Diagnosis & Overhaul - c6 Ford Cab & Chassis Ranger

APPLICATION

TRANSMISSION APPLICATION

IDENTIFICATION

An identification tag is located under lower front intermediate servo cover bolt. A number appearing after the suffix indicates internal parts in transmission have been changed after initial production start-up. For example, a PJA-AL 15 model transmission that has been changed internally would read PJA-AL 16. (Scheme 49) Identification tag is located under lower front intermediate servo cover bolt.

Scheme 49

TRANSMISSION IDENTIFICATION CODES

DESCRIPTION

Transmission is a 3-speed unit capable of providing automatic upshifts and downshifts through 3 forward gear ratios and also providing manual selection of 1st and 2nd gears. Transmission consists basically of a torque converter, compound planetary gear train controlled by a single band, 3 multiple disc clutches, a one-way, clutch and hydraulic control system.

LUBRICATION & ADJUSTMENTS

Note. See appropriate SERVICING article.

Removal

1. Loosen oil pan retaining bolts, tap pan to break it loose allowing fluid to drain. Remove oil pan and gasket. Remove and discard nylon shipping plug from filler tube hole. NOTE: This plug is used to retain fluid in transmission during shipment and should be discarded when oil pan is removed.
2. Remove valve body retaining bolts and lower valve body from transmission case.

Installation

Position valve body to case, ensure selector and downshift levers are engaged. Install and tighten retaining bolts evenly. Install oil pan with new gasket, and tighten retaining bolts evenly.

Remove engine rear support-to-crossmember bolt. Remove crossmember-to-frame retaining bolts and remove crossmember. Disconnect muffler inlet pipe from exhaust manifolds and allow pipe to hang. Place a drain pan under servo and remove cover retaining bolts. Remove cover, piston, spring and gasket. (Scheme 50)

Note. As piston is being removed, screw in band adjusting screw. This keeps tension on band, keeping struts properly engaged in band end notches as piston is removed.

Scheme 50

Seal Replacement

1. Apply air pressure to port in servo cover and remove piston and rod. Remove seal from cover. Replace complete piston and rod assembly if piston or piston sealing lips are damaged.
2. Dip new seal in transmission fluid and install on cover. Coat 2 new gaskets with petroleum and install on cover. Dip piston in transmission fluid and install in cover.

To install, reverse removal procedure. Install service identification tag and back off band adjusting screw as servo cover bolts are being tightened. Adjust intermediate band and refill transmission to correct fluid level.

Disconnect propeller shaft at transmission. Using a tapered chisel, carefully remove rear seal. Using a bushing remover tool, remove bushing from extension housing.

Note. Use tool carefully so that spline seal is not damaged.

1. Install bushing into extension housing using a bushing driver. Before installing a new seal, inspect sealing surface of propeller shaft yoke for wear or damage. If scores are found, replace yoke.
2. Using a seal driver, install seal in extension housing, ensure that it is fully seated in bore. Coat inside of seal and yoke spline with wheel bearing grease and install propeller shaft.

1. Remove propeller shaft. Remove transfer case (if equipped) and speedometer cable. Remove engine rear support-to-extension housing bolts. Raise transmission with jack to take weight off support and remove support from crossmember.
2. Place drain pan under rear of transmission and remove extension housing-to-case bolts. Slide housing off output shaft. Remove governor housing-to-flange bolts and separate governor from flange.

To install, reverse removal procedure. Tighten all nuts and bolts. Make sure all mating surfaces are kept clean and refill transmission to correct fluid level.

ROAD TEST

1. Check minimum throttle upshift in "D". Transmission should start in 1st gear, shift to 2nd, and then shift to 3rd as speed increases. See «SHIFT SPEED SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6__shift-speed-specifications) .
2. With transmission in 3rd gear, depress accelerator through detent (to floor). Transmission should shift from 3rd to 2nd or 3rd to 1st, depending on vehicle speed. See «SHIFT SPEED SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6__shift-speed-specifications) .
3. Check closed throttle downshift from 3rd to 1st by coasting down from about 30 MPH in 3rd gear. Shift should occur as shown in table.
4. With transmission selector lever in "2" position, transmission should operate only in 2nd gear.
5. With transmission in 3rd gear and road speed above 30 MPH, transmission should shift to 2nd gear when selector lever is moved from "D" into "2" or "1". When manual shift is made below 30 MPH, transmission should shift from 2nd or 3rd to 1st. NOTE: This check will determine if governor pressure and shift control valve are operating properly.
6. Slipping or engine speed flare-up in any gear usually indicates clutch or band problems. In most cases, the clutch or band that is slipping can be determined by noting transmission operation in all selector positions and comparing which internal units are applied in those positions. See «CLUTCH & BAND APPLICATION (ELEMENTS IN USE)»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table.

CLUTCH & BAND APPLICATION (ELEMENTS IN USE) (1)

SHIFT SPEED SPECIFICATIONS

Note. Specifications given are approximate. All shift speeds may vary somewhat due to production tolerances, rear axle ratios, or emission control equipment.

Use appropriate TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION table to identify column usage in the appropriate SHIFT SPEED SPECIFICATIONS table.

SHIFT SPEED SPECIFICATIONS (MODELS PJE-A, B, C - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PJE-A, B, C)

SHIFT SPEED SPECIFICATIONS (MODELS PJ D - BA, BB, BC - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PJ D - BA, BB, BC)

SHIFT SPEED SPECIFICATIONS (MODELS PJE-B, C / HIGH ALTITUDE - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PJE-B, C / HIGH ALTITUDE)

SHIFT SPEED SPECIFICATIONS (MODELS PGD-FB, FC - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PGD-FB, FC)

SHIFT SPEED SPECIFICATIONS (MODELS PGD-EV, EY / HIGH ALTITUDE - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PGD-EV, EY / HIGH ALTITUDE)

SHIFT SPEED SPECIFICATIONS (MODELS PGD-AW, EG / HIGH ALTITUDE - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PGD-AW, EG / HIGH ALTITUDE)

SHIFT SPEED SPECIFICATIONS (MODELS PGD-EV, EY - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PGD-EV, EY)

SHIFT SPEED SPECIFICATIONS (MODELS PGD-AW, EG, EK - MPH)

TIRE SIZE/AXLE RATIO & COLUMN USAGE IDENTIFICATION (MODELS PGD-AW, EG, EK)

Scheme 51

Scheme 52

1. Attach tachometer to engine. Install vacuum gauge (using "T") into manifold vacuum line at vacuum diaphragm unit. Attach a 0-400 psi gauge to control pressure take-off point at transmission. (Scheme 51)and (Scheme 52).
2. Apply both parking and service brakes. With engine at curb idle speed and normal operating temperature. Read and record control pressure in all selector positions at specified manifold vacuum. Compare control pressures obtained in tests with pressures given in appropriate CONTROL PRESSURE SPECIFICATIONS table.

Vacuum Pump Method

1. Attach tachometer to engine and a 0-400 psi gauge to pressure take-off point at transmission. Disconnect and plug manifold vacuum line at diaphragm unit.
2. Connect vacuum source (vacuum pump in distributor tester). Apply both parking and service brakes. Start engine and vacuum pump, setting vacuum to 15 in. Hg. Read and record control pressure in all shift selector positions.
3. Increase engine to 1000 RPM; and reduce vacuum to 10 in. Hg. Read and record control pressure in "D", "2" and "1" shift selector positions.
4. With engine still at 1000 RPM, reduce vacuum to 1 in. Hg. Read and record control pressure in "D", "2", "1" and "R". Compare control pressures obtained in tests with pressures given in appropriate CONTROL PRESSURE SPECIFICATIONS table. NOTE: Governor can be checked at same time control pressure test is performed.
5. With vehicle raised, place selector lever in "2", no load on engine and apply 10 in. Hg. Increase speed slowly while watching speedometer, check speed at which control pressure cutback occurs. It should occur between 10-20 MPH.
6. Decrease vacuum to 0.2 in. Hg. and repeat test. Control pressure cutback should occur between 30-50 MPH. If cutback does not occur within specifications, check shift speeds to make sure that it is the governor and not a stuck cutback valve. CAUTION: DO NOT exceed 60 MPH speedometer speed during test. If control pressures are not within specifications, proceed to «CONTROL PRESSURE TEST RESULTS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) to determine problems.

Low At Idle In All Ranges

Check for low fluid level, restricted intake screen or filter, and loose oil tubes. Check for loose valve body or regulator-to-case bolts. Check for excessive leakage in front pump, case or control valve body. Check for sticking control pressure regulator valve.

Okay At Idle In All Ranges, But Low At 10 in. Hg

Check vacuum diaphragm unit. Check if control rod or throttle valve is stuck.

High At Idle In All Ranges

Check vacuum diaphragm unit, manifold vacuum line, throttle rod, and control rod. Check for sticking regulator boost valve(s).

Okay At Idle In All Ranges, Okay At 10 In. Hg, But Low At 1 In. Hg

Check for excessive leakage, low pump capacity or restricted oil pan screen.

1. Low in "P" - Check valve body pressure regulator.
2. Low in "R" - Check high clutch and/or reverse clutch.
3. Low in "N" - Check valve body for correct operation.
4. Low in "D" - Check for faulty forward clutch operation.
5. Low in "2" - Check forward clutch and servo.
6. Low in "1" - Check forward clutch and/or reverse clutch.

CONTROL PRESSURE SPECIFICATIONS (PGD-EV-EY-FD-DW-DL)

CONTROL PRESSURE SPECIFICATIONS (PGD-AW-EG-FE-FF-PJE-B-C)

CONTROL PRESSURE SPECIFICATIONS (PGD-EK-FB-FC-PJE-A)

CONTROL PRESSURE SPECIFICATIONS (PJD-BA-BB-BC)

Vacuum Supply Check

1. Disconnect vacuum line at vacuum unit and connect vacuum gauge. With engine idling, gauge must show a steady acceptable vacuum. If reading is to low, check for vacuum leak or poor engine vacuum.
2. If reading is acceptable, rapidly accelerate engine momentarily, vacuum must drop rapidly at acceleration and return immediately upon deceleration. If vacuum reading does not change or changes slowly, vacuum line is plugged, restricted or connected to reservoir supply. Repair as required.

Vacuum Diaphragm Unit Check

1. Remove unit from transmission. Use tester equipped with vacuum pump. Start pump and set regulator knob so vacuum gauge reads 18 in. Hg with end of hose blocked off.
2. Connect vacuum hose to port on unit. If gauge still reads 18 in. Hg, unit is leaking. If vacuum does not hold at 18 in. Hg, unit is leaking and must be replaced.
3. When hose is removed from unit, hold finger over end of control rod. Internal spring in unit should push control rod outward. Also, check for presence of transmission fluid in vacuum side of diaphragm or in vacuum hose. If fluid is present, unit is leaking and must be replaced.

Operational Check & Adjustment (6.9L Diesel Only)

1. Shut engine off. Disconnect 2 port vacuum connector from VRV which is located on left side of fuel injection pump. Remove throttle cable from lever on right side of pump.
2. Remove throttle return spring. Install 1 end of spring over throttle lever ball stud and other end over throttle cable support bracket. Insert Gauge Block (T83T-7B200-AH), or 0.515" gauge block, between pump boss and throttle wide open stop. Ensure lever stop is against block.
3. Attach a vacuum pump to upper port of VRV (vacuum supply side). Attach a vacuum gauge to lower port of VRV, (labeled TRANS or VRV). Apply and maintain 20 in. Hg to VRV.
4. It will be necessary to pump vacuum up as it bleeds off. Gauge attached to lower port should indicate 6.5-7.5 in. Hg if reading is incorrect, adjust VRV.
5. To adjust, loosen 2 adjustment screws that attach VRV to fuel injection pump. Rotate VRV until proper vacuum is obtained. Tighten adjusting screws after correct vacuum is obtained. If VRV cannot be adjusted to proper specifications, replace VRV and repeat procedure in step 2 .
6. Remove gauge block. Reattach throttle return spring and throttle cable. Again apply and maintain 20 in. Hg to VRV. Vacuum gauge MUST indicate at least 13 in. Hg with throttle at idle position.
7. If vacuum gauge indicates less than 13 in. Hg, VRV must be replaced and procedure for adjustment must be repeated. After final adjustment, remove vacuum pump and gauge from VRV and reattach vacuum connector.
8. Start engine and check throttle operation and check transmission shifts.

STALL SPEED TEST

Testing Procedure

Install tachometer and fully apply parking brake and service brakes. Start engine and run at curb idle and at normal operating temperature. Stall test transmission in each driving range at full throttle. Note maximum RPM obtained. Engine speed should be within limits shown in STALL SPEED SPECIFICATIONS table.

Note. Allow cooling period of 15 seconds with transmission in Neutral and engine speed at 1000 RPM between each test.

Stall Speed Too High

In "D", "2", "1", and "R"; general transmission problems are indicated and a control pressure test should be made to locate faulty unit(s). In "D" only; planetary one-way clutch slippage is indicated. In "D", "2", and "1"; forward clutch slippage is indicated. In "R" only; high and/or reverse clutch slippage is indicated.

Stall Speed Too Low

Converter stator one-way clutch faulty.

STALL SPEED SPECIFICATIONS

AIR PRESSURE CHECKS

1. A "No Drive" condition can exist, even with correct transmission fluid pressure, because of inoperative clutches or bands. Erratic shifts could be caused by stuck governor valve.
2. The inoperative units can be located through a series of checks by substituting air pressure for the fluid pressure to determine location of malfunction.
3. To make air pressure checks, loosen oil pan bolts and allow transmission to drain. Remove oil pan and control valve body. Apply air at points noted. (Scheme 53) Check unit operations as follows

Forward Clutch

Apply air pressure to transmission case forward clutch passage. A dull thud can be heard when clutch piston is applied, or movement of piston can be felt by placing a finger on input shell.

Governor

Apply air pressure to governor control pressure passage and listen for sharp clicking or whistling noise, indicating governor valve movement.

Reverse-High Clutch

Apply air pressure to reverse-high clutch passage, dull thud should be heard when clutch piston is applied. If not, place finger tips on clutch drum, movement should be felt.

Intermediate Servo

Hold air nozzle in intermediate servo apply passages. Operation of servo will be indicated by tightening of intermediate band around drum. With air still applied at apply passage, use 2nd air nozzle to apply air at the servo release passage. Band should now release (combination of air pressure and spring on release side of piston should overcome apply pressure).

Low-Reverse Clutch

Apply air pressure to reverse clutch apply passage. A dull thud should be heard if clutch is operating properly.

Scheme 53

TORQUE CONVERTER

Note. Converter is a sealed unit and cannot be disassembled for service. Replace if found to be defective. Make the following tests to be certain converter is defective before replacing unit.

Flushing Converter

Whenever transmission has been disassembled to replace worn or damaged parts or because valve body sticks due to foreign material, converter and oil cooler must be cleaned using a mechanically agitated cleaner (Rotunda 14U028). Under no conditions should converter or oil cooler be cleaned by hand agitation using solvent.

Leak Test

Note. If torque converter welds indicate leakage, attach Torque Converter Leak Detector (Rotunda 720004) to converter and follow detector kit instructions.

Turbine & Stator End Play Check

1. Insert test tool (T80L-7902-D) into converter pump drive hub until it bottoms. Expand sleeve in turbine spline by tightening threaded inner post of test tool until tool is securely locked into spine. (Scheme 54)
2. Attach a dial indicator to tool with button on indicator on converter pump drive hub. Zero dial face. Lift tool upward as far as it will go and note indicator reading.
3. Reading is total end play of turbine and stator. If end play exceeds.021" (.53 mm) new or rebuilt converter, or.040" (1.02 mm) used converter, replace torque converter assembly.

Scheme 54

Stator One-Way Clutch Check

1. Insert one-way clutch holding tool into one of the grooves in the stator thrust washer. Insert torque adapter (T83L-7902-A1) into converter pump drive hub so as to engage one-way clutch inner race. (Scheme 55)
2. Attach a torque wrench to torque adapter. With clutch holding wire held stationary, turn torque wrench counterclockwise. The converter one-way clutch should lock-up and hold a 10 ft. lb. (14 N.m) force. One-way clutch should rotate freely in a clockwise direction.
3. Repeat lock-up test in at least 5 different locations around torque converter. If clutch fails to lock-up and hold, replace torque converter.

Scheme 55

Stator-To-Impeller Interference Check

1. Position front-pump assembly on bench with spline end of stator shaft pointing up. Mount converter on pump so splines of one-way clutch inner race engage splines of stator support and converter hub engages pump drive gear.
2. While holding pump stationary, rotate converter counterclockwise. Converter should rotate freely without interference or scraping within assembly. Should this condition exist, replace converter unit.

Stator-To-Turbine Interference Check

1. Place converter on bench, front side down. Install front pump assembly to engage mating splines of stator support, stator and pump drive gear lugs.
2. Install input shaft, engaging the splines with turbine hub. While holding pump stationary, rotate turbine with input shaft.
3. Turbine should rotate freely in both directions without interference or noise. If interference or noise exists, stator front thrust washer may be worn; the converter should be replaced.

Scheme 56

Scheme 57

1. With transmission in a holding fixture, remove oil pan and gasket. Remove retaining bolts and lift valve body assembly from transmission case.
2. Attach a dial indicator to front pump with indicator contact against input shaft. Install oil seal replacing tool (T61 L-7657-8) in extension housing to center output shaft. (Scheme 56)
3. Check transmission end play as follows: Push gear train to rear of case. Press input shaft inward until bottomed. Zero dial indicator.
4. Push gear train forward. Read and record end play for reference at reassembly. Compare reading with specifications. See «TRANSMISSION END PLAY SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table. Remove checking tools from transmission.
5. Remove vacuum diaphragm, rod and primary throttle valve from case. Slide input shaft from front pump. Remove front pump retaining bolts, pry gear train forward and remove pump. TRANSMISSION END PLAY SPECIFICATIONS Application In. (mm) C-6.008-.044 (.21-1.12)
6. Loosen band adjusting screw and remove 2 band struts. Rotate band 90° counterclockwise to align band ends with slot in case. Remove band from reverse-high clutch drum.
7. Remove forward part of gear train from transmission as an assembly. (Scheme 57) Remove servo cover retaining bolts, servo cover, piston, spring and gasket from case. Remove large snap ring securing reverse planet carrier in low-reverse clutch hub.
8. Lift carrier from drum. Remove snap ring securing reverse ring gear and hub on output shaft and slide assembly from shaft. Rotate low-reverse hub in clockwise direction and remove from case.
9. Remove reverse clutch snap ring and withdraw clutch discs, plates and pressure plate from case. Remove extension housing retaining bolts and vent tube from case.
10. Remove extension housing and gasket. Slide output shaft assembly from case. Remove distributor sleeve retaining bolts. Remove sleeve, parking pawl gear and thrust washer. NOTE: If thrust washer is staked in place, use a sharp chisel and cut off metal from behind thrust washer. Remove any metal particles from case.
11. Compress reverse clutch piston release spring. Remove snap ring and lift out springs and retainer assembly.
12. Remove one-way clutch inner race retaining bolts from rear of case and remove inner race. Remove reverse clutch piston by applying air pressure to low-reverse apply passage in case. NOTE: (Scheme 54)for location of low-reverse apply passage.

Scheme 58

1. Remove nut and lock washer securing outer downshift lever to transmission and remove lever. (Scheme 58) Slide downshift lever out from inside case and remove seal from recess in manual lever shaft.
2. Remove neutral safety switch bolts and remove switch. Remove "C" clip securing parking pawl actuating rod to manual lever. Remove rod from case.
3. Remove nut retaining inner manual lever to shaft. Remove inner lever from shaft. Slide outer lever and shaft from case. Remove seal from case using a puller and slide hammer.

Reassembly

1. Dip new seal in transmission fluid and install into case using installing tools. Slide outer manual lever and shaft into case. Position inner lever on shaft, making sure leaf spring roller is positioned in inner manual lever detent.
2. Install retaining nut and tighten. Install parking pawl actuating rod and secure to inner manual lever with "C" clip. Slide neutral safety switch onto outer shaft lever.
3. Install retaining bolt. With manual lever in neutral, rotate switch and install gauge pin (No. 43 drill) into gauge pin hole. Tighten switch retaining bolt.
4. Install a new downshift lever seal in outer lever shaft recess. Slide downshift lever and shaft into position. Place outer downshift lever on shaft. Install and tighten lock washer and nut.

Disassembly

1. Remove bolts retaining parking pawl guide plate to case. Remove plate. Remove spring, parking pawl and shaft from case. (Scheme 59)
2. Working from pan mounting surface, drill a 1/8" hole through center of cupped plug. Pull plug from case with a wire hook.
3. Unhook end of spring from park plate slot. Thread a 1/4-20 x 1 1/4" screw into park plate shaft. Pull shaft from case with screw. Remove spring and park plate.

1. Position spring and park plate in case and install shaft. Place end of spring into slot of park plate. Install a new cupped plug to retain shaft. Install parking pawl shaft in case.
2. Slip parking pawl and spring into place on shaft. Position guide plate on case, making sure actuating rod is seated in slot of plate. Secure plate with 2 bolts and lock washers.

Scheme 59

Working from inside case, carefully tap on servo apply lever shaft to remove the cup plug; shaft can be withdrawn by hand.

Hold servo apply lever in position and install shaft. Using fabricated shop tool (Scheme 60), drive cup plug into position in case. Make sure plug is flush with shoulder of counterbore.

Note. Cup plug should be coated with Loctite to prevent leakage.

Scheme 60

1. Remove 9 screws retaining screen-to-lower valve body and remove screen and gasket. Remove 5 upper-to-lower valve body and hold down plate retaining screws.
2. Remove 7 retaining screws from underside of lower valve body and separate bodies, removing separator plate and gasket. Be sure to avoid losing check balls and springs. Remove and clean separator plate screen. (Scheme 61)and (Scheme 62). NOTE: Do not clean screen gasket in solvent; wipe clean with a lint-free cloth.
3. Remove manual valve plunger retaining pin from upper valve body and remove plunger. Slide manual valve out of valve body. Cover downshift valve port with finger and remove downshift valve retainer. Remove spring and downshift valve.
4. Apply pressure to pressure boost valve sleeve and remove retaining clip from underside of valve body. Slowly release pressure and remove sleeve and pressure boost valve. Remove 2 springs, retainer and main regulator valve from bore.
5. Apply pressure to throttle boost valve plate and remove 2 retaining screws. Release pressure and remove plate, throttle boost valve, spring and manual low 2-1 scheduling valve and spring from bore.
6. Apply hand pressure on remaining valve body plate and remove 8 retaining screws. Hold valve body so plate faces upward. (Scheme 63)
7. Release hand pressure on plate and remove. Remove spring and intermediate servo modulator valve from body. Remove intermediate servo accumulator valve and springs.
8. Remove 2-3 back-out valve, spring and 3-2 shift timing valve plug (if not peened on end). Remove 2-3 shift valve, spring and throttle modulator valve.
9. Remove 1-2 shift valve, DR-2 shift valve and spring. Remove coasting regulator valve and cutback valve from body.

Note. Do not attempt to remove 3-2 shift timing plug if end is peened over. Condition will not affect transmission operation.

Scheme 61

Scheme 62

Scheme 63

To reassemble, reverse disassembly procedure. Coat check balls with petrolatum to hold in place during reassembly. When installing screen in separator plate, make sure tabs are flush with separator plate surface. Tighten all bolts and screws evenly.

FRONT PUMP

Note. Front seal can be replaced with pump installed in transmission.

1. Remove 2 seal rings and selective thrust washer. Remove large square cut seal from outside diameter of pump housing.
2. Remove 5 bolts securing stator support to pump housing. Lift support from housing. Remove drive and driven gears from housing. (Scheme 64)

Scheme 64

Pump Housing Bushing Replacement

Remove bushing from pump housing using a driver and hammer. Place new bushing into position. Make sure half moon slot in bushing is on top and in line with oil lube hole near seal bore. Press bushing in .060-.080" (15.24-2.03 mm) below front face of bushing bore.

Note. After assembly, half moon slot must be below lube hole to provide proper lubrication.

1. Install drive and driven gear into pump housing with identification mark or chamfered surface of each gear installed toward front of pump housing. Position stator support in pump housing. Install and tighten retaining bolts.
2. Carefully install 2 new seal rings on stator support. Make sure ends of rings are engaged to lock them in place. Install a new square cut seal on outside diameter of pump housing.
3. Install selective thrust washer. See «FRONT PUMP SELECTIVE THRUST WASHERS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table. Place pump on torque converter. Make sure drive gear engages converter hub. Rotate pump to ensure that gears rotate freely. NOTE: Different clutch assemblies are used in various models. When disassembling clutches, note number and location of plates used for reassembly reference. FRONT PUMP SELECTIVE THRUST WASHERS Color Code Thickness In. (mm) Blue .056-.060- (1.42-1.52) Natural (White) .073-.077 (1.85-1.96) Red .088-.092 (2.24-2.34)

1. Remove pressure plate snap ring by prying up with screwdriver. Remove pressure plate, drive and driven plates. Using Clutch Spring Compressor (T65L-77515-A) compress piston return springs. (Scheme 65)
2. Remove snap ring, spring retainer and springs. Apply air pressure to piston apply hole in drum and remove piston. Remove piston outer seal from piston and inner seal from clutch drum.

Scheme 65

Bushing Replacement

To remove front bushing, use a cape chisel and cut along bushing seam until chisel breaks through bushing wall. Pry loose ends of bushing up to remove. Remove rear bushing using a press ram and bushing adapter. Install bushings using bushing drivers.

Scheme 66

1. Dip new seals in transmission fluid and install one seal on piston and one in drum. Install piston into clutch drum. Position return springs in pockets as shown. (Scheme 66) Place spring retainer over springs. Using compressor tool, compress springs and install snap ring. NOTE: Before releasing tool, make sure snap ring is seated inside 4 snap ring guides on spring retainer.
2. Install clutch plates alternately starting with a steel drive plate. If new clutch plates are being installed, composition plates must be soaked in transmission fluid for 15 minutes before installation.
3. Install pressure plate and retaining Snap ring. See «CLUTCH PLATE APPLICATION»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table for the number of clutch plates required.
4. Using a feeler gauge, check clearance between pressure plate and snap ring. Hold pressure plate downward while measuring. Clearance should be.022-.036" (.56-.91 mm).
5. If clearance is not within specifications, selective snap rings are available in the following thickness:.056-.060" (1.42-1.52 mm).065-.069" (1.65-1.75 mm).074-.078" (1.88-1.98 mm).083-.087" (2.11-2.21 mm).092-.096" (2.34-2.44 mm).110-.114" (2.79-2.90 mm).128-.132" (3.25-3.35 mm) Install correct thickness snap ring and recheck clearance.

CLUTCH PLATE APPLICATION

1. Remove clutch pressure plate retaining snap ring. Remove rear pressure plate, drive and driven plates and forward pressure plate from clutch drum. (Scheme 67)
2. Remove snap ring securing disc spring in drum and remove disc spring. Apply air pressure to clutch apply passage in drum and remove piston. Remove seals from piston and drum.

Scheme 67

1. Dip 2 new seals in transmission fluid. Install smaller seal on clutch hub and other seal on piston. Install clutch piston in cylinder.
2. Make sure steel pressure ring is in groove on piston. Place disc spring in clutch drum with dished face downward. Secure in place with retaining snap ring. NOTE: If new composition plates are being installed, soak them in transmission fluid for 15 minutes prior to installation.
3. Install forward pressure plate with flat side up and beveled side downward. Dip clutch plates in transmission fluid.
4. Install clutch plates starting with the waved plate, then a steel plate and a composition plate. Install remaining plates in this sequence. NOTE: See «CLUTCH PLATE APPLICATION»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table for the number of clutch plates required.
5. Using a feeler gauge, check clearance between snap ring and pressure plate. Hold pressure plate down while measuring.
6. Clearance should be .021-.046" (.53-1.17 mm). If clearance is not within specifications, selective snap rings are available in following thicknesses: .056-.060" (1.42-1.52 mm) .065-.069" (1.65-1.75 mm) .074-.078" (1.88-1.98 mm) .083-.087" (2.11-2.21 mm) .092-.096" (2.34-2.44 mm) .110-.114" (2.79-2.90 mm) .128-.132" (3.25-3.35 mm). Install correct thickness snap ring and recheck clearance.

Remove rear (external) snap ring from sun gear and remove thrust washer from sun gear and input shell. Working inside input shell, remove sun gear. Remove forward (internal) snap ring from gear. (Scheme 68)

Scheme 68

Install forward snap ring on short end of sun gear. Working inside input shell, slide sun gear and snap ring into place. Making sure longer end of gear is at rear. Place thrust washer on rear side of input shell. Install rear snap ring.

Disassembly & Reassembly

If it is necessary to remove these parts, remove hub retaining snap ring and lift hub from ring gear. (Scheme 69) When installing, secure hub with retaining snap ring. Make sure snap ring is fully engaged in groove.

Scheme 69

Remove snap ring and bushing from rear of low-reverse clutch hub. Remove rollers from spring assembly. Lift spring assembly from hub. Remove remaining snap ring from hub. (Scheme 70)

Scheme 70

1. Install snap ring in forward groove of low-reverse clutch hub. Place hub on bench with forward end down. Install spring assembly on top of snap ring.
2. Install a roller into each spring assembly compartment. Install bushing on top of spring assembly. Install remaining snap ring at rear of clutch hub to secure assembly.

Apply air pressure to port in servo cover and remove piston assembly. Remove seal from cover.

Note. Piston and rod are serviced as an assembly. Replace if piston or sealing lips are damaged.

Dip new seal in transmission fluid and install on cover. Dip piston assembly in transmission fluid and install in cover.

LOW-REVERSE CLUTCH PISTON

Note. Clutch is assembled as part of transmission reassembly; replace seals as follows: Remove inner and outer seals from clutch piston. Dip new seals in transmission fluid and install on piston.

Remove governor retaining bolts and governor. Remove snap ring securing governor distributor to output shaft. Slide distributor off front of shaft. Remove seal rings from governor distributor. (Scheme 71)

Scheme 71

1. Carefully install new seal rings on distributor. Working from front end of output shaft, slide governor distributor into place on shaft.
2. Secure in place with snap ring. Make sure snap ring is fully seated in groove. Position governor on distributor. Install and tighten retaining screws.

TRANSMISSION REASSEMBLY

Note. To aid in reassembly (Scheme 72)

1. With transmission mounted in fixture, tap low-reverse clutch piston into case with soft mallet. Hold one-way clutch inner race in position, then install and tighten retaining bolts.
2. Install low-reverse clutch return spring and retainer assembly in clutch piston. Position snap ring on one-way clutch inner race. Compress return spring and retainer and seat snap ring in groove.
3. Place transmission case on bench with front end facing downward. Position parking gear thrust washer and gear on case. It is not necessary to restake thrust washer. Position oil distributor and tubes on rear of case.
4. Install and tighten retaining bolts. Install output shaft and governor as an assembly. Place a new gasket on rear of case. Install extension housing and retaining bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6__torque-specifications) . Install vent tube.
5. Coat 2 new servo cover gaskets with petroleum jelly and position them on servo cover. Place servo spring on piston rod and install in case.
6. Install retaining bolts. Make sure identification tag is under one of the cover bolts and tighten. Align low-reverse clutch hub and one-way clutch with inner race at rear of case.
7. Rotate low-reverse clutch hub clockwise while applying pressure to seat it on inner race. Install low-reverse clutch plates, starting with the waved plate next to piston and follow with a steel, then a composition plate until all plates are installed.
8. Retain plates with petroleum jelly. Install pressure plate and snap ring. Test operation of low-reverse clutch assembly by applying air pressure to clutch pressure apply hole in case.
9. Install reverse planet ring gear thrust washer, ring gear and hub assembly. Install snap ring in groove of output shaft. Install front and rear thrust washers onto reverse planet assembly. Retain with petroleum jelly.
10. Install assembly into ring gear and install snap ring. Place reverse-high clutch on bench with front end facing downward. Install thrust washer on rear end of assembly and retain with petroleum.
11. Install splined end of forward clutch into open end of reverse-high clutch with splines engaging direct clutch plates. Install thrust washer on front end of forward planet ring gear and hub. Retain with petroleum jelly.
12. Install ring gear into forward clutch and install thrust washer on front end of forward planet assembly and retain with petroleum jelly.
13. Install assembly into ring gear. Install input shell and sun assembly. Install reverse-high clutch, forward clutch, forward planet assembly, input shell and sun gear as an assembly into case.
14. Install intermediate band around direct clutch drum. Install band struts and tighten band adjusting screw enough to retain band.
15. Place selective bronze thrust washer on rear shoulder of stator support and retain with petroleum jelly.
16. If end play was not within specifications when disassembled, replace washer at this time with one of proper thickness. See «TRANSMISSION END PLAY SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6) table under TRANSMISSION DISASSEMBLY.
17. Using 5/16 x 3" bolts, make 2 alignment studs by cutting the heads off and grinding a taper on the cut end. Install the studs opposite each other in case mounting holes.
18. Slide a new gasket onto studs. Position pump on case, being careful not to damage seal on pump housing, and remove studs. Install 6 of the mounting bolts and tighten.
19. Tighten intermediate band adjusting screw to 10 ft. lbs. (14 N.m). Back off screw exactly 1 1/2 turns. Hold adjusting screw in this position and tighten lock nut to specification. See «TORQUE SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/automatic-trans/#diagnosis-overhaul-c6__torque-specifications) .
20. Install input shaft with long splined end inserted into forward clutch assembly. Check end play again to ensure correct assembly. Install control valve body into case, making sure levers engage valves properly.
21. Install primary throttle valve, rod and vacuum diaphragm in case. Install oil pan with new gasket. Install retaining bolts and tighten. Install torque converter.

Scheme 72

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• SHIFT SPEED SPECIFICATIONS
• CLUTCH & BAND APPLICATION (ELEMENTS IN USE)
• TORQUE SPECIFICATIONS