Ford - Lincoln LS - Workshop Manual - 2004 - 2004

AKPPHELP.RU Руководство по ремонту АКПП INTRODUCTION FORD 5R55S FORD 5R55W Updated March, 2004 The Ford 5R55S and 5R55W transmissions are both very similar in design to the Ford 5R55N transmission and use electronic shift controls. The 5R55S/W are both "Syncrounous" units, as they do not use the intermediate clutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions were introduced in 2002, found in the Ford Explorer and Mercury Mountaineer vehicles, and are available in both 2WD and 4WD configurations. For model year 2003 they are also in the Lincoln LS, Lincoln Aviator and Ford Thunderbird. They are designed for operation in longitudinal powertrains for rear wheel drive vehicles. 5R55S Gear Ratios 1st Gear = 3.22 2nd Gear =2.29 3rd Gear = 1.54 4th Gear = 1.00 5th Gear = 0.71 Reverse = 3.07 5R55W Gear Ratios 1st Gear = 3.22 2nd Gear =2.41 3rd Gear = 1.54 4th Gear = 1.00 5th Gear = 0.75 Reverse = 3.07 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. DALE ENGLAND FIELD SERVICE CONSULTANT Copyright © ATSG 2004 JIM DIAL 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 JERRY GOTT STANTON ANDERSON TECHNICAL CONSULTANT TECHNICAL CONSULTANT GERALD CAMPBELL ROLAND ALVAREZ TECHNICAL CONSULTANT TECHNICAL CONSULTANT MIKE SOUZA TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 1 AKPPHELP.RU Руководство по ремонту АКПП FORD MOTOR CO. 5R55W/S GOTO PAGE INDEX PREVIOUS MENU 5R55W/S TRANSMISSION IDENTIFICATION .............................................................................................. 3 COMPONENT APPLICATION CHART ........................................................................................................... 4 SOLENOID APPLICATION AND RESISTANCE CHARTS ........................................................................... 5 SOLENOID BODY PIN IDENTIFICATION .................................................................................................... 6 GENERAL DESCRIPTION AND OPERATION .............................................................................................. 7 MANUAL SHIFT SELECTOR OPERATION ................................................................................................... 9 BATTERY JUNCTION BOX FUSE AND RELAY LOCATIONS ..................................................................... 10 CENTRAL JUNCTION BOX FUSE LOCATIONS ........................................................................................... 10 DIGITAL TRANSMISSION RANGE SENSOR ................................................................................................ 11 VARIOUS CONNECTOR AND PIN IDENTIFICATION ................................................................................. 12 WIRING SCHEMATIC ....................................................................................................................................... 13 PCM LOCATION ................................................................................................................................................. 15 TRANSMISSION COMPONENT RESISTANCE CHART THROUGH PCM CONNECTOR ....................... 16 DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION .................................................................. 18 LINE PRESSURE TESTS .................................................................................................................................. 21 CHECKING TRANSMISSION FLUID LEVEL ............................................................................................... 22 TRANSMISSION DISASSEMBLY .................................................................................................................... 24 COMPONENT REBUILD SECTION......... OIL PUMP ASSEMBLY .................................................................................................................................. 39 COAST CLUTCH HOUSING ......................................................................................................................... 43 OVERDRIVE CARRIER AND OVERDRIVE SPRAG ASSEMBLY ............................................................ 47 DIRECT CLUTCH HOUSING ....................................................................................................................... 49 FORWARD CLUTCH HOUSING .................................................................................................................. 52 CENTER SUPPORT ASSEMBLY .................................................................................................................. 57 LOW SPRAG AND REVERSE DRUM ASSEMBLY ..................................................................................... 58 REAR RING GEAR AND HUB ASSEMBLY ................................................................................................. 58 FRONT AND REAR PLANETARY CARRIER ASSEMBLY ........................................................................ 60 SUN GEAR AND SHELL ASSEMBLY .......................................................................................................... 61 FRONT RING GEAR AND HUB ASSEMBLY .............................................................................................. 61 VALVE BODY ASSEMBLY ............................................................................................................................. 65 CHECKBALL LOCATIONS ........................................................................................................................... 66 REVERSE SERVO ASSEMBLY ..................................................................................................................... 68 SOLENOID BODY DIFFERENCES ............................................................................................................. 72 SOLENOID BODY ASSEMBLY ..................................................................................................................... 73 4WD ADAPTER HOUSING AND PARKING PAWL ASSEMBLY .............................................................. 74 TRANSMISSION CASE ASSEMBLY ............................................................................................................ 76 FINAL TRANSMISSION ASSEMBLY .............................................................................................................. 79 REAR END CLEARANCE PROCEDURES ...................................................................................................... 84 FRONT END CLEARANCE PROCEDURES ................................................................................................... 93 2WD EXTENSION HOUSING ASSEMBLY SECTION ................................................................................. 100 BOLT SIZE AND LENGTH CHART ................................................................................................................ 105 SPECIAL SERVICE TOOLS ............................................................................................................................. 106 TORQUE SPECIFICATIONS ............................................................................................................................ 108 5R55N VERSUS 5R55W/S DIFFERENCES ................................................................................................... 108 AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 Copyright © ATSG 2004 2 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORD 5R55W/S 5 = 5 Forward Speeds R = Rear Wheel Drive 5 = Relative Torque Capacity 5 } S or W = Syncrounous Ford 0061 N T EU RA 1 L 2 P- 7 F 2 9 3 -A A rd Fo L I.D. TAG INFORMATION FOUND ON RIGHT REAR SIDE OF TRANSMISSION 2L2P-DA BDX-A 004361 BD-2C17 1 2 3 4 P-DA 2L2 -A BDX 61 3 004 H17 9 BD - BD X-A 0 0 43 61 RJL-B 004361 Year Month Day 9 C 17 BDBuild Date 1. 2. 3. 4. Part Number, Basic = 7000 (Example 2L2Z-7000-DA) Transmission Model Code Serial Number Build Date (YMDD) 9=1999 0=2000 1=2001 2=2002 3=2003 A=Jan B=Feb C=Mar D=Apr E=May F=Jun G=Jul H=Aug J=Sep K=Oct L=Nov M=Dec Copyright © 2004 ATSG Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 3 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORD 5R55W/S COMPONENT APPLICATION CHART RANGE FWD DIR COAST O/D INT L/R O/D CLUT CLUT CLUT BAND BAND BAND SPRAG LOW SPRAG TCS Switch 5R55W RATIO 5R55S RATIO 3.07 3.07 Park Reverse ON ON HOLD Neutral "D"-1st Gear ON "D"-2nd Gear ON "D"-3rd Gear ON "D"-4th Gear ON ON "D"-5th Gear ON ON "D"-1st Gear ON "D"-2nd Gear ON "D"-3rd Gear ON "D"-4th Gear ON "3"-3rd Hold * ON "2"-2nd Hold ** ON "1"-1st Hold *** ON HOLD OFF 3.22 3.22 HOLD OFF 2.41 2.29 HOLD OFF 1.54 1.54 HOLD OFF 1.00 1.00 OFF 0.75 0.71 HOLD ON 3.22 3.22 HOLD ON 2.41 2.29 HOLD ON 1.54 1.54 HOLD ON 1.00 1.00 1.54 1.54 HOLD 2.41 2.29 HOLD 3.22 3.22 HOLD ON ON ON ON HOLD ON ON ON ON ON ON ON ON HOLD ON ON ON HOLD * Manual "3" is 3rd gear starts and hold. ** Manual "2" is 2nd gear starts and hold. *** Manual "1" provides 1st gear operation only. Coast Clutch Overdrive Band Direct Clutch Intermediate Band Forward Clutch Overdrive Sprag Low/Reverse Band Low/Reverse Sprag Copyright © 2004 ATSG Figure 2 4 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORD 5R55W/S SOLENOID APPLY CHART Shift Shift Shift Shift Pres Cont Pres Cont Pres Cont TCC Range And Gear Commanded Sol. "A" Sol. "B" Sol. "C" Sol. "D" Sol. "A" Sol. "B" Sol. "C" Solenoid Park/Neutral Reverse "D" - 1st Gear "D" - 2nd Gear "D" - 3rd Gear "D" - 4th Gear "D" - 5th Gear ON ON ON ON ON "V" "V" "V" "V" "H" "L" "V" "L" "L" "V" "L" "H" "L" "L" "L" "H" "H" "D" - 1st Gear "D" - 2nd Gear "D" - 3rd Gear "D" - 4th Gear ON ON ON "V" "L" "V" "V" "L" "V" "L" "V" "L" "L" "L" "H" "3" - 3rd Gear (Hold) ON "V" "V" "L" "2" - 2nd Gear (Hold) ON "V" "V" "L" ON "V" "V" "1" - 1st Gear (Hold) "L" = Lower Line Pressure "V" = Variable Line Pressure "H" = Higher Line Pressure ** = TCC may be On, and is dependent on vehicle speed and throttle position "L" ON ON ON ON ON ON ON ON ON ON ON ON ON ON "L" "L" "V" "L" ON ON ON ** ** ** ** ** ** ** CASE CONNECTOR PIN IDENTIFICATION AND RESISTANCE CHARTS Solenoid Resistance Chart Connector Terminals Component Resistance In Ohms Shift Solenoid "A" Shift Solenoid "B" Shift Solenoid "C" Shift Solenoid "D" Pressure Control Solenoid "A" Pressure Control Solenoid "B" Pressure Control Solenoid "C" TCC Solenoid 3 And 16 3 And 15 3 And 6 3 And 5 3 And 11 3 And 1 3 And 4 3 And 14 16-45 16-45 16-45 16-45 3.3-7.5 3.3-7.5 3.3-7.5 9-16 TOT Sensor 2 And 12 See Chart TOT Sensor Resistance Chart 0°F-31°F = 284k - 100k Ohms 32°F-68°F = 100k - 37k Ohms 69°F-104°F = 37k - 16k Ohms 105°F-158°F = 16k - 5k Ohms 159°F-194°F = 5k - 2.7k Ohms 195°F-230°F = 2.7k - 1.5k Ohms 231°F-266°F = 1.5k - 0.8k Ohms 267°F-302°F = 0.8k - 0.54k Ohms Refer To Figure 4 For Case Connector Pin Identification Copyright © 2004 ATSG Figure 3 AUTOMATIC TRANSMISSION SERVICE GROUP 5 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information CASE CONNECTOR PIN IDENTIFICATION View Looking Into Transmission Case Connector 11 1 16 6 SOLENOID PACK ASSEMBLY Copyright © 2004 ATSG Figure 4 "FAIL-SAFE" DESCRIPTION AND OPERATION If the Powertrain Control Module (PCM) detects an input sensor or signal fault, it may use Failure Management Effects Mode (FMEM) strategy and provide a substitute signal or value. If the transmission totally loses electronic control, it will operate in a Fail-Safe mode with all of the following features: Maximum line pressure in all transmission shifter positions. Fully functional "P", "R" and "N" transmission shifter positions. Operation in 4th gear only with coast braking when the selector is in the "D", "3", "2", or "1" positions. Torque Converter Clutch (TCC) will be released in all positions. 6 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information GENERAL DESCRIPTION AND OPERATION The 5R55W/S is a fully automatic rear wheel drive transmission. It provides Park, Reverse, Neutral, and five forward speeds with 5th gear being overdrive Internally it looks similar to the previous 5R55E transmission, but there are very few minor components that are actually the same, so be very cautious during the rebuild process. The major components used in this unit are as follows: 3 Multi-Plate Clutch Packs Coast Clutch Direct Clutch (Single Sided) Forward Clutch 2 One-Way Clutches Overdrive Sprag Clutch Low Sprag Clutch 3 Brake Bands Overdrive Band Intermediate Band Low/Reverse Band 3 Compound Planetary Gear Sets Overdrive Planetary Set Forward Planetary Set Rear Planetary Set The shift pattern is controlled electronically with four (On-Off) solenoids that recieve a ground signal from the PCM (Powertrain Control Module). The PCM will vary shift points, as it is constantly interpreting numerous electronic signals from various operational sensors located on the vehicle and inside the transmission. Line pressure and shift feel are also controlled electronically with three Pressure Control solenoids, referred to as PCA, PCB, and PCC. The PCM varies the current to the pressure control solenoids and Ford refers to them as Variable Force Solenoids. The PCM also controls application of the converter clutch and apply feel electronically, with a TCC solenoid, which is also Variable Force style. All solenoids are incorporated in the "Solenoid Body", located on the valve body, and are not serviced seperately. You must purchase the entire solenoid body assembly, if necessary. ELECTRONIC COMPONENTS The PCM also receives input signals from various sensors and switches, located internally and externally, that affect proper transmission operation. The following will provide a brief description of each of the sensors and actuators used for transmission operations. AIR CONDITIONING CLUTCH This switch is located on the suction accum/drier and when the A/C is engaged, operating pressures are adjusted to compensate for the additional engine load. BRAKE PEDAL POSITION (BPP) SWITCH This switch is located on the brake pedal and tells the PCM when the brakes are applied. The TCC is disengaged when the brakes are applied. The BPP switch closes when the brakes are applied and open when they are released. ENGINE COOLANT TEMPERATURE (ECT) SENSOR This sensor detects temperature of engine coolant and supplies the information to the PCM. The PCM uses this information to control Torque Converter Clutch (TCC) operation. ELECTRONIC IGNITION (EI) SYSTEM The ignition control module generates a Profile Ignition Pickup (PIP) signal (engine rpm) and sends it to the PCM. The PCM uses PIP signal in the transmission strategy for WOT shift control, TCC control and operating pressures. INTAKE AIR TEMPERATURE (IAT) SENSOR The Intake Air Temperature (IAT) sensor, located in the air cleaner outlet tube, is also used in the transmission strategy to determine control pressures. MASS AIR FLOW (MAF) SENSOR The Mass Air Flow (MAF) sensor, located in the air cleaner inlet tube, measures the amount of air flowing into the engine and sends this information (engine load) to the PCM. For transmission strategies the MAF is used to regulate electronic pressure control, shift timing and torque converter clutch scheduling. Continued On Next Page Copyright © 2004 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 7 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information ELECTRONIC COMPONENTS (Cont'd) TRANSMISSION CONTROL SWITCH (TCS) The Transmission Control Switch (TCS), located within the manual shift selector assembly, as shown in Figure 5, is a momentary contact switch. When this switch is pressed, overdrive (5th gear) will be canceled. After the TCS has been pressed to request overdrive cancel, the PCM turns ON the Transmission Control Indicator Lamp (TCIL) to indicate that overdrive cancel mode is activated. TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The Transmission Control Indicator Lamp (TCIL), is located on the manual shift lever, as shown in Figure 5, or in the instrument panel and illuminates when the TCS switch is pressed. When the TCIL is "ON", overdrive is OFF or canceled. The PCM will also "Flash" the TCIL when it detects a fault in one of the solenoids or monitered sensors or switches. THROTTLE POSITION SENSOR (TPS) The Throttle Position Sensor is a potentiometer located on the throttle body and is used to detect throttle plate position and send this information to the PCM. The PCM uses this information for shift scheduling, pressure control and TCC control. DIGITAL TRANSMISSION RANGE (TR) SENSOR The Digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual shift lever. The digital TR sensor completes the start circuit in Park and Neutral, and the back-up lamp circuit in Reverse. The digital TR sensor also opens or closes a set of four switches that are monitered by the PCM to determine the position of the manual lever (P, R, N, D, 3, 2, 1). TURBINE SHAFT SPEED (TSS) SENSOR The Turbine Shaft Speed (TSS) sensor is mounted externally on the transmission case, and triggered by the overdrive carrier. The PCM uses TSS to help determine appropriate operating pressures and TCC operation. INTERMEDIATE SHAFT SPEED (ISS) SENSOR The Intermediate Shaft Speed (ISS) sensor is mounted externally on the case, and triggered by the sun gear shell. The PCM uses ISS to aid in determining appropriate pressure requirements. 8 OUTPUT SHAFT SPEED (OSS) SENSOR The Output Shaft Speed (OSS) sensor is mounted externally on the transmission case, and triggered by a speed rotor on the parking gear on the output shaft. The PCM uses OSS to determine appropriate shift speed scheduling, operating pressures and TCC operation. PRESSURE CONTROL SOLENOIDS (PCA, PCB, PCC) The Pressure Control solenoids PCA, PCB and PCC are located in the solenoid body assembly and are a variable-force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator that combines a solenoid and a regulating valve. The PCM varies the current to all three pressure control solenoids. The line pressure tap is used to verify output pressure from "PCA" or "PCB" by turning off either one, while verifying the output from the other solenoid. The second pressure tap is used to verify the output pressure from "PCC" solenoid. SHIFT SOLENOIDS (SSA, SSB, SSC, SSD) The four On-Off Shift Solenoids are three-way, normally open style solenoids, and also located in the solenoid body assembly. The four shift solenoids, (SSA, SSB, SSC, SSD), provide gear selection of 1st through 5th and reverse gears by directing control pressures to the appropriate element. Coast braking and manual gear selections are also controlled by the shift solenoids. TORQUE CONVERTER CLUTCH (TCC) SOLENOID The Torque Converter Clutch (TCC) solenoid is a pulse width modulating type of solenoid and is used to control the apply and release of the TCC. Like the others, it is located in the solenoid body assembly. TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR The Transmission Fluid Temperature (TFT) sensor, located in the solenoid body, is a thermister type sensor that varies a reference signal to the PCM. The PCM uses this information to determine fluid temperature. The shift schedule is changed when fluid is cold. The PCM also inhibits TCC operation, and compensates pressure control solenoids when fluid is cold. The PCM uses TFT signal to help determine shift scheduling, TCC operation and pressure control requirements. AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2004 ATSG AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INSTRUMENT PANEL RANGE SELECTOR INDICATOR Vehicles equipped with the 5R55W/S series transmissions have a Transmission Control Switch (TCS) and a Transmission Control Indicator Lamp (TCIL), as shown in Figure 5. The shift quadrant has the following positions P, R, D, 3, 2 and 1, as shown in Figure 5. P R N D 3 2 1 INSTRUMENT PANEL RANGE SELECTOR INDICATOR "N" = Neutral When in the Neutral position, there is no power flow through the transmission, the output shaft is not held and is free to turn. The engine may be started and the key can not be removed. "D" = Overdrive (TCS "OFF") When in the D position, with the TCS switch "OFF", there will be automatic upshifts 1st through 5th gear, automatic downshifts 5th through 1st gear, and apply and release of the TCC depending on vehicle speed, throttle position and engine coolant temperature. This is the normal position for most forward driving and provides the maximum fuel economy during normal operation. This unit also has engine braking in 5th gear. "D" = With TCS "ON" TCS When in the D4 position, with the TCS switch "ON", there will be automatic upshifts 1st through 4th gear, automatic downshifts 4th through 1st gear, and apply and release of the TCC depending on vehicle speed, throttle position and engine coolant temperature. This position may be selected for towing, or driving in hilly terrain. This unit also has engine braking in 4th gear. "3" = 3rd Gear OVERDRIVE OFF TCIL Figure 5 MANUAL SHIFT SELECTOR "P" = Park When in the Park position, there is no power flow through the transmission and the parking pawl locks the output shaft to the case. The engine may be started and the key may be removed. "R" = Reverse When in the Reverse position, the vehicle may be operated in a rearward direction at a reduced gear ratio, and the back-up lamps are illuminated. This position provides a pull-in shift to 3rd gear with coast braking. After an automatic downshift, a 3rd gear hold occurs with coast braking. In this position 3rd gear starts occur. "2" = 2nd Gear This position provides a pull-in shift to 2nd gear with coast braking. After an automatic downshift, a 2nd gear hold occurs with coast braking. In this position 2nd gear starts occur. "1" = 1st Gear This position provides 1st gear operation only, and used for descending steep grades. If this position is selected at normal road speeds, the transmission will downshift to the next lower gear, and continue downshifting at safe pre-calibrated road speeds until it reaches 1st gear. Copyright © 2004 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 9 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information CENTRAL JUNCTION BOX CENTRAL JUNCTION BOX (UNDERDASH) Transmission Related Fuses Only FUSE APPLICATION F-5 F27 Digital Range Sensor (Reverse Lamps) (7.5A) F15 F29 Digital Transmission Range Sensor (10A) F14 F-4 F-3 F13 F-2 F12 F-1 F11 Located Under Dash Panel, Driver Side F30 F25 F20 F10 F29 F24 F19 F-9 F28 F23 F18 F-8 F27 F22 F17 F-7 F26 F21 F16 F-6 CENTRAL JUNCTION BOX BATTERY JUNCTION BOX Battery Junction Box BATTERY JUNCTION BOX (UNDERHOOD) Transmission Related Fuses Only FUSE NT FRO F-1 F-2 F-4 F-5 F-6 APPLICATION F11 PCM Power Relay (40A) F12 Starter/Ignition Relay (50A) F15 Powertrain Control Module PCM (15A) F17 4WD Control Module (20A) F18 4WD Control Module (20A) F37 A/C Relay, Trans Solenoid Body (Term 3) (15A) F40 Powertrain Control Module, MAF, Cruise (15A) F41 PCM Power Relay, PCM Power Diode (15A) F-7 F-21 F-22 F-23 F-29 F-30 F-33 F-34 F-36 F-18 F-19 F-17 F-20 BATTERY JUNCTION BOX F-28 F-13 F-16 F-12 F-27 F-11 F-15 F-10 F-26 F-9 F-14 Ignition Relay A/C Clut Relay PCM Power Diode Starter Relay F-42 F-43 F-41 F-40 F-39 F-38 F-37 F-44 F-45 F-46 PCM Power Relay Brake Pedal Relay Copyright © 2004 ATSG Figure 6 10 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DIGITAL TRANSMISSION RANGE (DTR) Scanner Data SENSOR DIAGNOSIS Scanner Data SELECTOR POSITION PID:TR PARK REVERSE NEUTRAL OVERDRIVE P/N REV NTRL OD* MANUAL 3 MANUAL 2 MANUAL 1 MAN 3 MAN 2 MAN 1 PID:TR_D PID:TR_V TR4 TR3A TR2 TR1 0 0 0 0 1 TR3A (175B pin 9 to sigrtn) 0.0 Volts 0 1 1 1 1 1 1 0 0 0 1 1 1 0 0 0 1 0 1 1.3 to 1.8 Volts 1.3 to 1.8 Volts 1.3 to 1.8 Volts 0.0 Volts 0.0 Volts 0 0 1 1 0.0 Volts * Will read "Drive" if OD is canceled. 5 4WD CONTROL MODULE 4 Red/White 8 2 Voltage from Fuse 27 in Central Junction Box Orange Starter Relay Located in Auxilliary Junction Box (Underhood) Reverse Lamps White/Pink 10 1 G102 Voltage from Fuse 29 in Central Junction Box P R N D 3/ 2 1 4 P R N D 3/ 2 1 4 9 3 Red/Lt Blue 7 Digital Transmission Range (DTR) Sensor Lt Blue/Yellow P R N D 3/ 2 1 4 TR3A 9 White/Black White/Black P R N D 3/ 2 1 4 TR4 10 6 12 P R N D 3/ 2 1 4 13 Black/Lt Blue Lt Blue/Yellow Gray/Red 7 17 Splice S101 Lt Blue/Black 12 TR2 18 11 POWERTRAIN CONTROL MODULE 21 P R N D 3/ 2 1 4 Gray/Red 11 Yellow/Black 3 TR1 22 Lt Blue/Black P R N D 3/ 2 1 4 PCM "Center" Connector No. 175B 5 Yellow/Black 4 4. Breakout Box readings are taken from PCM signal pins for TR1, TR2, TR3A, TR4 to Signal Return. Voltages for TR1, TR2, TR4: 0 = 0.0 Volts (Shorted to Ground) 1 = 9.0 to 14.0 Volts (Open Circuit) Voltages for TR3A: 0 = 0.0 Volts (Circuit Shorted to Ground) 1 = 1.3 to 5.0 Volts (Open Circuit) 1.8 to 5.0 Volts is an invalid reading and is usually an open in wires or bad resistor in DTR sensor. 2 1. TR_V is the voltage at PCM connector 175B, pin 9 (TR3A Circuit) to Signal Return. 2. "In-Between" reading may be caused by shift cable or DTR sensor misalignment or a DTR circuit failure of TR1, TR2, TR3A, TR4. 3. TR_D: 1 = Open DTR Switch 0 = Closed DTR Switch Black/Pink Copyright © 2004 ATSG Figure 7 AUTOMATIC TRANSMISSION SERVICE GROUP 11 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VARIOUS CONNECTOR AND PIN IDENTIFICATION (All Connector Views Are Looking Into Connectors With Connector Removed) PCM Connector Number 175A 17 8 1 13 23 37 30 PCM Connector Number 175C PCM Connector Number 175B 20 14 1 47 26 10 1 31 23 13 39 25 11 23 7 22 25 16 18 44 34 35 27 36 12 32 19 13 42 18 43 17 41 26 34 26 33 17 46 29 49 22 58 12 22 38 30 48 60 (PCM LOCATION, ENGINE COMPARTMENT - RH SIDE) Data Link Connector 1 8 9 16 Digital Transmission Range Sensor Connector Solenoid Body Connector 11 16 1 1 7 2 8 3 9 4 10 5 11 6 12 6 Copyright © 2004 ATSG Figure 8 12 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information WIRING SCHEMATIC FOR EXPLORER/MOUNTAINEER FUSE F27 (7.5A) FUSE F-41 15A Orange G102 P R N D 3/ 2 1 4 7 P R N D 3/ 2 1 4 12 11 P R N D 3/ 2 1 4 8 9 P R N D 3/ 2 1 4 Starter Relay TFT Sensor TCC Solenoid Black/Pink White/Pink 10 3 Violet/Yellow Orange/Black Gray/Red 12 2 Violet/Yellow 14 White Pressure Control "C" Red/Lt Blue Black/Lt Blue 3 6 P R N D 3/ 2 1 4 2 P R N D 3/ 2 1 4 5 Gray/Red 4 Digital Transmission Range (DTR) Sensor Located in Battery Junction Box (Underhood) Pressure Control "B" 1 Orange Orange/Yellow Lt Blue/Pink 2 Pink/Black Violet/Orange 1 3 Red/White Pressure Control "A" 4 Violet/Yellow Brown/Orange White/Yellow 5 White/Yellow 11 7 Shift Solenoid "D" 9 White/Black White/Black Lt Blue/Yellow Brown/Orange 10 White 5 12 Lt Blue/Pink Shift Solenoid "C" 13 Lt Blue/Yellow Gray/Red Pink/Black 17 Splice S101 Lt Blue/Black 6 18 Gray/Red Violet/Orange 21 Yellow/Black 15 ISS Lt Blue/Black P R N D 3/ 2 1 4 Yellow/Black 4 Gray/Red Yellow/Lt Green Gray/Red Gray/Red Dk Green/White Red/Lt Blue 2 Yellow/Lt Green Shift Solenoid "B" 22 TR2 PCM 1 Orange/Black Shift Solenoid "A" 23 Dk Blue/Yellow Orange/Yellow POWERTRAIN CONTROL MODULE OSS 26 TR3A Intermediate Speed Sensor 2 Dk Green/White 16 TSS 27 TR4 1 2 Red/White Gray/Red PCM TR1 1 Dk Blue/Yellow PCM "Center" Connector No. 175B Output Speed Sensor 11 4WD CONTROL MODULE Turbine Speed Sensor FUSE F29 (10A) Tan/Black Black PCM DIODE Red Violet Red Dk Green/Orange Violet Violet 33 FUSE F-11 40A FUSE F-40 15A FUSE F-37 15A HOT IN START ONLY CENTRAL JUNCTION BOX PCM POWER RELAY Violet/Yellow 32 BATTERY JUNCTION BOX (UNDERHOOD) Splice S130 Violet HOT IN START OR RUN HOT IN START OR RUN HOT AT ALL TIMES Red/Lt Blue PCM Connector No. 175A Reverse Lamps AUTOMATIC TRANSMISSION Copyright © 2004 ATSG Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP 13 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information PCM Connector Number 175B 17 8 20 14 1 26 10 TRANSMISSION CIRCUIT FUNCTION ONLY 1 Shift Solenoid "A" (SSA) ground signal from PCM 2 Shift Solenoid "B" (SSB) ground signal from PCM 3 Shift Solenoid "C" (SSC) ground signal from PCM 4 Shift Solenoid "D" (SSD) ground signal from PCM 5 Torque Converter Clutch (TCC) ground signal from PCM 7 Pressure Control Solenoid "A" (PC A) ground signal from PCM 22 11 23 7 32 19 13 PCM CONNECTOR NUMBER 175B PIN NO. 25 16 Solenoid Body Connector 9 Digital Transmission Range (DTR) Sensor TR3A signal to PCM 10 Digital Transmission Range (DTR) Sensor TR4 signal to PCM 12 Pressure Control Solenoid "C" (PC C) ground signal from PCM 13 Pressure Control Solenoid "B" (PC B) ground signal from PCM 17 Sensor signal return (Ground) 18 Digital Transmission Range (DTR) Sensor TR2 signal to PCM 21 Intermediate Shaft Speed (ISS) Sensor signal to PCM 22 Digital Transmission Range (DTR) Sensor TR1 signal to PCM 23 Transmission Fluid Temperature (TFT) Sensor signal to PCM 26 Output Shaft Speed (OSS) Sensor signal to PCM 27 Turbine Shaft Speed (TSS) Sensor signal to PCM SOLENOID BODY CONNECTOR PIN NO. 11 1 16 6 Pressure Control Solenoid "B" (PC B) ground signal from PCM 2 Transmission Fluid Temperature (TFT) Sensor signal to PCM 3 Battery Voltage in from Fuse 37 in Battery Junction Box 4 Pressure Control Solenoid "C" (PC C) ground signal from PCM 5 Shift Solenoid "D" (SSD) ground signal from PCM 6 Shift Solenoid "C" (SSC) ground signal from PCM 11 Pressure Control Solenoid "A" (PC A) ground signal from PCM 12 Sensor signal return (Ground) 14 Torque Converter Clutch (TCC) ground signal from PCM 15 Shift Solenoid "B" (SSB) ground signal from PCM 16 Shift Solenoid "A" (SSA) ground signal from PCM Digital Transmission Range Sensor Connector DIGITAL TRANS RANGE CONNECTOR PIN NO. 1 7 2 8 3 9 4 10 5 11 6 12 CIRCUIT FUNCTION 1 CIRCUIT FUNCTION 2 Sensor signal return (Ground) 3 Digital Transmission Range (DTR) Sensor TR3A signal to PCM 4 Digital Transmission Range (DTR) Sensor TR1 signal to PCM 5 Digital Transmission Range (DTR) Sensor TR2 signal to PCM 6 Digital Transmission Range (DTR) Sensor TR4 signal to PCM 7 Ground wire to G102 ground 8 Selector Lever Signal to 4WD Control Module 9 Battery Voltage from Fuse F27 in Central Junction Box for reverse lamps 10 Battery Voltage to starter relay in Battery Junction Box, in start position only 11 Battery Voltage to reverse lamps 12 Battery Voltage from Fuse F29 in Central Junction Box for starter circuit Copyright © 2004 ATSG Figure 10 14 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information POWERTRAIN CONTROL MODULE LOCATION PCM Connector Number 175C PCM Connector Number 175A PCM Connector Number 175C PCM Connector Number 175B Copyright © 2004 ATSG Figure 11 AUTOMATIC TRANSMISSION SERVICE GROUP 15 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information RESISTANCE CHART FOR TRANSMISSION COMPONENTS Battery Junction Box (Underhood) F-1 F-2 F-4 F-5 F-6 F-7 F-29 F-21 F-22 F-23 F-30 F-33 F-34 F-36 F-18 F-20 F-17 F-19 F-28 F-13 F-16 F-12 F-27 F-11 F-15 F-10 F-26 F-9 F-14 Ignition Relay A/C Clut Relay PCM Power Diode Starter Relay F-42 F-43 F-41 F-40 F-39 F-38 F-44 F-45 F-46 PCM Power Relay Brake Pedal Relay A 15 Remove 15 Amp Fuse F-37 Transmission Component Resistance Checks Through PCM Connector 175B 1. Remove Fuse 37 from Battery Junction Box, as shown. 2. Remove PCM Connector 175B, as shown below. 3. Use resistance chart found in Figure 13 for pin numbers. Remove PCM Connector (Center) Number 175B PCM Connector Number 175B (Face View) 17 8 22 11 23 32 19 13 16 PCM Connector Number 175C 26 10 7 PCM Connector Number 175B 20 14 1 PCM Connector Number 175A 25 Copyright © 2004 ATSG Figure 12 16 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information RESISTANCE CHART FOR TRANSMISSION COMPONENTS COMPONENT RESISTANCE CHART THROUGH PCM CONNECTOR Component Pin Numbers Resistance Shift Soleniod "A" 175B, Term 1 and F-37 Cavity 16-45 Ohms Shift Soleniod "B" 175B, Term 2 and F-37 Cavity 16-45 Ohms Shift Soleniod "C" 175B, Term 3 and F-37 Cavity 16-45 Ohms Shift Soleniod "D" 175B, Term 4 and F-37 Cavity 16-45 Ohms PC Soleniod "A" 175B, Term 7 and F-37 Cavity 3.3-7.5 Ohms PC Soleniod "B" 175B, Term 13 and F-37 Cavity 3.3-7.5 Ohms PC Soleniod "C" 175B, Term 12 and F-37 Cavity 3.3-7.5 Ohms TCC Soleniod 175B, Term 5 and F-37 Cavity 9-16 Ohms TFT Sensor 175B, Term 17 and Term 23 See Chart Below Turbine Speed Sensor Intermediate Speed Sensor Output Speed Sensor 175B, Term 17 and Term 27 175B, Term 17 and Term 21 175B, Term 17 and Term 26 325-485 Ohms @ 70°F 325-485 Ohms @ 70°F 325-485 Ohms @ 70°F CASE CONNECTOR PIN IDENTIFICATION AND RESISTANCE CHARTS Solenoid Resistance Chart TFT Sensor Resistance Chart Resistance Connector 0°F-31°F = 284k - 100k Ohms In Ohms Terminals Component 32°F-68°F = 100k - 37k Ohms 16-45 3 And 16 Shift Solenoid "A" 69°F-104°F = 37k - 16k Ohms 16-45 3 And 15 Shift Solenoid "B" 105°F-158°F = 16k - 5k Ohms 16-45 3 And 6 Shift Solenoid "C" 159°F-194°F = 5k - 2.7k Ohms 16-45 3 And 5 Shift Solenoid "D" 195°F-230°F = 2.7k - 1.5k Ohms 3.3-7.5 3 And 11 Pressure Control Solenoid "A" 231°F-266°F = 1.5k - 0.8k Ohms 3.3-7.5 3 And 1 Pressure Control Solenoid "B" 267°F-302°F = 0.8k - 0.54k Ohms 3.3-7.5 3 And 4 Pressure Control Solenoid "C" Transmission 9-16 3 And 14 TCC Solenoid Case Connector TOT Sensor 2 And 12 See Chart 11 1 16 6 Copyright © 2004 ATSG Figure 13 AUTOMATIC TRANSMISSION SERVICE GROUP 17 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DTC DIAGNOSTIC TROUBLE CODE (DTC) CHART AND DESCRIPTIONS DESCRIPTION P0102 P0103 P0112 P0113 P0114 P0116 P0117 P0118 P0121 P0122 P0123 P0300 P0308 P0320 P0340 P0500 P0503 P0705 P0708 P0712 P0713 P0715 P0717 P0718 P0720 P0721 P0722 P0731 P0732 P0733 P0734 P0735 P0740 P0741 Mass Air Flow (MAF) sensor system concerns Mass Air Flow (MAF) sensor system concerns Intake Air Temperature (IAT) sensor indicates 254°F (Grounded Circuit) Intake Air Temperature (IAT) sensor indicates -40°F (Open Circuit) Intake Air Temperature (IAT) sensor out of "On-Board Diagnostic" range Engine Coolant Temperature (ECT) sensor out of "On-Board Diagnostic" range Engine Coolant Temperature (ECT) sensor indicates 254°F (Grounded Circuit) Engine Coolant Temperature (ECT) sensor indicates -40°F (Open Circuit) Throttle Position (TP) sensor system intermittent Throttle Position (TP) sensor signal less than self test minimum Throttle Position (TP) sensor signal more than self test maximum Electronic Ignition (EI) multiple cylinder miss-fire or defective crank sensor Electronic Ignition (EI) missfire cylinder 8 Electronic Ignition (EI) two successive erratic PIP pulses have occured Electronic Ignition (EI) camshaft position sensor fault Vehicle Speed Sensor (VSS), insufficient input from ABS through SCP link Vehicle Speed Sensor (VSS), poor performance or noisy signal Digital Transmission Range (DTR) sensor circuit failure Digital Transmission Range (DTR) sensor circuit TR3A Open Transmission Fluid Temperature (TFT) circuit grounded, 315°F indicated Transmission Fluid Temperature (TFT) circuit open, -40°F indicated Turbine Shaft Speed (TSS) sensor, insufficient input Turbine Shaft Speed (TSS) intermittent sensor signal Turbine Shaft Speed (TSS) sensor signal noisy Output Shaft Speed (OSS) sensor, insufficient input Output Shaft Speed (OSS) sensor signal noisy Output Shaft Speed (OSS) intermittent sensor signal Gear Ratio Error, 1st Gear Gear Ratio Error, 2nd Gear Gear Ratio Error, 3rd Gear Gear Ratio Error, 4th Gear Gear Ratio Error, 5th Gear Torque Converter Clutch (TCC) circuit open or shorted Torque Converter Clutch (TCC) slippage detected Copyright © 2004 ATSG Figure 14 18 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DTC P0743 P0745 P0748 P0750 P0753 P0755 P0758 P0760 P0763 P0765 P0768 P0775 P0778 P0779 P0791 P0794 P0795 P0796 P0797 P0798 P0799 P0960 P0962 P0963 P0964 P0966 P0967 P0968 P0970 P0971 P1100 P1101 P1120 P1121 DIAGNOSTIC TROUBLE CODE (DTC) CHART AND DESCRIPTIONS DESCRIPTION Torque Converter Clutch (TCC) solenoid circuit failure during KOEO test Pressure Control "A" (PCA) solenoid, shorted circuit Pressure Control "A" (PCA) solenoid, mechanical failure Shift Solenoid "A" (SSA) circuit failure during KOEO test Shift Solenoid "A" (SSA) circuit failure open or shorted Shift Solenoid "B" (SSB) circuit failure during KOEO test Shift Solenoid "B" (SSB) circuit failure open or shorted Shift Solenoid "C" (SSC) circuit failure during KOEO test Shift Solenoid "C" (SSC) circuit failure, open or shorted Shift Solenoid "D" (SSD) circuit failure during KOEO test Shift Solenoid "D" (SSD) circuit failure open or shorted Pressure Control "B" (PCB) solenoid, shorted circuit Pressure Control "B" (PCB) solenoid, mechanical failure Pressure Control "B" (PCB) solenoid, intermittent short to ground Intermediate Shaft Speed (ISS) sensor signal failure Intermediate Shaft Speed (ISS) sensor signal intermittent Pressure Control "C" (PCC) solenoid, shorted circuit Pressure Control "C" (PCC) solenoid, open circuit Pressure Control "C" (PCC) solenoid failure Pressure Control "C" (PCC) solenoid, mechanical failure Pressure Control "C" (PCC) solenoid, intermittent short to ground Pressure Control "A" (PCA) solenoid, circuit open Pressure Control "A" (PCA) solenoid, shorted to ground Pressure Control "A" (PCA) solenoid, intermittent short to power or ground Pressure Control "B" (PCB) solenoid, open circuit Pressure Control "B" (PCB) solenoid, shorted to ground Pressure Control "B" (PCB) solenoid, intermittent short to power or ground Pressure Control "C" (PCC) solenoid, open circuit Pressure Control "C" (PCC) solenoid, shorted to ground Pressure Control "C" (PCC) solenoid, intermittent short to power or ground Mass Air Flow (MAF) sensor, circuit intermittent voltage input Mass Air Flow (MAF) sensor, signal was not 0.34-1.96 during self test Throttle Position (TP) sensor signal went to less than .49 volts Throttle Position (TP) sensor signal inconsistant with MAF signal Copyright © 2004 ATSG Figure 15 AUTOMATIC TRANSMISSION SERVICE GROUP 19 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DTC P1124 P1125 P1351 P1364 P1460 P1572 P1636 P1700 P1702 P1703 P1704 P1705 P1711 P1713 P1714 P1715 P1716 P1717 P1718 P1740 P1746 P1747 P1760 P1780 P1783 P1788 P1789 DIAGNOSTIC TROUBLE CODE (DTC) CHART AND DESCRIPTIONS DESCRIPTION Throttle Position (TP) sensor not in proper position for KOEO test Throttle Position (TP) sensor signal went to more than 4.60 volts Electronic Ignition (EI) concerns Electronic Ignition (EI) concerns Air Conditioning (AC) clutch cycling pressure switch error Brake Pedal Position (BPP) switch, circuit failed SSx ISIG communication error (Replace PCM) Internal transmission component failure Digital Transmission Range (DTR) sensor signal intermittent Brake Pedal Position (BPP) not cycled during KOER test, or switch circuit failed Digital Transmission Range (DTR) sensor, not in P or N during KOEO/KOER Digital Transmission Range (DTR), not in P or N during KOEO/KOER or circuit failure Transmission Fluid Temperature (TFT) out of On-Board diagnostic range Transmission Fluid Temperature (TFT), no change in TFT low range Shift Solenoid "A" (SSA), mechanical failure of solenoid detected Shift Solenoid "B" (SSB), mechanical failure of solenoid detected Shift Solenoid "C" (SSC), mechanical failure of solenoid detected Shift Solenoid "D" (SSD), mechanical failure of solenoid detected Transmission Fluid Temperature (TFT), no change in TFT high range Torque Converter Clutch (TCC), mechanical failure of solenoid detected Pressure Control "A" (PCA) solenoid, open circuit Pressure Control "A" (PCA) solenoid, shorted circuit Pressure Control "A" (PCA) solenoid, intermittent short to ground Transmission Control Switch (TCS) input incorrect, no OD cancel when moved Transmission Fluid Temperature (TFT), overtemp condition indicated Pressure Control "B" (PCB) solenoid, open circuit Pressure Control "B" (PCB) solenoid, shorted circuit Copyright © 2004 ATSG Figure 16 20 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information P-DA 2L2 B RJL- 61 3 004 C17 9 BD - Fo rd RJL Copyright © 2004 ATSG 361 Copyright © 2004 ATSG Figure 17 Figure 18 LINE PRESSURE TEST Special Note: The line pressure tap in Figure 17, is used to verify output pressure from PC "A" or from PC "B", by turning either one OFF while verifying pressure from the other solenoid. The 2nd pressure tap in Figure 18, is used to verify pressure readings from PC "C" solenoid. Use the chart below for proper specifications. 1. There are 3 Pressure Control solenoids located in the solenoid body, PC "A", PC "B", PC "C", used to control all application pressures. 2. Start engine and check line pressures using the chart provided below to determine if the line pressure is within specifications. Explorer/Mountaineer, 4.6L Engine 004 Pressure Control Solenoid "C" Pressure Tap Line Pressure Tap (Pressure Control Solenoids "A" And "B") Vehicle/Engine Explorer/Mountaineer, 4.0L Engine -B Range P/N Reverse (D), 3, 2, 1 P/N Reverse (D), 3, 2, 1 Idle Line Pres. 90-120 psi 100-140 psi 90-110 psi 90-120 psi 90-120 psi 80-110 psi WOT Line Pres. 282-380 psi 228-263 psi 282-380 psi 228-263 psi Idle PC "C" Pres. 0-15 psi 90-120 psi WOT PC "C" Pres. 0-15 psi 112-134 psi 0-15 psi 0-15 psi 90-120 psi 0-15 psi 112-134 psi 0-15 psi Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP 21 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORD 5R55S/W CHECKING FLUID LEVEL Checking the fluid level on any vehicle equipped with Ford Motor Companys new 5R55W/S transmission may become confusing to some technicians. There is a plug on the right rear of the transmission case, as shown in Figure 22, that would lead one to believe that this is where you check the fluid level, since some of the other manufacturers are currently checking fluid level in this manner. However, this is a "Fill" plug only on the new 5R55W/S transmission from Ford Motor Company, which is currently found in the Explorer and Mountaineer vehicles. To "Check" for the correct fluid level, you must remove the check plug, which is located in the center of the bottom pan drain plug, and is removed with an allen wrench, as shown in Figure 22, while holding the drain plug with the proper size wrench so as not to loosen the drain plug. We have provided you with a cut-away drawing of the bottom oil pan and the drain plug so that you will understand how this system works. Notice that the drain plug actually has a "stem" made on it that extends some distance up into the bottom pan, which is now our way to establish the proper fluid level in the transmission. By removing the "Check" plug from the "Drain" plug, the fluid should just trickle over the stem and out through the center of the drain plug, as shown in Figure 22. The "Fill" plug in the right rear of the case is your only way to replace and/or fill with fluid, in the 5R55W/S transmission. We have also identified the cooler line fittings and lines, as shown in Figure 21. "FROM COOLER" "TO COOLER" ord F 6538 A R3 T9 Ford L DA 8 RA Copyright © 2004 ATSG Figure 20 22 S A UT G 1 L 2 P- 7 F 2 9 3 -A A 0061 NE 40 A 6 5 19 3 R SPECIAL NOTE: THIS UNIT REQUIRES MERCON® V TRANSMISSION FLUID Copyright © 2004 ATSG Figure 21 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information CHECKING FLUID LEVEL Required Fluid Level In Pan Bottom Pan Oil Filter Bottom Pan Drain Plug Bottom Pan Bottom Pan Magnet Oil Level Check Plug A 2P2LD B RJL- 61 3 004 C17 9 BD - RJL -B 004 361 THIS IS A "FILL" PLUG ONLY Copyright © 2004 ATSG Figure 22 AUTOMATIC TRANSMISSION SERVICE GROUP 23 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Intermediate Shaft Speed Sensor Output Shaft Speed Sensor 1 L 2 P- 7 F 2 9 3 -A A 0061 Turbine Shaft Speed Sensor NE UT RA L Copyright © 2004 ATSG Figure 23 TRANSMISSION DISASSEMBLY EXTERNAL COMPONENTS 1. Remove the turbine shaft from the transmission as shown in Figure 23. Inspect the spline area on both ends and set aside for final assembly. 2. Remove the Turbine Shaft Sensor (TSS), the Intermediate Shaft Sensor (ISS) and the Output Shaft Sensor (OSS) from the transmission case, using a 30 Torx bit for the retaining bolts. (See Figure 23). 3. The Turbine and Output sensors are exactly the same part number. Refer to Figure 24 for the differences between them, and the Intermediate shaft speed sensor. 4. Remove and discard the "O" ring seals from all three speed sensors, and use the chart found in Figure 13 to ohms check the sensors for proper resistance readings. Turbine And Output Shaft Speed Sensor Ford XW4P-7H 103 AA Intermediate Shaft Speed Sensor XW4P-7M 103 AA Continued on Page 25 Copyright © 2004 ATSG Figure 24 24 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Manual Lever Fo rd Manual Lever Nut 0061 N RA 1 L 2 P- 7 F 2 9 3 -A A d Forrd T EU L Digital Transmission Range Sensor Retaining Bolts Copyright © 2004 ATSG Figure 25 EXTERNAL COMPONENTS (Cont'd) 5. Remove the manual lever retaining nut and the manual lever, as shown in Figure 25. 6. Remove the two Digital Transmission Range sensor retaining bolts, as shown in Figure 25, and remove the sensor. Universal Transmission Holding Fixture 7. Install a compatible holding fixture onto the transmission case, as shown in Figure 26, that will allow you to rotate the transmission when installed in the bench fixture. 8. Install the transmission into the bench fixture and rotate, so that the bottom pan is facing up, as shown in Figure 27. Continued on Page 26 rd Fo -1 62 CA 0 F 8 GA ord 6538 R3 T9 A Ford 6540 19 A R3 Copyright © 2004 ATSG Figure 26 Copyright © 2004 ATSG Figure 27 AUTOMATIC TRANSMISSION SERVICE GROUP 25 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information EXTERNAL COMPONENTS (Cont'd) 9. Rotate the transmission so that the bottom pan is facing up, as shown in Figure 27. 10. Remove the sixteen bottom pan bolts using an 8mm socket and remove oil pan, as shown in Figure 28. 11. Remove the bottom pan gasket from the case, as shown in Figure 28. Note: The bottom pan gasket is reuseable. Clean and inspect the gasket for damage, and if it is not damaged, it may be re-used. 12. Remove the two filter retaining bolts, as shown in Figure 29, and remove and discard the oil filter and seals. 13. Remove the four rear servo retaining bolts and remove the Low/Reverse Servo assembly, as shown in Figure 30. 14. Set the Low/Reverse Servo assembly aside for the component rebuild process. 15. Remove the eight solenoid body retaining bolts using a 30 Torx bit, as shown in Figure 30. 16. Remove the solenoid body assembly from the transmission, as shown in Figure 30, and set aside for testing in component rebuild. Continued on Page 28 PAN BOLTS (16 REQUIRED) OIL FILTER RETAINING BOLTS (82mm LENGTH) PAN GASKET -1 62 -1 62 CA 0 A Ford 6540 19 A R3 6538 R3 T9 CA 0 6538 A R3 T9 Ford ord 0 65419 A R3 ord F 8 GA 8 F GA Copyright © 2004 ATSG Figure 28 26 Copyright © 2004 ATSG Figure 29 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information LOW/REVERSE SERVO RETAINING BOLTS (70mm LENGTH) SOLENOID BODY RETAINING BOLTS (63mm LENGTH) SOLENOID BODY RETAINING BOLT (25mm LENGTH) LOW/REVERSE SERVO ASSEMBLY SOLENOID BODY ASSEMBLY -1 62 8 CA 0 F ord 6538 R3 T 9 A 0 65419 A R3 Ford GA Copyright © 2004 ATSG Figure 30 AUTOMATIC TRANSMISSION SERVICE GROUP 27 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information EXTERNAL COMPONENTS (Cont'd) 17. Remove the detent spring retaining bolt and the detent spring, as shown in Figure 31. Note: This is the only valve body retaining bolt that is 30mm in length. 18. Remove the only 45mm in length valve body bolt, as shown in Figure 31, and note location. DETENT SPRING BOLT "1" REQUIRED (30mm LENGTH) VALVE BODY RETAINING BOLT "1" REQUIRED (45mm LENGTH) VALVE BODY RETAINING BOLTS "18" REQUIRED (40mm LENGTH) 19. Remove the only 27mm in length valve body bolt, as shown in Figure 31, and note location. 20. Remove the remaining 18 valve body retaining bolts as shown in Figure 31, and they are all 40mm in length. 21. Remove valve body and spacer plate assembly, as shown in Figure 31, and set aside for the component rebuild section. DETENT SPRING VALVE BODY RETAINING BOLTS "18" REQUIRED (40mm LENGTH) VALVE BODY RETAINING BOLT (27mm LENGTH) VALVE BODY AND SPACER PLATE ASSEMBLY -1 62 8 CA 0 ord F 6538 R3 T9 A 0 65419 A R3 Ford GA Copyright © 2004 ATSG Figure 31 28 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Caution: Loosen, but "Do Not" yet remove center support bolt. -1 62 CA 0 ord F 6538 A R3 T9 0 65419 A R3 Ford 8 GA Copyright © 2004 ATSG Figure 32 EXTERNAL COMPONENTS (Cont'd) 22. Loosen, but do not remove, the center support retaining bolt (See Figure 32). 23. Loosen both band adjusting screws, as shown in Figure 33. 24. Caution: Failure to loosen OD band adjusting screw prior to pump removal may cause damage to the pump or OD band. 25. Remove and discard the locknuts from the band adjusting screws, as they are not reusable. Ford Continued on Page 30 Copyright © 2004 ATSG Figure 33 AUTOMATIC TRANSMISSION SERVICE GROUP 29 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 26. Rotate the transmission in bench fixture so that the pump is facing up, as shown in Figure 34. 27. Install the special pump puller, to be used with a slide hammer, as shown in Figure 35. 28. Remove the eight oil pump retaining bolts, as shown in Figure 36. Note: Ford Motor Co. recommends that the pump bolts not be reused, but replaced. Continued on Page 32 OIL PUMP ASSEMBLY RETAINING BOLTS (8 REQUIRED) OIL PUMP ASSEMBLY Copyright © 2004 ATSG Figure 34 98 OIL PUMP REMOVAL TOOL TO BE USED WITH SLIDE HAMMER XW 4P-7L6 /9 69-AB 09/01 9 OIL PUMP TO CASE GASKET Copyright © 2004 ATSG Figure 35 30 Copyright © 2004 ATSG Figure 36 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 29. Using the special pump rmoval tool and your slide hammer, remove the oil pump assembly, as shown in Figure 36. 30. Set the oil pump assembly aside for component rebuild section in this manual. 31. Remove the OD/Coast clutch drum assembly, as shown in Figure 37, and set drum aside for the component rebuild section. 32. Remove the overdrive band assembly and both band struts, as shown in Figure 38. Note: Notice the difference in the band struts and which side they are located, as shown in Figure 38. 33. Remove the coast clutch drum adapter and the overdrive sun gear from the overdrive carrier, as shown in Figure 39. OVERDRIVE BAND BAND STRUT SERVO SIDE BAND STRUT ADJUST SIDE Continued on Page 32 COAST CLUTCH DRUM ASSEMBLY Copyright © 2004 ATSG COAST CLUTCH DRUM ADAPTER 4P-7660-A A XW B4X4A XW 4P-7L6 69-AB 09/01 /99 Figure 38 OVERDRIVE SUN GEAR Copyright © 2004 ATSG Figure 37 Copyright © 2004 ATSG Figure 39 AUTOMATIC TRANSMISSION SERVICE GROUP 31 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE CARRIER AND CENTER SHAFT ASSEMBLY INTERNAL COMPONENTS (Cont'd) 34. Remove the overdrive carrier and center shaft assembly, as shown in Figure 40. 35. Now, remove the center support retaining bolt from the case, as shown in Figure 41, and also remove the locknut, as shown in Figure 42, to prevent it from falling into the assembly. 36. Remove the center support retaining snap ring from the case, as shown in Figure 42. 37. Remove center shaft thrust bearing (No. 3) from the center support, as shown in Figure 42 and tag it for I.D. and location. Continued on Page 33 CENTER SUPPORT "TAPERED" SNAP RING CENTER SHAFT THRUST BEARING (NO. 3) CENTER SUPPORT ASSEMBLY Copyright © 2004 ATSG Figure 40 M 07 1624 96 CENTER SUPPORT RETAINING BOLT (20mm LENGTH) ord DA 8 F S GA 6538 R3 T9 A 40 A 65 19 R3 Ford Copyright © 2004 ATSG Figure 41 32 Copyright © 2004 ATSG Figure 42 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 38. Remove the center support and set aside for component rebuild, as shown in Figure 43. 39. Remove the intermediate band assembly and both band struts, as shown in Figure 43. Note: Notice the difference in the band struts and which side they are located, as shown in Figure 43. 40. Remove and tag for I.D. direct clutch (No. 4) selective thrust bearing, as shown in Figure 44. 41. Remove the direct clutch housing assembly and set aside for component rebuild, as shown in Figure 44. 42. Remove and tag for I.D. forward clutch (No. 5) thrust bearing, as shown in Figure 44. 43. Remove the forward clutch housing assembly and set aside for component rebuild, as shown Figure 44. 44. Remove and tag for I.D. the forward clutch (No. 6A) thrust bearing (See Figure 44). Note: This bearing may stick to the forward clutch housing during removal. DIRECT CLUTCH "SELECTIVE" THRUST BEARING (NO. 4) DIRECT CLUTCH DRUM ASSEMBLY FORWARD CLUTCH THRUST BEARING (NO. 5) FORWARD CLUTCH DRUM ASSEMBLY Continued on Page 34 FORWARD CLUTCH THRUST BEARING (NO. 6A) INTERMEDIATE BAND BAND STRUT ADJUST SIDE BAND STRUT SERVO SIDE Copyright © 2004 ATSG Figure 43 Copyright © 2004 ATSG Figure 44 AUTOMATIC TRANSMISSION SERVICE GROUP 33 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 45. Remove forward ring gear and hub assembly along with the forward clutch (No. 6B) thrust washer, as shown in Figure 45. 46. Remove and tag for I.D. the forward planet (No. 7) thrust bearing (See Figure 45). Note: Bearing may come out with the forward ring gear and hub assembly. 47. Remove the forward planetary carrier assembly as shown in Figure 45, and set aside for the component rebuild section. 48. Remove the input sun gear and shell assembly, as shown in Figure 46. 49. Remove the low/reverse bearing spacer from transmission case, as shown in Figure 46. 50. Remove and tag for I.D. the rear planetary thrust bearing (No. 8), as shown in Figure 47. 51. Remove the rear planetary retaining snap ring from reverse drum, as shown in Figure 47. Continued on Page 35 FORWARD CLUTCH THRUST WASHER (NO. 6B) INPUT SUN SHELL AND SUN GEAR FORWARD RING GEAR AND HUB FORWARD PLANET THRUST BEARING (NO. 7) D1 E4A F ord CA 505 D "TALL" LOW/REVERSE SPACER FORWARD PLANET ASSEMBLY R FXW4 P Copyright © 2004 ATSG Figure 45 34 Copyright © 2004 ATSG Figure 46 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 52. Remove the rear planetary carrier from the reverse drum, as shown in Figure 47. 53. Remove the plastic lube dam from the rear planetary ring gear, as shown in Figure 48. 54. Remove the output shaft retaining snap ring from the output shaft, as shown in Figure 48. Caution: Install temporary strap on back of case, as shown in Figure 49, to retain the output shaft from falling out, "before" you remove the snap ring. REAR LUBE DAM OUTPUT SHAFT SNAP RING Continued on Page 36 REAR PLANETARY THRUST BEARING (NO. 8) REAR PLANETARY SNAP RING Copyright © 2004 ATSG Figure 48 REAR PLANETARY ASSEMBLY CAUTION: INSTALL TEMPORARY HOLDING STRAP AS SHOWN TO RETAIN OUTPUT SHAFT. Fo 1L 2P -7A 0 rd 39 -B A Copyright © 2004 ATSG Figure 47 Copyright © 2004 ATSG Figure 49 AUTOMATIC TRANSMISSION SERVICE GROUP 35 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) REAR PLANETARY RING GEAR THRUST BEARING (NO. 10) 55. Remove and tag for identification, the rear ring gear (No. 9) thrust bearing (See Figure 50). 56. Remove the rear planetary ring gear from the transmission, as shown in Figure 50. 57. Remove reverse drum and low sprag assembly by rotating and lifting drum out, as shown in Figure 51. 58. Remove and tag for I.D. the rear planetary gear thrust bearing (No. 10), as shown in Figure 51. 59. Remove the low/reverse band assembly from the case, as shown in Figure 51. 60. Rotate the transmission so that output shaft is facing up, as shown in Figure 52. REVERSE DRUM AND LOW SPRAG ASSEMBLY Continued on Page 37 LOW/REVERSE BAND ASSEMBLY REAR PLANETARY RING GEAR THRUST BEARING (NO. 9) REAR PLANETARY RING GEAR Copyright © 2004 ATSG Figure 50 36 Copyright © 2004 ATSG Figure 51 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 61. Remove the temporary retaining bracket and the output shaft, as shown in Figure 52. 62. Remove the seven retaining bolts from 4WD adapter, as shown in Figure 53. 63. Remove the 4WD adapter housing, as shown in Figure 53, and set aside for the component rebuild section. 64. Remove and discard the 4WD adapter housing gasket, as shown in Figure 53. Continued on Page 38 RETAINING BOLTS (7 REQUIRED) TEMPORARY BRACKET OUTPUT SHAFT (4WD VERSION SHOWN) Fo rd 1L 2P -7A 03 9-B A 4WD ADAPTER HOUSING EXTENSION GASKET -7A Fo rd 1L 2P 03 9 -B A Copyright © 2004 ATSG Figure 52 Copyright © 2004 ATSG Figure 53 AUTOMATIC TRANSMISSION SERVICE GROUP 37 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 65. Remove the park gear, as shown in Figure 54. 66. Remove and tag for I.D. the park gear thrust washer (No. 11), as shown in Figure 55. 67. This completes transmission disassembly. PARK GEAR NUMBER ELEVEN THRUST WASHER If replacement of the pump support assembly becomes necessary, ensure that replacement part has correct diameter recess for clearance of the different diameter O.D. sun gears, as shown below. 38 MM (0.75 Ratio) 46 MM (0.71 Ratio) Copyright © 2004 ATSG Figure 54 NUMBER ELEVEN THRUST WASHER - 7D XW4P 04 3 G 5F F or d PC Copyright © 2004 ATSG Figure 55 38 Copyright © 2004 ATSG Figure 56 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COMPONENT REBUILD SECTION OIL PUMP ASSEMBLY 1. Disassemble the oil pump assembly using the illustrations in Figure 57 as a guide. 2. Remove and discard the converter seal and all sealing rings (See Figure 57). 3. Inspect all oil pump parts thoroughly for any wear and/or damage. Note: If replacement of pump support is necessary, see Figure 56. 4. Clean all oil pump and cover parts throughly and dry with compressed air Continued on Page 40 OIL PUMP ASSEMBLY EXPLODED VIEW 2 3 4 1 98 Relief Valve "O" Ring 9 7 10 6 12 5 8 11 1. 2. 3. 4. 5. 6. FRONT PUMP OIL SEAL. FRONT PUMP COVER. FRONT PUMP COVER "D" RING SEAL. FRONT PUMP SPACER PLATE. FRONT PUMP INNER GEAR. FRONT PUMP OUTER GEAR. 7. 8. 9. 10. 11. 12. LINE PRESSURE RELIEF VALVE ASSEMBLY. FRONT PUMP STATOR SHAFT SEAL RING (BUTT-CUT). FRONT PUMP BODY AND STATOR ASSEMBLY. FRONT PUMP BODY TO COVER BOLTS (6 REQUIRED). OVERRUN CLUTCH SEAL RINGS. SELECTIVE THRUST WASHER (FRONT CLEARANCE) Figure 57 AUTOMATIC TRANSMISSION SERVICE GROUP 39 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OIL PUMP ASSEMBLY (Cont'd) 5. Install selective thrust washer that came with the unit and retain with Trans-Jel®, as shown in Figure 58. 6. Install the two overrun clutch seal rings into their grooves and insure that the scarf cuts are assembled properly (See Figure 58). 7. Install a new "O" ring on the inside diameter of the inner pump gear and ensure that it is fully seated in the groove (See Figure 60). Lube with a small amount of Trans-Jel®. 8. Dip the pump gears into transmission fluid and install them with the "Dots" facing down, as shown in Figure 60. Caution: The pump gears must be installed with the "Dots" facing down (See Figure 60). 9. Install a new "Solid" seal ring in the groove in the stator shaft, as shown in Figure 60. 10. Install the line pressure relief valve into the cavity in the pump, as shown in Figure 60. Caution: See Note In Figure 59. CAUTION: The Pump Relief Valve Assembly "Must" Have The "O" Ring In Place As Shown Below "O" RING IN PLACE ON RELIEF VALVE Copyright © 2004 ATSG Figure 59 INNER PUMP GEAR "O" RING CAUTION: Install Pump Gears With "Dots" Facing Down INNER PUMP GEAR SEAL RINGS OUTER PUMP GEAR RELIEF VALVE "O" RING SELECTIVE THRUST WASHER PUMP BODY "SOLID" SEAL RING FOR TCC LINE PRESSURE RELIEF VALVE ASSEMBLY PUMP BODY - 7D XW4P 04 3 G 5F F or d PC Copyright © 2004 ATSG Figure 58 40 Copyright © 2004 ATSG Figure 60 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OIL PUMP ASSEMBLY (Cont'd) 11. Install a new converter seal into the oil pump cover using the proper seal driver, as shown in Figure 61. 12. Install a new "D" ring seal into outer groove of the oil pump cover, as shown in Figure 61. 13. Lubricate both seals and bushing with a small amount of Trans-Jel®. 14. Place pump body and stator shaft assembly on bench with shaft facing up (See Figure 62). Note: Ensure that the "O" ring seal is still in place on the relief valve (See Figure 62). 15. Install oil pump spacer plate and pump cover onto pump body, as shown in Figure 62. OIL PUMP COVER ASSEMBLY 98 Continued on Page 42 OIL PUMP SPACER OIL PUMP CONVERTER HUB SEAL OIL PUMP COVER PUMP BODY ASSEMBLY 98 OIL PUMP "D" RING SEAL Ensure "O" Ring Is In Place On Relief Valve Copyright © 2004 ATSG Figure 61 Copyright © 2004 ATSG Figure 62 AUTOMATIC TRANSMISSION SERVICE GROUP 41 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OIL PUMP ASSEMBLY (Cont'd) Ford Motor Company Pump Alignment Tool (1) 307-S309 (1) 307-431 (1) 307-432 D C B A 16. Install the appropriate size sleeve into handle of Ford Motor Co.Pump Alignment Tools, shown in Figure 63, and install into pump. 17. Turn the assembly over and install the six bolts that retain the body to the cover, as shown in Figure 64. 18. With the alignment tool in place, torque all six bolts in a star pattern to 18 ft.lb. as shown in Figure 65. 19. Remove the alignment tool and ensure that the pump gears will turn after they are torqued, as shown in Figure 65. 20. Set the completed pump assembly aside for the final assembly process. Copyright © 2004 ATSG Figure 63 0 - 7D XW4P D 0 4 YA MA1 4 3 rd Fo G 5F PC F or d PUMP BODY TO COVER BOLTS (6 REQUIRED) RF XW 4P - 7B 32 5-A A ENSURE THAT GEARS TURN AFTER TORQUE 0 - 7D XW4P D 0 4 YA MA1 4 3 rd Fo G 5F F or d PC RF X W 4P -7B 32 5-A A 98 Copyright © 2004 ATSG Figure 64 42 Copyright © 2004 ATSG Figure 65 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COAST CLUTCH ASSEMBLY 1. Disassemble the coast clutch assembly using the illustrations in Figure 66 as a guide. 2. Remove and discard the coast clutch lip seals, as shown in Figure 66. 3. Inspect all coast clutch parts thoroughly for any wear and/or damage. 4. Clean all coast clutch parts thoroughly and dry with compressed air. Continued on Page 44 COAST CLUTCH EXPLODED VIEW 1 3 2 Thickness = .065" Width = .155" 4 5 7 10 8 11 9 8 1. 2. 3. 4. 5. 6. 6 COAST CLUTCH BACKING PLATE SNAP RING. COAST CLUTCH BACKING PLATE. COAST CLUTCH FRICTION PLATES. COAST CLUTCH STEEL PLATES. COAST CLUTCH SPRING RETAINER SNAP RING. COAST CLUTCH RETURN SPRING RETAINER. 7. 8. 9. 10. 11. COAST CLUTCH RETURN SPRINGS (20 REQUIRED). COAST CLUTCH PISTON. COAST CLUTCH INNER LIP SEAL. COAST CLUTCH OUTER LIP SEAL. COAST CLUTCH HOUSING. Copyright © 2004 ATSG Figure 66 AUTOMATIC TRANSMISSION SERVICE GROUP 43 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COAST CLUTCH ASSEMBLY (Cont'd) 5. Install a new inner lip seal into the groove in the coast clutch piston, with the lip facing down, as shown in Figure 67. 6. Install a new outer lip seal into the groove in the coast clutch piston, with the lip facing down, as shown in Figure 67. 7. Lubricate both inner and outer lip seals with a small amount of Trans-Jel®. 8. Lubricate both the inner and outer seal surfaces in coast clutch housing with a small amount of Trans-Jel®. 9. Install the completed coast clutch piston into the overrun clutch housing with twisting motion, as shown in Figure 68. Continued on Page 45 COAST CLUTCH PISTON 8 COAST CLUTCH PISTON ASSEMBLY COAST CLUTCH PISTON INNER LIP SEAL 8 COAST CLUTCH PISTON OUTER LIP SEAL COAST CLUTCH HOUSING COAST CLUTCH HOUSING Copyright © 2004 ATSG Figure 67 44 Copyright © 2004 ATSG Figure 68 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COAST CLUTCH ASSEMBLY (Cont'd) COAST CLUTCH RETURN SPRING RETAINER SNAP RING COAST CLUTCH RETURN SPRING RETAINER COAST CLUTCH PISTON RETURN SPRINGS (20) 10. Install the coast clutch piston return springs on the coast clutch piston, as shown in Figure 69. 11. Install the coast clutch return spring retainer on top of return springs, as shown in Figure 69. 12. Carefully compress the retainer and the return springs and install the retaining snap ring, as shown in Figure 69. 13. Remove the spring compressor and ensure that everything is fully seated. 14. Install the friction and steel coast clutch plates into the coast clutch drum, beginning with a steel plate and alternating with a friction plate, until you have installed two of each, as shown in Figure 70. CAUTION: Coast Clutch friction plates are directional and must be installed with the grooves facing clockwise, as shown in Figures 70 and 71. Friction plates should be soaked in Mercon® V for at least 30 minutes before installation. 15. Install the coast clutch backing plate, as shown in Figure 70. 16. Install the coast clutch backing plate snap ring, as shown in Figure 70 and ensure that it is fully seated in the groove (See Figure 70). 17. Install dial indicator on top of backing plate, as shown in Figure 72, and check the coast clutch clearance. Should be 1.3-2.0mm (.051"-.079"), as shown in Figure 72. 18. Change the selective backing plate snap ring as necessary, using the chart in Figure 72, to get the proper clutch clearance. 19. Set the completed coast clutch housing aside for the final assembly process. 8 Copyright © 2004 ATSG Figure 69 AUTOMATIC TRANSMISSION SERVICE GROUP 45 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COAST CLUTCH BACKING PLATE SNAP RING COAST CLUTCH PATTERN DIRECTION "Selective" Snap Ring COAST CLUTCH BACKING PLATE CAUTION: Coast Clutch friction plates are directional and must be installed with the grooves facing clockwise, as shown above. Figure 71 CHECKING COAST CLUTCH CLEARANCE CLEARANCE SHOULD BE 1.3 - 2.0mm (.051"-.079") COAST CLUTCH LINED AND STEEL 10 0 10 20 20 30 30 40 40 50 0 50 8 COAST CLUTCH HOUSING 8 Thickness mm in 1.37 .054" 1.73 .068" 2.08 .082" 2.44 .096" Part Number E860126-S E860127-S E860128-S E860129-S Copyright © 2004 ATSG Figure 70 46 Copyright © 2004 ATSG Figure 72 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE CARRIER AND SPRAG ASSEMBLY 1. Disassemble the overdrive carrier from center shaft using Figure 73 as a guide. 2. Inspect all of the overdrive carrier parts shown in Figure 73 for any wear and/or damage. 3. Clean all overdrive carrier parts thoroughly and dry with compressed air. 4. Install the overdrive sprag assembly into the overdrive center shaft, in the direction shown in Figure 74, until fully seated. 5. Install thrust bearing onto overdrive carrier, as shown in Figure 75, and retain with a small amount of Trans-Jel®. 6. Install completed overdrive center shaft onto the overdrive carrier by rotating shaft counter clockwise as you install (See Figure 76). 7. Verify proper overdrive sprag rotation, using Figure 76, and then set the overdrive planetary carrier assembly aside for final assembly. Continued on Page 48 OVERDRIVE CARRIER/SPRAG EXPLODED VIEW OVERDRIVE PLANETARY CARRIER ASSEMBLY OVERDRIVE RING GEAR OVERDRIVE PLANETARY CARRIER TO CENTER SHAFT THRUST BEARING OVERDRIVE SPRAG ASSEMBLY OVERDRIVE CENTER SHAFT CENTER SHAFT TO RING GEAR SNAP RING Copyright © 2004 ATSG Figure 73 AUTOMATIC TRANSMISSION SERVICE GROUP 47 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE SPRAG ASSEMBLY COMPLETED CENTER SHAFT AND RING GEAR ASSEMBLY ENSURE THAT SPRAG IS FULLY SEATED OVERDRIVE CARRIER ASSEMBLY OVERDRIVE CENTER SHAFT Copyright © 2004 ATSG Figure 74 VIEWED FROM CENTER SHAFT SIDE CENTER SHAFT TO CARRIER THRUST BEARING Center Shaft Must Freewheel "Counter-Clockwise" While Holding The Overdrive Carrier FREE WHEEL Copyright © 2004 ATSG Figure 75 48 Copyright © 2004 ATSG Figure 76 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DIRECT CLUTCH ASSEMBLY 1. Disassemble the direct clutch assembly using the illustrations in Figure 77 as a guide. 2. Remove and discard the direct clutch lip seals, as shown in Figure 77. 3. Inspect all direct clutch parts thoroughly for any wear and/or damage. 4. Clean all direct clutch parts thoroughly and dry with compressed air. Continued on Page 50 DIRECT CLUTCH EXPLODED VIEW 2 1 3 4 6 5 7 11 10 8 8 1. 2. 3. 4. 5. 6. 9 DIRECT CLUTCH BACKING PLATE "SELECTIVE" SNAP RING. DIRECT CLUTCH BACKING PLATE. DIRECT CLUTCH "SINGLE SIDED" INSIDE SPLINE PLATES. DIRECT CLUTCH "SINGLE SIDED" OUTSIDE SPLINE PLATES. DIRECT CLUTCH SPRING RETAINER SNAP RING. DIRECT CLUTCH RETURN SPRING RETAINER. 7. 8. 9. 10. 11. DIRECT CLUTCH RETURN SPRINGS (20 REQUIRED). DIRECT CLUTCH PISTON. DIRECT CLUTCH INNER LIP SEAL. DIRECT CLUTCH OUTER LIP SEAL. DIRECT CLUTCH HOUSING. Copyright © 2004 ATSG Figure 77 AUTOMATIC TRANSMISSION SERVICE GROUP 49 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DIRECT CLUTCH ASSEMBLY (Cont'd) 5. Install a new inner lip seal into the groove in the direct clutch piston, with the lip facing down, as shown in Figure 78. 6. Install a new outer lip seal into the groove in the direct clutch piston, with the lip facing down, as shown in Figure 78. 7. Lubricate both inner and outer lip seals with a small amount of Trans-Jel®. 8. Lubricate both the inner and outer seal surfaces in direct clutch housing with a small amount of Trans-Jel®. 9. Install the completed direct clutch piston into the direct clutch housing with twisting motion, as shown in Figure 80. 10. Install the direct clutch piston return springs on the direct clutch piston, as shown in Figure 81. 11. Install the direct clutch return spring retainer on top of return springs, as shown in Figure 81. 12. Carefully compress the retainer and the return springs and install the retaining snap ring, as shown in Figure 81. 13. Remove the spring compressor and ensure that everything is fully seated. CAUTION: Direct Clutch friction plates are directional and must be installed with the internal tooth plate grooves facing clockwise, and the external tooth plates grooves facing counterclockwise, as shown in Figure 79. DIRECT CLUTCH PATTERN DIRECTION CAUTION: Direct Clutch friction plates are directional and must be installed with the internal tooth plate grooves facing clockwise, and the external tooth plates grooves facing counterclockwise, as shown above. Figure 79 14. Install the direct clutches beginning with an outside spline plate and alternating with inside spline plates, until you have installed 5 of each, as shown in Figure 82. Caution: Friction plates should be soaked in Mercon® V, 3o minutes before installing. Continued on Page 51 DIRECT CLUTCH PISTON DIRECT CLUTCH PISTON ASSEMBLY 8 8 DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH HOUSING DIRECT CLUTCH PISTON OUTER LIP SEAL Copyright © 2004 ATSG Figure 78 50 Copyright © 2004 ATSG Figure 80 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DIRECT CLUTCH ASSEMBLY (Cont'd) 15. Install the direct clutch backing plate, as shown in Figure 82. 16. Install the direct clutch backing plate snap ring, as shown in Figure 82 and ensure that it is fully seated in the groove (See Figure 82). 17. Install dial indicator on top of backing plate, as shown in Figure 83, and check the direct clutch clearance. Should be 1.3-2.0mm (.051"-.079"), as shown in Figure 83. 18. Change the selective backing plate snap ring as necessary, using the chart in Figure 83, to get the proper direct clutch clearance. 19. Set the completed direct clutch housing aside for the final assembly process. DIRECT CLUTCH BACKING PLATE SNAP RING "Selective" Snap Ring DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH INSIDE SPLINE PLATES (5 Req) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS (20) DIRECT CLUTCH OUTSIDE SPLINE PLATES (5 Req) DIRECT CLUTCH HOUSING DIRECT CLUTCH HOUSING ASSEMBLY 8 8 Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 81 Figure 82 AUTOMATIC TRANSMISSION SERVICE GROUP 51 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information CHECKING DIRECT CLUTCH CLEARANCE CLEARANCE SHOULD BE 1.3 - 2.0mm (.051"-.079") 10 0 10 20 20 30 30 40 40 50 0 50 FORWARD CLUTCH HOUSING ASSEMBLY 8 Part Number E860126-S E860127-S E860128-S E860129-S Thickness mm in 1.37 .054" 1.73 .068" 2.08 .082" 2.44 .096" 1. Disassemble the forward clutch assembly using the illustrations in Figure 86 as a guide. 2. Inspect all forward clutch parts thoroughly for any wear and/or damage. 3. Clean all forward clutch parts thoroughly and dry with compressed air. 4. Install new sealing rings into their grooves on the forward clutch housing (See Figure 85). 5. Ensure that the sealing rings are seated and rotate freely in grooves (See Figure 84). Continued on Page 54 Copyright © 2004 ATSG FORWARD CLUTCH SEAL RINGS Figure 83 ENSURE RINGS ROTATE FREELY FORWARD CLUTCH HOUSING Copyright © 2004 ATSG Figure 84 52 Copyright © 2004 ATSG Figure 85 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORWARD CLUTCH ASSEMBLY EXPLODED VIEW 1 3 2 4 8 7 6 5 1. 2. 3. 4. FORWARD CLUTCH BACKING PLATE "SELECTIVE" SNAP RING. FORWARD CLUTCH BACKING PLATE. FORWARD CLUTCH FRICTION PLATES. FORWARD CLUTCH STEEL PLATES. 5. 6. 7. 8. FORWARD CLUTCH RETURN SPRING RETAINER SNAP RING. FORWARD CLUTCH PISTON RETURN SPRING ASSEMBLY. FORWARD CLUTCH PISTON (STAMPED STEEL MOLDED RUBBER). FORWARD CLUTCH HOUSING. Copyright © 2004 ATSG Figure 86 AUTOMATIC TRANSMISSION SERVICE GROUP 53 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORWARD CLUTCH HOUSING (Cont'd) 6. Lubricate both inner and outer lip seals on the stamped steel forward clutch piston assembly, as shown in Figure 87, with a small amount of Trans-Jel®. 7. Lubricate both seal surfaces in the housing with a small amount of Trans-Jel® and install the piston assembly with a twisting motion so as not to damage the seals (See Figure 87). 8. Install the return spring retainer assembly on top of the piston, as shown in Figure 88. 9. Compress the return springs and retainer and install the spring retainer snap ring, as shown in Figure 88, and ensure snap ring is seated. 10. Remove the spring compressor. 11. Install the forward clutch plates beginning with a steel plate and alternating with friction plates, until you have installed 5 of each, as shown in Figure 89. 13. Install forward clutch backing plate snap ring, as shown in Figure 89 and ensure that it is fully seated in the groove. 14. Install dial indicator on top of backing plate, as shown in Figure 91, and check the amount of forward clutch clearance. Clearance should be 1.3 - 2.0mm (.051" - .079") (See Figure 91). 15. Change the selective backing plate snap ring as necessary, using the chart in Figure 91, to get the proper forward clutch clearance. 16. Set the completed forward clutch housing aside for the final assembly process. FORWARD CLUTCH SNAP RING FORWARD CLUTCH RETURN SPRING RETAINER CAUTION: Forward Clutch friction plates are directional and must be installed with the grooves facing counterclockwise, as shown in Figure 90. Friction plates should be soaked in Mercon® V for 30 minutes before installing. FORWARD CLUTCH HOUSING 12. Install forward clutch backing plate, as shown in Figure 89. STAMPED STEEL FORWARD CLUTCH PISTON AND CUSHION RING Ensure that snap ring is fully seated FORWARD CLUTCH HOUSING Copyright © 2004 ATSG Figure 87 54 Copyright © 2004 ATSG Figure 88 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FORWARD CLUTCH PATTERN DIRECTION FORWARD CLUTCH BACKING PLATE SNAP RING "Selective" Snap Ring FORWARD CLUTCH BACKING PLATE CAUTION: Forward Clutch friction plates are directional and must be installed with the grooves facing counterclockwise, as shown above. Copyright © 2004 ATSG Figure 90 CHECKING FORWARD CLUTCH CLEARANCE FORWARD CLUTCH FRICTION PLATES (5 REQ) CLEARANCE SHOULD BE 1.3 - 2.0mm (.051"-.079") 10 0 10 20 20 30 30 40 40 50 0 50 FORWARD CLUTCH STEEL PLATES (5 REQ) FORWARD CLUTCH HOUSING Thickness mm in 1.73 .068" 2.08 .082" 2.44 .096" Part Number XW4Z-7D483-AB XW4Z-7D483-AC XW4Z-7D483-AD Copyright © 2004 ATSG Figure 89 Copyright © 2004 ATSG Figure 91 AUTOMATIC TRANSMISSION SERVICE GROUP 55 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information CHECK CENTER SUPPORT BEARING RACE FOR CRACKS CENTER SUPPORT Ford Copyright © 2004 ATSG Figure 92 EXAMPLE OF CRACKED RACE WITH BEARING TAKEN OFF INSTALL NEW SEAL RINGS ON CENTER SUPPORT Ford Ford CENTER SUPPORT SEAL RINGS Copyright © 2004 ATSG Figure 94 56 Copyright © 2004 ATSG Figure 95 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 1. The center support assembly will require some extra inspection to ensure it's integrity. 2. Inspect bearing race at the top of the bearing, as shown in Figure 93, for any visable cracks. 3. If there are any visable cracks, replacement of complete center support will be necessary, as the bearing is not available as a service item. 4. We have seen several supports with the bearing race cracked, as shown in Figure 94. This will create leakage of direct and forward clutch oil, into each others circuit. 5. If you cannot visually see any crack, install new sealing rings onto the center support, as shown in Figure 95. 6. The only positive way to verify the integrity of the center support, is to assemble the forward and direct clutch housings, with the appropriate thrust bearings, onto the support, as shown in Figure 96. 7. Now air check the direct and forward clutch passages to ensure these passages are not connected. Caution: This air check should be performed with every center support assembly, and then replaced as necessary. 8. After you have verified the integrity of center support assembly, set the completed support aside for the final assembly process. AIR CHECKING CENTER SUPPORT PASSAGES 8 Ford CENTER SUPPORT ASSEMBLY Lube Direct Clutch Forward Clutch Copyright © 2004 ATSG Figure 96 AUTOMATIC TRANSMISSION SERVICE GROUP 57 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information LOW SPRAG AND REVERSE DRUM ASSEMBLY REAR RING GEAR AND HUB ASSEMBLY 1. The low sprag assembly is not yet available as a service item. If the low sprag or the bearing assembly needs replacement, the complete reverse drum assembly must be purchased. 2. If you do take it apart, the bearing assembly must be installed first, in the direction shown in Figure 97. 3. Then install the low sprag assembly, with the tabs facing down, as shown in Figure 97, until it "Snaps" into the groove. 4. After inspection and re-assembly if necessary, set the completed reverse drum assembly aside for the final assembly process (See Figure 98). LOW SPRAG ASSEMBLY 1. Inspect all rear ring gear parts thoroughly as shown in Figure 99. 2. Remove and discard the sealing ring on the rear gear hub, as shown in Figure 99. 3. Assemble the rear ring gear hub into the rear ring gear and install the snap ring, as shown in Figure 99. 4. Install a new sealing ring into the groove in the ring gear hub, as shown in Figure 99. Caution: This sealing ring is manufactured with two small notches in the outside diameter as shown in Figure 100, and must be installed in this location. 5. Set completed rear ring gear and hub assembly, as shown in Figure 101, aside for the final assembly process. TABS FACING DOWN CAGED NEEDLE BEARING ASSEMBLY COMPLETED LOW SPRAG AND REVERSE DRUM ASSEMBLY REVERSE DRUM ASSEMBLY Copyright © 2004 ATSG Figure 97 58 Copyright © 2004 ATSG Figure 98 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information "SPECIAL" SEALING RING WITH NOTCHES UNIQUE SEALING RING FOR REAR RING GEAR HUB REAR RING GEAR TO HUB SNAP RING Two Notches Made In Sealing Ring Copyright © 2004 ATSG Figure 100 REAR RING GEAR HUB COMPLETED REAR RING GEAR AND HUB REAR RING GEAR Copyright © 2004 ATSG Figure 99 Copyright © 2004 ATSG Figure 101 AUTOMATIC TRANSMISSION SERVICE GROUP 59 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FRONT PLANETARY CARRIER ASSEMBLY 1. Inspect the front planetary carrier carefully for any wear and/or damage (See Figure 102). 2. Inspect the rear planetary carrier thrust bearing that is "Trapped" inside the planetary gears, for any wear and/or damage. 3. Inspect the front planetary carrier thrust washer for any wear and/or damage (See Figure 102). 4. Replace the thrust washer as necessary. 5. Install the front planetary carrier thrust washer by "Snapping" the tabs into place, as shown in Figure 102. 6. Set completed front planetary carrier assembly aside for the final assembly process. Refer to Figure 103. COMPLETED FRONT PLANETARY CARRIER ASSEMBLY Copyright © 2004 ATSG Figure 103 REAR PLANETARY CARRIER ASSEMBLY FRONT PLANETARY CARRIER THRUST WASHER FRONT PLANETARY CARRIER ASSEMBLY 1. Inspect the rear planetary carrier carefully for any wear and/or damage (See Figure 104). 2. Set completed rear planetary carrier assembly aside for the final assembly process. Refer to Figure 104. COMPLETED REAR PLANETARY CARRIER ASSEMBLY Copyright © 2004 ATSG Figure 102 60 Copyright © 2004 ATSG Figure 104 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information SUN GEAR AND SHELL ASSEMBLY FRONT INTERNAL RING GEAR HUB SNAP RING 1. The sun gear and shell cannot be disassembled. Refer to Figure 105. 2. Inspect the sun gear and shell parts thoroughly for any wear and/or damage. 3. Clean all sun gear shell parts thoroughly and dry with compressed air. FRONT RING GEAR AND HUB ASSEMBLY FRONT INTERNAL RING GEAR HUB 1. Inspect all rear ring gear parts thoroughly as shown in Figure 106. 2. Assemble the rear ring gear hub into the rear ring gear and install the snap ring, as shown in Figure 106. 3. Install the number 6B thrust washer into the ring gear hub, as shown in Figure 106, retain with small amount of Trans-Jel®. 4. Set completed rear ring gear and hub assembly, as shown in Figure 106, aside for the final assembly process. 5. Refer to Figure 107 and 108 for exploded view of complete gear train parts. FRONT INTERNAL RING GEAR Component Rebuild Continued on Page 64 SUN GEAR SHELL ASSEMBLY SUN GEAR AND SHELL ASSEMBLY NUMBER 6B THRUST WASHER COMPLETED RING GEAR ASSEMBLY Copyright © 2004 ATSG Figure 105 Copyright © 2004 ATSG Figure 106 AUTOMATIC TRANSMISSION SERVICE GROUP 61 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 7 5 6 8 Thickness = .068" Width = .233" 15 17 16 F ord D1 E4A R FXW4 P CA 505 D 21 20 19 18 23 22 Thickness = .050" Width = .155" Copyright © 2004 ATSG Figure 107 62 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 3 2 1 4 12 14 11 13 10 9 Thickness = .040" Width = .154" 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. LOW SPRAG ASSEMBLY. REVERSE DRUM TO INNER RACE CAGED NEEDLE BEARING. REVERSE DRUM ASSEMBLY. REAR RING GEAR HUB THRUST BEARING, NUMBER 10. REAR RING GEAR HUB RETAINING RING. REAR INTERNAL RING GEAR HUB. REAR INTERNAL RING GEAR. REAR PLANETARY CARRIER THRUST BEARING, NUMBER 9. OUTPUT SHAFT RETAINING RING. OUTPUT SHAFT LUBRICATION SLEEVE. REAR PLANETARY CARRIER ASSEMBLY. REAR CARRIER TO REVERSE DRUM RETAINING SNAP RING. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. REAR PLANETARY CARRIER THRUST BEARING, NUMBER 8. LOW/REVERSE SPACER (LONG ONE REQUIRED). SUN SHELL AND SUN GEAR ASSEMBLY. INPUT CARRIER TO SUN SHELL THRUST WASHER. INPUT CARRIER ASSEMBLY. INPUT CARRIER THRUST BEARING, NUMBER 7. INPUT INTERNAL RING GEAR. INPUT INTERNAL RING GEAR HUB. INPUT INTERNAL RING GEAR HUB RETAINING SNAP RING. NUMBER 6B THRUST WASHER. INPUT INTERNAL RING GEAR HUB THRUST BEARING, NUMBER 6A. Copyright © 2004 ATSG Figure 108 AUTOMATIC TRANSMISSION SERVICE GROUP 63 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VALVE BODY ASSEMBLY EXPLODED VIEW 71 60 64 56 61 62 57 68 72 59 Legend Found On Page 65 74 70 66 75 63 58 73 69 65 79 67 78 77 55 54 52 53 51 47 50 48 49 45 46 44 36 43 39 42 40 9 16 38 15 20 37 24 41 19 17 21 31 26 30 7 13 23 27 6 8 14 25 18 22 28 5 4 12 1 3 11 10 35 32 34 29 33 Copyright © 2004 ATSG Figure 109 64 AUTOMATIC TRANSMISSION SERVICE GROUP 2 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VALVE BODY ASSEMBLY 1. Disassemble the main valve body assembly using Figure 109 as a guide. 2. 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. Replace complete valve body as necessary. 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 109, lubricating them with Mercon V® as they are installed. 6. Refer to Figure 110 for the exact placement of retaining pins and clips, as some of them are installed inboard in the worm tracks of the valve body casting. 7. Extra care here will eliminate some of the troublesome problems encountered later. Continued on Page 66 VALVE BODY LEGEND FOR 5R55W/S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 COOLER BYPASS VALVE RETAINER CLIP COOLER BYPASS VALVE BORE PLUG THERMO VALVE ASSEMBLY COOLER BYPASS VALVE COOLER BYPASS VALVE SPRING CONVERTER CLUTCH CONTROL VALVE RETAINER CONVERTER CLUTCH CONTROL VALVE BORE PLUG CONVERTER CLUTCH CONTROL VALVE SPRING CONVERTER CLUTCH CONTROL VALVE COAST CLUTCH CONTROL VALVE RETAINER PLACE COAST CLUTCH CONTROL VALVE SPRING COAST CLUTCH CONTROL VALVE CONVERTER CLUTCH BACK PRESSURE VALVE RETAINER CLIP CONVERTER CLUTCH BACK PRESSURE VALVE BORE PLUG CONVERTER CLUTCH BACK PRESSURE VALVE CONVERTER CLUTCH BACK PRESSURE VALVE SPRING VARIABLE FORCE SOLENOID 2 MODULATOR VALVE RETAINER CLIP VARIABLE FORCE SOLENOID 2 MODULATOR VALVE BORE PLUG VARIABLE FORCE SOLENOID 2 MODULATOR VALVE VARIABLE FORCE SOLENOID 2 MODULATOR VALVE SPRING INTERMEDIATE SERVO RELEASE VALVE RETAINER CLIP INTERMEDIATE SERVO RELEASE VALVE BORE PLUG INTERMEDIATE SERVO RELEASE VALVE INTERMEDIATE SERVO RELEASE VALVE SPRING HIGH CLUTCH CONTROL VALVE RETAINER PLATE HIGH CLUTCH CONTROL VALVE SPRING HIGH CLUTCH CONTROL VALVE REVERSE MODULATOR VALVE RETAINER CLIP REVERSE MODULATOR VALVE BORE PLUG REVERSE MODULATOR VALVE REVERSE MODULATOR VALVE SPRING REVERSE ENGAGEMENT VALVE RETAINER CLIP REVERSE ENGAGEMENT VALVE BORE PLUG REVERSE ENGAGEMENT VALVE REVERSE ENGAGEMENT VALVE SPRING VARIABLE FORCE SOLENOID 1 MODULATOR VALVE RETAINER CLIP VARIABLE FORCE SOLENOID 1 MODULATOR VALVE BORE PLUG VARIABLE FORCE SOLENOID 1 MODULATOR VALVE VARIABLE FORCE SOLENOID 1 MODULATOR VALVE SPRING 40 41 42 43 44 45 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 74 75 77 78 79 MAIN REGULATOR BOOST VALVE SLEEVE RETAINER CLIP MAIN REGULATOR BOOST VALVE SLEEVE MAIN REGULATOR BOOST VALVE MAIN REGULATOR BOOST VALVE MAIN REGULATOR BOOST VALVE INNER SPRING MAIN REGULATOR BOOST VALVE OUTER SPRING MAIN REGULATOR BOOST VALVE SPRING RETAINER MAIN REGULATOR VALVE CONVERTER LIMIT VALVE RETAINER CLIP CONVERTER LIMIT VALVE BORE PLUG CONVERTER LIMIT VALVE SPRING CONVERTER LIMIT VALVE SOLENOID REGULATOR VALVE RETAINER PLATE SOLENOID REGULATOR VALVE SPRING SOLENOID REGULATOR VALVE MANUAL SHIFT CONTROL VALVE REAR SERVO CONTROL VALVE RETAINER CLIP REAR SERVO CONTROL VALVE BORE PLUG REAR SERVO CONTROL VALVE SPRING REAR SERVO CONTROL VALVE REAR SERVO/INT. SERVO APPLY SELECT VALVE RETAINER CLIP REAR SERVO/INT. SERVO APPLY SELECT VALVE BORE PLUG REAR SERVO/INT. SERVO APPLY SELECT VALVE SPRING REAR SERVO/INT. SERVO APPLY SELECT VALVE FORWARD ENGAGEMENT CONTROL VALVE RETAINER CLIP FORWARD ENGAGEMENT CONTROL VALVE BORE PLUG FORWARD ENGAGEMENT CONTROL VALVE SPRING FORWARD ENGAGEMENT CONTROL VALVE OVERDRIVE SERVO CONTROL VALVE RETAINER PLATE OVERDRIVE SERVO CONTROL VALVE SPRING OVERDRIVE SERVO CONTROL VALVE TCC MODULATOR CONTROL VALVE RETAINER CLIP TCC MODULATOR CONTROL VALVESLEEVE TCC MODULATOR CONTROL VALVE TCC MODULATOR CONTROL VALVE TCC MODULATOR CONTROL VALVE SPRING .250" DIAMETER CHECKBALL .250" DIAMETER CHECKBALL VALVE BODY CASTING Copyright © 2004 ATSG Figure 109 "LEGEND" AUTOMATIC TRANSMISSION SERVICE GROUP 65 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VALVE BODY ASSEMBLY (Cont'd) 8. Ensure that the valve train retainers have been installed in their proper locations, as shown in Figure 110. Note: The numbers in Figure 110 refer to the illustration numbers in the legend on Page 65. 9. Lubricate all installed valve trains with a small amount of Mercon V®, before installing the valve body spacer plate. 10. Install the two .250" Viton checkballs into the locations shown in Figure 110 and 111. 11. Install two valve body spacer plate alignment dowels in the locations shown in Figure 111. 12. Special Note: The valve body spacer plate has bonded gaskets on both sides, and Ford Motor Co. recommends replacement of the spacer plate on all rebuilds. 13. Most aftermarket gasket kits come equipped with new valve body gaskets, but the top and bottom gaskets are different. 14. These new gaskets may be used if you can successfully remove the old gaskets without damage to the spacer plate. 15. Install the new gaskets on the proper sides of spacer plate and place over alignment dowels, or install a new Ford spacer plate assembly, as shown in Figure 111. 16. Install the three spacer plate retaining bolts, as shown in Figure 111, and torque the bolts to 10 Nm (89 in.lb.). 17. Remove the alignment dowels and set the completed valve body assembly aside for the final assembly process. VALVE BODY ASSEMBLY RETAINER AND CHECKBALL LOCATIONS 52 59 60 48 68 64 71 40 36 6 TWO .250" DIAMETER CHECKBALLS 32 21 28 25 17 10 Figure 110 66 AUTOMATIC TRANSMISSION SERVICE GROUP 13 1 Copyright © 2004 ATSG AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VALVE BODY SPACER PLATE AND GASKETS SPACER PLATE RETAINING BOLT (3 REQUIRED) SPACER PLATE RETAINING BOLT (3 REQUIRED) "NEW" SPACER PLATE WITH BONDED GASKETS OR CLEAN PLATE WITH AFTERMARKET GASKETS .250" VITON BALLS (2 REQUIRED) ALIGNMENT DOWEL (2 REQUIRED) ALIGNMENT DOWEL (2 REQUIRED) Copyright © 2004 ATSG Figure 111 AUTOMATIC TRANSMISSION SERVICE GROUP 67 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information REVERSE SERVO ASSEMBLY 1. Disassemble the reverse servo assembly using Figure 113 as a guide. 2. Tabs on the reverse servo cover plate mate with slots in the reverse housing every 120 degrees. 3. Remove reverse servo cover plate by turning in either direction to release. Align the arrow on the cover plate with any slot on the housing, as shown in Figure 112. 4. Inspect all reverse servo parts thoroughly for any wear and/or damage. Note: The reverse servo piston has a molded seal, as shown in Figure 113. Replace the piston assembly as necessary. 5. Remove and discard the reverse servo piston inner "D" ring seal from the servo housing, as shown in Figure 113. 6. Remove and inspect the reverse servo check valve and spring, as shown in Figure 113. "5R55W" REVERSE SERVO COMPONENTS REVERSE SERVO COVER PLATE REVERSE SERVO PISTON RETURN SPRING Continued on Page 69 REVERSE SERVO MOLDED PISTON REMOVE BY ALIGNING ARROW WITH ANY SLOT ON SERVO HOUSING REVERSE SERVO PISTON INNER "D" RING SEAL REVERSE SERVO HOUSING OPEN REVERSE SERVO CHECK VALVE REVERSE SERVO CHECK VALVE SPRING REVERSE SERVO CHECK VALVE RETAINER Copyright © 2004 ATSG Figure 112 68 Copyright © 2004 ATSG Figure 113 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information EARLY DESIGN LATE DESIGN REVERSE SERVO PISTON INNER "D" RING SEAL Do Not use early design "O" ring seal. Replace reverse servo housing as necessary. Figure 114 REVERSE SERVO ASSEMBLY (Cont'd) 7. Install new reverse servo piston inner "D" ring seal into the groove in reverse servo housing, as shown in Figure 114, and lubricate with a small amount of Trans-Jel®. Note: If the original seal was an "O" ring seal (Early Design), replace the reverse servo housing and use the "D" ring seal. Refer to Figure 114 for the cross section. "Do Not" install a "D" ring seal into reverse servo housing designed for the "O" ring seal. 8. Lubricate the reverse servo check valve with Mercon® V, and install in housing, as shown in Figure 115, followed by the spring and the retainer. 9. Lubricate the reverse servo piston with a small amount of Trans-Jel®, and install into reverse servo housing, as shown in Figure 115. Continued on Page 70 REVERSE SERVO MOLDED PISTON REVERSE SERVO HOUSING REVERSE SERVO CHECK VALVE REVERSE SERVO CHECK VALVE SPRING REVERSE SERVO CHECK VALVE RETAINER Copyright © 2004 ATSG Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP 69 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information REVERSE SERVO ASSEMBLY (Cont'd) 10. Install the reverse servo piston return spring in reverse servo housing (See Figure 116). 11. Install the reverse servo cover plate over the return spring, compress the return spring with the cover plate and rotate the tabs into position in the slot, as shown in Figure 117. 12. Caution: The arrow on the cover plate must be aligned evenly between any two slots on the reverse servo housing (See Figure 118). 13. Set the completed reverse servo assembly aside for the final assembly process. REVERSE SERVO COVER PLATE REVERSE SERVO PISTON RETURN SPRING REVERSE SERVO HOUSING REVERSE SERVO PISTON RETURN SPRING Copyright © 2004 ATSG Figure 117 INSTALL BY ALIGNING ARROW ON COVER PLATE BETWEEN ANY TWO SLOTS ON SERVO HOUSING REVERSE SERVO HOUSING OPEN Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 116 70 Figure 118 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information A VERY HEARTY "THANK YOU" TO LEON AUTRY OF A & REDS TRANSMISSION PARTS FOR SUPPLYING US WITH THE TRANSMISSION THAT MADE A & REDS TRANSMISSION PARTS PLEASE FEEL FREE TO CALL TODAY 1 800 835-1007 WE HAVE WHAT YOU NEED FOR "ALL" YOUR TRANSMISSION NEEDS! For Fordd A & REDS Ford TRANSMISSION PARTS WICHITA, KANSAS 2001 APR KANSAS IM-EASY Copyright © 2004 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 71 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information SOLENOID BODY ASSEMBLY "DIFFERNCES" The solenoid bodies are different between the 5R55W/S and the 5R55N transmissions, and they "Will Not" interchange. The solenoid body differences and how to identify between the two, are shown in Figure 119 below. Extra care here when selecting replacement parts, including the solenoid body gasket, will eliminate some of the troublesome problems that may be encountered after installation. "5R55N" SOLENOID BODY "USES" REVERSE PRESSURE SWITCH "5R55W/S" SOLENOID BODY "DOES NOT" USE REVERSE PRESSURE SWITCH Continued in Page 73 11 1 11 1 16 6 16 6 "5R55N" "5R55N" "NOTICE" DIFFERENCE IN WORM TRACKS "NOTICE" DIFFERENCE IN GASKETS "5R55W/S" "5R55W/S" Figure 119 72 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information SOLENOID BODY ASSEMBLY SOLENOID BODY ASSEMBLY 1. The solenoid body is serviced as a complete assembly only, from Ford Motor Company, however the aftermarket gasket sets do come with a new gasket and "O" rings. 2. Remove the worm track plate by prying back the locking tabs (See Figure 121). 3. Remove and discard the solenoid body to worm track plate gasket (See Figure 121). 4. Remove and discard the two solenoid body to case "O" rings, as shown in Figure 121. 5. Ensure that you have the proper gasket for the 5R55W/S, as shown in Figure 120. Refer to Figure 119 for the differences. 6. Install the new solenoid body to worm track plate gasket over the dowels on the solenoid body, as shown in Figure 121. 7. Install the worm track plate over the dowels on the solenoid body, as shown in Figure 121, and snap into position. 8. Install two new solenoid body to case "O" ring seals, as shown in Figure 121. 9. Set the completed solenoid body aside for the final assembly process (See Figure 122). 1 12394 2 3 4 1. 2. 3. 4. SOLENOID BODY WORM TRACK PLATE SOLENOID BODY TO WORM TRACK PLATE GASKET SOLENOID BODY TO CASE "O" RINGS (2 REQUIRED) SOLENOID BODY ASSEMBLY Copyright © 2004 ATSG Figure 121 5R55W/S SOLENOID BODY GASKET COMPLETED SOLENOID BODY ASSEMBLY 12394 Copyright © 2004 ATSG Figure 120 Copyright © 2004 ATSG Figure 122 AUTOMATIC TRANSMISSION SERVICE GROUP 73 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information EXTENSION/4WD ADAPTER HOUSING EXTENSION HOUSING SEAL EXTENSION HOUSING BUSHING EXTENSION HOUSING 2WD MODELS 1. Inspect the 2WD extension housing bushing for any wear and/or damage. 2. Replace the 2WD extension housing bushing as necessary, using the appropriate puller and bushing driver. Use Figure 123 as a guide. 3. Install a new extension housing yoke seal, as shown in Figure 123, using the appropriate seal driver. 4. If you have a 4WD, install new adapter housing seal, as shown in Figure 124, using the proper seal driver. 5. Turn the 2WD extension housing or the 4WD adapter housing over to install the park pawl components, as shown in Figure 125, as the procedure is the same for either model. 6. Install the parking pawl return spring onto the adapter housing, with the leg of the return spring in front of housing shoulder, as shown in Figure 126. 7. Install the parking pawl pivot pin through the center of return spring, as shown in Figure 127. 8. Install the parking pawl over the pivot pin and hook the return spring on the parking pawl, as shown in Figure 128. 9. Set the completed extension housing aside for the final assembly process. Ford ® 1L2P-7A038-AB 4WD ADAPTER HOUSING SEAL Copyright © 2004 ATSG Figure 123 4WD ADAPTER HOUSING 1 Fo rd L2 P7A 03 9- B A Copyright © 2004 ATSG Figure 124 74 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information PARKING PAWL PARKING PAWL PARKING PAWL PIVOT PIN 6 PARKING PAWL RETURN SPRING 4WD ADAPTER HOUSING 6 INSTALL PARKING PAWL PIVOT PIN AS SHOWN THROUGH CENTER OF SPRING Copyright © 2004 ATSG Figure 125 Copyright © 2004 ATSG Figure 127 COMPLETED EXTENSION HOUSING INSTALL PARKING PAWL RETURN SPRING AS SHOWN WITH SPRING LEG IN FRONT OF HOUSING SHOULDER 6 6 INSTALL PARKING PAWL RETURN SPRING AS SHOWN WITH SRING HOOKED ON PARKING PAWL Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 126 Figure 128 AUTOMATIC TRANSMISSION SERVICE GROUP 75 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information TRANSMISSION CASE ASSEMBLY 1. Inspect the transmission case thoroughly for wear, damaged surfaces, or stripped threads. 2. Inspect the rear case caged needle bearing and replace as necessary using the appropriate tools to remove and install (See Figure 131). Note: If replacement is necessary ensure that the sealing ring end of the bearing faces rear, as shown in Figure 131. 3. Install new manual lever seal into case using the appropriate seal driver (See Figure 129). 4. There are two different styles of manual lever design, as shown in Figure 129. 5. Install the manual lever, inside detent lever and park rod assembly, manual lever retaining pin and torque nut to 48Nm (35 ft.lb.). Refer to Figure 130. Note: Do Not allow the wrench to strike the manual valve inner detent lever pin. 6. Install the number 11 thrust washer into rear of case, as shown in Figure 131, and retain with a small amount of Trans-Jel®. Continued on Page 78 MANUAL LEVER RETAINING PIN INSIDE DETENT LEVER PARK ROD Copyright © 2004 ATSG Figure 130 NUMBER ELEVEN THRUST WASHER If Bearing Replacement Is Necessary, Ensure Sealing Ring Faces Rear MANUAL LINKAGE SEAL MANUAL LINKAGE MANUAL LINKAGE RETAINING PIN Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 129 76 Figure 131 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE SERVO COMPONENTS INTERMEDIATE SERVO COMPONENTS INTERMEDIATE SERVO RETURN SPRING OVERDRIVE SERVO RETURN SPRING INTERMEDIATE SERVO PISTON ASSEMBLY OVERDRIVE SERVO PISTON ASSEMBLY INTERMEDIATE SERVO COVER "O" RING SEAL OVERDRIVE SERVO COVER "O" RING SEALS INTERMEDIATE SERVO COVER OVERDRIVE SERVO COVER INTERMEDIATE SERVO COVER SNAP RING OVERDRIVE SERVO COVER SNAP RING Copyright © 2004 ATSG Figure 132 Copyright © 2004 ATSG Figure 133 AUTOMATIC TRANSMISSION SERVICE GROUP 77 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information TRANSMISSION CASE ASSEMBLY (Cont'd) 7. Install the transmission case into the fixture and rotate so that pan surface is facing up, as shown in Figure 134. 8. Install new "O" ring seals into the overdrive servo cover grooves, as shown in Figure 132, and lubricate with small amount of Trans-Jel®. 9. Inspect the molded lip seal on the overdrive servo piston for any wear and/or damage and replace piston assembly as necessary. 10. Lubricate molded seal and the overdrive servo case bore with a small amount of Trans-Jel®, and install return spring on back side, as shown in Figure 132. 11. Install the overdrive servo cover assembly into the case bore, compress the return spring and install the snap ring (See Figure 134). 12. Install new "O" ring seals into the intermediate servo cover grooves, as shown in Figure 133, and lubricate with small amount of Trans-Jel®. 13. Inspect the molded lip seals on the intermediate servo piston for any wear and/or damage and replace piston assembly as necessary. 14. Lubricate molded seals and both intermediate servo cover bores with a small amount of Trans-Jel®. 15. Install the intermediate servo piston into the cover with a twisting motion, until it is fully seated (See Figure 133). 16. Install the servo return spring over the pin on the back side as shown in Figure 133. 17. Install the intermediate servo assembly into the case bore, compress the return spring and install the snap ring (See Figure 134). 18. With these two servo assemblies installed, you are now ready for the final assembly process. SERVOS INSTALLED IN TRANSMISSION CASE OVERDRIVE SERVO INTERMEDIATE SERVO 62 -1 8 CA 0 ord F 6538 R3 T 9 A 0 65419 A R3 Ford GA Copyright © 2004 ATSG Figure 134 78 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information FINAL TRANSMISSION ASSEMBLY INTERNAL COMPONENTS 1. Rotate transmission in fixture so that rear of the case is facing up, as shown in Figure 135. 2. Ensure that the number 11 thrust washer is still in place, as shown in Figure 135. 3. Install the park gear and output shaft, as shown in Figure 135. 4. Install the extension housing gasket, as shown in Figure 136, and retain with a small amount of Trans-Jel®. OUTPUT SHAFT (4WD VERSION SHOWN) Continued on Page 80 PARK GEAR EXTENSION GASKET NUMBER ELEVEN THRUST WASHER Copyright © 2004 ATSG Figure 135 Copyright © 2004 ATSG Figure 136 AUTOMATIC TRANSMISSION SERVICE GROUP 79 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 5. Install the preassembled 4WD adapter housing ensuring that the parking pawl is engaged on the park rod properly (See Figure 137). 6. Install the seven 4WD adapter housing bolts and torque bolts to 39 N•m (29 ft.lb.), as shown in Figure 138. 7. Install the temporary holding strap, as shown in Figure 139, to retain the output shaft in the transmission intill snap ring is installed. Continued on Page 81 RETAINING BOLTS (7 REQUIRED) Fo 1L 2P -7A 03 9-B rd A Fo rd 1L 2P -7A 03 9-B Copyright © 2004 ATSG Figure 138 A 4WD ADAPTER HOUSING CAUTION: INSTALL TEMPORARY HOLDING STRAP AS SHOWN TO RETAIN OUTPUT SHAFT. Fo rd 1L 2P -7A 03 9-B A Copyright © 2004 ATSG Figure 137 80 Copyright © 2004 ATSG Figure 139 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information REAR PLANETARY RING GEAR THRUST BEARING (NO. 10) REVERSE DRUM AND LOW SPRAG ASSEMBLY LOW/REVERSE BAND ASSEMBLY INTERNAL COMPONENTS (Cont'd) 8. Rotate transmission in fixture so that front of case is facing up, as shown in Figure 140. 9. Install the reverse band into transmission, as shown in Figure 140, ensuring that it engages on the band anchor lugs in the case. 10. Compress the reverse band enough to engage the reverse band laver into the notches in the reverse band. 11. Install reverse drum and low sprag assembly into the reverse band, as shown in Figure 140, by rotating in a clock-wise direction untill it falls into position. 12. Install rear planetary ring gear thrust bearing (No. 10) into the case in the direction that is shown in Figure 140. 13. Install the pre-assembled rear planetary ring gear that has the seal ring with the notches in it, as shown in Figure 141, and ensure that it is fully seated against bearing. Continued on Page 82 REAR PLANETARY RING GEAR Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 140 Figure 141 AUTOMATIC TRANSMISSION SERVICE GROUP 81 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 14. Install a new output shaft snap ring onto output shaft, as shown in Figure 142, and ensure that it is fully seated. Note: Ford Motor Company recommends a new snap ring in this location "every time", and after this ring is installed you may now remove the temporary strap. 15. Install the plastic rear lube dam into the ring gear in the direction shown in Figure 142. 16. Install the rear planetary thrust bearing (No. 9) on top of rear ring, in the direction shown in Figure 143, and retain with small amount of Trans-Jel®. 17. Install the rear planetary carrier assembly, as shown in Figure 143, by rotating into position until fully seated. 18. Install the rear planetary carrier snap ring into groove in the reverse drum and ensure that it is fully seated (See Figure 143). Note: Reverse drum must be lifted up to install the snap ring. 19. Install the rear planetary thrust bearing (No. 8) on top of the rear planetary carrier, in direction shown in Figure 143, and retain with a small amount of Trans-Jel®. Continued on Page 83 REAR PLANETARY THRUST BEARING (NO. 8) REAR PLANETARY SNAP RING REAR PLANETARY ASSEMBLY REAR LUBE DAM REAR PLANETARY THRUST BEARING (NO. 9) OUTPUT SHAFT SNAP RING Copyright © 2004 ATSG Figure 142 82 Copyright © 2004 ATSG Figure 143 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 20. Install the "Tall" low/reverse spacer on top of the No. 8 thrust bearing, in the direction shown in Figure 144. 21. Install the input sun gear and shell assembly, as shown in Figure 144. 22. Install the forward planetary carrier with the No. 6 thrust washer, as shown in Figure 145, by rotating into position. Caution: Ensure that snapped in thrust washer is still in position. 23. Install forward planetary carrier thrust bearing (No. 7) in the direction shown in Figure 145, and retain with small amount of Trans-Jel®. 24. Install the forward ring gear and hub, as shown in Figure 145, by rotating into position. 25. Install forward clutch thrust washer (No. 6B), as shown in Figure 145. Continued on Page 84 FORWARD CLUTCH THRUST WASHER (NO. 6B) INPUT SUN SHELL AND SUN GEAR FORWARD RING GEAR AND HUB FORWARD PLANET THRUST BEARING (NO. 7) "TALL" LOW/REVERSE SPACER FORWARD PLANET ASSEMBLY F ord CA 505 D D1 E4A R FXW4 P Copyright © 2004 ATSG Figure 144 Copyright © 2004 ATSG Figure 145 AUTOMATIC TRANSMISSION SERVICE GROUP 83 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 26. Install forward clutch thrust bearing (No 6A) onto the back side of pre-assembled forward clutch drum, in direction shown in Figure 146, and retain with a small amount of Trans-Jel®. 27. Install forward clutch thrust bearing (No 5) on front side of forward clutch drum, in direction shown in Figure 146, and retain with a small amount of Trans-Jel®. 28. Install forward clutch housing, with bearings, as an assembly, as shown in Figure 146. 29. Caution: The thrust bearing (No 4) that goes between direct clutch drum and center support is "Selective" and a measurement must be made before installation. FORWARD CLUTCH THRUST BEARING (NO. 5) 30. Assemble the selective bearing, direct clutch housing and center support, on the bench, as shown in Figure 147. 31. Measure with a dial caliper through the speed sensor hole down to the surface of the direct clutch housing, as shown in Figure 147, and record this as dimension "A". 32. After you have recorded the first measurment, install the pre-assembled direct clutch housing, as shown in Figure 148. 33. Install the number 4 thrust bearing in position on the direct clutch drum, in the direction that is shown in Figure 148. 34. Install the intermediate band into transmission and around the direct clutch housing, as shown in Figure 149. 35. Install the intermediate band struts on each side of the band exactly as shown in Figure 150. Continued on Page 86 FORWARD CLUTCH DRUM ASSEMBLY 0 10 20 1 2 3 4 5 6 7 8 9 1 40 50 60 0 70 1 2 3 4 5 6 7 8 9 AUTO POWER- OFF 00.725 2 mm/in IN 1 2 3 4 5 6 7 8 9 30 FORWARD CLUTCH THRUST BEARING (NO. 6A) M 07 1624 96 3 90 4 100 1 2 3 4 5 6 7 8 9 80 110 120 1 2 3 4 5 6 7 8 9 5 140 150 1 2 3 4 5 6 7 8 9 130 DIAL CALIPER 6 in mm ELECTRONIC DIGITAL C ALIPER CENTER SUPPORT NO. 4 SELECTIVE THRUST BEARING DIRECT CLUTCH HOUSING Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 146 84 Figure 147 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DIRECT CLUTCH "SELECTIVE" THRUST BEARING (NO. 4) INTERMEDIATE BAND "Selective" DIRECT CLUTCH DRUM ASSEMBLY BAND STRUT ADJUST SIDE BAND STRUT SERVO SIDE Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 148 Figure 149 CORRECT INTERMEDIATE BAND STRUT INSTALLATION Small Notch Facing Up Large Notch Facing Down End View End View Faces Up Faces Up Caution: The apply or servo side must have the strut installed that is illustrated above, and installed in the direction shown above. Caution: The adjustment side must have the strut installed that is illustrated above, and installed in the direction shown above. Figure 150 AUTOMATIC TRANSMISSION SERVICE GROUP 85 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 36. Install the center support assembly, ensuring that you align the hole for the center support with the proper passage (See Figure 151). 37. Loosely install the center support retaining bolt as shown in Figure 152. CENTER SUPPORT "TAPERED" SNAP RING Continued on Page 87 CENTER SHAFT THRUST BEARING (NO. 3) CENTER SUPPORT ASSEMBLY M 07 1624 CENTER SUPPORT RETAINING BOLT (20mm LENGTH) 96 Ford 86 A Copyright © 2004 ATSG 6538 R3 T9 0 65419 A R3 Figure 151 CA 0 ord F 8 GA Copyright © 2004 ATSG Figure 152 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) SELECTIVE NO. 4 THRUST BEARING CHART 38. Install the center support snap ring with the opening in the snap ring to the opening in the center support, as shown in Figure 153. 39. Now we must once again measure with the dial caliper through the speed sensor hole down to the surface of the direct clutch housing with all of the parts installed in the case, as shown in Figure 155, and record this as dimension "B". 40. Subtract previously recorded dimension "A" from now recorded dimension "B", and this will give you the rear end clearance. Example: Dimension "B" = .735" Dimension "A" = .725" Difference = .010" 41. Rear end clearance should be .008" to .012". Change the selective No. 4 thrust bearing using the chart in Figure 154, as necessary to arrive at the proper end play. THICKNESS .104" - .110" .111" - .117" .118" - .125" .126" - .132" PART NO. XW4Z-7D014-CA XW4Z-7D014-DA XW4Z-7D014-EA XW4Z-7D014-FA I.D. NOTCHES None One Two Three I.D. NOTCHES Continued on Page 88 Figure 154 MEASURING DIMENSION "B" 0 "TAPERED" SNAP RING 10 20 1 2 3 4 5 6 7 8 9 1 40 50 60 0 70 1 2 3 4 5 6 7 8 9 00.735 2 AUTO POWER- OFF mm/in IN 1 2 3 4 5 6 7 8 9 30 CASE CENTER SUPPORT ASSEMBLY 3 90 4 100 1 2 3 4 5 6 7 8 9 80 110 120 1 2 3 4 5 6 7 8 9 5 140 150 1 2 3 4 5 6 7 8 9 130 DIAL CALIPER 6 Checking For End Clearance Here in mm ELECTRONIC DIGITAL C ALIPER CENTER SUPPORT NO. 4 SELECTIVE THRUST BEARING Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 153 Figure 155 AUTOMATIC TRANSMISSION SERVICE GROUP 87 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) Continued on Page 92 COAST CLUTCH DRUM ADAPTER 4P-7660-A A XW Caution: There are two different overdrive ratios for this unit, 0.75 and 0.71. This will affect the overdrive carrier, overdrive ring gear, overdrive sun gear, overdrive sun gear adapter plate and the coast clutch housing. For overdrive planetary carrier identification refer to Figure 158. For overdrive planetary ring gear identification refer to Figure 159. For overdrive sun gear and sun gear adapter plate identification refer to Figure 160. For the coast clutch housing identification refer to Figure 161. 44. Install the overdrive sun gear into overdrive carrier, as shown in Figure 157, by rotating into position. 45. Install the coast clutch housing adapter plate on overdrive sun gear, as shown in Figure 157, and ensure that it is fully seated. B4X4A 42. Install the center shaft to center support thrust bearing (No. 3) onto the center support, as shown in Figure 156. 43. Install the pre-assembled overdrive carrier and center shaft assembly, as shown in Figure 157, ensuring that it is splined into the forward clutch housing and fully seated. OVERDRIVE SUN GEAR NONE OF THE PARTS LISTED ABOVE ARE COMPATABLE WITH ONE ANOTHER CENTER SHAFT THRUST BEARING (NO. 3) OVERDRIVE CARRIER AND CENTER SHAFT ASSEMBLY Copyright © 2004 ATSG Figure 156 88 Copyright © 2004 ATSG Figure 157 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE PLANETARY CARRIER 0.75 Ratio Overdrive Carrier 25 Tooth Pinion Gears 0.71 Ratio Overdrive Carrier 28 Tooth Pinion Gears Copyright © 2004 ATSG Figure 158 AUTOMATIC TRANSMISSION SERVICE GROUP 89 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE INTERNAL RING GEAR 0.75 Ring Gear 72 Teeth Snap Ring Thickness = .060" Width = .155" 0.71 Ring Gear 94 Teeth Snap Ring Thickness = .050" Width = .194" Copyright © 2004 ATSG Figure 159 90 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information OVERDRIVE SUN GEAR AND ADAPTER PLATE B 4 X X X X AB A X 4 0- X 6 6 X X X 2L2P -7 0.75 Ratio 24 Teeth X B4X4A 4P-7660-A A XW X 0.71 Ratio 38 Teeth Copyright © 2004 ATSG Figure 160 OVERDRIVE SUN GEAR ADAPTER PLATE AND COAST CLUTCH HOUSING 4P-7660-A A XW 4 X X A X X X B 4 X 0.71 Ratio 0.75 Ratio X 2L2 7 66 X X P0-A B B4X4A X X Different Configuration Where Adapter Plate Splines Into The Coast Clutch Housing Copyright © 2004 ATSG Figure 161 AUTOMATIC TRANSMISSION SERVICE GROUP 91 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information COAST CLUTCH DRUM ASSEMBLY XW 4P-7L6 69-AB 09/01 /99 OVERDRIVE BAND BAND STRUT ADJUST SIDE XW 4P-7L6 /9 69-AB 09/01 9 BAND STRUT SERVO SIDE Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 162 Figure 163 CORRECT OVERDRIVE BAND STRUT INSTALLATION Small Notch Facing Up Large Notch Facing Down End View End View Faces Up Faces Up Caution: The apply or servo side must have the strut installed that is illustrated above, and installed in the direction shown above. Caution: The adjustment side must have the strut installed that is illustrated above, and installed in the direction shown above. Figure 164 92 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 50. Install pump gasket onto the pre-assembled oil pump, as shown in Figure 166. 51. Place the "H" gauge with the previously set center rod onto the oil pump in the opposite direction, with the center rod placed over the selective washer, as shown in Figure 166. 52. Measure with a feeler gage between the center rod and selective thrust washer, as shown in Figure 166. 53. Front end clearance should be .012" - .018". Change the selective oil pump thrust washer from the chart below, as necessary, to achieve proper front end clearance. Continued on Page 94 SELECTIVE OIL PUMP THRUST WASHER CHART THICKNESS .066" - .069" .073" - .075" .080" - .082" .087" - .089" .094" - .096" PART NO. I.D. COLOR/NO. XW4Z-7D014-XA Brown/"8" XW4Z-7D014-NA Red/"4" XW4Z-7D014-RA Black/"6" XW4Z-7D014-YA Orange/"9" XW4Z-7D014-ZA Purple/"10" - 7D XW4P 46. Install the pre-assembled coast clutch housing, as shown in Figure 162, by rotating back and forth to engage clutches on hub, until fully seated. 47. Install the overdrive band into transmission and around the coast clutch housing, as shown in Figure 163. 48. Install the overdrive band struts on each side of the band, exactly as shown in Figure 163. Caution: The anchor or adjustment side must have strut installed that is illustrated in Figure 164 and must be installed with the small notch facing the top of transmission. The apply or servo side must also be installed, as shown in Figure 164. 49. Install "H" gauge onto case pump surface and move center rod down to surface on the coast clutch where selective thrust washer rides, as shown in Figure 165. D 0 4 YA MA1 04 3 rd Fo G 5F F or d X W4 P-7L669-AB 09/01/99 PC RF X W 4P -7B 32 5-A A Copyright © 2004 ATSG Figure 165 Copyright © 2004 ATSG Figure 166 AUTOMATIC TRANSMISSION SERVICE GROUP 93 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) OIL PUMP ASSEMBLY RETAINING BOLTS (8 REQUIRED) OIL PUMP ASSEMBLY 54. Install the oil pump to case gasket into case, as shown in Figure 167, and align holes. 55. Lubricate the case bore where the "O" ring rides with a small amount of Trans-Jel®. 56. Install the pre-assembled oil pump assembly into the case, as shown in Figure 167, using care not to damage the pump "O" ring. 57. Install the eight oil pump assembly retaining bolts, and torque to 25Nm (18 ft.lb.), as shown in Figure 168. 58. Rotate the transmission so that the valve body surface is facing up, as shown in Figure 169. 59. Torque the center support retaining bolt down to 11 Nm (100 in.lb.), (See Figure 169). 98 Continued on Page 95 OIL PUMP TO CASE GASKET XW 4P-7L6 69-AB 09/01 /99 TORQUE PUMP BOLTS TO 25 Nm (18 ft.lb.) Copyright © 2004 ATSG Figure 167 94 Copyright © 2004 ATSG Figure 168 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 63. Install new locking nuts on both band adjusting screws, using care not to let the adjusting screw come out, so that the band anchors will not fall out and into transmission (See Figure 170). 64. Adjust the overdrive band by turning adjusting screw in while holding the lock nut. Torque the adjusting screw to 14 Nm (10 ft.lb.) and then back out exactly 2 full turns for W/S models in trucks and 1-1/2 turns for S models in cars. Refer to Figure 170. 65. Adjust intermediate band by turning adjusting screw in while holding the lock nut. Torque the adjusting screw to 14 Nm (10 ft.lb.) and then back out exactly 2 full turns for W/S models in trucks and 1-1/2 turns for S models in cars. Refer to Figure 170. 66. Torque both locking nuts to 54 N•m (40 ft.lb.), while holding adjusting screw. OVERDRIVE BAND ADJUSTING SCREW INTERMEDIATE BAND ADJUSTING SCREW Ford INTERNAL COMPONENTS (Cont'd) Continued on Page 97 Copyright © 2001 ATSG Figure 170 TORQUE CENTER SUPPORT BOLT TO 11 Nm (100 in.lb.) CA 0 ord F 6538 R3 T9 A 0 65419 A R3 Ford 8 GA Copyright © 2004 ATSG Figure 169 AUTOMATIC TRANSMISSION SERVICE GROUP 95 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information DETENT SPRING BOLT "1" REQUIRED (30mm LENGTH) VALVE BODY RETAINING BOLT "1" REQUIRED (45mm LENGTH) VALVE BODY RETAINING BOLTS "18" REQUIRED (40mm LENGTH) DETENT SPRING VALVE BODY RETAINING BOLTS "18" REQUIRED (40mm LENGTH) VALVE BODY RETAINING BOLT "1" REQUIRED (27mm LENGTH) VALVE BODY AND SPACER PLATE ASSEMBLY VALVE BODY ALIGNMENT DOWELS -1 62 CA 0 ord F 6538 A R3 T9 0 65419 A R3 Ford 8 GA Copyright © 2004 ATSG Figure 171 96 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 67. Install the two valve body alignment dowels in the locations shown in Figure 171. 68. Install the pre-assembled valve body and spacer plate, as shown in Figure 171. Caution: Ensure that manual valve is engaged on the inside detent lever properly. 69. There are four different lengths of valve body bolts, as shown in Figure 172. 70. Install the 27mm length bolt finger tight only, in the location shown in Figure 173. 71. Install the 45mm length bolt finger tight only, in the location shown in Figure 173. 72. Install the remaining 18, 40mm length valve body bolts, in locations shown in Figure 173, and finger tighten only at this time. 73. Install the detent spring assembly, as shown in Figure 171, using the only 30mm length bolt, and finger tighten only at this time. VALVE BODY BOLT IDENTIFICATION 8 mm 8 mm Valve Body (1) (27mm) Detent Spring (1) (30mm) Shown Actual Size 8 mm Valve Body (1) (45mm) Continued on Page 99 8 mm Valve Body (18) (40mm) Copyright © 2004 ATSG Figure 172 VALVE BODY RETAINING BOLT "1" REQUIRED (27mm LENGTH) THE REMAINING 18 VALVE BODY BOLTS ARE 40mm LENGTH VALVE BODY RETAINING BOLT "1" REQUIRED (45mm LENGTH) Figure 173 AUTOMATIC TRANSMISSION SERVICE GROUP 97 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information LOW/REVERSE SERVO RETAINING BOLTS (70mm LENGTH) SOLENOID BODY RETAINING BOLTS (63mm LENGTH) SOLENOID BODY RETAINING BOLT (25mm LENGTH) LOW/REVERSE SERVO ASSEMBLY SOLENOID BODY ASSEMBLY -1 62 8 CA 0 F GA ord 6538 R 3 T9 A Ford 0 65419 A R3 Copyright © 2004 ATSG Figure 174 98 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information INTERNAL COMPONENTS (Cont'd) 74. Install the pre-checked solenoid body assembly onto transmission, as shown in Figure 174, and finger tighten only at this time. Caution: Use small amount of Trans-Jel® on solenoid body connector "O" rings to help prevent damage. 75. Install pre-assembled reverse servo assembly onto spacer plate, as shown in Figure 174, and finger tighten only at this time. 76. Torque all of the valve body bolts to 10 N•m (89 in.lb.), beginning in the center and working outward in a circle. 77. Torque all of the solenoid body bolts to 8 N•m (71 in.lb.), using a criss-cross pattern. 78. Torque all of the reverse servo bolts to 10 N•m (89 in.lb.), using a criss-cross pattern. 79. Install new filter seals on new filter and install filter assembly, as shown in Figure 175. 80. Torque both filter bolts to 10 N•m (89 in.lb.). 81. Install new pan gasket onto transmission case, as shown in Figure 176. Note: The bottom pan gasket is reuseable. Clean and inspect the gasket for damage, and if it is not damaged, it may be re-used. 82. Install the bottom pan assembly and the sixteen bottom pan bolts, as shown in Figure 176, and torque pan bolts to 11 N•m (8 ft.lb.) using the criss-cross pattern. 83. Rotate transmission in fixture so that the rear is facing up, as shown in Figure 177. 84. Remove the output shaft holding strap if you have not already done so (See Figure 177). Continued on Page 100 PAN BOLTS (16 REQUIRED) OIL FILTER RETAINING BOLTS (82mm LENGTH) PAN GASKET -1 62 -1 62 CA 0 6538 A Ford A 6540 19 A R3 R3 T9 ord F 6538 R3 T9 Ford 6540 19 A R3 8 GA CA 0 ord F 8 GA Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 175 Figure 176 AUTOMATIC TRANSMISSION SERVICE GROUP 99 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information TWO WHEEL DRIVE ASSEMBLY 1. Inspect and replace extension housing bushing as necessary using the proper removal tool and bushing driver (See Figure 178). 2. Install a new extension housing yoke seal, as shown in Figure 178, using the proper driver. 3. Install a new extension housing gasket onto the case, as shown in Figure 179. 4. Install the completed extension housing onto the transmission, as shown in Figure 179. 5. Install the seven extension housing bolts, as shown in Figure 179. Note: The extension housing bolts for the 2WD version are longer than the 4WD adapter housing bolts (See Figure 180). 6. Torque the extension housing bolts down to 26 N•m (19 ft.lb.), as shown in Figure 181. EXTENSION HOUSING SEAL Continued on Page 102 TEMPORARY BRACKET EXTENSION HOUSING BUSHING EXTENSION HOUSING 2WD MODELS Fo rd 1L 2P - 7A 03 9 -B A Ford ® 1L2P-7A038-AB Copyright © 2004 ATSG Figure 177 100 Copyright © 2004 ATSG Figure 178 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 10 mm 10 mm 1 SFT 8.8 SFT 8.8 SFT 8.8 SFT 8.8 SFT 8.8 SFT 8.8 Shown Actual Size SFT 8.8 Ford ® 1L2P-7A038-AB 4WD Adapter Housing (7) (29mm) 2WD Extn Housing (7) (44mm) Copyright © 2004 ATSG 2 Figure 180 3 SFT 8.8 SFT 8.8 Ford ® 1L2P-7A038-AB SFT 8.8 1. EXTENSION HOUSING BOLTS (7 REQUIRED). 2. 2WD EXTENSION HOUSING. 3. EXTENSION HOUSING GASKET. Copyright © 2004 ATSG Figure 179 SFT 8.8 Copyright © 2004 ATSG Figure 181 AUTOMATIC TRANSMISSION SERVICE GROUP 101 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information A 93-A AL UTR NE F2 F7TP-7 Ford Most DTR Sensors Have Neutral Marks Manual Lever rd Fo Manual Lever Nut 0061 TR 1 L 2 P- 7 F 2 9 3 -A A d Fordr U NE AL Digital Transmission Range Sensor Retaining Bolts Copyright © 2004 ATSG Figure 182 EXTERNAL COMPONENTS 1. Place the manual lever in the neutral position and install the Digital Transmission Range sensor, as shown in Figure 182. 2. Install the two DTR retaining bolts finger tight at this time (See Figure 182). 3. Install the adjustment gage and tighten the two DTR bolts by alternating from side to side, and torque to 10 Nm (89 in.lb.). Continued on Page 103 Intermediate Shaft Speed Sensor Output Shaft Speed Sensor 1 L 2 P- 7 F 2 9 3 -A A 0061 NE UT RA L Turbine Shaft Speed Sensor Figure 183 102 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2004 ATSG AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information EXTERNAL COMPONENTS (Cont'd) 4. Install the outer manual control lever and nut, torque nut to 48 N•m ( 35 ft.lb.). 5. Install a new "O" ring on turbine speed sensor and install into case in the location, as shown in Figure 183. Note: Use Figure 184 to identify the three speed sensor assemblies, and use the chart on Page 17 for proper Ohms readings. 6. Install a new "O" ring on the intermediate shaft speed sensor and install into case in the location shown in Figure 183. Note: Use Figure 184 to identify the three speed sensor assemblies, and use the chart on Page 17 for proper Ohms readings. 7. Install a new "O" ring on output shaft speed sensor and install in case in the location shown in Figure 183. Note: Use Figure 184 to identify the three speed sensor assemblies, and use the chart on Page 17 for proper Ohms readings. 8. Torque all three speed sensor retaining bolts to 10 Nm (89 in.lb.). 9. Check and ensure that both oil pressure plugs are tight, as shown in Figure 185. Continued on Page 104 Fo rd Line Pressure Tap (Pressure Control Solenoids "A" And "B") Turbine And Output Shaft Speed Sensor Ford XW4P-7H 103 AA C 4P-A XW B RJL 361 004 C17 BD-9 Intermediate Shaft Speed Sensor XW4P-7M 103 AA RJ L-B 00 43 61 Pressure Control Solenoid "C" Pressure Tap Copyright © 2004 ATSG Figure 184 Figure 185 AUTOMATIC TRANSMISSION SERVICE GROUP 103 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Short Spline End Into Transmission Copyright © 2004 ATSG Figure 186 EXTERNAL COMPONENTS 9. Install the input shaft into the transmission, as shown in Figure 186. Caution: The splines on input shaft are not the same length on both ends. The end with the shorter splines goes into transmission, as shown in Figure 186. 10. Remove form bench fixture and remove the universal transmission fixture. SPECIAL NOTE: THIS UNIT REQUIRES MERCON® V. AUTOMATIC TRANSMISSION SERVICE GROUP 1 L 2 P- 7 F 2 9 3 -A A 104 0061 CONGRATULATIONS! YOU ARE FINISHED. N EU TR AL AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information BOLT CHART 30 Torx 8 mm 8 mm 8 mm 8 mm Pan Bolts (16) (19mm) DTR Sensor (2) (25mm) Valve Body (1) (27mm) Detent Spring (1) (30mm) 30 Torx 30 Torx 30 Torx 8 mm Valve Body (1) (45mm) 30 Torx 8 mm 8 mm Valve Body (18) (40mm) 40 Torx Rev Servo (4) (68mm) 10 mm Speed Sensors (3) (19mm) Spacer Plate (3) (20mm) 8 mm Filter (2) (60mm) 10 mm 10 mm Center Support (1) (20mm) Solenoid Body (1) (25mm) Stator To Pump Body (6) (35mm) Solenoid Body (7 Req.) (63mm) Pump to Case (8) (32mm) 4WD Adapter Housing (7) (29mm) 2WD Extn Housing (7) (44mm) Copyright © 2004 ATSG Figure 187 AUTOMATIC TRANSMISSION SERVICE GROUP 105 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information SPECIAL SERVICE TOOLS FORD OR "ROTUNDA" PART NUMBERS ARE REFERENCED IMPACT SLIDE HAMMER 100-001 (T50T-100-A) OIL PUMP ALIGNMENT TOOL 307-S039 (T74P-77103-X) OUTPUT SHAFT FLANGE INSTALLER 307-404 PUMP GEAR "O" RING SIZER 307-338 (T95L-700-10-G) SERVO COVER COMPRESSOR 307-402 DIAL INDICATOR 100-002 (TOOL-4201-C) INT CUSHION SPRING COMPRESSOR 307-401 TRS ALIGNMENT TOOL 307-351 (T97L-70010-A) OIL PUMP ALIGNMENT DOWELS 307-399 RETAINING RING PLIERS 307-343 (T95P-77001-AHR) DEPTH MICROMETER 303-D206 (D8OP-4201-A) OUTPUT SHAFT BEARING INSTALLER 307-348 (T97T-77110-A) VALVE BODY GUIDE PIN (.248") 307-334 (T95L-70010-C) (2 REQUIRED) BEARING REMOVER 308-047 (T77F-1102-A) OUTPUT FLANGE INSTALLER 205-479 BAND ADJUSTMENT TOOL 307-S022 (T71P-77370-A) Copyright © 2004 ATSG Figure 188 106 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information SPECIAL SERVICE TOOLS FORD OR "ROTUNDA" PART NUMBERS ARE REFERENCED EXTENSION HOUSING SEAL INSTALLER 307-038 (T74P-77052-A) COAST AND DIRECT CLUTCH INNER LIP SEAL PROTECTOR 307-049 (T74P-77404-A) FORWARD CLUTCH INNER LIP SEAL PROTECTOR 307-051 (T74P-77548-A) FORWARD CLUTCH OUTER LIP SEAL PROTECTOR 307-052 (T74P-77548-B) FRONT PUMP SEAL INSTALLER 307-349 (T97T-77000-A) AIR TEST PLATE 307-405 FRONT PUMP REMOVAL TOOL 307-397 UNIVERSAL PULLER 307-001 (TOOL-1175-AC) A very acceptable alternative for this tool is available from Trans-Tool in San Antonio and is universal so it works on many other models. Their part number is T-0033. OUTPUT FLANGE REMOVAL TOOL 307-408 Copyright © 2004 ATSG Figure 189 AUTOMATIC TRANSMISSION SERVICE GROUP 107 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information TORQUE SPECIFICATIONS Description Pump Stator To Pump Cover ................................................................... Spacer Plate Retaining Bolts ................................................................... Inside Detent Lever Nut ........................................................................... Oil Pump To Case Bolts ........................................................................... Center Support Bolt ................................................................................ Valve Body Bolts ..................................................................................... Valve Body Cover Bolts ........................................................................... Solenoid Body Bolts ............................................................................... Reverse Servo Bolts ................................................................................ Filter Bolts .............................................................................................. Bottom Pan Bolts .................................................................................... Extension Housing Bolts ......................................................................... Output Flange Retaining Nut .................................................................. Transmission Range Sensor .................................................................... Outer Manual Shift Lever Nut ................................................................. Speed Sensors ......................................................................................... Nm 25 10 48 25 11 10 10 8 10 10 11 39 131 10 48 10 In.Lb. Ft.Lb. 18 89 35 18 100 89 89 71 89 89 100 29 97 89 35 89 Figure 190 FORD 5R55N VERSUS 5R55W TRANSMISSION DIFFERENCES The Ford Motor Companys 5R55N (Non Sync.) transmission first appeared in the 2000 Lincoln "LS" and some of the Jaguar Models, which we are already somewhat familiar with. Beginning at the start of production for model year 2002, Ford has introduced the 5R55W (Wide Ratio) transmission into the some 4WD models of the Ranger and Explorer, and the 5R55S (Sync) transmission into some of the 2WD Ranger/Explorer and the 2004 Thunderbird. The internal parts look almost identical, but will not interchange with their look alikes in the 5R55N transmission. The information in this bulletin will help you in getting the proper replacement parts back into the proper unit. Externally these transmissions are easy to identify and we have provided illustrations of both transmissions in Figure 191. Figure 192 is an illustration of the two different turbine shafts. They are identical in every respect except for the overall length. Figures 193 and 194 show you the differences in the overdrive sun gear and drive plate. Notice the differences in the tooth count on the sun gear. Figures 195 and 196 are illustrations of the two different coast clutch housings. Notice that the slots to accept the tabs on the adapter plate are narrower and angled to the left at a very slight angle. This means that it will engage into the coast clutch housing in only one direction. Continued on next Page 109 108 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2004 ATSG AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Figure 197 illustrates the internal components of the forward clutch housing for the 5R55N. Figure 198 illustrates the internal components of the forward clutch housing for the 5R55W/S. The only difference in the empty forward clutch housings is the champfer in the 5R55W/S is wider. Figure 199 is illustrations of the two different, completed forward clutch housing assemblies. Notice that the only visible difference is the piston and the return spring retainer. Figure 200 and 201 are illustrations of the two different forward planetary carriers and the two different forward planetary internal ring gears. Notice the different tooth count on the planetary carrier pinions and the different tooth counts on the forward internal ring gear. Figure 202 and 203 are illustrations of the two different sun gear and shell assemblies. Notice that the 5R55N uses an intermediate sprag and the 5R55W/S does not. This required a taller spacer as shown in Figure 203. Notice also the difference in tooth count of the forward sun gear, but the rear sun gear remains the same. Figure 204 shows 3 dimensional illustrations of the two different valve body assemblies. The most noticeable difference is the 5R55W/S does not use a cover plate. The bolt pattern however, is exactly the same as the 5R55N transmission. Figure 205 shows illustrations of the two different valve body assemblies in the worm track area, different amount of checkballs and the locations, and the retainer locations for both valve bodies. Figure 206 is illustrations of the two different valve body spacer plates. One hole location for the spacer plate retaining bolts has changed to help prevent you from a mis-match. Figure 207 and 208 are illustrations of the two different reverse servo housings. Notice that the 5R55W/S transmission has two feed holes in the housing, has a larger diameter for the inner piston seal, and has a different reverse servo check valve. Figure 209 is illustrations of the two different reverse servo return springs. Notice the difference in the spring dimensions. Figure 210 is illustrations of the two different of the two different reverse servo pistons. Notice the difference in the outside diameter of the body, to accommodate the larger diameter in the housing. Figures 211 and 212 are illustrations of the two different intermediate servo covers and the intermediate servo pistons. CAUTION: NONE OF THE COMPONENTS LISTED ABOVE WILL INTERCHANGE BETWEEN THESE TWO SIMILAR TRANSMISSIONS AUTOMATIC TRANSMISSION SERVICE GROUP 109 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 5R55N 5R55W/S (4WD Version Shown) Ford 0061 NE UT RA 1 L 2 P- 7 F 2 9 3 -A A rd Fo Ford L rd Fo Copyright © 2004 ATSG Figure 191 TURBINE SHAFT DIFFERENCES "5R55N" Turbine Shaft "5R55W/S" Turbine Shaft .200" Longer Copyright © 2004 ATSG Figure 192 110 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 4P-7660-A A XW X X A 4 X X X B 4 X 2 66 0-A B4X4A X X B 4P-7660-A A XW 7 X X X L2P - "5R55N", "5R55W/S" Overdrive Sun Gear 38 Teeth "5R55N", "5R55W/S" Overdrive Sun Gear 24 Teeth 4 X A X X X B 4 X X 6 X -7 X X 2L2P 6 0- AB X B4X4A X Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 193 Figure 194 5R55N OVERRUN DRUM 5R55W/S OVERRUN DRUM 4 X X A X X X X B 4 4P-7660-A A W X X 2L2 66 0-A B X X B4X4A Figure 195 7 X X P- Copyright © 2004 ATSG Copyright © 2004 ATSG Figure 196 AUTOMATIC TRANSMISSION SERVICE GROUP 111 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 5R55N FORWARD CLUTCH COMPONENTS Cushion Plate Forward Clutch Aluminum Piston Return Spring Retainer Return Springs (15 Required) Forward Clutch Aluminum Piston Forward Clutch Housing Forward Clutch Housing Copyright © 2004 ATSG Figure 197 112 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 5R55W/S AND LATE 5R55N FORWARD CLUTCH COMPONENTS Return Spring Assembly Stamped Steel, Molded Rubber Forward Clutch Piston Forward Clutch Housing Copyright © 2004 ATSG Figure 198 COMPLETED "5R55N" FORWARD CLUTCH HOUSING COMPLETED "5R55W/S" FORWARD CLUTCH HOUSING Copyright © 2004 ATSG Figure 199 AUTOMATIC TRANSMISSION SERVICE GROUP 113 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 5R55N FORWARD PLANETARY 5R55W/S FORWARD PLANETARY 85 Teeth 101 Teeth 85 Teeth 101 Teeth 19 Tooth Pinions 23 Tooth Pinions D1 E4A RF1 L 2P- 7 D 0 5 5- D A ord F CA 505 D d For D 2 V0 A R FXW4 P Copyright © 2004 ATSG Figure 200 114 Copyright © 2004 ATSG Figure 201 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information 5R55N SUN SHELL 5R55W/S SUN SHELL Requires "Short" Spacer 27 Tooth Sun Gear Requires "Tall" Spacer 27 Tooth Sun Gear Requires Sprag Does Not Use Sprag Requires Bearing 47 Tooth Sun Gear No Bearing (Has Bushing) 55 Tooth Sun Gear Copyright © 2004 ATSG Figure 202 Copyright © 2004 ATSG Figure 203 AUTOMATIC TRANSMISSION SERVICE GROUP 115 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information VALVE BODY COMPARISON "5R55N" VALVE BODY ASSEMBLY "5R55W/S" VALVE BODY ASSEMBLY Copyright © 2004 ATSG Figure 204 "5R55N" VALVE BODY WORM TRACKS "Three" .250" Check Balls "5R55W/S" VALVE BODY WORM TRACKS "Two" .250" Check Balls Copyright © 2004 ATSG Figure 205 116 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information "5R55N" SPACER PLATE "5R55W/S" SPACER PLATE Copyright © 2004 ATSG Figure 206 "5R55N" REVERSE SERVO HOUSING FEED HOLE TO SERVO AND VALVE SMALLER DIAMETER "5R55W/S" REVERSE SERVO HOUSING LARGER DIAMETER FEED HOLE TO SERVO FEED HOLE TO VALVE REVERSE SERVO HOUSING REVERSE SERVO HOUSING REVERSE SERVO CHECK VALVE REVERSE SERVO CHECK VALVE REVERSE SERVO CHECK VALVE SPRING REVERSE SERVO CHECK VALVE SPRING REVERSE SERVO CHECK VALVE RETAINER FREE LENGTH = 1.472" SPRING DIAMETER = .450" WIRE DIAMETER = .037" REVERSE SERVO CHECK VALVE RETAINER FREE LENGTH = 1.625" SPRING DIAMETER = .332" WIRE DIAMETER = .041" Copyright © 2004 ATSG Figure 207 Copyright © 2004 ATSG Figure 208 AUTOMATIC TRANSMISSION SERVICE GROUP 117 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information REVERSE SERVO RETURN SPRING COMPARISON Wire Diameter = .123" Approximately 7.375" Free Length Wire Diameter = .134" Approximately 6.312" Free Length "5R55N" SERVO SPRING "5R55W/S" SERVO SPRING Copyright © 2004 ATSG Figure 209 REVERSE SERVO PISTON COMPARISON Approximately .125" Difference In Overall Height Approximately 1.395" Outside Diameter Approximately 1.870" Outside Diameter "5R55N" SERVO PISTON "5R55W/S" SERVO PISTON Copyright © 2004 ATSG Figure 210 118 AUTOMATIC TRANSMISSION SERVICE GROUP AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information "5R55N" INTERMEDIATE SERVO COMPONENTS "5R55W/S" INTERMEDIATE SERVO COMPONENTS INTERMEDIATE SERVO RETURN SPRING INTERMEDIATE SERVO RETURN SPRING INTERMEDIATE SERVO PISTON ASSEMBLY INTERMEDIATE SERVO PISTON ASSEMBLY INTERMEDIATE SERVO COVER "O" RING SEALS INTERMEDIATE SERVO COVER "O" RING SEAL INTERMEDIATE SERVO COVER INTERMEDIATE SERVO COVER INTERMEDIATE SERVO COVER SNAP RING INTERMEDIATE SERVO COVER SNAP RING Copyright © 2004 ATSG Figure 211 Copyright © 2004 ATSG Figure 212 AUTOMATIC TRANSMISSION SERVICE GROUP 119 AKPPHELP.RU Руководство по ремонту АКПП Technical Service Information Notes 120 AUTOMATIC TRANSMISSION SERVICE GROUP