transaxle - fordfestiva.com · 2012-09-20 · 37. remove the 12 transaxle case-to-converter housing...

« 1997 Aspire Table of Contents»«Group 07: TRANSAXLE»«Section 07-01: Transaxle, Automatic»«DISASSEMBLY»

Transaxle

CAUTION:To prevent dirt from entering the transaxle, it should be disassembled and kept in a clean area. Remove the torque converter, taking care not to spill the transmission fluid. Before disassembly, clean the outer surface of the transaxle by using steam, cleaning fluid, etc.

CAUTION:During disassembly, avoid using rags that can leave fabric particles on components as this can block passages and cause valves to stick. Clean the disassembled parts, and clean the oil passages with compressed air and check to be sure they are not clogged.

Note:The casings allow separate repairs to be carried out on either the automatic transaxle or the final drive section. When a problem exists that only requires work on one section, separate the transaxle. Cover the section not requiring attention to prevent foreign material from entering the assembly. SPECIAL SERVICE TOOL(S) REQUIRED

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≥ Description ≥ Tool Number ≥

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≥ Bench Mounted Holding Fixture ≥ T57L-500-B ≥


≥ Clutch Compressor ≥ T87C-77000-B ≥


≥ Stator and Driven Sprocket Bearing Remover ≥ T86P-70043-A ≥


≥ Puller ≥ T58L-101-B ≥


≥ Impact Slide Hammer ≥ T50T-100-A ≥


≥ Driver Handle ≥ T80T-4000-W ≥

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1. Mount the transaxle to Bench Mounted Holding Fixture T57L-500-B.

Torque Converter, Oil Pump, Main Control Valve Body and Externally Mounted Controls

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≥ Item ≥ Part Number ≥ Description ≥

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≥ 1 ≥ -- ≥ Speedometer Cable Sleeve Bolt ≥


≥ 2 ≥ 17B301 ≥ Speedometer Cable Sleeve ≥


≥ 3 ≥ 17271 ≥ Speedometer Gear ≥


≥ 4 ≥ 7A020 ≥ Fluid Level Indicator ≥


≥ 5 ≥ -- ≥ Oil Filler Tube Bolt ≥


≥ 6 ≥ 7A228 ≥ Oil Filler Tube ≥


≥ 7 ≥ 7A103 ≥ Oil Pump ≥


≥ 8 ≥ -- ≥ Oil Pump-to-Transaxle Bolts (8 Req'd) ≥


≥ 9 ≥ -- ≥ Check Ball ≥


≥ 10 ≥ 7A286 ≥ Case Detent Spring ≥


≥ 11 ≥ -- ≥ Main Control Valve Body Bolts (9 Req'd) ≥


≥ 12 ≥ -- ≥ Transmission Oil Pan Bolts (16 Req'd) ≥


≥ 13 ≥ 7A194 ≥ Transmission Fluid Pan ≥


≥ 14 ≥ 7A191 ≥ Oil Pan to Case Gasket ≥


≥ 15 ≥ 7A100 ≥ Main Control Valve Body ≥


≥ 16 ≥ 7A247 ≥ Park/Neutral Position Switch (PNP ≥

≥ ≥ ≥ Switch) ≥


≥ 17 ≥ 7F037 ≥ Kickdown Solenoid ≥


≥ 18 ≥ 7A377 ≥ Vacuum Throttle Valve Diaphragm ≥


≥ 19 ≥ 7F351 ≥ Turbine Shaft ≥


≥ 20 ≥ 7902 ≥ Torque Converter ≥


≥ 21 ≥ 7B328 ≥ Oil Pump Shaft ≥


≥ A ≥ -- ≥ Tighten to 8-11 N-m (71-97 Lb-In) ≥


≥ B ≥ -- ≥ Tighten to 7-10 N-m (61-87 Lb-In) ≥


≥ C ≥ -- ≥ Tighten to 15-22 N-m (11-16 Lb-Ft) ≥


≥ D ≥ -- ≥ Tighten to 5-8 N-m (43-69 Lb-In) ≥

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2. Pull the oil pump shaft (7B328) out of the turbine shaft (7F351).

3. Pull the turbine shaft out of the torque converter stator support.

4. Separate the kickdown solenoid wire from the wiring harness and remove the kickdown solenoid.

5. Remove the Park/Neutral Position Switch (PNP switch) (7A247).

6. Remove the vacuum throttle valve diaphragm (7A377) from the transaxle case. If it is difficult to

remove, use pliers to grasp the flange. Remove the throttle control valve rod (7A380).

7. Remove the oil filler tube bolt securing the oil filler tube (7A228) to the transaxle. Remove the oil

filler tube and fluid level indicator (7A020).

8. Remove the speedometer cable sleeve bolt securing the speedometer cable sleeve (17B301) and

speedometer gear assembly to the transaxle and remove the speedometer cable sleeve and speedometer gear assembly.

9. Remove the 16 transmission oil pan bolts and remove the transmission fluid pan (7A194) from the

transaxle. Discard the oil pan to case gasket (7A191).

10. Note: Be careful not to lose the check ball and detent spring (7D017), located in the slotted hole.

Remove the nine main control valve body bolts securing the main control valve body (7A100) and filter. Remove the main control valve body from the transaxle. Note the position of each main control valve body bolt for installation reference.

11. Position the transaxle with the oil pump end facing down. With a flat-blade screwdriver inserted in

the wide slot between the front clutch drum and the sun shell, pry down on the front clutch drum. Do this several times as you rotate the assembly two complete revolutions.

12. Measure the direct clutch drum end play by checking the clearance of the small slot between the

direct clutch drum tabs and the sun shell slots. Record this measurement for reference upon reassembly. The standard end play is 0.5-0.8mm (0.020-0.031 inch).

13. Remove the oil cooler hose fittings from the oil pump body.

14. Secure the direct clutch in place by tightening the band adjusting stop (7C492).

15. Remove the eight oil pump-to-transaxle bolts and note the position of each bolt for installation

reference. Remove the oil pump assembly from the transaxle.

16. Place the oil pump assembly on a workbench with the outer surface face down.

Hydraulic Apply Devices, Governor Assembly, and Front Planetary Gearset




≥ 1 ≥ 7D028 ≥ Servo Piston Spring ≥


≥ 2 ≥ -- ≥ Servo Piston ≥


≥ 3 ≥ 7D027 ≥ Intermediate Band Servo Retainer ≥


≥ 4 ≥ 7D064 ≥ Sun Shell ≥


≥ 5 ≥ 7D484 ≥ Sun Gear Spacer ≥


≥ 6 ≥ 7D063 ≥ Sun Gear ≥


≥ 7 ≥ 7A398 ≥ Front Planet Carrier ≥


≥ 8 ≥ -- ≥ Front Ring Gear ≥


≥ 9 ≥ 7D029 ≥ Band Strut ≥


≥ 10 ≥ 7D034 ≥ Intermediate Band ≥


≥ 11 ≥ -- ≥ Direct Clutch Assembly ≥


≥ 12 ≥ 7A360 ≥ Forward Clutch Drum ≥


≥ 13 ≥ 7C492 ≥ Band Adjusting Stop ≥


≥ 14 ≥ 7Z114 ≥ Band Adjusting Stop Nut ≥


≥ 15 ≥ -- ≥ Governor Cover Bolt (3 Req'd) ≥


≥ 16 ≥ 7A301 ≥ Governor Cover ≥


≥ 17 ≥ 7C053 ≥ Governor Valve ≥


≥ A ≥ -- ≥ Tighten to 55-80 N-m (41-59 Lb-Ft) ≥




17. Remove the band adjusting stop and band adjusting stop nut (7Z114) from the transaxle case. As the band adjusting stop is removed, retrieve the intermediate band strut from inside the transaxle case.

18. Remove the intermediate band from the transaxle case through the oil pump opening.

19. Remove the direct clutch assembly.

20. Remove the forward clutch drum needle bearing located on the forward clutch drum.




≥ 1 ≥ 7D044 ≥ Direct Clutch Drum ≥


≥ 2 ≥ 7D029 ≥ Intermediate Band Strut ≥


≥ 3 ≥ 7D034 ≥ Intermediate Band ≥


≥ 4 ≥ 7F374 ≥ Forward Clutch Drum Needle Bearing ≥


≥ 5 ≥ 7A360 ≥ Forward Clutch Drum ≥


21. Remove the front ring gear.

22. Remove the oil pump thrust washer if the thrust washer did not stay with the oil pump.

23. Remove the thrust bearing (7C096) located on the front ring gear.

24. Remove the forward clutch hub assembly.

25. Remove the thrust bearing and sun gear spacer (7D480) from the front planet carrier.




≥ 1 ≥ 7C096 ≥ Thrust Bearing ≥


≥ 2 ≥ 7A360 ≥ Front Ring Gear ≥


≥ 3 ≥ 7D014 ≥ Thrust Washer ≥


≥ 4 ≥ 7F374 ≥ Front Ring Gear Needle Bearing ≥


≥ 5 ≥ 7A166 ≥ Front Planet Carrier Thrust Washer ≥


≥ 6 ≥ 7A398 ≥ Front Planet Carrier ≥




≥ 8 ≥ 7D063 ≥ Sun Gear ≥


26. Remove the front planet carrier.

27. Remove the sun gear.

28. Remove the sun gear spacer.

29. Remove the sun shell.

30. Remove the sun shell thrust washer and thrust bearing.






≥ 2 ≥ 7D063 ≥ Sun Gear ≥




≥ 4 ≥ 7D064 ≥ Sun Shell ≥


≥ 5 ≥ 7D066 ≥ Sun Shell Thrust Washer ≥


31. Use a C-clamp and a socket to compress the servo piston into the transaxle case as shown.

32. WARNING: TO AVOID PERSONAL INJURY, WEAR EYE PROTECTION DURING THE

FOLLOWING PROCEDURE.

Use a flat-blade screwdriver to remove the servo piston retaining snap ring (7381).

33. Remove the servo retainer, servo piston and servo piston spring (7D028) by slowly loosening the C-clamp.

34. Disassemble the band apply servo by removing the servo piston spring. Remove the servo piston

large seal (7D024). Discard the servo piston large seal.

35. Remove the governor cover bolts, governor cover and governor gasket (7B391). Discard the

governor gasket.

36. Remove the governor (7C053) from the transaxle case.

37. Remove the 12 transaxle case-to-converter housing bolts.

38. Separate the transaxle case from the converter housing using a flat-blade screwdriver to pry the cases apart at the point shown. Remove the transaxle case.

39. Position the converter housing to remove the differential (4026).

Internal Linkages, Rear Planetary Gearset and Low/Reverse Clutch




≥ 1 ≥ -- ≥ Drum Hub Assembly ≥


≥ 2 ≥ 7C096 ≥ Needle Bearing ≥


≥ 3 ≥ 7A166 ≥ Thrust Washer ≥


≥ 4 ≥ 7D171 ≥ Low One-Way Clutch Inner Race ≥


≥ 5 ≥ 7D006 ≥ Rear Carrier ≥


≥ 6 ≥ 7G347 ≥ Retaining Ring ≥




≥ 8 ≥ 7D066 ≥ Sun Shell Thrust Washer ≥


≥ 9 ≥ 7D483 ≥ Low/Reverse Snap Ring ≥


≥ 10 ≥ 7A089 ≥ One-Way Clutch ≥


≥ 11 ≥ 7B066 ≥ Retaining Plate, One-Way Clutch ≥


≥ 12 ≥ 7A286 ≥ Case Detent Spring ≥


≥ 13 ≥ -- ≥ Detent Check Ball ≥


≥ 14 ≥ 7C493 ≥ Manual Control Lever Shaft ≥


≥ 15 ≥ 7F337 ≥ Manual Control Lever Shaft Seal ≥


≥ 16 ≥ 7E415 ≥ Ferrule ≥


≥ 17 ≥ 7E416 ≥ Spring ≥


≥ 18 ≥ -- ≥ Washer ≥


≥ 19 ≥ -- ≥ Retaining Pin ≥


≥ 20 ≥ -- ≥ Circlip ≥


≥ 21 ≥ 7C495 ≥ Park Lever Plate ≥


≥ 22 ≥ -- ≥ Manual Control Lever Nut ≥


≥ 23 ≥ 7A121 ≥ Park Actuator Support ≥


≥ 24 ≥ -- ≥ Park Actuator Lever ≥


≥ 25 ≥ -- ≥ Pivot Pin ≥


≥ 26 ≥ 7A232 ≥ Parking Lever Actuating Rod ≥


≥ 27 ≥ 7A206 ≥ Governor Inlet Tube ≥


≥ 28 ≥ 7D499 ≥ Governor Outlet Tube ≥


≥ 29 ≥ 7G101 ≥ Support ≥


≥ 30 ≥ -- ≥ Support Retaining Bolt ≥


≥ 31 ≥ 7A256 ≥ Manual Control Lever ≥


≥ 32 ≥ -- ≥ Manual Control Lever Arm ≥


≥ 33 ≥ 7A441 ≥ Parking Pawl ≥


≥ 34 ≥ 7D070 ≥ Parking Pawl Return Spring ≥


≥ 35 ≥ 7D071 ≥ Parking Pawl Shaft ≥


≥ 36 ≥ 7E085 ≥ Low/Reverse Clutch Dished Plate ≥


≥ 37 ≥ 7B164 ≥ Low/Reverse Clutch External Spline ≥

≥ ≥ ≥ Clutch Plate ≥


≥ 38 ≥ 7B442 ≥ Low/Reverse Clutch Internal Spline ≥

≥ ≥ ≥ Clutch Plate ≥


≥ 39 ≥ 7D483(1) ≥ Low/Reverse Clutch Pressure Plate ≥

≥ ≥ ≥ Retainer Snap Ring ≥


≥ 40 ≥ 7F341 ≥ Low and Reverse Clutch Hub ≥


≥ 41 ≥ 7D402 ≥ Low/Reverse Clutch Piston ≥


≥ 42 ≥ 7A548 ≥ Reverse Clutch Piston Large Seal ≥


≥ 43 ≥ 7D404 ≥ Reverse Clutch Piston Small Seal ≥


≥ 44 ≥ 7341 ≥ Manual Shaft O-Ring ≥


≥ 45 ≥ -- ≥ Manual Control Lever Nut ≥




(1) - NOT used when the transaxle is assembled in production, however, it is

required in assembly when servicing the transaxle.

40. Place a screwdriver underneath the governor outlet tube (7D469) and governor inlet tube (7A206) and gently pry outward. Remove the governor outlet tube and governor inlet tube.

41. Note the position of the parking pawl return spring (7D070) for installation reference. Remove the

parking pawl assembly by pulling the parking pawl shaft (7D071) straight out.

42. Remove the drum hub assembly from the transaxle case.

43. Remove the one-way clutch race (7D171) and rear planet carrier from the converter housing.

44. Use a flat-blade screwdriver to remove the low/reverse snap ring from the one-way clutch race.

45. Separate the rear planetary carrier from the one-way clutch race.

46. Remove the rear planet carrier to ring gear needle bearing and rear planet carrier to ring gear

thrust washer from the rear planet carrier.




≥ 1 ≥ 7D171 ≥ One-Way Clutch Race ≥


≥ 2 ≥ 7D006 ≥ Rear Planet Carrier ≥


≥ 3 ≥ 7G347 ≥ Snap Ring ≥


≥ 4 ≥ 7A166 ≥ Rear Carrier to Ring Gear Thrust Washer ≥


≥ 5 ≥ -- ≥ Drum Hub Assembly ≥


≥ 6 ≥ 7C096 ≥ Rear Carrier to Ring Gear Needle Bearing ≥


47. Before removing the one-way clutch (7A089) , use a feeler gauge to measure the clearance of the one-way clutch retaining plate and the one-way clutch. The clearance should be 0.8-1.05mm (0.032-0.041 inch). If the clearance is out of specification, adjust it by selecting the proper one-way clutch retaining plate at the time of installation.



Use a flat-blade screwdriver to remove the snap ring securing the one-way clutch and the one-way clutch retaining plate to the transaxle case. Remove the one-way clutch and the one-way clutch retaining plate.

49. Remove the low/reverse clutch pack and the low/reverse clutch dished plate.

50. Use Clutch Compressor T87C-77000-B to place the recessed side of the large plate over the low

and reverse clutch hub (7F341). Place the small plate on the opposite side of the case. Insert the bolt through the clutch compressor plates and tighten the nut until the tension is relieved from the low/reverse snap ring.



Use a flat-blade screwdriver to pry the low/reverse snap ring from the snap ring groove.

52. Remove Clutch Compressor T87C-77000-B.

53. Remove the low/reverse clutch hub.

54. Remove the return springs from the low/reverse clutch piston.

55. WARNING: WHEN PERFORMING THE FOLLOWING PROCEDURE, USE CARE TO PROTECT YOURSELF FROM THE FORCE OF THE PISTON. KEEP YOUR FINGERS FROM BETWEEN THE WOOD BLOCK AND THE PISTON. EYE PROTECTION SHOULD ALSO BE USED WHEN PERFORMING THIS OPERATION.

To remove the low/reverse clutch piston, hold a wood block over the low/reverse clutch piston and apply a short burst of air pressure (not to exceed 400 kPa [60 psi]) into the low/reverse clutch piston apply port in the transaxle case as shown.

56. Remove the parking pawl actuator support bolts. Remove the parking pawl actuator support.

57. Remove the manual control lever nut at the end of the manual control lever assembly, holding the

manual control lever (7A256) with an open-end wrench.

58. Remove the two circlips from the park actuator support (7A121).

59. Remove the park lever plate (7C495) and park actuator support from the manual control lever.

60. Remove the two manual control lever support bolts from the manual control lever support and slide

the manual control lever out of the transaxle case.

61. Remove the parking lever actuating rod (7A232) and ferrule as an assembly from the transaxle

case.

62. Position the transaxle with the oil pan opening facing up. Remove the roll pin securing the manual

control lever shaft (7C493) to the transaxle case by lightly tapping the roll pin with a 3/32 inch pin punch and a hammer.

63. Carefully slide the manual control lever shaft out of the transaxle case, making sure not to lose the

detent ball and case detent spring (7A286).

64. Remove the detent ball.

65. Use a small flat-blade screwdriver to remove the case detent spring.

Differential, Idler Gear Assembly and Output Shaft




≥ 1 ≥ 4026 ≥ Differential ≥


≥ 2 ≥ -- ≥ Idler Gear and Idler Gear Shaft ≥


≥ 3 ≥ -- ≥ Idler Gear Shaft Roll Pin ≥


≥ 4 ≥ -- ≥ Bearing Housing Bolt (8 Req'd) ≥


≥ 5 ≥ -- ≥ Bearing Housing (Part of 7005) ≥


≥ 6 ≥ 7060 ≥ Output Shaft ≥


≥ 7 ≥ -- ≥ Torque Converter Stator Support Bolt (6 ≥

≥ ≥ ≥ Req'd) ≥


≥ 8 ≥ 7A108 ≥ Torque Converter Stator Support ≥


≥ 9 ≥ 1177 ≥ Differential Oil Seal ≥






66. Lift the differential out of the converter housing.

67. Remove the idler gear shaft roll pin. Discard the idler gear shaft roll pin.

68. Remove the eight bearing housing bolts attaching the bearing housing to the converter housing.

69. Remove the idler gear and output gear assemblies by lightly tapping the idler gear shaft (7F358)

with a brass drift and hammer.

70. Use a brass drift and hammer and tap lightly on the idler gear shaft to remove the idler gear and

output gear assembly from the bearing housing.

71. Note: Separate or mark each output shaft bearing selective shim (7F405) upon removal for installation reference.

Use Stator and Driven Sprocket Bearing Remover T86P-70043-A, Puller T58L-101-B, and Impact Slide Hammer T50T-100-A to remove the bearing race from the bearing housing. Remove the output shaft bearing selective shim from the bearing housing.

72. Use Puller T58L-101-B, Stator and Driven Sprocket Bearing Remover T86P-70043-A, and Impact

Slide Hammer T50T-100-A to remove the differential side bearing races from the transaxle case and from the converter housing.

Transaxle Case

Converter Housing

73. Use a flat-blade screwdriver to remove the differential oil seals.

74. Use Seal Remover TOOL-1175-AC or equivalent, and Impact Slide Hammer T50T-100-A to

remove the converter impeller hub seal (7F401) from the torque converter stator support.

75. Use Puller T58L-101-B and Impact Slide Hammer T50T-100-A to remove the output shaft bearing

race from the torque converter stator support (still mounted in the converter housing).

76. Remove the six torque converter stator support bolts.

77. CAUTION: Have an assistant hold the torque converter stator support to prevent it from

falling on the floor and being damaged.

Use the appropriate step plate from Step Plate Adapter Set D80L-630-A or equivalent and Driver

Handle T80T-4000-W to remove the torque converter stator support.

78. Refer to «Cleaning and Inspection» for transaxle inspection.

transaxle - fordfestiva.com · 2012-09-20 · 37. remove the 12 transaxle case-to-converter housing...

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