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Home >> Lincoln >> 2002 >> Navigator 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Disassembly >> Transmission >> Disassembly Procedure

Disassembly Procedure

NOTE: Refer to the DISASSEMBLED VIEWS  for component location and orientation.
    WARNING: The torque converter is very heavy.
    NOTE: Fluid loss will occur when the torque converter is removed.
    Fig 1: Removing Torque Converter From Transmission
    G03443682Courtesy of FORD MOTOR CO.
  1. Using special tools, remove the torque converter from the transmission.
    2. CAUTION: The turbine shaft speed sensor (TSS) will need to be removed or damage to the sensors will occur.
    Fig 2: Removing Turbine Shaft Sensor (TSS) & Bolt
    G03443683Courtesy of FORD MOTOR CO.
  2. Remove the turbine shaft sensor (TSS).
    1. Remove the bolt.
    2. Remove the turbine shaft sensor (TSS).
    3. CAUTION: The output shaft speed sensor (OSS) will need to be removed or damage to the sensors will occur.
    Fig 3: Removing Output Shaft Speed Sensor (OSS) & Bolt
    G03443684Courtesy of FORD MOTOR CO.
  3. Remove the output shaft speed sensor (OSS).
    1. Remove the bolt.
    2. Remove the output shaft speed sensor (OSS).
  4. Mount the transmission into a suitable stand.
    5. CAUTION: Install the input shaft and the overdrive planet assembly as mating components.
    Fig 4: Removing Input Shaft
    G03443685Courtesy of FORD MOTOR CO.
  5. Remove the input shaft.
    6. CAUTION: The sealing washers can fall off the cooler tube case fittings.
    NOTE: The bolts are part of the cooler bypass valve (CBV) assembly.
    Fig 5: Removing Cooler Bypass Valve
    G03443686Courtesy of FORD MOTOR CO.
  6. Remove the cooler bypass valve.
    1. Remove the cooler tube case fittings.
    2. Remove the cooler bypass valve.
  7. Remove the transmission range (TR) sensor.
    1. Remove the bolts.
    2. Remove the transmission range (TR) sensor.
    Fig 6: Removing Transmission Range (TR) Sensor & Bolts
    G03443687Courtesy of FORD MOTOR CO.
    8. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
    Fig 7: Removing Transmission Fluid Pan & Bolts
    G03443688Courtesy of FORD MOTOR CO.
  8. Remove the transmission fluid pan and the gasket.
    9. CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.
    NOTE: After removal, discard the filter and seal assembly.
    Fig 8: Removing Filter & Seal Assembly
    G03443689Courtesy of FORD MOTOR CO.
  9. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
  10. Remove the bolts, nuts and the accumulator body.
    Fig 9: Removing Accumulator Body, Nuts & Bolts
    G03443690Courtesy of FORD MOTOR CO.
    11. NOTE: Do not remove the lower-to-upper main control valve body assembly bolts. Keep the main control valve bodies attached as an assembly.
    Fig 10: Removing Main Control Valve Body
    G03443691Courtesy of FORD MOTOR CO.
  11. Remove the main control valve body.
    1. Do not remove the two lower-to-upper main control valve body assembly bolts.
  12. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
    Fig 11: Removing Bolts, Nut & Solenoid Body Assembly
    G03443692Courtesy of FORD MOTOR CO.
  13. Remove the solenoid screen assembly by rotating and pulling.
    Fig 12: Removing Solenoid Screen Assembly
    G03443693Courtesy of FORD MOTOR CO.
    14. CAUTION: The steel electronic pressure control (EPC) check ball is spring-loaded under the valve body separator plate.
    Fig 13: Removing Separator Plate Reinforcing Plate & Valve Body Separator Plate With Gaskets
    G03443694Courtesy of FORD MOTOR CO.
  14. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
    15. NOTE: The steel EPC check ball has a 0.5 mm (0.02 in) diameter and is smaller than the other check balls.
    Fig 14: Removing Steel EPC Check Ball & Spring
    G03443695Courtesy of FORD MOTOR CO.
  15. Remove the steel EPC check ball and spring.
    16. CAUTION: Use care not to damage the rubber check balls. Transmission shift problems can occur.
    Fig 15: Removing Rubber Check Balls
    G03443696Courtesy of FORD MOTOR CO.
  16. Using a small screwdriver, carefully remove the 8 rubber check balls.
  17. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
    Fig 16: Taping On Intermediate Band Servo Assembly Piston
    G03443697Courtesy of FORD MOTOR CO.
    18. CAUTION: After removal, discard the feedbolts. The bolts will not retain torque specification if reused.
    Fig 17: Removing Feedbolts
    G03443698Courtesy of FORD MOTOR CO.
  18. Remove and discard the feedbolts.
  19. Remove the pump bolts and discard the washers.
    Fig 18: Removing Pump Bolts
    G03443699Courtesy of FORD MOTOR CO.
    20. NOTE: The special tools should be installed into the pump threaded holes as shown.
    Fig 19: Removing Pump Using Special Tools
    G03443700Courtesy of FORD MOTOR CO.
  20. Using the special tools, remove the pump.
    21. NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing can stay with the pump.
    Fig 20: Removing No. 1 Pump Thrust Washer, No. 2A Overdrive Sun Gear Thrust Bearing & Pump Gasket
    G03443701Courtesy of FORD MOTOR CO.
  21. Remove the No. 1 pump thrust washer.
    1. Remove the No. 1 pump thrust washer.
    2. Remove the No. 2A overdrive sun gear thrust bearing.
    3. Remove the pump gasket and discard.
    22. CAUTION: The coast clutch, overdrive ring gear and centershaft assembly must be removed as an assembly using the special service tool or damage to the overdrive one-way clutch can occur.
    Fig 21: Removing Coast Clutch, Overdrive Ring Gear & Centershaft Assembly
    G03443702Courtesy of FORD MOTOR CO.
  22. Using the special tool remove the coast clutch, overdrive ring gear and centershaft assembly.
    23. NOTE: The No. 5 thrust bearing can remaining on the center shaft or the center support.
    Fig 22: Removing No. 5 Overdrive Center Shaft Thrust Bearing Assembly
    G03443703Courtesy of FORD MOTOR CO.
  23. Remove the No. 5 overdrive center shaft thrust bearing assembly.
  24. Remove the overdrive clutch pressure plate retainer snap ring.
    Fig 23: Removing Overdrive Clutch Pressure Plate Retainer Snap Ring
    G03443704Courtesy of FORD MOTOR CO.
    25. NOTE: Tag the parts for identification during installation.
    Fig 24: Removing Overdrive Clutch Pressure Plate & Clutch Pack
    G03443705Courtesy of FORD MOTOR CO.
  25. Remove the overdrive clutch pressure plate and the clutch pack.
  26. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
    Fig 25: Removing Intermediate/Overdrive Cylinder Retaining Ring
    G03443706Courtesy of FORD MOTOR CO.
    27. CAUTION: During removal, do not mislaying the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.
    Fig 26: Removing Intermediate/Overdrive Cylinder Assembly
    G03443707Courtesy of FORD MOTOR CO.
  27. Remove the intermediate/overdrive cylinder assembly.
  28. Remove the intermediate clutch piston return spring.
    Fig 27: Removing Intermediate Clutch Piston Return Spring
    G03443708Courtesy of FORD MOTOR CO.
    29. CAUTION: During removal, do not mislaying the center support in the case bore. This can damage the case bore.
    Fig 28: Removing Center Support Assembly
    G03443709Courtesy of FORD MOTOR CO.
  29. Carefully remove the center support assembly.
  30. Remove the No. 6 center support thrust washer.
    Fig 29: Removing No. 6 Center Support Thrust Washer
    G03443710Courtesy of FORD MOTOR CO.
    31. NOTE: Tag the parts for identification during installation.
    Fig 30: Removing Intermediate Clutch Pack, Apply Plate & Rear Pressure Plate
    G03443711Courtesy of FORD MOTOR CO.
  31. Remove the intermediate clutch rear pressure plate.
    1. Remove the intermediate clutch pressure apply plate.
    2. Remove the intermediate clutch pack.
    3. Remove the intermediate clutch rear pressure plate.
  32. Remove the intermediate band.
    Fig 31: Removing Intermediate Band
    G03443712Courtesy of FORD MOTOR CO.
    33. NOTE: When installing the special tool, each leg of the tool must be rotated separately to engage notches on the input shell. Prior to tightening the top cross bar.
    Fig 32: Removing Direct Clutch, Forward Clutch & Input Shell Assembly
    G03443713Courtesy of FORD MOTOR CO.
  33. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
  34. Remove the reverse planet retaining ring.
    Fig 33: Removing Reverse Planet Retaining Ring
    G03443714Courtesy of FORD MOTOR CO.
  35. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
    Fig 34: Removing No. 10B Reverse Planet Assembly & No. 11 Reverse Planet Carrier Thrust Washers
    G03443715Courtesy of FORD MOTOR CO.
    36. WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.
    Fig 35: Removing Output Shaft Retaining Ring
    G03443716Courtesy of FORD MOTOR CO.
  36. Remove the output shaft retaining ring.
  37. Remove the output shaft ring gear and hub assembly.
    Fig 36: Removing Output Shaft Ring Gear & Hub Assembly
    G03443717Courtesy of FORD MOTOR CO.
    38. WARNING: Use care not to drop the output shaft while rotating the transmission.
    Fig 37: Removing Reverse Clutch Pack, Clutch Hub & Low/Reverse One Way Clutch Assembly
    G03443718Courtesy of FORD MOTOR CO.
  38. Remove the following parts as an assembly.
    1. Reverse clutch pack (pressure plate, friction plate and seals).
    2. Reverse clutch hub.
    3. Low/reverse one way clutch assembly.
  39. Using the special tools, remove the extension housing seal.
    Fig 38: Removing Extension Housing Seal
    G03443719Courtesy of FORD MOTOR CO.
  40. Using the special tool, remove the extension housing bushing.
    Fig 39: Removing Extension Housing Bushing
    G03443720Courtesy of FORD MOTOR CO.
  41. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
    Fig 40: Removing Extension Housing Bolts
    G03443721Courtesy of FORD MOTOR CO.
    42. NOTE: Be sure not to damage the output shaft drive sprocket speed sensor wheel or the park gear.
    NOTE: The parking gear and output shaft drive sprocket speed sensor wheel are a press fit to the output shaft.
    Fig 41: Removing Output Shaft
    G03443722Courtesy of FORD MOTOR CO.
  42. Remove the output shaft.
  43. Remove the No. 13 thrust bearing.
    Fig 42: Removing No. 13 Thrust Bearing
    G03443723Courtesy of FORD MOTOR CO.
  44. Remove the plastic orifice lube plug from the rear of the case and discard.
    Fig 43: Removing Plastic Orifice Lube Plug From Rear Of Case
    G03443724Courtesy of FORD MOTOR CO.
  45. Remove the five bolts retaining the low/reverse one-way clutch inner race to the case.
    Fig 44: Removing Bolts Retaining Low/Reverse One-Way Clutch Inner Race To Case
    G03443725Courtesy of FORD MOTOR CO.
  46. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
    Fig 45: Removing Low/Reverse One-Way Clutch Inner Race & Reverse Clutch Return Spring Assembly
    G03443726Courtesy of FORD MOTOR CO.
  47. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to restrain the reverse clutch piston.
    Fig 46: Installing Reverse Clutch Pressure Plate & Retainer Snap Ring
    G03443727Courtesy of FORD MOTOR CO.
  48. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
    Fig 47: Blowing Into Reverse Clutch Feed Port Using Compressed Air
    G03443728Courtesy of FORD MOTOR CO.
  49. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
    Fig 48: Removing Reverse Clutch Pressure Plate Retainer Snap Ring & Plate
    G03443729Courtesy of FORD MOTOR CO.
  50. If required, remove the parking rod guide plate.
    Fig 49: Removing Parking Rod Guide Plate
    G03443730Courtesy of FORD MOTOR CO.
  51. If required, remove the parking pawl.
    1. Remove the parking pawl return spring.
    2. Remove the parking pawl.
    3. Remove the parking pawl shaft.
    Fig 50: Removing Parking Pawl, Shaft & Return Spring
    G03443731Courtesy of FORD MOTOR CO.
    52. CAUTION: The Torx®-head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new one installed.
    Fig 51: Removing Parking Pawl Abutment
    G03443732Courtesy of FORD MOTOR CO.
  52. If required, remove the parking pawl abutment.
    53. NOTE: A No. 53 drill bit (1/16-inch) can be used instead to capture and remove the manual lever shaft retaining pin.
    Fig 52: Removing Manual Lever Shaft Retaining Pin
    G03443733Courtesy of FORD MOTOR CO.
  53. Using the special tool, remove the manual lever shaft retaining pin.
    54. CAUTION: Use care not to damage the manual control lever bore.
    NOTE: The manual control lever and manual control lever shaft are one piece.
    Fig 53: Removing Manual Control Lever Shaft Assembly
    G03443734Courtesy of FORD MOTOR CO.
  54. Remove the manual control lever shaft assembly.
      NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.
    1. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod.
    2. Remove the manual control lever shaft assembly.
    3. Remove the bolt and the manual control valve detent lever spring.
  55. Using the special tool, remove the manual control lever seal.
    Fig 54: Removing Manual Control Lever Seal
    G03443735Courtesy of FORD MOTOR CO.
    56. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
    Fig 55: Removing Short Fluid Inlet Tube
    G03443736Courtesy of FORD MOTOR CO.
  56. If required, remove the short fluid inlet tube.
  57. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
  58. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
  59. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the helicoil kit.
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