Transaxle Assembly

1. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.

2. NOTICE: Make sure to install the No 1 thrust bearing with the flat side facing up or damage to the transaxle can occur





Install the No. 1 thrust bearing with the flat side facing up. See Figure 53.

3. Install the overdrive/direct clutch assembly.

4. NOTICE: Make sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur





Install the No. 3 thrust bearing with the flat side facing down. See Figure 54.

5. Install the direct/intermediate clutch hub and rear planetary sun gear and shell assembly.





6. Install the intermediate (2, 6) wave spring assembly. See Figure 55.





7. Soak the original intermediate (2, 6) clutch assembly in clean transmission fluid See Figure 56.

8. Install the original intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.

9. Install the Shim Selection Gauge # 307-300 on the transaxle case.





10. Using a suitable depth gauge, measure the distance from the Shim Selection Gauge # 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances Record this as measurement A. See Figure 57.





11. Using a suitable depth gauge, measure the distance from the top of Shim Selection Gauge # 307-300 to the transaxle case step above the intermediate (2, 6) clutch Record this as measurement B. See Figure 58.

12. Subtract measurement B from measurement A. The clearance should be between 0.240 mm (0009 in) and 260 mm (0.102 in). If the clearance is out of range, check the intermediate (2,6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, call the SSSC for authorization to replace the intermediate (2, 6) clutch pack.

13. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.

Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.

14. Install the One-Way Clutch (OWC) assembly.

15. Install the rear planetary carrier/center ring gear assembly.

16. NOTE: The position of the low/reverse pressure plate is important. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.





Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate. See Figure 59.





17. Soak the original low/reverse clutch pack in clean automatic transmission fluid. See Figure 60.

18. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case, temporarily reversing the wave spring and top steel plate.





19. Install the Shim Selection Gauge # 307-300 on the side of the center support with the long support legs. See Figure 61.





20. Using a suitable depth gauge, measure the distance from the top of Shim Selection Gauge # 307-300 to the contact surface of the low/reverse clutch piston Record this as measurement A. See Figure 62.





21. Using a suitable depth gauge, measure the distance from the top of Shim Selection Gauge # 307-300 to the leg surface of the center support Record this as measurement B. See Figure 63.





22. Subtract measurement B from measurement A and record as measurement C.

23. Install the Shim Selection Gauge # 307-300 on the transaxle case.





24. Using a suitable depth micrometer measure the distance from the Shim Selection Gauge # 307-300 to the top of the OWC Record this as measurement D. See Figure 64.





25. Using a suitable depth gauge measure the distance from the top of Shim Selection Gauge # 307300 to the top of the low/reverse clutch at 3 different points and average the 3 distances Record this as measurement E. See Figure 65.





26. Subtract measurement E from measurement D and record as measurement F.





27. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is still out of range, call the SSSC for authorization to replace the low/reverse clutch pack.

28. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.

Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.

29. NOTE: Make sure the center support is installed with the long center support legs facing down and the feed holes facing the front of the transaxle case. Improper alignment will cause transmission failure.





Install the center support with the long center support legs facing down and the feed holes aligned with the feed holes in the transaxle case. See Figure 66.

1. Long center support legs face down.

2. Feed holes face the front of the transaxle case.





30. Install the No. 5 and No. 6 thrust bearings. See Figure 67.

1. No. 5 thrust bearing

2. No. 6 thrust bearing





31. Install the center planetary sun gear. See Figure 68.

32. Install the center planetary carrier/front ring gear assembly. See Figure 68.





33. Install the No. 7 and No. 8 thrust bearings. See Figure 69.

1. No. 7 thrust bearing

2. No. 8 thrust bearing





34. Install the front planetary carrier/rear ring gear assembly. See Figure 70.

35. Install the forward (1, 2, 3, 4) clutch wave spring See Figure 70





36. Soak the new forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid. See Figure 71.

37. Install the new forward (1, 2, 3, 4) clutch pack.

38. Install the forward (1, 2, 3, 4) clutch pressure plate.

NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose causing damage to the transaxle.





Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle. See Figure 72.

1. Forward (1, 2, 3, 4) clutch snap ring.

2. Forward (1, 2, 3, 4) clutch snap ring gap.





40. Using a suitable tool, seat the snap ring in the snap ring groove. See Figure 73.





41. Install Dial Indicator Gauge with Holding Fixture # 100002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate. See Figure 74.





42. Install new low/reverse and forward (1, 2, 3, 4) transaxle case-to-center support seals in the transaxle case. See Figure 75.





43. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. See Figure 76.

44. Install the front planetary sun gear and shell assembly.





45. Install the No.10 front sun gear and shell assembly thrust bearing. See Figure 77.

46. Install the park pawl.

47. Install the park pawl pin and spring.





48. Install the 5 new clutch feed seals. See Figure 78.

49. Position the transmission fluid baffle in place.

50. Install the lube funnel and position the alignment pin in the alignment hole.

51. Position the lube funnel hold-down bracket in place and install the 2 bolts.

^ Tighten to 12 Nm (106 lb-in).





52. Install the No. 12 driven sprocket thrust bearing. See Figure 79.

53. Simultaneously install the drive and driven sprocket and chain assembly Lightly tap on the driven sprocket to be sure it is fully seated in the case.





54. Install the No. 11 drive sprocket thrust bearing. See Figure 80.





55. Install the No.13 thrust washer. See Figure 81.

56. Install the differential planetary sun gear.

57. Install the differential assembly.





58. Install the No. 15 differential thrust bearing. See Figure 82.

59. Install the Turbine Shaft Seal Protector # 307-635 on the input shaft.

60. Clean the torque converter housing sealing surface.

61. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.

Apply silicone (Motorcraft(R) TA-29 or equivalent) to the sealing surface of the transaxle case.

62. NOTE: Be sure the stud bolt is in the correct location as recorded during disassembly.





Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque converter housing bolts. See Figure 83.

1. Tighten to 24 Nm (18 lb-ft)

2. Stud bolt location

63. Remove the Turbine Shaft Seal Protector 307-635.

64. Install the Output Shaft Speed (OSS) sensor and the bolt.

Tighten to 10 Nm (89 lb-in).





65. Assemble the internal cooler bypass valve in the sleeve and install the assembly in the case. See Figure 84.

1. Bypass valve.

2. Bypass valve sleeve





66. Install the internal cooler bypass valve spring. See Figure 85.

67. Install the new main control-to-transaxle separator plate and align it on the stud and the guide pin.

68. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.





Position the main control assembly in place and align the manual valve on the TR sensor. Install the nut hand-tight. See Figure 86.





69. Install the short main control Torx(R) bolts hand-tight. See Figure 87.





70. Install the long main control Torx(R) bolts hand-tight. See Figure 88.

71. Tighten the 22 main control Torx(R) bolts and the nut in a crisscross pattern.

Tighten to 10 Nm (89 lb-in).

72. NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.

Install the new solenoid body-to-main control cover seal.

73. Connect the TR sensor electrical connector.

74. Connect the OSS sensor electrical connector.

75. Apply silicone (Motorcraft(R) TA 29 or equivalent) to the main control sealing surface of the transaxle case.

76. Position the main control cover in place.

77. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.





Install the 13 main control cover bolts. See Figure 89.

^ Tighten to 12 Nm (106 lb-in).

1. Bolt location

2. Stud bolt location

78. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result. Using the Torque Converter Handle 307-091 install the torque converter.

79. Remove the Torque Converter Handle 3O7-091.

80. Install the Torque Converter Retainer 307-566.

81. Remove the transaxle from the bench-mounted holding fixture.

82. Remove the Transaxle Holding Fixture # 307-625.