Automatic Transmission - 4R100: Removal & Installation Ford Econoline E150

Removal

Note. If the transmission has been disassembled to replace worn or damaged parts, and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a suitable torque converter/fluid cooler cleaner.

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Installation

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1. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the rear transmission mount nuts.
3. Position the high-lift transmission jack under the transmission.
4. Remove the rear transmission mount. Raise the transmission up off the rear crossmember support. Remove the bolts. Remove the rear transmission mount.
5. Lower the transmission to gain access to the TSS sensor and the OSS sensor.
6. Remove the TSS sensor. Remove the bolt. Remove the TSS sensor.
7. Remove the OSS sensor. Remove the bolt. Remove the OSS sensor.

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1. Install the OSS sensor. Lubricate and install the OSS sensor. Install the bolt.
2. Install the TSS sensor. Lubricate and install the TSS sensor. Install the bolt.
3. Install the rear transmission mount. Raise the transmission up. Install the rear transmission mount. Install the bolts.
4. Lower the transmission on to the rear crossmember support.
5. Install the rear transmission mount nuts.
6. Lower the vehicle.

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1. Remove the main control valve body. For additional information, refer to «MAIN CONTROL VALVE BODY - ACCUMULATOR BODY, SOLENOID BODY»(ref-210155-S30848193112005121300000) .
2. Remove the intermediate servo.

1. Install the intermediate band servo.
2. Install the main control valve body.

Note. For internal park mechanism service, refer to MANUAL CONTROL LEVER SHAFT AND SEAL .

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1. Remove the extension housing and the extension housing gasket. For additional information, refer to «EXTENSION HOUSING SEAL AND BUSHING»(ref-210155-S30554328792005121300000) .
2. Remove the parking rod guide plate. Remove the bolts. Remove the parking rod guide plate.
3. Remove the park pawl shaft. Remove the park pawl return spring. Remove the park pawl. Remove the park pawl shaft.

Scheme 110

1. Install the park pawl shaft. Install the park pawl shaft. Install the park pawl. Install the park pawl return spring.
2. Install the parking rod guide plate. Install the parking rod guide plate. Install the bolts.
3. Install the extension housing gasket and the extension housing.

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SPECIAL TOOL(S)

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1. If equipped, remove the TSS sensor. Remove the bolt. Remove the TSS sensor.
2. Install the transmission into a suitable stand.
3. Remove the input shaft.
4. Remove the cooler bypass valve. Remove and discard the sealing washers and the cooler line case fittings.
5. Remove the transmission range (TR) sensor. Remove the bolts. Remove the TR sensor.
6. Remove the transmission fluid pan and gasket.
7. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.
8. Remove the bolts, nuts and the accumulator body.
9. Remove the main control valve body. Do not remove the two lower-to-upper main control valve body assembly bolts.
10. Remove the bolts, nut and the solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.
11. Remove the solenoid screen assembly by rotating and pulling.
12. Remove the separator plate reinforcing plate and the valve body separator plate with the two gaskets. Discard both gaskets.
13. Remove the steel EPC check ball and spring.
14. Using a small screwdriver, carefully remove the 8 rubber check balls.
15. Using a plastic or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.
16. Remove and discard the feedbolts.
17. Remove the pump bolts and discard the washers.
18. Using the special tools, remove the pump.
19. Remove the No. 1 pump thrust washer. Remove the No. 1 pump thrust washer. Remove the No. 2A overdrive sun gear thrust bearing. Remove the pump gasket and discard.
20. Using the special tool, remove the coast clutch, overdrive ring gear, and centershaft assembly.
21. Remove the No. 5 overdrive centershaft thrust bearing assembly.
22. Remove the overdrive clutch pressure plate retainer snap ring.
23. Remove the overdrive clutch pressure plate and the clutch pack.
24. Using the special tool, remove the intermediate/overdrive cylinder retaining ring.
25. Remove the intermediate/overdrive cylinder assembly.
26. Remove the intermediate clutch piston return spring.
27. Carefully remove the center support assembly.
28. Remove the No. 6 center support thrust washer.
29. Remove the intermediate clutch rear pressure plate. Remove the intermediate clutch pressure apply plate. Remove the intermediate clutch pack. Remove the intermediate clutch rear pressure plate.
30. Remove the intermediate band.
31. Using the special tool, remove the direct clutch, forward clutch and input shell as an assembly.
32. Remove the reverse planet retaining ring.
33. Remove the reverse planet assembly, No. 10B, and the No. 11 reverse planet carrier thrust washers.
34. Remove the output shaft retaining ring.
35. Remove the output shaft ring gear and hub assembly
36. Remove the following parts as an assembly. Reverse clutch pack (pressure plate, friction plate and seals). Reverse clutch hub. Low/reverse one way clutch assembly.
37. Using the special tools, remove the extension housing seal.
38. Using the special tool, remove the extension housing bushing.
39. Remove the eight bolts, one stud and the extension housing. Remove and discard the extension housing gasket.
40. Remove the output shaft and park gear assembly.
41. Remove the No. 13 thrust bearing.
42. Remove the plastic orifice lube plug from the rear of the case and discard.
43. Remove the 5 bolts retaining the low/reverse one-way clutch inner race to the case.
44. Remove the low/reverse one-way clutch inner race and the reverse clutch return spring assembly.
45. To remove the reverse clutch piston, reinstall the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring to restrain the reverse clutch piston.
46. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.
47. Remove the reverse clutch pressure plate retainer snap ring, the reverse clutch pressure plate and the reverse clutch piston.
48. If required, remove the parking rod guide plate.
49. If required, remove the parking pawl. Remove the parking pawl return spring. Remove the parking pawl. Remove the parking pawl shaft.
50. If required, remove the parking pawl abutment.
51. Using the special tool, remove the manual lever shaft retaining pin.
52. Remove the manual control lever shaft assembly. NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut. Remove the nut, the inner manual valve detent lever and the parking pawl actuating rod. Remove the manual control lever shaft assembly. Remove the bolt and the manual control valve detent lever spring.
53. Using the special tool, remove the manual control lever seal.
54. If required, remove the short fluid inlet tube.
55. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
56. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
57. If the transmission case assembly thread is damaged, repair kits (heli-coil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the heli-coil kit.

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