A/T - AXODE/AX4S No Gear Engagement/Noise
Article No.94-20-9
10/05/94
TRANSAXLE - AXOD-E/AX4S - REVISED REAR LUBE TUBE RETENTION BRACKET
FORD:
1991-95 TAURUS
1993-95 TAURUS SHO
LINCOLN-MERCURY:
1991-94 CONTINENTAL
1991-95 SABLE
LIGHT TRUCK:
1995 WINDSTAR
ISSUE:
Some vehicles equipped with AXOD-E/AX4S Transaxles may experience a lack of Drive and/or Reverse when the vehicle is at a standstill or a reduced amount of drive and/or reverse (that may be preceded by a grinding or popping noise) during vehicle motion which causes a gradual slowing. This may be caused by the radial seal rear lube tube coming out of the case hole at the chain cover end of the transaxle. The loss of adequate lubrication to the front and rear planetary systems can result in planetary wear-out.
ACTION:
Install SHO-type tube retention brackets, which provide improved retention of the rear lube tube to prevent the tube from coming out of its position in the case. Refer to the following procedure for service details.
Use the two-piece design main tube bracket assembly kit (upper and lower brackets) with a center screw and a new flatted low/intermediate servo release tube, Figure 1, when:
1. Updating any 1991-93 AXOD-E/AX4S transaxle with the radial-type seal in the rear planetary support, Figure 2, or
2. When servicing any already-updated 1991-93 AXOD-E/AX4S transaxle, 1993 AX4S-SHO or AX4S Police transaxle, or late production 1993 or 1994 AX4S transaxle with the radial-type seal in the rear planetary support.
NOTE:
IF THE REAR PLANETARY SUPPORT HAS BEEN REMOVED DURING DISASSEMBLY OF A TRANSAXLE WITH A RADIAL-TYPE SEAL FOR THE REAR LUBE TUBE, OR IF THE REAR LUBE TUBE IS LOOSE OR MOVES AT THE CHAIN COVER (PRESS-FIT) END OF THE TUBE, THE REAR LUBE TUBE MUST BE REPLACED UPON REBUILD.
NOTE:
AFTER REMOVAL OF THE PLANETARY SUPPORT ASSEMBLY, CHECK THE RADIAL-TYPE SEAL FOR ANY CUTS OR TEARS OF THE SEAL BEADS; IF THE SEAL IS DAMAGED, REPLACE THE SEAL (F3DZ-7GO85-A).
NOTE:
IT IS NORMAL TO HAVE SOME MOVEMENT OF THE REAR LUBE TUBE AT THE REAR PLANET SUPPORT (CROSSOVER) END, FIGURE 2, DUE TO THE NEW DESIGN OF THE TUBE AND SEAL. THE TUBE IS NOT A PRESS-FIT AT THE CROSSOVER END.
GENERAL INSTRUCTIONS
1. If present, the old style tube bracket assembly (E6DZ-7G353-C), Figure 3, should be removed and discarded. Replace with new-design two-piece main tube bracket and center screw kit.
2. If any transaxle with the two-piece main tube bracket assembly and center screw already installed is serviced and the center screw is removed, the center screw and the two-piece main tube bracket assembly (upper and lower) should be replaced with the new kit.
3. To remove a radial-type seal rear lube tube, wrap a piece of wire around the tube end near the chain cover. Use one hand to pull on the wire (use a screwdriver through the wire, if needed) and the other hand to pull the crossover end of the rear lube tube out of the rear planetary support and the case hole.
4. To install a new rear lube tube:
a. Align tube in position and while holding the tube straight, gently install crossover end (rear planetary support end) by hand until the tube can be felt going into the seal in the rear planetary support.
NOTE:
DO NOT FULLY SEAT THE CROSSOVER END YET.
b. With one hand, support the crossover end of the rear lube tube and align the other end in the center of the case hole.
c. Using a plastic-tipped hammer, gently tap the tube straight into the case hole by tapping the tube directly above the tube end, Figure 4.
d. Finish fully seating the crossover end by hand.
e. Check the rear lube tube for tightness at the chain cover end by applying finger pressure on the bottom side of the rear lube tube near the bracket area to see if the tube will move outward, Figure 5, then press with your thumb at the chain cover end of the rear lube tube to see if the tube will move inward, Figure 6. If the rear lube tube moves at the chain cover end, replace the rear lube tube.
5. To install the new two-piece design main tube bracket kit:
a. Install a new low/intermediate servo release (LISR) tube with a flat near the bracket area if not already present, Figure 7. This is needed to make room for the M5 center screw to be installed later.
NOTE:
IF REMOVAL OF A NON-FLATTED LISR TUBE IS REQUIRED, USE LUBE TUBE REMOVER T86P-70001-A AND IMPACT SLIDE HAMMER T59L-100-B TO REMOVE THE OLD TUBE. DISCARD THE OLD TUBE.
b. To install a new flatted LISR tube, align the tube ends into the center of the two case holes, then gently tap the tube in until fully seated by alternately tapping each end of the tube. A change in noise can be heard when the tube bottoms out in the case holes.
c. The upper tube bracket assembly (thicker stock steel with a nut welded to it) should be installed on the case bosses with the nut toward the case. If the bracket is being put on the transaxle with the reverse clutch tube already in, it is possible that the upper bracket will interfere with the already installed reverse clutch tube. If this happens, remove and discard the reverse clutch tube and install a new tube (E6DZ-7G199-B).
d. When a new reverse clutch tube needs to be installed during transaxle servicing, the upper bracket assembly should be placed on the case bosses and temporarily held in place during installation of the new tube using the loose (N807811-SVMR) bolt provided in the kit.
e. After installing all tubes and seating the upper tube bracket on the case bosses, the lower bracket assembly (thin stock steel with an off-center hole in it) can be placed on top of the upper bracket and located by starting the two (N807811-SVMR) bolts (one of the bolts is part of the lower assembly) into the threaded case holes.
NOTE:
TO AID IN INSTALLATION OF THE M5 CENTER SCREW (N807812-SVMR), THE SCREW CAN BE PLACED THROUGH THE HOLE IN THE LOWER BRACKET BETWEEN THE LOW/INTERMEDIATE SERVO APPLY (LISA) AND RELEASE (LISR) TUBES, AND HAND STARTED INTO THE NUT IN THE UPPER BRACKET.
f. Tighten the two N807811-SVMR bolts to 9-12 N-m (80-106 lb.in.). Tighten the N807812-SVMR M5 center screw until the screw contacts the lower bracket and the bracket contacts both the LISA and LISR tubes (usually about 2.5 N-m (22 lb.in.).
The bracket kit F4DZ-7G353-B includes the following:
^ 1 (one) main bracket
^ 1 (one) upper bracket
^ 1 (one) bolt
^ 1 (one) screw
Parts Block
OTHER APPLICABLE ARTICLES: 93-16-5
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 501000, 502000, 503000, 504000