Assembly

Special Tools:

CAUTION: Before beginning assembly, perform/inspect the following:

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. The necessary torques can be found in the Specifications.

When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.

Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.

Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.

1. If removed, use Case Rear Bushing Replacer and Impact Slide Hammer to install the rear case bushing.
1. Position the rear case bushing and Case Rear Bushing Replacer from inside of the case.
2. Thread Impact Slide Hammer into Case Rear Bushing Replacer through the back of case.
2. Place the transmission in the vertical position.

3. Coat No. 9 case rear bearing with petroleum jelly and install on the case boss.

4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur.

Install the (A) output shaft, (B) output shaft ring gear and the (C) direct clutch as an assembly.

5. Note: The reverse band support retaining ring is used during production only. The reverse band support retaining ring is not required during assembly, and it will not affect the operation of the transmission.

Install the reverse band support retaining ring.

6. Note: Make sure the band is seated on the anchor pins.

Install the reverse band.

7. Note: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.

Note: The top of the planetary gear support must be below the snap ring groove.

Install the planetary assembly and planetary gear support as a unit.
^ Rotate the output shaft to fully seat the planetary assembly.

8. Install the case to planet support spring.

9. Install the center support retaining ring.
^ Reference the retaining ring tabs to the band anchor pin location.

10. Install the forward clutch sun gear, No. 5 forward clutch sun gear bearing and the reverse sun gear.

11. Install the No. 4 forward clutch hub bearing.

12. Install the intermediate stub shaft.

13. Install the (A) forward clutch hub and the (B) No. 3 forward clutch hub front bearing.

14. Install the forward clutch assembly.

15. Note: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.

Install the (1) reverse clutch cylinder assembly and the (2) No. 2 forward clutch bearing.

16. Install the overdrive band.
^ Position the overdrive band pocket onto the anchor pin.

17. Install the overdrive servo spring.
1. Install the overdrive servo piston return sprint.
2. Install the overdrive servo piston.

18. Verify the tip of the piston assembly engages the pocket of the overdrive band.

19. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.

20. Install the intermediate clutch pressure plate.

21. Install the intermediate clutch pack and selective steel plate.

22. Using the special tool, check the intermediate clutch clearance.
1. Position Gauge Bar on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.

Selective Steel Plates

23. Using the special tool, measure end clearance for the No.1 front pump thrust washer.
1. Position Gauge Bar on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.
Use the No.1 thrust washer chart to select the proper washer.

No.1 Thrust Washer Chart

24. Install the No.1 front pump support thrust washer.
^ Use petroleum jelly to hold the washer in mace.

25. Install an alignment pin at the top of the case.

26. Note: Make sure the gasket is positioned correctly and the case passages are not covered.

Install the pump gasket.

27. Note: To aid assembly, shake the input shaft while pushing down on the pump.

Install the pump assembly.

28. Remove the alignment pin and install the front pump bolts.
^ Alternate bolt tightening to set the pump.
29. Rotate the transmission to the horizontal position.

30. Install the parking pawl.
1. Position the parking pawl return spring.
2. Position the parking pawl.
3. Install the parking pawl shaft.

31. Install a new extension housing gasket and the extension housing.
1. Position the extension housing.
2. Install the four bolts and two nuts.

32. Using the special tool, install a new extension housing seal.

33. Install the Output Shaft Speed (OSS) sensor.
1. Position the OSS sensor.
2. Install the bolt.

34. Using the special tool, install the manual control lever seal.

35. Note: Lubricate the Electronic Pressure Control (EPC) solenoid O-rings with transmission fluid. Install the EPC solenoid.

36. Install the (A) manual valve detent lever and (B) parking lever actuating rod.

37. Install the manual control lever shaft.
1. Slide the manual control shaft into the case.
2. Install the manual lever shaft inner nut.
3. Install the manual lever shaft retaining pin.

38. Install the fluid screen.

39. Install the 1-2 accumulator piston assembly.
1. Install the 1-2 accumulator upper spring.
2. Install the 1-2 accumulator.
3. Install the 1-2 accumulator lower spring.
4. Install the 1-2 accumulator cover and seal.

40. Using the special tool, install the 1-2 accumulator retaining ring.

41. Note: This is not an ordinary installation procedure and does not compensate for band wear. When piston and rod assembly replacement becomes necessary, or when the reverse band has been replaced, the reverse piston and rod length must tee adjusted.

Note: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.

Install the reverse servo piston and return spring.

42. Install Servo Piston Tool.
^ Tighten the bolt.

43. Attach Dial Indicator with Bracketry.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.

44. Loosen the bolt until the piston stops against the tool.

45. Verify the amount of piston travel on the dial indicator is within specification.

46. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two grooves, or (C) three grooves to bring the servo piston travel within specification.

47. Remove the Dial Indicator and Servo Piston Tool.

48. Install the proper servo rod, piston assembly and the reverse servo piston cover and seal.

49. Using the special tool, install the reverse servo retaining ring.
1. Compress the reverse band servo.
2. Install the reverse band servo retaining ring.

50. Install the 2-3 accumulator assembly.
1. Install the accumulator piston.
2. Install the accumulator piston spring.
3. Install the accumulator spring retainer.

51. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.

52. Note: The tab on the electrical connector is secured by main control valve body.

Install the electrical connector into the case.

53. Note: The alignment bolts are valve body assembly bolts and are in the valve body.

Align the main control valve body alignment bolts and position the main control valve body.

54. Note: The main control valve body bolts will be tightened in later steps.

Loosely install the 11 long main control valve body bolts.

55. Note: The main control valve body bolts will be tightened in later steps.

Loosely install the 12 short main control valve body bolts.

56. Install the manual control valve detent lever spring.
1. Position the manual control valve detent lever spring.
2. Install the bolt.

57. Tighten the bolts in the sequence shown.

58. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector.
^ Connect the EPC solenoid.
^ Connect the TCC solenoid.
^ Connect the shift solenoid SSA and SSB.

59. Install the fluid filter and seal assembly.

60. Position the (B) pan magnet onto the (A) fluid pan.

61. Note: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused.

Install the fluid pan.
1. Position the transmission fluid pan.
2. Install the 14 transmission fluid pan bolts.

62. Install the digital Transmission Range (TR) sensor.
1. Install the digital TR sensor.
2. Loosely install the digital TR bolts.

63. Note: The tool is designed to fit snug.

Note: Manual shift lever must be in the neutral position.

Using the special tool, align the digital TR sensor slots.

64. Tighten the bolts.

65. Lightly lubricate the converter hub with MERCON(R) V Automatic Transmission Fluid XT-5-QM, or equivalent meeting Ford specification MERCON(R) V.

66. WARNING: The torque converter can fall out if the transmission is tipped.

CAUTION: Do not damage the pump drive gear O-ring when installing the torque converter.

CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Using the special tools, install the torque converter.

67. Use Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B. Lubricate the torque converter pilot hub.