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Ford 307-01-1 User Manual

Automatic transaxle/transmission
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307-01-1

ASSEMBLY

Transmission

Special Tool(s)
Adjustment Set, Transmission
Band
307-S022 (T71P-77370-A)
Holding Fixture, Transmission
307-003 (T57L-500-B)
Depth Micrometer
303-D026 (D80P-4201-A) or
equivalent
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
Installer, Transmission
Extension Housing Oil Seal
307-038 (T74P-77052-A)
Sizer, Piston Seal
307-338 (T95L-70010-G)
(Continued)
Copyright
2004, Ford Motor Company
Last updated: 8/11/2005
Automatic Transaxle/Transmission
Special Tool(s)
(Continued)
307-01-1
Alignment Set, Fluid Pump
307-S039 (T74P-77103-X)
Aligner, Fluid Pump Handle
307-431
Aligner, Fluid Pump Pilot
307-432
Gauge Bar
307-400
Compressor, Servo Cover
307-402
Installer, Shift Shaft Fluid Seal
307-050 (T74P-77498-A)
Handle, Torque Converter
307-091 (T81P-7902-C)
2005 Mustang, 12/2004

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  Summary of Contents for Ford 307-01-1

  • Page 1 307-351 (T97L-70010-A) Installer, Transmission Extension Housing Oil Seal 307-038 (T74P-77052-A) Sizer, Piston Seal 307-338 (T95L-70010-G) (Continued) Copyright 2004, Ford Motor Company Last updated: 8/11/2005 Automatic Transaxle/Transmission Special Tool(s) (Continued) 307-01-1 Alignment Set, Fluid Pump 307-S039 (T74P-77103-X) Aligner, Fluid Pump Handle...
  • Page 2 307-01-2 ASSEMBLY (Continued) Special Tool(s) Compressor, Cushion Spring 307-401 Aligner, Valve Body 307-334 (T95L-70010-C) Alignment Pins, Transmission Pump 307-399 Aligner, Flex Plate 307-403 Air Test Plate 307-433-01, 307-433-2, 307-433-3 Installer, Drive Pinion flange 205-479 Installer, Output Shaft Flange 307-404 Automatic Transaxle/Transmission Material Item MERCON...
  • Page 3 307-01-3 ASSEMBLY (Continued) 4. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case. WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.
  • Page 4 307-01-4 ASSEMBLY (Continued) 9. Assemble the manual valve inner lever and parking lever actuating rod as shown. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft. Install the manual control lever shaft. 11.
  • Page 5 307-01-5 ASSEMBLY (Continued) CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated. Install the output shaft thrust washer (No. 11). • Coat the output shaft thrust washer with petroleum jelly.
  • Page 6 307-01-6 ASSEMBLY (Continued) 20. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever. 21. Install the No. 10 needle bearing into the case. CAUTION: Do not damage the seal against the case during assembly. Install the output shaft ring gear, hub and seal.
  • Page 7 307-01-7 ASSEMBLY (Continued) CAUTION: Make sure the needle bearings stay in place. Install the low/reverse planetary assembly. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring. Install the retaining ring. 28. Install the No. 8 thrust bearing. Automatic Transaxle/Transmission 29.
  • Page 8 307-01-8 ASSEMBLY (Continued) 32. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place. 33. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub. 34.
  • Page 9 307-01-9 ASSEMBLY (Continued) 38. Install the intermediate servo piston and spring. • Lubricate the servo bore with clean automatic transmission fluid. 39. Using the special tool, install the retaining ring. 40. Install the direct clutch drum. Automatic Transaxle/Transmission 41. Using a depth micrometer with an 8-inch extension, measure from the top of the gauge bar to center support ledge in case at 4 places 90 degrees apart.
  • Page 10 307-01-10 ASSEMBLY (Continued) 43. NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
  • Page 11 307-01-11 ASSEMBLY (Continued) 48. Install the intermediate band anchor strut. CAUTION: To avoid a ‘‘fall-out’’ condition of the strut from the screw during assembly and function, the small ‘‘U’’ shape notch should be toward the band/case side and the large ‘‘U’’ shape notch toward the main control side.
  • Page 12 307-01-12 ASSEMBLY (Continued) CAUTION: If the strut is installed incorrectly, transmission damage will occur. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod. 54. Install the selected No. 4 thrust washer on the direct clutch drum.
  • Page 13 307-01-13 ASSEMBLY (Continued) CAUTION: Install the center support retaining ring with the tapered side facing CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring. Install the center support retaining ring. 1 Make sure the center support retaining ring is installed with the tapered side facing up.
  • Page 14 307-01-14 ASSEMBLY (Continued) 62. Install the overdrive brake drum and coast clutch drum assembly. 63. Install the overdrive band servo piston and spring. • Lubricate the servo bore with clean automatic transmission fluid. 64. Using the special tools, install the retaining ring.
  • Page 15 307-01-15 ASSEMBLY (Continued) CAUTION: To avoid a ‘‘fall-out’’ condition of the strut from the screw during assembly and function, the small ‘‘U’’ shape notch should be toward the band/case side and the large ‘‘U’’ shape notch toward the main control side. Position the strut in the transmission case.
  • Page 16 307-01-16 ASSEMBLY (Continued) CAUTION: If the strut is installed incorrectly, transmission damage will occur. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod. CAUTION: The torque specifications are critical for this procedure.
  • Page 17 307-01-17 ASSEMBLY (Continued) Service Part Number Dimension D 38.29-38.42 mm (1.51 in) 38.43-38.61 mm (1.51-1.52 in) 38.62-38.74 mm (1.52-1.53 78. Install the selected No. 1 fluid pump input thrust washer. • Coat the fluid pump input thrust washer with petroleum jelly. 79.
  • Page 18 307-01-18 ASSEMBLY (Continued) CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage. Using the special tool, align the fluid pump to the adapter plate. 83. Install screws. Tighten the screws in a star pattern.
  • Page 19 307-01-19 ASSEMBLY (Continued) CAUTION: The overdrive servo must be installed prior to band adjustment. Using the special tool, tighten the overdrive band adjustment screw. Then back off the screw exactly 1.5 turns and hold that position. • Tighten to 14 Nm (10 lb-ft). 87.
  • Page 20 307-01-20 ASSEMBLY (Continued) 91. Tighten the center support screw. • Tighten to 11 Nm (8 lb-ft). 92. Using the special tools, carry out the air pressure test procedure. For additional information, refer to Special Testing Procedures in this section. 93. Install the special tools into the transmission case.
  • Page 21 307-01-21 ASSEMBLY (Continued) 96. Tighten the screws in the sequence shown. • Tighten to 10 Nm (89 lb-in). 97. With the manual lever in the NEUTRAL position, install the manual valve detent spring. • Tighten to 10 Nm (89 lb-in). Automatic Transaxle/Transmission 98.
  • Page 22 307-01-22 ASSEMBLY (Continued) CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, transmission leak may occur. Install the solenoid body. Tighten the screws in sequence shown. • Tighten to 8 Nm (71 lb-in). 100.
  • Page 23 307-01-23 ASSEMBLY (Continued) 104. Install the parking pawl assembly and gasket. 1 Install the parking pawl shaft. 2 Install the parking pawl return spring. 3 Install the parking pawl. 4 Install a new gasket. 105. Install the extension housing. • Tighten to 25 Nm (18 lb-ft). 106.
  • Page 24 307-01-24 ASSEMBLY (Continued) 110. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
  • Page 25 307-01-25 ASSEMBLY (Continued) 114. CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter. CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal. CAUTION: If the torque converter slides out, the hub seal may be damaged.
  • Page 26 307-01-26 ASSEMBLY (Continued) 118. Remove the special tool and install the remaining torque converter flex plate adapter nuts. • Tighten to 44 Nm (33 lb-ft). 119. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.

This manual is also suitable for:

2005 mustang