TION AND OPERATION Procedure revision date: 01/22/1999

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1 TION AND OPERATION Procedure revision date: 01/22/1999 Main Components and Functions AX4S Main Components (1 of 9) [7/21/2007 4:10:26 PM]

2 Item Part Number Torque Converter Description 2 Torque Converter Clutch (Piston Plate Clutch and Damper Assy) (Part of 7902) 3 Converter Cover (Part of 7902) 4 Turbine (Part of 7902) 5 Impeller(Part of 7902) 6 Reactor (Part of 7902) 7 7B328 Pump Driveshaft 8 7A360 Front Clutch Cylinder 9 7A098 Low One-Way Clutch 10 7F196 Overdrive Band 11 7G120 Direct Clutch 12 7A089 Direct One-Way Clutch 13 7G120 Intermediate Clutch 14 7B164 Reverse Clutch 15 7A398/7D006 Front Planet/Rear Planet 16 7A233 Park Gear 17 7D034 Low and Intermediate Band 18 7F342 Final Drive Sun Gear 19 7F465 Final Drive Planet and Carrier 20 7G112 Differential Thrust Bearing and Race 21 7G129 Drive Sprocket 22 7G249 Drive Chain 23 7G132 Driven Sprocket 24 7A100 Main Control Valve Body 25 Pump Assembly (Part of 7A100) Torque Converter Components (2 of 9) [7/21/2007 4:10:26 PM]

3 Item Part Number 1 7R190 Pump Driveshaft 2 7F213 Turbine Shaft Description Front Cover and Impeller Assy 4 Reactor Thrust Washer 5 One-Way Clutch Assy 6 Rear Cover 7 Torque Converter Piston and Damper Assy 8 O-Ring 9 Turbine (3 of 9) [7/21/2007 4:10:26 PM]

4 10 Reactor Torque Converter The AX4S torque converter is a four-element assembly. It contains an impeller, a turbine, a reactor and a torque converter clutch (TCC) for increased fuel economy. Impeller and Cover The impeller and cover assembly drives the impeller blades and pump assembly. The impeller is primarily responsible for driving the turbine with hydraulic fluid by means of centrifugal force. The cover provides a mating surface for the torque converter clutch piston and damper assembly. Turbine The turbine is driven by centrifugal fluid force from the impeller. The turbine transmits input torque to the drive chain and driven sprocket through the turbine shaft. Reactor The reactor redirects fluid flow from the turbine back to the impeller so that fluid rotates in the same direction as the impeller. This action also assists in torque multiplication. Torque Converter Clutch (TCC) The torque converter clutch (TCC) provides a mechanical link or direct drive between the engine crankshaft and turbine shaft when applied. The application of the torque converter clutch is controlled by the powertrain control module (PCM) (12A650). Under certain conditions, the PCM sends the appropriate signal to the torque converter clutch (TCC) solenoid which allows fluid pressure within the torque converter to force the TCC piston plate and damper assembly against the cover creating a mechanical link between the engine and transaxle. Geartrain The geartrain consists of the planetary gearsets, apply components, final drive gearset and differential. Planetary Gearsets (4 of 9) [7/21/2007 4:10:26 PM]

5 The AX4S transaxle has two planetary gearsets to provide operation in reverse and four forward speeds. The gearsets are comprised of the following components: front sun gear (part of the front sun gear and shell assembly) front carrier rear ring gear front ring gear and rear carrier rear sun gear Item Part Number Description 1 7D064 Gear and Shell Assy Front Sun 2 7A153 Gear Rear Ring 3 7D006 Planet Rear Gear Assy 4 7A626 Rear Sun Gear Assy 5 7A398 Planet Front Gear Assy (5 of 9) [7/21/2007 4:10:26 PM]

6 Turbine Shaft The turbine shaft is splined to both the torque converter stator and the drive sprocket. This allows input torque to be transmitted from the torque converter to the drive chain and driven sprocket. Output Shaft The output shaft is splined to one of the differential side gears on one end, supported by the driven sprocket and driven sprocket support on the other end. This allows power flow through the differential for even output torque to the drive axles. Drive Chain and Sprockets A chain drive transfers torque from the torque converter turbine to the planetary gearsets. The chain drive is composed of the following components: drive sprocket driven sprocket silent-type drive chain The transaxle case has a support for the drive sprocket that also serves as the support for the torque converter stator. A driven sprocket support mounts in the barrel of the transaxle case and also supports the clutches and gearset components. (6 of 9) [7/21/2007 4:10:26 PM]

7 Final Drive Gearset The final drive consists of a planetary gearset that transfers and multiplies torque from the planetary gearsets to the differential. The final drive consists of the following components: sun gear carrier (part of the differential case) ring gear The sun gear is splined to the front ring gear and rear carrier of the planetary gearsets. The sun gear acts as the driving member and the carrier as the driven member. The ring gear is held stationary inside the case (7005) using lugged teeth. Differential The differential allows the halfshafts and wheels to rotate at different speeds during cornering. The differential assembly consists of the following components: differential case (part of the final drive carrier) (7 of 9) [7/21/2007 4:10:26 PM]

8 two pinion gears supported by a pinion shaft two side gears supported by the differential case and halfshafts When driving in a straight line both front wheels rotate at relatively the same speed. This means both side gears are rotating at the same speed as well while both pinion gears revolve (but do not rotate) with the side gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque. Apply Components Band Overdrive The overdrive band holds the front planetary sun gear stationary in fourth gear (overdrive). Band Low-Intermediate The low-intermediate band allows the transaxle case to hold the rear sun gear and drum (7A626) stationary. The low-intermediate band is applied in 2nd and manual 1st gears. Clutch Forward The forward clutch locks the driven sprocket (7G132) to the low one-way clutch. Clutch Direct The direct clutch locks the sun gear of the front planetary gearset to the direct one-way clutch in third gear. Clutch Intermediate The intermediate clutch connects the driven sprocket to the front planetary carrier and rear planetary ring gear in second and third gears. Clutch Reverse The reverse clutch holds the front planetary gearset and the rear ring gear of the rear planetary gearset stationary in reverse gear. Clutch Low One-Way (8 of 9) [7/21/2007 4:10:26 PM]

9 The low one-way clutch transmits torque from the driven sprocket to the sun gear of the front planetary gearset in first gear. Clutch Direct One-Way The direct one-way clutch transmits torque from the driven sprocket to the front planetary sun gear in third gear and provides engine braking in manual low in connection with the direct clutch. (9 of 9) [7/21/2007 4:10:26 PM]

10 Section 05-04: Halfshaft, Front Wheel 1998 Windstar Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 01/22/1999 Halfshafts, Front Wheel CAUTION: Do not move vehicle without the outboard CV joint properly installed. Damage to the wheel bearing may occur. The front wheel drive halfshafts have the following characteristics: Employ constant velocity (cv) joints at both the inboard and outboard ends for operating smoothness. The front wheel driveshaft joints are connected by an interconnecting shaft which is splined at both ends and retained in the inboard and outboard front wheel driveshaft joint by circlips. The inboard front wheel driveshaft joint stub shaft is splined and held in the differential side gear by a circlip. The outboard front wheel driveshaft joint stub shaft is pressed in and secured with a prevailing torque nut. The front wheel driveshaft joints are lube-for-life with a special front wheel driveshaft joint grease and require no periodic lubrication. The front wheel drive halfshafts operate in the following manner: The front wheel drive halfshafts transmit engine torque from the transaxle to the front wheels. Halfshafts operate at varying angles and can change length to allow for vertical suspension (wheel) travel and dynamic engine movement. Inboard CV joints are double-offset type joint which provides for axial movement to effect shaft length changes. The following are the only serviceable components of the front wheel driveshaft and joint assembly: The front wheel driveshaft joint boot (3A331) is serviced as a kit and includes driveshaft joint boot and clamps, retainer circlips, stop ring and replacement grease. The RH inboard joint uses a silicone boot. The inboard front wheel driveshaft joint (3B414) (plunge type) is serviced as a kit and includes the inner race, ball bearings, cage snap ring, housing, front wheel driveshaft joint boot clamps, retainer circlips and stop ring (1 of 4) [7/21/2007 4:11:29 PM]

11 retainer circlip front wheel dust shield (3K070) front wheel driveshaft and joint (3B437) is serviced as a kit and includes the outboard front wheel driveshaft joint (fixed type), outboard front wheel driveshaft joint boot and clamps, anti-lock brake sensor indicator and front wheel dust shield assembled to the interconnecting shaft. Retainer circlips and a stop ring are also included with the service kit, but are not assembled to the interconnecting shaft The outboard front wheel driveshaft joint, anti-lock brake sensor indicator and interconnecting shaft cannot be serviced separately. Front Wheel Driveshaft and Joint Assemblies Item Part Number Description 1 3K206 Front Wheel Hub and Spindle 2 N S101 Washer 3 N S192 Nut 4 3B436 Front Wheel Driveshaft and Joint (RH) (2 of 4) [7/21/2007 4:11:29 PM]

12 5 3B437 Front Wheel Driveshaft and Joint (LH) 6 3K185 Front Wheel Knuckle Front Wheel Driveshaft and Joint Assembly, GKN Design Item Part Number Description 1 N S192 2 N S101 Nut Washer Wheel Hub (LH) 4 3B437 Front Wheel Driveshaft and Joint 5 3K070 Front Wheel Dust Shield 6 Anti-Lock Brake Sensor Indicator (Part of 3B436/3B437) (3 of 4) [7/21/2007 4:11:29 PM]

13 7 3B478 Front Wheel Driveshaft Joint Boot Clamp (Part of 3A331, 3B437 and 3B414) 8 3A331 Front Wheel Driveshaft Joint Boot 9 3B478 Front Wheel Driveshaft Joint Boot Clamp (Part of 3A331, 3B437 and 3B414) 10 Interconnecting Shaft (Part of 3B436/3B437) 11 Stop Ring (Part of 3A331, 3B436/3B437 and 3B414) 12 3Z498 Retainer Circlip (Also Part of 3A331, 3B436/3B437 and 3B414) 13 3B478 Front Wheel Driveshaft Joint Boot Clamp (Part of 3A331, 3B436/3B437 and 3B414) 14 Ball Retaining Ring (Part of 3B414) 15 Cage (Part of 3B414) 16 Balls (6 Req'd)(Part of 3B414) 17 Inner Race (Part of 3B414) 18 Housing (Part of LH 3B414) 19 3B414 Front Wheel Driveshaft Joint (Plunge Type, LH Inboard) Wheel Hub (RH) 21 3B436 Front Wheel Driveshaft and Joint 20 3B478 Front Wheel Driveshaft Joint Boot Clamp (Part of 3A331, 3B436 and 3B414) 22 3A331 Front Wheel Driveshaft Joint Boot (Silicone, RH Only) 23 3B478 Front Wheel Driveshaft Joint Boot Clamp (Part of 3A331, 3B436 and 3B414) 24 3B414 Front Wheel Driveshaft Joint (Plunge Type, RH Inboard) 25 Housing (Part of RH 3B414) 26 Retainer Circlip (Part of 3A331, 3B436/3B437 and 3B414) (4 of 4) [7/21/2007 4:11:29 PM]

14 Section 05-04: Halfshaft, Front Wheel 1998 Windstar Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 01/22/1999 Halfshafts, Front Wheel Inspection and Verification NOTE: Inboard front wheel driveshaft joints (3B414) should not be replaced unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the front wheel driveshaft joint boots (3A331), watch for indentations ("dimples") in the boot convolutions. If an indentation is observed, it must be removed. Refer to CV Joint Boot Indentation procedure as described under Cleaning and Inspection. 1. Inspect front wheel driveshaft joint boots for evidence of cracks, tears or splits. 2. Inspect underbody for any indication of grease splatter in vicinity of front wheel driveshaft joint boots, outboard and inboard locations, which is an indication of front wheel driveshaft joint boot and/or front wheel driveshaft joint boot clamp damage. 3. Inspect for inboard front wheel driveshaft joint stub shaft pilot bearing housing seal leakage at inboard front wheel driveshaft joint. 4. Make sure the nut retaining the front wheel driveshaft and joint assembly to the front wheel hub is the correct prevailing torque type. 5. The RH inboard silicone front wheel driveshaft joint boot will sweat during operation, causing a light film of grease to show on the outside of the front wheel driveshaft joint boot. This condition is normal. Symptom Chart NOTE: Halfshafts are not balanced and do not contribute to rotational vibration. For additional noise, vibration and harshness (NVH) diagnostics, refer to Section (1 of 3) [7/21/2007 4:12:16 PM]

15 NOISE AND VIBRATION DIAGNOSIS Condition Possible Source Action Clicking, Popping or Grinding Noises While Turning Inadequate or contaminated lube in outboard front wheel driveshaft joint (fixed type). Inspect, clean and lubricate as required. Another component contacting front wheel driveshaft and joint assembly. Inspect and service as required. Worn, damaged or improperly installed wheel bearings, brakes, suspension or steering components. Inspect and service as required. Refer to Section 04-00, Section or Section Vibration at Highway Speeds Out of balance front wheels or tires. Out of round front tires. Refer to Section Improperly seated outboard front wheel driveshaft joint (fixed type) in wheel hub. Refer to halfshaft assembly, outboard. Shudder, Vibration During Acceleration Excessively high front wheel driveshaft joint operating angles caused by improper ride height. Check ride height, verify proper spring rate. Service as required. (2 of 3) [7/21/2007 4:12:16 PM]

16 Excessively worn or damaged inboard front wheel driveshaft joint (plunge type). Inspect and replace as required. Front Wheel Driveshaft Joint Pullout Inboard front wheel driveshaft joint retainer circlip missing or not properly seated in differential side gear. Inspect and service or replace as required. Engine/transaxle assembly mispositioned. Check engine mounts for damage or wear. Service as required. Frame rail or shock tower out of position or damaged. Check underbody dimensions. Refer to Section Front suspension components worn or damaged. Check for worn bushings or bent components (front stabilizer bar, front suspension lower arm, etc.). Service as required. (3 of 3) [7/21/2007 4:12:16 PM]

Halfshaft. Special Tool(s) Differential Plug (T89P-4850-B) Differential Seal Protector Halfshaft Removal Tool

Halfshaft. Special Tool(s) Differential Plug (T89P-4850-B) Differential Seal Protector Halfshaft Removal Tool Halfshaft Special Tool(s) Differential Plug 205-294 (T89P-4850-B) Differential Seal Protector 205-461 Halfshaft Removal Tool 205-475 Hub Remover/Replacer 204-069 (T81P-1104-C) Metric Hub Remover Adapter