Part 1

ASSEMBLE





1. Use Differential Bearing Cup Replacer T88C-7025-BH and Driver Handle T80T-4000-W to install the differential bearing outer race into the converter housing.

NOTE:
- Whenever the transaxle is disassembled, the bearing preload must be adjusted. The differential bearing preload is adjusted by selecting shim(s) to insert under the differential bearing outer race in the transaxle case.
- Do not install the differential bearing shim at this time.

2. Place the differential into the converter housing.

Torque Converter Housing Spacers:

3. Place six Spacers (part of T88C-77000-JF) on the converter housing at the positions shown.
4. Place Shim Selection Gauge (part of T88C-77000-C) onto the differential bearing. Turn the two halves of the gauge to eliminate any gap between them.
5. Place the differential bearing race on top of Shim Selection Gauge (part of T88C-77000-C).





6. Place the transaxle case onto the Spacers and install the Shim Selection Tool Bolt Set T92P-77000-DH. Tighten the bolts to 43-47 Nm (32-35 ft. lbs.)





7. Use the Pins (part of T88C-77000-JF) to open the gauge halves until all the free play is gone and the differential bearing race is seated.
8. Turn the gauge halves in the opposite direction to eliminate any gap between the gauge halves.
9. Engage Differential Rotator T92P-77000-BH and an inch-pound torque wrench to the differential.





10. Turn the differential and measure the turning torque while the differential is turning.
11. Use the pins to separate the gauge halves until a turning torque of 0.78-1.37 Nm (6.9-12.2 inch lbs.) is achieved.





12. Use a feeler gauge the measure the gap between the two gauge halves.

NOTE: Always measure the gauge halve gap at four points, 90 degrees apart. Use the largest of these measurements.

13. Use the Differential Bearing Shim Specifications chart to determine the proper thickness required for a differential bearing shim, based on the gap measured between the two gauge halves.

Differential Bearing Shim Specifications
Thickness and Part Number:
0.48 mm (0.0189 inch): F3XY-4067-A
0.52 mm (0.0205 inch): F3XY-4067-B
0.56 mm (0.0220 inch): F3XY-4067-C
0.60 mm (0.0236 inch): F3XY-4067-D
0.64 mm (0.0252 inch): F3XY-4067-E
0.68 mm (0.0268 inch): F3XY-4067-F
0.72 mm (0.0283 inch): F3XY-4067-G
0.76 mm (0.0299 inch): F3XY-4067-H
0.80 mm (0.0315 inch): F3XY-4067-J
0.84 mm (0.0331 inch): F3XY-4067-K
0.88 mm (0.0346 inch): F3XY-4067-M
0.92 mm (0.0362 inch): F3XY-4A053-B

14. Remove the bolts and separate the transaxle case from the torque converter housing.
15. Remove the spacers, gauge halves and differential.
16. Install the appropriate differential bearing shim in the transaxle case.





17. Use Differential Bearing Cup Replacer T88C-7025-BH and Driver Handle T80T-4000-W to install the differential bearing outer race into the transaxle case.





18. Use Shifter Shaft Seal Replacer T92P-77000-EH to install the manual control lever oil seal.

NOTE: Apply transmission fluid to the manual control lever oil seal.

19. Install the manual shift linkage rod, manual detent lever and park actuator support into the transaxle case.





20. Align the groove of the manual shift linkage rod with the hole in the transaxle.
21. Install a new manual shift linkage rod roll pin to the bottom of the hole in the manual shift linkage rod.

CAUTION: If the manual shift linkage rod roll pin protrudes further than the bottom of the manual shift linkage rod, it may cause binding.

22. Install a new park actuator support roll pin into the park actuator support.

NOTE: Install the new park actuator support roll pin so that both of the ends protrude approximately 3 mm (0.12 inch).

23. Install the parking lever actuating rod onto the park actuator support.





24. Install a new manual detent lever inner pin into the manual detent lever.

NOTE: Install the new manual detent lever inner pin so that both of the ends protrude approximately 3 mm (0.12 inch).





25. Install the manual detent spring and the manual detent spring bolt. Tighten the manual detent spring bolt to 6.4-7.5 Nm (57-66 inch lbs.).





26. Use Differential Seal Replacer T87C-77000-H to install the differential oil seal on the transaxle.





27. Use Differential Seal Replacer T87C-77000-H to install the differential oil seal on the torque converter housing.
28. Install the reduction gear bearing outer race. Tighten the seven reduction gear bearing outer race bolts to 109-123 Nm (80-90 ft. lbs.)





29. Install the parking actuator support and the two parking actuator support bolts. Tighten the parking actuator support bolts to 20-24 Nm (14-17 ft. lbs.)

NOTE: Ensure that the parking actuator support tab faces down during assembly.





30. Install the parking pawl shaft into the transaxle.





31. Install the parking pawl over the parking pawl shaft and install the parking pawl return spring.





32. Place the transaxle case onto the reduction gear.





33. Place the idler gear bearing into the transaxle case to measure dimensions B. C, and D to calculate A (distance between the surface of the idler gear bearing inner race and the reduction gear adjusting shim mating surface of the reduction gear).





34. Use Depth Micrometer D80P-4201-A, or equivalent, and Gauge Bar T80L-77003-A to measure dimension B (distance between the end of the reduction gear and the surface of the transaxle case) in at least two places.

NOTE:
- Always make measurements in at least two places.
- Gauge Bar TO0L-77003-A is 17.78mm (0.700 inch) thick.





35. Use Depth Micrometer D80P-4201-A, or equivalent, and Gauge Bar T80L-77003-A to measure dimension C (distance between the surface of the idler gear bearing inner race and the surface of the transaxle case) in at least two places.

NOTE:
- Always make measurements in at least two places.
- Gauge Bar T80L-77003-A is 17.78 mm (0.700 inch) thick.





36. Use Depth Micrometer D80P-4201-A, or equivalent, and Gauge Bar T80L-77003-A to measure dimension D (distance between the end of the reduction gear and the reduction gear adjusting shim mating surface of the reduction gear) in at least two places.

NOTE:
- Always make measurements in at least two places.
- Gauge Bar T80L-77003-A is 17.78 mm (0.700 inch) thick.

37. Calculate dimension A. Use the equation A = D - (B + C).

Dimension "E" Measurement:

38. Measure dimension E (distance between the end of the idler gear and the idler gear bearing inner race mating surface) in at least two places.

NOTE: Always make measurements in at least two places.

39. Select the proper thickness of the reduction gear bearing adjusting shim. Use the equation for shim thickness = A - E - 0.5 mm (0.0020 inch).
Select an appropriate shim from one of the reduction gear bearing adjusting shim kits.
Reduction Gear Bearing Adjusting Shim Kits
- F3XY-7N 112-A for shims 5.00-5.52 mm (0.1969-0.2173 inch).
- F3XY-7N 112-B for shims 5.54-6.06 mm (0.2181-0.2386 inch).
- F3XY-7N 112-C for shims 6.08-6.72 mm (0.2394-0.2646 inch).

NOTE: Idler gear bearing preload specification is 0.05 mm (0.0020 inch).

40. Install the reduction gear and the reduction gear bearing adjusting shim into the transaxle case.





41. Use Step Plate Adapter D80L-630-10 or equivalent and Bearing Cone Replacer T88T-7025-B to press the idler gear bearing inner race onto the idler gear.





42. Use Differential Bearing Cup Replacer T88C-77000-FH and Driver Handle T80T-4000-W to install the idler gear bearing outer race into the transaxle case.





43. Use a new locknut to press the idler gear onto the reduction gear.

NOTE: After installation, ensure that the idler gear can be locked by the parking pawl.

44. Tighten the locknut to 294-324 Nm (217-239 ft. lbs.)

NOTE: Use the parking pawl to lock the idler gear while tightening the locknut.





45. Use Locknut Socket T87T-7025-AH and a preload gauge to measure the reduction gear turning torque. The turning torque should measure 0.05-0.39 Nm (0.43-3.47 inch lbs.).

NOTE: Spin the reduction gear several times in each direction to seat the bearing rollers properly.

46. If turning torque is too low, increase the thickness of the reduction gear bearing adjusting shim. If the turning torque is too high, reduce the reduction gear bearing adjusting shim thickness.





47. After the turning torque has been set within specifications, use Mainshaft Locknut Staking Tool T77J-7025-F to stake the lock nut.





48. Install the new lubrication circuit seal rings onto the output shaft and output shaft bearing retainer.

CAUTION: The output shaft lubrication circuit seal rings must be replaced.

NOTE: Pack the output shaft and output shaft bearing retainer lubrication circuit seal ring grooves with petroleum jelly.





49. Install the output shaft bearing retainer. Tighten the output shaft bearing retainer bolts to 20-24 Nm (14-17 ft. lbs.)





50. Install the output shaft hub thrust washer.





51. Install the output shaft assembly into the transaxle case.





52. Place a straightedge across the side cover mating surface and measure from the straightedge to the output shaft hub thrust washer surface. This measurement is A1.

NOTE:
- Use the equation T = A - B to select the output shaft bearing selective shim.
- To determine dimension A, subtract 17.78 mm (0.700 inch) (the thickness of Gauge Bar T80L-77003-A) from A1. Always make measurements in at least two places.

53. Subtract the thickness of Gauge Bar T80L-77003A (17.78 mm [0.700 inch]) from measurement A1.
The result is measurement A.





54. Place Gauge Bar T80L-77003-A across the output shaft hub thrust washer and measure down to the transaxle case. This is measurement B1.

NOTE: To determine dimension B. subtract 17.78 mm (0.700 inch) (gauge bar thickness) from B1.

Output Shaft Bearing "A" Measurement:

55. Use the equation A - B = output shaft bearing selective shim thickness, to select a output shaft bearing selective shim which results in the output shaft end play (T) of 0.0-0.15 mm (0.0-0.0059 inch).

Output Shaft Bearing Selective Shim Specifications
Thickness and Part Number:
0.80 mm (0.0315 inch): F3XY-7F405-A
0.84 mm (0.0331 inch): F3XY-7F405-B
0.88 mm (0.0346 inch): F3XY-7F405-C
0.92 mm (0.0362 inch): F3XY-7F405-D
0.96 mm (0.0378 inch): F3XY-7F405-E
1.00 mm (0.0394 inch): F3XY-7F405-F
1.04 mm (0.0409 inch): F3XY-7F405-G
1.08 mm (0.0425 inch): F3XY-7F405-H
1.12 mm (0.0441 inch): F3XY-7F405-J
1.16 mm (0.0457 inch): F3XY-7F405-K
1.20 mm (0.0472 inch): F3XY-7F405-L

56. Install the output shaft bearing selective shim onto the output shaft.





57. Apply Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5 to the inside of the transaxle case mating surface.

NOTE: Ensure that the transaxle case mating surfaces are clean and free from all old sealant material and transmission fluid.





58. Place the side cover onto the transaxle case Tighten the four new self-sealing transaxle case side cover A bolts and the ten remaining transaxle case side cover B bolts to 26-30 Nm (20-22 ft. lbs.)





59. Install the low/reverse clutch front pressure plate, six low/reverse clutch internal spline clutch plates, six low/reverse clutch external spline clutch plates, low/reverse clutch dish plate and low/reverse clutch rear pressure plate.
60. install the low/reverse clutch pressure plate retainer snap ring.





61. Measure the clearance between the low/reverse clutch front pressure plate and the transaxle case.
62. The standard clearance is 1.7-2.1 mm (0.067-0.083 inch) with a maximum of 3.5 mm (0.138 inch). If the clearance is not within the maximum specification, select and insert the proper low/reverse clutch pressure plate from the Low/Reverse Clutch Pressure Plate Specifications chart to obtain the standard clearance.

Low/Reverse Clutch Pressure Plate Specifications
Thickness and Part Number:
2.0 mm (0.079): F3XY-7B066-ABA
2.2 mm (0.087): F3XY-7B066-ACA
2.4 mm (O.O94): F3XY-7B066-ADA
2.6 mm (0.102): F3XY-7B066-AEA
2.8 mm (0.110): F3XY-7B066-AFA
3.0 mm (0.118): F3XY-7B066-AGA
3.2 mm (0.126): F3XY-7B066-AHA
3.4 mm (0.134): F3XY-7B066-AJA
5.4 mm (0.213): --------------





63. Place the forward clutch hub assembly lower thrust washer into the transaxle case.

NOTE: Place the forward clutch hub assembly lower thrust washer in the transaxle case with the black side facing up. Coat the forward clutch hub assembly lower thrust washer with petroleum jelly.





64. Install the forward clutch assembly. When the forward clutch assembly is properly installed, the edge of the forward clutch cylinder and bearing retainer should be at almost the same level.

NOTE: Align the teeth of the internal spline clutch plates for the low/reverse clutch before installing the forward clutch assembly. Ensure that the bearing retainer seal rings are not spread.





65. Install the forward clutch hub upper thrust washer into the transaxle case.

NOTE: Coat the forward clutch hub upper thrust washer with petroleum jelly.

66. Install the coasting clutch upper thrust washer on the coasting clutch hub.

NOTE: Ensure that the tabs on the coasting clutch upper thrust washer are facing the coasting clutch hub.





67. Install the coasting clutch hub into the transaxle case.

NOTE: Align the internal spline clutch plate teeth of the coasting clutch before installing.





68. Hold the forward clutch hub and turn the ring gear. If the ring gear turns counterclockwise and is installed properly, replace the forward one-way clutch (sprag).





69. Install the forward clutch hub and ring gear assembly into the transaxle case.

NOTE: Align the teeth of the forward clutch internal spline drive plates before installing. Ensure that the three tabs on the thrust washer are properly aligned after installation.





70. Install the rear sun gear rear thrust bearing and rear planet thrust bearing onto the rear planet.

NOTE: Coat the rear sun gear rear thrust bearing and rear planet thrust bearing with petroleum jelly.





71. Install the rear sun gear into the rear planet.





72. Install the rear planet assembly into the transaxle case.





73. Install the rear sun gear front thrust bearing onto the front planet. Then place the front planet and rear sun gear front thrust bearing into the transaxle case.

NOTE: Apply petroleum jelly to the rear sun gear front thrust bearing. Ensure that the rear sun gear front thrust bearing is properly installed with the black side to the front planet.





74. Set and align the low/reverse clutch piston.





75. Set and align the return springs to the transaxle case gutters.





76. Install the low/reverse clutch piston and low/reverse clutch piston retainer assembly into the transaxle case.

NOTE:
- Generously coat the low/reverse clutch piston and low/reverse clutch piston retainer assembly with petroleum jelly. This will hold the two pieces together during installation.
- Align the bracket to the specified gutter.

77. Push the low/reverse clutch piston and low/reverse clutch piston retainer assembly evenly and confirm that they move smoothly. If they do not move smoothly, remove the low/reverse clutch piston and return spring assembly. Align the return spring and reinstall the low/reverse clutch piston and return spring assembly.

Low/Reverse Clutch Piston Pressure Plate Installation:

78. Place the low/reverse clutch piston pressure plate retainer snap ring over the turbine shaft, and install the Intermediate Clutch Spring Compressor T81P-70222-A, Shim Selection Tool Bolt Set T92P-77000-DH, Shifter Shaft Seal Replacer T92P-77000-EH (as a step plate), Clutch Spring Compressor Bar T92P-77000-GH and Bolts (part of T88C-77000-JF).