Assembly Ford Explorer Sport Trac I

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

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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

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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

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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

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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

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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

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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.

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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

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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

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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.

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Scheme 633