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Ford - 4R100 - Workshop Manual - 2003 - 2003
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Summary of Content
FORD 4R100
INDEX
IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................... 3
GENERAL DESCRIPTION AND OPERATION .....................................................................................
4
COMPONENT AND SOLENOID APPLICATION CHART ...................................................................
5
"PTO" GENERAL REQUIREMENTS ....................................................................................................
6
ELECTRICAL COMPONENT DIAGNOSIS ...........................................................................................
8
FLUID REQUIREMENTS ....................................................................................................................... 12
SOLENOID PACK TESTING .................................................................................................................. 12
ABBREVIATION DESCRIPTION .......................................................................................................... 14
DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION ........................................................ 15
LINE PRESSURE TEST .......................................................................................................................... 21
NON-PTO AND PTO HYDRAULIC DIFFERENCES ........................................................................... 22
PWM AND NON-PWM OIL PUMP DIFFERENCES ........................................................................... 34
CASE CHECKBALL LOCATIONS ......................................................................................................... 38
VALVE BODY CHECKBALL LOCATIONS ........................................................................................... 39
AIR PRESSURE CHECKS ...................................................................................................................... 40
TRANSMISSION DISASSEMBLY ......................................................................................................... 41
COMPONENT REBUILD SECTION
TRANSMISSION CASE ASSEMBLY ................................................................................................ 55
FRONT AND REAR PLANETARY CARRIERS ............................................................................... 64
FORWARD CLUTCH HOUSING ...................................................................................................... 66
DIRECT CLUTCH HOUSING ........................................................................................................... 69
FORWARD, DIRECT, SUN SHELL SUB-ASSEMBLY .................................................................... 76
CENTER SUPPORT ASSEMBLY ...................................................................................................... 80
INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY ............................................................. 82
OVERDRIVE GEARSET ASSEMBLY ............................................................................................... 84
COAST CLUTCH HOUSING DIFFERENCES ................................................................................ 88
COAST CLUTCH HOUSING ASSEMBLY ........................................................................................ 90
OIL PUMP ASSEMBLY ...................................................................................................................... 94
VALVE BODY ASSEMBLY ............................................................................................................... 100
TRANSMISSION FINAL ASSEMBLY ................................................................................................. 102
MANUAL VALVE CHECK .................................................................................................................... 111
MANUAL SHIFT LEVER DIFFERENCES ........................................................................................ 112
TORQUE SPECIFICATIONS ............................................................................................................... 115
VALVE BODY BOLT CHART AND IDENTIFICATION .................................................................... 116
BOLT CHART AND IDENTIFICATION ............................................................................................. 117
SPECIAL SERVICE TOOLS ................................................................................................................. 118
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Copyright © ATSG 2003
INTRODUCTION
FORD 4R100
Updated
October, 2003
The Ford 4R100 transmission is an updated version of the E4OD and was first introduced in the 1999 model
year, and is currently found in the F250, F350, F450 and F550 Super Duty trucks, E150, E250, E350, E450 vans
and the Expedition/Navigator/Excursion vehicles equipped with the 5.4L, 6.8L, and 7.3L engines. Some of the
4R100 units are equipped with a Power-Take-Off (PTO) window on the left hand side of the transmission case.
The revisions in the 4R100 have created many new engineering changes that have affected many of the internal
and external parts that will affect the servicing, repairing and overhaul of these units.
We wish to thank Ford Motor Company
for the information and illustrations
that have made this booklet possible.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
The information and part numbers contained in this booklet have
been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2003
DALE ENGLAND
JIM DIAL
FIELD SERVICE CONSULTANT
TECHNICAL CONSULTANT
WAYNE COLONNA
ED KRUSE
TECHNICAL SUPERVISOR
TECHNICAL CONSULTANT
PETER LUBAN
GREGORY LIPNICK
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
JON GLATSTEIN
DAVID CHALKER
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
ROLAND ALVAREZ
JERRY GOTT
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
GERALD CAMPBELL
TECHNICAL CONSULTANT
MIKE SOUZA
TECHNICAL CONSULTANT
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
1
Technical Service Information
TRANSMISSION IDENTIFICATION
WITH POWER TAKE OFF OPTION
Note: PTO is available as an option on 8500 GVW or above, Super Duty
F-Series trucks with 6.8L gasoline and 7.3L Diesel engines.
Ford 4R100 transmissions on other models are not PTO capable.
Ford
RF
XW4P-AC
RJL-B
006F81P-7
004361
17
BD-9C
BA
98
d
For
Year
Month
Day
9
C
17
BD-
6520
1
2
3
4
004361
1
2
3
4
Build
Date
9=1999
0=2000
1=2001
2=2002
3=2003
4X4
5G
XW4P-AC
RJL-B
004361
BD-9C17
A=Jan
B=Feb
C=Mar
D=Apr
E=May
F=Jun
G=Jul
H=Aug
J=Sep
K=Oct
L=Nov
M=Dec
Assembly Part Number, Prefix And Suffix
Transmission Model
Serial Number
Build Date (Year, Month, Day)
Copyright © 2003 ATSG
Figure 1
AUTOMATIC TRANSMISSION SERVICE GROUP
3
Technical Service Information
TRANSMISSION
DESCRIPTION AND OPERATION
General Description
The Ford 4R100 automatic transmission is a four
forward speed unit with electronic shift control. It is
designed for longitudinal powertrains for rear wheel
drive vehicles.
The 4R100 transmission features a four element
torque converter design that includes Torque
Converter Clutch (TCC) and a gear train that includes
three planetary gearsets.
Some models provide for Power Take Off (PTO)
operation in all transmission shift lever positions.
During PTO operation in OD, 4th gear is disabled.
The hydraulic control system of the 4R100 unit has
five electronically controlled solenoids for:
Shift feel, through line pressure control.
Shift scheduling, through shift valve position.
Engine braking during coast conditions.
TCC apply (On/Off or Modulating).
Major Internal Components
"Seven Friction Apply Elements"
Intermediate Band
Coast Clutch, Multi-disc
Overdrive Clutch, Multi-disc
Intermediate Clutch, Multi-disc
Direct Clutch, Multi-disc
Forward Clutch, Multi-disc
Low/Reverse Clutch, Multi-disc
Shift Quadrant Indicator
Vehicles equipped with the 4R100 transmission have
a Transmission Control Switch (TCS), also referred to
as "Overdrive Cancel Switch", and a Transmission
Control Indicator Lamp (TCIL), located on the end of
the manual gear shift lever, as shown in Figure 3. The
TCS is a momentary contact switch. When this
switch is pressed, a signal is sent to the PCM to allow
automatic shifts from 1st to 4th gear or from 1st to 3rd
gear. After the TCS has been pressed the PCM turns
on the TCIL lamp ("OFF"), to indicate that overdrive
has been canceled, as shown in Figure 3.
The shift quadrant has the following positions, as
shown in Figure 2: P, R, N, D , 2 and 1.
D position (TCS OFF) provides 1-2-3-4 automatic
upshifts and downshifts. Coast braking occurs in 4th
gear. (TCIL Not Illuminated)
D position (TCS ON) provides 1-2-3 automatic
upshifts and downshifts. Coast braking occurs in 3rd
gear. (TCIL Illuminated)
2 position provides a pull-in shift to 3rd gear with
coast braking. After an automatic downshift, a 2nd
gear hold occurs with coast braking.
1 position provides a pull-in shift to 2nd gear with
coast braking. After an automatic downshift, a 1st
gear hold occurs with coast braking.
"Three One-Way Clutches"
Overdrive Roller Clutch
Intermediate Sprag
Low Roller Clutch
"Three Simple Planetary Gearsets"
Overdrive
Forward
Reverse
"Typical" Shift Quadrant Indicator
TCS
SWITCH
P R N D 2 1
OVERDRIVE OFF
TCIL LAMP
Copyright © 2003 ATSG
Figure 2
4
Figure 3
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD MOTOR COMPANY
4R100 ("PTO" Version Illustrated)
Intermediate
Clutch
Overdrive
Clutch
Coast
Clutch
Low/Reverse
Clutch
Direct Forward
Clutch Clutch
GEAR RATIOS
Reverse - 2.18
1st Gear - 2.71
2nd Gear - 1.54
3rd Gear - 1.00
4th Gear - 0.71
Low
Roller Clutch
Overdrive
Roller Clutch
Intermediate
Band
Intermediate
Sprag
COMPONENT AND SOLENOID APPLICATION CHART
GEAR
Park/Neut
Reverse
OD-1st
OD-2nd
OD-3rd
OD-4th
OD-3rd**
M-2nd
M-1st
Fwd Int Dir O.D. Cst Int
Clut Clut Clut Clut Clut Band
ON
ON
L/R
Clut
ON
ON
Hold
Hold
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
SOLENOIDS
O.D.
Int
Low
Roller Sprag Roller SS1 SS2 CCS TCC EPC
Hold
Hold
Hold
Hold
ON
ON
ON
ON
Hold
ON
Hold
ON
Hold
Hold
Hold
On
Off
Off
Off Mod
On
Off
Off
Off Mod
On
Off *Off *On Mod
On
On *Off *On Mod
Off
On *Off *On Mod
Off
Off
Off *On Mod
Off
On
On *On Mod
On
On
On *On Mod
On
Off
On
Off Mod
OD-3rd** = TCS "On" with TCIL illuminated showing "Off"
*On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may
be On (Modulating with PWM TCC units) in any forward gear except Manual 1st.
*Off = Will be "On", if the TCS switch is pushed.
Mod = Modulating at all times by the PCM and line pressure will be regulated based on throttle position,
engine load and vehicle speed.
Copyright © 2003 ATSG
Figure 4
AUTOMATIC TRANSMISSION SERVICE GROUP
5
Technical Service Information
(5) Shift Solenoid 2 and the Coast Clutch Solenoid
must be energized when the PTO is turned ON.
"GENERAL" CONDITIONS FOR OPERATION
(1) The vehicle is not in the crank or start mode.
(2) The transmission range selector must be in the P,
R, O.D, 2 or 1 position. The PTO will not operate
when selector is in the neutral position.
(3) PTO operation is inhibited when in cranking
mode, neutral, or 4th gear.
(4) Transmission only operates 1st through 3rd
gears. Computer strategy does not allow 4th
gear to engage, under any conditions.
(5) Transmission Fluid Temperature Sensor (TFT)
reading must be up to operating temperature.
GASOLINE ENGINE PTO OPERATION:
(1) PTO installer must obtain a "High Idle Throttle
Control" from an aftermarket source.
(2) Auxiliary Powertrain Control Module seen on
Page seven, does not work on the gasoline engine
models. APCM module works only on the 7.3L
diesel engine.
(3) For stationary PTO operation an engine idle
speed of 1300 RPM is required.
(4) The Torque Converter Clutch (TCC) engages
once the engine reaches 1300 RPM.
6
PTO
Window
Ford
RFF81
XW4P-AC
RJL-B
004361
17
BD-9C
A
P-7006-B
98
Ford
PTO "GENERAL" REQUIREMENTS:
(1) Obviously the case must be PTO capable with
the cast-in window in the transmission where the
PTO unit mounts to the transmission, as shown in
Figure 5.
(2) Designed for use during Mobile (Some Models)
or Stationary conditions.
(3) PTO is available as an option only on 8500 GVW
or above, Super Duty F-Series trucks with 6.8L
Gasoline and 7.3L Diesel engines. Ford 4R100
transmissions on other models are not PTO
capable.
(4) Battery voltage must be supplied to the
Powertrain Control Module (PCM) input pin 4
on gasoline models, or pin 66 on diesel models,
when the PTO is engaged. The processor uses
this information to raise EPC pressure to
approximately 55 PSI so that you do not burn the
coast clutch. This voltage must be provided by
the PTO installer.
Copyright © 2003 ATSG
Figure 5
TRANSMISSION FUNCTIONS
DURING PTO OPERATION:
(1) Shift Solenoid 2 and Coast Clutch Solenoids are
turned on, the coast clutch activates and does not
allow 4th gear operation during PTO operation.
(2) Electronic Pressure Control (EPC) pressure is
raised to approximately 55 PSI. This is why the
coast clutch will be smoked in a short period of
time if a battery voltage wire is not supplied to
EEC input pin 4 (gasoline) or pin 66 (diesel)
when the PTO is engaged, as this rise in pressure
would not occur.
(3) The Transmission Control Indicator Lamp
(TCIL) illuminates.
(4) When the PTO is turned ON, the transmission
operates only in 1st through 3rd gears.
Overdrive 4th gear is not allowed by the PCM
strategy.
(5) The transmission shift schedule is early and shift
feel is very firm.
(6) PTO operation can cause transmission fluid
temperature to exceed the recommended
maximum limit of 250 degrees F. Failure mode
logic within PCM strategy prevents transmission
damage by disabling the PTO above this
temperature limit.
Specific Operation For Diesel, See Page 7.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
DIESEL ENGINE PTO OPERATION:
"AUXILIARY" POWERTRAIN CONTROL MODULE
7.3L DIESEL ENGINE (ONLY)
The Auxiliary Powertrain Control Module (APCM) commands the Electronic Engine Control
(EEC) module to increase the idle speed during PTO operation. The APCM controls engine
speed from 1300 to 2500 RPM.
The Auxiliary Powertrain Control Module is a seperate option, it does not come standard with a
PTO capable transmission, and is for 7.3L diesel applications only.
Intended for stationary use only, and in stationary operation the PTO requires an engine idle speed
of 1300 RPM. During stationary PTO operation on the 7.3L diesel, the EEC increases the idle to
1300 RPM automatically.
During stationary PTO operation, the Torque Converter Clutch (TCC) engages once the RPM
reaches 1200-1300 RPM.
The following conditions must be met before the idle speed is increased:
1.
2.
3.
4.
5.
Parking brake must be engaged for all applications.
No hydraulic brake actuation.
Accelerator pedal must be in the idle position.
Vehicle speed must be zero MPH.
Brake lights must be functional.
Ford
AUXILIARY POWERTRAIN CONTROL MODULE
CHARGE PROTECTION
APPLICATION
Charge Protection is used for maintaining battery charge.
In Charge Protection mode, the battery voltage is monitored and the
engine idle speed is increased as necessary, so the battery charge is
maintained as required.
Charge Protection can be activated from in-cab and can be
programmed to activate automatically on engine start-up.
Exclusively for light trucks with the 7.3L Diesel Engine.
Intended for Stationary Use Only.
Order Guide Option Code 961.
KITS INCLUDE
RPM CONTROL
RPM Control is used for
RPM Control mode can be
activated from in-cab and
can be programmed to
activate automatically on
engine start-up.
The programmable speed
presets range from 1300 to
RPM
CONTROL
CHARGE
PROTECT
POWER
Ford
2500
Aux. Powertrain Control Module.
Mounting Hardware and Bracket.
Wiring Harness.
Instruction Booklet.
Operators Card.
LCD screen displays the current
engine speed or battery voltage.
Each Single Arrow key contains a
preset speed allowing for four
programmable RPM settings.
The Double Arrow keys can also be
used to manually raise or lower the
engine speed at a faster or slower
rate.
This is the recommended
method of elevating idle
speed for PTO operations.
Copyright © 2003 ATSG
Figure 6
AUTOMATIC TRANSMISSION SERVICE GROUP
7
Technical Service Information
DIAGNOSTIC CONCERNS WITH PTO
EQUIPPED VEHICLES:
(1) Always ensure that PTO is turned OFF, before
any diagnostic procedures begin.
(2) Never perform any transmission special tests
(i.e. pressure test, stall test etc.) when the PTO is
turned ON.
(3) If a transmission concern or symptom goes
away with the PTO turned OFF, it is most likely
not a transmission concern.
(4) On Board Diagnostics operate normally during
PTO operation with the exception of the engine
misfire monitor. The circuit checks made by the
PCM and Failure Mode Effect Management
(FMEM) capability will continue. The PTO
must be turned OFF to access Diagnostic
Trouble Codes (DTC's) and perform OBD tests.
CENTRAL JUNCTION BOX
FUSE 19
Caution: If the batteries are disconnected for any
reason, the PCM "must" have a 7 mile drive cycle at
speeds above 50 MPH, before it remembers that it is
capable of running a PTO
Red/Yellow
ELECTRICAL COMPONENT DIAGNOSIS
Accelerator Pedal Position Sensor (Diesel Only)
The Accelerator Pedal (AP) position sensor is
mounted on the accelerator pedal inside the vehicle
and detects the position of the accelerator pedal and
sends this information as a varying voltage signal to
the PCM. The PCM then uses the monitored voltage
level of the AP sensor for control of EPC pressure and
shift scheduling.
The Idle Validation Switch is fed voltage through
fuse number 19, as well as the Transmission Control
Switch, as shown in Figure 7.
If the Idle Validation Switch feed voltage is lost for
any reason, the engine will immediately return to
idle and stay there until feed voltage is restored.
4X4 Low Switch
The 4X4 Low Switch is used to the PCM that the
transfer case system is operating in LOW range. The
PCM receives the 4X4 Low Switch input signal and
modifies shift scheduling for the lower gear ratio
(See Figure 8).
If the 4X4 LOW indicator fuse is blown, the
transmission will shift according to the 4X4 LOW
shift schedule, regardless of transfer case lever
position.
Transmission Control Switch (TCS)
Clutch Pedal Position (CPP) (Std Trans Only)
Idle Validation Switch (IVS) (Diesel Only)
Overhead Trip Computer Module
Generic Electronic Module (GEM)
Instrument Cluster Terminal A12
Instrument Cluster Terminal B11
Copyright © 2003 ATSG
Figure 7
PCM PIN 14
Lt. Blue/Black
Figure 8
8
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Turbine Shaft Speed Sensor
The Turbine Shaft Speed (TSS) sensor is a magnetic
pickup that sends the PCM a frequency signal related
to the rotating speed of the transmission input shaft.
The TSS mounts on the top front of the case on some
models, as shown in Figure 9. We have also provided
you with the resistance readings and OEM part
numbers on both Turbine Speed Sensors, as the PTO
and Non-PTO models use different sensors, as shown
in Figure 9.
The PCM uses the TSS sensor signal to control EPC
pressure and TCC strategy.
Turbine Shaft Speed Sensor
Output Shaft Speed Sensor
The Output Shaft Speed (OSS) sensor is a magnetic
pickup that sends the PCM a frequency signal related
to the rotating speed of the transmission output shaft.
The OSS sensor was added to the top of extension
housing, as shown in Figure 10. The OSS is triggered
by an added rotor pressed onto the output shaft. The
park gear is also now pressed onto the output shaft,
and the number 13 thrust washer has changed to a
thrust bearing, as shown in Figure 11. We have
provided you with the resistance reading and the
OEM part number for the output shaft speed sensor.
Refer to Figure 10 for output shaft speed sensor
information.
The PCM uses the OSS sensor signal to control EPC
pressure, shift scheduling and TCC strategy.
PTO Models Only = 496-1244 Ohms Resistance
Part Number F81Z-7M101-BA
Non PTO Models Only = 781-1979 Ohms Resistance
Part Number F81Z-7M101-AA
The Park Gear is also a press fit to the output
shaft, and the number 13 thrust washer, between
the case and the park gear has been replaced
with a needle bearing.
Copyright © 2003 ATSG
Figure 9
Output Shaft Speed Sensor
All Models = 781-1979 Ohms Resistance
Part Number F81Z-7M101-AA
OSS Rotor
Park Gear
(Press Fit)
(Press Fit)
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 10
Figure 11
AUTOMATIC TRANSMISSION SERVICE GROUP
9
Technical Service Information
ELECTRICAL COMPONENT DIAGNOSIS
Digital Transmission Range Sensor
The Digital Transmission Range (DTR) sensor has a
twelve pin electrical connector and is located on the
outside of the transmission at the manual lever, as
shown in Figure 12.
The DTR sensor completes the start circuit in Park
and Neutral, the backup lamp circuit in Reverse, and
the neutral sense circuit (4WD Only) when in Neutral.
The DTR sensor also opens or closes a set of four
different switches that are monitored by the
Powertrain Control Module (PCM) to determine the
position of the transmission manual lever. Refer to
Figure 13.
DTR TESTING PROCEDURE
In Figure 13 we have provided you with pin number
identification for both the transmission range sensor
and the vehicle harness. We have also provided a
chart that will give you the open/closed state of each
internal switch, dependent on selector position, and
notice that three positions read a 270W resistor, that is
also internal.
Note: All testing that we have provided for you is
done with a DVOM, set to the ohms position, and all
tests are performed with the ignition switch in the
"OFF" position.
(1) Testing the transmission range 3A switch, and
the 270W internal resistor is done across pins 2
and 3 of the DTR sensor, and must be checked in
each selector position to determine the switch
and resistor integrity. Refer to Figure 13.
(2) Testing the transmission range 1 switch is done
across pins 2 and 4 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.
(3) Testing the transmission range 2 switch is done
across pins 2 and 5 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.
Ford
XW4P-AC
RJL-B
004361
BD-9C17
7006-BA
RFF81P98
(4) Testing the transmission range 4 switch is done
across pins 2 and 6 of the DTR sensor, and must
be checked in each selector position to
determine switch integrity. Refer to Figure 13.
(5) Testing the reverse lamp circuit is done across
pins 9 and 11 of the DTR sensor, and must be
checked in each selector position to determine
switch integrity. Refer to Figure 13.
Ford
(6) Testing the neutral start circuit is done across
pins 10 and 12 of the DTR sensor, and must be
checked in each selector position to determine
switch integrity. Refer to Figure 13.
L L
TRA
NEU
d
For
93-A A
F7TP-7F2
C
Copyright © 2003 ATSG
Figure 12
10
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
6
12
5
11
4
10
6
3
9
2
8
1
7
Function
Not Used
Signal Return (Ground)
TR3A (5 Volts from PCM)
TR1 (10-12 Volts from PCM)
TR2 (10-12 Volts from PCM)
TR4 (10-12 Volts from PCM)
P
TERMINALS
1
12 11 10
9
8
7
R
Pin No.
7
8
9
10
11
12
Function
Ground
Neutral
Battery Voltage Feed
Fuse 21, Hot In Start
Back-up Lamps
Starter Relay
N
D
2
270 W
OPEN
OPEN
OPEN
9 AND 11
10 AND 12
OPEN CLOSED OPEN
CLOSED OPEN CLOSED
OPEN
OPEN
11
1
2
12
10
1
P
R
2
N
D
4
5
1
P
R
2
N
D
1
R
2
N
CLOSED CLOSED
OPEN
OPEN
CLOSED OPEN
OPEN CLOSED
OPEN
OPEN
2
P
D
1
OPEN
OPEN
6
3
1
P
R
2
N
D
1
P
R
2
N
D
270 W
D
2
CLOSED 270 W
270 W
CLOSED CLOSED CLOSED
CLOSED CLOSED OPEN
CLOSED OPEN CLOSED
P
N
3
2 AND 3
2 AND 4
2 AND 5
2 AND 6
9
R
4
View looking into DTR Sensor
harness connector-terminal side
View looking into DTR Sensor
Pin No.
1
2
3
4
5
6
5
DIGITAL TRANSMISSION RANGE SENSOR
Copyright © 2003 ATSG
Figure 13
AUTOMATIC TRANSMISSION SERVICE GROUP
11
Technical Service Information
ELECTRICAL COMPONENT DIAGNOSIS
Solenoid Assembly
The Solenoid Assembly is bolted to the case and
located inside the bottom pan. The Solenoid
Assembly contains shift solenoid 1, shift solenoid 2,
coast clutch solenoid, TCC solenoid, EPC solenoid
and the TFT sensor. The solenoids are not serviced
individually. You must replace the entire assembly, as
shown in Figure 14. Some of these units are equipped
with an ON/OFF TCC solenoid and some are
equipped with a PWM TCC solenoid, so it is
important to determine which you have.
SOLENOID PACK ASSEMBLY
SOLENOID PACK TESTING PROCEDURE
In Figure 16 we have provided you with pin number
identification for both the transmission case
connector and the vehicle harness. We have also
provided a chart that will give you the function of
each and the ohms readings you should see on each of
the solenoids and the TFT sensor.
Note: All testing that we have provided for you is
done with a DVOM, set to the ohms position, and all
tests are performed with the ignition switch in the
"OFF" position.
(1) Shift Solenoid 1 is tested across pins 1 and 3,
and should read 20-30 ohms resistance. Refer
to Figure 16.
(2) Shift Solenoid 2 is tested across pins 1 and 2,
and should read 20-30 ohms resistance. Refer
to Figure 16.
(3) TCC On/Off Solenoid is tested across pins 1 and
4, and should read 20-30 ohms resistance.
Refer to Figure 16.
(4) TCC PWM Solenoid is tested across pins 1 and
4, and should read 10-20 ohms resistance.
Refer to Figure 16.
(5) Coast Clutch Solenoid is tested across pins 1
and 5, and should read 20-30 ohms resistance.
Refer to Figure 16.
(6) EPC Solenoid is tested across pins 11 and 12,
and should read 3.0-5.0 ohms resistance. Refer
to Figure 16.
Copyright © 2003 ATSG
(7) TFT sensor is tested across pins 7 and 8. Refer
to the chart provided in Figure 15.
Figure 14
Transmission Fluid Temperature
°C
°F
Resistance
-40 to -20
-40 to -4
1062k - 284k W
-19 to -1
-3 to 31
284k - 100k W
0 - 20
21-40
41-70
32-68
69-104
105-158
159-194
100k - 37k W
37k - 16k W
16k - 5k W
195-230
231-266
2.7k - 1.5k W
1.5k - 0.8k W
267-302
0.8k - 0.54k W
71-90
91-110
111-130
131-150
5k - 2.7k W
4R100 FLUID REQUIREMENTS
Only Motorcraft Mercon® multi-purpose automatic
transmission fluid XT-2-QDX or an equivalent
Mercon® fluid should be used in all Ford 4R100
transmissions. Before adding any fluid, ensure that it
is the correct type.
Checking Fluid
Always use the transmission fluid level indicator
(Dipstick) to set the correct fluid level. Set the fluid
level at normal operating temperature which is 150°
to 170°F, engine at idle in Park.
Figure 15
12
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
SOLENOID BODY PIN IDENTIFICATION AND FUNCTION
VEHICLE HARNESS
SOLENOID BODY
CONNECTOR
CONNECTOR
7 8
12
11 12
6 5 4
3
2
1
7
1
Solenoid Resistance Chart
Solenoid Body
Solenoid
Pin Numbers
Shift Solenoid "B" (2)
Shift Solenoid "A" (1)
TCC Solenoid, (On-Off)
TCC Solenoid, (PWM)
Coast Clutch Solenoid
Electronic Pressure Control Solenoid
Transmission Fluid Temp Sensor
1 and 2
1 and 3
1 and 4
1 and 4
1 and 5
11 and 12
7 and 8
6
Resistance
20-30 Ohms
20-30 Ohms
20-30 Ohms
10-20 Ohms
20-30 Ohms
3.0-5.0 Ohms
See Chart Below
Solenoid Connector Pin Identification and Function
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Description
Vehicle Power In For Solenoids (VPWR)
Shift Solenoid "B" (2) Ground from PCM
Shift Solenoid "A" (1) Ground from PCM
Converter Clutch Solenoid Ground from PCM
Coast Clutch Solenoid Ground from PCM
Not Used
Transmission Fluid Temp Sensor
Transmission Fluid Temp Sensor (Signal Return)
Not Used
Not Used
Electronic Pressure Control (EPC)
Vehicle Power In For EPC Solenoid (VPWR)
Figure 16
PCM Connector Pin
Gas & Diesel (Cal) Diesel (49 State)
71, 97
71, 97
11
1
6
27
54
28
20
53
37
91
37
91
81
71, 97
81
71, 97
AUTOMATIC TRANSMISSION SERVICE GROUP
13
Technical Service Information
FORD 4R100
Abbreviation Description
Abbreviation
4X4L
ABS
A/C
ACCS
AP
APGND
ARPMDES
BARO
BOO
BPA
BPP
BUS +
BUS CASE GND
CCS
CID
CMP
CPP
CRUISE
DLC
DTC
DTC CNT
DTR
EBP
ECT
EOT
EPC
EPR
FEPS
FUEL PW
GP
GPC
GPL
IAT
14
Description
4X4 Low Switch
Antilock Brake System
Air Conditioning
Air Conditioning Clutch Status
Accelerator Pedal Position Sensor
Abbreviation Description
ICP
IPR
IVS
KAM
KAPWR
Accelerator Pedal Sensor Ground
KOEO
Ancillary Engine Speed Desired
KOER
Barometric Pressure Sensor
MAF
Brake ON/OFF Switch
MAP
Brake Pressure Applied
MIL
Brake Pedal Position
OCT ADJ
Data Link Connector
OSS
Data Link Connector
PBA
Case Ground
PCM
Coast Clutch Solenoid
PIP
Cylinder Identification
ROM
Camshaft Position Sensor
RPM
Clutch Pedal Position
SCCS
Cruise Control Mode (Driving)
SS1
Data Link Connector
SS2
Diagnostic Trouble Code
SSA
Diagnostic Trouble Code Count
SSB
Digital Transmission Range Sensor SPOUT
Exhaust Back Pressure
TAC
Engine Coolant Temperature
TCC
Engine Oil Temperature
TCIL
Electronic Pressure Control
TCS
Exhaust Pressure Regulator
TFT
Flash EPROM Power Supply
TP
Fuel Pulse Width
TSS
Glow Plug
VPWR
Glow Plug Control Duty Cycle
VREF
Glow Plug Lamp
VSS
Intake Air Temperature
WOT
Figure 17
Injector Control Pressure Sensor
Injector Pressure Regulator
Idle Validation Switch
Keep Alive Memory
Keep Alive Power
Key On Engine Off
Key On Engine Running
Mass Air Flow Sensor
Manifold Absolute Pressure Sensor
Malfunction Indicator Lamp
Octane Adjust
Output Shaft Speed Sensor
Parking Brake Applied
Powertrain Control Module
Profile Ignition Pickup
Read Only Memory
Engine Speed
Speed Control Command Switch
Shift Solenoid "1"
Shift Solenoid "2"
Shift Solenoid "A"
Shift Solenoid "B"
Spark Output
Tachometer Signal
Torque Converter Clutch
Trans Control Indicator Lamp
Transmission Control Switch
Transmission Fluid Temperature
Throttle Position Sensor
Turbine Shaft Speed Sensor
Vehicle Power Supply
Vehicle Reference Voltage
Vehicle Speed Sensor
Wide Open Throttle
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD 4R100
Diagnostic Trouble Code Chart
Diagnostic Code
P0102
P0103
P0107
P0108
Description
MAF sensor system fails to operate in a
normal manner, which may cause a
transmission concern.
BARO sensor circuit signal higher or lower
than expected.
Symptom
High EPC pressure. Firm shifts
and engagements. May flash TCIL.
Firm shift feel, late shifts at higher
altitudes.
P0122
(TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel,
Accelerator Pedal Position sensor below abnormal shift schedule, abnormal
specification during normal operation.
TCC operation or does not engage.
P0123
(TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel,
Accelerator Pedal Position sensor above or abnormal shift schedule, abnormal
below normal specifications during normal TCC operation or does not engage.
operation.
P0235
MAP sensor or circuit open, shorted to ground Firm shift feel, late shifts at higher
altitudes.
or to 5V.
P0236
MAP sensor signal higher or lower than Firm shift feel, late shifts at higher
expected or no response due to vacuum hose altitudes.
circuit damaged, disconnected or restricted.
P0237
MAP sensor out of On-Board Diagnostics Rerun On-Board Diagnostics and
range.
No response during Dynamic perform "Goose" test when asked.
Response (Goose) test.
P0340
P0341
P0344
(DI) Distributor Ignition circuit concern or Engine will stall or will not run.
(CKP) Crankshaft Position sensor failure.
May flash TCIL.
P0500
P0503
Insufficient or intermittent vehicle speed Harsh engagements, firm shift feel,
input from VSS/ABS.
abnormal shift pattern, unexpected
downshifts may occur at closed
throttle, abnormal TCC operation or
engages only at WOT. May flash
TCIL.
(BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage
not connected.
when brake is applied.
P0571
P0703
(BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage
not connected.
when brake is applied.
P0705
(DTR) Digital Transmission Range sensor Harsh engagements, firm shift feel.
circuit malfunction.
May flash TCIL.
P0708
(DTR) Digital Transmission Range sensor Slight increase in EPC pressure.
circuit malfunction.
P0712
TFT sensor circuit grounded, exceeds scale set Harsh engagements, firm shift feel,
abnormal shift schedule, abnormal
for temperature of 315°F.
TCC operation or does not engage.
Figure 18
AUTOMATIC TRANSMISSION SERVICE GROUP
15
Technical Service Information
FORD 4R100
Diagnostic Trouble Code Chart
Diagnostic Code
P0713
Description
Symptom
TFT sensor circuit open, exceeds scale set for TCC and stabilized shift schedule
temperature of minus 40°F.
may be enabled sooner after cold
start. May flash TCIL.
P0715
Insufficient input from TSS sensor.
Set DTC, Flash TCIL and Flash
MIL.
P0717
TSS sensor signal intermittent.
Set DTC, Flash TCIL.
P0718
TSS sensor signal noisy.
Set DTC.
P0720
Insufficient input from OSS sensor.
Set DTC, Flash TCIL and Flash
MIL.
P0721
OSS sensor signal noisy.
Set DTC.
P0722
OSS sensor signal intermittent.
P0731
Set DTC, Flash TCIL.
1-2 shift error because of SSA, SSB, or Improper gear selection depending
internal transmission components.
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
P0732
2-3 shift error because of SSA, SSB, or Improper gear selection depending
on failure mode and transmission
internal transmission components.
range selector position. Refer to
shift solenoid operation chart.
P0733
3-4 shift error because of SSA, SSB, or Improper gear selection depending
on failure mode and transmission
internal transmission components.
range selector position. Refer to
shift solenoid operation chart.
P0741
The PCM picked up an excessive amount of TCC slippage/erratic or no torque
TCC slippage during normal operation.
converter clutch operation. Flash
TCIL.
TCC Solenoid circuit failure.
Short Circuit: Engine stalls in "D"
or "2" at idle with brake applied.
Open Circuit: TCC never engaged.
P0743
P0750
SSA circuit failure.
Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
P0755
SSB circuit failure.
Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
Figure 19
16
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD 4R100
Diagnostic Trouble Code Chart
Diagnostic Code
Description
Symptom
P0781
1-2 shift error because of SSA, SSB, or Improper gear selection depending
internal transmission components.
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
P0782
2-3 shift error because of SSA, SSB, or Improper gear selection depending
on failure mode and transmission
internal transmission components.
range selector position. Refer to
shift solenoid operation chart.
P0783
3-4 shift error because of SSA, SSB, or Improper gear selection depending
on failure mode and transmission
internal transmission components.
range selector position. Refer to
shift solenoid operation chart.
P1100
P1101
MAF sensor system fails to operate in a High EPC pressure. Firm shifts
normal manner, which may cause a and engagements. May flash TCIL.
transmission concern.
P1111
System Pass.
P1120
Throttle Position Sensor voltage lower than Harsh engagements, firm shift feel,
expected.
abnormal shift schedule, abnormal
TCC operation or does not engage.
P1124
Throttle Position Sensor out of On-Board TP sensor (Gas Engines) not at idle
position during KOEO test.
Diagnostics range during KOEO test.
P1280
Injection Control Pressure (ICP) sensor May result in firm shifts.
circuit failure (Diesel Engine), or out of range
low.
P1281
Injection Control Pressure (ICP) sensor May result in firm shifts.
circuit failure (Diesel Engine), or out of range
high.
P1460
P1463
P1464
A/C switch error.
P1500
Insufficient or intermittent vehicle speed Harsh engagements, firm shift feel,
input from VSS/ABS.
abnormal shift pattern, unexpected
downshifts may occur at closed
throttle, abnormal TCC operation or
engages only at WOT. May flash
TCIL.
No Codes Detected.
Failed On: EPC pressure slightly
low with A/C off.
Failed Off: EPC pressure slightly
low with A/C on.
Figure 20
AUTOMATIC TRANSMISSION SERVICE GROUP
17
Technical Service Information
FORD 4R100
Diagnostic Trouble Code Chart
Diagnostic Code
P1702
Description
Symptom
Digital Transmission Range (DTR) sensor Erratic harsh shift engagements.
signal intermittent.
P1703
(BPP) Brake Pedal Position switch not Failed on or not connected, TCC
will not engage at less than oneactuated during KOER test.
third throttle opening.
P1704
Digital Transmission Range (DTR) sensor Increase in EPC pressure.
misaligned or failed electronically.
P1705
Digital Transmission Range (DTR) sensor not Rerun On-Board Diagnostics.
run in park or neutral during On-Board
Diagnostics KOEO or KOER tests.
P1711
Transmission not at operating temperature Warm vehicle to normal operating
temperature and rerun On-Board
during On-Board Diagnostics.
Diagnostics.
P1713
P1714
No change in TFT sensor - Low range.
SSA mechanical failure detected.
May flash TCIL.
P1715
SSB mechanical failure detected.
Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
P1718
P1728
No change in TFT sensor - High range.
P1729
4X4 Low switch circuit failure.
Early or delayed shift schedule.
P1740
TCC solenoid mechanical failure detected.
Harsh shift, may flash TCIL.
P1744
The PCM picked up an excessive amount of TCC slippage/erratic or no torque
TCC slippage during normal operation.
converter clutch operation. Flash
TCIL.
P1746
Failure of the EPC control pressure driver Open circuit causes maximum EPC
pressure, harsh engagements and
located inside the PCM.
shifts. May flash TCIL.
P1747
EPC shorted circuit failure, or PCM.
Improper gear selection depending
on failure mode and transmission
range selector position. Refer to
shift solenoid operation chart.
May flash TCIL.
Excessive amount of transmission slippage Transmission slippage, erratic or no
TCC operation. May flash TCIL.
has been detected.
Shorted circuit causes minimum
EPC pressure, limits engine torque
with partial fuel shut off and heavy
misfire. Flashing TCIL.
Figure 21
18
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD 4R100
Diagnostic Trouble Code Chart
Diagnostic Code
P1754
Description
Symptom
CCS circuit failure.
Failed Off: No third gear engine
braking in O.D. cancel.
Failed On: Third gear engine
braking in O.D. range. Coast clutch
may be damaged causing eventual
failure.
P1760
EPC signal intermittent short.
Short circuit causes minimum EPC
pressure.
P1780
TCS not cycled during the On-Board No overdrive cancel when switch is
cycled.
Diagnostics or the circuit is open or shorted.
P1781
4X4 Low switch circuit failure.
P1783
Transmission Fluid Temperature has Slight increase in EPC pressure.
exceeded 270°F.
May flash TCIL.
Early or delayed shift schedule.
Figure 22
AUTOMATIC TRANSMISSION SERVICE GROUP
19
Technical Service Information
Shift Solenoid Application Chart
Selector Lever Commanded
Range
Gear
P/R/N
D
D
D
D
D
Cancel
MANUAL 2
MANUAL 1
MANUAL 1
*
1
1
2
3
4
Shift
Solenoid "A"
Shift
Solenoid "B"
TCC
Solenoid
Coast Clutch
Solenoid
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
*
*
*
*
*
*
*
*
*
*
First Through 3rd Gear Only, SSA, SSB, TCC, Same as Overdrive, CCS Always On.
2
2
1
*
*
*
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
Controlled by PCM
SHIFT SOLENOID TROUBLE CHART GUIDE
SHIFT SOLENOID "A" ALWAYS OFF
Selector Lever Position
D
2
1
PCM Gear
Commanded
Actual Gear Obtained
1st
4
2
1
2nd
3
2
2
3rd
3
2
2
4th
4
2
2
SHIFT SOLENOID "B" ALWAYS OFF
Selector Lever Position
D
2
1
PCM Gear
Commanded
Actual Gear Obtained
1st
1
2
1
2nd
1
2
1
3rd
4
2
2
4th
4
2
2
SHIFT SOLENOID "A" ALWAYS ON
Selector Lever Position
D
2
1
PCM Gear
Commanded
Actual Gear Obtained
1st
1
2
1
2nd
2
2
1
3rd
2
2
1
4th
1
2
1
SHIFT SOLENOID "B" ALWAYS ON
Selector Lever Position
D
2
1
PCM Gear
Commanded
Actual Gear Obtained
1st
2
2
1
2nd
2
2
1
3rd
3
2
2
4th
3
2
2
Figure 23
20
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
LINE PRESSURE TEST
llllllll
lll
ll
llll
llllllllll
llll
llllllllllll
lll
lll
Ford
-700
RFF81P
98
C
XW4P-A
RJL-B
004361
7
BD-9C1
6-BA
d
For
LINE PRESSURE SPECIFICATION CHART
NOTE: On vehicles equipped with PTO units,
Gear
Idle
Stall
access to the line pressure port may require that you
P, N
50-65 psi
remove the PTO unit depending on the type of unit
R
70-100 psi
220-240 psi
installed. If required, remove the PTO unit and
install PTO cover and gasket "Before" doing the
OD, M2
50-65 psi
136-156 psi
line pressure test.
M1
70-115 psi
175-210 psi
Copyright © 2003 ATSG
Figure 24
LINE PRESSURE TEST
NOTE: Perform the line pressure test before
performing the "Stall" test. If the line pressure is
low at "Idle", DO NOT perform the "Stall" test or
further transmission damage will occur.
Do Not Maintain Wide Open Throttle in any gear
range for more than "5 Seconds" or transmission
damage may occur.
NOTE: If equipped, turn "Off" the PTO unit to
ensure proper test results.
1. Install a 300 psi line pressure gauge to the line
pressure tap, as shown in Figure 24.
2. Start the engine and check line pressure in all
ranges at "Idle". Refer to the chart shown in
Figure 24 to determine if they are within the
specifications.
3. If the line pressures are within the specifications
at "Idle", now you can perform the "Stall" test
to determine if specifications are okay there.
4. Once again, refer to the chart in Figure 24, to
determine proper specifications at "Stall".
AUTOMATIC TRANSMISSION SERVICE GROUP
21
Technical Service Information
FORD 4R100
"NON-PTO" AND "PTO"
HYDRAULIC DIFFERENCES
CHANGE: Begining at the start of production for 1999 models, Ford Motor Company made available a "Power
Take Off" option for some F250, F350, F450 and F550 Super Duty Trucks, equipped with 5.4L,
6.8L and 7.3L engines.
REASON: The "PTO" option addition, to the 4R100, required many changes to the transmission to make the
"PTO" function. The "PTO" window, added to the case, the "PTO" drive gear and other cosmetic
changes were covered on Page 6 in this manual. Hydraulic changes also had to be made to make
the coast clutch operate in ranges other than the Drive ranges (See Figure 35).
PARTS AFFECTED:
(1) TRANSMISSION CASE: The transmission case was changed to accommodate the "PTO"
window, as shown in this manual. All 4R100 Cases, "NON-PTO"and "PTO,"also had a "Dam"
added to seperate "Rear Lube" and to incorporate "Central Lube"as shown in Figure 25.
(2) VALVE BODY TO CASE SPACER PLATE: The Valve Body to Case Spacer plate on the "PTO"
versions had a hole added to supply the 3-4 Shift Valve with Line Pressure, as shown in Figure 27. A
hole was also added to the Spacer Plate on "NON-PTO" and "PTO" versions to connect "Solenoid
Regulator Valve" oil to supply "Central Lubrication." Refer to Figures 26 and 27 for identification
of "NON-PTO"and "PTO" Valve Body To Case Spacer Plates.
(3) MAIN VALVE BODY: A passage was added on the "Upper Side" of the Main Valve Body on
"PTO" versions, as shown in Figure 29, to supply Line Pressure to the 3-4 Shift Valve. A passage
was also added, on the "Lower Side" of the Main Valve Body, to connect the 3-4 Shift Valve (Coast
Clutch Circuit) to an exhaust as shown in Figure 31. The spring side of the 3-4 Shift Valve was also
seperated from the Low/Reverse circuit as shown in Figure 31. Refer to Figures 28 thru 31 for
identification of "NON-PTO" and "PTO" Main Valvebody's.
(4) LOWER VALVE BODY: The Lower Valve Body has a passage added, as shown in Figure 33, to
connect to the "new"exhaust passage in the Main Valve Body. Refer to Figures 32 and 33, for
identification of "NON-PTO" and "PTO" Lower Valvebody's.
(5) LOWER VALVE BODY SPACER PLATE: The Lower Valve Body Spacer Plate had a hole added
to connect the "new" exhaust passage in the Main Valve Body to the "new" exhaust passage in the
Lower Valve body a shown in Figure 34. Refer to Figure 34 for "NON-PTO" and "PTO" Lower
Valve Body Spacer Plate identification.
INTERCHANGEABILITY:
None of the parts listed above will interchange between "NON-PTO" and "PTO" versions.
SERVICE INFORMATION:
Valve Body To Case Spacer Plate (Non-PTO) .................. ................................F81Z-7A008-DA
Valve Body To Case Spacer Plate (PTO) ...........................................................F81Z-7A008-BA
Copyright © 2003 ATSG
22
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
4R100 CASE ASSEMBLY
"NON-PTO" AND "PTO" MODELS
ADDED OIL
DAM
CENTRAL LUBE
REAR LUBE
Copyright © 2003 ATSG
Figure 25
AUTOMATIC TRANSMISSION SERVICE GROUP
23
Technical Service Information
97
12
4R100 MAIN SPACER PLATE
"NON-PTO" MODELS ONLY
I.D.- 1 DOVE TAIL
PART NUMBER
F81Z-7A008-DA
F81P-DA
CENTRAL LUBE
ORIFICE
Copyright © 2003 ATSG
Figure 26
24
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
98
6
4R100 MAIN SPACER PLATE
"PTO" MODELS ONLY
CENTRAL LUBE
ORIFICE
I.D.- 2 DOVE TAILS
PART NUMBER
F81Z-7A008-BA
F81P-BA
ADDED MAIN LINE PRESSURE HOLE
FROM PRESSURE REGULATOR VALVE
Copyright © 2003 ATSG
Figure 27
AUTOMATIC TRANSMISSION SERVICE GROUP
25
Technical Service Information
"UPPER SIDE" 4R100 MAIN VALVE BODY
"NON-PTO" MODELS ONLY
Copyright © 2003 ATSG
Figure 28
26
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
"UPPER SIDE" 4R100 MAIN VALVE BODY
"PTO" MODELS ONLY
PASSAGE ADDED TO
FEED LINE PRESSURE TO
THE 3-4 SHIFT VALVE
Copyright © 2003 ATSG
Figure 29
AUTOMATIC TRANSMISSION SERVICE GROUP
27
Technical Service Information
"LOWER SIDE" 4R100 MAIN VALVE BODY
"NON-PTO" MODELS ONLY
RFF61P7A092-AB
6
Ford
09328
Du Page
I.D.-ROUGH FORGING
NUMBER OF "RF-F6" WHICH
INDICATES "96"
LOW/REVERSE
CLUTCH
Copyright © 2003 ATSG
Figure 30
28
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
"LOWER SIDE" 4R100 MAIN VALVE BODY
"PTO" MODELS ONLY
P
RFF81P7A092-AA
1
Ford
19538
Du Page
I.D.-ROUGH FORGING
NUMBER OF "RF-F8" WHICH
INDICATES "98"
PASSAGE ADDED
LEADING TO THE
EXHAUST IN THE
LOWER VALVE BODY
LOW/REVERSE
PASSAGE RE-MOVED
FROM SPRING SIDE
OF 3-4 SHIFT VALVE
LOW/REVERSE
CLUTCH
Copyright © 2003 ATSG
Figure 31
AUTOMATIC TRANSMISSION SERVICE GROUP
29
Technical Service Information
5
Du Page
Ford
RFF61P-7A101
A
4R100 LOWER VALVE BODY
"NON-PTO" MODELS ONLY
09828
I.D.-ROUGH FORGING
NUMBER OF "RF-F6" WHICH
INDICATES "96"
Copyright © 2003 ATSG
Figure 32
30
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
I.D.-ROUGH FORGING
NUMBER OF "RF-F8" WHICH
INDICATES "98"
14018
1
EXHAUST PASSAGE
ADDED FROM COAST
CLUTCH VALVE TO
3-4 SHIFT VALVE
DUPAGE
P
Ford
RFF81P-7A101
AA
4R100 LOWER VALVE BODY
"PTO" MODELS ONLY
Copyright © 2003 ATSG
Figure 33
AUTOMATIC TRANSMISSION SERVICE GROUP
31
Technical Service Information
4R100 LOWER VALVE BODY SPACER PLATE
"NON-PTO" MODELS ONLY
"PTO" MODELS ONLY
I.D.- 1 DOVE TAIL
I.D.- 2 DOVE TAILS
HOLE ADDED TO CONNECT
WITH EXHAUST PASSAGE
IN LOWER VALVE BODY
Copyright © 2003 ATSG
Figure 34
32
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
"NON-PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT
FROM SOLENOID 4
COAST CLUTCH SOLENOID
FROM SOLENOID 2
LINE PRESSURE
FROM MANUAL VALVE
"OD CIRCUIT"
TO CB3/COAST
CLUTCH
LINE PRESSURE
FROM MANUAL VALVE
"REVERSE"
COAST CLUTCH SHIFT VALVE
3-4 SHIFT
VALVE
TO CB7/OVERDRIVE CLUTCH
FROM 2-3
SHIFT VALVE
FROM CB15 / 2-3
SHIFT VALVE
X
"PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT
FROM SOLENOID 4
COAST CLUTCH SOLENOID
FROM SOLENOID 2
TO CB3/COAST
CLUTCH
LINE PRESSURE
FROM PRESSURE
REGULATOR VALVE
FIGURE 29
FIGURE 7
COAST CLUTCH SHIFT VALVE
3-4 SHIFT
VALVE
TO CB7/OVERDRIVE CLUTCH
FROM 2-3
SHIFT VALVE
FIGURE 33
X
X
Copyright © 2003 ATSG
Figure 35
AUTOMATIC TRANSMISSION SERVICE GROUP
33
Technical Service Information
FORD 4R100
"PWM" AND "NON-PWM"
PUMP DIFFERENCES
CHANGE: Beginning at the start of production in 1999, the 4R100 transmission was offered with two
different torque converter clutch application strategies. A "PWM" (Pulse Width Modulated)
version, was added for V-10 gas powered vehicles and all diesels, and a "NON-PWM" version,
offered in all other gas powered vehicles. This required two different solenoid packs as well as two
different pump assemblies.
REASON: For smooth converter clutch apply on V-10 gas and diesel engine models.
PARTS AFFECTED:
(1) PUMP ASSEMBLY:
• The pump cover assembly had the rear of the Converter Clutch Valve bore enlarged approximately
.070" to accommodate the enlarged land of the Converter Clutch Valve as shown in Figure 36.
A .036" orifice and an air bleed were added to the TCC Solenoid signal passage as shown in Figure
• 38.
The Converter Clutch Control Valve's rear spool was enlarged approximately .070." There was
• also a bushing and valve added to the end of the valve train as shown in Figure 36.
A hole was added to the pump cover to connect the Converter Clutch Control Valve Bushing to
• Converter Regulator Valve oil, as shown in Figure 38.
The Converter release orifice in the NON-PWM pump cover, as shown in Figure 37, was removed
• from the PWM pump cover as shown in Figure 38.
THE SOLENOID PACK:
(2) The PWM solenoid pack requires a Pulse Width Modulated torque converter clutch solenoid and
• the NON-PWM solenoid pack requires an on-off torque converter clutch solenoid.
INTERCHANGABILITY:
None of the parts listed above are interchangable from model to model.
SERVICE INFORMATION:
"NON-PWM" Pump assy. (with "Cast Iron" coast clutch drum).................F81Z-7A103-AA
"NON-PWM" Pump assy. (with "Stamped Steel" coast clutch drum)..........F81Z-7A103-BA
"PWM" Pump assy. (with "Stamped Steel" coast clutch drum)....................F81Z-7A103-CA
"NON-PWM" Solenoid Pack...........................................................................F81Z-7G391-BA
"PWM" Solenoid Pack.....................................................................................F81Z-7G391-AB
Copyright © 2003 ATSG
34
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
CONVERTER CLUTCH CONTROL VALVE
"NON-PWM"
"PWM"
.530"
.600"
.485"
.545"
THE DIAMETER AND THE LENGTH OF THE SPOOL ON THE VALVE LAND SHOWN ABOVE,
WERE INCREASED ON PWM VERSIONS. THE BORE IN THE PUMP COVER WAS ALSO ENLARGED
APPROXIMATELY .070" TO ACOMMODATE THE CHANGES IN THE DIAMETER OF THE VALVE
Copyright © 2003 ATSG
Figure 36
AUTOMATIC TRANSMISSION SERVICE GROUP
35
Technical Service Information
4R100 PUMP COVER ASSEMBLY
"NON-PWM" MODELS ONLY
CONVERTER CLUTCH
CONTROL VALVE
CONVERTER REGULATOR
VALVE
PRESSURE REGULATOR
VALVE
CONVERTER RELEASE
ORIFICE .070"
RETAINER
LUBE ORIFICE
.090"
Copyright © 2003 ATSG
Figure 37
36
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
4R100 PUMP COVER ASSEMBLY
"PWM" MODELS ONLY
CONVERTER CLUTCH
CONTROL VALVE
CONVERTER REGULATOR
VALVE
HOLE ADDED TO
CONNECT TO HOLE IN
CONTROL VALVE BUSHING
PRESSURE REGULATOR
VALVE
CONVERTER RELEASE
ORIFICE OMITTED
RETAINER
LUBE ORIFICE
.090"
ADDED ORIFICE IN
TCC PWM SOLENOID
SIGNAL PASSAGE
.036"
ADDED AIR
BLEED
Copyright © 2003 ATSG
Figure 38
AUTOMATIC TRANSMISSION SERVICE GROUP
37
Technical Service Information
4R100 CASE CHECKBALL LOCATIONS
"NON-PTO" AND "PTO" MODELS
CB7
CB8
BS3
BS1
EPC Ball
And Spring
CB1
CB9
CB14
CB6
Requires Eight 5/16" Diameter Rubber Checkballs
Plus The EPC Ball And Spring, As Shown Above.
Copyright © 2003 ATSG
Figure 39
38
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
4R100 VALVE BODY CHECKBALL LOCATIONS
"NON-PTO" AND "PTO" MODELS
CB16
1/4" Rubber
CB15
5/16" Rubber
RFF61P7A092-AB
6
Ford
09328
Du Page
X
BS2
1/4" Rubber
CB13
5/16" Rubber
Copyright © 2003 ATSG
Figure 40
AUTOMATIC TRANSMISSION SERVICE GROUP
39
Technical Service Information
Direct
Clutch
AIR PRESSURE CHECKS
Forward
Clutch
Coast
Clutch
Low/Reverse
Clutch
Overdrive
Clutch
Intermediate
Lube
Intermediate
Clutch
Copyright © 2003 ATSG
Figure 41
Ford
XW4P-AC
RJL-B
004361
BD-9C17
BA
-7006RFF81P
98
Ford
Copyright © 2003 ATSG
Figure 42
40
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Ford
XW4P-AC
RJL-B
RETAINING
BOLTS (2)
004361
BD-9C17
BA
-7006RFF81P
98
d
For
DIGITAL TRANSMISSION
RANGE SENSOR
External Components
1. Remove the turbine shaft from the transmission
as shown in Figure 42. Inspect the spline area
on both ends and set aside for final assembly.
2. Remove the two Digital Transmission Range
sensor retaining bolts, as shown in Figure 43,
and remove the DTR sensor.
3. If equipped, the turbine shaft speed sensor and
output shaft speed sensor must be removed to
prevent damage, as shown in Figure 44 and 45.
4. Install a compatible holding fixture onto the
transmission case, as shown in Figure 46, that
will allow you to safely rotate the transmission
when installed in the bench fixture.
5. Rotate the transmission so that the bottom pan
is facing up, as shown in Figure 47.
Copyright © 2003 ATSG
Figure 43
Continued on Page 42.
TURBINE SHAFT
SPEED SENSOR
Copyright © 2003 ATSG
TRANSMISSION
HOLDING FIXTURE
Figure 44
OUTPUT SHAFT
SPEED SENSOR
Ford
XW4P-AC
RJL-B
004361
BD-9C17
BA
-7006RFF81P
98
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 45
Figure 46
AUTOMATIC TRANSMISSION SERVICE GROUP
41
Technical Service Information
TRANSMISSION DISASSEMBLY
BOTTOM
PAN
PAN BOLTS (20)
U
P
62
PAN GASKET
Bottom Pan Components
1. Remove the 20 bottom pan bolts, the bottom
pan and the bottom pan gasket, as shown in
Figure 47.
2. Remove the bottom pan oil filter, as shown in
Figure 48, by prying up with screwdriver.
3. Remove two accumulator valve body retaining
nuts and 11 bolts, as shown in Figure 49, and
remove accumulator valve body.
4. Set the accumulator valve body aside for the
component rebuild section.
5. Remove two main valve body retaining nuts
and the 14 bolts, as shown in Figure 50, and
remove upper and lower valve bodies together
as a package.
Note: Do not remove the two bolts holding
the upper and lower valve bodies together.
Refer to Figure 50.
6. Set the main upper and lower valve bodies
aside for the component rebuild section.
Continued on Page 43.
Copyright © 2003 ATSG
RETAINING NUTS (2)
Figure 47
RETAINING BOLTS (11)
ACCUMULATOR
VALVE BODY
U
P
U
P
62
62
BOTTOM PAN
OIL FILTER
Copyright © 2003 ATSG
Figure 48
42
Copyright © 2003 ATSG
Figure 49
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
RETAINING
BOLTS (9)
TRANSMISSION DISASSEMBLY
RETAINING NUT
SOLENOID
BODY ASSEMBLY
"O" RING
U
P
62
Bottom Pan Components
7. Remove the solenoid body retaining nut and
the 9 retaining bolts, as shown in Figure 51,
and remove the solenoid body assembly.
8. Remove the solenoid body by lifting up with
a small twist to free the connector "O" ring
from the case bore (See Figure 51).
9. Remove and discard the spacer plate to main
valve body gasket, as shown in Figure 52.
10. Remove the solenoid body screen from spacer
plate, as shown in Figure 52, by rotating and
lifting straight up.
Continued on Page 44.
Copyright © 2003 ATSG
Figure 51
186
RETAINING BOLTS (14)
RETAINING NUTS (2)
187
U
P
62
U
P
DO NOT REMOVE
THESE TWO BOLTS
62
UPPER AND LOWER
MAIN VALVE BODIES
186 SPACER PLATE TO MAIN VALVE BODY GASKET
187 SOLENOID SCREEN ASSEMBLY
Copyright © 2003 ATSG
Figure 50
Copyright © 2003 ATSG
Figure 52
AUTOMATIC TRANSMISSION SERVICE GROUP
43
Technical Service Information
TRANSMISSION DISASSEMBLY
189
Bottom Pan Components (Cont'd)
11. Remove the 3 retaining bolts for the reinforcing
plate, as shown in Figure 53, and remove the
reinforcing plate and the spacer plate.
12. Remove and discard the spacer plate to case
gasket, as shown in Figure 53.
14. Remove 1/4" Dia. steel EPC ball, and spring
from the case pocket, as shown in Figure 54.
15. Remove the manual intermediate servo piston,
as shown in Figure 54, by tapping gently on the
piston with a rubber mallet to release it from
case bore.
16. Remove the eight checkballs from their case
pockets, as shown in Figure 55, using a small
screwdriver.
17. The case checkballs are 5/16" diameter rubber
material, so use care to avoid any damage.
18. Remove and discard the 3 support feed bolts,
as shown in Figure 56.
U
P
188
185
62
184
.312" DIAMETER RUBBER
CHECKBALLS
184
185
188
189
SPACER PLATE TO CASE GASKET
SPACER PLATE
SPACER PLATE REINFORCING PLATE
REINFORCING PL ATE RETAINING BOLT, M6 X 1.0 X 42 (3)
Copyright © 2003 ATSG
Figure 53
55
62
183
182
.312" DIA. RUBBER
CHECKBALLS
55 MANUAL INTERMEDIATE SERVO ASSEMBLY
182 EPC BLOW-OFF BALL, .250" DIAMETER STEEL BALL
183 EPC BLOW-OFF SPRING
Copyright © 2003 ATSG
Figure 54
44
Copyright © 2003 ATSG
Figure 55
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
KXV
9.8
KXV
9.8
7
Internal Components
1. Remove the nine oil pump assembly retaining
bolts, as shown in Figure 57.
2. Remove and discard the sealing washers from
the nine pump retaining bolts.
3. Using two slide hammers, remove the oil pump
assembly, as shown in Figure 57, and set aside
for the component rebuild section.
4. Remove and discard the oil pump assembly to
case gasket, as shown in Figure 57.
5. Remove the number 1 thrust washer, as shown
in Figure 57, which may be stuck to oil pump
assembly.
Note: The number 1 thrust washer is not
used on the PTO equipped models.
6. Remove the number 2 thrust bearing, as shown
in Figure 57, which may be stuck to oil pump
assembly.
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
d
or
F
9
RF-F81P
7A105-AA
11
Continued on Page 46.
10
13
7
9
10
11
13
FEED BOLTS
OIL PUMP ASM. RETAINING BOLTS, M8 X 1.25 X 65 (9 REQ.)
OIL PUMP AND COVER ASSEMBLY
NUMBER 1 THRUST WASHER (USED NON-PTO MODELS ONLY)
OIL PUMP ASSEMBLY TO CASE GASKET
NUMBER 2 THRUST BEARING, PUMP TO O.D. SUN GEAR
Copyright © 2003 ATSG
Figure 56
Copyright © 2003 ATSG
Figure 57
AUTOMATIC TRANSMISSION SERVICE GROUP
45
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
7. Remove the coast clutch housing, as shown in
Figure 58, and set aside for component rebuild
section.
Note: There are three different versions of
the coast clutch housing, which we will show
you in the component rebuild section. Shown
here is the PTO version.
8. Remove the overdrive clutch backing plate
snap ring, as shown in Figure 59, using a large
screwdriver.
Note: This snap ring is a selective thickness
and should be measured at this time.
9. Remove the overdrive clutch backing plate and
overdrive clutch pack, as shown in Figure 59.
31
34
Continued on Page 47.
COAST CLUTCH
HOUSING ASSEMBLY
FOR "PTO" MODELS
35
36
31 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
34 OVERDRIVE CLUTCH BACKING PLATE
35 OVERDRIVE CLUTCH FRICTION PLATES
Copyright © 2003 ATSG
Figure 58
46
Copyright © 2003 ATSG
Figure 59
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
10. Remove the overdrive carrier and center shaft
assembly, as shown in Figure 60, and set aside
for the component rebuild section.
11. Remove the number 5 thrust bearing, as shown
in Figure 60, which may be on center support.
12. Install clutch spring compressor as shown in
Figure 61, or equivalent, to compress the
intermediate/overdrive clutch cylinder so that
snap ring can be removed.
13. Remove snap ring with large a screwdriver as
shown in Figure 62, and then remove the
compressor tool.
TIGHTEN CENTER
BOLT TO 7 N·m
(65 IN.LB.)
Continued on Page 48.
CLUTCH SPRING
FIXTURE
OVERDRIVE CARRIER
AND CENTER SHAFT
ASSEMBLY
CLUTCH SPRING
COMPRESSOR BAR
CLUTCH SPRING
COMPRESSOR PLATE
NUMBER 5
THRUST BEARING
Figure 61
CLUTCH SPRING
COMPRESSOR BAR
SNAP RING
Copyright © 2003 ATSG
Figure 60
Figure 62
AUTOMATIC TRANSMISSION SERVICE GROUP
47
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
14. Remove snap ring and intermediate/overdrive
cylinder assembly, as shown in Figure 63, and
set aside for component rebuild section.
15. Remove the intermediate clutch piston return
spring, as shown in Figure 64.
16. Remove the center support assembly, as shown
in Figure 64, and set aside for the component
rebuild section.
17. Remove the number 6 thrust washer, center
support to direct clutch housing, as shown in
Figure 64.
18. Remove the intermediate clutch pack and the
backing plate, as shown in Figure 65.
19. Remove the intermediate band assembly, as
shown in Figure 66.
Continued on Page 49.
46
40
48
42
49
40 INTERMEDIATE/OVERDRIVE CYLINDER SNAP RING
42 INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY
46 INTERMEDIATE CLUTCH PISTON RETURN SPRING
48 CENTER SUPPORT ASSEMBLY
49 NUMBER 6 THRUST WASHER, CENTER SUPPORT
Copyright © 2003 ATSG
Figure 63
48
Copyright © 2003 ATSG
Figure 64
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
20. Install the removal tool and remove the direct
clutch drum, forward clutch drum and the sun
shell as an assembly, as shown in Figure 66.
21. Set the direct drum, forward drum and the sun
shell assembly aside for the component rebuild
section.
INTERMEDIATE
BAND ASSEMBLY
Continued on Page 50.
REMOVAL TOOL
T89T-70010-E
53
DIRECT CLUTCH,
FORWARD CLUTCH
AND SUN SHELL
ASSEMBLY
52
54
52 INTERMEDIATE CLUTCH FRICTION PLATES
53 INTERMEDIATE CLUTCH STEEL PLATES
54 INTERMEDIATE CLUTCH BACKING PLATE
Copyright © 2003 ATSG
Figure 65
Copyright © 2003 ATSG
Figure 66
AUTOMATIC TRANSMISSION SERVICE GROUP
49
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
22. Remove the snap ring retaining rear planetary
carrier in reverse clutch hub (See Figure 67).
23. Remove the rear planetary carrier and both of
the thrust washers, as shown in Figure 67.
24. Remove the output shaft snap ring using snap
ring pliers, as shown in Figure 68.
25. Remove snap ring, rear planetary ring gear and
the number 12 thrust bearing (See Figure 69).
Continued on Page 51.
102
OUTPUT SHAFT
SNAP RING
Figure 68
103
106
104
107
105
112
102 REAR CARRIER TO REVERSE HUB RETAINING SNAP RING
103 NUMBER 10B THRUST WASHER
104 REAR PL ANETARY CARRIER ASSEMBLY
106 OUTPUT SHAFT SNAP RING
107 REAR PL ANETARY RING GEAR
112 NUMBER 12 THRUST BEARING (RING GEAR TO INNER RACE)
Copyright © 2003 ATSG
Figure 67
50
Copyright © 2003 ATSG
Figure 69
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
26. Remove the reverse clutch hub and low roller
clutch assembly, as shown in Figure 70, and set
aside for component rebuild.
27. Remove the snap ring retaining the low/reverse
clutch pack, using a large screwdriver as shown
in Figure 71, from the groove in case.
28. Remove the snap ring from case, as shown in
Figure 72.
SNAP
RING
Continued on Page 52.
Figure 71
110
LOW REVERSE CLUTCH
SNAP RING
110 REVERSE CLUTCH HUB AND LOW ROLLER CLUTCH ASM.
Copyright © 2003 ATSG
Figure 70
Copyright © 2003 ATSG
Figure 72
AUTOMATIC TRANSMISSION SERVICE GROUP
51
Technical Service Information
TRANSMISSION DISASSEMBLY
EXTENSION HOUSING
RETAINING BOLTS
9.8
9.8
9.8
9.8
Internal Components (Cont'd)
29. Remove the low/reverse clutch pack including
wave plate, as shown in Figure 73.
30. Rotate transmission in fixture so output shaft
is facing up, as shown in Figure 74.
31. Remove the extension housing retaining bolts
and housing, as shown in Figure 74.
32. We have illustrated the typical 4WD version in
Figure 74, and the 2WD version in Figure 75.
9.8
Continued on Page 53.
9.8
98
9.8
9.8
EXTENSION
HOUSING
99
100
101
EXTENSION
HOUSING GASKET
OUTPUT
SHAFT
9.8
Figure 73
52
5G
9594 000
00066
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
Copyright © 2003 ATSG
MP-4 X
4
98 LOW/REVERSE CLUTCH BACKING PLATE
99 LOW/REVERSE CLUTCH FRICTION PLATES (6)
100 LOW/REVERSE CLUTCH STEEL PLATES (6)
Copyright © 2003 ATSG
Figure 74
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
33. Notice that the 2WD version has a speed sensor
reluctor wheel that must be pressed off and on,
if necessary to replace, as shown in Figure 75.
34. Remove and discard the extension housing
gasket, as shown in Figure 74.
35. Remove the park rod guide plate, parking pawl,
park pawl pivot pin and return spring, as shown
in Figure 76.
SPACER, ROTUNDA
PART NUMBER 307-388
Continued on Page 54.
RETAINING
BOLTS
9.8
9.8
PARK PAWL,
PIVOT PIN,
AND RETURN
SPRING
PARK ROD
GUIDE PLATE
OUTPUT
SHAFT
SPEED SENSOR
RELUCTOR WHEEL
9.8
5G
9594 000
00066
XC3P-GA
PRB-AU
00000066
BD-8H17
9594 000
00066
5G
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
Figure 75
MP-4 X
4
MP-4 X
4
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 76
AUTOMATIC TRANSMISSION SERVICE GROUP
53
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
36. Remove the output shaft by pulling straight up,
as shown in Figure 77.
37. Remove the number 13 thrust bearing from the
back of case, as shown in Figure 77.
38. Remove and discard the lube orifice plug from
rear of case, as shown in Figure 78.
LUBE ORIFICE
PLUG
Continued on Page 55.
OUTPUT SHAFT
AND PARK GEAR
Copyright © 2003 ATSG
Figure 78
9.8
9.8
9.8
9.8
9.8
NUMBER 13
THRUST BEARING
9.8
9.8
9.8
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
9594 000
00066
5G
MP-4 X
4
XC3P-GA
PRB-AU
00000066
BD-8H17
9594 000
00066
MP-4 X
4
9.8
5G
LOW ROLLER CLUTCH INNER
RACE RETAINING BOLTS (5)
Copyright © 2003 ATSG
Figure 77
54
Copyright © 2003 ATSG
Figure 79
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TRANSMISSION DISASSEMBLY
Internal Components (Cont'd)
39. Rotate the transmission in fixture so the pan
rail surface is facing down (See Figure 79).
40. Remove the 5 low roller clutch inner race bolts,
as shown in Figure 79.
41. Rotate the transmission in fixture so the bell
housing is facing up, as shown in Figure 80.
42. Remove the low roller clutch inner race, the
reverse clutch piston return spring assembly,
and reverse clutch piston (See Figure 80).
43. Remove and discard the reverse clutch piston
inner and outer lip seals (See Figure 80).
113
114
115
117
COMPONENT REBUILD
Transmission Case Assembly
116
1. Remove the inside detent lever retaining nut,
using a cresent wrench to hold the external
shift lever, to avoid damage to the inside detent
spring (See Figure 80).
Caution: If this procedure is not followed,
damage to the detent spring will occur and
replacement will be necessary.
Continued on Page 56.
Hold External Shift Lever With Cresent
Wrench When Removing The
Inside Detent Lever Retaining Nut
INSIDE
DETENT
LEVER
62
RETAINING
NUT
113
114
115
116
117
LOW ROLLER CLUTCH INNER RACE
REVERSE CLUTCH PISTON RETURN SPRING ASSEMBLY
REVERSE CLUTCH PISTON INNER LIP SEAL
REVERSE CLUTCH PISTON OUTER LIP SEAL
REVERSE CLUTCH PISTON
Copyright © 2003 ATSG
Figure 80
Copyright © 2003 ATSG
Figure 81
AUTOMATIC TRANSMISSION SERVICE GROUP
55
Technical Service Information
COMPONENT REBUILD
Transmission Case Assembly (Cont'd)
2. Remove the shift lever retaining roll pin from
the case, using pin removal tool T87P-3504-N,
as shown in Figure 82.
3. Remove external shift lever from case and
remove shift lever seal from case using the
proper puller.
4. Clean all case parts thoroughly and dry with
compressed air.
5. Inspect all case parts thoroughly for any wear
and/or damage. Replace as necessary.
6. Install new shift lever seal into the case bore
using the proper seal driver
PIN REMOVER
T87P-3504-N
ROLL
PIN
7. Install the external shift lever, inside detent
lever and retaining nut. Torque the retaining
nut to 41-54 N·m (30-40 ft.lb.), again using a
cresent wrench to hold external shift lever.
(See Figure 81).
8. Install a new lube orifice plug into the case, as
shown in Figure 83, and ensure fully seated.
9. Install new inner and outer lip seals in grooves
of the reverse piston, with the lips facing the
direction shown in Figure 85.
10. Lubricate both lip seals with a small amount
of Trans-Jel®.
11. Install the reverse piston into the case with a
rotating motion, using care not to damage the
lip seals (See Figure 85).
12. Install the reverse clutch piston return spring
assembly, as shown in Figure 85.
13. Install two threaded rods into the low roller
inner race, as shown in Figure 84. They can be
made from bolts with the head removed.
Note: The lube hole in the race should be
positioned in the 5 o'clock position when it
is installed. The 6 o'clock position is the
bottom of the case.
14. Install the low roller clutch inner race in case,
as shown in Figure 86, and install two nuts on
the threaded rods.
Continued on Page 57.
TWO THREADED RODS
5/16"-24 X 3 INCH LONG
Figure 82
LUBE ORIFICE
PLUG
LUBE HOLE
LOW ROLLER CLUTCH
INNER RACE
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 83
56
Figure 84
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
Transmission Case Assembly (Cont'd)
113
15. Tighten the nuts to compress the reverse clutch
return spring assembly, as shown in Figure 86.
16. Install 3 low roller inner race retaining bolts, as
shown in Figure 86, and remove the 2 threaded
rods and nuts.
17. Install the two remaining retaining bolts and
torque all five to 24-34 N·m (18-25 ft.lb.) in a
criss-cross pattern, as shown in Figure 87.
114
Continued on Page 58.
115
INSTALL THREE
LOW ROLLER CLUTCH INNER
RACE RETAINING BOLTS
9.8
9.8
117
9.8
116
XC3P-GA
PRB-AU
00000066
BD-8H17
9594 000
00066
MP-4 X
4
5G
TWO THREADED RODS
Copyright © 2003 ATSG
Figure 86
Sn
ap
9.8
-O
n
9.8
9.8
9.8
XC3P-GA
PRB-AU
00000066
BD-8H17
5G
Copyright © 2003 ATSG
Figure 85
9594 000
00066
9.8
LOW ROLLER CLUTCH INNER RACE
REVERSE CLUTCH PISTON RETURN SPRING ASSEMBLY
REVERSE CLUTCH PISTON INNER LIP SEAL
REVERSE CLUTCH PISTON OUTER LIP SEAL
REVERSE CLUTCH PISTON
MP-4 X
4
113
114
115
116
117
Copyright © 2003 ATSG
Figure 87
AUTOMATIC TRANSMISSION SERVICE GROUP
57
Technical Service Information
COMPONENT REBUILD
"2WD VERSION"
Transmission Case Assembly (Cont'd)
18. Install the number 13 thrust bearing onto case,
in the direction shown in Figure 88.
19. Install the output shaft into the case, as shown
in Figure 88.
Note: We have illustrated the 4WD version
in Figure 88.
SPEED SENSOR
RELUCTOR WHEEL
SPACER, ROTUNDA
PART NUMBER 307-388
PARK
GEAR
Continued on Page 59.
"4WD VERSION"
OUTPUT
SHAFT
SPEED SENSOR
RELUCTOR WHEEL
OUTPUT SHAFT
AND PARK GEAR
NUMBER 13
THRUST BEARING
OUTPUT
SHAFT
SPEED SENSOR
RELUCTOR WHEEL
9.8
9.8
9.8
9.8
9.8
9.8
58
9594 000
00066
XC3P-GA
PRB-AU
00000066
BD-8H17
5G
9594 000
00066
5G
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
Figure 88
MP-4 X
4
MP-4 X
4
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 89
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
Transmission Case Assembly (Cont'd)
20. The 2WD version is illustrated in Figure 89,
and notice that it has a speed sensor reluctor
wheel pressed on next to the park gear, which
is also a press fit on the output shaft.
Caution: If the speed sensor reluctor wheel
was removed for any reason, special spacer,
Rotunda number 307-388, must be used to
locate the reluctor wheel in proper position.
21. Install the parking pawl, pivot pin and return
spring, as shown in Figure 90, and ensure that
it is hooked properly behind the case, as shown
in Figure 91.
22. Install the parking rod guide plate, as shown in
Figure 90.
23. Install the two park rod guide plate retaining
bolts and torque to 16-27 N·m (12-20 ft.lb.).
Note: Ensure that park rod operates freely
through the guide plate (See Figure 91).
24. The Torx head bolt retaining the park pawl
abutment plate, shown in Figure 91, has thread
locking compound and should not be removed
unless damage is apparent.
Note: If it was removed, Ford recommends
that it be discarded and a new bolt installed
and torqued to 16-27 N·m (12-20 ft.lb.).
Continued on Page 60.
RETAINING
BOLTS
9.8
9.8
RETURN SPRING
IS HOOKED ON
CASE
Copyright © 2003 ATSG
ENSURE THAT
PARK ROD
TRAVELS FREELY
PARK ROD
GUIDE PLATE
9.8
9594 000
00066
5G
9594 000
00066
XC3P-GA
PRB-AU
00000066
BD-8H17
5G
MP-4 X
4
THIS TORX HEAD BOLT
MUST BE DISCARDED AND
REPLACED, IF REMOVED
Copyright © 2003 ATSG
Figure 90
MP-4 X
4
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
PARK PAWL,
PIVOT PIN,
AND RETURN
SPRING
Copyright © 2003 ATSG
Figure 91
AUTOMATIC TRANSMISSION SERVICE GROUP
59
Technical Service Information
EXTENSION HOUSING
RETAINING BOLTS
COMPONENT REBUILD
Transmission Case Assembly (Cont'd)
25. Install new extension housing gasket on case
surface, as shown in Figure 92.
26. Install the 4WD extension housing, as shown
in Figure 92.
Note: The 4R100 unit requires an extension
housing with the added boss, or shoulder
(4X4), as illustrated in Figure 94, to retain
the lube orifice plug. If replacement becomes
necessary, refer to Figure 94 for a proper
replacement.
27. If installing a 2WD version extension housing,
install a new rear seal using the proper driver.
28. Install extension housing and retaining bolts, as
shown in Figure 92.
29. Torque the extension housing bolts, as shown
in Figure 93 to 41-54 N·m (30-40 ft.lb.).
9.8
9.8
9.8
9.8
9.8
9.8
9.8
9.8
EXTENSION
HOUSING
Continued on Page 62.
EXTENSION
HOUSING GASKET
OUTPUT
SHAFT
9.8
9.8
9.8
9.8
9.8
9.8
9.8
9594 000
00066
XC3P-GA
PRB-AU
00000066
BD-8H17
5G
9594 000
00066
5G
XC3P-GA
PRB-AU
00000066
BD-8H17
9.8
60
9.8
Figure 92
MP-4 X
4
MP-4 X
4
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 93
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
4R100 TYPICAL
4 WHEEL DRIVE
E4OD 4X4 WITHOUT
LUBE PLUG
SHOULDER
FORD 4R100
6.8L AND 7.3L
2 WHEEL DRIVE
NO SHOULDER
ALL OTHER 4R100
2 WHEEL DRIVE
APPLICATIONS
ADDED BOSS
E4OD WITHOUT
LUBE PLUG
SHOULDER
NO SHOULDER
Copyright © 2003 ATSG
Figure 94
AUTOMATIC TRANSMISSION SERVICE GROUP
61
Technical Service Information
"INCORRECT" INSTALLATION
IF THE ROLLER CLUTCH IS INSTALLED IN
THIS DIRECTION, THE REVERSE HUB WILL
FREEWHEEL IN BOTH DIRECTIONS,
WHEN INSTALLED IN CASE.
COMPONENT REBUILD
Transmission Case Assembly (Cont'd)
30. Install the low roller clutch into the reverse hub
in the direction shown in Figure 96, and rotate
slightly clock-wise to lock it in place.
Caution: If the roller clutch is installed in
reverse hub in the direction shown in Figure
95, the reverse hub will freewheel in both
directions, when installed in case.
31. Rotate the transmission in fixture so the bell
housing is facing up, as shown in Figure 97.
32. Install the reverse hub and low roller clutch
assembly into the case by rotating clockwise,
as shown in Figure 97, until fully seated.
Note: Reverse clutch hub should freewheel
clockwise and lock counter-clockwise after
installation in case.
33. Install the reverse clutch "Wave" plate on top
of the reverse piston in the case, as shown in
Figure 98.
34. Install the reverse clutch pack beginning with
a steel plate and alternating with a friction plate
as shown in Figure 98, until the proper amount
of plates are installed.
Figure 95
Continued on Page 63.
"CORRECT" INSTALLATION
LOW ROLLER
CLUTCH ASM.
110
REVERSE HUB
ASSEMBLY
INSTALL IN THIS DIRECTION AND
TURN SLIGHTLY CLOCK-WISE TO
LOCK IN PLACE
110 REVERSE CLUTCH HUB AND LOW ROLLER CLUTCH ASM.
Copyright © 2003 ATSG
Figure 96
62
Copyright © 2003 ATSG
Figure 97
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
97
98
99
100
Transmission Case Assembly (Cont'd)
35. Install the reverse clutch backing plate on top
of the last friction, as shown in Figure 98.
36. Install the reverse clutch backing plate snap
ring, as shown in Figure 98, and ensure that it
is fully seated in case groove.
Note: The number of reverse plates is model
sensitive and may vary from the illustration.
A stack-up clearance measurement is not
required for the reverse clutch.
37. Install the number 12 thrust bearing and rear
ring gear into case, as shown in Figure 99.
Note: Before installing snap ring provisions
must be made to retain output shaft fully
seated against rear bearing.
38. Install the output shaft snap ring onto output
shaft, as shown in Figure 99
Note: Do not over stretch snap ring during
installation. Ford recommends a new snap
ring for this location.
39. Ensure that snap ring is fully seated in groove
in output shaft, and the case is finally ready
for the final assembly process.
101
106
107
112
97
98
99
100
101
LOW/REVERSE CLUTCH BACKING PLATE SNAP RING
LOW/REVERSE CLUTCH BACKING PLATE
LOW/REVERSE CLUTCH FRICTION PLATES (6)
LOW/REVERSE CLUTCH STEEL PLATES (6)
LOW/REVERSE CLUTCH "WAVE" PLATE
106 OUTPUT SHAFT SNAP RING
107 REAR PL ANETARY RING GEAR
112 NUMBER 12 THRUST BEARING (RING GEAR TO INNER RACE)
Copyright © 2003 ATSG
Figure 98
Copyright © 2003 ATSG
Figure 99
AUTOMATIC TRANSMISSION SERVICE GROUP
63
Technical Service Information
4 PINION REAR CARRIER
6 PINION REAR CARRIER
REQUIRES 4 TANG
THRUST WASHERS
BOTH SIDES
REQUIRES 3 TANG
THRUST WASHER
F0TZ-7A166-D
4 PINION REAR
PLANETARY CARRIER
6 PINION REAR
PLANETARY CARRIER
F81Z-7D006-AA
REQUIRES 4 TANG
THRUST WASHERS
BOTH SIDES
REQUIRES 3 TANG
THRUST WASHER
F0TZ-7A166-D
Copyright © 2003 ATSG
Figure 100
Planetary Carrier Differences
Both planetary carriers are model sensitive parts, and
may contain a 4 pinion carrier or a 6 pinion carrier, as
shown in Figures 100, 101. Obviously the 6 pinion
carrier has much more torque carrying capacity and is
highly recommended, especially in heavy duty
applications.
The 6 pinion rear carrier also requires 3 tang thrust
washers on both sides of the carrier. We have
provided you with the part numbers, in Figure 100,
that were current at the time of printing this manual.
COMPONENT REBUILD
Front And Rear Planetary Carriers
1. Inspect planetary carriers for the following;
Carrier pins for loosness or damage.
Pinion gears for damaged or worn teeth.
Pinion gears for free rotation, and wobble.
Carrier for cracks, wear and/or damage.
2. Use a new service part if any of the above
conditions exist.
3. Set the carriers aside for final assembly.
4 PINION REAR CARRIER
Continued on Page 66.
6 PINION REAR CARRIER
4 PINION FORWARD
PLANETARY CARRIER
6 PINION FORWARD
PLANETARY CARRIER
F81Z-7A398-CA
Copyright © 2003 ATSG
Figure 101
64
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORWARD CLUTCH EXPLODED VIEW
84
83
82
80
79
81
78
77
75
74
76
72
73
72
73
74
75
76
77
78
79
80
81
82
83
84
FORWARD CLUTCH HOUSING
FORWARD CLUTCH HOUSING INNER "O" RING SEAL
FORWARD PISTON OUTER LIP SEAL
FORWARD CLUTCH PISTON ASSEMBLY
FORWARD CLUTCH PISTON APPLY RING
FORWARD CLUTCH PISTON "BELLVILLE" RETURN SPRING
FORWARD CLUTCH RETURN SPRING SNAP RING
FORWARD CLUTCH APPLY PLATE
FORWARD CLUTCH "WAVE" PLATE
FORWARD CLUTCH FRICTION PLATES
FORWARD CLUTCH STEEL PLATES
FORWARD CLUTCH BACKING PLATE
FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
Copyright © 2003 ATSG
Figure 102
AUTOMATIC TRANSMISSION SERVICE GROUP
65
Technical Service Information
COMPONENT REBUILD
Forward Clutch Housing
1. Disassemble the forward clutch housing using
Figure 102 as a guide.
2. Clean all forward clutch housing parts using
a suitable cleaning solution and dry with
compressed air.
3. Inspect all forward clutch housing parts for any
wear and/or damage.
Note: Ensure that the air bleed ball in the
forward clutch piston is free and operational
(See Figure 104).
4. Remove and discard the forward clutch inner
and outer seals.
5. Place the forward clutch housing on a flat work
surface, in the direction shown in Figure 103,
and install new sealing rings.
76
75
ENSURE THAT
BALL IS FREE
AND SEALS
74
Continued on Page 67.
70
73
72
72
70 FORWARD CLUTCH SEALING RINGS (2 REQUIRED)
72 FORWARD CLUTCH HOUSING ASSEMBLY
72
73
74
75
FORWARD CLUTCH HOUSING
FORWARD CLUTCH HOUSING INNER "O" RING SEAL
FORWARD PISTON OUTER LIP SEAL
FORWARD CLUTCH PISTON ASSEMBLY
Copyright © 2003 ATSG
Figure 103
66
Copyright © 2003 ATSG
Figure 104
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Forward Clutch Housing (Cont'd)
6. Turn forward clutch housing over, as shown in
Figure 104, and install forward clutch piston
inner "O" ring seal into drum (See Figure 104).
7. Install forward clutch piston outer lip seal into
groove in piston, with lip facing the direction
shown in Figure 104.
8. Lubricate both seals with a small amount of
Trans-Jel®, and install piston into the forward
clutch housing with a twisting motion, using
care not to damage seals (See Figure 104).
9. Install the forward clutch piston apply ring into
groove on top of piston (See Figure 104).
10. Install the forward clutch "Bellville" return
spring into housing in the direction shown in
Figure 105.
11. Compress the return spring and install return
spring snap ring, and ensure it is fully seated
(See Figure 105).
12. Install the forward clutch apply plate with the
flat side facing up, as shown in Figure 106.
13. Install the forward clutch "Wave" plate on top
of the apply plate, as shown in Figure 106.
Continued on Page 68.
78
80
79
77
77 FORWARD CLUTCH PISTON "BELLVILLE" RETURN SPRING
78 FORWARD CLUTCH RETURN SPRING SNAP RING
79 FORWARD CLUTCH APPLY PLATE
80 FORWARD CLUTCH "WAVE" PLATE
Copyright © 2003 ATSG
Figure 105
Copyright © 2003 ATSG
Figure 106
AUTOMATIC TRANSMISSION SERVICE GROUP
67
Technical Service Information
"SELECTIVE"
SNAP RING
84
83
Forward Clutch Housing (Cont'd)
14. Install forward clutch pack beginning with a
steel plate and alternating with a friction plate,
as shown in Figure 107, until the proper
amount of plates are installed.
Note: The number of forward plates is model
sensitive and may vary from the illustration.
15. Install the forward clutch backing plate, as
shown in Figure 107.
16. Install selective forward clutch backing plate
snap ring, as shown in Figure 107, and ensure
that it is fully seated.
17. Measure the forward clutch clearance between
the selective snap ring and the backing plate,
as shown in Figure 108.
18. Forward clutch clearance should measure:
0.76 - 1.40mm (.030" - .055").
19. Change the selective snap ring as necessary to
obtain the proper clearance (See Figure 108).
20. Set the completed forward clutch housing aside
for future sub assembly.
81
82
Forward Clutch Clearance Should Be
0.76 - 1.40mm (.030" - .055")
81
82
83
84
FORWARD CLUTCH FRICTION PLATES
FORWARD CLUTCH STEEL PLATES
FORWARD CLUTCH BACKING PLATE
FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
Selective Snap Rings Available
1.42-1.52mm (.056" - .060")
1.88-1.98mm (.074" - .078")
2.34-2.44mm (.092" - .096")
2.79-2.90mm (.110" - .114")
3.25-3.35mm (.128" - .132")
Copyright © 2003 ATSG
Figure 107
68
Copyright © 2003 ATSG
Figure 108
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
DIRECT CLUTCH HOUSING "FRONT SIDE" EXPLODED VIEW
58
59
57
57 INTERMEDIATE SPRAG ASSEMBLY
58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NUMBER 7)
59 DIRECT CLUTCH HOUSING ASSEMBLY
"DO NOT USE" REPLACE WITH PARTS SHOWN ABOVE
"DIODE" ONE-WAY
CLUTCH ASSEMBLY
DIRECT DRUM FOR
"DIODE" ONE-WAY
CLUTCH ASSEMBLY
"DO NOT USE" REPLACE WITH PARTS SHOWN ABOVE
Copyright © 2003 ATSG
Figure 109
AUTOMATIC TRANSMISSION SERVICE GROUP
69
Technical Service Information
DIRECT CLUTCH HOUSING "REAR SIDE" EXPLODED VIEW
59
62
61
60
L20
T
F9
A
P -7
A
2 62-C
Ford
69
67
68
63
64
"SELECTIVE"
SNAP RING
59
60
61
62
63
64
66
67
68
69
66
DIRECT CLUTCH HOUSING ASSEMBLY
DIRECT CLUTCH PISTON INNER LIP SEAL
DIRECT CLUTCH PISTON OUTER LIP SEAL
DIRECT CLUTCH PISTON ASSEMBLY
DIRECT CLUTCH PISTON RETURN SPRING ASSEMBLY
DIRECT CLUTCH PISTON RETURN SPRING SNAP RING
DIRECT CLUTCH FRICTION PLATES
DIRECT CLUTCH STEEL PLATES
DIRECT CLUTCH BACKING PLATE
DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
Copyright © 2003 ATSG
Figure 110
70
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
Direct Clutch Housing
1. Disassemble the direct clutch housing using
Figures 109 and 110 as a guide.
2. Clean all direct clutch parts with a suitable
cleaning solution and dry with compressed air.
3. Inspect all direct clutch parts for any wear
and/or damage. Replace as necessary.
"EARLY" DESIGN LEVEL
4. Refer to Figures 111 and 112 to ensure that you
have compatable parts, especially if it was
necessary to replace the sun shell or the direct
clutch housing.
Note: Use extra care at this step to ensure
compatable parts for direct clutch drum.
"LATE" DESIGN LEVEL
No "Tabs"
Added "Tabs"
INPUT SUN SHELL - NOTE: Using the early style sun
shell "Requires" that you use the number 8A thrust washer
on direct drum, and the direct drum that accepts it.
SLOTS TO ACCEPT
NUMBER 8A
THRUST WASHER
INPUT SUN SHELL - New design have "Tabs" added to
the center of the sun shell slots, as shown above, which now
support the direct drum for the required clearance between
the direct and forward clutch housings, and allows
elimination of the number 8A thrust washer.
"Late" design sun shell will retro-fit back on all models.
NUMBER 8A
THRUST WASHER
"NO" SLOTS
A
P -7
A
2 62-C
L-
T
F9
20
Ford
Copyright © 2003 ATSG
Figure 111
Copyright © 2003 ATSG
Figure 112
AUTOMATIC TRANSMISSION SERVICE GROUP
71
Technical Service Information
COMPONENT REBUILD
DO NOT USE THIS STYLE DRUM
"DIODE" STYLE
ONE-WAY CLUTCH
DIRECT DRUM FOR
"DIODE" STYLE
ONE-WAY CLUTCH
Copyright © 2003 ATSG
Figure 113
Direct Clutch Housing (Cont'd)
5. We have illustrated the "Diode" style one-way
intermediate clutch and the associated direct
clutch drum in Figure 113.
Note: Do Not use this type of one-way clutch
in this unit. It will not live.
6. Place the direct clutch housing on a flat work
surface in the direction shown in Figure 114.
7. Install the number 7 thrust washer, as shown in
Figure 114, and retain with Trans-Jel®.
57
58
59
58
59
58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NO. 7)
59 DIRECT CLUTCH HOUSING ASSEMBLY
57 INTERMEDIATE SPRAG ASSEMBLY
58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NO. 7)
59 DIRECT CLUTCH HOUSING ASSEMBLY
Copyright © 2003 ATSG
Figure 114
72
Copyright © 2003 ATSG
Figure 115
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
62
T
F9
P
A
2 62-C
-7A
L-
20
Ford
Direct Clutch Housing (Cont'd)
8. Install the intermediate sprag assembly and the
outer sprag race, as shown in Figure 115.
9. After installing intermediate sprag assembly,
check to ensure proper operation, as shown in
Figure 116.
Note: Outer sprag race should freewheel
counter-clockwise and lock clockwise, as
shown in Figure 116.
10. Turn the direct clutch housing over on a flat
work surface, as shown in Figure 117.
11. Install the inner direct clutch piston lip seal in
the groove in drum, with the lip facing in the
direction shown in Figure 117.
12. Install the outer direct clutch piston lip seal in
the groove in drum, with the lip facing in the
direction shown in Figure 117.
13. Lubricate both seals and both piston surfaces
with a small amount of Trans-Jel®.
14. Install the direct clutch piston assembly into
direct clutch housing with a twisting motion,
using care so as not to damage the lip seals.
(See Figure 117).
61
60
Continued on Page 74.
59
FREEWHEEL OUTER
SPRAG RACE
FREEWHEEL
HOLD DIRECT
CLUTCH DRUM
59 DIRECT CLUTCH HOUSING ASSEMBLY
60 DIRECT CLUTCH PISTON INNER LIP SEAL
61 DIRECT CLUTCH PISTON OUTER LIP SEAL
Copyright © 2003 ATSG
Figure 116
Copyright © 2003 ATSG
Figure 117
AUTOMATIC TRANSMISSION SERVICE GROUP
73
Technical Service Information
COMPONENT REBUILD
Direct Clutch Housing (Cont'd)
15. Install the direct clutch piston return spring into
direct clutch housing, as shown in Figure 118.
16. Compress the return spring assembly using a
foot press and install the direct clutch return
spring snap ring (See Figure 118).
17. Install the number 8A thrust washer at this time
if your unit requires one because of the early
style sun shell (See Figure 119)
Note: Refer to Figures 111 and 112 for the
information regarding the 8A thrust washer,
and compatable parts.
64
63
18. Install the direct clutch pack beginning with a
steel plate and alternating with a friction plate,
as shown in Figure 120, until you have proper
amount of plates installed.
Note: The number of direct plates is model
sensitive and may vary from illustration.
19. Install the direct clutch backing plate on top of
the last friction plate, as shown in Figure 120.
20. Install the selective direct clutch backing plate
snap ring, as shown in Figure 120, and ensure
that it is fully seated.
21. Measure the direct clutch clearance between
the selective snap ring and the backing plate,
as shown in Figure 121.
22. Direct clutch clearance should measure:
1.15 - 2.06mm (.045" - .081").
23. Change the selective snap ring as necessary to
obtain the proper clutch clearance. Refer to
Figure 121 for snap rings available.
24. Set the completed direct clutch housing aside
for future sub-assembly.
65
59
A
P -7
A
2 62-C
L-
T
F9
20
Ford
59 DIRECT CLUTCH HOUSING ASSEMBLY
63 DIRECT CLUTCH PISTON RETURN SPRING ASSEMBLY
64 DIRECT CLUTCH PISTON RETURN SPRING SNAP RING
65 NUMBER 8A THRUST WASHER (NOT USED ALL MODELS)
Copyright © 2003 ATSG
Figure 118
74
Copyright © 2003 ATSG
Figure 119
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
69
"SELECTIVE"
SNAP RING
68
A
P -7
A
2 62-C
L-
T
F9
20
Ford
66
67
Direct Clutch Clearance Should Be
1.15 - 2.06mm (.045" - .081")
Selective Snap Rings Available
1.65-1.75mm (.065" - .069")
1.88-1.98mm (.074" - .078")
2.10-2.20mm (.083" - .087")
Copyright © 2003 ATSG
Figure 121
-C A
A262
P -7
L-
T
F9
20
Ford
66 DIRECT CLUTCH FRICTION PLATES
67 DIRECT CLUTCH STEEL PLATES
68 DIRECT CLUTCH BACKING PLATE
Copyright © 2003 ATSG
Figure 120
AUTOMATIC TRANSMISSION SERVICE GROUP
75
Technical Service Information
COMPONENT REBUILD
Forward And Direct Clutch Sub-Assemblies
1. We are once again showing you the difference
between the "Early" and "Late" direct clutch
housings in Figures 122 and 123, as this is the
last chance you will have to install the number
8A thrust washer, if you require one.
2. Place the completed direct clutch housing on a
flat work surface in the direction that is shown
in Figure 123.
3. Install the completed forward clutch housing
into the completed direct clutch housing by
rotating back and forth until fully seated, as
shown in Figure 123.
4. Install the number 9A thrust bearing into the
forward clutch housing in the direction shown
in Figure 124, with black side facing up.
5. Install the number 8C thrust washer onto the
forward ring gear and hub assembly, as shown
in Figure 125, and retain with Trans-Jel®.
6. Install forward ring gear and thrust washer into
forward clutch plates, as shown in Figure 126,
by rotating back and forth until fully seated.
Continued on Page 78.
72
Some Models
Only
NUMBER 8A
THRUST WASHER
Does Not Use
Number 8A
Thrust Washer
And Requires
Late Sun Shell
59
T
F9
A
P -7
A
2 62-C
59
L-
20
Ford
59 "EARLY" DIRECT CLUTCH HOUSING ASSEMBLY
59 "L ATE" DIRECT CLUTCH HOUSING ASSEMBLY
72 FORWARD CLUTCH HOUSING ASSEMBLY
Copyright © 2003 ATSG
Figure 122
76
Copyright © 2003 ATSG
Figure 123
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
NUMBER 8C
THRUST WASHER
FORWARD RING
GEAR AND HUB
ASSEMBLY
Copyright © 2003 ATSG
Figure 125
88
89
72
72
T
F9
A
P -7
A
2 62-C
59
T
F9
A
P -7
A
2 62-C
59
L-
20
Ford
L-
20
Ford
59 DIRECT CLUTCH HOUSING ASSEMBLY
72 FORWARD CLUTCH HOUSING ASSEMBLY
89 NUMBER 9A THRUST BEARING ASSEMBLY
59 DIRECT CLUTCH HOUSING ASSEMBLY
72 FORWARD CLUTCH HOUSING ASSEMBLY
88 FORWARD RING GEAR AND HUB ASSEMBLY
Copyright © 2003 ATSG
Figure 124
Copyright © 2003 ATSG
Figure 126
AUTOMATIC TRANSMISSION SERVICE GROUP
77
Technical Service Information
COMPONENT REBUILD
NUMBER 10A
THRUST BEARING
FORWARD
PLANETARY
Forward And Direct Clutch Sub-Assemblies
7. Install the number 10A thrust bearing onto the
forward planetary carrier, in the direction that
is shown in Figure 127, and retain the bearing
with Trans-Jel®.
8. Turn the planetary carrier over and install the
number 9B thrust bearing into the planetary
carrier in the direction shown in Figure 128.
Note: Black side faces up.
9. Install the complete forward planetary carrier
assembly into the ring gear, by rotating into
position, as shown in Figure 129.
Continued on Page 79.
91
Copyright © 2003 ATSG
Figure 127
72
NUMBER 9B
THRUST BEARING
T
F9
-C A
A262
P -7
59
L-
FORWARD
PLANETARY
20
Ford
59 DIRECT CLUTCH HOUSING ASSEMBLY
72 FORWARD CLUTCH HOUSING ASSEMBLY
91 "6 PINION" FORWARD PLANETARY CARRIER ASSEMBLY
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 128
78
Figure 129
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
Forward And Direct Clutch Sub-Assemblies
10. Install the proper sun gear shell over the entire
assembly, as shown in Figure 130.
11. Hold the completed assembly together and roll
complete assembly over so that it is setting on
the sun gear, as shown in Figure 131.
12. Install the number 8B thrust washer onto the
forward clutch drum surface, in the direction
shown in Figure 131.
13. Install the installation tool onto the complete
assembly, as shown in Figure 131, and set the
completed assembly aside for final assembly.
NUMBER 8B
THRUST BEARING
94
72
COMPLETED FORWARD/DIRECT ASSEMBLY
T
F9
A
P -7
A
2 62-C
59
L-
20
Ford
59 DIRECT CLUTCH HOUSING ASSEMBLY
72 FORWARD CLUTCH HOUSING ASSEMBLY
94 "L ATE" SUN GEAR AND SHELL ASSEMBLY
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 130
Figure 131
AUTOMATIC TRANSMISSION SERVICE GROUP
79
Technical Service Information
CENTER SUPPORT EXPLODED VIEW
CENTER
SUPPORT
CENTER SUPPORT HUB
CENTER
SUPPORT
BALL BEARING
50
49
RETAINING
BOLTS (3)
48 CENTER SUPPORT ASM. (SERVICED AS ASSEMBLY)
49 CENTER SUPPORT DIRECT CLUTCH SEALING RINGS (2)
50 NUMBER 6 THRUST WASHER
48
Copyright © 2003 ATSG
Figure 132
CENTER
SUPPORT
BALL BEARING
BALL BEARING
(KOYO 6906)
RETAINING
BOLTS (3)
CENTER
SUPPORT
CENTER
SUPPORT
HUB
COMPONENT REBUILD
Center Support Assembly
1. Disassemble center support, if necessary, using
Figure 132 as a guide.
2. Clean all center support parts thoroughly using
a suitable cleaning solution and blow dry with
compressed air.
3. Inspect all center support parts thoroughly for
any wear and/or damage.
4. Remove and discard the two center support
direct clutch sealing rings (See Figure 132).
5. It is not necessary to remove the center support
from the hub, but if you did, assemble the hub
to support as shown in Figure 133, and torque
the retaining bolts to 9 -14 N·m (80-100 in.lb.).
6. The ball bearing in the center support is not
serviced by Ford, but is available from your
local bearing supply house using the number
supplied in Figure 133.
7. Install a new ball bearing into center support,
as shown in Figure 133, using proper bearing
drivers.
8. Turn the center support over and install new
sealing rings into the grooves in center support
hub, as shown in Figure 134.
Continued on Page 81.
Copyright © 2003 ATSG
Figure 133
80
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COMPONENT REBUILD
Center Support Assembly
9. If the sealing rings are the "Hook" joint type,
ensure that they are properly hooked and that
they rotate freely in the grooves.
10. Install the number 6 thrust washer onto center
support, as shown in Figure 134, and retain
with Trans-Jel®.
11. Set the completed center support assembly
aside for final assembly (See Figure 135).
50
49
48
Component Rebuild
Continued on Page 82.
48 CENTER SUPPORT ASM. (SERVICED AS ASSEMBLY)
49 CENTER SUPPORT DIRECT CLUTCH SEALING RINGS (2)
50 NUMBER 6 THRUST WASHER
Copyright © 2003 ATSG
Figure 134
COMPLETED CENTER SUPPORT ASSEMBLY
Copyright © 2003 ATSG
Figure 135
AUTOMATIC TRANSMISSION SERVICE GROUP
81
Technical Service Information
INTERMEDIATE/OVERDRIVE SUPPORT ASSEMBLY EXPLODED VIEW
38
37
44
45
41
37
38
39
41
42
39
42 INTERMEDIATE AND OVERDRIVE CLUTCH CYLINDER
44 INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL
45 INTERMEDIATE CLUTCH PISTON
OVERDRIVE CLUTCH PISTON RETURN SPRING SNAP RING
OVERDRIVE CLUTCH PISTON RETURN SPRING
OVERDRIVE CLUTCH PISTON
INTERMEDIATE CLUTCH PISTON INNER LIP SEAL
Copyright © 2003 ATSG
Figure 136
COMPONENT REBUILD
Intermediate/Overdrive Support Assembly
1. Disassemble intermediate/overdrive cylinder
using Figure 136 as a guide.
2. Clean all intermediate/overdrive cylinder parts
thoroughly using a suitable cleaning solution.
3. Inspect all intermediate/overdrive cylinder
parts thoroughly for any wear and/or damage.
4. Remove and discard overdrive clutch molded
piston and both intermediate clutch piston lip
seals.
5. Place the intermediate/overdrive cylinder on a
flat work surface, in the direction shown in
Figure 137.
82
6. Install a new intermediate clutch piston inner
lip seal into the groove in cylinder, with the lip
facing the direction shown in Figure 137.
7. Install a new intermediate clutch piston outer
lip seal into the groove in piston, with the lip
facing the direction shown in Figure 137.
8. Lubricate both lip seals with Trans-Jel®, and
install piston assembly into cylinder, as shown
in Figure 137.
9. Turn the cylinder over, as shown in Figure 138,
and install a new overdrive molded piston.
Continued on Page 83.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
45
37
38
44
39
41
42
42
37 OVERDRIVE CLUTCH PISTON RETURN SPRING SNAP RING
38 OVERDRIVE CLUTCH PISTON RETURN SPRING
39 OVERDRIVE CLUTCH MOLDED PISTON ASSEMBLY
41
42
44
45
INTERMEDIATE CLUTCH PISTON INNER LIP SEAL
INTERMEDIATE AND OVERDRIVE CLUTCH CYLINDER
INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL
INTERMEDIATE CLUTCH PISTON
Copyright © 2003 ATSG
Figure 138
Copyright © 2003 ATSG
Figure 137
Intermediate/Overdrive Support Assembly (Cont'd)
10. Install the overdrive clutch piston return spring
in the direction shown in Figure 138.
11. Compress the return spring and install snap ring
and ensure it is fully seated (See Figure 138).
12. Set completed intermediate/overdrive clutch
cylinder aside for the final assembly process.
(See Figure 139).
Copyright © 2003 ATSG
Figure 139
AUTOMATIC TRANSMISSION SERVICE GROUP
83
Technical Service Information
OVERDRIVE GEARSET EXPLODED VIEW
24
29
25
27
30
32
33
28
24
25
26
27
28
29
30
32
33
26
OVERDRIVE ROLLER OUTER RACE "FLAT" SNAP RING
OVERDRIVE ROLLER OUTER RACE
NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER
OVERDRIVE PLANETARY CARRIER ASSEMBLY
NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT
OVERDRIVE INTERNAL RING GEAR
CENTER SHAFT ASSEMBLY
CENTER SHAFT TO RING GEAR "WAVE" SNAP RING
NUMBER 5 THRUST BEARING, CENTER SHAFT TO SUPPORT
Copyright © 2003 ATSG
Figure 140
COMPONENT REBUILD
Overdrive Gearset Assembly
1. Disassemble overdrive gearset using Figure 140
as a guide.
2. Clean all overdrive gearset parts thoroughly
using a suitable cleaning solution.
3. Inspect all overdrive gearset parts thoroughly
for any wear and/or damage.
84
4. Position the overdrive ring gear on a flat work
surface, as shown in Figure 141.
5. Install overdrive roller clutch outer race into
overdrive ring gear, as shown in Figure 141.
Note: Groove in outer race must face up,
as shown in Figure 141.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
24
GROOVE
FACING UP
Ensure that snap ring is fully seated.
25
Copyright © 2003 ATSG
Figure 142
29
26
27
24 OVERDRIVE ROLLER OUTER RACE "FLAT" SNAP RING
25 OVERDRIVE ROLLER OUTER RACE
29 OVERDRIVE INTERNAL RING GEAR
Copyright © 2003 ATSG
Figure 141
Overdrive Gearset Assembly (Cont'd)
6. Install the flat snap ring into the groove in ring
gear, as shown in Figure 141, and ensure that
it is fully seated, as shown in Figure 142.
7. Install number 3 thrust washer onto back of the
overdrive planetary carrier and retain with a
small amount of Trans-Jel® (See Figure 143).
26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER
27 OVERDRIVE PLANETARY CARRIER ASSEMBLY
Copyright © 2003 ATSG
Figure 143
Continued on Page 86.
AUTOMATIC TRANSMISSION SERVICE GROUP
85
Technical Service Information
COMPONENT REBUILD
Overdrive Gearset Assembly (Cont'd)
8. Flip the overdrive planetary carrier over with
the number 3 thrust washer installed, as shown
in Figure 144.
9. Install the number 6 thrust bearing onto the
overdrive planetary carrier in the direction
shown in Figure 144.
10. Install completed overdrive planetary carrier
into the pre-assembled overdrive ring gear, as
shown in Figure 145, by rotating into position
until fully seated.
11. Install the overdrive center shaft onto overdrive
planetary carrier, as shown in Figure 146.
12. Install the wave center shaft snap ring into the
groove in ring gear, as shown in Figure 146.
Note: Use a brass drift against the wave
snap ring to ensure that it is fully seated.
13. Install the number 5 thrust bearing on overdrive
center shaft, in direction shown in Figure 146,
and retain with Trans-Jel®.
14. Set the completed overdrive gearset aside for
additional sub-assembly after the coast clutch
housing is built (See Figure 147).
Component Rebuild
Continued on Page 88.
28
27
26
28
29
27
26
26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER
27 OVERDRIVE PLANETARY CARRIER ASSEMBLY
28 NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT
26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER
27 OVERDRIVE PLANETARY CARRIER ASSEMBLY
28 NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT
Copyright © 2003 ATSG
Figure 144
86
Copyright © 2003 ATSG
Figure 145
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
32
COMPLETED OVERDRIVE GEARSET
33
30
Copyright © 2003 ATSG
Figure 147
30 CENTER SHAFT ASSEMBLY
32 CENTER SHAFT TO RING GEAR "WAVE" SNAP RING
33 NUMBER 5 THRUST BEARING, CENTER SHAFT TO SUPPORT
Copyright © 2003 ATSG
Figure 146
AUTOMATIC TRANSMISSION SERVICE GROUP
87
Technical Service Information
60 Tooth
Coast Clutch
Steel Plates
Required With
This Style
64 Tooth
Overdrive Clutch
Friction Plates
Required With
This Style
"CAST IRON" COAST CLUTCH DRUM USED
WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION
32 Tooth
Coast Clutch
Steel Plates
Required With
This Style
32 Tooth
Overdrive Clutch
Friction Plates
Required With
This Style
"STAMPED STEEL" COAST CLUTCH DRUM USED
WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION
32 Tooth
Coast Clutch
Steel Plates
Required With
This Style
32 Tooth
Overdrive Clutch
Friction Plates
Required With
This Style
"STAMPED STEEL" COAST CLUTCH DRUM USED
WITH 6.8L AND 7.3L "WITH" PTO OPTION
Copyright © 2003 ATSG
Figure 148
Coast Clutch Housing Changes
The coast clutch housing is model sensitive and there
are three different versions, as shown above. The
"Cast-Iron" coast clutch housing is the same as the
E4OD housing. When the "Stamped Steel" version
was introduced, it affected other parts in the
transmission, like the coast clutch steel plates and the
overdrive friction plates, as shown above.
88
The sealing ring locations on the oil pump stator
were also affected, which makes the oil pump stator
shaft model sensitive, depending on which coast
clutch housing you have, but we will discuss this in
the oil pump section of this manaul.
The rebuild procedure on all 3 coast clutch housings
is very similar and begins on Page 90.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
13
15
16
14
17
18
21
20
COAST CLUTCH HOUSING
"PTO" EQUIPPED MODELS
19
BALL BEARING
KOYO 6912 C3
13
14
15
16
17
18
19
20
21
COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN)
OVERDRIVE ROLLER CLUTCH ASSEMBLY
COAST CLUTCH MOLDED PISTON
COAST CLUTCH PISTON RETURN SPRING ASSEMBLY
COAST CLUTCH PISTON RETURN SPRING SNAP RING
COAST CLUTCH FRICTION PLATES
COAST CLUTCH STEEL PLATES
COAST CLUTCH BACKING PLATE
COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
KOYO 6912 C3 (AVAILABLE LOCAL BEARING SUPPLY HOUSE)
Copyright © 2003 ATSG
Figure 149
AUTOMATIC TRANSMISSION SERVICE GROUP
89
Technical Service Information
COMPONENT REBUILD
BALL BEARING
KOYO 6912 C3
COAST CLUTCH HOUSING
"PTO" EQUIPPED MODELS
KOYO 6912 C3 (AVAILABLE LOCAL BEARING SUPPLY HOUSE)
Coast Clutch Housing
1. Disassemble the coast clutch housing using
Figures 148 and 149 as a guide.
Note: Figure 148 illustrates the 3 different
coast clutch housings available in 4R100
transmissions. The procedures for rebuild
are very similar. We will be illustrating the
"PTO" version.
2. Clean all coast clutch housing parts thoroughly
using a suitable cleaning solution and dry with
compressed air.
3. Inspect all coast clutch parts thoroughly for any
wear and/or damage.
4. Remove and discard the molded coast clutch
piston. (See Figure 149).
5. Replace the ball bearing as necessary using the
proper pullers and press (See Figure 150).
Note: This ball bearing is not available from
Ford individualy, but is available from your
local bearing supply under KOYO 6912 C3.
6. Place the coast clutch housing on a flat work
surface, as shown in Figure 151.
Copyright © 2003 ATSG
Continued on Page 91.
Figure 150
17
15
16
SEAL
PROTECTOR
307-387
13
13 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN)
15 COAST CLUTCH MOLDED PISTON
16 COAST CLUTCH PISTON RETURN SPRING ASSEMBLY
17 COAST CLUTCH PISTON RETURN SPRING SNAP RING
Copyright © 2003 ATSG
Figure 151
90
Copyright © 2003 ATSG
Figure 152
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Coast Clutch Housing (Cont'd)
7. Install lip seal protector 307-387 onto the coast
clutch housing, as shown in Figure 151.
8. Lubricate both seals on the new coast clutch
piston and install piston into the coast clutch
housing, as shown in Figure 151.
9. Install the coast clutch piston return spring
assembly, as shown in Figure 152.
10. Compress the return spring assembly using a
foot press and install the return spring snap
ring, as shown in Figure 152, and ensure that
it is fully seated.
11. Install the overdrive roller clutch assembly, as
shown in Figure 153, and rotate roller clutch
counter-clockwise to lock it in position.
12. Install the coast clutch plates in coast clutch
housing, as shown in Figure 154, beginning
with a steel plate and alternating with friction
plates, until you have proper amount installed.
Note: The number of coast plates is model
sensitive and may vary from illustration.
13. Install the coast clutch backing plate, as shown
in Figure 154.
21
20
18
19
Continued on Page 92.
14
13
13 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN)
14 OVERDRIVE ROLLER CLUTCH ASSEMBLY
13
18
19
20
21
COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN)
COAST CLUTCH FRICTION PLATES
COAST CLUTCH STEEL PLATES
COAST CLUTCH BACKING PLATE
COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
Copyright © 2003 ATSG
Figure 153
Copyright © 2003 ATSG
Figure 154
AUTOMATIC TRANSMISSION SERVICE GROUP
91
Technical Service Information
COMPLETED
OVERDRIVE GEARSET
ASSEMBLY
COAST CLUTCH
ASSEMBLY WITH
CLUTCHES REMOVED
Coast Clutch Clearance Should Be
0.76 - 1.27mm (.030" - .050")
Selective Snap Rings Available
1.35 - 1.45mm (.053" - .057")
1.75 - 1.85mm (.068" - .072")
2.15 - 2.25mm (.084" - .088")
Copyright © 2003 ATSG
Figure 155
Coast Clutch Housing (Cont'd)
14. Install the selective coast clutch backing plate
snap ring, as shown in Figure 154, and ensure
that it is fully seated.
15. Measure the coast clutch clearance between the
selective snap ring and backing plate, as shown
in Figure 155. Coast clutch clearance should be
0.76 - 1.27mm (.030" - .050").
16. Change the selective snap ring as necessary to
obtain proper clutch clearance. Refer to Figure
155 for snap ring thickness' available.
17. After you have obtained the proper clearance,
remove all of the coast clutch plates.
18. With coast clutch plates removed, install the
pre-assembled overdrive gearset onto coast
clutch housing, as shown in Figure 156, by
rotating counter-clockwise until fully seated.
Note: After installation, overdrive gearset
should freewheel counter-clockwise and lock
in a clockwise direction, while holding the
coast clutch housing.
92
Copyright © 2003 ATSG
Figure 156
Coast Clutch Housing (Cont'd)
19. Re-install the coast clutch plates, as shown in
Figure 157.
20. Install the coast clutch remover/installer, as
shown in Figure 158.
Special Note: This tool is almost mandatory
for the "PTO" version. The overdrive
clutches must be installed "before" the coast
clutch housing is installed, as they will not
pass by the PTO gear.
21. If you are rebuilding the "Non-PTO" version,
the input shaft can be used, with transmission
centerline horizontal, to install this assembly
and then install the overdrive clutches. We do
not have that luxury with the "PTO" version,
please use the installation tool.
Caution: The overdrive one-way clutch may
be damaged if the tool is not used or installed
correctly. The tool must tightly hold entire
assembly.
22. Set the completed assembly aside for the final
assembly process (See Figure 158).
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
21
"REQUIRED"
ASSEMBLY TOOL
307 S383
20
18
19
Copyright © 2003 ATSG
Figure 158
COMPLETED
OVERDRIVE GEARSET
ASSEMBLY
13
13
18
19
20
21
COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN)
COAST CLUTCH FRICTION PLATES
COAST CLUTCH STEEL PLATES
COAST CLUTCH BACKING PLATE
COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
Copyright © 2003 ATSG
Figure 157
AUTOMATIC TRANSMISSION SERVICE GROUP
93
Technical Service Information
OIL PUMP ASSEMBLY "FRONT" SIDE EXPLODED VIEW
3
4
8
1
6
5
2
7
d
RF-F81P
7A105-AA
or
F
OIL PUMP ASSEMBLY "REAR" SIDE EXPLODED VIEW
12
13
11
KXV
9.8
10
KXV
9.8
Ford
98
OIL PUMP CONVERTER SEAL
OIL PUMP CONVERTER HUB BUS HING
OIL PUMP BODY
OIL PUMP BODY TO CASE "O" RING SEAL
OIL PUMP INNER GEAR
OIL PUMP OUTER GEAR
STATOR SHAFT CONVERTER SEAL RING
STATOR SHAFT AND OIL PUMP COVER ASSEMBLY
COAST CLUTCH SEAL RINGS (2 REQUIRED)
STATOR SHAFT TO OIL PUMP COVER RETAINING BOLTS (3 REQUIRED)
STATOR SHAFT ASSEMBLY
OIL PUMP COVER ASSEMBLY
OIL PUMP COVER TO OIL PUMP BODY RETAINING BOLTS (12 REQUIRED)
RF-F81P-7B324-AA
KXV
9.8
KXV
9.8
1
2
3
4
5
6
7
8
9
10
11
12
13
107
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
9
Refer to Page 34 through 37 for
specific Oil Pump Differences
between "PWM" and "NON-PWM"
Copyright © 2003 ATSG
Figure 159
94
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD 4R100
VALVE LINE-UPS IN PUMP ASSEMBLY
15
12
13
11
14
8
9
10
11
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PRESSURE REGUL ATOR VALVE
PRESSURE REGUL ATOR VALVE SPRING RETAINER
PRESSURE REGUL ATOR VALVE OUTER SPRING
PRESSURE REGUL ATOR VALVE INNER SPRING
PRESSURE REGUL ATOR BOOST VALVE
PRESSURE REGUL ATOR BOOST VALVE SLEEVE
PRESSURE REGUL ATOR BOOST VALVE SLEEVE SNAP RING
CONVERTER CLUTCH REGULATOR VALVE
CONVERTER CLUTCH REGULATOR VALVE SPRING
CONVERTER CLUTCH REGULATOR VALVE BORE PLUG
BORE PLUG RETAINER
CONVERTER CLUTCH CONTROL VALVE ("ON-OFF" ONLY)
CONVERTER CLUTCH CONTROL SPRING ("ON-OFF" ONLY)
CONVERTER CLUTCH CONTROL VALVE BORE PLUG
CONVERTER CLUTCH CONTROL VALVE LINE-UP ("PWM" ONLY)
5
6
7
Refer to Page 34 through 37 for
specific Oil Pump Differences
between "PWM" and "NON-PWM"
Copyright © 2003 ATSG
Figure 160
AUTOMATIC TRANSMISSION SERVICE GROUP
95
Technical Service Information
COMPONENT REBUILD
OIL PUMP BODY
CONVERTER SEAL
OIL PUMP BODY
CONVERTER
BUSHING
d
or
F
RF-F81P
7A105-AA
OIL PUMP BODY
Copyright © 2003 ATSG
Figure 161
I.D. DOT MUST
FACE UP
OIL PUMP
INNER GEAR
OIL PUMP
OUTER GEAR
Oil Pump Body And Cover Assembly
1. Disassemble the oil pump and cover assembly
using Figure 159 as a guide.
2. Clean all of the oil pump and cover parts using
a suitable cleaning solution.
3. Inspect all oil pump and cover parts for any
wear and/or damage.
Note: Refer to Pages 34 through 37 for the
differences between PWM and NON-PWM,
if any parts replacement is necessary.
4. Remove and discard oil pump converter seal,
oil pump body to case seal ring, and the two
coast clutch seal rings (See Figure 159).
5. Install new converter bushing into the oil pump
body, as shown in Figure 161, using the proper
drivers for removal and installation.
6. Install new converter hub seal into the oil pump
body, as shown in Figure 161, using the proper
drivers for removal and installation.
7. Turn the oil pump body over and install inner
and outer pump gears, as shown in Figure 162,
and lubricate with transmission fluid.
8. Set the completed pump body aside for the
future sub-assembly (See Figure 163).
9. Install the valves, springs and bore plugs into
the oil pump cover assembly exactly as shown
in Figure 160.
Note: Refer to Pages 34 through 37 for the
specific differences between PWM and the
NON-PWM pump covers.
10. It is not necessary to remove the stator shaft
assembly from the pump cover unless damage
is apparent (See Figure 164).
Continued on Page 97.
OIL PUMP
BODY
COMPLETED OIL PUMP BODY ASSEMBLY
Copyright © 2003 ATSG
Figure 162
96
Copyright © 2003 ATSG
Figure 163
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
COAST CLUTCH
SEAL RINGS ARE HIGHER
ON THE PUMP TOWER
COAST CLUTCH
SEAL RINGS ARE
LOW ON PUMP TOWER
(LIKE E4OD)
USED WITH THE "CAST IRON"
COAST CLUTCH DRUM
USED WITH THE "STAMPED STEEL"
COAST CLUTCH DRUM
Copyright © 2003 ATSG
Figure 164
COAST CLUTCH
SEAL RINGS (2)
RETAINING
BOLTS (3)
OIL PUMP
STATOR SHAFT
ASSEMBLY
Oil Pump Body And Cover Assembly (Cont'd)
11. If removal was necessary because of damage,
refer to Figure 164, to ensure the replacement
part is correct.
12. Install the stator shaft assembly into the pump
cover, as shown in Figure 165, and torque the
3 retaining bolts to 9-11 N·m (80-100 in.lb.),
as shown in Figure 166.
13. Install the two coast clutch sealing rings into
their grooves in the stator shaft assembly, as
shown in Figure 165.
Continued on Page 98.
OIL PUMP
COVER
Sn
ap
-O
n
98
Ford
107
RF-F81P-7B324-AA
98
Ford
107
RF-F81P-7B324-AA
Copyright © 2003 ATSG
Figure 165
Copyright © 2003 ATSG
Figure 166
AUTOMATIC TRANSMISSION SERVICE GROUP
97
Technical Service Information
STATOR SHAFT
SEALING RING
PUMP BODY TO
PUMP COVER BOLTS
(12 REQUIRED)
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
Copyright © 2003 ATSG
98
Figure 167
Oil Pump Body And Cover Assembly (Cont'd)
14. Turn the oil pump cover over and install the
sealing ring on the front of the stator shaft, as
shown in Figure 167, and ensure that it is free
turning in the groove.
15. Set the completed oil pump body assembly, as
shown in Figure 168, over a hole in the work
bench so that stator shaft will pass through the
hole (See Figure 168).
16. Install the completed oil pump cover assembly
onto oil pump body, as shown in Figure 168.
17. Install the 12 pump body to pump cover bolts
in the locations shown in Figure 168, and hand
tighten only at this time.
18. Install the oil pump alignment strap, as shown
in Figure 169, and tighten securely.
19. Torque the 12 pump body to pump cover bolts,
working in a criss-cross pattern. Torque the
bolts to 24-31 N·m (18-23 ft.lb.), as shown in
Figure 169, and then remove alignment strap.
20. Install the number 1 thrust washer, as shown in
Figure 170, and retain with Trans-Jel®, if you
are building a unit that is not PTO equipped.
Note: The number 1 thrust washer is not
used on PTO equipped vehicles. The ball
bearing rests directly on stator on PTO models.
98
Ford
107
RF-F81P-7B324-AA
Copyright © 2003 ATSG
Figure 168
21. Install the number 2A thrust bearing in the
direction shown in Figure 170, and retain with
Trans-Jel®.
Continued on Page 99.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
PUMP BODY TO
CASE SEAL RING
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
98
RF-F81P-7B324-AA
KXV
9.8
107
Ford
KXV
9.8
ALIGNMENT
STRAP
Copyright © 2003 ATSG
d
or
F
Figure 169
Oil Pump Body And Cover Assembly (Cont'd)
22. Install pump body to case seal ring, as shown
in Figure 171, and ensure that it is not twisted
in the groove.
23. Set the completed oil pump assembly aside for
the final assembly process (See Figure 172).
RF-F81P
7A105-AA
NUMBER 2A
THRUST BEARING
NUMBER 1
THRUST WASHER
Copyright © 2003 ATSG
NOT USED ON
"PTO" MODELS
Figure 171
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
d
or
F
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
98
RF-F81P
7A105-AA
Ford
107
RF-F81P-7B324-AA
KXV
9.8
KXV
9.8
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 170
Figure 172
AUTOMATIC TRANSMISSION SERVICE GROUP
99
Technical Service Information
FORD 4R100
MAIN, LOWER, AND ACCUMULATOR VALVE BODIES DISASSEMBLED
1
2
5
8
7
6
4
9
3
14
15
13
11
10
12
12
20
30
29
28
19
18 17
16
TP- B
RF-F6
92-A
7A0
32
31
33
37
36
34
38
24
39
35
23
22
26
44
21
25
27
43
40
42
41
46
73
72
71
70
47
69
48
68
67
49
66
65
50
64
51
52
54
63
53
62
55
61
56
57
58
59
Copyright © 2003 ATSG
60
Figure 173
100
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FORD 4R100
MAIN, LOWER, AND ACCUMULATOR VALVE BODY LEGEND
Item
Description
Item
1 LOWER VALVE BODY CASTING
2 HEX HEAD BOLT, (2 REQUIRED)
3 RETAINING PLATE
4 MANUAL 1-2 TRANSITION VALVE SPRING
5 MANUAL 1-2 TRANSITION VALVE
6 SPRING CLIP BORE PLUG RETAINER
7 ENGAGEMENT VALVE BORE PLUG
8 ENGAGEMENT VALVE SPRING
9 ENGAGEMENT VALVE
10 MAIN VALVE BODY CASTING
11 CHECKBALL 1/4", (2 REQUIRED)
12 CHECKBALL 5/16", (2 REQUIRED)
13 MANUAL CONTROL VALVE
14 MANUAL VALVE "E" CLIP
15 SPRING CLIP BORE PLUG RETAINER
16 LOW REVERSE MODULATOR VALVE SLEEVE
17 LOW REVERSE MODULATOR VALVE PLUNGER
18 LOW MODULATOR VALVE SPRING
19 LOW MODULATOR VALVE
20 LOW REVERSE MODULATOR VALVE
21 SPRING CLIP BORE PLUG RETAINER
22 3-4 SHIFT VALVE BORE PLUG
23 3-4 SHIFT VALVE SPRING
24 3-4 SHIFT VALVE
25 2-3 SHIFT VALVE SPRING RETAINING PLATE
26 2-3 SHIFT VALVE SPRING
27 2-3 SHIFT VALVE
28 SOLENOID REGUL ATOR VALVE SPRING RETAINING PLATE
29 SOLENOID REGUL ATOR VALVE SPRING
30 SOLENOID REGUL ATOR VALVE
31 COAST CLUTCH SHIFT VALVE SPRING RETAINING PLATE
32 COAST CLUTCH SHIFT VALVE SPRING
33 COAST CLUTCH SHIFT VALVE
34 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER RETAINING PLATE
35 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER SPRING
36 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER
37
38
39
40
41
42
43
44
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
Description
4-3-2 SHIFT TIMING VALVE RETAINING PLATE
4-3-2 SHIFT TIMING VALVE
4-3-2 SHIFT TIMING VALVE SPRING
SPRING CLIP BORE PLUG RETAINER
1-2 SHIFT VALVE BORE PLUG
DRIVE 2 VALVE
1-2 SHIFT VALVE
1-2 SHIFT VALVE SPRING
ACCUMULATOR VALVE BODY CASTING (MODEL SENSITIVE)
SPRING CLIP BORE PLUG RETAINER
DIRECT CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG
DIRECT CLUTCH ACCUM REGULATOR PLUNGER SPRING
DIRECT CLUTCH ACCUM REGULATOR PLUNGER
DIRECT CLUTCH ACCUM REGULATOR VALVE RETAINER
DIRECT CLUTCH ACCUM REGULATOR VALVE SPRING
DIRECT CLUTCH ACCUM REGULATOR VALVE
SPRING CLIP BORE PLUG RETAINER
O.D. CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG
O.D. CLUTCH ACCUM REGULATOR PLUNGER SPRING
O.D. CLUTCH ACCUM REGULATOR PLUNGER
O.D. CLUTCH ACCUM REGULATOR VALVE RETAINER
O.D. CLUTCH ACCUM REGULATOR VALVE SPRING
O.D. CLUTCH ACCUM REGULATOR VALVE
SPRING CLIP BORE PLUG RETAINER
INT. CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG
INT. CLUTCH ACCUM REGULATOR PLUNGER SPRING
INT. CLUTCH ACCUM REGULATOR PLUNGER
INT. CLUTCH ACCUM REGULATOR VALVE RETAINER
INT. CLUTCH ACCUM REGULATOR VALVE SPRING
INT. CLUTCH ACCUM REGULATOR VALVE
SPRING CLIP BORE PLUG RETAINER
LINE PRESSURE MODUL ATOR SLEEVE
LINE PRESSURE MODUL ATOR PLUNGER
LINE PRESSURE MODUL ATOR SPRING AND RETAINER ASSEMBLY
LINE PRESSURE MODUL ATOR VALVE SPRING
LINE PRESSURE MODUL ATOR VALVE
Figure 173 Legend
COMPONENT REBUILD
Valve Body Assemblies
1. Disassemble the main valve body, the lower
valve body and the accumulator valve body
using Figure 173 as a guide.
2. Disassemble the valve bodies one at a time.
Lay each valve line-up out in order as you
remove them from the valve body casting.
3. Inspect each valve, valve spring, bore plug and
retainers for any wear and/or damage.
Caution: Refer to Pages 22 through 33 for
the differences in "PTO" valve bodies and
the NON-PTO valve bodies and spacer plate.
None of these parts will interchange, so if
replacement is necessary, use extra care in
the inspection process for replacement parts.
4. Clean all valve body parts thoroughly and dry
with compressed air.
5. Install each valve train back into their bores
exactly as shown in Figure 173, lubricating
them with Mercon® fluid as they are installed.
6. Install the checkballs in the main valve body
in the locations shown in Figure 173, or refer
to Figure 40 for more detail.
7. Install the lower valve body onto main valve
body and install the 2 retaining bolts, as shown
in Figure 173, and finger tighten only.
8. Set the completed valve bodies aside for the
final assembly process.
AUTOMATIC TRANSMISSION SERVICE GROUP
101
Technical Service Information
FINAL ASSEMBLY
Internal Case Components
1. Rotate the pre-assembled case assembly in the
fixture so bell housing is facing up, as shown
in Figure 174.
2. Install the pre-assembled rear planetary carrier
with the washers secured with Trans-Jel® into
the reverse hub, as shown in Figure 174, and
rotate into position.
102
103
3. Install the rear carrier retaining snap ring, into
the reverse clutch hub, as shown in Figure 174,
and ensure it is fully seated.
Note: The reverse hub may have to be raised
up slightly to gain access to the snap ring
groove in the reverse clutch hub.
4. Install the pre-assembled direct clutch, forward
clutch and sun shell assembly using installation
tool, as shown in Figure 175, by rotating into
position until fully seated.
5. Remove the T89T-70010-E installation tool.
6. Install intermediate band assembly, as shown
in Figure 175, and ensure engagement on the
case band anchor. You may want to install the
intermediate servo piston at this time to help
hold the band in position.
INTERMEDIATE
BAND ASSEMBLY
104
105
INSTALLATION TOOL
T89T-70010-E
PRE-ASSEMBLED
DIRECT CLUTCH,
FORWARD CLUTCH
AND SUN SHELL
ASSEMBLY
102 REAR CARRIER TO REVERSE HUB RETAINING SNAP RING
103 NUMBER 10B THRUST WASHER
104 6 PINION REAR PL ANETARY CARRIER ASSEMBLY
Copyright © 2003 ATSG
Figure 174
102
Copyright © 2003 ATSG
Figure 175
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
Internal Case Components (Cont'd)
7. Install the intermediate clutch backing plate, as
shown in Figure 176, with the gaps in the steel
plates at the 6 and 12 o'clock positions in case.
8. Install the intermediate clutch plates, as shown
in Figure 176, beginning with a friction plate
and alternating with steel plates until you have
the proper amount installed.
9. Again the gaps in the steel plates should be at
the 6 and 12 o'clock positions in the case.
10. Install pre-assembled center support assembly,
as shown in Figure 177, ensuring that the
number 6 thrust washer is in place, and align
the feed holes.
11. Loosely install the two center support feedbolts
as shown in Figure 178.
12. Install intermediate clutch piston return spring,
as shown in Figure 177, with one spring tab at
the 6 o'clock position.
Continued on Page 104.
GAPS IN THE
6 AND 12 O'CLOCK
POSITIONS
46
53
48
52
54
49
GAPS IN THE
6 AND 12 O'CLOCK
POSITIONS
52 INTERMEDIATE CLUTCH FRICTION PLATES
53 INTERMEDIATE CLUTCH STEEL PLATES
54 INTERMEDIATE CLUTCH BACKING PLATE
46 INTERMEDIATE CLUTCH PISTON RETURN SPRING
48 CENTER SUPPORT ASSEMBLY
49 NUMBER 6 THRUST WASHER, CENTER SUPPORT
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 176
Figure 177
AUTOMATIC TRANSMISSION SERVICE GROUP
103
Technical Service Information
FINAL ASSEMBLY
Internal Case Components (Cont'd)
13. Install pre-assembled intermediate/overdrive
cylinder assembly, as shown in Figure 179, and
align the feed hole.
14. Place the snap ring into the case and install the
clutch spring compressor tool 307-S223, as
shown in Figure 180, and tighten the center
bolt in the tool to 7 N·m (65 in.lb.).
15. Install the snap ring into the case groove with
the gap at 6 o'clock (bottom) position in case.
16. Ensure that the snap ring is fully seated and
remove the clutch spring compressor tool.
17. Loosely install a new overdrive clutch cylinder
feedbolt as shown in Figure 178.
18. Since we are building the "PTO" version, we
must now install the overdrive clutch pack as
the overdrive clutches will not pass by the PTO
gear on the coast clutch housing.
Continued on Page 105.
40
OVERDRIVE
CYLINDER
FEED BOLT
42
CENTER SUPPORT
FEED BOLTS
40 INTERMEDIATE/OVERDRIVE CYLINDER SNAP RING
42 INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 178
104
Figure 179
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
Internal Case Components (Cont'd)
19. With the units that are not equipped with PTO,
the procedure would be the same as E4OD.
20. Install the overdrive clutch pack into the case,
as shown in Figure 181, beginning with a steel
plate and alternating with friction plates, until
you have installed the proper amount.
Note: The number of overdrive plates is model
sensitive and may vary from illustration.
21. Install the overdrive clutch backing plate on
top of the last friction plate, with the "dimple"
facing up and in the 12 o'clock (top) position
in the case (See Figure 181).
22. Install overdrive clutch backing plate selective
snap ring, as shown in Figure 181, and ensure
that it is fully seated in case groove, with the
snap ring gap at the 6 o'clock position.
31
34
"DIMPLE"
Continued on Page 106.
35
36
TIGHTEN CENTER
BOLT TO 7 N·m
(65 IN.LB.)
CLUTCH SPRING
FIXTURE
CLUTCH SPRING
COMPRESSOR BAR
31 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE)
34 OVERDRIVE CLUTCH BACKING PLATE
35 OVERDRIVE CLUTCH FRICTION PLATES
CLUTCH SPRING
COMPRESSOR PLATE
Copyright © 2003 ATSG
Figure 180
Figure 181
AUTOMATIC TRANSMISSION SERVICE GROUP
105
Technical Service Information
FINAL ASSEMBLY
Internal Case Components (Cont'd)
23. Measure the overdrive clutch clearance using
a feeler gauge between the selective snap ring
and the backing plate (See Figure 182).
24. Refer to Figure 182 for the specification as the
2 plate and 3 plate stacks are different.
25. Change the selective snap ring as necessary to
obtain the proper clearance. The selective snap
rings available are listed in Figure 182, along
with the OEM part number.
26. Install the pre-assembled coast clutch housing
and overdrive gearset as an assembly using the
required installation tool 307 S383, as shown
in Figure 183. Ensure that the number 5 thrust
bearing is still in place on center shaft.
Caution: The overdrive one-way roller clutch
may be damaged if this tool is not used on the
"PTO" equipped transmissions
27. The assembly will have to be rotated back and
forth to engage the center shaft splines and all
of the overdrive friction plates, and extra care
must be used during installation to avoid any
damage until fully seated.
"REQUIRED"
ASSEMBLY TOOL
307 S383
PRE-ASSEMBLED
COAST CLUTCH AND
OVERDRIVE GEARSET
Continued on Page 107.
NUMBER 5
THRUST BEARING
OVERDRIVE CLUTCH CLEARANCE
2 PLATE
0.68 - 1.33mm
(0.27" - 0.52")
3 PLATE
0.81 - 1.47mm
(0.32" - 0.58")
Selective Snap Rings Available
1.95 - 2.05mm (.077" - .081") = E9TZ-7B421-BA
2.50 - 2.60mm (.098" - .102") = E9TZ-7B421-CA
3.00 - 3.10mm (.118" - .122") = E9TZ-7B421-DA
3.50 - 3.60mm (.138" - .142") = E9TZ-7B421-EA
Copyright © 2003 ATSG
Figure 182
106
Figure 183
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
KXV
9.8
Internal Case Components (Cont'd)
28. After coast clutch is fully seated, remove the
installation tool.
29. Install an alignment dowel in one of the pump
holes in case, as shown in Figure 184.
30. Install the input shaft into transmission, to also
help with alignment concerns (See Figure 184).
31. Install a new oil pump to case gasket on case
surface, as shown in Figure 185, and use small
amount of Trans-Jel® to help secure in place.
32. Install the pre-assembled oil pump assembly,
ensuring the number 2 thrust bearing is secure
with Trans-Jel® (See Figure 185).
33. Ensure that the number 1 thrust washer is held
in place with Trans-Jel®, if it is used.
Note: The number 1 thrust washer is not used
on "PTO" models.
34. Fully seat the pump assembly using only hand
pressure. Do not use the bolts to pull the pump
assembly into the case.
35. Install new washers on pump bolts and install,
as shown in Figure 185, hand tight only.
KXV
9.8
7
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8
d
or
F
9
RF-F81P
7A105-AA
11
10
Continued on Page 108.
13
INPUT
SHAFT
ALIGNMENT
DOWEL
7
9
10
11
13
OIL PUMP ASM. RETAINING BOLTS, M8 X 1.25 X 65 (9 REQ.)
OIL PUMP AND COVER ASSEMBLY
NUMBER 1 THRUST WASHER (USED NON-PTO MODELS ONLY)
OIL PUMP ASSEMBLY TO CASE GASKET
NUMBER 2 THRUST BEARING, PUMP TO O.D. SUN GEAR
Copyright © 2003 ATSG
Figure 184
Copyright © 2003 ATSG
Figure 185
AUTOMATIC TRANSMISSION SERVICE GROUP
107
Technical Service Information
FINAL ASSEMBLY
Internal Case Components (Cont'd)
36. After all pump bolts are installed, torque them
to 24-31 N·m (18-23 ft.lb.), using a criss-cross
pattern (See Figure 186).
37. Remove input shaft as shown in Figure 186.
38. Rotate transmission in fixture so that bottom
pan surface is facing up.
39. Ensure that new feed bolts are used for center
support and overdrive clutch cylinder.
40. Torque overdrive clutch cylinder feed bolt to,
8-14 N·m (6-10 ft.lb.) (See Figure 187).
41. Torque both of the center support feed bolts to,
11-16 N·m (8-12 ft.lb.). (See Figure 187).
Caution: Overtightening the feed bolts will
cause the case to warp, and result in
transmission failure.
Final Assembly
Continued on Page 109.
OVERDRIVE CYLINDER
FEED BOLT. TORQUE TO
8-14 N·m (6-10 ft.lb.)
Sn
ap
-
O
n
CENTER SUPPORT
FEED BOLTS
TORQUE TO
11-16 N·m (8-12 ft.lb.)
Copyright © 2003 ATSG
Figure 186
108
Copyright © 2003 ATSG
Figure 187
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
55
183
182
62
Bottom Pan Components
1. Install eight (8) 5/16" diameter checkballs in
their case pockets, as shown in Figure 188.
2. Install EPC blow-off spring and .250" diameter
steel ball on top of spring, in location shown in
Figures 188 and 189.
3. Install the manual intermediate servo piston, as
shown in Figure 189, and ensure engagement
with the target area on manual band.
4. Install new spacer plate to case gasket on case
surface, as shown in Figure 190.
5. Install spacer plate, reinforcing plate and the 3
retaining bolts, as shown in Figure 190, and
hand tighten only at this time.
Note: The stamped word "UP" on reinforcing
plate should be facing up.
55 MANUAL INTERMEDIATE SERVO ASSEMBLY
182 EPC BLOW-OFF BALL, .250" DIAMETER STEEL BALL
183 EPC BLOW-OFF SPRING
Copyright © 2003 ATSG
Continued on Page 110.
Figure 189
189
.312" DIAMETER RUBBER
CHECKBALLS
U
P
188
185
62
184
.312" DIA. RUBBER
CHECKBALLS
EPC BLOW-OFF
LOCATION
184
185
188
189
SPACER PLATE TO CASE GASKET
SPACER PLATE
SPACER PLATE REINFORCING PLATE
REINFORCING PL ATE RETAINING BOLT, M6 X 1.0 X 42 (3)
Copyright © 2003 ATSG
Copyright © 2003 ATSG
Figure 188
Figure 190
AUTOMATIC TRANSMISSION SERVICE GROUP
109
Technical Service Information
FINAL ASSEMBLY
186
U
P
62
187
Bottom Pan Components (Cont'd)
6. Install the solenoid screen into the spacer plate,
as shown in Figure 191, and rotate clockwise
to lock in place.
7. Install the spacer plate to valve body gasket on
spacer plate, as shown in Figure 191.
8. Install new "O" ring seal on the solenoid case
connector, as shown in Figure 192, lube the
"O" ring with Trans-Jel®, and install solenoid
body (See Figure 192).
9. Install the nine solenoid body bolts and the one
nut, as shown in Figure 192, and hand tighten
only at this time.
Note: Refer to Valve Body Bolt Chart found
on Page 116 for proper locations.
10. Install the pre-assembled upper and lower main
valve bodies, as shown in Figure 193, ensuring
that manual valve is engaged on manual lever.
11. Install the 14 valve body retaining bolts and the
two nuts, as shown in Figure 193, and hand
tighten only at this time.
Note: Refer to Valve Body Bolt Chart found
on Page 116 for proper locations.
Continued on Page 111.
186 SPACER PLATE TO MAIN VALVE BODY GASKET
187 SOLENOID SCREEN ASSEMBLY
Copyright © 2003 ATSG
Figure 191
RETAINING BOLTS (14)
RETAINING
BOLTS (9)
RETAINING NUTS (2)
RETAINING NUT
UPPER AND LOWER
MAIN VALVE BODIES
SOLENOID
BODY ASSEMBLY
U
P
U
P
62
62
"O" RING
Copyright © 2003 ATSG
Figure 192
110
Copyright © 2003 ATSG
Figure 193
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
RETAINING NUTS (2)
RETAINING BOLTS (11)
U
P
62
ACCUMULATOR
VALVE BODY
Copyright © 2003 ATSG
Figure 194
Bottom Pan Components (Cont'd)
12. Install the accumulator valve body, as shown in
Figure 194, install 11 retaining bolts and the
two nuts and hand tighten at this time.
Note: Refer to Valve Body Bolt Chart found
on Page 116 for proper locations.
13. Finish tightening the bolts and nuts on the
accumulator body (11 bolts, 2 nuts), main
control valve body (14 bolts, two nuts), the
solenoid body (9 bolts, one nut) and reinforcing
plate (3 bolts).
Note: Refer to Valve Body Bolt Chart found
on Page 116 for proper locations.
14. Torque all valve body bolts and nuts, as shown
in Figure 195 to: 9-11 N·m (80-100 in.lb.).
Note: Place the manual lever in the reverse
position and measure distance that manual
valve is protruding past the rear of the valve
body casting. It should be approximately
.050", as shown in Figure 195. If dimension
is not correct, replace the detent spring and
roller assembly with a "New" one.
15. Lubricate the seal on the new filter with small
amount of Trans-Jel®, and install new filter
into bore in oil pump, as shown in Figure 196.
Manual Valve should protrude .050" past
the rear of valve body casting, with the
manual lever in the reverse position.
Continued on Page 112.
P R N D 2 1
MANUAL VALVE
Approx .050"
BOTTOM PAN
OIL FILTER
-O
n
U
P
U
P
62
62
Sn
ap
Copyright © 2003 ATSG
Figure 195
Copyright © 2003 ATSG
Figure 196
AUTOMATIC TRANSMISSION SERVICE GROUP
111
Technical Service Information
FINAL ASSEMBLY
BOTTOM
PAN
PAN BOLTS (20)
Bottom Pan Components (Cont'd)
16. Install a new pan gasket on case surface, as
shown in Figure 197.
17. Install the bottom pan on top of pan gasket, as
shown in Figure 197.
18. Install the twenty (20) pan bolts, as shown in
Figure 197, and torque all bottom pan bolts to,
14-16 N·m (10-12 ft.lb.).
19. Rotate transmission in fixture so bottom pan is
facing down, as shown in Figure 199.
PAN GASKET
U
P
62
FINAL ASSEMBLY
Copyright © 2003 ATSG
Figure 197
External Components
1. The manual shift levers are also model sensitive
as shown in Figure 198. Ensure that you have
the proper manual shift lever for the model that
you are building.
2. Install the Digital Transmission Range (DTR)
sensor, as shown in Figure 199, install 307-351
alignment tool (or equivalent).
3. Install the two sensor retaining bolts, as shown
in Figure 199, and torque retaining bolts to,
8-10 N·m (71-88 in.lb.).
Continued on Page 113.
FORD 4R100
MANUAL SHIFT LEVERS
"With" PTO OPTION
STAMPED F81P-AA
"Without" PTO OPTION
STAMPED F75P-BB
Ford
-7006RFF81P
98
XW4P-AC
RJL-B
004361
BD-9C17
BA
RETAINING
BOLTS (2)
d
For
FORD PART NUMBER
F81Z-7A256-AA
FORD PART NUMBER
F7UZ-7A256-BB
Figure 198
112
DIGITAL TRANSMISSION
RANGE SENSOR
Copyright © 2003 ATSG
Figure 199
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
FINAL ASSEMBLY
TURBINE SHAFT
SPEED SENSOR
Copyright © 2003 ATSG
Figure 200
External Components (Cont'd)
4. Install turbine shaft speed sensor, if equipped,
as shown in Figure 200, and torque the bolt to,
8-10 N·m (71-88 in.lb.).
5. Install output shaft speed sensor, if equipped,
as shown in Figure 201, and torque the bolt to,
8-10 N·m (71-81 in lb.)
Note: The TSS and OSS are model dependant.
6. Install the cooler bypass valve with the sealing
washers positioned as shown in Figure 202,
and install threaded cooler line case fittings.
7. Torque front fitting to, 30 N·m (22 ft.lb.).
Torque rear fitting to, 36 N·m (27 ft.lb.)
OUTPUT SHAFT
SPEED SENSOR
Continued on Page 114.
Copyright © 2003 ATSG
Figure 201
"4R100" COOLER BYPASS
VALVE ASSEMBLY
Front
"To Cooler"
Sealing Washers
OEM PART NUMBER
F81Z-7H322-AA
Rear
"From Cooler"
Sealing Washers
COOLER LINE
FITTINGS
Copyright © 2003 ATSG
Figure 202
AUTOMATIC TRANSMISSION SERVICE GROUP
113
Technical Service Information
INPUT SHAFT
Ford
XW4P-AC
RJL-B
004361
BD-9C17
BA
-7006RFF81P
98
LONGER SPLINES
Ford
Copyright © 2003 ATSG
Figure 203
FINAL ASSEMBLY
External Components (Cont'd)
8. Remove the transmission from bench fixture
and set on flat work surface (See Figure 203).
9. Install the input shaft, as shown in Figure 203,
with the long spline end going in first.
10. Lubricate the converter hub with Mercon®
fluid XT-2-QDX, or equivalent, as shown in
Figure 204.
11. Install torque converter and check the seating
by placing a straight-edge across the front of
case, as shown in Figure 205.
12. Ensure that there is a gap between the converter
pilot face and the straight-edge, as shown in
Figure 205.
CONGRATULATIONS-YOU ARE FINISHED!
SPACE
Figure 204
114
Figure 205
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
TORQUE SPECIFICATIONS
DESCRIPTION
Oil Pump Assembly to Case (9)
Oil Pump Cover to Oil Pump Body (12)
Stator Shaft to Oil Pump Cover (3)
Center Support Feed Bolts (2)
Center Support to Center Support Hub Bolts (3)
Overdrive/Intermediate Cylinder Feed Bolt (1)
Valve Body and Solenoid Body Bolts and Nuts (All)
Spacer Plate Reinforcing Plate to Case (3)
Inner Manual Valve Detent Lever Nut (1)
Detent Spring to Case (1)
Transmission Range Sensor to Case (2)
Line Pressure Plug (1)
Low One-Way Roller Clutch Inner Race to Case (5)
Parking Pawl Abutment Plate to Case (1)
Parking Pawl Guide Plate to Case (2)
Extension Housing Bolts (9)
Front Cooler Line Connector to Case (1)
Rear Cooler Line Connector to Case (1)
Transmission Oil Pan to Case (20)
N·m
ft.lbs.
24-31
24-31
9-11
11-16
9-14
8-14
9-11
9-11
41-54
9-11
8-10
8-16
24-34
22-27
22-27
41-54
30
36
14-16
18-23
18-23
in.lbs.
80-100
8-12
80-120
6-10
80-100
80-100
30-40
80-100
75-85
6-12
18-25
16-20
16-20
30-40
22
27
10-12
Copyright © 2003 ATSG
Figure 206
AUTOMATIC TRANSMISSION SERVICE GROUP
115
Technical Service Information
VALVE BODY BOLT CHART
"A"
"B"
"B"
"C"
"D"
"E"
"F"
"G"
"H"
30 Torx
Head
8 mm
Head
8 mm
Head
8 mm
Head
8 mm
Head
8 mm
Head
8 mm
Head
8 mm
Head
8 mm
Head
9.8
9.8
9.8
9.8
Lower V.B.
to Case Nut
(1)
Main V.B.
to Case Nut
(1)
Accum V.B.
to Case Nut
(2)
Solenoid Body
to Case Nut
(1)
"J"
8 mm
Head
Solenoid
Body
(9)
(40mm)
Accum
Valve Body
to Case
(11)
(42mm)
Main
Valve Body
to Case
(7)
(42mm)
Lower V.B.
to Main V.B.
(2)
(35mm)
9.8
Lower V.B.
to Case
(7)
(65mm)
G
B
B
Reinforcing
Plate
(3)
(16mm)
B
B
B
B
B
B
B
B
B
B
J
C
J
D
B
J
C
B
D
D
B
D
D
E
D
B
A
A
D
A
A
A
B
B
A
G
B
H
A
A
A
Copyright © 2003 ATSG
Figure 207
116
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
BOLT CHART
13 mm
Head
13 mm
Head
13 mm
Head
13 mm
Head
13 mm
Head
13 mm
Head
9.8
9.8
9.8
9.8
Center
Support
(2)
(30mm)
"PTO"
Cover
(6)
(19mm)
O.D.
Cylinder
(1)
(24mm)
Extn
Hsng
(7)
(40mm)
Extn
Hsng
(1 Some)
(40mm)
10 mm
Head
10 mm
Head
10 mm
Head
9.8
KXV
9.8
9.8
J
7/16"
Head
Oil Pan
to Case
(20)
(14mm)
Pump Cover
to Pump Body
(9)
(45mm)
30 Torx
Head
Stator
Shaft
(3)
(17mm)
Case to
Inner Race
(5)
(1.875")
8 mm
Head
13 mm
Head
9.8
9.8
Center
Support Hub
(3)
(16mm)
Extn
Hsng
(2)
(92mm)
Park Rod
Guide Plate
(2)
(23mm)
BOLTS DRAWN
ACTUAL SIZE
Pump to
Case
(9)
(65mm)
Copyright © 2003 ATSG
Figure 208
AUTOMATIC TRANSMISSION SERVICE GROUP
117
Technical Service Information
Copyright © 2003 ATSG
118
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2003 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
119
Technical Service Information
Copyright © 2003 ATSG
120
AUTOMATIC TRANSMISSION SERVICE GROUP
