Automatic Transmission - CD4E: Component Locations — Ford Escape I facelift (2004-2007)

Special Tool(s)

SPECIAL TOOLS DESCRIPTION CD4E Cable 418-F113 (007-00125) or equivalent MLP-D Cable 418-F117 (007-00129) or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73 III Digital Multimeter 105-R0057 or equivalent Alignment Gauge, TR Sensor 307-351 (T97L-70010-A) Air Test Plate, Transmission 307-301 (T94P-77000-S) Transmission Tester 307-F016 (007-00130) or equivalent 12 Volt UV Spot Lamp 164-R0751 or equivalent

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Scheme 67: Special Tool(s)

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Diagnosing an electronically controlled automatic transaxle is simplified by using the following procedures. One of the most important things to remember is that there is a definite procedure. Do not take short cuts or assume that critical checks or adjustments have already been made. Follow the procedures as written to avoid missing critical components or steps. By following the diagnostic sequence, the repair technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics With Diagnostic Tool

Note. For detailed instructions and other diagnostic methods using the diagnostic tool, refer to INTRODUCTION - GASOLINE article for Escape (gasoline) and Mariner or INTRODUCTION- HYBRID ESCAPE article for Escape (Hybrid) or diagnostic tool instruction guide.

Note. If using a generic diagnostic tool, refer to INTRODUCTION - GASOLINE article for Escape (gasoline) and Mariner or INTRODUCTION- HYBRID ESCAPE article for Escape (Hybrid) article diagnostic tool instruction guide.

The Quick Tests can be used to diagnose the powertrain control module, sensors and actuators of this transaxle.

The following is a guide for using the on-board diagnostic (OBD) Quick Tests and the diagnostic tool.

Quick Test 1.0 - Visual Inspection
Quick Test 2.0 - Set Up
Quick Test 3.0 - Key On/Engine Off
Quick Test 4.0 - Continuous Memory
Quick Test 5.0 - Key On/Engine Running
Special Test Mode Wiggle Test Mode Output Test Mode
PCM Reset Mode
Clearing DTCs
OBD II Drive Cycle
Other Diagnostic Tool Features

For additional information on other diagnostic testing features using the diagnostic tool, refer to INTRODUCTION - GASOLINE article for Escape (gasoline) and Mariner or INTRODUCTION- HYBRID ESCAPE article for Escape (Hybrid). Other diagnostic methods include the following

Parameter identification (PID) access mode, used to monitor sensors and actuators.
Freeze frame data access mode, used to view emission-related data values from specific PIDs.
Oxygen sensor monitor mode, used to monitor the oxygen sensor.

SPECIAL TOOLS DESCRIPTION Air Test Plate, Transmission 307-301 (T94P-77000-S) Test Plate Screw Set, Transmission 307-126 (T82P-7006-C)

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The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portion of the transaxle.

SPECIAL TOOLS DESCRIPTION Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A) Installer, Halfshaft Output Fluid Seal 307-157 (T86P-1177-B)

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Scheme 75: Special Tool(s)

SPECIAL TOOLS DESCRIPTION Remover, Input Shaft Oil Seal 308-375 Slide Hammer 100-001 (T50T-100-A) Installer, Halfshaft Output Fluid Seal 307-157 (T86P-1177-B) Remover, RH Halfshaft Fluid Seal 307-429 Installer, RH Halfshaft Fluid Seal 307-428

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SPECIAL TOOLS DESCRIPTION Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)

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Scheme 78: Removal

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Remove the battery and tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254) .
Remove the transmission range (TR) sensor. Disconnect the TR sensor electrical connector. Remove the TR sensor retaining bolts. Remove the TR sensor.

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Scheme 80: Installation

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Install the TR sensor and loosely install the bolts.
Using the special tool, align the TR sensor and tighten the bolts. Tighten to 11 Nm (8 lb-ft).
Connect the TR sensor electrical connector.
Install the battery and tray. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(ref-232254) .
Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position.

SPECIAL TOOLS DESCRIPTION Remover/Installer, Servo Cover 307-295 (T94P-77000-L)

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Scheme 82: Special Tool(s)

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Remove the 7 retainers and the LH splash shield.
Remove the transmission fluid cooler line bracket and bolt and position it aside.
Using the special tool, remove the servo retaining ring. Install the special tool. Compress the servo assembly by tightening the bolt. Remove the retaining ring.
Remove the servo cover assembly.
Remove the intermediate and overdrive servo piston and return spring.
Wipe the servo piston and the servo cover cap with a lint free cloth.
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 is attached to the servo rod.
Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.
Inspect the servo retainer spring for cracks, breaks or deformation.

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Scheme 85: Installation

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Install the return spring and the intermediate overdrive servo piston.
Install the servo cover cap.
Install the special tool.
Tighten the special tool bolt. Install the servo cover retaining ring.
If the case is stamped "WG", install a wide-groove snap ring, or the servo will be damaged.
Loosen the special tool bolt. When the spring tension is released, remove the special tool.
Install the transmission fluid cooler line and bolt. Tighten to 13 Nm (10 lb-ft).
Install the LH splash shield and the 7 retainers. Tighten to 10 Nm (89 lb-in).
Start the vehicle. Place the transmission range selector lever in each gear and allow to engage. Check for leaks.
Check the transmission fluid.

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Scheme 87: Transaxle Support Insulator - Lower, Front

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Scheme 88: Removal

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Remove the LH splash shield.
Remove the 7 retainers and the LH splash shield.
Remove the 4 bolts and the cross brace.
Remove the bolt for the mount and the 2 bolts for the brace.
Remove the rear bolt and remove the brace.
Remove the 2 bolts from the mount and remove the mount.

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Install a new mount onto the brace and install the bolts. Tighten to 40 Nm (30 lb-ft).
Position the brace in place and install the nut. Tighten to 150 Nm (111 lb-ft).
Install the 2 bolts for the brace. Tighten to 90 Nm (66 lb-ft).
Install the bolt for the mount. Tighten to 115 Nm (85 lb-ft).
Install the cross brace and the 4 bolts. Tighten to 48 Nm (35 lb-ft).
Install the LH splash shield and the 7 retainers. Tighten to 10 Nm (89 lb-in).
Install the LH splash shield.

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Scheme 94: Transaxle Support Insulator - Lower, Rear, 3.0L DOHC

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Scheme 95: Removal and Installation

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Disconnect the breather tube and mass air flow (MAF) sensor.
Remove the intake tube and air cleaner cover.
Remove the air cleaner assembly.
Remove the mount through bolt. To install, tighten to 120 Nm (89 lb-ft).
Remove the 1 retaining bolt and the 2 nuts for the mount and remove the mount. To install, tighten to 90 Nm (66 lb-ft).
To install, reverse the removal procedure.

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Scheme 98: Transaxle Support Insulator - Lower, Rear, 2.3L

SPECIAL TOOLS DESCRIPTION Adapter for 303-290A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A Adapters for 303-290 303-290A-01 Engine Lifting Chains (Part of Spreader Bar) 303-D089 (D93P-6001-A3) or equivalent

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Scheme 99: Special Tool(s)

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Disconnect the breather tube and mass air flow (MAF) sensor.
Remove the intake tube and air cleaner cover.
Remove the air cleaner as an assembly.
Install the special tools.
Install the special tools.
Remove the upper transaxle mount through bolt. To install, tighten to 103 Nm (76 lb-ft).
Remove the 4 upper transaxle mount bolts and remove the mount. To install, tighten to 55 Nm (41 lb-ft).
To install, reverse the removal procedure.

SPECIAL TOOLS DESCRIPTION Adapter for 303-290A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A Adapters for 303-290 303-290A-01 Retainer, Torque Converter 307-346 (T97T-7902-A) Front Hub Remover 205-D070 (D93P-1175-B) or equivalent Slide Hammer 100-001 (T50T-100-A) Remover, Halfshaft 205-241 (T86P-3541-A)

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Scheme 107: Removal

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Remove the battery and the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
Remove the air cleaner as an assembly. Remove the bolt. Disconnect the mass air flow (MAF) sensor electrical connector. Disconnect the brake booster vacuum hose. Disconnect the wiring harness retainer. Disconnect the breather tube. Loosen the clamp and remove the air cleaner assembly.
Disconnect the power take-off (PTO) vent hose from the clip located on the fill tube.
Remove the nut holding the wiring harness bracket and unplug the bulkhead electrical connector.
Remove the 2 bolts from the shift cable bracket and disconnect the shift cable from the manual lever.
Disconnect the transmission range (TR) sensor electrical connector.
Remove the 3 upper transaxle retaining bolts.
Install the special tools.
Install the special tools.
Remove the LH transaxle mount through bolt.
Remove the 2 nuts, the bolt and the through bolt and remove the rear transaxle mount.
Remove the 6 bolts holding the driveshaft to the PTO.
Remove the 2 center bearing nuts and position the driveshaft aside with mechanic's wire.
Remove the 4 bolts and remove the cross brace.
Remove the 7 retainers and the LH splash shield.
Remove the 5 retainers and the RH splash shield.
Remove the bolt for the mount and the 2 bolts from the cross brace.
Remove the rear nut and the cross brace.
Remove the drain plug and drain the fluid.
Remove and discard the LH front axle wheel hub nut.
Remove the frame bolt from the LH and RH control arms.
Using the special tool, separate the LH half shaft from the front wheel knuckle.
Using the special tools, remove the LH halfshaft and disconnect the RH halfshaft from the intermediate shaft.
Remove the 2 intermediate shaft retaining nuts.
Remove the intermediate shaft.
Remove the 2 bolts which hold the exhaust bracket to the intermediate shaft bracket.
Remove the 2 nuts on the other end of the exhaust-to-intermediate shaft bracket and remove the bracket.
Remove the 3 nuts and separate the flexpipe from the exhaust manifold.
Remove the 6 bolts holding the engine bracket to the PTO and remove the bracket.
Remove the 3 bolts and the PTO assembly.
Remove the 3 bolts and the dampener.
Remove the 3 bolts holding the transaxle front mount plate.
Remove the fluid cooler line.
Remove the fluid cooler tube. Disconnect the output shaft speed (OSS) sensor electrical connector (black). Disconnect the turbine shaft speed (TSS) sensor electrical connector (white). Disconnect the wiring harness retainer from the transmission case and position the harness aside. Remove the transmission fluid cooler line retaining bracket bolt. Remove the fluid cooler tube and position it aside.
Remove the OSS sensor.
Disconnect the starter terminals. Remove the battery cable nut. Remove the starter solenoid terminal nut.
Remove the wire harness clip retainer and the ground wire from the starter bolts.
Remove the 3 bolts and remove the starter.
Remove the starter motor isolator.
Remove and discard the 4 torque converter nuts.
Using the special tool, lower the transmission.
Push the converter back from the flexplate. Use a suitable transmission jack to support the transaxle and remove the 3 rear bellhousing bolts.
Remove the 4 remaining transaxle-to-engine bolts.
Move the transaxle back far enough to install the special tool.
Lower the transaxle from the engine compartment.

SPECIAL TOOLS DESCRIPTION Adapter for 303-290-A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A Adapters for 303-290 303-290A-01 Engine Lifting Chains (Part of Spreader Bar) 303-D089 (D93P-6001-A3) or equivalent Retainer, Torque Converter 307-346 (T97T-7902-A) Slide Hammer 100-001 (T50T-100-A) Remover, Halfshaft 205-241 (T86P-3541-A) Tie Rod End Remover 211-105 (T85M-3395-A)

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Scheme 145: Removal

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-232183) .
Remove the battery and the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
Remove the air cleaner as an assembly. Disconnect the breather tube. Disconnect the mass air flow (MAF) sensor electrical connector. Remove the air intake tube. Remove the air cleaner assembly retaining bolt. Remove the air cleaner assembly.
Disconnect the transmission range (TR) sensor.
Disconnect the transaxle harness connector, remove the wire harness bracket nut and position the harness bracket aside.
Remove the main control cover vent tube.
Disconnect the EVAP and power takeoff (PTO) vent hoses from the transmission filler tube.
Disconnect the wire harness from the battery tray hold-down bracket.
Disconnect the shift cable from the manual lever.
Remove the 2 retaining bolts from the shift cable bracket, and position the cable and bracket aside.
Disconnect the starter motor harness connector.
Disconnect the ground wire.
Remove the 2 starter bolts and remove the starter motor.
Install the special tools.
Remove and disconnect both electrical connectors from the upper intake to gain access to the engine for installing the lifting bracket.
Install the special tools.
Install the special tools.
Remove the upper transaxle retaining bolts.
Loosen, but do not remove, the 4 retaining nuts holding the bracket to the transaxle case. Remove the LH upper transaxle mount bolt.
Remove the RH upper engine mount bolt.
Using the special tool, raise the front of the engine.
Remove the 7 retainers and the LH splash shield.
Remove the 7 retainers and the RH splash shield.
If transaxle disassembly is necessary, remove the drain plug and drain the transmission fluid. After the fluid has drained, install the drain plug.
Disconnect the LH suspension. Disconnect the sway bar link. Remove the tie rod end nut cotter pin. Remove the tie rod end retaining nut. Remove the lower knuckle bolt.
Disconnect the RH suspension. Disconnect the sway bar link. Remove the tie rod end nut cotter pin. Remove the tie rod end retaining nut. Remove the lower control arm knuckle bolt.
Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
Carefully pry down on the LH and RH lower control arms and disconnect the steering knuckle from the lower ball joint and position the steering knuckle aside.
Using the special tool, remove the RH outer halfshaft.
Using a pry bar between the transaxle case and the LH axle shaft, carefully disconnect the halfshaft from the transaxle case.
Remove the retaining screw for the generator shield.
Remove the retaining bolt for the generator shield and remove the shield.
Disconnect the HO2S sensor connector and remove the 2 clips from the oil pan bolt studs.
Remove the 2 intermediate shaft retaining nuts.
Remove the intermediate shaft.
Remove the cross brace.
Disconnect the exhaust pipe. Remove the rubber hanger. Remove the nuts and disconnect the pipe.
Disconnect the front exhaust pipe flange.
Disconnect the rear exhaust pipe flange and remove the exhaust pipe.
For vehicles equipped with a PTO, remove the rear driveshaft bolts and separate the driveshaft from the PTO.
Position the driveshaft aside.
Vehicles equipped with a PTO, remove the RH catalytic converter to gain access to the PTO bracket. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
Remove the bolts and the bracket.
Remove the bolt for the mount and the 2 bolts for the cross brace.
Remove the rear nut and the cross brace.
Remove the electrical connectors from the lower mount bracket.
Vehicles not equipped with a PTO, remove the dampener.
Remove the bolts from the transfer case unit.
Remove the transfer case bolt and remove the transfer case unit.
Remove the center bolt from the rear transaxle mount.
Lower the transaxle enough to clear the frame.
Remove the access cover.
Remove and discard the 4 torque converter nuts.
Remove the fluid cooler tube. Disconnect the output shaft speed (OSS) sensor. Disconnect the turbine shaft speed (TSS) sensor (white connector). Remove the bolt. Remove the fluid cooler tube and position it aside.
Remove the OSS sensor.
Remove the fluid cooler tube.
Support the transaxle with a high-lift jack.
Remove the bolts.
Remove the bolt.
Remove the bolt.
Remove the transaxle mount bracket.
Move the transaxle back far enough to install the special tool.
Lower the transaxle from the engine compartment.

SPECIAL TOOLS DESCRIPTION Holding Fixture, Transmission 307-003 (T57L-500-B) Actuator Pin (Dia 3/16 Inch) 3O3-D011 (D80L-100-G) Remover, Input Shaft Oil Seal 308-375 Remover/Installer, Servo Cover 307-295 (T94P-77000-L) Remover, Transmission Fluid Pump 307-289 (T94P-77000-G) Retainer, Torque Converter 307-346 (T97T-7902-A) Handle, Torque Converter 307-091 (T81P-7902-C) Holding Fixture, Transmission 307-288 (T94P-77000-F) Cross Block 307-109 (T81P-78103-A) Remover, RH Halfshaft Fluid Seal 307-429 Slide Hammer 100-001 (T50T-100-A) Collet, 3/4 to 7/8 Inch 303-D019 (D80L-100-Q)

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Scheme 184: Disassembly

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Inspect transaxle during disassembly.
Remove the special tool.
Using the special tool, remove the torque converter.
Remove the turbine shaft speed (TSS) sensor. Remove the bolt. Remove the TSS sensor.
Remove and discard the TSS and OSS sensor O-ring seals.
Remove the transmission range (TR) sensor. Remove the bolts. Remove the TR sensor from the manual valve detent lever shaft.
Using the special tool, secure the transaxle to the bench.
Position the drain pan under the transaxle, remove the drain plug, and drain the transmission fluid.
Remove the pump assembly driveshaft.
Using the special tools, remove and discard the torque converter impeller hub seal.
Using the special tools, remove the LH differential seal.
If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal.
If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal.
Remove the transaxle fluid filler tube bolt.
Remove the transaxle fluid filler tube.
Remove and discard the transaxle filler tube grommet.
Remove the main control cover bolts, studs and cover.
Remove the gasket.
Inspect the fitting of the main control cover vent tube for blockage.
Remove the main control valve body bolts.
Disconnect the manual valve link from the manual valve when lifting the main control valve body from the case.
Remove the solenoid body electrical connector. Release the retaining tabs and push the connector through the transaxle case.
Support the manual valve and remove the main control.
Remove the thermostatic fluid level control valve bracket. Remove the bolt. Remove the bracket.
Remove the thermostatic fluid level control valve.
Using the special tool, remove the servo assembly. Install the special tool. Compress the servo assembly by tightening the bolt. Remove the retaining ring.
Remove the servo cover assembly.
Remove the intermediate and overdrive servo piston and return spring.
Inspect the intermediate and overdrive servo assembly and bore for damage or wear. Servo cover with bonded seal. Cushion spring Servo apply rod Servo return spring Case servo bore
Remove the 20 bolts.
Separate the torque converter housing from the transaxle case. Remove and discard the transaxle split flange gasket.
Remove the differential bearing and shim. Remove the No. 15 differential bearing. Remove the No. 14 differential bearing shim.
Remove the final drive carrier and differential assembly.
Remove the No. 13 driven sprocket thrust bearing.
Unclip and remove the chain pan cover.
Remove the No. 10 driven sprocket thrust washer from the reverse/overdrive ring gear assembly.
Remove the chain drive, reverse/overdrive ring gear and driven sprocket assembly.
Separate the drive chain assembly from the driven sprocket assembly and reverse/overdrive ring gear assembly.
Remove the chain pan (with the magnet retained) from the transaxle case.
Assemble the special tools.
Using the special tools, remove and discard fluid filter recirculating regulator exhaust seal.
Remove the fluid filter and seal assembly. Discard the fluid filter. Discard the fluid filter seal.
Remove the No. 12 driven sprocket bearing.
Remove the No. 11 driven sprocket shim (selective fit).
Disconnect the parking lever actuating rod from the parking cam actuator lever assembly.
Disconnect the parking lever actuation rod from the manual valve detent lever, and remove the parking lever actuation rod.
Remove the No. 9 reverse/overdrive ring gear thrust bearing.
Remove the reverse/overdrive carrier assembly with captured No. 8 thrust bearing.
Remove the reverse/overdrive sun gear and shell assembly.
Remove the reverse/overdrive sun gear and No. 7 shell thrust bearing.
Remove the low/intermediate ring gear assembly.
Remove the No. 6 low/intermediate carrier thrust bearing.
Remove the low/intermediate carrier assembly.
Remove the No. 5 low/intermediate sun gear thrust bearing and tag for installation.
Remove the forward one-way clutch and low/intermediate sun gear.
Remove the No. 4 turbine shaft thrust bearing.
Remove the turbine shaft assembly.
Remove the forward/coast/direct cylinder assembly and reverse clutch drum assembly from the transaxle.
Remove the No. 1 pump support thrust bearing and tag for installation.
Remove the low one-way clutch retaining ring.
If equipped with a sprag-type one-way clutch, remove the low one-way clutch thrust plate.
If equipped with a mechanical diode, there is no thrust plate.
Remove the low one-way clutch assembly.
Remove the thin, 8-wave low/reverse clutch wave spring.
Remove the low/reverse clutch plates. Inspect the friction plates for partially stripped, broken or bent spline teeth, burnt, worn or flaked-off friction material and warped or bent friction discs. Inspect the steel plates for heat discoloration or warpage.
Remove the thick, 10-wave low/reverse clutch wave spring.
Remove the low/reverse clutch return spring retaining ring.
Remove the low/reverse clutch return spring assembly.
Remove the low/reverse clutch piston.
Remove the pump assembly bolts.
Using the special tools, remove the pump assembly. Install the special tool. Assemble the special tools. Using the special tools, remove the pump assembly.
Remove the intermediate and overdrive band assembly from the case. Inspect the intermediate and overdrive band assembly for damage and wear.

SPECIAL TOOLS DESCRIPTION Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) Installer, Needle Bearing 307-294 (T94P-77000-K) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Slide Hammer 100-001 (T50T-100-A) Remover, Input Shaft Bearing 308-201 (T91T-7127-A)

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Scheme 232: Special Tool(s)

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Scheme 235: Disassembly

Using the special tools, remove the No. 16 reverse/overdrive ring gear bearing, as necessary.
Using the special tools, remove the No. 17 stator support bearing, as necessary.

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Scheme 236: Assembly

Position the No. 16 reverse/overdrive ring gear bearing on the special tools. Position the bearing with the part number facing toward the handle of the special tool.
Using the special tools, install the No. 16 reverse/overdrive ring gear bearing.
Position the No. 17 stator support bearing on the special tools. Position the bearing with the part number facing toward the handle of the special tool.
Using the special tools, install the No. 17 stator support bearing into the stator support sprocket.

SPECIAL TOOLS DESCRIPTION Installer, Lube Tube 307-306 (T94P-77000-U1)

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Scheme 237: Disassembly

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Remove and discard the cooler tube fitting.
Remove the final drive ring gear retaining ring.
Remove the final drive ring gear.
Inspect the final drive ring gear, housing lug teeth and final drive ring gear teeth for damage or wear.
Remove the differential lube tube bolt.
Pull the differential lube tube from the housing.
Inspect the converter housing for: stator support area wear. case mating surfaces for nicks or deformation. differential bushing wear.
Check the converter housing hydraulic passages for blockage. Differential lubrication passage Front lubrication passage Converter turbine passage Converter impeller passage Cooler passage
Check for blockage at the converter seal return hole.

Scheme 245

Position a new differential lube tube in the torque converter housing.
Using the special tool, install the differential lube tube.
Install the differential lube tube bolt. Tighten to 13 Nm (10 lb-ft).
Install the final drive ring gear.
Install the final drive ring gear retaining ring.
Install the cooler tube fitting. Tighten to 48 Nm (35 lb-ft).

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Scheme 246: Final Drive Carrier and Differential Assembly

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Scheme 247: Disassembly

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Inspect the differential for wear or damage. Install new components as required.
Measure the final drive planet gear end play with a feeler gauge.
Remove the differential pinion shaft. Remove the pinion shaft roll pin. Remove the differential pinion shaft.
Remove the pinion gears and thrust washers. Turn the differential pinion gears 90 degrees and remove.
Remove the differential side gears and differential side gear thrust washers.
Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
Inspect the differential parts for damage and wear. Gear teeth Thrust washer surface Thrust bearing surface Pinion shaft
Inspect the final drive planet and carrier. Pinion gear teeth Thrust bearing surfaces Bushing surfaces

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Install the differential side gears and thrust washers.
Install the differential pinion gears and thrust washers. Rotate the differential pinion gears 90 degrees.
Install the differential pinion shaft. Push the pinion shaft in place. Install the roll pin.

SPECIAL TOOLS DESCRIPTION Installer, Transmission Sprag 307-293 (T94P-77000-J)

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Scheme 252: Special Tool(s)

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Scheme 254: Disassembly

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Remove the coast clutch hub retaining ring.
Remove the coast clutch hub.
Remove the forward one-way clutch outer race and sprag assembly with end caps.
Remove the forward one-way clutch end caps from the sprag assembly.
Remove the forward one-way clutch retainer.
Remove the retaining ring down over the gear.
Clean all parts thoroughly in clean solvent and blow dry with moisture-free compressed air.
Inspect the forward one-way clutch parts for damage and wear. Outer race Sprag assembly and end caps Inner race and low-intermediate sun gear assembly Lube holes Coast clutch hub

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Install the retaining ring.
Install the forward one-way clutch retainer.
Install the forward one-way clutch end caps onto the sprag assembly.
Using the special tool, install the one-way clutch bearing into the one-way outer race.
Install the sprag assembly and end caps in the outer race.
Rotate the outer race and sprag assembly (with end caps) over and install it on the forward one-way clutch inner race.
Install the coast clutch hub.
Install the coast clutch hub retaining ring.
Check the operation of the forward one-way clutch with the low/intermediate sun gear facing upward. Hold the outer race firmly. Rotate the low/intermediate sun gear clockwise. The low/intermediate sun gear should rotate with a slight drag without attempting to rotate the outer race. Rotate the low/intermediate sun gear counterclockwise. The low/intermediate sun gear should rotate the outer race.

SPECIAL TOOLS DESCRIPTION Dial Indicator Gauge with Holding Fixture 100-D002 (D78P-4201-B) Protector, Piston Seal 307-282 (T94P-77000-D3) Compressor, Clutch Spring 307-015 (T65L-77515-A) Remover, O-Ring Seal 100-010 (T71P-19703-C)

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Scheme 262: Special Tool(s)

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SPECIAL TOOLS DESCRIPTION Sizer, Hub Seal 307-283 (T94P-77000-D4)

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Install the No. 2 direct clutch thrust washer on the forward/coast/direct clutch cylinder with the tabs facing downward.
Install the 2 reverse clutch cylinder seals.
Position the reverse clutch cylinder seals. Correct installation. Incorrect installation.
Support the forward/coast/direct clutch cylinder assembly on a block of wood so that the direct clutch faces upward.
Install the direct clutch hub and shell on the forward/coast/direct clutch cylinder.
Install the reverse clutch drum assembly.
Install the reverse clutch hub.
Support the reverse clutch drum on a block of wood while installing the reverse clutch hub retaining ring.
Install the forward/coast/direct clutch cylinder hub seal.
Leave special tool attached until the forward/coast/direct clutch cylinder is installed into the transaxle housing.

Scheme 270

Scheme 270: Disassembly

Scheme 271

Scheme 272

Scheme 273

Inspect the low one-way clutch components: Low one-way clutch inner race Roller assemble Low one-way clutch outer race Outer race groove Inner race groove
Position the low one-way clutch so the inner and outer race grooves are facing upward.
Remove the inner race.
Remove the roller assembly.
Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
Inspect the low one-way clutch parts for damage and wear. Outer race Sprag assembly Inner race Lubrication holes

Scheme 274

Scheme 274: Assembly

Install the roller assembly into the outer race with the groove facing up.
Install the inner race with the grooves facing up.
Check the operation of the one-way clutch as follows: Hold the outer race. Rotate the inner race clockwise. It should rotate with a slight drag without attempting to rotate the outer race. Rotate the inner race counterclockwise. The inner race should rotate the outer race.

Scheme 275

Scheme 275: Disassembly

Scheme 276

Remove and discard the low/reverse clutch piston outer seal on the low/reverse clutch piston.
Remove and discard the low/reverse clutch piston inner seal on the low/reverse clutch piston.

SPECIAL TOOLS DESCRIPTION Alignment Pins, Valve Body 307-299 (T94P-77000-N)

Scheme 277

Scheme 277: Special Tool(s)

Scheme 278

Scheme 279

Scheme 279: Disassembly

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Remove the manual valve.
Remove the 2 solenoid valve body bolts and the solenoid valve body.
Remove and discard the solenoid valve body gasket.
Remove the 3 pressure tap plate bolts and the pressure tap plate.
Remove and discard the pressure plate tap gasket.
Remove the control valve body to transfer plate bolts, and remove the manual valve detent spring assembly.
Remove the accumulator body-to-transfer plate bolts.
Separate the accumulator body from the main control valve body. Remove the accumulator body assembly. Remove and discard the accumulator body separator gasket. Remove the accumulator body separator plate. Remove and discard the accumulator body separator gasket. Remove the main control valve body.
Separate the transfer plate from the main control valve body. Remove the main control valve body. Remove and discard the valve body separator plate gasket. Remove the valve body separator plate. Remove and discard the valve body separator plate gasket. Remove the transfer plate.
Remove the intermediate and overdrive accumulator valve plug retaining plate from the accumulator body assembly.
Remove the intermediate and overdrive accumulator valve plug.
Remove and discard the intermediate and overdrive accumulator plug seal.
As necessary, disassemble the parts of the accumulator body and main control valve body assemblies. Lubricate and reassemble the parts as soon as possible to avoid accidental damage or incorrect installation.

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Install a new intermediate and overdrive accumulator plug seal and coat with petroleum jelly.
Install the intermediate and overdrive accumulator valve plug.
Install the intermediate and overdrive accumulator valve plug retaining plate.
Install the special tool.
Using the special tool, install the valve body separator plate gaskets and valve body separator plate. Install a new valve body separator plate gasket. Install the valve body separator plate. Install a new valve body separator plate gasket.
Using the special tool, install the main control valve body.
Using the special tool, install the accumulator body separator plate and gaskets. Install a new accumulator body separator plate gasket. Install the accumulator body separator plate. Install a new accumulator body separator plate gasket.
Using the special tool, install the accumulator body assembly.
Starting with the bolts in the middle and working outward, install the accumulator body transfer plate. Tighten to 12 Nm (9 lb-ft).
Starting with the bolts in the middle and working outward, install the main control valve body to transfer plate and install the detent spring. Tighten to 12 Nm (9 lb-ft).
Install a new pressure tap plate gasket.
Install the pressure tap plate and bolts. Tighten to 8 Nm (71 lb-in).
Install the solenoid valve body. Install the solenoid valve body gasket. Install the solenoid valve body. Install the 2 solenoid valve body bolts. Tighten to 10 Nm (89 lb-in).
Install the manual valve.

SPECIAL TOOLS DESCRIPTION Installer, Lube Tube Fluid Seal 307-240 (T91P-76085-A) Remover/Installer, Needle Bearing 307-286 (T94P-77000-E1) Remover/Installer Servo Plug 307-287 (T94P-77000-ER2) Installer, Throttle Shaft Fluid Seal 307-097 (T81P-70337-A) Drawbar, Rear Axle 205-098 (T75T-1176-A) Installer, Lube Tube 307-307 (T94P-77000-U2)

Scheme 296

Scheme 296: Special Tool(s)

Scheme 297

Scheme 298

Scheme 298: Disassembly

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Remove and discard the final drive lube tube.
Using the special tool, remove and discard the final drive lube tube seal.
Remove the parking pawl ratchet spring.
Remove the manual control lever outer assembly.
Remove the manual control lever shaft assembly.
Remove the parking pawl shaft retainer and bolt.
Remove the parking pawl shaft.
Remove the parking pawl assembly. Remove the parking pawl. Remove the parking pawl return spring.
Remove and discard the manual control lever seal.
Remove the manual valve actuator rod (manual valve link).
Remove and discard the manual valve detent lever shaft retaining pin.
Remove the manual valve detent lever shaft retaining pin.
Remove the manual valve detent lever and shaft assembly. Pull the manual valve detent lever and manual valve detent lever shaft from the transaxle case. Lift the manual valve detent lever from the transaxle case.
Remove and discard the manual control seal.
If a new case is being installed, remove the line pressure port plug.
If a new case is being installed, remove and discard the cooler tube fitting.
As necessary, remove the No. 18 driven sprocket bearing assembly from transaxle case. Install the special tool into the transaxle. Position the special tool. Remove the bearing.
Using the special tools, remove the No. 18 driven sprocket bearing assembly. Position the special tool. Position the special tool. Remove the No. 18 driven sprocket bearing.
Clean all components with a suitable solvent and use moisture-free compressed air to dry all parts and clean fluid passages. Check the following before assembling: Final drive lubrication tube for damage Manual control linkage for damage or wear Case mating surfaces for nicks or deformation Bearing wear Support area wear

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

As necessary, install the No. 18 driven sprocket bearing into the transaxle case. Position the special tool. Position the special tool. Install new bearing.
Using the special tools, install the No. 18 driven sprocket bearing assembly by pressing it into the transaxle case. Install the bearing on the special tool. Position the special tool. Install the No. 18 driven sprocket bearing.
Install the cooler tube fitting. Tighten to 40 Nm (30 lb-ft).
Install the line pressure port plug. Tighten to 24 Nm (18 lb-ft).
Using the special tool, install a new manual control seal.
Install the manual valve detent lever assembly and the manual valve detent lever shaft assembly. Position the manual valve detent lever into the transaxle case. Install the manual valve detent lever shaft into the transaxle case and lever.
Install a new manual shaft retaining pin.
Install a new manual valve detent lever shaft retaining pin. Verify that the manual valve detent lever shaft rotates without binding.
Install the manual valve actuator rod (manual valve link).
Install the parking pawl assembly. Install the parking pawl return spring. Install the parking pawl.
Install the parking pawl shaft.
Install the parking pawl shaft retainer and bolt. Tighten to 8 Nm (71 lb-in).
Install the manual control lever shaft assembly. Tighten to 74 Nm (55 lb-ft).
Install the parking pawl ratchet spring.
Install the manual control lever outer assembly and bolt.
Using the special tool, install a new final drive lube tube seal.
Install the final drive lube tube into the seal.
Using the special tool, install the final drive lube tube into the case.

SPECIAL TOOLS DESCRIPTION Depth Micrometer 303-D026 (D80P-4201-A) Shim Selection Gauge 307-300 (T94P-77000-Q) Alignment Pins, Transmission Main Control Body 307-127 (T94P-77000-P)

Scheme 321

Scheme 321: Special Tool(s)

SPECIAL TOOLS DESCRIPTION Protector, Piston Seal 307-281 (T94P-77000-D2) Compressor, Clutch Spring 307-015 (T65L-77515-A)

Scheme 322

Scheme 322: Special Tool(s)

SPECIAL TOOLS DESCRIPTION Protector, Piston Seal 307-280 (T94P-77000-D1) (17-060-01) Installer, Torque Converter Fluid Seal 307-273 (T94P-77000-C) (17-052) Depth Micrometer 303-D026 (D80P-4201-A) Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) Shim Selection Depth Gauge 307-300-01 (T94P-77000-T) (17-055-01) Installer, Halfshaft Output Fluid Seal 307-157 (T86P-1177-B) Shim Selection Preload Plate 307-304 (T94P-77000-R1) (17-057) Remover/Installer, Servo Cover 307-295 (T94P-77000-L) Installer, Shift Shaft Fluid Seal 307-002 (TOOL-77288) Selector, Servo Piston Rod 307-S296 (T94P-77000-M) (17-059) Test Plate Screw Set, Transmission 307-126 (T82P-7006-C) Alignment Gauge, TR Sensor 307-351 (T97L-70010-A) Adapter for 307-304 307-304-02 (T94P-77000-R3) (17-057-02) Adapter for 307-304 307-304-03 (T94P-77000-R4) Alignment Pins, Valve Body 307-299 (T94P-77700-N) Aligner, Pump Housing 307-076 (T80L-77100-A) Protector, Piston Seal 307-284 (T94P-77000-D5) (17-060-05) Handle, Torque Converter 307-091 (T81P-7902-C) Holding Fixture, Transmission 307-003 (T57L-500-B) Holding Fixture, Transmission 307-288 (T94P-7700-F) Installer, RH Halfshaft Fluid Seal 307-428 Adapter For 307-304 307-304-01 (T94P-77000-R2) (17-057-01) Air Test Plate, Transmission 307-301 (T94P-77000-S) (17-056) End Play Gauge, Transmission 307-519

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

SPECIAL TOOLS DESCRIPTION Adapter for 303-290-A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A Adapters for 303-290 303-290A-01 Retainer, Torque Converter 307-346 (T97T-7902-A) Installer, Halfshaft 204-161 (T97P-1175-A)or equivalent

SPECIAL TOOLS DESCRIPTION Adapter for 303-290-A (Support Leg) 303-290A-03A Support Bar, Engine 303-290A Adapters for 303-290 303-290A-01 Engine Lifting Chains (Part of Spreader Bar) 303-D089 (D93P-6001-A3) or equivalent Alignment Gauge, TR Sensor 307-351 (T97L-70010-A) Retainer, Torque Converter 307-346 (T97T-7902-A)

Automatic Transmission - CD4E: Component Locations Ford Escape I facelift