Steps 1-50

Special Tools:

1. Prepare the transaxle for assembly by proceeding with the following steps:
- Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
- Dry all parts with moisture-free regulated compressed air (do not use shop towels).
- Lubricate all internal parts (including friction plates) with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specifications. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.
- Order the required repair parts.
- Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
- Drive sprocket thrust washers
- Driven sprocket thrust bearing shims
- Differential case thrust bearing shims
- Low/reverse clutch pressure plates
- During assembly, use petroleum jelly to hold the parts in place (do not use grease).
- When tightening fasteners, use an accurate torque wrench.
- Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.

2. Install intermediate and overdrive band assembly into the transaxle case.

3. Install Pump Removal Bolts and pump assembly into the case.

NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.

4. Install the pump assembly bolts.

5. Install the low/reverse clutch piston.

NOTE: Lubricate seals and piston bore with clean Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification.

6. Install the low/reverse clutch return spring assembly.

7. Install the low/reverse clutch return spring retaining ring.

8. Install the low/reverse clutch wave spring.

CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.

9. Install the low/reverse clutch plates.
1 Install the low/reverse clutch external spline (steel) clutch plates.
2 Install the low/reverse clutch internal spline (friction) clutch plates.
3 Install the low/reverse clutch pressure plate.

10. Install the low one-way clutch thrust plate.

CAUTION: The low one-way clutch thrust plate is fitted in the position for measurement purposes only.

11. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate.
- Take a second measurement on the opposite side.
- Average the two measurements to get the clearance.
- If the clearance is not within specification, select and fit the proper thickness pressure plate to obtain the specified clearance.
- Pressure plate sizes:
- 2.57-2.47 mm
- 2.36-2.26 mm
- 2.16-2.06 mm

12. Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction).
1 Low one-way clutch thrust plate.
2 Low/reverse clutch pressure plate.
3 Low/reverse clutch external spline clutch plates (steel).
4 Low/reverse clutch wave spring.
5 Low/reverse clutch internal spline clutch plates (friction).

NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.

13. Install the (number 1) pump support thrust bearing assembly.

14. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.

NOTE: Remove Seal Sizer from forward/coast/direct clutch cylinder.

15. Install the turbine shaft.

16. Install the turbine shaft thrust bearing (number 4).

17. Install the forward one-way clutch and low-intermediate sun gear assembly.

18. Install the low-intermediate sun gear thrust bearing (number 5).

19. Install the low-intermediate carrier assembly.

20. Install the low-intermediate carrier thrust bearing (number 6).

21. Install the low-intermediate ring gear assembly.

Reverse/Overdrive Sun Gear Thrust Bearing Installation:

22. Install the reverse/overdrive sun gear thrust bearing (number 7).

23. Install the reverse/overdrive sun gear and shell assembly.

24. Install the reverse/overdrive carrier assembly with the captured (number 8) thrust bearing.

25. Install the low/reverse clutch plates.
1 Install the low/reverse clutch external spline (steel) clutch plates.
2 Install the low/reverse clutch internal spline (friction) clutch plates.
3 Install the low/reverse clutch pressure plate previously selected.

26. Install the low/reverse clutch wave spring.

27. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.

28. Install the low one-way clutch thrust plate.

29. Install the low one-way clutch retaining ring.

NOTE: Make sure to position the low one-way clutch retaining ring as shown.

30. Install the manual valve detent lever actuating rod assembly.
- Install the parking cam actuator lever.

31. Install the manual valve detent lever.

32. Install the pre-load tools.

33. Install Gauge Bar with short spacers.

34. Measure the distance from the top of Gauge Bar to the driven sprocket bearing surface area (number 12).
- Record this first dimension.

35. Measure the distance from the top of Gauge Bar to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
- Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
- The average of these two dimensions is the second dimension.
- Remove Gauge Bar and Pre Load Tool.
36. Subtract the second dimension from the first dimension to get the third dimension.
37. Use the third dimension to select the correct driven sprocket shim (number 11).
- Select a shim from the driven sprocket shim chart in specifications. Specifications

38. Install and lubricate the following:
1 Lubricate the needles and seals in the driven sprocket bearing (number 18).
2 Install the selected driven sprocket shim (number 11).
3 Install the driven sprocket bearing (number 12).

39. Install the reverse/overdrive ring gear thrust bearing (number 9).

40. Install the reverse/overdrive ring gear assembly.

NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.

41. Install the pre load tools.

42. Install Gauge Bar with short spacers.

43. Measure the distance from the top of Gauge Bar to the face of the reverse/overdrive ring gear assembly surface area.
- Repeat this measurement on the other side of the face of the reverse/overdrive ring gear assembly area 180 degrees from the first measurement.
- The average of these two dimensions is the first dimension.
- Remove Gauge Bar and Pre-Load Tool.
44. Add 25.4 mm (Gauge Bar thickness) and short spacers' thickness.
- This is the second dimension.
45. Subtract the first dimension from the second dimension.
- This is the third dimension.
46. Select thrust washer (number 10) from the drive sprocket thrust washer chart in specifications. Specifications
- Use the third dimension to select the drive sprocket thrust washer (number 10).

47. Use petroleum jelly and install the selected drive sprocket thrust washer (number 10) on the torque converter housing.

48. Remove the reverse/overdrive ring gear assembly.

49. Install the filter and seal assembly.

50. Install one Guide Pin in the filter eyelet and transaxle hole.