Assembly. NOTE: Before beginning assembly, perform/inspect the following:

Page 1 of 31 Home Account Contact ALLDATA Log Out Help DAN GRIMWOOD DAN GRIMWOOD00002 Select Vehicle New TSBs Technician's Reference Component Search: OK 1997 Ford Truck F 150 2WD Pickup V6-4.2L VIN 2 Conversion Calculator Vehicle Level Transmission and Drivetrain Automatic Transmission/Transaxle Service and Repair Overhaul Assembly Assembly NOTE: Before beginning assembly, perform/inspect the following: - When building up subassemblies and assembling the transmission, always use new gaskets and seals. - All fasteners must be tightened to the torque specification indicated. - When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. - Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. - Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. 1. If removed, use Case Rear Bushing Replacer T80L-77110-A and Impact Slide Hammer T50T-100-A to install the rear case bushing. (1) Position the rear case bushing and Case Rear Bushing Replacer T80L-

Page 2 of 31 77110-A from inside of the case. (2) Thread Impact Slide Hammer T50T-100-A into Case Rear Bushing Replacer T80L-77110-A through the back of case. 2. Place the transmission in the vertical position. 3. Coat No. 9 case rear bearing with petroleum jelly and install on the case boss. 4. Install the (A) output shaft, (B) output shaft ring gear and the (C) direct clutch as an assembly. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed properly.

Page 3 of 31 5. Install the reverse band support retaining ring. 6. Install the reverse band. NOTE: Make sure the band is seated on the anchor pins.

Page 4 of 31 7. Install the planetary assembly and planetary gear support as a unit. - Rotate the output shaft to fully seat the planetary assembly. NOTE: - The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin. - The top of the planetary gear support must be below the snap ring groove. 8. Install the case to planet support spring. 9. Install the center support retaining ring.

Page 5 of 31 - Reference the retaining ring tabs to the band anchor pin location. 10. Install the forward clutch sun gear, No. 5 forward clutch sun gear bearing and the reverse sun gear. 11. Install the No. 4 forward clutch hub bearing.

Page 6 of 31 12. Install the intermediate stub shaft. 13. Install the (A) forward clutch hub and the (B) No. 3 forward clutch hub front bearing. 14. Install the forward clutch assembly.

Page 7 of 31 15. Install the (A) reverse clutch cylinder assembly and the (B) No. 2 forward clutch bearing. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear. 16. Install the overdrive band. - Position the overdrive band pocket onto the anchor pin.

Page 8 of 31 17. Install the (A) overdrive servo spring and the (B) overdrive servo piston assembly. 18. Verify the tip of the piston assembly engages the pocket of the overdrive band.

Page 9 of 31 19. Use (A) Servo Piston Remover/Replacer T92P-70023-A to compress the overdrive servo assembly and install the (B) overdrive servo retaining ring. 20. Install the intermediate clutch pressure plate. 21. Install the intermediate clutch pack and selective steel plate.

Page 10 of 31 22. Check the intermediate clutch clearance. (1) Position Gauge Bar T80L-77003-A on the pump case mounting surface. (2) Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification. If the intermediate clutch is not within specification, install a correct selective plate. Selective Steel Plates 1.80-1.7 mm (0.071-0.067 in) 2.05-1.95 mm (0.081-0.077 in) 2.31-2.20 mm (0.091-0.087 in) 2.56-2.46 mm (0.101-0.097 in)

Page 11 of 31 23. Measure end clearance for the No. 1 front pump thrust washer. (1) Position Gauge Bar T80L-77003-A on the pump case mounting surface. (2) Maintaining downward pressure, use a depth micrometer to measure end play clearance. - Use the No.1 thrust washer chart to select the proper washer. 24. Install the No. 1 front pump support thrust washer. - Use petroleum jelly to hold the washer in place.

Page 12 of 31 25. Install an alignment pin at the top of the case. 26. Install the pump gasket. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered. 27. Install the pump assembly. NOTE: To aid assembly, shake the input shaft while pushing down on the pump. 28. Remove the alignment pin and install the front pump bolts. - Alternate bolt tightening to set the pump.

Page 13 of 31 29. Rotate the transmission to the horizontal position. 30. Install the parking pawl. (1) Position the parking pawl return spring. (2) Position the parking pawl. (3) Install the parking pawl shaft. 31. Install a new extension housing gasket and the extension housing. (1) Position the extension housing. (2) Install the four bolts and two nuts.

Page 14 of 31 32. Install a new extension housing seal. (1) Position Seal Replacer T61L-7657-A and the seal. (2) Install the extension housing seal. 33. Install the OSS. (1) Position the OSS. (2) Install the bolt.

Page 15 of 31 34. Use (A) Shift Lever Seal Replacer T74P-77498-A to install the (B) manual control lever seal. 35. Install the EPC solenoid. NOTE: Lubricate the EPC solenoid O-rings with transmission fluid.

Page 16 of 31 36. Install the (A) manual valve detent lever and (B) parking lever actuating rod. 37. Install the manual control lever shaft. (1) Slide the manual control shaft into the case. (2) Install the manual lever shaft inner nut. (3) Install the manual lever shaft retaining pin. 38. Install the fluid screen.

Page 17 of 31 39. Install the reverse servo piston and return spring. NOTE: - This is not an ordinary installation procedure and does not compensate for band wear. When piston and rod assembly replacement becomes necessary, or when the reverse band has been replaced, the reverse piston and rod length must be adjusted. - Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. 40. Install Servo Piston Selection Tool T80L-77030-A. - Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A.

Page 18 of 31 41. Attach Dial Indicator With Bracketry TOOL-4201-C or equivalent. - Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 42. Loosen the bolt until the piston stops against the tool.

Page 19 of 31 43. Verify the amount of piston travel on the dial indicator is within specification. 44. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two grooves, or (C) three grooves to bring the servo piston travel within specification. 45. Remove the dial indicator and servo selection tool.

Page 20 of 31 46. Install the proper servo rod, piston assembly and the reverse servo piston cover and seal. 47. Use (A) Servo Piston Remover/Replacer T92P-70023-A to install the (B) reverse servo retaining ring.

Page 21 of 31 48. Install the 2-3 accumulator assembly. (1) Install the upper accumulator seal and lower accumulator seal and the accumulator piston. (2) Install the accumulator piston spring. (3) Install the accumulator spring retainer. 49. Install the 1-2 accumulator piston assembly. (1) If equipped, install the 1-2 accumulator inner spring (model dependent). (2) Install the 1-2 accumulator piston. (3) Install the 1-2 accumulator outer spring. (4) Install the 1-2 accumulator cover and seal.

Page 22 of 31 50. Use (A) Servo Piston Remover/Replacer T92P-70023-A to install the (B) 1-2 accumulator retaining ring. 51. Install the electrical connector into case. NOTE: The tab on the electrical connector is secured by main control valve body. 52. Align the main control valve body alignment bolts and position the main control valve body. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.

Page 23 of 31 53. Loosely install the 11 long main control valve body bolts. NOTE: The main control valve body bolts will be tightened in later steps.

Page 24 of 31 54. Loosely install the 12 short main control valve body bolts. NOTE: The main control valve body bolts will be tightened in later steps. 55. Install the manual control valve detent lever spring.

Page 25 of 31 (1) Position the manual control valve detent lever spring. (2) Install the bolt. 56. Tighten the main control valve body bolts in the sequence shown. 57. Connect the solenoid and sensor electrical connectors. NOTE: Anytime an electrical connector is disconnected, inspect the connector for terminal condition, corrosion and contamination. Clean, repair or replace as required.

Page 26 of 31 58. Install the fluid filter and seal assembly. 59. Position the (B) pan magnet onto the (A) fluid pan. 60. Install the fluid pan.

Page 27 of 31 (1) Position the transmission fluid pan. (2) Install the 14 transmission fluid pan bolts. NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 61. Install the TR or DTR sensor. (1) Position the TR or DTR sensor. (2) Loosely install the two TR or DTR sensor bolts. 62. Use Digital Transmission Range (DTR) Sensor Alignment Tool T97L-70010- A to align the DTR sensor slots. NOTE: Manual shift lever must be in the NEUTRAL position.

Page 28 of 31 63. Tighten the DTR sensor bolts. 64. Install the manual control lever. (1) Position the manual control lever. (2) Install the nut.

Page 29 of 31 65. Install the transmission vent tube. (1) Position the vent tube. (2) Install the bolt. 66. Lightly lubricate the converter hub with MERCON transmission fluid, meeting Motorcraft specification WSP-M2C185-A.

Page 30 of 31 67. Using torque converter handles, install the torque converter. WARNING: THE TORQUE CONVERTER CAN FALL OUT IF THE TRANSMISSION IS TIPPED. CAUTION: - Do not damage the pump drive gear O-ring when installing the torque converter. - Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal. - If the torque converter slides out, the hub seal may be damaged. 68. Use Ford Multi-Purpose Grease meeting Ford specifications ESA-M1C45-A. Lubricate the torque converter pilot hub.