Ford Mustang (1999-2004) Service Manual: Transmission (ASSEMBLY)

Special Tool(s)

Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
Rubber Tip Air Nozzle 100-D009 (D93L-7000-A)
Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)
Slide Hammer 100-001 (T50T-100-A)
Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)
Shim Selection Gauge 307-072 (T80L-77003-A)
Installer, Servo Piston 307-073 (T80L-77030-A)
Remover/Installer, Transmission Extension Housing 307-077 (T80L-77110-A)
Handle, Torque Converter 307-091 (T81P-7902-C)
Test Plate Screw Set, Transmission 307-126 (T82P-7006-C)
Air Test Plate, Transmission 307-246 (T92P-7006-A)
Remover/Installer, Servo Piston 307-251 (T92P-70023-A)
Retainer, Torque Converter 307-346 (T97T-7902-A)
Installer, Transmission Extension Housing Oil Seal 308-002 (T61L-7657-A)
Gauge, Transmission Solenoid Connectors 307-426

Material

Item Specification
Multi-Purpose Grease D0AZ-19584-AA ESB-M1C93- B
MERCON V Automatic Transmission Fluid XT-5-QM, XT-5-DM MERCON V

CAUTION: Before beginning assembly, carry out and 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. In addition to appearing in the section, the necessary torques can be found in the General Specifications Chart.

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. Use the special tools to install the rear case bushing if removed.

1. Position the rear case bushing and the special tool inside the case.

2. Assemble the special tools through the back of the case.

Transmission (ASSEMBLY)

2. Place the transmission in the vertical position.

3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.

Transmission (ASSEMBLY)

4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur.

Install the output shaft and output shaft ring gear.

Transmission (ASSEMBLY)

5. Install the No. 8 bearing

Transmission (ASSEMBLY)

6. Install the direct clutch.

Transmission (ASSEMBLY)

7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.

Install the reverse band support retaining ring.

Transmission (ASSEMBLY)

8. NOTE: Make sure the band is seated on the anchor pins.

Install the reverse band.

Transmission (ASSEMBLY)

9. 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.

NOTE: The top of the planetary gear support must be below the snap ring groove.

Install the planetary assembly and planetary gear support as a unit.

  • Rotate the output shaft to fully seat the planetary assembly.

Transmission (ASSEMBLY)

10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly both ends of the spring will be visible.

Install the case to the planet support spring located at the 1 o'clock position.

Transmission (ASSEMBLY)

11. Install the center support retaining ring.

  • Reference the retaining ring tabs to the band anchor pin location.

Transmission (ASSEMBLY)

12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse sun gear.

Transmission (ASSEMBLY)

13. Install the No. 4 forward clutch hub bearing.

Transmission (ASSEMBLY)

14. Install the intermediate stub shaft.

Transmission (ASSEMBLY)

15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.

Transmission (ASSEMBLY)

16. Install the forward clutch assembly.

Transmission (ASSEMBLY)

17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.

Install the reverse clutch cylinder assembly.

1. Install the reverse clutch cylinder.

2. Install the No. 2 forward clutch bearing.

Transmission (ASSEMBLY)

18. Install the overdrive band.

  • Position the overdrive band pocket onto the anchor pin.

Transmission (ASSEMBLY)

19. Install the overdrive servo spring.

1. Install the overdrive servo piston return spring.

2. Install the overdrive servo piston.

Transmission (ASSEMBLY)

20. Verify the tip of the piston assembly engages the pocket of the overdrive band.

Transmission (ASSEMBLY)

21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.

Transmission (ASSEMBLY)

22. Install the intermediate clutch pressure plate.

Transmission (ASSEMBLY)

23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.

Install the intermediate clutch pack and selective steel plate.

Transmission (ASSEMBLY)

24. Using the special tool, check the intermediate clutch clearance.

1. Position the special tool 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

Selective Steel Plates

 

Selective Steel Plates

25. Install the intermediate anti-rattle clip, if equipped.

Selective Steel Plates

26. Using the special tool, measure end clearance for the No.1 front pump thrust washer.

1. Position the special tool 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 correct washer.

No.1 Thrust Washer Chart

No.1 Thrust Washer Chart

No.1 Thrust Washer Chart

27. Install the No.1 front pump support thrust washer.

  • Use petroleum jelly to hold the washer in place.

No.1 Thrust Washer Chart

28. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 in) bolt with the head removed.

Install an alignment pin at the top of the case.

No.1 Thrust Washer Chart

29. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.

Install the pump gasket.

30. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.

Install the pump assembly.

No.1 Thrust Washer Chart

31. Remove the alignment pin and install the front pump bolts.

  • Alternate bolt tightening to set the pump.

No.1 Thrust Washer Chart

32. Rotate the transmission to the horizontal position.

33. Install the parking pawl.

1. Position the parking pawl return spring.

2. Position the parking pawl.

3. Install the parking pawl shaft.

No.1 Thrust Washer Chart

34. Install a new extension housing gasket and the extension housing.

1. Position the extension housing.

2. Install the four bolts and two nuts.

No.1 Thrust Washer Chart

35. Using the special tool, install a new extension housing seal.

No.1 Thrust Washer Chart

36. Install the output shaft speed (OSS) sensor.

1. Position the OSS sensor.

2. Install the bolt.

No.1 Thrust Washer Chart

37. Using the special tool, install the manual control lever seal.

No.1 Thrust Washer Chart

38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.

Install the EPC solenoid.

1. Install the EPC solenoid.

2. Install the EPC solenoid bracket and bolt.

No.1 Thrust Washer Chart

39. Install the manual valve detent lever and parking lever actuating rod.

No.1 Thrust Washer Chart

40. 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.

No.1 Thrust Washer Chart

41. Install the 1-2 accumulator piston assembly.

1. Install the 1-2 accumulator upper spring.

2. Install the 1-2 accumulator.

3. Install the 1-2 accumulator lower spring.

4. Install the 1-2 accumulator cover and seal.

No.1 Thrust Washer Chart

42. Install the 1-2 accumulator retaining ring.

No.1 Thrust Washer Chart

43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear.

When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.

NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.

NOTE: Do not install the reverse servo piston cover and seal at this time.

Install the reverse servo piston and rod assembly.

No.1 Thrust Washer Chart

44. Install the special tool.

  • Tighten the bolt.

No.1 Thrust Washer Chart

45. Install the special tool.

  • Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.

No.1 Thrust Washer Chart

46. Loosen the bolt until the piston stops against the tool.

No.1 Thrust Washer Chart

47. Verify that the amount of piston travel on the dial indicator is within specification.

No.1 Thrust Washer Chart

47. Verify that the amount of piston travel on the dial indicator is within specification.

1. One groove

2. Two grooves

3. Three grooves

No.1 Thrust Washer Chart

49. Remove the special tools.

No.1 Thrust Washer Chart

50. Install the reverse servo piston cover and seal assembly.

No.1 Thrust Washer Chart

51. Using the special tool, install the reverse servo retaining ring.

1. Compress the reverse band servo.

2. Install the reverse band servo retaining ring.

No.1 Thrust Washer Chart

52. Install the 2-3 accumulator assembly.

1. Install the accumulator piston.

2. Install the accumulator piston spring.

3. Install the accumulator spring retainer.

No.1 Thrust Washer Chart

53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.

No.1 Thrust Washer Chart

54. NOTE: The tab on the electrical connector is secured by main control valve body.

Install the electrical connector into the case.

No.1 Thrust Washer Chart

55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.

Align the main control valve body alignment bolts and position the main control valve body.

No.1 Thrust Washer Chart

56. NOTE: The main control valve body bolts will be tightened in later steps.

Loosely install the 11 long main control valve body bolts.

No.1 Thrust Washer Chart

57. NOTE: The main control valve body bolts will be tightened in later steps.

Loosely install the 12 short main control valve body bolts.

No.1 Thrust Washer Chart

58. Install the manual control valve detent lever spring.

1. Position the manual control valve detent lever spring.

2. Install the bolt.

No.1 Thrust Washer Chart

59. Tighten the bolts in the sequence shown.

No.1 Thrust Washer Chart

60. Inspect the lead frame for damage.

  • Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
  • If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.

No.1 Thrust Washer Chart

61. Connect the molded lead frame to the solenoids.

  • Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
  • Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
  • Connect the TCC by pressing it in place by hand and fully seating the connector in place.

    Make sure that the terminals pass fully through the connector slots.

  • Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.

No.1 Thrust Washer Chart

62. Install the fluid filter and seal assembly.

No.1 Thrust Washer Chart

63. Position the pan magnet onto the fluid pan.

No.1 Thrust Washer Chart

64. NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket should be reused.

Install the fluid pan.

1. Position the transmission fluid pan.

2. Install the 14 transmission fluid pan bolts.

No.1 Thrust Washer Chart

65. Install the digital transmission range (TR) sensor.

1. Install the digital TR sensor.

2. Loosely install the digital TR bolts.

No.1 Thrust Washer Chart

66. NOTE: The tool is designed to fit snugly.

NOTE: Manual shift lever must be in the neutral position.

Using the special tool, align the digital TR sensor slots.

No.1 Thrust Washer Chart

67. Tighten the bolts.

No.1 Thrust Washer Chart

68. Lightly lubricate the converter hub with clean automatic transmission fluid.

No.1 Thrust Washer Chart

69. WARNING: The torque converter can fall out if the transmission is tipped.

CAUTION: Make sure the converter hub is fully engaged in the front 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.

Using the special tools, install the torque converter.

No.1 Thrust Washer Chart

70. Lubricate the torque converter pilot hub with multi-purpose grease.

No.1 Thrust Washer Chart

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    Transmission (INSTALLATION)
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