Overhaul- CD4E Automatic Transmission: Specifications Ford Escape I

Torque Converter

1. A new or remanufactured torque converter must be installed if one or more of the following statements are true: A torque converter malfunction has been detected based on completed diagnostic procedures. NOTE: Stud threads can be repaired using a "thread chase". Converter stud(s), impeller hub or bushing is damaged. If there is a discoloration of the torque converter (due to overheating). The torque converter is found to be out of specification, when carrying out the following checks: Torque converter pump insert check Torque converter end play check Torque converter turbine torque check Torque converter leakage check If there is evidence of transmission assembly damage or fluid contamination due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failures Component wear which results in metallic contamination

Torque Converter Cleaning And Inspection

1. When a new or remanufactured torque converter is installed the following actions must take place: All cooler lines must be thoroughly cleaned by back and forward flushing using service manual procedures. All coolers (in-tank and auxiliary) must be thoroughly cleaned by back and forward flushing using service manual procedures. Carry out transmission cooler flow test as outlined in this section. If the transmission cooling system fails the flow test, new coolers or lines must be installed. If new cooler lines are to be installed, refer to «OIL COOLER TUBES»(ref-141219-S19610701432006020700000) for 2001 models or «OIL COOLER TUBES»(ref-141472-S37802072182002062600000) on 2002 models. If new coolers are to be installed, use only factory approved service parts.
2. If a new or remanufactured torque converter is not being installed, do the following: Thoroughly clean the torque converter. All cooler lines must be thoroughly cleaned by back and forward flushing using service manual procedures. All coolers (in-tank and auxiliary) must be thoroughly cleaned by back and forward flushing using service manual procedures. Carry out transmission cooler flow test as outlined in this section. If the transmission cooling system fails the flow test, new coolers or lines must be installed. If new cooler lines are to be installed, refer to «OIL COOLER TUBES»(ref-141219-S19610701432006020700000) for 2001 models or «OIL COOLER TUBES»(ref-141472-S37802072182002062600000) on 2002 models. If new coolers are to be installed, use only factory approved service parts.
3. Carry out all torque converter checks listed.
4. Check seal contact surface on impeller hub of torque converter for excessive wear or scoring.
5. Inspect the torque converter studs for damage.

Scheme 292

1. Partially fill the torque converter using clean automatic transmission fluid.
2. Hand agitate the converter, then thoroughly drain the fluid.
3. Repeat this procedure until the converter is clean.
4. After flushing, drain the remainder of the solvent.
5. Add 1.9 liters (2 quarts) of clean automatic transmission fluid and agitate by hand.
6. Thoroughly drain the converter.
7. Refill the torque converter with clean automatic transmission fluid and install into transaxle.

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1. Clean the outside surface of the torque converter.
2. Install the special tool into converter hub.
3. Position the torque converter with the installed special tool into an arbor press. Secure press. Apply enough force from press to seal tool into torque converter.
4. Using the special tool, apply air pressure to the valve.
5. With the special tool installed and air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, install a new converter.
6. Remove air hose. Release the pressure and then slowly release the press, and the tool. Remove the converter from the press.

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1. Insert the special tools in the turbine.
2. Tighten the center collet of the tool.
3. Using the special tool, position the indicator button on the converter housing and set the dial at zero.
4. Pull up on the special tool and observe the dial indicator reading.
5. If the end play exceeds specification, install a new or remanufactured torque converter.

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1. Install the oil pump drive shaft into the torque converter.
2. Install a torque wrench with a 5/16 inch Allen head socket attached on the oil pump drive shaft.
3. Verify that the insert can hold torque.
4. If the insert cannot hold the specified torque, install a new torque converter.

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1. Install special tools into the turbine splines in the torque converter.
2. Attach a torque wrench and determine the torque required to turn the turbine.
3. If the torque exceeds specification, install a new torque converter.

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1. Prepare the transaxle for assembly by proceeding with the following steps: Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent. Dry all parts with moisture-free regulated compressed air (do not use shop towels). Lubricate all internal parts (including friction plates) with clean automatic transmission fluid. Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly: Drive sprocket thrust washers. Driven sprocket thrust bearing shims. Differential case thrust bearing shims. Low/reverse clutch pressure plates. During assembly, use petroleum jelly to hold the parts in place (do not use grease). Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
2. Install intermediate and overdrive band assembly into the transaxle case.
3. Install the No.1 pump support thrust bearing. Lubricate the seal rings with clean automatic transmission fluid.
4. Install pump assembly into the case.
5. Install the pump assembly bolts.
6. Using the special tools, install the low/reverse clutch piston. Lubricate seals and piston bore with clean automatic transmission fluid.
7. Install the low/reverse clutch return spring assembly.
8. Install the low/reverse clutch return spring retaining ring.
9. Install the low/reverse clutch wave spring.
10. Install the low/reverse clutch plates. Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the low/reverse clutch pressure plate.
11. Install the low one-way clutch thrust plate.
12. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate. Take a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance. Pressure plate sizes: 2.57-2.46 mm (0.101-0.097 in) 2.36-2.26 mm (0.092-0.089 in) 2.16-2.06 mm (0.085-0.081 in)
13. Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction). Low one-way clutch thrust plate. Low/reverse clutch pressure plate. Low/reverse clutch external spline clutch plates (steel). Low/reverse clutch wave spring. Low/reverse clutch internal spline clutch plates (friction).
14. Install the No. 1 pump support thrust bearing assembly.
15. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
16. Install the turbine shaft.
17. Install the No. 4 turbine shaft thrust bearing.
18. Install the forward one-way clutch and low/intermediate sun gear assembly.
19. Install the No. 5 low/intermediate sun gear thrust bearing.
20. Install the low/intermediate carrier assembly.
21. Install the No. 6 low/intermediate carrier thrust bearing.
22. Install the low/intermediate ring gear assembly.
23. Install the No. 7 reverse/overdrive sun gear thrust bearing.
24. Install the reverse/overdrive sun gear and shell assembly.
25. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
26. Install the low/reverse clutch plates (model dependent). Install the low/reverse clutch external spline (steel) clutch plates. Install the low/reverse clutch internal spline (friction) clutch plates. Install the low/reverse clutch pressure plate previously selected.
27. Install the low/reverse clutch wave spring.
28. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
29. Install the low one-way clutch thrust plate.
30. Install the low one-way clutch retaining ring.
31. Install the manual valve detent lever actuating rod assembly. Install the parking cam actuator lever.
32. Install the manual valve detent lever.
33. Install the special tools.
34. Install the special tool with short spacers.
35. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area. Record this dimension. This dimension is designated with A.
36. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft. Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement. The average of these two dimensions is dimension B. Remove the special tools.
37. Subtract dimension B from dimension A to get dimension C.
38. Use the third dimension to select the correct No. 11 driven sprocket shim. Select a shim from the driven sprocket shim chart.
39. Install and lubricate the following: Lubricate the needles and seals in the No. 18 driven sprocket bearing. Install the selected No. 11 driven sprocket shim. Install the No. 12 driven sprocket bearing.
40. Install the No. 9 reverse/overdrive ring gear thrust bearing.
41. Install the reverse/overdrive ring gear assembly. NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
42. Install the special tools.
43. Install the special tool with short spacers.
44. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area. Repeat this measurement 180 degrees from the first measurement. The average of these two dimensions is dimension A. Remove the special tools.
45. Add 25.4 mm (1.01 in) (thickness of special tool) and thickness of short spacers. This is the dimension B.
46. Subtract dimension A from dimension B. This is dimension C.
47. Select No. 10 thrust washer from the drive sprocket thrust washer chart. Use the third dimension to select the No. 10 drive sprocket thrust washer.
48. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
49. Remove the reverse/overdrive ring gear assembly.
50. Install the filter and seal assembly.
51. Install the special tool in the filter eyelet and transaxle hole.
52. Using the special tool, install the filter recirculating regulator exhaust seal. NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
53. Install the chain pan in the transaxle case.
54. Assemble and install the drive chain assembly. Drive chain (copper colored link facing upward). Driven sprocket assembly. Reverse/overdrive ring gear assembly. Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
55. Install the chain pan cover by snapping it into place.
56. Install the No. 13 driven sprocket thrust bearing.
57. Install the final drive carrier and differential assembly.
58. Install the special tools. NOTE: Plastic washers should be placed between bolt heads and special tool. Install the special tool. Install the special tool and bolts.
59. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub. The special tools will need to be re-located to carry out the second measurement. Repeat this measurement 180 degrees from the first measurement. The average of these two dimensions is dimension B.
60. Use combined thickness of the special tool with long spacers 177.8 mm (7.11 in) as dimension A.
61. Subtract dimension B from dimension A. This is dimension C.
62. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart. DIFFERENTIAL END PLAY NO. 14 SHIM CHART If Dimension "C" is: Use No. 14 Differential Shim: 130.76 to 130.46 mm (5.148 to 5.136 in.) 1.08 to 0.98 mm (0.042 to 0.038 in.) 130.45 to 130.16 mm (5.136 to 5.124 in.) 1.38 to 1.28 mm (0.054 to 0.050 in.) 130.15 to 129.87 mm (5.124 to 5.133 in.) 1.67 to 1.57 mm (0.065 to 0.061 in.) 129.86 to 129.57 mm (5.113 to 5.101 in.) 1.97 to 1.87 mm (0.077 to 0.073 in.) 129.56 to 129.27 mm (5.101 to 5.089 in.) 2.27 to 2.17 mm (0.089 to 0.085 in.)
63. Install the differential bearing assembly Install the No. 14 differential bearing shim (selective fit). Install the No. 15 differential bearing.
64. Install the torque converter housing onto the transaxle case. NOTE: Check for correct alignment of the lube tube on the converter housing. Position and install the split flange gasket.
65. Install the torque converter housing-to-transaxle case bolts. NOTE: Tighten the bolts in the indicated sequence.
66. Lubricate the assembly with clean MERCON(R) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting MERCON(R) specification. NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly. Install the intermediate and overdrive servo apply rod and piston assembly. Install the overdrive servo apply rod spring.
67. Install the special tool.
68. Assemble the special tool. NOTE: Struts on the special tool fit into the servo cover retaining ring groove. Install struts. Install bar. Install bolts. Install the center bolt.
69. Using the special tool, measure the distance to the bar of special tool. Record this as dimension A.
70. Back off the center bolt of special tool until the piston movement stops. Vehicles with narrow groove case
71. Using the special tool, measure the dimension to the bar of special tool record as dimension B. Subtract dimension A from B to find the travel. If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly. Vehicles with wide groove case
72. Using the special tool, measure the dimension to the bar of special tool record as dimension B. Subtract dimension A from B to find the travel. If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly. All applications
73. Wipe the servo piston and the servo cover cap with a lint-free cloth.
74. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attached to the servo rod. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.
75. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
76. Inspect the servo retainer spring for cracks, breaks or deformation.
77. Assemble the special tool. WARNING: Servo return spring force is very high. Failure to follow these instructions can result in personal injury.
78. Install the special tool.
79. Tighten the special tool bolt. CAUTION: If the case is stamped "WG", install a wide-groove snap ring, or damage to the servo will result. CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed. Install the servo cover retaining ring, using retaining ring pliers.
80. Loosen the special tool bolt. When spring tension is released, remove the special tool.
81. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 19 kPa (2.76 psi) of moisture-free regulated compressed air. CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston. NOTE: If any leaks occur, make sure the special tool is correctly seated. Reverse clutch test port. Forward clutch test port. Direct clutch test port. Low/reverse clutch test port. Servo release test port. Servo apply test port. Transmission air test plate. If air leakage is detected, disassemble the transaxle and locate source of leakage.
82. Install the thermostatic fluid level control valve. Position the thermostatic fluid level control valve. Install the bracket. Install the thermostatic fluid level control valve bracket bolt.
83. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case. CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
84. Connect the manual valve. CAUTION: Handle main control valve body with care to prevent manual valve damage. Lift the main control away from the case. Connect the Z-link to the manual valve.
85. 85. NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others. Install the main control valve body mounting bolts.
86. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
87. Move the manual control lever shaft to the "D" position. Install pin to hold special tool in place.
88. Move the manual valve detent lever assembly to the "D" position.
89. Tighten the nut on the ball. Remove the shifter pin from the special tool.
90. Tighten the detent nut. Rotate back to "D" position to recheck the adjustment.
91. Using the special tool, recheck the manual control lever assembly setting.
92. Install the manual control lever.
93. Rotate the manual valve detent lever assembly to the NEUTRAL position. Low 1 Low 2 Drive Neutral Reverse Park
94. Position the transmission range (TR) sensor.
95. Using the special tool, align the TR sensor and tighten the bolts.
96. Install the main control cover gasket.
97. Install the main control cover. NOTE: Tighten the bolts in the indicated sequence.
98. Install the vent tube.
99. Install a new transmission filler tube grommet.
100. Install the transmission filler tube assembly. Install the tube. Install the transmission filler tube bolt. Install the fluid level indicator.
101. Install the turbine shaft speed (TSS) sensor. Use petroleum jelly on the O-ring seal and position the TSS sensor. Install a new O-ring seal. Install the TSS sensor bolt.
102. Using the special tool, install the LH differential seal.
103. Using the special tool, install the RH differential seal.
104. Using the special tool, install the torque converter fluid seal. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal. Coat the torque converter seal garter spring with petroleum jelly.
105. Install the drain plug.
106. Install the output shaft speed (OSS) sensor.
107. Install the pump drive shaft. NOTE: Check for correct rotation of the pump drive shaft.
108. Using the special tool, install the torque converter.
109. Remove the transaxle from the special tool.