

Tighten the nut.

22. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.

Install the output shaft thrust washer (No. 11).
- Coat the output shaft thrust washer with petroleum jelly.

23. Install the park gear on the output shaft.

24. Install the output shaft and park gear.

25. CAUTION: Make sure band is resting on the two anchor pins in the case.

Install the low/reverse band over the low/reverse bake drum.

26. Install the low/reverse brake drum.
- Rotate the low/reverse brake drum clockwise to install.

27. Note: The reverse band actuating lever must fit into the notches in the band.

Install the reverse band actuating lever into the reverse band.

28. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.

29. Install the No.10 needle bearing into the case.

30. CAUTION: Do not damage the seal against the case during assembly.

Install the output shaft ring gear, hub, and seal.

31. CAUTION:
Always install a new output shaft retaining ring.

Install a new output shaft retaining ring.

32. Note: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.

Install the output shaft sleeve.

33. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.

34. CAUTION: Make sure the needle bearings stay in place.

Install the low/reverse planetary assembly.

35. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.

Install the retaining ring.

36. Install the No. 8 thrust bearing.

37. Install the low and reverse gear spacer.

38. CAUTION: If new clutch plates are being used they should be soaked in clean MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V 30 minutes prior to installation. The friction side of the plates must face down toward cylinder.

Install the new clutch plates in an alternating order starting with an internally splined clutch plate into the clutch cylinder.
39. Install the clutch plate retaining ring.

40. Install the intermediate clutch assembly.

41. Install the intermediate clutch housing and piston assembly.

42. Install the special tools.

43. Install the special tools.

44. CAUTION: Do not use the original intermediate clutch retaining ring that was removed during disassembly.

Using the special tools, install a new service intermediate clutch retaining ring.

45. Note: The recess portion of the spray must face down during installation.

Install the spray and race assembly.

46. Install the input shell and sun gear assembly.

47. Note: The No. 13 bearing must be properly seated in the forward planet assembly so the sun gear can be installed correctly.

Install the forward planetary assembly.

48. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.

49. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.

50. Install the forward ring gear and hub as an assembly.

51. Install the No. 6A forward ring gear hub thrust bearing into the forward clutch. Use petroleum jelly to hold the bearing in place.

52. Install the forward clutch cylinder.

53. Install the No. 5 thrust bearing.

54. Install the direct clutch drum.

55. Using the special tool, measure from the top of the gauge bar to center support ledge in ease at four places 90 degrees apart.
- Add the four measurements, divide by four, and record as dimension "A".

56. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

Install the special tool.
1 Install the special tool and the bolts using the two pump screw locations at approximately 6 and 12 o'clock positions.
2 Tighten the center screw.

57. Note: Align the disc holes on special tool with the slot in gauge bar for correct measurement.

Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension "B". Repeat measurement 180 degrees opposite side of the special tool and record as dimension "C".
58. Add dimension "B" to "C", divide by two and record as dimension "D".
59. Subtract "A" from "D", and record as dimension "E".
60. Select bearing from the following chart using dimension "E".

61. Note: Make sure that the intermediate apply strut is aligned with the band notch.

Install the intermediate band.

62. Install the intermediate band anchor strut.

63. CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.

64. Loosely install the screw.

65. Install the intermediate band apply strut.

66. CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.

67. Install the selected No. 4 thrust washer on the direct clutch drum.
- Coat the thrust washer with petroleum jelly.

68. Note: Align the center support screw hole with correct case hole.

Install the center support.