Automatic Transmission Ford Explorer Sport Trac I

GENERAL SPECIFICATION

GENERAL SPECIFICATION

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

SERVICE IDENTIFICATION MODEL CHART

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

LINE PRESSURE CHART

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 128

STALL SPEED

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 129

Scheme 130

Scheme 131

FORWARD CLUTCH PACK (4.0L)

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 132

DIRECT CLUTCH PACK

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 133

COAST CLUTCH PACK

Note. Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.

Scheme 134

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSMISSION DESCRIPTION

The transmission has the following features

1. Five Forward Speeds
2. Electronic Shift, Pressure and Torque Converter Clutch Controls
3. Three Compound Planetary Gearsets
4. Three Bands
5. Three Multi-Plate Clutches
6. Two One-Way Clutches

All hydraulic functions are directed by electronic solenoids to control

1. Engagement feel.
2. Shift feel.
3. Shift scheduling.
4. Modulated torque converter clutch (TCC) applications.
5. Timing of the 3-2 torque demand and kickdown shifts.
6. Engine braking (with O/D canceled) utilizing the coast clutch.
7. Manual 1st timing.

Scheme 135

Scheme 136

All vehicles are equipped with a Vehicle Certification Label, located on the driver side door lock post. Refer to the code in the space marked TR. For service ID level or build date information, refer to the transmission service ID tag located on the transmission case.

RANGE SELECTION

The transmission has six range positions: P, R, N, (D), 2 and 1.

Scheme 137

Park

In the PARK position

1. There is no power flow through the transmission.
2. The parking pawl locks the output shaft to the case.
3. The engine may be started.
4. The ignition key may be removed.

Reverse

In the REVERSE position

1. The vehicle may be operated in a rearward direction, at a reduced gear ratio.

Neutral

In the NEUTRAL position

1. There is no power flow through the transmission.
2. The output shaft is not held and is free to turn.
3. The engine may be started.

Overdrive

Overdrive is the normal position for most forward driving.

The OVERDRIVE position provides

1. Automatic shifts.
2. Apply and release of the torque converter clutch.
3. Maximum fuel economy during normal operation.
4. Automatic shift 1-4 with O/D canceled.
5. Engine braking is available with the coast clutch applied in manual 1 position, manual 2nd (3rd gear) position and 4th gear with overdrive canceled.

2nd Position - 3rd Gear

The 2nd position provides

1. Third gear start and hold.
2. The torque converter clutch may apply and release.
3. Improved traction on slippery roads.
4. Engine braking.

Manual Low Position

If this position is selected at normal road speeds, the transmission will shift into third gear, then into first when the vehicle reaches a speed below approximately 48 km/h (30 mph).

This position provides

1. First gear operation only.
2. Engine braking for descending steep grades.

Upshifts

Transmission upshifting is controlled by the powertrain control module (PCM). The PCM receives inputs from various engine or vehicle sensors and driver demands to control shift scheduling, shift feel and torque converter clutch (TCC) operation.

The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected, or a new battery installed certain transmission operating parameters may be lost. The Powertrain Control Module (PCM) must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM.

Downshifts

Under certain conditions the transmission will downshift automatically to a lower gear range (without moving the gearshift lever). There are three categories of automatic downshifts; Coastdown, Torque Demand and Forced or Kickdown shifts.

Coastdown

The coastdown downshift occurs when the vehicle is coasting down to a stop.

Torque Demand

The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration.

Kickdown

For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are subject to variations due to tire size, engine and transmission calibration requirements.

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

TORQUE CONVERTER

The torque converter transmits and multiplies torque. The torque converter is a four-element device

1. Impeller Assembly
2. Turbine Assembly
3. Reactor Assembly
4. Clutch & Damper Assembly

The standard torque converter components operate as follows

Scheme 146

1. Rotation of the converter housing and impeller set the fluid in motion.
2. The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft.
3. The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
4. The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency.
5. Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft.

GEARTRAIN

Power is transmitted from the torque converter to the planetary gearsets through the input shaft. Bands and clutches are used to hold and drive certain combinations of gearsets. This results in five forward ratios and one reverse ratio, which are transmitted to the output shaft.

Scheme 147

Scheme 148

Scheme 149

The planetary gear front carrier is driven by the input shaft.

1. The front planetary gearset carrier drives the center shaft via the overdrive one-way clutch in 1st, 3rd and 4th gears.
2. In 2nd, the front sun gear is held causing the pinion gears to rotate around the front sun gear.
3. The pinion gears in turn drive the front ring gear and, with the front band applied, results in a 2nd gear ratio of 1.87 to 1.
4. In 5th, the front sun gear is held causing the pinion gears to rotate around the front sun gear.
5. The pinion gears in turn drive the front ring gear and, with the intermediate band applied, results in a 5th (overdrive) gear ratio of 0.75 to 1.
6. The front planetary gearset is internally splined to the coast clutch for engine braking.

Scheme 150

The forward planetary gearset is splined to the output shaft.

1. The forward planetary gearset is driven by the forward ring gear when the forward clutch is applied.
2. The forward planetary gearset pinions drive the forward sun gear.
3. The forward sun gear is splined to the input shell.

Scheme 151

The low/reverse planetary gearset is connected to the reverse brake drum by lugs from the low/reverse brake drum to the lugs of the low/reverse planetary gearset.

1. The low/reverse planetary gearset is driven by the forward sun gear which is splined to the input shell.
2. The splines of the forward sun gear drive the pinions in the low/reverse planetary gearset.
3. The pinions of the low/reverse planetary gearset drive the output shaft ring gear and output shaft hub which is splined to the output shaft.
4. The low/reverse planetary gearset is held by the low one-way clutch in the low/reverse brake drum, when the low/reverse band is applied.

Input Shaft

The input shaft is supported by two bushings in the stator support.

1. End positioning of the input shaft is controlled by the splines in the converter turbine and the front planetary carrier.

Output Shaft

The output shaft is supported by a bearing in the case and by the slip yoke bushing in the extension housing. End positioning is controlled by the parking pawl gear and snap ring shoulder and by the reverse ring gear hub and snap ring.

Scheme 152

Hydraulic pressure is applied to the front side of the front servo.

1. This pressure causes the servo to stroke and apply force to the band.
2. This action causes the front brake and coast clutch drum to be held.
3. The front band holds the front brake and coast clutch drum to the case in 2nd and 5th gears.
4. This causes the front sun gear to be held stationary through the coast clutch adapter and the front brake and coast clutch drum.

Scheme 153

Hydraulic pressure is applied to the front side of the low/reverse servo.

1. This pressure causes the servo to stroke and apply force to the band.
2. This action causes the front brake and coast clutch drum to be held.
3. The low/reverse band holds the low/reverse brake to the case in 1st position and reverse gears.
4. This causes the low/reverse planetary assembly to be held stationary.

Scheme 154

Hydraulic pressure is applied to the front side of the intermediate servo.

1. This pressure causes the servo to stroke and apply force to the intermediate band.
2. This action causes the intermediate brake and direct clutch drum to be held.
3. The intermediate band holds the intermediate brake and direct clutch drum to the case in 3rd gear.
4. This causes the input shell and forward sun gear to be held stationary.

Scheme 155

The direct clutch is a multi-disc clutch made up of steel and friction plates.

1. The direct clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of the hydraulic pressure.
2. It is housed in the intermediate brake and direct clutch drum.
3. In drive, the direct clutch is applied and coupled to the forward clutch. This drives the input shell and forward sun gear in 4th and 5th gears.
4. In reverse, the direct clutch is applied and coupled to the input shell and forward sun gear.
5. This action causes the forward sun gear to drive the pinions of the low/reverse planetary carrier.
6. Since the low/reverse planetary carrier is held stationary by the low/reverse band, the pinions drive the output shaft ring gear in reverse.

Scheme 156

The forward clutch is a multi-disc clutch made up of steel and friction plates.

1. The forward clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of the hydraulic pressure.
2. The forward clutch is applied in all forward gears.
3. When applied, the forward clutch provides a direct mechanical coupling between the input shaft and the forward ring gear and hub.

Scheme 157

The coast clutch is a multi-disc clutch made up of steel and friction plates.

1. The coast clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of the hydraulic pressure.
2. The coast clutch is housed in the front brake and coast clutch drum.
3. The coast clutch is applied when the TCS switch is on, energizing SSD, and 5th gear operation is inhibited (4th gear only).
4. The coast clutch is hydraulically applied when the transmission is in the manual 2nd and manual 1st position.
5. When applied, the coast clutch locks the input shaft to the front planetary carrier, thus preventing the one-way clutch from overrunning when the vehicle is coasting.
6. This allows the use of engine compression to help slow the vehicle and provide engine braking.

Scheme 158

The front one-way clutch is a sprag-type one-way clutch that is pressed into the center shaft.

1. The front one-way clutch is driven by the ring gear of the front planetary carrier.
2. The front one-way clutch holds and drives the outer splines of the center shaft in 1st, 3rd, and 4th gears.
3. The front one-way clutch overruns during all coast operations and at all times in 2nd and 5th gear.

Scheme 159

The low/reverse one-way clutch is a sprag-type one-way clutch.

1. The low/reverse one-way clutch holds the low/reverse brake drum and low/reverse planetary assembly to the case in 1st gear only.
2. In all other gears the low/reverse one-way clutch overruns.

Scheme 160

Scheme 161

Scheme 162

Scheme 163

1. All fluid drawn from the transmission fluid pan by the fluid pump passes through the fluid filter.
2. The transmission fluid filter and its accompanying seals are part of the fluid path from the sump (pan) to the fluid pump. The transmission fluid filter has a bypass section which allows fluid vented at the main regulator valve to be recirculated to the fluid pump, without passing through the transmission fluid filter.
3. The main control valve body and related components are part of the pressure side of the hydraulic system.
4. The main control valve body consists of the solenoids, the valve body assembly and the separator plate.
5. These components combine to convert electrical signals into hydraulic actions. All valves in the main control assembly are anodized aluminum and cannot be sanded, filed, or dressed in any other way. Any damage to the valves that prevents or restricts their movement, requires installation of a new main control valve body.

Electronic System Description

The powertrain control module (PCM) and its input/output network control the following transmission operations

1. Adaptive controls (model dependent)
2. Shift timing
3. Line pressure (shift feel)
4. Torque converter clutch

The transmission control is separate from the engine control strategy in the PCM, although some of the input signals are shared. When determining the best operating strategy for transmission operation, the PCM uses input information from certain engine-related and driver-demand related sensors and switches.

In addition, the PCM receives input signals from certain transmission-related sensors and switches. The PCM also uses these signals when determining transmission operating strategy.

Using all of these inputs signals, the PCM can determine when the time and conditions are right for a shift, or when to apply or release the torque converter clutch. It will also determine the best line pressure needed to optimize shift feel. To accomplish this, the PCM uses six output solenoids to control transmission operation.

The following provides a brief description of each of the sensors and actuators used to control transmission operation.

Intake Air Temperature (IAT) Sensor

The intake air temperature (IAT) sensor provides the sequential fuel injection (SFI) system mixture temperature information. The IAT sensor is used both as a density corrector for air flow calculation and to proportion cold enrichment fuel flow. The IAT sensor is installed in the air cleaner outlet tube. The IAT sensor is also used in determining electronic pressure control (EPC) pressures.

Throttle Position (TP) Sensor

The throttle position (TP) sensor is a potentiometer mounted on the throttle body. The TP sensor detects the position of the throttle plate and sends this information to the powertrain control module. The TP sensor is used for shift scheduling, electronic pressure control and torque converter clutch (TCC) control.

Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor detects temperature of engine coolant and supplies the information to the powertrain control module (PCM). The ECT sensor is used to control torque converter clutch (TCC) operation.

Anti-Lock Brake Speed Sensor

The programmable speedometer/odometer module (PSOM) receives input from the rear brake anti-lock sensor. After processing the signal, the PSOM relays it to the powertrain control module (PCM) and the speed control module. Information from the PSOM is used to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC).

Mass Air Flow (MAF) Sensor

The mass air flow (MAF) sensor measures the mass of air flowing into the engine. The MAF sensor output signal is used by the powertrain control module (PCM) to calculate injector pulse width. For transmission strategies, the MAF sensor is used to regulate electronic pressure control, shift and torque converter clutch scheduling.

Air Conditioning (A/C) Clutch

An electromagnetic clutch is energized when the clutch cycling pressure switch closes. The switch is located on the suction accumulator/drier. The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor driveshaft. When the A/C is engaged, electronic pressure control (EPC) pressure is adjusted to compensate for additional load on the engine.

Electronic Ignition (EI) System

The electronic ignition consists of a crankshaft position sensor, two four-tower ignition coils and the powertrain control module (PCM). The ignition control module operates by sending crankshaft position information from the crankshaft position sensor to the ignition control module. The ignition control module generates a profile ignition pickup (PIP) signal (engine RPM) and sends it to the PCM. The PCM uses PIP signal in the transmission strategy, wide-open throttle (WOT) shift control, torque converter clutch control and EPC pressure.

Brake Pedal Position (BPP) Switch

The brake pedal position (BPP) switch tells the powertrain control module when the brakes are applied. The torque converter clutch disengages when the brakes are applied. The BPP switch closes when the brakes are applied and opens when they are released.

Transmission Control Switch (TCS)

The transmission control switch (TCS) is a momentary contact switch that allows the driver to cancel operation of 5th (overdrive) gear.

The TCS is located on the end of the selector lever.

When the driver initially presses the TCS a signal is sent to the powertrain control module (PCM).

The PCM uses the shift solenoids to disengage/disable 5th gear operation and activate the coast clutch.

At the same time, the PCM illuminates the transmission control indicator lamp (TCIL) to notify the driver that 5th gear is canceled.

When the TCS is pressed again, 5th gear operation is enabled, the coast clutch is released and the TCIL is turned off.

Whenever the ignition is cycled (vehicle shut off then started again), the TCS is turned off and 5th gear will be enabled, even if the TCS had been on when the ignition was shut off.

Transmission Control Indicator Lamp (TCIL)

The transmission control indicator lamp (TCIL) is located in the instrument panel and is labeled O/D OFF. It is illuminated in conjunction with the transmission switch (TCS).

The TCIL will flash if the EPC solenoid circuit is shorted or a fault has been detected in a monitored sensor used for transmission operation.

Turbine Shaft Speed (TSS) Sensor

The turbine shaft speed (TSS) sensor is a magnetic pickup that sends torque converter turbine speed information to the powertrain control module (PCM).

The TSS sensor is mounted internally on the center support.

The PCM uses TSS information to help determine electronic pressure control (EPC) and torque converter clutch (TCC) operation.

4x4 Low (4x4L) Switch

The 4x4 low (4x4L) range switch is located on the transfer case cover. It provides an indication of when the 4x4 transfer case gear system is in the low range. The powertrain control module (PCM) then modifies the shift schedule for 4x4L transfer case gear ratio.

Output Shaft Speed (OSS) Sensor

The output shaft speed (OSS) sensor is a magnetic pickup, located at the park gear/trigger wheel assembly, that sends a signal to the powertrain control module (PCM) to indicate transmission output shaft speed. The OSS is used for torque converter clutch control, speed scheduling and to determine electronic pressure control.

Intermediate Shaft Speed (ISS) Sensor

The intermediate shaft speed (ISS) sensor is a magnetic pickup that sends planetary sun gear speed information to the powertrain control module (PCM). The ISS is mounted externally on the center of the case.

The PCM uses the ISS information to aid in determining pressure requirements.

Digital Transmission Range (TR) Sensor

The digital transmission range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK and NEUTRAL, the back-up lamp circuit in REVERSE and the neutral sense circuit (4x4 only) in NEUTRAL. The digital TR sensor also opens and closes a set of four switches that are monitored by the powertrain control module (PCM) to determine the position of the manual lever (P, R, N, D, 2, 1).

Transmission Fluid Temperature (TFT) Sensor

1. The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature.
2. The TFT is located on the main control body wiring harness assembly.
3. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC).

Electronic Pressure Control (EPC) Solenoid

The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.

The powertrain control module (PCM) varies the current to the EPC solenoid.

This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures.

The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters.

During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM.

Shift Solenoids - A, B, C & D

Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.

1. The solenoids are two-way, normally open style.
2. The shift solenoids (SSA, SSB, SSC and SSD) provide gear selection by controlling the pressures of the shift valves.
3. SSD is also used to apply and release the coast clutch.

Torque Converter Clutch (TCC) Solenoid

The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.

Powertrain Control Module (PCM)

The operation of the transmission is controlled by the powertrain control module (PCM). Many input sensors provide information to the PCM. The PCM then controls actuators which determine transmission operation.

DIAGNOSTIC STRATEGY

Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.

Note. Do not take any 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.

To correctly diagnose a concern have the following publications available

1. Transmission Reference Manual
2. «SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-self-diagnostics-eec-v-gasoline-ngv)
3. TSBs
4. Wiring Diagram

These publications provide the information required when diagnosing transmission concerns.

Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.

Preliminary Inspection

1. Know and understand the customer's concern.
2. Verify the concern by operating the vehicle.
3. Check the fluid levels and condition.
4. Check for non-factory add-on items.
5. Check shift linkages for correct adjustment.
6. Check TSBs regarding the concern.

Diagnostics

1. Carry out on-board diagnostic procedures key on engine off (KOEO) and key on engine running (KOER).
2. Record all diagnostic trouble codes (DTCs).
3. Repair all non-transmission codes first.
4. Repair all transmission codes second.
5. Erase all continuous codes and attempt to repeat them.
6. Repair all continuous codes.
7. If only pass codes are obtained, refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) for further information and diagnosis.

Follow the diagnostic sequence to diagnose and repair the concern the first time.

Scheme 164

The following items must be checked prior to beginning the diagnostic procedures

Know & Understand Concern

In order to correctly diagnose a concern, first understand the customer complaint or condition.

Customer contact may be required in order to begin to verify the concern. Understand the conditions as to when the concern occurs, for example

1. Hot Or Cold Vehicle Temperature
2. Hot Or Cold Ambient Temperature
3. Vehicle Driving Conditions
4. Vehicle Loaded/Unloaded

After understanding when and how the concern occurs, proceed to verify the concern.

Verification Of Condition

This section provides information that must be used in both determining the actual cause of customer concerns and carrying out the appropriate procedures.

The following procedures must be used when verifying customer concerns for the engine.

Determine Customer Concern

Note. Some transmission conditions can cause engine concerns. An electronic pressure control short circuit can cause engine misfiring. The torque converter clutch not disengaging will stall the engine.

Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the following items

1. Hot or cold vehicle operating temperature.
2. Hot or cold ambient temperatures.
3. Type of terrain.
4. Vehicle loaded/unloaded.
5. City/highway driving.
6. Upshift.
7. Downshift.
8. Coasting.
9. Engagement
10. Noise/vibration - check for dependencies, either RPM dependent, vehicle speed dependent, shift dependent, gear dependent, range dependent, or temperature dependent

Check Fluid Level & Condition

Note. Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (18.75 miles). If the vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather or while pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking.

Note. The transmission fluid level should be checked at normal operating temperatures, 66°C-77°C (150°F-170°F), on a level surface. The normal operating temperature can be reached after approximately 32 km (20 miles) of driving.

However, you can check the fluid level without driving if the outside temperature is above 10°C (50°F). When the vehicle has not been driven, and the outside is above 10°C (50°F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66-77°C (150-170°F).

Scheme 165

1. Drive the vehicle 30 km (18.75 miles) or until the vehicle reaches normal operating temperatures.
2. Park the vehicle on a level surface and apply the parking brake.
3. With the parking brake applied and your foot on the brake pedal, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage.
4. Place the range selector lever in (P) park and leave the engine running.
5. Remove the fluid level indicator and wipe it clean with a lint free cloth.
6. Install the fluid level indicator until it is fully seated into the filler tube.
7. Remove the fluid level indicator and inspect the fluid level. The fluid level should be in the designated area for normal and room temperature.

High Fluid Level

Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission.

Low Fluid Level

DO NOT DRIVE the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator or not on the fluid level indicator, and the outside temperatures are above 10°C (50°F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets.

Adding Fluid

Before adding fluid be sure that the correct type is being used. The type of fluid used is found on the fluid level indicator, on the handle, in the owner manual, and in the specification section.

If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid.

Fluid Condition Check

1. Check the fluid level.
2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black.
3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time.
6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines.
7. Carry out diagnostic checks and adjustments. For additional information, refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .

ROAD TESTING VEHICLE

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Note. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The powertrain control module (PCM) must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM.

The Shift Point Road Test and Torque Converter Clutch Operation Test provide diagnostic information on transmission shift controls and torque converter operation.

SHIFT POINT ROAD TEST

This test verifies that the shift control system is operating correctly.

1. Bring engine and transmission up to normal operating temperature.
2. Operate vehicle with selector lever in (D) range.
3. Apply minimum throttle and observe speeds at which upshift occurs and torque converter engages. Refer to the following Shift Speeds Chart. Also refer to the Automatic Transmission Specifications.
4. Stop the vehicle. Depress transmission control switch (TCS) to activate D range. Repeat Step 3. Transmission will make all upshifts except 4-5, and torque converter clutch apply should occur above 46 km/h (29 mph).
5. Press accelerator pedal to floor, wide open throttle (WOT). Transmission should shift from fourth to third, third to second, or third to first, depending on vehicle speed, and torque converter clutch should release.
6. With vehicle speed above 48 km/h (30 mph), move transmission range selector lever from (D) range to 1 range (LOW) and release accelerator pedal. Transmission should immediately downshift to third gear. When vehicle speed drops below 32 km/h (20 mph), transmission should downshift into first gear.
7. If transmission fails to upshift/downshift or torque converter clutch does not apply/release, refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) for possible causes.

Shift Speeds

Note. Shift speed ranges are approximate for all applications. For specific applications (engine, axle ratio and application), refer to the Automatic Transmission Specification booklet.

Scheme 166

TORQUE CONVERTER DIAGNOSIS

Prior to installing new or remanufactured torque converters, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection.
2. Know and Understand the Customer's Concern.
3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test. Refer to the «TORQUE CONVERTER OPERATION TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__torque-converter-operation-test) .
4. Carry out Diagnostic Procedures. Run on-board diagnostics. Refer to the «ON-BOARD DIAGNOSTICS WITH DIAGNOSTIC TOOL»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__on-board-diagnostics-with-diagnostic-tool) . Repair all non-transmission related DTCs first. Repair all transmission DTCs. Rerun on-board diagnostics to verify repair. Carry out Line Pressure Test. Refer to the «LINE PRESSURE TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__line-pressure-test) . Carry out Stall Speed Test. Refer to the «STALL SPEED TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__stall-speed-test) . Carry out Diagnosis by Symptom Index. For additional information, refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) . Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and service as required before servicing the torque converter.

Torque Converter Operation Test

This test verifies that the torque converter clutch control system and the torque converter are operating correctly.

1. Carry out Quick Test. Refer to the «ON-BOARD DIAGNOSTICS WITH DIAGNOSTIC TOOL»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__on-board-diagnostics-with-diagnostic-tool) . Check for DTCs. Refer to the «DIAGNOSTIC TROUBLE CODE CHARTS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__diagnostic-trouble-code-chart) .
2. Connect a tachometer to the engine.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot.
5. Engine RPM should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to the Torque Converter Operation Concerns in «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. If the vehicle stalls in (D) or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to the Torque Converter Operation Concerns in Diagnosis By Symptom. Repair as required. If the vehicle does not stall in (D), refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .

VISUAL INSPECTION

This inspection will identify modifications or additions to the vehicle operating system that may affect diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as

1. Electronic add-on items: Air Conditioning Generator (Alternator) Engine Turbo Cellular Telephone Cruise Control CB Radio Linear Booster Backup Alarm Signal Computer
2. Vehicle modification: These items, if not installed correctly, will affect the powertrain control module (PCM), or transmission function. Pay particular attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire size, or axle ratio changes.
3. Leaks, refer to the «LEAKAGE INSPECTION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__leakage-inspection) .
4. Correct linkage adjustments. For additional information, «EXTERNAL CONTROLS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#transmission-external-controls) .

Shift Linkage Check

Check for an incorrectly adjusted shift linkage by matching the detents in the transmission range selector lever with those in the transmission. If they match, the incorrect adjustment is in the indicator. Do not adjust the shift linkage.

Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating if the linkage is not correctly adjusted. Refer to EXTERNAL CONTROLS for shift linkage adjustment.

Check TSBs

Refer to the technical service bulletins which pertain to the transmission concern and follow the procedure as outlined.

Carry Out On-Board Diagnostics (KOEO, KOER)

After a road test, with the vehicle warm and before disconnecting any connectors, carry out the Quick Test using the scan tool. Refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV for diagnosis and testing of the powertrain control system.

Scheme 167

Scheme 168

Diagnosing electronically controlled automatic transmissions is simplified using the following procedures. It is important to remember that there is a definite procedure to follow. 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 technician will be able to diagnose and repair the concern the first time.

On-Board Diagnostics With Diagnostic Tool

Note. For detailed instruction and other diagnostic methods using the scan tool, refer to the scan tool tester and the SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV .

These quick tests should be used to diagnose the powertrain control module (PCM) and should be carried out in order.

1. Quick Test 1.0 - Visual Inspection
2. Quick Test 2.0 - Set Up
3. Quick Test 3.0 - Key On, Engine Off
4. Quick Test 4.0 - Continuous Memory
5. Quick Test 5.0 - Key On, Engine Running
6. Special Test Mode Wiggle Test Mode Output Test Mode
7. PCM Reset Mode
8. Clearing DTCs
9. OBD II Drive Cycle
10. Other Scan Tool Features

For additional information on other diagnostic testing features using the scan tool, refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV . Other diagnostic methods include the following

1. Parameter Identification (PID) Access Mode
2. Freeze Frame Data Access Mode
3. Oxygen Sensor Monitor Mode

OUTPUT STATE CONTROL (OSC) MODE

Output state control (OSC) allows the technician to take control of certain parameters to function the transmission. For example, OSC allows the technician to shift the transmission only when commanding a gear change. If the technician commands 1st gear in OSC, the transmission will remain in 1st gear until the technician commands the next gear. For another example, the technician can command a shift solenoid to turn on or off while carrying out an electrical circuit check. OSC has two modes of operation for transmission, the BENCH MODE and the DRIVE MODE. Each mode/parameter has a unique set of vehicle operating requirements that the technician is required to meet before being allowed to operate OSC.

Note. To operate OSC the digital transmission range (TR) sensor and the vehicle speed sensor (VSS) must be operational. No diagnostic trouble codes (DTCs) related to the digital TR sensor or the VSS can be present.

1. The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to the vehicle requirements for each individual test.
2. If the vehicle requirements are NOT MET when SENDING the OSC value, an ERROR MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be restarted.
3. If AFTER SENDING an OSC value, and the vehicle requirements are no longer met, the PCM will cancel the OSC value and NO ERROR message will appear.
4. The OSC value [XXX] may be sent anytime to cancel OSC.

Output State Control (OSC) Procedures

Output State Control (OSC) Procedures

1. Carry out visual inspection and vehicle preparation as required.
2. Select "Vehicle and Engine Selection" menu.
3. Select appropriate vehicle and engine.
4. Select "Diagnostic Data Link."
5. Select "Powertrain Control Module."
6. Select "Diagnostic Test Mode."
7. Select "KOEO On-Demand Self Test and KOER On-Demand Self Tests."
8. Carry out test and record DTCs.
9. Repair all NON-Transmission DTCs.
10. Repair all VSS and digital TR sensor DTCs.
11. Make sure that VSS/digital TR sensors are functional.
12. Select "Active Command Modes."
13. Select "Trans - Bench Mode or Trans - Drive Mode."

OSC - Transmission Bench Modes

The following Transmission Bench Modes may be used or required during diagnostics.

SSA, SSB, SSC, SSD & TCC In BENCH MODE

The BENCH MODE allows the technician to carry out electrical circuit checks on the following components

1. SSA - Activates SS#1 OFF or ON.
2. SSB - Activates SS#2 OFF or ON.
3. SSC - Activates SS#3 OFF or ON.
4. SSD - Activates SS#4 OFF or ON.
5. TCC - Activates TCC OFF or ON.

OSC "SSA, SSB, SSC, SSD, TCC" BENCH MODE Operates ONLY when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Transmission range selector lever in P.
4. Key ON.
5. Engine OFF.

OSC Command Values

1. [OFF] - Turns solenoid OFF.
2. [ON] - Turns solenoid ON.
3. [XXX] - Cancels OSC value sent.
4. [SEND] - Sends the values to PCM.

BENCH MODE Procedure for SSA, SSB, SSC, SSD, and TCC.

Follow operating instructions from the scan tool menu screen

1. Select "Output State Control."
2. Select "Trans - Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - SSA, SSB, SSC, SSD, or TCC."
6. Select "ON" to turn solenoid ON.
7. Press "SEND" to send command ON.
8. Select "OFF" to turn solenoid OFF.
9. Press "SEND" to send command OFF.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

EPC In BENCH MODE

The BENCH MODE is also used to test the functionality of the transmission's electronic pressure control. During BENCH MODE, the EPC solenoid can ramp in increments of 15 psi from 0 to 90 psi and 90 to 0 psi.

The OSC functions for the parameter EPC allows the technician to choose the following options

1. EPC - Activates EPC to selected values.
2. [00] - Sets EPC pressure to 0 psi.
3. [15] - Sets EPC pressure to 15 psi.
4. [30] - Sets EPC pressure to 30 psi.
5. [45] - Sets EPC pressure to 45 psi.
6. [60] - Sets EPC pressure to 60 psi.
7. [75] - Sets EPC pressure to 75 psi.
8. [90] - Sets EPC pressure to 90 psi.

OSC "EPC" - BENCH MODE should ONLY be operated to check PRESSURE FUNCTIONALITY using an installed pressure gauge (300 psi) when

1. VSS and digital TR Sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Transmission range selector lever in P.
4. Pressure gauge installed.
5. Key ON.
6. Engine ON.
7. Engine RPM at 1,500.

OSC "EPC" - BENCH MODE should ONLY be operated to complete EPC SOLENOID CIRCUIT PINPOINT TESTS when

1. VSS and Digital TR Sensor are operational.
2. No VSS and Digital TR Sensor DTCs are present.
3. Transmission range selector lever is in "P" or "N".
4. Key "ON".
5. Engine "OFF".

OSC Command Values

1. [00] - Sets EPC pressure to 0 psi.
2. [15] - Sets EPC pressure to 15 psi.
3. [30] - Sets EPC pressure to 30 psi.
4. [45] - Sets EPC pressure to 45 psi.
5. [60] - Sets EPC pressure to 60 psi.
6. [75] - Sets EPC pressure to 75 psi.
7. [90] - Sets EPC pressure to 90 psi.
8. [OFF] - Turns solenoid OFF.
9. [ON] - Turns solenoid ON.
10. [XXX] - Cancels OSC value sent.
11. [SEND] - Sends the values to PCM.

BENCH MODE Procedure For EPC

Following operating instructions from the scan tool menu screen.

1. Select "Output State Control."
2. Select "Trans - Bench Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - EPC."
6. Select Value "0 - 90 psi."
7. Press "SEND" to send command.
8. Select "XXX" to cancel at any time.
9. Press "SEND."

OSC - Transmission DRIVE MODES

The DRIVE MODE allows control of three transmission parameters. Each mode/parameter has a unique set of vehicle operating requirements that the technician is required to meet before being allowed to operate OSC. The recommended procedure, when using the DRIVE MODE, is to control one parameter at a time.

The DRIVE MODE allows the technician to carry out the following functions on the transmission

1. GR_CM - Allows upshifts or downshifts.
2. TCC - Engages or disengages the torque converter clutch.
3. EPC - Increases/decreases EPC pressure.

GR_CM in DRIVE MODE

This OSC function is used to test the transmission shift functions.

The OSC functions for the GR_CM parameter allows the technician to choose the following options

1. [1] - PCM selects 1st gear.
2. [2] - PCM selects 2nd gear.
3. [3] - PCM selects 3rd gear.
4. [4] - PCM selects 4th gear.
5. [5] - PCM selects 5th gear.

OSC "GR_CM" Mode Operates ONLY when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Engine "ON."
4. TCC "OFF."
5. Transmission range selector lever on O/D.
6. Vehicle speed is greater than 2 mph.

OSC Command Values

1. [1] - PCM selects 1st gear.
2. [2] - PCM selects 2nd gear.
3. [3] - PCM selects 3rd gear.
4. [4] - PCM selects 4th gear.
5. [5] - PCM selects 5th gear.
6. [OFF] - Turns solenoid OFF.
7. [ON] - Turns solenoid ON.
8. [XXX] - Cancels OSC value sent.
9. [SEND] - Sends the values to PCM.

DRIVE MODE Procedure for GR_CM

Follow operating instructions from the scan tool menu screen.

1. Select "Output State Control."
2. Select "Trans - DRIVE MODE."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - GR_CM."
6. Select Value "1-5."
7. Press "SEND" to send command.
8. Re-Select Value "1-5."
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

TCC In DRIVE MODE

This OSC function is used to test whether the torque converter clutch is engaging and disengaging correctly.

The OSC functions for the TCC parameter allows the technician to choose the following

1. TCC - Activates TCC OFF and ON.
2. [ON] - Turns TCC solenoid ON.
3. [OFF] - Turns TCC solenoid OFF.

OSC "TCC OFF" DRIVE MODE Operates ONLY when

1. VSS and digital TR sensors are operational.
2. No VSS and digital TR sensor DTCs present.
3. Engine ON.
4. Transmission range selector lever in O/D.
5. Vehicle speed is greater than 2 mph.

OSC "TCC ON" DRIVE MODE Operates ONLY when

1. VSS and digital TR sensors are operational.
2. No VSS and digital TR sensor DTCs present.
3. Engine on.
4. Transmission range selector lever in O/D.
5. Vehicle speed is greater than 2 mph.
6. Transmission in 2nd gear or higher.
7. TFT is between 60°F and 275°F.
8. Brake not applied "OFF" below 20 mph.
9. Not an excessive load on engine (engine lugging).

OSC Command Values

1. [OFF] - Turns TCC OFF.
2. [ON] - Turns TCC ON.
3. [XXX] - Cancels OSC value sent.
4. [SEND] - Sends the values to PCM.

Drive Mode Procedures For TCC

Follow operating instructions from the scan tool menu screen.

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - TCC."
6. Select "ON" to turn solenoid ON.
7. Press "SEND" to send command ON.
8. Select "OFF" to turn solenoid OFF.
9. Press "SEND" to send command OFF.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

EPC in DRIVE MODE

This OSC function is used to increase the EPC pressure while testing the transmission shift functions. This OSC function can only increase the EPC pressure greater than what the PCM normally commands. If an OSC value, such as [75] or [90] psi is sent, the upshifts and downshifts should exhibit a harsher shift. Harsher shifts would indicate that the EPC pressure control works at higher pressures. The best test for the EPC is to use the BENCH MODE and a hydraulic pressure gauge. Using EPC in the BENCH MODE will confirm that the EPC works at both the higher and lower pressures.

The OSC functions for the parameter EPC allows the technician to choose the following options

1. EPC - Activates EPC To Selected: [00] - sets EPC pressure to 0 psi. [15] - sets EPC pressure to 15 psi. [30] - sets EPC pressure to 30 psi. [45] - sets EPC pressure to 45 psi. [60] - sets EPC pressure to 60 psi. [75] - sets EPC pressure to 75 psi. [90] - sets EPC pressure to 90 psi.

OSC "EPC" DRIVE MODE Operates ONLY when

1. VSS and digital TR sensor are operational.
2. No VSS and digital TR sensor DTCs.
3. Transmission range selector lever in O/D.
4. Pressure gauge installed.
5. Key ON.
6. Engine ON.
7. Vehicle speed greater than 2 mph.
8. OSC value for EPC must be greater than what the PCM commands (see EPC PID).

OSC Command Values

1. [00] - sets EPC pressure to 0 psi.
2. [15] - sets EPC pressure to 15 psi.
3. [30] - sets EPC pressure to 30 psi.
4. [45] - sets EPC pressure to 45 psi.
5. [60] - sets EPC pressure to 60 psi.
6. [75] - sets EPC pressure to 75 psi.
7. [90] - sets EPC pressure to 90 psi.
8. [OFF] - turns solenoid OFF.
9. [ON] - turns solenoid ON.
10. [XXX] - cancels OSC value sent.
11. [SEND] - sends the values to PCM.

DRIVE MODE Procedure for EPC.

Follow operating instructions from the scan tool menu screen.

1. Select "Output State Control."
2. Select "Trans - Drive Mode."
3. Select "PIDs" to be monitored.
4. Monitor all selected PIDs during test.
5. Select "Parameters - EPC."
6. Select Value "0-90 psi."
7. Press "SEND" to send command.
8. Re-Select Value "0-90 psi."
9. Press "SEND" to send command.
10. Select "XXX" to cancel at any time.
11. Press "SEND."

Using Output State Control (OSC) & Accessing PIDs

To confirm that the OSC value was sent by the scan tool and the EEC has accepted the OSC substitution, a corresponding PID for each OSC parameter must be monitored. Additional PIDs should be monitored to help the technician adequately diagnose the transmission.

Refer to the OSC parameters list and their corresponding PID.

Scheme 169

To confirm that the OSC substitution occurred, SEND the OSC value and monitor the corresponding PID value. If no ERROR MESSAGE was received and the value of the corresponding PID remains the same as the value sent from OSC, then the OSC substitution was successful.

TRANSMISSION DRIVE CYCLE TEST

Note. Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.

Note. The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur four times consecutively for shift error DTC code to be set, and five times consecutively for continuous torque converter clutch code to set.

Note. While carrying out the Transmission Drive Cycle Test, refer to the Solenoid Application Chart for correct solenoid operation.

After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous codes.

1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With transmission in Overdrive, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fifth gear. Hold speed and throttle open steady for a minimum of 15 seconds.
5. With transmission in fifth gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stoplamps. Then hold speed and throttle steady for a minimum of five seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous DTCs. If the DTCs are still present, refer to the «DIAGNOSTIC TROUBLE CODE CHARTS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__diagnostic-trouble-code-chart) . Repair all non-transmission DTCs first as they can directly affect the operation of the transmission. Repeat the Quick Test and the Road Test to verify the correction. Erase the DTCs, carry out the Drive Cycle Test and repeat the Quick Test after completing repair on the DTC. If the continuous test passes and a concern is still present, refer to «DIAGNOSIS BY SYMPTOM»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) and TSBs for concerns.

After On-Board Diagnostics

Note. The vehicle wiring harness, powertrain control module (PCM) and non-transmission sensors may affect transmission operations. Repair these concerns first.

After the on-board diagnostic procedures are completed, repair all DTCs.

Begin with non-transmission related DTCs, then repair any transmission related DTCs. Refer to the DIAGNOSTIC TROUBLE CODE CHARTS for information on conditions and symptoms. This chart will be helpful in referring to the correct manual(s) and aids in diagnosing internal transmission concerns and external non-transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns. Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV will aid in diagnosing non-transmission electronic components.

Before Pinpoint Tests

Note. Prior to entering pinpoint tests, check the powertrain control module (PCM) wiring harness for correct connections, bent or broken pins, corrosion, loose wires, correct routing, correct seals and their condition. Check the PCM, sensors and actuators for damage. Refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV .

Note. If a concern still exists after electrical diagnosis has been carried out, refer to DIAGNOSIS BY SYMPTOM .

If DTCs appear while carrying out the on-board diagnostics, refer to the DIAGNOSTIC TROUBLE CODE CHARTS for the appropriate repair procedure. Prior to entering pinpoint tests, refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV and any TSBs for transmission concerns.

DIAGNOSTIC TROUBLE CODE CHART

DIAGNOSTIC TROUBLE CODE CHART

Rotunda Transmission Tester

The Rotunda Transmission Tester is used to diagnose electronically controlled transmissions and is used in conjunction with the pinpoint tests. The tests should be carried out in order. Installing the Rotunda Transmission Tester allows separation of the vehicle electronics from transmission electronics; refer to the Rotunda Transmission Tester manual for these tests.

1. Digital Transmission Range (TR) Sensor Testing
2. Resistance/Continuity Test
3. Switch Test - PARK/NEUTRAL, Backup Lamp, and Optional Circuits

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

1. TR_V is the voltage at the PCM pin 64 (TR3A Circuit) to signal return.
2. "In Between" reading could be caused by a shift cable or digital TR sensor misaligned or a digital TR sensor circuit failure of TR1, TR2, TR3A, or TR4.
3. TR_D: 1 = Open digital TR switch, 0 = Closed digital TR switch.
4. EEC-V Control System Breakout Box Readings: Taken from PCM signal pins for TR1, TR2, TR3A, TR4 to signal return. Voltages for TR1, TR2, TR4: 0 = 0.0 volts. 1 = 9.0-14.0 volts. Voltage for TR3A: 0 = 0.0 volts. 1 = 1.3-1.8 volts.

Wiggle Test Information For Open/Shorts

1. TR4, TR3A, TR2, and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TR_D).
2. TR4, TR3A, TR2, and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TR_D, unplug the TR and see if the short goes away. If the short is still present unplug the transaxle harness and see if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness.

PINPOINT TESTS - OSC EQUIPPED VEHICLES

Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector as required.

Shift Solenoid Pre-Diagnosis

Use the following shift solenoid operation information while carrying out PINPOINT TEST A .

Scheme 176

Shift Solenoid Failure Mode Chart "Always On"

Failed OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON.

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Shift Solenoid Failure Mode Chart "Always Off"

Failed ON due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck OFF.

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Pinpoint Test A: Shift & Torque Converter Clutch (TCC) Solenoids

Note. Refer to the Transmission Vehicle Harness Connector illustration preceding these pinpoint tests. (Scheme 170)

Note. Refer to the Transmission Internal Harness Connector illustration preceding these pinpoint tests. (Scheme 171)

Note. Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired before entering Output State Control (OSC).

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Pinpoint Test B: Transmission Fluid Temperature (TFT) Sensor

Note. Refer to the Transmission Vehicle Harness Connector illustration preceding these pinpoint tests. (Scheme 170)

Note. Refer to the Transmission Internal Harness Connector illustration preceding these pinpoint tests. (Scheme 171)

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Pinpoint Test C: Digital Transmission Range (TR) Sensor

Note. Refer to the Digital Transmission Range (TR) Sensor Connector illustration preceding these pinpoint tests. (Scheme 172)

Note. Refer to the Digital Transmission Range (TR) Sensor Diagnosis Chart preceding these pinpoint tests. (Scheme 175)

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Pinpoint Test D: Electronic Pressure Control (EPC) Solenoid

Note. Refer to the Transmission Vehicle Harness Connector illustration preceding these pinpoint tests. (Scheme 170)

Note. Refer to the Transmission Internal Harness Connector illustration preceding these pinpoint tests. (Scheme 171)

Note. Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired before entering Output State Control (OSC).

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Pinpoint Test E: Turbine Shaft Speed (TSS), Intermediate Shaft Speed (ISS) & Output Shaft Speed (OSS) Sensors

Note. Refer to the turbine shaft speed (TSS), intermediate shaft speed (ISS), and output shaft speed (OSS) sensor connector illustrations preceding these pinpoint tests. (Scheme 170), (Scheme 173) and (Scheme 174).

Scheme 210

Scheme 211

Scheme 212

Pinpoint Test F: Solenoid Mechanical Failure

Note. Repair all other DTCs before repairing the following DTCs: P1714, P1715, P1716, P1717, P1740.

Scheme 213

Scheme 214

SPECIAL TESTING PROCEDURES

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

Engine Idle Speed Check

Refer to SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV for diagnosis and testing of the engine idle speed.

Line Pressure Test

Note. Certain sensor failures may cause high EPC, FMEM (Failure Mode Effect Management) actions. Be sure that self test and electrical repairs have been carried out, or test results may be incorrect.

This test verifies that the line pressure is within specifications.

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

1. Connect pressure gauge to the line pressure tap on the transmission and a tachometer to the engine.
2. Start the engine, increase and maintain 1,000 engine RPM and check line pressures. Refer to the line pressure chart in Diagnostics for specification to determine if line pressure is within specifications. NOTE: Prior to using this chart, you should check the transmission identification tag. Some early built units will use a different specification.
3. If line pressure is not within specifications, check EPC pressure.
4. Connect Pressure Gauge to EPC pressure tap.
5. Start the engine, increase and maintain 1,000 engine RPM and check EPC pressure. See the line pressure chart for specification. (Scheme 216)
6. If EPC pressure is not within specification, GO to Pinpoint Test E to diagnose EPC operation. See «PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED (ISS) & OUTPUT SHAFT SPEED (OSS) SENSORS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__pinpoint-test-e-turbine-shaft-speed). If EPC operation is OK, see the line pressure diagnosis chart for line pressure concern causes. (Scheme 218)and (Scheme 219).

Stall Speed Test

This test checks operation of the following items

1. Torque Converter Clutch
2. Forward Clutch
3. Low One-Way Clutch (OWC) Assembly
4. Driveability Concerns

Note. The Stall Speed Test should be carried out with the engine and transmission at normal operating temperatures.

1. Connect tachometer to the engine.
2. Press accelerator pedal to floor Wide Open Throttle (WOT) in each range. Record RPM reached in each range. Stall speeds should be as follows

Scheme 220

If stall speeds were too high, see the Stall Speed Diagnosis Chart. If stall speeds were too low, first check the engine idle speed. If engine idle is OK, remove torque converter and check the torque converter clutch for slippage.

Scheme 221

Scheme 222

A no-drive condition can exist even with correct transmission fluid pressure because of inoperative clutches or bands. An erratic shift can be located through a series of checks by substituting air pressure for fluid pressure to determine the location of the malfunction.

Follow the procedure to determine the location of the inoperative clutch or band by introducing air pressure into the various test plate passages.

Note. Use only dry, regulated (276 kPa [40 psi] maximum) air pressure.

Apply air to the appropriate passage(s). A dull thud should be felt or heard or movement could be observed when the component applies. There should be no hissing sound when the component is fully applied.

Note. Cover the vent hole in the test plate with a clean, lint-free shop towel to prevent spray when the air is applied. Plugging the vent hole during testing will result in inaccurate results.

1. Drain transmission fluid and remove the transmission fluid pan.
2. Remove the main control valve body.
3. Install Transmission Test Plate and gasket. Tighten bolts to 11 Nm (8 lb-ft).
4. Apply air to the appropriate clutch port (refer to the diagram). A dull thud may be heard or movement felt when the component is applied or released. If clutch seals or check balls are leaking, a hissing sound may be heard.

If test results find that the servos do not operate, disassemble, clean and inspect them to locate the source of the concern.

If air pressure applied to the clutch passages fails to operate a clutch, or operates another clutch simultaneously, disassemble and use air pressure to check the fluid passages in the center support and clutches to detect obstructions.

LEAKAGE INSPECTION

Leakage at the transmission fluid pan to case gasket often can be stopped by tightening the attaching bolts to 14 Nm (10 lb-ft). If necessary, install a new oil pan case gasket.

Check the fluid filler tube connection at the transmission case. If leakage is found here, install a new grommet.

Check fluid lines and fittings between the transmission and the cooler in the radiator tank for looseness, wear, or damage. If leakage cannot be stopped by tightening a fluid tube nut, a new cooler line may need to be installed. When fluid is found leaking between the case and cooler line fitting, check for missing or damaged O-ring, then tighten the fitting to maximum specification.

If the leak continues, install a new cooler line fitting and tighten to specification. The same procedure should be followed for fluid leaks between the radiator cooler and the cooler line fittings. Refer to TRANSMISSION COOLING .

Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the radiator is probably leaking.

The cooler can be further checked for leaks by disconnecting the lines for the cooler fittings and applying no more than 345 kPa (50 psi) air pressure to the fittings. Remove the radiator cap to relieve the pressure buildup at the exterior of the oil cooler tank. If the cooler is leaking and/or will not hold pressure, install a new cooler.

If leakage is found at the transmission range selector lever, install a new seal.

If leakage is found at the transmission internal harness connector, install a new O-ring.

External Sealing

The transmission has the following parts to prevent external fluid leakage

1. Gaskets
2. Lip-Type Seals
3. O-Ring Seals
4. Seal Rings
5. Seal Grommets
6. Thread Sealant

Scheme 223

Fluid Leakage In Torque Converter Area

In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area, use the following procedures to locate the exact cause of the leakage. Leakage at the front of transmission, as evidenced by fluid around the torque converter housing, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of leak before removing the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the illustration. The five steps following correspond with the numbers in the illustration. (Scheme 224)

Scheme 224

1. Fluid leaking by the front pump seal lip will tend to move along the impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near the outside diameter of the housing.
2. Fluid leakage by the outside diameter of the front pump seal and front pump body will follow the same path that leaks by the inside diameter of the front pump seal follow.
3. Fluid that leaks by a front pump to case screw or pump gasket will be deposited on the inside of the torque converter housing only. Fluid will not be deposited on the back of the torque converter.
4. Fluid leakage from the converter drain plug (model dependent), converter seal weld or converter to flexplate stud weld will appear at the outside diameter of the torque converter, on the back face of the flexplate, and in the converter housing only near the flexplate. Fluid leaks from the torque converter will leave a ring of fluid around the inside of the torque converter housing.
5. Engine oil leaks are sometimes incorrectly diagnosed as transmission pump gasket leaks. The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the concern. Leakage at the valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to be present in or at the bottom of the torque converter housing. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing. Leakage at oil pressure sensor.

Leak Check Test

1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable amount of makeup fluid has been added or the fluid has been changed, the red color should assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the torque converter area by washing with a suitable nonflammable solvent and blow dry with compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage. Raise and support vehicle on a hoist. Run the engine at fast idle, then at engine idle, occasionally shifting to the OVERDRIVE and REVERSE ranges to increase pressure within the transmission. Observe the front of the flexplate, back of the cylinder block (in as far as possible), and inside the torque converter housing and front of the case. Run the engine until fluid leakage is evident and the probable source of leakage can be determined.

Leak Check Test With Black Light

Fluid soluble aniline or fluorescent dyes premixed at the rate of 2.5 ml (1/2 teaspoon) of dye powder to 0.24 L (1/2 pint) of automatic transmission fluid have proven helpful in locating the source of fluid leakage. Such dyes may be used to determine whether an engine fluid or transmission fluid leak is present, or if the fluid in the transmission fluid cooler hose leaks into the engine coolant system. An ultraviolet light must be used to detect the fluorescent dye solution.

TRANSMISSION FLUID COOLER

Note. Cleaning and backflushing the transmission fluid cooling system along with following all the normal cleaning and inspection procedures as outlined during disassembly and reassembly will keep contamination from re-entering the transmission and causing a repeat repair.

When internal wear or damage has occurred in the transmission, metal particles, clutch plate material, or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back in use.

Transmission Fluid Cooler Flow Test

Note. The transmission linkage/cable adjustment, fluid level and line pressure must be within specification before carrying out this test. Refer to GENERAL PROCEDURES for adjustments.

1. Remove fluid level indicator from fluid filler tube.
2. Place funnel in fluid filler tube.
3. Raise vehicle on a hoist and place suitable safety stands under the vehicle.
4. Remove the cooler return line (rear fitting) from the fitting on the transmission case.
5. Connect one end of a hose to the cooler return line and route other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube.
6. Remove the safety stands and lower the vehicle. Insert the end of the hose into the funnel.
7. Start the engine and run it at idle with the transmission in NEUTRAL position.
8. Once a steady flow of fluid (without air bubbles) is observed, remove the hose from the funnel and place the hose in a measuring container for 15 seconds. After 15 seconds place the hose back into the funnel and turn the engine off. Measure the amount of fluid in the container. If adequate flow was observed, approximately 2.37 ml (8 ounces) will be in the measuring container; the test is now complete.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter outline fitting (front fitting) on the transmission case.
10. Repeat Steps 7 and 8. If flow is now approximately 2.37 ml (8 ounces) in 15 seconds, refer to Transmission Fluid Cooler - Backflushing and Cleaning. Refer to «TRANSMISSION COOLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#transmission-cooling) for fluid cooler diagnosis. If the flow is still not approximately 2.37 ml (8 ounces) in 15 seconds, service the pump, main control and/or converter.

Transmission Fluid Cooler Tube

For installation of new fluid cooler tubes, refer to TRANSMISSION COOLING .

Scheme 225

Scheme 226

The Diagnosis by Symptom Index gives the technician diagnostic information, direction, and suggests possible components, using a symptom as a starting point.

The Diagnosis by Symptom Index is divided into two categories: Electrical Routines, indicated by 200 series numbers, and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible electrical components that could cause or contribute to the symptom described. The Hydraulic/Mechanical Routines list the possible hydraulic or mechanical components that could cause or contribute to the symptom described.

Diagnosis By Symptom Chart Directions

1. Using the Symptom Index, select the Concern/Symptom that best describes the condition.
2. Refer to the routine indicated in the Diagnosis by Symptom Index. Refer to «DIAGNOSIS BY SYMPTOM INDEX»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
3. Always begin diagnosis of a symptom with: Preliminary inspections. Verifications of condition. Checking the fluid levels. Carrying out other test procedures as directed.
4. Begin with the Electrical Routine, if indicated. Follow the reference or action required statements. Always carry out the on-board diagnostic tests as required. Never skip steps. Repair as required. If the concern is still present after electrical diagnosis, then proceed to the Hydraulic/Mechanical Routine listed.
5. The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could cause the concern. These components are listed in the removal sequence and by most probable cause. All components listed must be inspected to ensure correct repair.

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

TRANSMISSION FLUID COOLER - BACKFLUSHING & CLEANING

1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described. Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.

Scheme 300

Scheme 301

Draining

Note. This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine.

1. Position the vehicle on a hoist. Place in PARK.
2. Use a suitable flush and fill machine to change the fluid.
3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers.
4. Carry out the fluid exchange process.

Refill

1. Use only clean automatic transmission fluid.
2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes.
3. Install a new in-line transmission fluid filter.
4. Lower the vehicle.
5. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).

Scheme 302

Scheme 303

Scheme 304

Scheme 305

1. Position the vehicle on a hoist. Place in PARK.
2. If equipped, loosen the nut and position the heat shield aside.
3. Place a drain pan under the transmission fluid pan.
4. Drain the transmission fluid. Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan. Remove the transmission fluid pan. Remove and discard the transmission fluid pan gasket.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.

Scheme 306

Scheme 307

Scheme 308

1. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Install and align the transmission fluid pan. Loosely install the transmission fluid pan screws.
2. Tighten the transmission fluid pan bolts. Tighten the transmission fluid pan bolts in a crisscross sequence.
3. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
4. Install a new in-line transmission fluid filter.
5. Lower the vehicle.
6. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
7. Apply the park brake, and start the engine.
8. Move the range selector lever through all the gears.
9. Check the transmission fluid level.

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

1. Position the vehicle on a hoist. Place in NEUTRAL.
2. If equipped, loosen the nut and position the heat shield out of the way.
3. Place a drain pan under the transmission fluid pan.
4. Drain transmission fluid. Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan. Remove the transmission fluid pan. Remove and discard the transmission fluid pan gasket.
6. Remove and discard the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
7. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.
8. Flush the transmission fluid cooler and transmission fluid cooler lines. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING & CLEANING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__transmission-fluid-cooler-backflushing) .

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

1. Lube and install new O-ring seals onto the transmission fluid filter. Install a new transmission fluid filter. Position the transmission fluid filter on the main control valve body.
2. Install the transmission fluid filter.
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Install and align the transmission fluid pan. Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
7. Lower the vehicle.
8. Apply the park brake, and start the engine.
9. Fill transmission with clean automatic transmission fluid to the correct fluid level and check for correct transmission operation.
10. Move the range selector lever through all the gears.
11. Recheck the transmission fluid level.

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Place a drain pan under the transmission fluid pan.
4. Disconnect the shift cable from the manual control lever.
5. Disconnect the digital transmission range (TR) sensor electrical connector.
6. Remove the manual control outer lever nut and manual control outer lever.
7. Loosen the screws on the digital TR sensor.
8. If equipped, loosen the nut and position the heat shield out of the way.
9. Drain transmission fluid. Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan screws.
10. Remove the transmission fluid pan. Remove the transmission fluid pan. Remove and discard the transmission fluid pan gasket.
11. Remove and discard the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
12. Unclip main control valve body wire harness. Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps.
13. Disconnect the six solenoid electrical connectors. Disconnect the SSA, SSB, SSC and SSD electrical connectors. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
14. Remove the manual control valve detent lever spring. Remove the manual control valve detent lever spring screw. Remove the manual control valve detent lever spring.
15. Remove the low/reverse servo. Remove the low/reverse servo cover screws. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket.
16. Remove the low/reverse band servo piston and rod.
17. Do not remove the two (gold) screws specified.
18. Remove the screws.
19. Remove the main control valve body.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

1. Install the special tool into the transmission case.
2. Position the main control valve body with the two special tools as a guide.
3. Loosely install four M6 x 45 mm (1.8 in) screws.
4. Loosely install two M6 x 35 mm (1.4 in) screws.
5. Remove the special tools.
6. Loosely install the M6 x 30 mm (1.2 in) screw.
7. Loosely install the sixteen M6 x 40 mm (1.6 in) main control valve body screws.
8. Tighten the main control valve body screws in the sequence shown.
9. Rotate the manual lever into the NEUTRAL position.
10. Install the manual control valve detent lever spring.
11. Install the low/reverse band servo piston and rod.
12. Install the low/reverse band servo cover. Install the low/reverse band servo cover and gasket. Loosely install the low/reverse servo piston cover screws.
13. Tighten the servo cover screws in the sequence shown.
14. Connect the six solenoid electrical connectors. Connect SSA, SSB, SSC, and SSD electrical connectors. Connect the torque converter clutch (TCC) solenoid electrical connector. Connect the electronic pressure control (EPC) solenoid electrical connector.
15. Install the main control valve body wire harness. Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body wire harness guide and protector.
16. Install the transmission fluid filter. Install the transmission fluid filter. Install the transmission fluid filter screw.
17. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Install and align the transmission fluid pan.
18. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
19. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
20. Install the manual control outer lever and nut.
21. Connect the digital transmission range (TR) sensor electrical connector.
22. Connect the shift cable to the manual control lever.
23. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
24. Install a new in-line transmission fluid filter kit or filter.
25. Lower the vehicle.
26. Connect the battery ground cable.
27. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 347

Scheme 348

1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor. Remove the OSS sensor screw. Remove the OSS sensor from the transmission. Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 349

Scheme 350

1. Inspect and lubricate O-ring with petroleum jelly. Install the OSS sensor into the transmission. Tighten OSS sensor screw.
2. Connect OSS sensor electrical connector.
3. Lower the vehicle.

Scheme 351

Scheme 352

1. Raise and support the vehicle.
2. Disconnect intermediate shaft speed (ISS) sensor electrical connector.
3. Remove ISS sensor. Remove the ISS sensor screw. Remove the ISS sensor from the transmission. Inspect the ISS sensor O-ring for damage. If damaged, install a NEW O-ring.

Scheme 353

Scheme 354

1. Inspect and lubricate O-ring with petroleum jelly. Install the ISS sensor into the transmission. Tighten ISS sensor screw.
2. Connect ISS sensor electrical connector.
3. Lower the vehicle.

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

1. Position the vehicle on a hoist. Place in NEUTRAL.
2. Mark the rear driveshaft.
3. Remove the rear driveshaft. Remove the rear driveshaft bolts. Remove the rear driveshaft.
4. Using the special tools, remove the extension housing seal.
5. Using the special tool, remove the extension housing bushing.

Scheme 361

Scheme 362

1. Position the extension housing bushing into the extension housing.
2. Using the special tool, install the extension housing bushing.
3. Position new extension housing seal with drain hole in the 6 o'clock position.
4. Using the special tool, install the extension housing seal.
5. Align the driveshaft with the marks made during removal to make sure balance is correct.
6. Install the rear driveshaft bolts.
7. Lower the vehicle.
8. Fill the transmission to the correct fluid level with clean automatic transmission fluid and check for correct transmission operation.

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Scheme 367

1. Raise and support the vehicle.
2. Mark the rear driveshaft.
3. Remove the rear driveshaft. Remove the bolts. Remove the rear driveshaft
4. Remove the nuts.
5. Raise and support the transmission.
6. Remove the transmission mount. Remove the screws. Remove the transmission mount.
7. Remove the extension housing screws and studs.
8. Remove the extension housing. Discard the extension housing gasket.

Scheme 368

Scheme 369

Scheme 370

Scheme 371

1. Clean the extension housing and install new extension housing gasket. Make sure that the parking pawl, spring and shaft are correctly installed.
2. Install the extension housing. Position the extension housing. Install the extension housing screws. Install the extension housing studs.
3. Install the transmission mount. Position the transmission mount on the extension housing. Install the transmission mount-to-extension housing screws.
4. Install the transmission mount into the crossmember and tighten the transmission mount nuts.
5. Align and install the rear driveshaft.
6. Install the bolts.
7. Lower the vehicle.
8. Fill the transmission to the correct fluid level and check for correct transmission operation. Use MERCON® V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON® V specification.

Scheme 372

Scheme 373

Scheme 374

Scheme 375

1. Raise and support the vehicle.
2. Mark the rear driveshaft.
3. Remove the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
4. Remove the wire harness locators from the extension housing wire bracket.
5. Remove the transmission mount nuts.
6. Raise and support the transmission.
7. Remove the transmission mount. Remove the transmission mount-to-extension housing screws. Remove the transmission mount.
8. Remove the six extension housing screws and studs.
9. Remove the extension housing. Discard the extension housing gasket.

Scheme 376

Scheme 377

Scheme 378

Scheme 379

1. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring and shaft are correctly installed.
2. Install the extension housing. Position the extension housing and install the six extension housing screws and studs.
3. Install the transmission mount. Position the transmission mount on the extension housing. Install the screws.
4. Install the transmission mount into the crossmember and tighten the nuts.
5. Install the wire harness locators from the extension housing wire bracket.
6. Install the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
7. Align and install the rear driveshaft.
8. Install the bolts.
9. Fill the transmission to correct fluid level and check for correct transmission operation. Use MERCON® V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON® V specification.

Scheme 380

Scheme 381

Scheme 382

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan.
5. Drain the transmission fluid. For additional information, refer to «FLUID PAN, GASKET & FILTER»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. Remove the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
7. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps.
8. Disconnect the appropriate solenoid electrical connector. Disconnect shift solenoids electrical connectors. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
9. Remove the shift solenoids. Remove the wire harness. Remove the solenoid clamp screws. Remove the solenoid clamp. Remove the appropriate solenoid(s).

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

1. Install the new solenoid(s).
2. Install the solenoid clamp. Position the solenoid clamp on the main control valve body. Install the solenoid clamp screws.
3. Connect the six solenoid electrical connectors. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. Connect the torque converter clutch (TCC) solenoid electrical connector. Connect the electrical pressure control (EPC) solenoid electrical connector.
4. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector.
5. Install the transmission fluid filter. Install the transmission fluid filter. Install the transmission fluid filter screw.
6. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Align and install the transmission fluid pan. Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
8. Position the servo heat shield over the servos and clip it to the pan rail.
9. Lower the vehicle.
10. Connect the battery ground cable.
11. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

1. Disconnect the battery ground cable.
2. Raise and support vehicle.
3. If equipped, loosen the nut and position the heat shield out of the way.
4. Remove the transmission fluid pan. For additional information, refer to «FLUID PAN, GASKET & FILTER»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
5. Remove the digital transmission range (TR) sensor. For additional information, refer to «DIGITAL TRANSMISSION RANGE (TR) SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. Remove the manual control valve detent lever spring. Remove the manual control valve detent lever spring screw. Remove the manual control valve detent lever spring.
7. Remove the manual valve inner lever nut.
8. Separate the manual valve inner lever and the parking lever actuating rod.
9. Remove the manual control lever shaft spring pin. Tap lightly on each side of the manual control lever shaft spring pin with a drift punch. Pry the spring pin out of its bore.
10. Remove the manual control lever shaft.
11. Remove the manual control lever shaft seal.

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

1. Using the special tool, install the manual control lever shaft seal. Lubricate the manual control lever shaft seal with petroleum jelly.
2. Install the manual control lever shaft.
3. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Tap the manual control lever shaft spring pin into the transmission case.
4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.
5. Install the manual valve inner lever nut.
6. Verify that the output shaft is locked in the PARK position.
7. Rotate the manual lever into the NEUTRAL position and install the manual valve detent spring.
8. Install the transmission fluid pan with new pan gasket.
9. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
10. Install the digital transmission range (TR) sensor. For additional information, refer to «DIGITAL TRANSMISSION RANGE (TR) SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
11. Lower the vehicle.
12. Connect the battery ground cable.
13. Fill the transmission to correct level and check for correct transmission operation.

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect the shift cable from the manual control lever.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
6. Remove the screws and the digital TR sensor.

Scheme 404

Scheme 405

Scheme 406

Scheme 407

1. Install the digital TR sensor and loosely install the screws.
2. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever and nut.
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. For additional information, refer to «EXTERNAL CONTROLS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#transmission-external-controls) .
7. Lower the vehicle.
8. Connect the battery ground cable.

Scheme 408

1. Raise and support the vehicle.
2. If equipped, remove the transmission servo heat shield. Remove the transmission servo heat shield nut. Remove the transmission servo heat shield.

Scheme 409

1. Follow the removal procedure in reverse order.

Scheme 410

Scheme 411

Scheme 412

Scheme 413

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Disconnect vehicle harness from transmission case (16-pin) connector.
4. Drain the transmission fluid. For additional information, refer to «FLUID PAN, GASKET & FILTER»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
5. Remove the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
6. Remove main control valve body wire loom. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps.
7. Disconnect the solenoid electrical connectors. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
8. Remove the EPC and SSB solenoids. Remove the solenoid clamp screws. Remove the solenoid clamp. Remove the EPC and SSB solenoids.
9. Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case (16-pin) electrical connector. Disconnect the TSS sensor electrical connector. Remove from the TSS sensor wire locator.
10. Remove the transmission case (16-pin) electrical connector retaining spring.
11. Remove the transmission case (16-pin) electrical connector. Compress the tabs on the transmission case (16-pin) electrical connector. Push the transmission case (16-pin) electrical connector out of transmission case.

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

1. Install the transmission case (16-pin) electrical connector. Lubricate the transmission case (16-pin) electrical connector O-rings with petroleum jelly.
2. Press the transmission case (16-pin) electrical connector through the case until a click is heard.
3. Install the TSS sensor wire. Install TSS sensor wire into (16-pin) case connector. Install TSS sensor wire into the locator.
4. Install the transmission case (16-pin) electrical connector retaining spring.
5. Install the EPC and SSB solenoids.
6. Install the solenoid clamp. Position the solenoid clamp on the main control valve body. Install the solenoid clamp screws.
7. Connect the SSA and SSC shift (SS) solenoid electrical connectors.
8. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors.
9. Install the wire harness guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness guide and protector.
10. Install the transmission fluid filter. Install the transmission fluid filter. Install the transmission fluid filter screw.
11. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Align and install the transmission fluid pan. Loosely install the transmission fluid pan screws.
12. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
13. Connect vehicle harness to transmission (16-pin) connector. Make sure lock is fully engaged.
14. Lower the vehicle.
15. Connect the battery ground cable.
16. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 422

Scheme 423

Scheme 424

Scheme 425

Scheme 426

Scheme 427

1. Position the vehicle on a hoist. Place in NEUTRAL.
2. Disconnect the battery ground cable.
3. If equipped, loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan.
5. Drain transmission fluid. Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws.
6. Remove the transmission fluid pan. Remove the transmission fluid pan. Remove and discard the transmission fluid pan gasket.
7. Remove the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
8. Remove the low/reverse band servo cover. Remove the low/reverse band servo cover screws. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket.
9. Remove the low/reverse band servo piston and rod assembly.

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston and rod.
2. Install the low/reverse band servo piston and rod. Install the low/reverse band servo piston and rod assembly. Install a new low/reverse band servo separator plate cover gasket. Install the low/reverse band servo cover. Loosely install the low/reverse band servo piston cover screws.
3. Tighten the servo cover screws in the sequence shown.
4. Install the transmission fluid filter.
5. Install the transmission fluid pan. Position a new transmission fluid pan gasket on the transmission fluid pan. Install and align the transmission fluid pan. Loosely install the transmission fluid pan screws.
6. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
7. Lower the vehicle.
8. Connect the battery ground cable.
9. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 433

Scheme 434

Scheme 435

Scheme 436

1. Disconnect the battery ground cable.
2. Raise and support vehicle.
3. Remove the shift cable. Disconnect the shift cable from the manual control lever. Remove the shift cable from the bracket.
4. Remove the digital transmission range (TR) sensor. For additional information, refer to «DIGITAL TRANSMISSION RANGE (TR) SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
5. Remove the main control valve body. For additional information, refer to the «MAIN CONTROL VALVE BODY»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. Remove the three way catalytic converter (TWC).
7. Loosen the nut and position the heat shield out of the way.
8. Remove the front band locknut and unscrew the front band adjusting screw. Discard the front band locknut after removal.
9. Using the special tool, remove the front band servo cover retaining ring. Slowly remove tension on the J-hook nut and remove the servo cover compressor.
10. Using the special tool, remove the front band servo cover, servo piston and servo piston spring. Insert the special tool into the transmission case, locate on servo rod, and remove the front band servo cover, servo piston and servo piston spring.

Scheme 437

Scheme 438

Scheme 439

Scheme 440

1. Assemble the front band servo cover, front band servo piston and the servo piston spring. Install the front band servo piston into the front band servo cover. Install the servo piston spring on the front band servo piston.
2. Install the front band servo assembly into the transmission case. Lubricate the front band servo cover O-ring with petroleum jelly.
3. Using the special tool, install the front band servo cover retaining ring.
4. Install the main control valve body.
5. Adjust the front band. For additional information, refer to «FRONT BAND ADJUSTMENT»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. If equipped, position the transmission servo heat shield on the transmission and install the nut.
7. Install the three way catalytic converter.
8. Install the shift cable. Install the shift cable. Install the shift cable to the manual control lever.
9. Install the digital transmission range (TR) sensor.
10. Lower the vehicle.
11. Connect the battery ground cable.
12. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 441

Scheme 442

Scheme 443

Scheme 444

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Remove the shift cable. Disconnect the shift cable from the manual control lever. Remove the shift cable from the bracket.
4. Remove the digital transmission range (TR) sensor. For additional information, refer to the «DIGITAL TRANSMISSION RANGE (TR) SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
5. Remove the three way catalytic converter (TWC).
6. Remove the main control valve body. For additional information, refer to «MAIN CONTROL VALVE BODY»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
7. Loosen the nut and position the heat shield out of the way.
8. Remove the intermediate band locknut and unscrew the screw. Discard the intermediate band locknut after removal.
9. Using the special tool, remove the intermediate band servo cover retaining ring. Slowly remove tension on the J-hook nut and remove the servo cover compressor.
10. Using the special tool, remove the intermediate band servo cover, intermediate band servo piston and servo piston spring. Insert the special tool into the transmission case, and remove the servo cover, intermediate band servo piston and servo piston spring.

Scheme 445

Scheme 446

Scheme 447

Scheme 448

1. Assemble the intermediate band servo cover, intermediate band servo piston and the servo piston spring. Install the intermediate band servo piston into the intermediate band servo cover. Install the servo piston spring on the intermediate band servo piston.
2. Install the intermediate band servo piston assembly into the transmission case. Lubricate intermediate band servo cover O-ring with petroleum jelly.
3. Using the special tool, install the intermediate band servo cover retaining ring.
4. Adjust the intermediate band. For additional information, refer to «INTERMEDIATE BAND ADJUSTMENT»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
5. Install the main control valve body.
6. Install the digital transmission range (TR) sensor.
7. If equipped, position the transmission servo heat shield on the transmission and install the nut.
8. Install the shift cable. Install the shift cable. Install the shift cable to the manual control lever.
9. Install the three way catalytic converter.
10. Lower the vehicle.
11. Connect the battery ground cable.
12. Fill the transmission to the correct fluid level and check for correct transmission operation.

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

1. Position the vehicle on a hoist. Place in NEUTRAL.
2. Disconnect the battery ground cable.
3. Loosen the nut and position the heat shield out of the way.
4. Disconnect the shift cable from the manual control lever.
5. Disconnect the digital transmission range (TR) sensor electrical connector.
6. Remove the manual control outer lever nut and manual control outer lever.
7. Loosen the screws on the digital TR sensor.
8. Remove the transmission fluid pan. Remove the transmission fluid pan. Remove and discard the transmission fluid pan gasket.
9. Remove the transmission fluid filter. Remove the transmission fluid filter screw. Remove the transmission fluid filter.
10. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps.
11. Disconnect the solenoid electrical connectors. Disconnect shift solenoids SSB and SSD electrical connectors. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
12. Remove the EPC, SSB, and SSD solenoids. Remove the wire harness. Remove the solenoid clamp screws. Remove the solenoid clamp. Remove the EPC, SSB and SSD solenoids.
13. Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case (16-pin) electrical connector. Disconnect the TSS sensor electrical connector. Remove the TSS sensor wire locator.
14. Remove the transmission case (16-pin) electrical connector retaining spring.
15. Remove the transmission case (16-pin) electrical connector. Compress the tabs on the connector. Push the connector out of the transmission case.
16. Remove the manual control valve detent lever spring. Remove the screw. Remove the spring.
17. Remove the manual valve inner lever nut.
18. Remove the manual valve inner lever and parking lever actuating rod.
19. Mark the rear driveshaft.
20. Remove the rear driveshaft. Remove the bolts. Remove the rear driveshaft.
21. If equipped, remove the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
22. Remove the extension housing and discard the extension housing gasket.
23. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft. Install new components if required.

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

1. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.
2. Install the manual valve inner lever nut.
3. Rotate the manual lever into the NEUTRAL position, and install the manual valve detent spring.
4. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring and shaft is correctly installed.
5. Install the extension housing. Position the extension housing. Install the extension housing screws. Install the extension housing stud.
6. If equipped, install the transfer case.
7. Install the rear driveshaft bolts.
8. Install the transmission case (16-pin) electrical connector. Lubricate the transmission case (16-pin) electrical connector O-ring seals with petroleum jelly.
9. Press the transmission case (16-pin) electrical connector through the case until a click is heard.
10. Install the TSS sensor wire. Install the TSS sensor wire into (16-pin) electrical connector. Install the TSS sensor wire into locator.
11. Install the transmission case (16-pin) electrical connector retaining spring.
12. Install the EPC, SSD and SSB solenoids.
13. Install the solenoid clamp. Position the solenoid clamp on the main control valve body. Install the solenoid clamp screws.
14. Connect the TCC, SSD, SSB and EPC solenoid electrical connectors.
15. Install the wire loom guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide and protector.
16. Install the transmission fluid filter.
17. Install the transmission fluid pan. Install a new transmission fluid pan gasket on the transmission fluid pan. Install and align the transmission fluid pan. Loosely install the transmission fluid pan screws.
18. Tighten the transmission fluid pan screws. Tighten the transmission fluid pan screws in a crisscross sequence.
19. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
20. Install the manual control outer lever and nut.
21. Connect the digital transmission range (TR) sensor electrical connector.
22. Connect the shift cable to the manual control lever.
23. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
24. Lower the vehicle.
25. Connect the battery ground cable.
26. Fill transmission to correct fluid level and check for correct transmission operation.

Scheme 474

Scheme 475

Scheme 476

Scheme 477

1. Raise and support vehicle on a hoist.
2. Disconnect the shift cable. Disconnect the shift cable from the manual control lever. Disconnect the shift cable from the bracket.
3. Remove and discard the locknut.
4. Using the special tool, tighten front band adjustment screw then, back off the front band adjustment screw exactly two (2) turns and hold that position.
5. Tighten the front band locknut. Hold the front band adjustment screw stationary. Tighten the front band locknut.
6. Install the shift cable. Install the shift cable. Install the shift cable to the manual control lever.
7. Lower the vehicle.

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

1. Raise and support the vehicle.
2. Remove the shift cable. Disconnect the shift cable from the manual control lever. Remove the shift cable from the bracket.
3. Remove the digital transmission range (TR) sensor. For additional information, refer to the «DIGITAL TRANSMISSION RANGE (TR) SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
4. Remove and discard the locknut.
5. Using the special tool, tighten the screw then, back off the screw exactly two (2) turns and hold that position.
6. Tighten the intermediate band locknut. Hold the screw stationary. Tighten the intermediate band locknut.
7. Install the digital TR sensor. Position the digital TR sensor. Loosely install the screws.
8. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
9. Install the manual control outer lever. Install the manual control outer lever. Install the manual control outer lever nut.
10. Connect the digital transmission range (TR) sensor electrical connector.
11. Connect the shift cable. Connect the shift cable to the bracket. Connect the shift cable to the manual control lever.
12. Verify that the shift cable is adjusted. For additional information, refer to «EXTERNAL CONTROLS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#transmission-external-controls) .
13. Lower the vehicle.

Removal

Note. 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed.

Scheme 484

Scheme 485

Scheme 486

Scheme 487

1. Raise and support the vehicle.
2. Mark the rear driveshaft.
3. Remove the rear driveshaft. Remove the bolts. Remove the rear driveshaft.
4. Remove the transmission mount nuts.
5. Raise and support the transmission.
6. Remove the transmission mount. Remove the screws. Remove the transmission mount.

Scheme 488

Scheme 489

Scheme 490

1. Install the transmission mount. Position the transmission mount on the extension housing. Install the transmission mount-to-extension housing screws.
2. Install the transmission mount into the crossmember and tighten the nuts.
3. Align and install the rear driveshaft.
4. Install the bolts.
5. Lower the vehicle.

Scheme 491

Note. If the transmission is to be removed for a period of time, support the engine with a safety stand and a wood block.

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

1. Disconnect the battery ground cable.
2. Place the selector lever in NEUTRAL position.
3. Remove the nut, and remove the transmission upper fill tube.
4. Raise and support the vehicle.
5. If transmission disassembly is required, drain the transmission fluid. For additional information, refer to «FLUID PAN, GASKET & FILTER»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) .
6. Vehicles equipped with 4WD, remove the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
7. To maintain initial driveshaft balance, mark the driveshaft yoke and axle flange, so they can be installed in their original positions.
8. Remove the rear driveshaft. Remove the four bolts. Remove the driveshaft.
9. Remove the starter motor. For additional information, refer to «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) .
10. Remove the four nuts. Rotate the crankshaft for access to the flexplate nuts.
11. Disconnect the shift cable. Disconnect the shift cable from the manual control lever. Disconnect the shift cable from the bracket.
12. Disconnect the transmission wiring harness. Disconnect the transmission connector. Disconnect the intermediate shaft speed (ISS) sensor. Disconnect the digital transmission range (TR) sensor connector. Disconnect the output shaft speed (OSS) sensor
13. Remove the three-way catalytic converter.
14. Hold the case fitting and remove the transmission cooler lines.
15. Remove the nuts.
16. Position the High-Lift Transmission Jack under the transmission. Raise and support the transmission.
17. Remove the crossmember. Remove the six bolts (three each side). Remove the crossmember.
18. Remove the transmission mount. Remove the screws. Remove the transmission mount.
19. Remove the transmission-to-engine screws.
20. On 4x4 models, remove the vent tube.
21. Install the special tool before lowering the transmission from the vehicle.
22. Lower the transmission.
23. Carry out the Transmission Fluid Cooler Back Flushing/Cleaning. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING & CLEANING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__transmission-fluid-cooler-backflushing) .

Note. The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

1. Place the transmission on a workbench.
2. Remove the special tool.
3. Using the special tool, remove the torque converter.
4. Remove the input shaft.
5. Remove output shaft speed (OSS) sensor. Remove the OSS screw. Remove OSS sensor.
6. If equipped, remove the intermediate shaft speed (ISS) sensor. Remove the ISS screw. Remove ISS sensor.
7. If equipped, remove the heat shield. Remove the nut. Remove the heat shield.
8. Remove manual control outer lever nut and manual control outer lever.
9. Remove the digital transmission range (TR) sensor. Remove the screws. Remove the digital TR sensor.
10. Using the special tools, remove the extension housing seal.
11. Using the special tool, remove the extension housing bushing. Inspect the extension housing bushing and driveshaft slip yoke for nicks, gauges, scoring and wear.
12. Remove the screws, studs, and the extension housing. Discard the extension housing gasket.
13. Remove the parking pawl assembly. Remove the parking pawl shaft. Remove the parking pawl. Remove the parking pawl return spring.
14. Install the special tool.
15. Assemble the special tools.
16. Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.
17. Remove the transmission fluid pan and transmission pan gasket and then discard gasket.
18. Remove the transmission fluid filter and discard. Remove the screw. Remove the transmission fluid filter.
19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
20. Disconnect the solenoid electrical connectors. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
21. Remove the manual control valve detent lever spring. Remove the screw. Remove the manual control valve detent lever spring.
22. Remove the low/reverse band servo cover. Remove the screws. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket. Discard the low/reverse servo separator plate cover gasket.
23. Remove the low/reverse band servo piston and rod assembly.
24. Do not remove the two (gold colored) screws specified.
25. Remove the twenty-three valve body screws.
26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket. Discard gaskets.
27. Remove the locknuts. Back off the screws.
28. Using the special tool, remove the intermediate servo cover retaining ring. Remove the special tool.
29. Using the special tool, release the intermediate band servo piston.
30. Remove the intermediate band servo cover, piston and spring.
31. Using the special tool, remove the overdrive servo retaining ring and cover.
32. Using the special tool, release the overdrive band servo piston.
33. Remove the overdrive band servo cover, piston and spring.
34. Rotate the transmission so the converter housing faces up.
35. Remove and discard the screws.
36. Remove the converter housing and fluid pump support. Turn and lift the converter housing and fluid pump support from the case.
37. Remove the fluid pump input thrust washer (No. 1). Tag and identify the thrust washer.
38. Remove the front band adjusting screw.
39. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
40. Remove the front band.
41. Remove the front brake and coast clutch drum.
42. Remove the front band apply strut.
43. Remove the front band actuating lever shaft.
44. Remove the planetary gear overdrive carrier.
45. Remove the front band servo lever and front band lever to case bracket.
46. Remove the front planet thrust bearing (No. 2).
47. Remove the front ring gear, front one-way clutch assembly, and center shaft as an assembly.
48. Remove the No. 3 center shaft thrust bearing.
49. Remove the center support cap screw.
50. Remove the locknut and cage.
51. Disconnect the turbine shaft speed (TSS) sensor electrical connector. Remove the TSS sensor electrical connector from the transmission case (16-pin) electrical connector. Remove the TSS sensor connector wires from wire locator.
52. Remove the TSS sensor. Remove the screw. Remove the TSS sensor.
53. Remove the transmission case (16-pin) electrical connector retaining spring.
54. Compress the tabs on the transmission case (16-pin) electrical connector. Push the transmission case (16-pin) electrical connector out of transmission case.
55. Remove the center support retaining ring.
56. Remove the center support.
57. Remove the intermediate brake drum thrust bearing (No. 4).
58. Remove the intermediate band anchor strut and adjusting screw.
59. Remove the intermediate band.
60. Remove the intermediate band apply strut.
61. Remove the intermediate band actuating lever shaft.
62. Remove the intermediate servo actuating lever.
63. Rotate the transmission so the transmission fluid pan surface is facing up.
64. Remove the intermediate brake and direct clutch drum.
65. Remove the forward clutch cylinder thrust bearing (No. 5) tag and identify.
66. Remove the forward clutch cylinder.
67. Remove the forward ring gear hub thrust bearing (No. 6A).
68. Remove the forward ring gear and forward ring gear hub as an assembly.
69. Remove forward clutch thrust washer (No. 6B) from the forward ring gear hub.
70. Remove the forward planet thrust bearing (No. 7).
71. Remove the forward planetary assembly.
72. Remove input shell with the forward sun gear.
73. Remove the low/reverse planetary carrier thrust bearing (No. 8).
74. Remove the low/reverse planetary retaining ring.
75. Remove low/reverse planetary assembly.
76. Remove the low/reverse planetary carrier thrust bearing (No. 9).
77. Remove the output shaft sleeve.
78. Remove and discard the output shaft retaining ring.
79. Remove the output shaft ring gear and the output shaft hub.
80. Remove the output shaft thrust bearing (No. 10).
81. Remove the low/reverse brake drum and one-way clutch assembly.
82. Remove the reverse band.
83. Remove the output shaft.
84. Remove the park gear.
85. Remove the output shaft thrust washer (No. 11).
86. Remove the manual control valve inner lever nut.
87. Remove the manual control valve inner lever and the parking lever actuating rod.
88. Remove the manual control lever shaft spring pin. Tap lightly on each side of the manual control lever shaft spring pin with a drift punch. Pry the spring pin out of its bore.
89. Remove the manual control lever shaft.
90. Remove the manual control lever seal.

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

1. Remove the SSA and the SSC clamp and SSA and SSC solenoid. Remove the solenoid clamp screw. Remove the solenoid clamp. Remove the SSA and SSC solenoids.
2. Remove the SSB, SSD, torque converter clutch solenoid, and the EPC solenoid. Remove the solenoid clamp screw. Remove the solenoid clamp. Remove the SSB, SSD, torque converter clutch solenoid and the EPC solenoids.
3. Rotate the main control valve body so that the main control separating plate is facing up.
4. Remove the valve body separator plate screws.
5. Remove valve body separator plate.
6. Remove the extension housing lube orifice.
7. Remove the black plastic converter relief valve and spring.
8. Remove the four main control valve body check balls.

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

1. Thoroughly clean all parts in solvent and blow dry with moisture free compressed air.
2. After cleaning the main control valve body, carry out the following: Inspect all valve and plug bores for scoring or burrs. Check all fluid passages for obstructions. Inspect all valves and plugs for burrs. Inspect all mating surfaces for burrs or distortion. Inspect all springs for distortion. Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight into their respective bores. Roll the manual valve on a flat surface to check for a bent condition.
3. Clean and inspect the EPC solenoid screens.
4. Remove and install new shift solenoid O-rings.
5. Clean and inspect the torque converter clutch solenoid.
6. Install the four main control valve body check balls.
7. Install the dark color plastic converter relief valve and spring.
8. Install the extension housing lube orifice.
9. Install the main control valve body separator plate to the main control.
10. Install the special tools into the main control valve body.
11. Tighten the screws.
12. Remove the special tools from the main control valve body.
13. Rotate the main control valve body so the valve body separator plate is facing down.
14. Install the SSB, SSD, TCC and EPC solenoids. Install the TCC solenoid. Install the SSB and SSD solenoids. Install the EPC solenoid.
15. Install the solenoid clamp and the screw. Position the solenoid clamp on the main control valve body. Install the screw.
16. Install the SSA and the SSC shift solenoids.
17. Install the solenoid clamp and the screw. Position the solenoid clamp on the main control valve body. Install the screw.

Scheme 568

Scheme 569

Scheme 570

Scheme 571

Scheme 572

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

1. Remove the fluid pump gasket and fluid pump seal rings. Remove and discard the fluid pump gasket. Remove and discard the fluid pump seal ring (square cut).
2. Remove the fluid pump support seal ring.
3. Remove the fluid pump housing. Remove the six fluid pump screws. Remove the fluid pump support and gear and the fluid pump adapter plate.
4. Inspect the fluid pump support needle bearings and cage for scored or missing rollers and alignment of lube holes.
5. Inspect the coast clutch feed hole for blockage or damage. Rotate the pump bearing and locate the coast clutch feed hole. Inspect the coast clutch feed hole for blockage or damage.
6. Remove the lower seal.
7. Assemble the special tools onto the front pump assembly.
8. Using the special tools, remove the needle bearing.
9. Inspect the front pump outer race for scoring or nicks, if any damage is found new pump assembly must be installed.
10. Remove the fluid pump gears and front pump adapter plate.
11. Remove the drive gear O-ring seal and discard. Inspect the fluid pump gears for cracks and scoring. Install a new front pump support and gear assembly if damaged.
12. Inspect front pump. Inspect the front pump support gear pockets for scoring and wear. Clean and inspect the front and rear input shaft bushings.
13. Inspect the fluid pump adapter plate for scoring and wear.
14. Inspect the fluid pump-to-converter housing bushing and converter hub-to-converter housing seal. Install a new converter housing assembly if necessary.
15. Using the special tool, remove the converter hub-to-converter housing seal.

Assembly

1. Thoroughly clean all parts and blow dry with moisture-free compressed air.
2. Inspect the converter housing and fluid pump components for the following: Cracks and scoring of the pump gears. Front and rear input shaft bushings for scoring and wear. Fluid pump support needle bearing and cage for scored or missing rollers. Pump gear pockets for scoring and wear. Fluid pump adapter plate for scoring and wear. Fluid pump to converter housing bushing for scoring and wear. Pump body and case for burrs. Fluid passages for obstructions. Converter housing for cracks.
3. Install a new converter hub-to-housing seal onto the special tool.
4. Using the special tool, install the new converter hub-to-converter housing seal into the converter housing, until it bottoms in the housing.
5. Clean and lubricate the outer surface with petroleum jelly.
6. Place the bearing over the pump assembly, making sure that the lube feed hole is facing down.
7. Using the special tool, install the bearing.
8. Verify that the bearing is correctly seated on the pump. Inspect the top portion of the pump to make sure that it was not damaged, and the bearing rotates freely.

Scheme 581

Scheme 582

Scheme 583

Scheme 584

1. Remove the coast clutch pressure plate. Remove the coast clutch retaining ring. Remove the coast clutch pressure plate.
2. Remove the coast clutch disc pack. Inspect for wear, install new as necessary.
3. Using the special tool, remove the coast clutch piston retaining ring.
4. Relieve the direct clutch spring tension and remove the special tool.
5. Remove the coast clutch piston springs. Remove the coast clutch piston spring retainer. Remove the (20) clutch piston springs.
6. Remove the coast clutch piston. Apply air pressure to the hole in the drum to remove coast clutch piston while blocking other hole with finger.
7. Remove the coast clutch piston inner seal and the coast clutch piston outer seal. Clean and install new as necessary.

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

1. Install the new coast clutch piston inner and outer seal.
2. Install the coast clutch piston into the special tool.
3. Inspect the coast clutch components for damage or wear. Install a new as necessary. Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be installed as new. Inspect the clutch piston bore and the clutch piston and the piston inner and outer bearing surfaces for scores. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions. Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Install new plates that are badly scored, worn or do not fit freely in the hub serrations. Inspect the clutch pressure plate for scores on the clutch plate surface. Check the clutch release spring(s) for distortion.
4. Verify the check ball in the front band brake and coast clutch drum is free to move and clear of debris.
5. Carefully remove the coast clutch piston from the special tool.
6. Install the coast clutch piston into the front band brake and coast clutch drum.
7. Install the coast clutch piston springs. Install the twenty (20) coast clutch piston springs. Position the coast clutch piston spring retainer on the coast clutch piston springs.
8. Using the special tool, install the coast clutch piston spring retainer ring.
9. Relieve the direct clutch spring tension and remove the special tool.
10. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
11. Install the two steel clutch plates and two friction clutch plates in alternating order starting with a steel clutch plate.
12. Install the coast clutch pressure plate. Install the clutch pressure plate. Install the original coast clutch retaining ring.
13. Air check the assembly. Apply air pressure to the hole in the drum while blocking the other hole with a finger.
14. Check the coast clutch disc pack free play. Push down on the coast clutch pressure plate. Check clearance between the coast clutch retaining ring and coast clutch pressure plate. Clearance should be 1.3-2.0 mm (0.051-0.079 in). If clearance is not within the specification, install a new coast clutch retaining ring that will correct free play adjustment. see scheme 636

Scheme 591

Scheme 592

Scheme 593

Scheme 594

1. Remove the direct clutch retaining ring and the direct clutch pressure plate. Remove the direct clutch retaining ring. Remove the direct clutch pressure plate.
2. Remove the direct clutch disc pack. Inspect and install new steel and friction plates if worn, damaged, or overheated. Measure and record the thickness of the steel plates for assembly.
3. Using the special tool, remove the direct clutch piston retaining ring.
4. Relieve the direct clutch spring tension and remove the special tool.
5. Remove the direct clutch piston spring retainer and the 20 direct clutch piston springs. Lift the direct clutch piston spring retainer off the direct clutch piston springs. Remove the direct clutch piston springs.
6. Using compressed air, remove the direct clutch piston from the intermediate brake and direct clutch drum. Apply air pressure to the hole in the drum while blocking the other with a finger.
7. Remove the direct clutch piston inner and outer seal. Remove the direct clutch piston inner seal. Remove the direct clutch piston outer seal.

Scheme 595

Scheme 596

Scheme 597

Scheme 598

Scheme 599

1. Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
2. Install the direct clutch piston into the special tool.
3. Inspect the intermediate brake and direct clutch drum and components for the following: Intermediate brake and direct clutch band surface for scoring. Clutch piston bore and the piston inner and outer bearing surfaces for scoring. The fluid passages for obstructions. All fluid passages must be clean and free of debris. Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Install new plates that are badly scored, worn or do not fit freely in the hub serrations. Inspect the direct clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release springs for distortion.
4. Verify that the intermediate brake and direct clutch drum check ball is clean and free of debris.
5. Carefully remove the direct clutch piston from the special tool.
6. Install the direct clutch piston. Position the direct clutch piston in the intermediate brake and direct clutch drum. Push down evenly around the piston circumference.
7. Install the direct clutch piston spring retainer and the 20 direct clutch piston springs. Install the direct clutch piston springs. Place the direct clutch piston spring retainer on the direct clutch piston springs.
8. Using the special tool, install the direct clutch piston retaining ring.
9. Relieve the direct clutch spring tension and remove the special tool.
10. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.
11. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
12. Install the direct clutch pressure plate. Install the direct clutch pressure plate. Install the original direct clutch retaining ring on the direct clutch disc pack.
13. Check the operation using compressed air. Apply air pressure to the hole in the drum while blocking the other hole with a finger.
14. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge. If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge. see scheme 657

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

Scheme 605

1. Remove the forward clutch pressure plate. Remove the forward clutch retaining ring. Remove the forward clutch pressure plate.
2. Remove the forward clutch disc pack. Inspect the forward clutch plates for wear, damage or overheating.
3. Using the special tool to remove the forward clutch piston retaining ring.
4. Relieve the forward clutch spring tension and remove the special tool.
5. Remove the forward clutch piston spring retainer and 15 forward clutch piston springs. Remove the forward clutch piston spring retainer. Remove the 15 forward clutch piston springs. Inspect the forward clutch piston springs for distortion.
6. Remove the forward clutch piston. Place the forward clutch cylinder with forward clutch piston facing down. Install the center support on the forward clutch cylinder. Apply air pressure to the left port of the center support.
7. Remove and discard the forward clutch piston seals. Remove the forward clutch piston outer seal and inspect the forward clutch piston for cracks. Remove forward clutch cushion spring. Remove the forward clutch piston inner seal.
8. Inspect the remaining forward clutch drum components for damage or wear, install new components as necessary. Inspect the forward clutch cylinder surfaces for scores or burrs. Minor scores or burrs can be removed with a crocus cloth. Install a new forward clutch cylinder if it is badly scored or damaged. Inspect forward clutch piston for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new forward clutch cylinder if it is badly scored or damaged. Make sure the check ball is free and clear of debris, has freedom of movement, and is correctly seated.
9. Inspect the forward clutch drum components. Inspect clutch plate serration for scores or burrs. Inspect fluid passages for obstructions. Clean out all passages. Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surface. Install new parts that are deeply scored. Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. Inspect for damage or wear to the clutch disc grooves and retaining ring grooves.
10. Inspect the needle bearing for damage.
11. Using the special tools, remove the forward clutch bearing.
12. Inspect the forward clutch outer race for scoring or nicks, if any damage is found installation of a new forward clutch drum will needed.

Scheme 606

Scheme 607

Scheme 608

Scheme 609

1. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.
2. Clean and lubricate the outer surface with clean transmission fluid.
3. Install the forward clutch bearing with the rectangular hole facing up.
4. Using the special tools, install the forward clutch bearing.
5. Inspect that the bearing is correctly seated on the drum. Inspect the top portion of the drum that it was not damaged, and the bearing rotates freely.
6. Install new forward clutch piston seals. Install the forward clutch piston outer seal. Install forward clutch cushion spring. Install the forward clutch piston inner seal.
7. Install lip seal protector tools on the forward clutch piston. Install the special tool to the forward clutch piston outer seal. Install the special tool to the forward clutch piston inner seal.
8. As you install the forward clutch piston into the forward clutch cylinder, remove the special tools.
9. Install the 15 forward clutch piston springs and the forward clutch piston spring retainer. Install the 15 forward clutch piston springs. Install the forward clutch piston spring retainer.
10. Using the special tool, install the forward clutch piston spring retaining ring.
11. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
12. Install the steel clutch plates and friction clutch plates (quantity model dependent) in alternating order starting with a steel clutch plate.
13. Install the forward clutch pressure plate and the original selective retaining ring. Install the forward clutch pressure plate. Install the forward clutch retaining ring.
14. Air check the forward clutch piston. Place the forward clutch cylinder with forward clutch piston facing down. Install the transmission center support on the forward clutch cylinder. Apply air pressure to the left port of the center support.
15. Check forward clutch disc pack free play. Press down on forward clutch disc pack. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate. If the clearance is not within specifications, install the correct size retaining ring.

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

1. Install the forward clutch cylinder thrust bearing (No. 5) on the forward clutch cylinder assembly. Use petroleum jelly to hold the forward clutch cylinder thrust bearing (No. 5) in place.
2. Install the forward clutch cylinder assembly into the intermediate brake and direct clutch drum assembly.
3. Install the forward ring gear hub thrust bearing (No. 6A) with the tabs facing up.
4. Install the forward clutch thrust washer (No. 6B) into the forward ring gear hub. Use petroleum jelly to hold the forward clutch thrust washer (No. 6B) in place.
5. Install the forward ring gear into the forward clutch cylinder.
6. Install the forward planetary thrust bearing (No. 7) into the forward ring gear.
7. Install the forward planetary assembly into the forward ring gear.
8. Inspect sun gear and input shell for damage or wear. If sun gear or input shell are damaged, install new as necessary. Install the input shell and forward sun gear assembly into planetary gearset.
9. Remove the rear retaining ring, sun gear and the retaining ring from the sun gear. Remove the rear retaining ring. Remove the sun gear.
10. Remove the front retaining ring from the sun gear.
11. Install a new retaining ring onto the sun gear.
12. Install the sun gear into the input shell.
13. Install a new rear retaining ring.

Scheme 620

Scheme 621

Scheme 622

Scheme 623

1. Inspect the one-way clutch. Temporarily insert the front planetary gear carrier assembly into the center shaft and one-way clutch assembly for verification of the one-way clutch. The planetary gear must rotate counterclockwise and hold when rotated clockwise. Remove the planetary gear carrier assembly.
2. Remove the overdrive center shaft from the front ring gear. Remove the front center shaft retaining ring. Remove the center shaft from the ring gear.
3. Clean and inspect the front one-way clutch and center shaft. Inspect the roller cage for cracks. Inspect the roller clutch for wear. Inspect the press fit of the one-way clutch to the center shaft. Inspect the spring and roller cage for bent or damaged spring retainers.
4. Insert a screwdriver through the holes, remove the front one-way clutch from the center shaft.
5. Inspect the center shaft bore for damage. If the outer race of the center shaft bore is damaged, a new front one-way clutch and center shaft must be installed.

Scheme 624

1. Install the front one-way clutch into the special tool with the brass end cap facing up.
2. Inspect that the front one-way clutch is flush with the special tool.
3. Assemble the special tools with the front one-way clutch onto the center shaft.
4. Push down on the center shaft to seat the front one-way clutch into the center shaft.
5. Inspect the front one-way clutch for correct installation and function. The front one-way clutch tabs should be flush with the center shaft.
6. Install the center shaft and one-way clutch onto the overdrive ring gear. Install the center shaft and one-way clutch. Install the center shaft retaining ring.

Scheme 625

Scheme 626

Scheme 627

Scheme 628

1. Before installing a planetary assembly, the shaft retaining pins should be checked for adequate staking. Use a new planetary assembly if either of the following conditions exist. Check the pins and shafts in the planetary assemblies for loose fit and or complete disengagement.
2. Inspect the pinion gears for damaged or excessively worn teeth, and for free rotation.
3. Inspect the front one-way clutch inner race for scoring. If the front one-way clutch inner race is scored or damaged installation of new front planetary gear, center shaft, and one-way will be needed.
4. Inspect the inner and outer races for scored or damaged surface areas where the rollers contact the races.
5. Remove and inspect the No. 2 front planetary thrust bearing on the nose of the front planetary gear carrier assembly.
6. Remove the front sun gear. Remove the coast clutch to front carrier adapter. Remove the front sun gear.
7. Inspect the No. 12 bearing for damage.

Scheme 629

1. Install the No. 2 front planetary thrust bearing.
2. Install the front planetary gear carrier into the center shaft and front ring gear.
3. Install the front sun gear. Install the front sun gear. Install the coast clutch to front carrier adapter.

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Disassembly

Note. Thoroughly clean center support assembly and blow dry with compressed air.

Note. The center support is serviced as an assembly. Any damage requires installation of a new component.

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

1. Inspect the center support assembly for wear or damage. Inspect the thrust surfaces for wear, scoring or damage. Inspect the center support sealing surface. Inspect the fluid passage for blockage or damage.
2. Inspect the seal rings for damage.
3. Inspect the bearing for missing rollers or damage.
4. Inspect the direct clutch feed hole for blockage or damage. Rotate center support bearing to locate the direct clutch feed hole. Inspect the direct clutch feed hole for blockage or damage.
5. Remove the lower seal.
6. Assemble the special tools onto the center support.
7. Using the special tools, remove the needle bearing.
8. Inspect the front pump outer race for scoring or nicks. If any damage is found installation of a new pump assembly will be needed.

Scheme 640

Scheme 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

1. Align two of the center lower bearing holes with the lube hole in the bottom of the bearing.
2. Using a black felt tip marker, draw a line from the top of the center support snout to the hole at the bottom of the center support. This will be used as an alignment when installing the bearing.
3. Make an alignment mark on the top of the center support
4. Using a black felt tip marker, draw a line from the bottom lower holes to the top of the bearing. This will be used as an alignment when installing the bearing.
5. Install the bearing onto the center support.
6. Using the special tools, install the center support bearing.
7. After the center support bearing has been installed inspect the top of the bearing and center support for any damage.

Scheme 646

Scheme 647

1. Inspect the reverse brake drum for damage. Inspect the low reverse one-way clutch. Inspect the roller bearing. Inspect the reverse brake drum.
2. With the reverse clutch drum supported, use a flat drift punch to tap the one-way clutch and the roller bearing out of the drum.
3. Inspect the low reverse one-way clutch inner race and roller bearing inner race for scoring, and nicks. If damage is indicated, the reverse clutch drum will need to be installed new as an assembly.

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

1. Install the roller bearing with the lip facing up toward the low reverse one-way clutch.
2. Install the special tool.
3. Install the low reverse one-way clutch with the tabs facing down toward the roller bearing.
4. Using the special tools, install the one-way clutch by pressing down on the tool to seat the bearing.
5. Inspect the reverse clutch drum to see if the low reverse one-way clutch is seated correctly.

Scheme 653

Scheme 654

Scheme 655

Scheme 656

1. Inspect the output shaft ring gear, output shaft hub, needle bearing (10B), and needle bearing race (10A) assembly for damage. If service is required use the following procedure.
2. Remove the No. 10B needle bearing.
3. Remove the No. 10A needle bearing race assembly.
4. Remove the output shaft hub from the output shaft ring gear. Remove the retaining ring. Remove the output shaft hub.

Scheme 657

Scheme 658

1. Install the output shaft hub onto the output shaft ring gear. Install the output shaft hub. Install the retaining ring.
2. Install the No. 10A needle bearing race assembly. Snap the needle bearing race assembly onto the output shaft hub.
3. Install the No. 10B needle bearing onto output shaft ring gear and output shaft hub.

1. The installation of new or remanufactured torque converters must be carried out if one or more of the following statements are true: A torque converter malfunction has been determined based on complete diagnostic procedures. Converter stud(s), impeller hub or bushing are damaged. Discoloration of the torque converter (due to overheating). The torque converter is found to be out of specification when performing one of the following torque converter checks: One-Way Clutch Check End Play Check Stator to Turbine Interference Check Stator to Impeller Interference Check Torque Converter Leak Check Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major Metallic Failure Multiple Clutches or Clutch Plate Failures Sufficient Component Wear which results in Metallic Contamination

TORQUE CONVERTER CLEANING & INSPECTION

1. If a new or remanufactured torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new or remanufactured torque converter is not being installed, the following procedures must be carried out: The torque converter must be thoroughly cleaned. Torque converters with drain plugs can be cleaned by using a suitable torque converter fluid cooler cleaner. Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for transmission, and reinstall. All in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING & CLEANING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__transmission-fluid-cooler-backflushing) . All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING & CLEANING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission__transmission-fluid-cooler-backflushing) . All cooler bypass valves (CBV), if equipped, must be thoroughly cleaned. Carry out Transmission Fluid Cooler Flow Test. For additional information, refer to the Transmission Fluid Cooler Flow Test in Diagnostics. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, the installation of a new fluid cooler, cooler bypass valve, and/or cooler lines must be carried out. For additional information, refer to «REMOVAL AND INSTALLATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#transmission-cooling) . If the installation of new fluid coolers are being carried out, refer to «EXPLORER, EXPLORER SPORT, EXPLORER SPORT TRAC»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing__explorer-explorer-sport-explorer-sport-trac) . Use only factory-approved service parts.

TORQUE CONVERTER FLUSHING

1. Following the instructions included with any suitable torque converter fluid cooler cleaner, flush the torque converter.
2. After flushing, drain the remainder of the solvent.
3. Add 1.9 liter (2 qt) of clean MERCON®R V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON®R V specification into the converter fluid filler tube and agitate by hand.
4. Thoroughly drain the solution.

Scheme 659

Scheme 660

Scheme 661

Scheme 662

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

TORQUE CONVERTER IMPELLER TO PUMP STATOR INTERFERENCE CHECK

Note. The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.

Scheme 663

Scheme 664

1. Install fluid pump support into torque converter. Engage splines of the one-way clutch inner race with the mating splines of the front pump support.
2. While holding the fluid pump support stationary, rotate the torque converter clockwise and counterclockwise. The torque converter should rotate freely with no signs of scraping. If there are signs of scraping, install a new or remanufactured torque converter.

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

1. Install special tool into the torque converter. Insert special tool into the torque converter until it bottoms. Tighten the inner post until the tool is securely locked.
2. Install the special tool as shown. Position the dial indicator bottom on the converter impeller housing and zero the dial.
3. Lift up on the special tool and note the dial indicator reading. If the reading exceeds end play limits, install a new or remanufactured torque converter. see scheme 767

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Note. The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735