Attachment III - Technical Information
AX4N PARK PAWL SHAFT INSPECTION AND/OR REPLACEMENTSERVICE KIT PART NUMBER: F4DZ-7D071-BA KIT CONTENT
PART NUMBER DESCRIPTION QUANTITY
-N802947- CUP PLUG 1
-7G100- ROLL PIN 1
-7D071- PARK PAWL 1
SHAFT
I.S. 8205 INSTRUCTION 1
SHEET
Affected Vehicles:
1996 Continental, Sable, Taurus and Taurus SHO
Preliminary Inspection
1. Check transaxle build date on the ID tag located on the top of the transaxle converter housing. Only transaxles built through June 10, 1996, require further inspection. See Figure 1.
2. If transaxle was built after June 10,1996, release the vehicle. Otherwise, proceed to Secondary Inspection and Repair.
SECONDARY INSPECTION AND REPAIR
1. Obtain required tools (Rotunda Tool Kit No. T97P-77000-AH) shown in Figure 2. Also obtain Roll Pin Extractor and Tee Handle from Roll Pin Extractor Kit previously ordered for Safety Recall 96S39.
2. Set parking brake. Place transaxle range selector lever in neutral.
3. Raise vehicle and place drain pan under transaxle.
4. Remove the transaxle pan from the transaxle (do not discard elastomeric pan gasket, if equipped).
5. Clean and dry a visible portion of the park pawl shaft. Place a mark on the park pawl shaft with the marker from the tool kit or equivalent. See Figure 3.
6. Using pliers from tool kit (Rotunda No. T97P-77000-AH), check park pawl shaft rotation. The shaft must rotate freely one full turn. See Figure 4.
7. If the park pawl shaft rotates freely one full turn, no repair is necessary. Go to step 27.
8. If the park pawl shaft does not rotate freely, the park pawl shaft must be replaced. Go to step 7.
9. Use two (2) pan bolts to mount the AX4N bridge from tool kit (Rotunda No. T97P-77000-AH) to the transaxle case. Large hole must be over the roll pin. Tighten the pan bolts to 10 N-m (89 lb/in). See Figure 5.
10. Assemble the extractor (supplied in extractor kit, previously ordered for Safety Recall 96S39). See Figure 6.
11. Insert the extractor through the large hole in the bridge, and turn the extractor clockwise three or four turns to thread it on the O.D. of the roll pin. See Figure 7.
12. Using a 15/16-inch (24 mm) wrench, tighten the nut on the extractor while holding the tee handle. See Figure 8.
13. Tighten the nut until the roll pin is removed from the transaxle case.
14. Using vise-grip type pliers to hold the roll pin, turn the extractor counterclockwise to remove the roll pin from the extractor tip.
15. Remove the bridge from the transaxle.
16. On Continental and Taurus SHO vehicles, remove the dual converter y-pipe. Refer to Section 09-00 of appropriate service manual.
17. Using support bar and threaded bolt (cup plug remover) from tool kit (Rotunda No. T97P-77000-AH), remove park pawl shaft cup plug as follows:
a. Thread bolt into cup plug. See Figure 9.
b. Tap support bar with a hammer until the cup plug is removed. See Figure 10.
18. Note the orientation of the park pawl return spring and the park pawl to the case. Using an Allen wrench and magnet, push/pull the park pawl shaft out far enough to grasp with a pair of pliers. See Figure 11.
19. Using pliers, remove and discard the park pawl shaft. Retain the park pawl and park pawl return spring to be reinstalled later.
20. Install the burnishing tool into the case where the shaft was removed. See Figure 12.
21. Using a 1/4-inch drive ratchet, turn the burnishing tool in the case bore. Turn the burnishing tool four to five times.
22. Remove burnishing tool, and clean the park pawl shaft bore and the roll pin hole in the transaxle case.
23. Assemble the original park pawl and the park pawl return spring. Make sure the park pawl return spring is assembled correctly. See Figure 13.
24. Position the park pawl and the park pawl return spring to the case, and install the new design park pawl shaft. Make sure park pawl shaft goes through both coils of the park pawl return spring on each side of the park pawl. See Figure 14.
25. Install new cup plug, using a hammer and the cup plug installer from tool kit (Rotunda No. T97P-77000-AH). See Figure 15.
26. Use the tee handle (supplied in extractor kit, previously ordered for Safety Recall 96S39) to properly install the new roll pin. Install the roll pin by first inserting the large end of the roll pin into the counter-bored end of the tee handle. See Figure 16. Using the tee handle, place the small end of the roll pin into the case hole, and tap on the tee handle until the roll pin is fully seated.
27. Place a mark on the park pawl shaft with the marker from the tool kit or equivalent. See Figure 17.
28. Verify that the park pawl shaft turns freely by rotating it one full turn (as done in Step 6), and make sure the park pawl moves freely on the park pawl shaft. Push on the park pawl and release it two or three times to ensure that the park pawl return spring is correctly installed.
29. Clean, inspect, and reuse if not damaged, the elastomeric pan gasket and install the transaxle pan. Tighten retaining bolts to 10-14 N-m (89-124 lb-in). For units with cork gaskets, install a new gasket and tighten retaining bolts to 14-15 N-m (115-132 lb/in).
30. On Continental and Taurus SHO vehicles that required a shaft replacement, install the dual converter y-pipe. Refer to Section 09-00 of appropriate service manual.
31. Refill the transaxle with Mercon Automatic Transmission Fluid. Follow refill procedures in the service manual to top off fluid level. Be sure to recheck fluid level after transaxle reaches operating temperature.
32. Verify that the park mechanism in the transaxle works properly before returning the vehicle to the owner.