Part 2

79. Turn the center bolt on the clutch spring compressor until the snap ring groove is exposed.
80. Position the low/reverse clutch piston pressure plate retainer snap ring into the snap ring groove. Then remove the clutch spring compressor, bolts, transaxle shift seal installer, and clutch spring compressor bar.





81. Install the low one-way clutch (roller) into the front planet by turning the front planet clockwise.

CAUTION: After installing the low one-way clutch (roller), ensure that the low one-way clutch rotates in only the clockwise direction.





82. Use a screwdriver to install the low one-way clutch pressure plate retainer snap ring.





83. Install the primary sun gear lower thrust washer onto the front planet.

NOTE: Coat the primary sun gear lower thrust washer with petroleum jelly.





84. Install the primary sun gear bearing race, primary sun gear upper thrust washer and the 3-4 clutch hub onto the primary sun gear.

NOTE: Coat the primary sun gear upper thrust washer with petroleum jelly.





85. Install the 3-4 clutch hub and the primary sun gear into the transaxle case.





86. Install the 3-4 clutch drum and input shaft upper thrust washers and the 3-4 clutch hub bearing onto the 3-4 clutch hub.

NOTE: Coat the 3-4 clutch drum and input shaft upper and lower thrust washers with petroleum jelly.

87. Align the reverse clutch drive plates.





88. Install the input shaft and 3-4 clutch assembly into the reverse clutch assembly.

NOTE: Remove any paper and/or tape used to keep the oil distributor sleeve seals in place.

89. Align the teeth of the 3-4 clutch internal spline clutch plates.





90. Install the 3-4 clutch/reverse clutch assembly into the transaxle case.
91. Place Gauge Bar T80L-77003-A across the output shaft rear bearing surface.

NOTE: Total end play and reverse clutch drum end play must be adjusted when one or more of the following items are replaced.
- Transaxle case.
- Coasting clutch hub.
- Ring gear.
- Rear planet.
- Rear sun gear.
- Front planet.
- Primary sun gear.
- 3-4 clutch hub.
- Forward clutch cylinder and shaft.
- Oil pump cover.
- Reverse clutch drum.





92. Using Depth Micrometer D80P-4201-A, or equivalent, measure from the top of the gauge bar to the mating surface of the oil pump assembly. This is measurement A.

NOTE: Always make measurements in at least two places.

93. Subtract the gauge bar thickness, 17.78 mm (0.700 inch), from measurement A. This is measurement B.
94. Place the gauge bar across the oil pump mating surface.

CAUTION: Ensure that the oil pump gasket is installed on the transaxle case oil pump mating surface prior to making the following measurements. Readings will be incorrect if the oil pump gasket is not present.





95. Measure from the top of the gauge bar to the 3-4 clutch drum and input shaft upper thrust washer. This is measurement C.

NOTE: Always make measurements in at least two places.

96. Subtract the thickness of the gauge bar 17.78 mm (0.700 inch), from measurement C to get measurement D.
(C - 17.78 mm [0.700 inch] = D).
97. Subtract measurement B from measurement D to get total end play (D-B = total end play).
98. Select a bearing race to bring the end play within 0.25-0.55 mm (0.0098-0.0217 inch).

3-4 Clutch Bearing Race Size
Thickness and Part Number:
0.8 mm (0.031 inch): F3XY-7L165-A
0.9 mm (0.035 inch): F3XY-7L165-H
1.0 mm (0.039 inch): F3XY-7L165-B
1.1 mm (0.043 inch): F3XY-7L165-J
1.2 mm (0.047 inch): F3XY-7L165-C
1.3 mm (0.051 inch): F3XY-7L165-K
1.4 mm (0.055 inch): F3XY-7L165-D
1.5 mm (0.059 inch): F3XY-7L165-L
1.6 mm (0.063 inch): F3XY-7L165-E
1.7 mm (0.067 inch): F3XY-7L165-M
1.8 mm (0.071 inch): F3XY-7L165-F
1.9 mm (0.075 inch): F3XY-7L165-N
2.0 mm (0.079 inch): F3XY-7L165-G





99. Place Gauge Bar T80L-77003-A across the top of the output shaft rear bearing surface.
100. Use Depth Micrometer D80P-4201-A to measure from the gauge bar to the oil pump mating surface. This is measurement A.

NOTE: Always make measurements in at least two places.





101. With the gauge bar in the same position, measure to the reverse clutch drum thrust washer mating surface. This is measurement B.

NOTE: Always make measurements in at least two places.

102. Measurement B subtracted from measurement A equals C (A - B = C).





103. Place the gauge bar across the oil pump mating surface and measure to the reverse clutch drum mating surface. This is measurement D.

CAUTION: Ensure that the oil pump gasket is installed on the transaxle case oil pump mating surface prior to making the following measurements. Readings will be incorrect if the oil pump gasket is not present.

NOTE: Always make measurements in at least two places.

104. Subtract the thickness of the gauge bar, 17.78 mm (0.700 inch), from measurement D to get measurement E
(D - 17.78 mm [0.700 inch] = E).
105. Subtract measurement C from measurement E to get the reverse clutch drum end play (E - C = reverse clutch drum end play).
106. Select a thrust washer to bring the reverse clutch drum end play within 0.55-0.9O mm (0.0217-0.0354 inch).

Reverse Clutch Drum End Thrust Washer Size
Thickness and Part Number:
0.80 mm (0.0315 inch): F3XY-7D061-A
0.95 mm (0.0374 inch): F3XY-7D061-C
1.10 mm (0.0433 inch): F3XY-7D061-D
1.25 mm (0.0492 inch): F3XY-7D061-E
1.40 mm (0.0551 inch): F3XY-7D061-B
1.55 mm (0.0610 inch): F3XY-7D061-F
1.70 mm (0.0669 inch): F3XY-7D061-G
1.85 mm (0.0728 inch): F3XY-7D061-H





107. Install the 2-4 band adjusting stop and band adjusting stop locknut into the transaxle case.

NOTE: Ensure that the 2-4 band adjusting stop is clean of any old sealant.





108. Place the 2-4 band and band strut around the reverse clutch drum.





109. Install the 2-4 servo piston assembly and the 2-4 servo piston spring into the transaxle case.





110. Position the new gasket and fourth apply piston retainer. Install the three fourth apply piston retainer bolts. Tighten the fourth apply piston retainer bolts to 20-24 Nm (14-17 inch lbs.).
111. Tighten the band adjusting stop until the 2-4 band fits evenly around the reverse clutch drum.





112. Install the 3-4 clutch drum bearing race selected in the total end play procedure onto the oil pump.

NOTE: Coat the 3-4 clutch drum bearing race with petroleum jelly.

113. Place the reverse clutch drum thrust washer selected in the reverse clutch end play onto the reverse clutch drum.

NOTE: Coat the reverse clutch drum thrust washer with petroleum jelly.

114. Install the oil pump, the oil pump gasket and the oil pump baffle plate onto the transaxle case.
115. Install and tighten the eight oil pump bolts to 18-21 Nm (13-15 ft. lbs.)





116. Install a new input shaft O-ring onto the input shaft.

NOTE: Coat the new input shaft O-ring with transaxle fluid.

117. Tighten the band adjusting stop to 4-6 Nm (35-53 inch lbs.).
118. Back the band adjusting stop off 2.5 turns. Tighten the band adjusting stop locknut to 31-36 Nm (23-27 ft. lbs.)





119. Apply compressed air to the transaxle case and check that the 2-4 band operates properly. Check through both passages.





120. Install the differential into the transaxle case.





121. Install the differential lubricant tube into the torque converter housing. Install and tighten the three differential lubricant tube bolts to 5-7 Nm (44-61 inch lbs.).





122. Install a new differential oil port O-ring onto the differential oil port of the transaxle case.

CAUTION: Ensure the new differential oil port O-ring is properly installed on the transaxle case.





123. Apply Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5 to the torque converter housing mating surface.

CAUTION: Use only Gasket Maker E2AZ-19562-B sealant or equivalent meeting Ford specification WSK-M2G348-A5.

NOTE: Wash the transaxle case and torque converter housing mating surfaces with a brake cleaner type solvent. Ensure that the mating surfaces are smooth and clean.





124. Install the converter housing onto the transaxle case. Install and tighten the 21 torque converter housing-to-transaxle case bolts to 43-47 Nm (32-35 ft. lbs.)





125. Install the rear lube oil transfer tube seal, low/reverse clutch apply oil transfer tube, and two low/reverse clutch apply oil transfer tube bolts. Tighten the two low/reverse clutch apply oil transfer tube bolts to 5-7 Nm (44-61 inch lbs.).
126. Check the contact surfaces of the accumulator pistons for damage. Replace the accumulator pistons if necessary.
127. Apply transmission fluid onto the new upper accumulator seals and install the upper accumulator seals onto the N-D accumulator.

NOTE: Apply transmission fluid to the inner surface of the transaxle case.





128. Install the D-R accumulator piston in its bore.





129. Install the D-R accumulator return spring on the D-R accumulator piston.





130. Install the N-D accumulator piston spring in its bore.
131. Apply transmission fluid onto the new accumulator retainer seal and install the accumulator retainer seals onto the N-D accumulator piston.





132. Install the N-D accumulator piston in its bore.





133. Use compressed air to check the operation of the clutches and the 2-4 band.

CAUTION: Do not apply over 392 kPa (57 psi) of air pressure.





134. Install four new O-rings onto the transaxle case.

NOTE: Apply petroleum jelly to the O-rings.





135. Route the valve body wiring harness through the transaxle case and clip the spring clip in place.

NOTE: Apply transmission fluid to the manual valve.

136. Set the manual shift linkage rod to the NEUTRAL position.





137. Install the main control valve body into the transaxle case while aligning the manual valve with the manual detent lever.

Valve Body Bolt Specifications:

Valve Body Bolt Removal:

138. Tighten the valve body bolts a, b, and c to 7-9 Nm (62-79 inch lbs.).
139. Ensure that the transaxle and transmission oil pan mating surfaces are smooth and clean.





140. Install the two oil pan magnets into the transmission fluid pan.

CAUTION: The magnetic field created by the oil pan magnets disturbs the operation of the solenoid valves. To ensure proper solenoid valve operation, install the oil pan magnets in the same location they were removed.

141. Install a new oil pan to case gasket and the transmission fluid pan to the transaxle.
142. Install and tighten the 21 new transmission oil pan bolts in a crisscross pattern to 7-9 Nm (62-79 inch lbs.).
143. Install the transmission drain plug and a new transmission drain plug gasket. Tighten the transmission drain plug to 29-39 Nm (22-29 ft. lbs.)
144. Place the manual shift linkage rod in the PARK position.
145. Temporarily install the Transmission Range (TR) switch onto the manual shift linkage rod.
146. Move the manual shift linkage rod to the NEUTRAL position.





147. Insert Gear Position Sensor Adjuster T92P-70010-CH into the TR switch and manual shaft adjustment holes as vertically as possible.
148. Tighten the TR switch bolts to 3 Nm (27 inch lbs.).
149. Remove the pin from the TR switch.





150. Install the transmission oil cooler tube onto the transaxle. Tighten the transmission oil cooler tube bolts to 29-49 Nm (22-36 ft. lbs.) Tighten the transmission oil cooler tube bracket bolt to 4.4-5.8 Nm (39-51 inch lbs.).
151. If a new torque converter is used, add approximately 1 liter (1.125 qt.) of specified transmission fluid to the torque converter.
152. If the old torque converter is used, add the same amount of transmission fluid as the amount which was drained from the torque converter during removal.





153. Install the torque converter while aligning the torque converter notches and the oil pump assembly notches.

Torque Converter Installation:

154. Measure distance A to ensure that the torque converter is in the proper position. Distance A should measure at least 19 mm (0.75 inch).
155. If the torque converter is not in the proper position, reseat the torque converter.
156. Remove the transaxle from the holding fixture.