A/T - AX4S Extended/No 2-3 Shift
Article No.97-9-12
04/28/97
TRANSAXLE - AX4S - EXTENDED 2-3 SHIFT AND/OR HIGHER THAN EXPECTED ENGINE RPM DURING 2-3 SHIFT AT LIGHT TO MEDIUM THROTTLE AND/OR NO 2-3 SHIFT-VEHICLES EQUIPPED WITH 3.0L ENGINE - SERVICE TIP
FORD:
1996-97 TAURUS
LINCOLN-MERCURY:
1996-97 SABLE
LIGHT TRUCK:
1996-97 WINDSTAR
This TSB article is being republished in its entirety to correct the art in Figure 1.
ISSUE:
An extended 2-3 shift and/or higher than expected engine rpm at light to medium throttle and/or no 2-3 shift may occur on some vehicles. This may be caused by any or all of the following items.
^ Mis-machined direct cylinder hub (Figure 1) with step more than 1 mm.
^ Direct clutch steel plates binding in clutch cylinder due to cylinder being out of round
^ Direct clutch inner piston seal rolled in cylinder groove
^ Low/intermediate servo piston rod binding in transaxle case due to mis-assembled servo spring retainer (Figure 2) or nicks/burrs in servo rod bore of transaxle case (Figure 3)
^ Intermediate clutch shuttle valve stuck in main control bore (Bore # 42) (Figure 4)
ACTION:
When servicing a transaxle, replace any/or all of the items listed above as required. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Inspect direct clutch hub machining in the area shown in Figure 1. Replace direct/intermediate clutch cylinder if it is mis-machined. Step at bottom of bevel must be 1 mm or less.
2. Check for free movement of steel clutch plates in the direct clutch cylinder by installing and removing the plates into and out of the direct clutch cylinder several times, turning the plates clockwise 2-3 splines each time. Replace the direct/intermediate clutch cylinder if the steel plates bind or stick in any position.
3. Check for evidence of witness marks on the direct clutch inner piston seal. Always install new seals and gaskets throughout when servicing a transaxle.
4. Check the low/intermediate servo for free movement in the case bore.
^ The three (3) tabs on the servo spring retainer must fit on the outside edge of the spring. Refer to Figure 2. Replace the servo spring retainer if it is bent or damaged from an incorrect installation.
^ Inspect the servo rod case bore for burrs and nicks. Refer to Figure 3. Replace the transaxle case if the low/intermediate servo rod does not move freely in the case bore due to a rough bore finish.
5. Check the intermediate clutch shuttle valve (Bore # 42) in the main control to be sure it is not stuck. Refer to Figure 4. Repair or replace the main control if the valve is found to be stuck.
NOTE:
FOR CORRECT APPLICATION OF DIRECT/INTERMEDIATE CLUTCH CYLINDER ASSEMBLY, REFER TO TSB ARTICLE 96-23-10
PART NUMBER PART NAME
F6DZ-7G120-A Direct/Intermediate Clutch Cylinder Assembly (13.0 mm Spline)
F6DZ-7G120-BA Direct/Intermediate Clutch Cylinder Assembly (10.0 mm Spine)
F1DZ-7153-AA Seal Kit
F68Z-7005-DA case
F6DZ-7A100-C Main control
F0DZ-7G151-A Servo Spring Retainer
OTHER APPLICABLE ARTICLES: 96-23-10
SUPERSEDES: 96-26-13
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 501000, 502000, 503000, 504000