Automatic Transmission: Disassembly: Transmission

Fig 1: Identifying Special Tool(s)

Courtesy of FORD MOTOR CO.

1. Using the special tools, remove torque converter.
   Fig 2: Removing Torque Converter

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2. Using the special tool, mount the transmission to the bench.
   Fig 3: Mounting Transmission To Bench

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NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
Fig 4: Removing Transmission Fluid Pan
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3. Remove the transmission fluid pan and transmission fluid pan gasket.
   1. Remove the bolts.
   2. Remove the transmission fluid pan and transmission fluid pan-to-case gasket.
4. Clean the transmission fluid pan and pan magnet.
   Fig 5: Cleaning Transmission Fluid Pan

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CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present.
Fig 6: Removing Fluid Filter And Grommet
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5. Remove the fluid filter and grommet.
CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids.
Fig 7: Disconnecting Bulkhead Interconnector
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6. Disconnect the molded lead frame from the solenoids.
   1. Disconnect the shift solenoid SSA and SSB.
   2. Disconnect the torque converter clutch (TCC).
   3. Disconnect the electronic pressure control (EPC) solenoid.
   4. Disconnect the bulkhead interconnector.
7. Remove the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor plug.
   1. Remove the OSS speed sensor bolt.
   2. Remove the OSS speed sensor.
   3. Remove the TSS speed sensor plug bolt.
   4. Remove the TSS speed sensor plug.
   Fig 8: Removing Output Shaft Speed (OSS) Sensor

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8. Remove the digital transmission range (TR) sensor.
   1. Remove the bolts.
   2. Remove the digital TR sensor.
   Fig 9: Removing Digital Transmission Range (TR) Sensor

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9. Remove the manual control valve detent lever spring.
   1. Remove the bolt.
   2. Remove the manual control valve detent lever spring.
   Fig 10: Removing Manual Control Valve Detent Lever Spring

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10. Remove the 24 main control valve body bolts and the main control valve body.
    Fig 11: Removing Main Control Valve Body Bolts

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11. Remove and discard the pump outlet screen.
    Fig 12: Removing Pump Outlet Screen

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NOTE: Use a shop cloth to protect the transmission case surface.
Fig 13: Removing Manual Lever Shaft Retaining Pin
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12. Remove the manual lever shaft retaining pin.
13. Remove the manual lever shaft inner nut.
    • Slide the manual control lever shaft out of the case while removing the inner nut.
    Fig 14: Removing Manual Lever Shaft Inner Nut

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14. Remove the parking lever actuating rod.
    1. Remove the manual valve detent.
    2. Remove the parking lever actuating rod.
    Fig 15: Removing Parking Lever Actuating Rod

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CAUTION: Use care not to damage the manual control lever shaft bore. If the bore is damaged, the new seal may leak.
Fig 16: Removing Manual Control Lever Shaft Seal
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15. Remove the manual control lever shaft seal.
16. Remove the EPC solenoid.
    1. Remove the bolt and EPC solenoid bracket.
    2. Remove the EPC solenoid.
    Fig 17: Removing EPC Solenoid

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17. Remove the 2-3 accumulator spring retainer.
    Fig 18: Removing 2-3 Accumulator Spring Retainer

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18. Remove the 2-3 accumulator piston.
    1. Remove the 2-3 accumulator spring.
    2. Remove the 2-3 accumulator piston.
    Fig 19: Removing 2-3 Accumulator Piston

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19. Using the special tool, remove the reverse band servo retaining ring.
    Fig 20: Removing Reverse Band Servo Retaining Ring

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20. Remove the reverse servo assembly.
    1. Remove the reverse band servo cover.
    2. Remove the reverse band servo piston and rod.
    3. Remove the reverse band servo spring.
    Fig 21: Removing Reverse Servo Assembly

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NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on internal retaining ring.
Fig 22: Removing Overdrive Servo Piston Retainer
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21. Using the special tool, compress the piston spring, then remove the overdrive servo piston retainer.
22. Remove the overdrive servo piston.
    1. Remove the overdrive servo piston.
    2. Remove the overdrive servo piston return spring.
    Fig 23: Removing Overdrive Servo Piston

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23. Compress the 1-2 accumulator cover and remove the retaining ring.
    Fig 24: Removing Retaining Ring

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24. Remove the 1-2 accumulator upper spring.
    1. Remove the 1-2 accumulator spring cover.
    2. Remove the 1-2 accumulator lower spring.
    3. Remove the 1-2 accumulator.
    4. Remove the 1-2 accumulator upper spring.
    Fig 25: Removing 1-2 Accumulator Upper Spring

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25. Using the special tools, remove the extension housing seal.
    Fig 26: Removing Extension Housing Seal

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NOTE: These bolts have been coated with a sealant. High break torque may be required to remove these bolts.
Fig 27: Removing Extension Housing
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26. Remove the extension housing.
    1. Remove the four bolts and two nuts.
    2. Remove the extension housing and the extension housing gasket.
27. Remove the parking pawl.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl return spring.
    3. Remove the parking pawl.
    Fig 28: Removing Parking Pawl

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28. Rotate the transmission to the vertical position with the output shaft toward the floor.
CAUTION: Extreme care must be taken during transmission connector removal. Do not use a hammer on the connector body.
Fig 29: Removing Transmission Connector
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29. Place a screwdriver on the flat portion of the connector and push the connector out through the bottom of the case.
30. Using the special tools, remove the front pump seal.
    Fig 30: Removing Front Pump Seal

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NOTE: These bolts have been coated with sealant. High break torque may be required to remove the bolts.
Fig 31: Removing Bolts
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31. Remove the bolts.
32. Using the special tools, remove the front pump support.
    Fig 32: Removing Front Pump Support

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33. Remove and discard the pump gasket.
    • Remove the intermediate clutch piston return spring.
    • Remove the intermediate clutch piston return spring support.
34. Remove the intermediate anti-rattle clip, if equipped.
    Fig 33: Removing Intermediate Anti-Rattle Clip

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CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
Fig 34: Removing Intermediate Clutch Pack
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35. Remove the following components as an assembly:
    • Intermediate clutch pack.
    • Intermediate one-way clutch.
    • Reverse clutch.
    • Forward clutch assembly.
36. Disengage and remove the overdrive band.
    Fig 35: Removing Overdrive Band

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37. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
    Fig 36: Removing Forward Clutch Hub

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38. Remove the intermediate stub shaft.
    Fig 37: Removing Intermediate Stub Shaft

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39. Align the reverse sun shell with the overdrive band anchor pin for removal.
    Fig 38: Aligning Reverse Sun Shell With Overdrive Band Anchor Pin

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40. Remove the following components as an assembly:
    • Forward clutch sun gear.
    • No. 5 forward clutch sun gear bearing.
    • Reverse clutch sun gear.
    • No. 4 forward clutch hub bearing.
    Fig 39: Removing Forward Clutch Sun Gear

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41. Remove the center support retaining ring and note location for assembly.
    Fig 40: Removing Center Support Retaining Ring

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42. Remove the case-to-planet support spring.
    Fig 41: Removing Case-To-Planet Support Spring

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43. Remove the planetary gear support and planetary as an assembly.
    Fig 42: Removing Planetary Gear Support

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44. Remove the reverse clutch band.
    Fig 43: Removing Reverse Clutch Band

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45. Remove the retaining ring.
    Fig 44: Removing Retaining Ring

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46. Remove the direct clutch pack.
    Fig 45: Removing Direct Clutch Pack

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47. Remove the No. 8 bearing.
    Fig 46: Removing No. 8 Bearing

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48. Remove the output shaft and output shaft ring gear assembly.
    Fig 47: Removing Output Shaft And Output Shaft Ring Gear Assembly

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49. Remove the No. 9 case rear bearing.
    Fig 48: Removing No. 9 Case Rear Bearing

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50. Inspect and, if necessary, use the special tools to remove the rear case bushing.
    Fig 49: Removing Rear Case Bushing

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