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Transaxle

Thrust Bearing/Washer Locations

1. Use Driver Handle T80T-4000-W and Bearing Cup Replacer T77F-1217-B to install the bearing cup into the converter housing.

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Driver Handle T80T-4000-W

Bearing Cup Replacer T77F-1217-B

Shim Selection Set T88C-77000-JF

Shim Gauge Adapter Ring T90P-7025-AH

Differential Rotator T90P-7025-BH

Valve Body Guide Pins T80L-77100-A

Turbine Shaft Holder T88C-77000-KH

Clutch Housing Alignment Adapter T75L-4201-A

Converter Seal Replacer T88C-77000-BH

Item Part Number Description

1 7F241 Planet Gear Thrust Bearing

7D014 Thrust Washer

2 7D234 Thrust Bearing

3 7A623 One-Way Overrunning Clutch Bearing



7F368 Planet Gear Bearing Thrust Washer

6 7D234 Thrust Bearing

7 7F404 Thrust Bearing

of 151996 Escort/Tracer

8/9/2010http://www.fordtechservice.dealerconnection.com/pubs/content/~WSTF/~MUS~LEN/19/S...

2. Place the differential (4026) into the converter housing.

3. Place six Collars (part of T88C-77000-JF) on the converter housing at the positions shown.

4. Place the rear bearing cup over the differential bearing (4221).

5. Place Shim Selection Gauge (part of T88C-77000-JF) and Shim Gauge Adapter Ring T90P-7025-AH on the output gear. Turn the two halves of the gauge to eliminate any gap between them.

6. Place the transaxle case on the collars, then install six collar Bolts and Washers (part of T88C-77000-JF). Tighten the collar bolts to 19-26 Nm (14-19 lb-ft).

7. Use Rods (part of T88C-77000-JF) to unthread the gauge halves until the free play is removed and the bearing cup is seated. Then thread the gauge halves back together.


1 — Shim Selection Gauge (Part of T88C-77000-JF)

2 T90P-7025-AH Shim Selection Adapter Ring

3 4026 Differential

4 7005 Converter Housing

5 — Collar (Part of T88C-77000-JF) (6 Req'd)


1 — Rod (Part of T88C-77000-JF)



8. NOTE: Read the preload when the differential starts to turn.

Engage Torque Adapter T90P-7025-BH and attach a torque wrench to the adapter. Measure the drag on the differential bearing.

9. Turn the gauge using the rods until a reading of 0.5 Nm (4.3 lb-in) is obtained on the torque wrench.

10. Use a feeler gauge to measure the gap between the two halves of the shim selection gauge. Measure the gap at four spots at 90 degree intervals. Use the largest measurement.

11. NOTE: Use no more than three shims.

Add 0.3mm (0.0118 inch) to the largest measurement. Select the shim(s) closest (or slightly larger) to this final value from the following chart.

12. Remove the bolts, washers, transaxle case, gauge, and bearing cup.

13. Use Driver Handle T80T-4000-W and Bearing Cup Replacer T77F-1217-B to install the selected shim(s) and bearing cup into the transaxle case.

2 — Washer (Part of T88C-77000-JF)

3 7005 Transaxle Case

4 — Bolt (Part of T88C-77000-JF) (6 Req'd)

DIFFERENTIAL SHIM (THICKNESS)

mm (inch) mm (inch)

0.500 (0.020) 1.000 (0.039)

0.525 (0.021) 1.025 (0.040)

0.550 (0.022) 1.050 (0.041)

0.575 (0.023) 1.075 (0.042)

0.600 (0.024) 1.100 (0.043)

0.625 (0.025) 1.125 (0.044)

0.650 (0.026) 1.150 (0.045)

0.675 (0.027) 1.175 (0.046)

0.700 (0.028) 1.200 (0.047)

0.725 (0.029) 1.225 (0.048)

0.750 (0.030) 1.250 (0.049)

0.775 (0.031) 1.275 (0.050)

0.800 (0.031) 1.300 (0.051)

0.825 (0.032) 1.325 (0.052)

0.850 (0.033) 1.350 (0.053)

0.875 (0.034) 1.375 (0.054)

0.900 (0.035) 1.400 (0.055)

0.925 (0.036) 1.425 (0.056)

0.950 (0.037) 1.450 (0.057)

0.975 (0.038)



14. Install the transaxle case. Tighten the transaxle case-to-converter housing bolts to 37-52 Nm (27-38 lb-ft).

15. Measure the bearing preload. The preload should be 2.9-3.9 Nm (26-35 lb-in). Repeat the gauging process if the preload measurement is not within specification.

16. When the proper preload specification has been obtained, remove the transaxle case.

17. Use Valve Body Guide Pins T80L-77100-A to align the torque converter stator support. Use Step Plate D80L-630-6 or equivalent to press the torque converter stator support into the converter housing.

18. Install the eight torque converter stator support bolts. Tighten the torque converter stator support bolts to 11-14 Nm (8-10 lb-ft).

19. Install the idler gear (7F475) and output gear as an assembly by lightly tapping them in with a hammer.

20. Install the bearing housing onto the converter housing.

21. Align the groove on the idler gear shaft (7F358) with the mark on the bearing housing.

22. Install the eleven bearing housing bolts and tighten to 19-26 Nm (14-19 lb-ft).



23. Tap a new roll pin into the bearing housing using a 5/32-inch pin punch and hammer.

4EAT Shift Linkage



2 7A441 Parking Pawl

3 7D070 Parking Pawl Return Spring

4 — Clip

5 7D071 Parking Pawl Shaft

6 7A256 Manual Control Lever

7 7D417 Parking Plate Torsion Spring

8 7C495 Park Lever Plate

9 7D414 Parking Rod Support Plate

10 — Parking Rod Support Plate Bolt

11 7A121 Park Actuator Support

12 7A232 Parking Lever Actuating Rod

13 7Z037 Washer

14 — Manual Control Lever Nut

15 7A115 Manual Valve Detent Lever

16 — Support Bolts

17 7G101 Support

A — Tighten to 7.8-11 Nm (69-95 Lb-In)



24. Install the parking pawl return spring (7D070) and snap clip.

25. Install the parking pawl (7A441) and parking pawl shaft (7D071).

26. Install the support (7G101) with new bolts. Tighten the support bolts to 11-14 Nm (8-10 lb-ft).

27. Install the park lever plate (7C495) and parking plate torsion spring (7D417).

28. Install the park actuator support (7A121) and the parking lever actuating rod (7A232) as an assembly.

29. Install the parking rod support plate (7D414) and bolt. Tighten the parking rod support plate bolt to 7.8-11 Nm (69-95 lb-in).

30. Install the manual control lever (7A256).

B — Tighten to 41-55 Nm (30-41 Lb-Ft)

C — Tighten to 11-14 Nm (8-10 Lb-Ft)



31. Install the manual valve detent lever (7A115), washer, and manual control lever nut securing the manual control lever. Tighten the manual control lever nut to 41-55 Nm (30-41 lb-ft).

32. Install the differential.

33. Install the front sun shell (7D064) to the output shaft.

34. Apply a thin coat of silicone sealant to the contact surfaces of the converter housing and transaxle case.

35. Install new O-rings onto the oil passage ports.

36. Attach the transaxle case to the converter housing and install the thirteen transaxle case-to-converter housing bolts. Tighten the transaxle case-to-converter housing bolts to 37-52 Nm (27-38 lb-ft).

37. If necessary, assemble the 3-4 clutch. Refer to the 3-4 Clutch Assembly procedure in this section.

38. Install Turbine Shaft Holder T88C-77000-KH on the transaxle to keep the turbine shaft (7F351) in position during assembly.

39. Assemble the turbine shaft and 3-4 clutch assembly.

40. NOTE: The converter turbine shaft seal (7N243) shou ld be installed on the inner groove of the turbine shaft.

Position the thrust bearing between the 3-4 clutch assembly and the front sun shell.



41. Install the turbine shaft and the 3-4 clutch assembly into the transaxle case.

42. NOTE: Install the ring gear (7A153) with the extern al gear side down.

Install the ring gear into the 3-4 clutch assembly.

43. Install the clutch pressure plate retainer snap ring (7A577).

44. Position the thrust bearing between the carrier hub assembly and the 3-4 clutch cylinder (7F283).

45. Hold the turbine shaft with one hand to keep it from rotating while installing the carrier hub.

46. Install the carrier hub into the 3-4 clutch cylinder by rotating it to align the carrier hub with the 3-4 clutch pack.

47. Install the low/reverse clutch pack.

The order of installation is as follows:

1. Low/reverse external spline clutch plate 2. Low/reverse internal spline clutch plate 3. Low/reverse external spline clutch plate 4. Low/reverse internal spline clutch plate 5. Low/reverse external spline clutch plate 6. Low/reverse internal spline clutch plate 7. Low/reverse external spline clutch plate 8. Low/reverse internal spline clutch plate

48. Install the low/reverse clutch pressure plate.

49. Install the low/reverse clutch pressure plate retainer snap ring.

50. Install the one-way clutch thrust washer (7G400).



51. CAUTION: The one-way clutch (7A089) can be install ed improperly. Be certain that after installing the one-way clutch, you can rotate the carrier by hand in a counterclockwise direction while working from the r ear side of the transaxle. If the one-way clutch is installed improperly, gear ranges may not function or the geartrain may lock up. This may cause overheating of the tran saxle and unnecessary overhauling of the unit.

Install the one-way clutch horizontally. Rotate the carrier counterclockwise while installing the one-way clutch.

52. Install the clutch pressure plate retainer snap ring (7D483).

53. Install the servo band lever (7330) and the 2-4 band actuating lever shaft into the transaxle case.

54. Install the 2-4 band into the transaxle case so it is fully expanded.

55. Interlock the 2-4 band and the servo band lever as shown.

56. Install the spacer onto the servo piston stem.

57. Install the new servo piston small seal (7D025) and the new servo piston large seal (7D024) onto the servo band piston (7D022) and the servo piston cover seal (7D026) onto the 2-4 band servo retainer. Apply a liberal coat of Motorcraft Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent Mercon® Fluid to the seals.


1 7D022 Servo Band Piston

2 7D024 Servo Piston Large Seal

3 7D028 Servo Piston Spring


5 7D190 Servo Piston Stem

6 7D300 Spacer

7 — Clip

8 7D027 2-4 Band Servo Retainer

9 7D026 Servo Piston Cover Seal

10 7D025 Servo Piston Small Seal



58. Install the servo band piston onto the servo piston stem.

59. Install the clip onto the servo piston stem.

60. Install the 2-4 band servo retainer onto the servo band piston.

61. Install the servo piston spring (7D028) onto the servo piston stem.

62. NOTE: Be sure the piston stem seats properly with t he 2-4 band.

Install the servo assembly and servo piston spring into the transaxle case.

63. Compress the servo assembly into its bore and install the servo piston retaining snap ring (7381).

64. Install Dial Indicator Bracketry D78P-4201-F, Dial Indicator D78P-4201-G or equivalent, and Clutch Housing Alignment Adapter T75L-4201-A onto the transaxle case.

65. Apply 393 kPa (57 psi) of compressed air to the third fluid passage beneath the throttle control lever (9A776) as shown.

66. The 2-4 servo piston stem should move 1.0-1.7mm (0.0394-0.0669 inch). If not within specification, select the correct length stem from the following chart.

67. Install the selected piston stem and recheck.

2-4 SERVO PISTON STEM LENGTH

95.0mm (3.740 inch)

95.5mm (3.760 inch)

96.0mm (3.780 inch)

96.5mm (3.799 inch)

97.0mm (3.819 inch)

97.5mm (3.839 inch)

98.0mm (3.858 inch)

98.5mm (3.878 inch)

99.0mm (3.898 inch)



68. Assemble the primary sun gear (7A399) and one-way clutch with the forward and reverse clutch drum assembly.

69. Position the planet gear thrust bearing (7F241) and the planet gear bearing thrust washer (7F368) between the carrier hub assembly and the primary sun gear and one-way clutch assembly.

70. Install the rear sun gear, one-way clutch, and forward and reverse clutch drum assembly using screwdrivers to spread open the 2-4 band as shown.

71. Rotate the rear sun gear, one-way clutch, and forward and reverse clutch drum assembly to line up to the clutch pack and gears.

72. Install a new turbine shaft snap ring into the bottom groove of the turbine shaft.

73. Remove Turbine Shaft Holder T88C-77000-KH from the transaxle.

74. NOTE: If clearance is greater than 0.9mm (0.035 inc h), recheck/reassemble clutch pack(s) as needed.

Measure the height difference between the reverse clutch drum (7D044) and the transaxle case. Maximum clearance should be 0.9mm (0.035 inch).

75. To adjust the total end play, set the planet gear thrust bearing onto the reverse clutch drum.

76. Remove the previously used thrust washer (7D014) and oil pump gasket (7A136) located on the oil pump.

77. Set the thickest thrust washer, 2.2mm (0.087 inch), on the oil pump.

78. Set the oil pump onto the clutch assembly.

79. Use a feeler gauge to measure the clearance between the transaxle case and the oil pump.



80. Select a suitable thrust washer from the following chart.

81. Remove the oil pump.

82. NOTE: Use petroleum jelly to hold the planet gear t hrust bearing and thrust washer in position.

Place the selected thrust washer, the planet gear thrust bearing, and a new oil pump gasket onto the oil pump.

83. Install the oil pump onto the clutch assembly. Secure it with the ten oil pump-to-transaxle case bolts. Tighten the oil pump-to-transaxle case bolts to 19-26 Nm (14-19 lb-ft).

84. Install a new O-ring onto the throttle valve control actuating cable bracket and insert the throttle valve control actuating cable (7F042) into the transaxle.

85. Connect the throttle valve control actuating cable to the throttle pulley in the transaxle.

86. Install the throttle valve control actuating cable bracket and secure with a bolt. Tighten the throttle valve control actuating cable bracket-to-transaxle bolt to 7.8-11 Nm (69-95 lb-in).

87. Connect the solenoid valve connector.

88. Install the retaining clip and bolt.

THRUST WASHER CHART

Clearance mm (inch) Select this thrust washer mm (inch)

0.91-1.10 (0.036-0.043) 1.2 (0.047)

0.71-0.90 (0.028-0.035) 1.4 (0.055)

0.51-0.70 (0.020-0.027) 1.6 (0.063)

0.31-0.50 (0.012-0.019) 1.8 (0.071)

0.11-0.30 (0.004-0.011) 2.0 (0.078)

0-0.10 (0) 2.2 (0.087)



89. Position the main control valve body (7A100) to the transaxle case. Align the manual valve with the pin on the manual valve detent lever.

90. Install the nine bolts securing the main control valve body. Refer to the illustration for bolt lengths and positions. Tighten the valve body bolts to 7.8-11 Nm (69-95 lb-in).

91. Connect the wiring connectors on the main control valve body.

92. Install a new oil pan to case gasket (7A191) onto the transmission fluid pan (7A194). Be certain to properly position the oil pan magnets (7L027) in the transmission fluid pan.

93. Position the transmission fluid pan onto the transaxle case and install the nineteen transmission oil pan bolts. Tighten the transmission oil pan bolts to 7.8-11 Nm (69-95 lb-in).

94. Install the pulse signal generator (PSG), PSG bolt, and solenoid connector. Tighten the PSG bolt to 7.8-11 Nm (69-95 lb-in).

95. Install and adjust the transmission range (TR). Refer to Section 07-14A for the installation procedure.

96. Install the remaining wiring brackets to the transaxle case.

97. Install a new O-ring onto the oil filler tube (7A228).

98. Install the oil filler tube and bolt into the transaxle case. Tighten the oil filler tube bolt to 7-11 Nm (62-95 lb-in).



99. Use Converter Seal Replacer T88C-77000-BH to install a new converter impeller hub seal (7F401) onto the transaxle.

100. Install a new converter turbine shaft seal on the turbine shaft.

101. Install the oil pump shaft (7B328) into the transaxle.

102. NOTE: If a new torque converter (7902) is being ins talled, pour 1 liter (1 quart) of Motorcraft Mercon ® Multi-Purpose Automatic Transmission Fluid XT-2-Q DX or equivalent Mercon® Fluid into the torque converter before installation.

Position the torque converter to the converter housing and rotate it to align the splines.



103. NOTE: The torque converter should slide into the tr ansaxle very easily. Do not force the torque conver ter into the transaxle.

To ensure that the torque converter has aligned properly, measure the distance between the torque converter and the edge of the converter housing. The distance should be at least 13.6mm (0.535 inch).



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