Assembly 69 - 137

69. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.

Install the pump gears into the fluid pump housing. Apply Ford Multi-Purpose Grease DOAZ-19584-A meeting Ford specification ESA-MC193-B to pump gear to prevent scoring at start up.





70. CAUTION: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.





71. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.

Note: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.

Install the fluid pump on the converter housing.
- Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.





72. Loosely install the fluid pump screws.





73. CAUTION: Fluid Pump Alignment Set must be used to properly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Align the fluid pump to the fluid pump adapter plate and select the gauge from the Fluid Pump Alignment Set that is the snuggest fit when placed over the fluid pump.





74. Thread the gauge into Pump Alignment Handle and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.





75. Tighten the fluid pump bolts in a star pattern and remove the pump alignment handle.





76. Install a new fluid pump seal ring.
- Coat the fluid pump seal ring with petroleum jelly.





77. Note: Make sure the fluid pump seal ring is installed on the housing and pump assembly.

Install a new fluid pump gasket.
- Hold the fluid pump gasket in place with petroleum jelly.





78. CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.

Install the front pump support seal.





79. Install the selected No. 1 fluid pump thrust washer.
- Coat the fluid pump thrust washer with petroleum jelly.





80. Install Converter Guide Pins into the transmission case.





81. CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splices go into the assembly.

Install the input shaft.





82. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1) selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring remain in the correct position throughout this step.

Install the fluid pump and converter housing onto the case.





83. Note: Lubricate O-rings on converter housing screws.

Remove Converter Guide Pins. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.





84. Remove the input shaft.

85. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury.

Rotate transmission assembly so the fluid pan rails are facing up.





86. Assemble the front servo assembly.
1. Install the front servo cover O-ring on front servo cover. Coat the front servo cover O-ring with petroleum jelly.
2. Install front servo piston into the front servo cover.
3. Install the front servo piston spring on the front servo piston.





87. CAUTION: Do not damage the front servo to case O-ring during installation.

CAUTION: Do not press the front servo cover and O-ring past the relief hole in the case or O-ring damage may occur.

Using the Servo Cover Compressor, install the front servo assembly into the case.
1. Install Servo Cover Compressor.
2. Insert the front servo assembly into front servo bore in the transmission case.
3. Compress front servo cover and install the front servo cover retaining ring.





88. Assemble the intermediate servo assembly.
1. Install the intermediate servo cover O-ring on intermediate servo cover. Coat the intermediate servo cover O-ring with petroleum jelly.
2. Install intermediate servo piston into the intermediate servo cover.
3. Install the intermediate servo piston spring on the intermediate servo piston.





89. CAUTION: Do not damage servo cover to case O-ring during installation.

CAUTION: Do not press the intermediate servo cover and O-ring past the relief hole in the case or O-ring damage may occur.

Install the intermediate servo assembly into the case.
1. Install Servo Cover Compressor.
2. Insert the intermediate servo assembly into intermediate servo bore in the transmission case. Compress servo cover and install the intermediate servo cover retaining ring.





90. CAUTION: Do not allow front band adjustment screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install new locknut on the band adjustment screw.





91. CAUTION: The front servo must be installed prior to band adjustment.

Note: The wrench will click at the specified torque.

Tighten front band adjustment screw using the Band Adjuster Wrench Kit and back off front band adjustment screw exactly two (2) turns and hold that position.





92. Tighten the front band locknut.
1. Hold the front band adjustment screw stationary.
2. Tighten the front band locknut.





93. CAUTION: Do not allow intermediate band adjusting screw to back out. Band strut could fall out of position.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install new nut on the band adjustment screw.





94. CAUTION: The intermediate servo must be installed prior to band adjustment.

Note: The wrench will click at the specified torque.

Tighten intermediate band adjusting screw using the Band Adjuster Wrench Kit and back off intermediate band adjusting screw exactly two (2) turns and hold that position.





95. Tighten the intermediate band locknut.
1. Hold the intermediate band adjustment screw stationary.
2. Tighten the intermediate band locknut.





96. CAUTION: Install new O-rings on the 16-pin electrical connector. Coat the O-rings with petroleum jelly.

Note: Make sure that the tab is in the lock position.

Position the transmission case (16-pin) electrical connector into the case bore.
- Press the transmission case (16-pin) electrical connector through the case until a click is heard.





97. CAUTION: Do not overstretch the retaining spring.

Install the 16-pin electrical connector retaining spring.





98. CAUTION: Align the slot on the turbine shaft speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.

Install the TSS sensor electrical connector info the transmission case (16-pin) electrical connector.
1. Connect the ISS sensor electrical connector.
2. Insert the ISS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.





99. Install the Valve Body Guide Pins into the transmission case.
1. Install the large Valve Body Guide Pin (0.248).
2. Install the small Valve Body Guide Pin (0.235).





100. CAUTION: Make sure main control valve body gasket is aligned.

CAUTION: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.

Position the main control valve body into the transmission case.





101. Note: The screws will be tightened in Later steps.

Loosely install the four m6 x 45mm screws.





102. Note: The main control valve body screws will be tightened in later steps.

Loosely install the two m6 x 35mm screws.





103. Note: The main control valve body screw will be tightened in later steps.

Loosely install m6 x 30mm screw.





104. Remove the valve body guide pins.





105. Note: The main control valve body screws will be tightened in later steps.

Loosely install the sixteen m6 x 40mm screws.





106. Tighten the screws in the sequence shown.





107. Install the manual control valve detent lever spring.
1. Position the manual control valve detent lever spring on the main control valve body.
2. Install the screw.





108. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
2. Loosely install the screws.





109. Tighten the screws in the sequence shown.





110. Connect the solenoid electrical connectors.
1. Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
2. Connect the torque converter clutch (TCC) solenoid electrical connector.
3. Connect the electronic pressure control (EPC) solenoid electrical connector.





111. CAUTION: Excessive pressure may break the locating pins.

Install wiring loom protector and guide.
- Align the pins in the holes of the solenoid clamps and gently push down.





112. CAUTION: Make sure that both fluid pan filter O-rings are properly installed on the fluid pan filter prior to installation.

Install the fluid pan filter O-rings.
- Coat the fluid pan filter O-rings with MERCON V Automatic Transmission fluid XT-5-QM meeting Ford specification MERCON V.





113. Install the fluid pan filter.
1. Position fluid pan filter on the main control valve body.
2. Install the screw.





114. Install the transmission fluid pan and transmission fluid pan gasket.
- Loosely install the screws.





115. Tighten the screws.





116. Remove the transmission from the Holding Fixture and place on a flat surface.





117. Remove the fixture arm of the Holding Fixture from the A4LD Holding Fixture Adapter.





118. Note: Use petroleum jelly to hold the gasket in place.

Install a new extension housing gasket.





119. Note: The guide cup is press-fit into the extension housing and is not serviced separately.

Install the parking pawl assembly.
1. Install the parking pawl shaft into the extension housing.
2. Install the parking pawl.
3. Install the parking pawl return spring.





120. CAUTION: Make sure the parking lever actuating rod is correctly seated into the transmission case parking rod guide cup.

Install the extension housing.
1. Install the extension housing and gasket.
2. Install the screws.
3. Install the stud(s).





121. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.

Note: Install the extension housing bushing (7A034) only if removed in disassembly.

Note: Remove any burrs from the extension housing counterbore.

Align lube hole with the lube groove in extension housing. This groove is located at the 3 o'clock position when viewed from the rear.





122. CAUTION: Tool will bottom when bushing is in the proper position.

Using the Housing Bushing Replacer, install the extension housing bushing.
1. Position the Housing Bushing Replacer.
2. Install extension housing bushing.





123. Position new extension housing seal with drain hole in the 6 o'clock position.





124. Using Align Extension Housing Seal Replacer, install a new extension housing seal.
1. Align Extension Housing Seal Replacer.
2. Install the extension housing seal.





125. Install the digital transmission range (TR) sensor.
1. Position the digital TR sensor on the transmission.
2. Loosely install the screws.
3. Rotate manual lever to neutral position (two detents rearward).





126. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.

Note: The manual lever must be in the neutral position.

Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.





127. Install the manual control lever.
1. Install the Lever.
2. Install the nut.





128. Install transmission servo heat shield and nut.





129. Note: Inspect O-ring for damage. Replace if damaged.

Install the output shaft speed (OSS) sensor.
1. Install the sensor.
2. Install the screw.





130. CAUTION: The splices of the input shaft are not the same length on both ends. The shaft end with the shorter splices goes into the fluid pump.

Install the input shaft.





131. Check that the fluid pump gear seal ring is seated.
- Insert the Front Pump Seal Sizing Tool into the fluid pump drive gear.





132. CAUTION: Do not damage the fluid pump gear O-ring when installing 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.

Lubricate the converter hub with MERCON V; Automatic Transmission Fluid XT-5-QM or equivalent Meeting Ford MERCON 03 V specification.





133. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may result in personal injury.

Use the Torque Converter Handles to install the torque converter by pushing and rotating.





134. Note: Dimension "A" should be 10.23 - 14.43 mm (0.43 - 0.56 inch).

Make sure the torque converter is installed to specification.





135. Lubricate the torque converter pilot hub with Multi-Purpose Grease DOAZ-19584-A meeting Ford specification ESB-M1C93-B.
136. Before installing transmission, make sure that the transmission cooling system (line and cooler [s]) have been thoroughly flushed. If contamination cannot be removed or proper flow cannot be obtained, replace cooler(s) and/or lines.





137. Install the Torque Converter Holding Tool on case.