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Transaxle Reassembly

NOTE: Handle all components carefully to avoid damaging bearings and mating surfaces. Lubricate all components with clean ATF. Use petroleum jelly on gaskets, thrust washers and needle bearings to retain in place. Use all NEW gaskets and seals. Tighten bolts evenly. Soak NEW band and clutch plates in transmission fluid for at least 2 hours prior to installation. Refer to illustration for thrust washer and needle bearing location. See Fig 12 .
NOTE: When transaxle is disassembled, differential bearing preload MUST be adjusted by selecting shims to insert under bearing cup.
  1. Install front bearing cup into converter housing using appropriate bearing cup replacer. Insert differential gear into converter housing. Place rear bearing cup over differential bearing and 6 collars of Shim Selector Set (T88C-77000-JF) on converter housing. See Fig 1 .
  2. Install Shim Selector Gauge, part of (T88C-77000-JF) and Shim Gauge Adapter Ring (T90P-7025-AH) on output gear. Turn both halves of gauge to eliminate any gap. Place transaxle case on collars. Install 6 bolts and washers of Shim Selector Set (T88C-77000-JF). Tighten bolts to 27-38 ft. lbs. (37-51 N.m).
  3. Install Preload Torque Adapter (T90P-7025-BH) on output gear. Using pins provided in Shim Selector Set (T88C-77000-JF), loosen gauge halves until all free play is removed and bearing cup is seated. Thread gauge halves together.
  4. Measure drag on output gear bearing using an INCH-lb. torque wrench. Read preload when output gear starts to turn. Turn gauge using pins until starting preload is 4.3 INCH lbs. (.5 N.m).
  5. Using a feeler gauge, measure gap between 2 halves of shim selection gauge in 4 locations at 90 degree intervals. See Fig 1 . Add .012" (.30 mm) to the largest measurement. This will provide preload. Select shim closest in value to measurement. Use no more than 3 shims. Shims are available in thicknesses of .020-.057" (.50-1.45 mm) in .001" (.025 mm) increments.
    Fig 1: Measuring Differential Preload
    G92J15403Courtesy of FORD MOTOR CO.
  6. Remove bolts, washers, transaxle case, gauge and bearing cup. Install selected shim(s) and bearing cup into bearing housing. Install bearing housing onto transaxle case. Tighten retaining bolts to 28-38 ft. lbs. (37-51 N.m). Rotate gear several times before checking preload. Using an INCH-lb. torque wrench, measure bearing preload. If preload is not 27-35 INCH lbs. (3.0-3.9 N.m), repeat steps  1 - 6 . Remove bearing housing when proper preload specification is obtained.
  7. Install output shaft and idler gear as an assembly into converter housing. If necessary, tap lightly on gear and shaft assembly with a plastic hammer to seat fully into case. Install bearing housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Align groove on idler gear shaft with matching mark on bearing housing. Install NEW bearing housing roll pin using pin punch and hammer.
  8. Install differential. Install parking pawl return spring, parking pawl and parking pawl shaft. Install park actuator support, using NEW support bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Install park lever plate and parking plate torsion spring.
  9. Install manual lever holder, manual shaft plate and lever holder nut. Tighten nut to specification. See TORQUE SPECIFICATIONS  . Install manual control lever and manual valve detent lever, washer and nut. Tighten nut to specification. Install output shell onto output shaft. Install needle bearing onto output shell.
  10. Apply thin bead of silicone sealant to contact surfaces of converter housing and transaxle case. Install NEW "O" rings into oil passage ports. Install converter housing onto transaxle case, and tighten retaining bolts to specification. If necessary, assemble 3-4 clutch and turbine shaft assembly. See 3-4 CLUTCH  .
  11. Ensure needle bearing and thrust washer are installed between 3-4 clutch and output shell. See Fig 12 . Install 3-4 clutch, needle bearing and turbine shaft assembly into case. See Fig 2 . Install Turbine Shaft Holder (T88C-77000-KH) to turbine shaft. Ensure converter turbine shaft seal is installed on inner groove of turbine shaft.
  12. Install ring gear with external gear side down, and secure with retaining ring. Install needle bearing and carrier hub assembly into 3-4 clutch cylinder. See Fig 3 . Rotate carrier hub to align splines with 3-4 clutch pack. Install low/reverse clutch pack, pressure plate and previously selected retaining ring into transaxle case.
    Fig 2: Installing Turbine Shaft, 3-4 Clutch Assembly & Ring Gear
    G96F04393Courtesy of FORD MOTOR CO.
    Fig 3: Installing Carrier Hub Assembly Into 3-4 Clutch
    G99H54863Courtesy of FORD MOTOR CO.
    13. CAUTION: One-way clutch can be installed incorrectly. Ensure carrier hub rotates counterclockwise easily by hand after one-way clutch is installed.
  13. Install one-way clutch wave washer. Carefully install one-way clutch while turning carrier hub assembly counterclockwise. Install retaining ring. Install 2-4 servo piston, spring, cover and retaining ring. Mark servo piston stem at point that it meets case. See Fig 4 . Apply compressed air to 2-4 band apply port. See Figure . With servo piston stem fully extended, measure stroke of servo piston. Servo piston stroke should not exceed .039-.067" (1.00-1.70 mm).
  14. If servo piston stroke is not within specification, disassemble servo assembly and replace with correct length replacement stem. Stem lengths range from 3.74-3.90" (95.0-99.0 mm) in .020" (.50 mm) increments. Recheck servo movement once stem is installed.
  15. Install anchor strut and anchor strut shaft into transaxle case. Install 2-4 band in case fully expanded. Interlock 2-4 band and band anchor strut. Install servo assembly and servo piston spring into case. Ensure piston stem engages properly in 2-4 band. Compress servo assembly into bore and install servo cover retaining ring.
  16. Install primary sun gear and one-way clutch into carrier hub. Ensure planet gear bearing thrust washer and needle bearing are installed between carrier hub assembly and primary sun gear and one-way clutch. See Fig 5 . Rotate primary sun gear and one-way clutch for easier assembly.
    Fig 4: Measuring 2-4 Servo Travel
    G98I01329Courtesy of FORD MOTOR CO.
    Fig 5: Installing Primary Sun Gear & One-Way Clutch
    G99I54864Courtesy of FORD MOTOR CO.
  17. Install forward/coasting/reverse clutch drum assembly. Ensure needle bearing is installed onto forward/coasting/reverse clutch assembly. See Fig 6 . Insert 2 screwdrivers through access hole in bottom of case to spread 2-4 band. Rotate one-way clutch and forward/coasting/reverse clutch drum assembly to align clutch pack and gears. Install NEW turbine shaft retaining ring into bottom groove of turbine shaft.
  18. Remove turbine shaft holder. Measure height difference between reverse clutch drum and transaxle case. See Fig 7 . If assembled height is more than .035" (.90 mm), recheck all assembled components.
    Fig 6: Installing Forward/Coasting/Reverse Clutch Assembly
    G99J54865Courtesy of FORD MOTOR CO.
    Fig 7: Measuring Height Difference Of Case & Clutch
    G99B54867Courtesy of FORD MOTOR CO.
  19. To adjust total end play, place planet gear needle bearing on reverse clutch assembly. Remove previously used thrust washer and gasket from oil pump. Place an .087" (2.2 mm) thrust washer onto oil pump. Set oil pump into forward/coasting/reverse clutch assembly and transaxle case.
  20. Using a feeler gauge, measure clearance between transaxle case and oil pump in several locations. See Fig 8 . Take an average of the measurements. Correct end play is .010-.020" (.25-.50 mm). Select correct end play thrust washer to install. See END PLAY THRUST WASHER SELECTION  table.
    END PLAY THRUST WASHER SELECTION

    Measured Clearance - In. (mm) Thrust Washer Thickness - In. (mm)
    .000-.004 (0.00-0.10) .087 (2.20)
    .004-.012 (0.11-0.30) .079 (2.00)
    .012-.020 (0.31-0.50) .071 (1.80)
    .020-.027 (0.51-0.70) .063 (1.60)
    .028-.035 (0.71-0.90) .055 (1.40)
    .036-.043 (0.91-1.10) .047 (1.20)
    Fig 8: Measuring Oil Pump-To-Case Clearance
    G92H15427Courtesy of FORD MOTOR CO.
  21. Remove oil pump. Using petroleum jelly, place selected thrust washer and planet gear needle bearing on oil pump. Install NEW gasket and place oil pump on forward/coasting/reverse clutch assembly. Install oil pump-to-transaxle bolts, and tighten in a crisscross pattern to specification. See TORQUE SPECIFICATIONS  .
  22. Install solenoid harness connector with NEW "O" ring, in case. Align manual valve with pin on manual valve detent lever. Install valve body into transaxle case and install valve body bolts in correct locations. See Fig 9 . Tighten bolts to 71-97 INCH lbs. (8-11 N.m).
    Fig 9: Locating Valve Body Bolts
    G99H54848Courtesy of FORD MOTOR CO.
    Fig 10: View Of Valve Body Harness & Connectors
    G99I54849Courtesy of KIA MOTORS AMERICA, INC.
  23. Connect harness to solenoids. See Fig 10 . Install EPC solenoid and connect wiring harness. Install oil filter with NEW "O" ring. Ensure magnets are correctly positioned in oil pan. Install oil pan and NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Install TSS and VSS.
  24. Turn manual shaft to "N" position. Install TR sensor. Finger tighten retaining bolts. Align TR sensor. See TRANSMISSION RANGE SENSOR  under ON-VEHICLE SERVICE.
  25. Tighten sensor retaining bolts to 71-97 INCH lbs. (8-11 N.m). Install manual shaft lever and tighten nut to specification. Install dipstick tube using NEW "O" ring.
  26. Install fluid cooler line with check ball, spring, washers and bolt. See Fig 11 . Tighten cooler line bolt to specification. Secure fluid cooler line bracket to case with bolt. Using appropriate seal replacer, install converter seal. Install NEW "O" ring on turbine shaft. Fill torque converter with specified fluid. See LUBRICATION  . Install oil pump shaft into torque converter. Carefully install torque converter while rotating to align splines.
  27. Measure distance between torque converter and end of converter housing. Torque converter setback should be at least .54" (13.6 mm). See Fig 13 . Remove transaxle from holding fixture. Using appropriate seal installer, install differential oil seals.
Fig 11: Installing Fluid Cooler Line, Check Ball, Bolt & Spring
G99A54866Courtesy of FORD MOTOR CO.
Fig 12: Locating Thrust Washers & Needle Bearings
G92E15424Courtesy of FORD MOTOR CO.
Fig 13: Measuring Torque Converter Setback
G92I15428Courtesy of FORD MOTOR CO.
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