Automatic Transmission: Overhaul Ford Focus I facelift

DISASSEMBLY

1. Inspect the transaxle during disassembly.
2. Remove the output shaft speed (OSS) sensor. Remove the bolt. Remove the OSS.
3. Remove the turbine shaft speed (TSS) sensor.
4. While holding the manual control lever, remove the manual control lever bolt.
5. Remove the transmission range (TR) sensor.
6. Remove the special tool.
7. Remove the rubber vent cap.
8. Using the special tool, remove the torque converter.
9. Remove the differential opening cover.
10. Remove the LH and RH axle seals.
11. Using the special tool, mount the transaxle to a bench.
12. Remove the bolts.
13. Using the two 10-mm (50 mm [2 in] long) bolts, remove the fluid pump.
14. Remove the fluid pump seals.
15. Remove the forward clutch thrust washer.
16. Remove the forward clutch assembly.
17. Remove the forward clutch hub.
18. Rotate the transaxle 180 degrees.
19. Remove the end cover.
20. Clean the silicone from the end cover and transaxle case surfaces thoroughly with metal surface cleaner.
21. Remove the direct clutch hub bearing shim.
22. Remove the end cover seals.
23. Remove the end cover-to-case seals.
24. Remove the direct clutch cylinder thrust bearing.
25. Remove the intermediate/overdrive band anchor bolt.
26. Remove the intermediate/overdrive band.
27. Remove the intermediate/overdrive drum assembly.
28. Remove the planet gear assembly.
29. Remove the low/reverse clutch plate retaining ring.
30. Remove the low/reverse clutch plates, pressure plate and wave spring.
31. Remove the low one-way clutch retaining ring.
32. Remove the low one-way clutch inner race.
33. Remove the low/reverse clutch return spring.
34. Remove the low/reverse clutch piston.
35. Using a suitable tool, remove the transmission fluid pan. Remove the bolts. Using a suitable tool, remove the transmission fluid pan.
36. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.
37. Disconnect the transmission fluid temperature (TFT) sensor.
38. Remove the transmission fluid filter.
39. Remove the ground wire bolt, disconnect the electrical connectors and remove the wire harness. Solenoid SSC, Color N (Neutral). Solenoid SSE, Color G (Green). Solenoid SSD, Color L (Blue). Solenoid PCA, Color B (Black). Solenoid SSA, Color N (Neutral). Solenoid SSB, Color B (Black).
40. Remove the 13 main control valve body bolts.
41. Remove the transaxle internal harness electrical connector.
42. Remove the accumulator pistons and springs.
43. Remove the manual lever shaft roll pin.
44. Remove the manual lever shaft.
45. Remove the O-ring seals from the manual lever shaft.
46. Remove the control lever assembly.
47. Remove the 3 intermediate/overdrive piston servo cover bolts and the servo cover.
48. Remove the O-ring seal.
49. Remove the intermediate/overdrive servo piston.
50. Remove the intermediate/overdrive servo piston return spring.
51. Rotate the transaxle 180 degrees.
52. Remove the bolts and separate the converter housing from the transaxle case.
53. Remove the differential assembly.
54. Remove the parking pawl assembly cover. Remove the bolts and the parking pawl assembly cover.
55. Remove the parking pawl abutment. Unclip the spring. Remove the pin. Remove the lever. Remove the parking pawl abutment.
56. Remove the spring.
57. Remove the transfer shaft gears.
58. Using the special tool, lock the final drive input gear.
59. Rotate the transaxle 180 degrees.
60. Using the special tools, remove the final drive input gear bearing retainer nut.
61. Remove the special tools.
62. Rotate the transaxle 180 degrees.
63. Remove the special tool.
64. Rotate the transaxle 180 degrees.
65. Remove the final drive input gear bearing by lightly tapping on the end of the gear.
66. Remove and discard the collapsible spacer.
67. Using a suitable chisel, remove the final drive input gear bearing.
68. Using the special tools, remove the final drive input gear bearing inner race.
69. Clean the converter housing and transaxle case surfaces thoroughly with metal surface cleaner.

Final Drive Carrier and Differential Assembly

Special Tools Illustration Tool Name Tool Number Installer Differential Bearing 205-062 (15-025A) Step Plate 205-D015 (T80L-630-4) Bearing Puller 205-D064 (D84L-1123-A) Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C)

Material

1. Using the special tools, remove the differential case bearings.
2. Remove the differential pinion shaft. Remove and discard the roll pin. Remove the pinion shaft.
3. Remove the differential side gears. Rotate the differential pinion gears 90 degrees and remove the differential pinion gears with the thrust washers. Remove the differential side gears with the thrust washers.
4. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
5. Inspect the differential parts of damage and wear. Pinion gear teeth and bores Side gear teeth and 5 splines Thrust washers Differential pinion shaft Differential case bearing and surfaces

ASSEMBLY

1. Lubricate the gears and thrust washers with clean automatic transmission fluid.
2. Install the different pinion gears and thrust washers. Install the differential side gears and thrust washers. Install the differential pinion gears and thrust washers by rotating 90 degrees.
3. Install the differential pinion shaft. Install the pinion shaft. Install the roll pin.
4. Using the special tool, install the differential case bearings.

Pump Assembly

Special Tools Illustration Tool Name Tool Number Installer, Drive Pinion Oil Seal 205-115 (15058)

Material

1. Remove the top portion of the pump.
2. Inspect the lower portion of the pump and gear pocket for nicks, scratches, gouges or wear.
3. Remove the pump seal.
4. Inspect the upper portion of the pump for nicks, scratches or gouges.
5. Inspect the pump gears for nicks, scratches or gouges.

1. Lubricate the gears and thrust washers with clean automatic transmission fluid.
2. Using the special tool, install the pump seal. Lubricate the gears and thrust washers with automatic transmission fluid.
3. Install the top portion of the pump. Tighten to 10 Nm (89 lb-in).

1. Using the special tools, remove the RH transfer shaft gear bearing.
2. Using the special tool and a press, remove the LH transfer shaft gear bearing while separating the gears.

1. Using the special tool, install the RH transfer shaft gear and park gear assembly.
2. Using the special tool, assemble the gears and install the LH transfer shaft gear bearing.

1. Remove the forward clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, install the forward clutch assembly in a suitable press.
3. Using the special tool, remove the forward clutch balance piston snap ring.
4. Remove and inspect the forward clutch balance piston.
5. Remove the forward piston return spring.
6. Remove the forward clutch piston assembly.

1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Inspect the forward clutch piston bore surfaces for nicks or scratches. Install a new balance piston if necessary.
3. Lubricate and install the forward clutch piston assembly.
4. Install the forward piston return spring.
5. Lubricate and install the forward clutch balance piston.
6. Using the special tool, install the forward clutch assembly in a suitable press.
7. Using the special tool, install the forward clutch balance piston snap ring.
8. Install the forward clutch pressure, friction and steel plates. Install the plates. Install the retaining ring.
9. Measure the clutch pack clearance. Install the forward clutch on the pump assembly. Install the special tool. Mount the dial indicator holding fixture on the pump assembly and position the dial indicator plunger on the pressure plate. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the dial indicator in 3 different areas. Average the measurements.
10. Compare the forward clutch pack clearance to the specification (1.5-1.8 mm [0.0590-0.0708] in). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance. Part Number Thickness - 1.15-1.25 mm (0.0452-0.0492 in) - 1.35-1.45 mm (0.0531-0.0570 in) - 1.55-1.65 mm (0.0610-0.0649 in) - 1.75-1.85 mm (0.0688-0.0728 in) - 1.95-2.05 mm (0.0767-0.0807 in) - 2.15-2.25 mm (0.0846-0.0885 in)

Scheme 39

1. Remove the reverse drum snap ring.
2. Remove the sun gear.
3. Remove the sun gear thrust bearing.
4. Remove the direct clutch hub.
5. Remove the direct clutch thrust bearing.
6. Remove the direct clutch assembly.

1. To assemble, reverse the disassembly procedure.

1. Remove the direct clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the selective snap ring.
3. Remove the direct clutch balance piston.
4. Remove the direct clutch return spring.
5. Remove and inspect the direct clutch piston.

1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Inspect the direct clutch piston bore surfaces for nicks or scratches. Install a new direct clutch piston if necessary.
3. Lubricate and install the direct clutch piston.
4. Install the direct clutch return spring.
5. Install the direct clutch balance piston.
6. Using the special tool, install the selective snap ring.
7. Install the direct clutch pressure, friction and steel plates. Install the plates. Install the retaining ring.
8. Measure the clutch pack clearance. Install the direct clutch on the transaxle end cover. Install the special tool. Mount the dial indicator holding fixture on the transaxle end cover and position the dial indicator plunger on the pressure plate. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the dial indicator in 3 different areas. Average the measurements.
9. Compare the direct clutch pack clearance to the specification (1.0-1.3 mm [0.0393-0.0511 in]). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance. Part Number Thickness - 1.15-1.25 mm (0.0452-0.0492 in) - 1.35-1.45 mm (0.0531-0.0570 in) - 1.55-1.65 mm (0.0610-0.0649 in) - 1.75-1.85 mm (0.0688-0.0728 in) - 1.95-2.05 mm (0.0767-0.0807 in) - 2.15-2.25 mm (0.0846-0.0885 in)

1. Remove the reverse clutch pressure, friction and steel plates. Remove the retaining ring. Remove the plates.
2. Using the special tool, remove the reverse clutch piston return spring retainer ring and retainer.
3. Remove the reverse clutch piston return spring.
4. Remove the reverse clutch piston assembly.
5. Inspect the seal bore in drum, inner and outer seals.

1. Soak the internal spline clutch plates in clean automatic transmission fluid.
2. Lubricate and install the reverse clutch piston assembly.
3. Install the reverse clutch piston return spring.
4. Using the special tool, install the reverse clutch piston return spring retainer and retainer ring.
5. Install the reverse clutch pressure, friction and steel plates. Install the plates. Install the retaining ring. Check the clearance. For additional information, refer to «SPECIFICATIONS»(ref-278257-S32627545172008012400000) .

1. Inspect the planet internal bearing for damage.
2. Remove the snap ring.
3. Remove the rear planet assembly.
4. Remove the thrust bearing.
5. Remove the forward planet sun gear.
6. Remove the thrust bearing.
7. Remove the forward planet assembly.
8. Inspect the low and reverse ring gear.
9. Remove the top retainer of the one-way clutch.
10. Remove the top one-way clutch ring.
11. Remove the low one-way clutch assembly.
12. Remove the lower one-way ring.

1. Install the lower one-way ring.
2. Inspect the rollers and the springs of the one-way clutch.
3. Make sure the low one-way clutch is installed with the tab pointing in the direction as shown.
4. Install the low one-way clutch.
5. Install the top one-way clutch ring.
6. Install the top retainer of the one-way clutch.
7. Install the forward planet assembly.
8. Install the thrust bearing.
9. Inspect the front sun gear retaining ring.
10. Install the forward planet sun gear.
11. Install the thrust bearing.
12. Install the rear planet assembly.
13. Install the snap ring.

Scheme 40

1. Remove the solenoid body bolts and the solenoid body.
2. Remove and discard the solenoid body gaskets.
3. Remove and discard the seals.
4. Disassemble the main control valve body.

1. Install new control valve body plate assembly and separator gaskets.
2. Assemble the main control valve body and loosely install the bolts.
3. Install the seals.
4. Install a new solenoid body gasket.
5. Install the solenoid body and loosely install the bolts.
6. Tighten the solenoid body bolts in the sequence shown. Tighten to 9 Nm (80 lb-in).

1. Remove the halfshaft seals (LH shown).
2. Using the special tools, remove the differential case bearing cups (LH shown).
3. Using the special tools, remove the final drive input gear bearing cup.
4. Using the special tool, remove the transfer shaft gear bearing cups (LH shown).
5. Remove the funnel.
6. Rotate the transaxle 180 degrees.
7. Using the special tools, remove the final drive input gear bearing cup.

1. Using the special tools, install the final drive input gear bearing cup.
2. Rotate the transaxle 180 degrees.
3. Install the funnel.
4. Using the special tools, install the LH transfer shaft gear bearing cup.
5. Using the special tools, install the final drive input gear bearing cup (LH shown).
6. Using the special tools, install the LH differential case bearing cup.
7. Using the special tools, install the halfshaft seals (LH shown).

1. Using the special tool, install the final drive input gear bearing. Install the final drive input gear bearing. Install the special tool.
2. Using an arbor press and the special tools, seat the final drive input gear bearing.
3. Install a new collapsible spacer.
4. Using the special tool, position the final drive input gear.
5. Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case or damage to the input gear can occur. Rotate the transaxle 180 degrees.
6. Using the special tools, install the final drive input gear bearing.
7. Rotate the transaxle 180 degrees.
8. Using the special tool, lock the final drive input gear.
9. Rotate the transaxle 180 degrees.
10. Using the special tools, tighten the nut to achieve the preload specification.
11. Rotate the transaxle 180 degrees.
12. Unlock the special tool.
13. Rotate the transaxle 180 degrees.
14. Make sure the bearing preload is between 0.4-0.7 Nm (3.5-6.2 lb-in) or bearing failure can occur. NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated. Using the special tools, measure the rotating torque. Rotational torque is 0.4-0.7 Nm (3.5-6.2 lb-in).
15. After achieving the correct rotating torque specification, remove the special tools and stake the nut to prevent movement.
16. Rotate the transaxle 180 degrees.
17. Position the transfer shaft gears in the transaxle case.
18. Install the parking pawl return spring.
19. Connect the spring. Install the parking pawl abutment. Install the lever. Install the pin. Connect the spring.
20. Install the parking pawl assembly cover and bolts. Tighten to 13 Nm (10 lb-ft).
21. Install the differential case assembly.
22. Position the bearing cups.
23. Install the special tools.
24. Do not use the bolts from special service kit 308-164, they will not work. Use only the bolts from the special service kit 308-161 or damage to the transaxle case threads can occur. NOTE: The converter housing cover must be installed evenly or an incorrect reading will result. Using the special tools, assemble the transaxle for end play measurement. Position the converter housing. Install the special tool bolts and seat the case cover flat. Tighten to 5 Nm (44 lb-in).
25. Remove the converter housing. Remove bolts. Remove the converter housing.
26. Remove the special tools.
27. Remove the bearing cups.
28. To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim. For additional information, refer to «SPECIFICATIONS»(ref-278257-S32627545172008012400000) .
29. To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim. For additional information, refer to «SPECIFICATIONS»(ref-278257-S32627545172008012400000) .
30. Using the special tool, install the correct transfer shaft shim and bearing cup into the converter housing.
31. Using the special tool, install the correct differential shaft shim and differential case bearing cup into the converter housing.
32. Apply a 1 mm (0.04 in) thick bead of sealer to the case half.
33. Position the converter housing on the transaxle case and install the bolts. Tighten to 22 Nm (16 lb-ft).
34. Install the intermediate/overdrive band servo piston return spring.
35. Install the intermediate/overdrive servo piston.
36. Install the O-ring seal.
37. Install the intermediate/overdrive band servo piston cover. Tighten to 13 Nm (10 lb-ft).
38. Install the park pawl assembly and bolt. Tighten to 13 Nm (10 lb-ft).
39. Install the new O-rings on the manual control lever shaft.
40. Install the manual control lever shaft.
41. Install a new manual control lever shaft roll pin.
42. Loosely install the transmission range (TR) sensor.
43. Install the thinner and longer neutral drive accumulator springs.
44. Install the neutral drive accumulator piston.
45. Install the 1-2 accumulator springs.
46. Install the 1-2 accumulator piston.
47. Inspect the seals. Lubricate the seals in clean transmission fluid. Install the transaxle internal harness electrical connector.
48. Install the main control valve body.
49. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown. Tighten to 9 Nm (80 lb-in).
50. Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt. Solenoid SSC, color N (neutral/white). Solenoid SSE, color G (green). Solenoid SSD, color L (blue). Solenoid PCA, color B (black). Solenoid SSA, color N (neutral). Solenoid SSB, color B (black). Tighten to 10 Nm (89 lb-in).
51. Install the transmission fluid filter.
52. Connect the transmission fluid temperature (TFT) sensor.
53. Apply a bead 1.5 mm (0.06 in) diameter of sealer to the transmission fluid pan.
54. Install the transmission fluid pan. Tighten to 10 Nm (89 lb-in).
55. Rotate the transaxle 180 degrees.
56. Install the low/reverse clutch piston.
57. Install the low/reverse clutch return spring.
58. Install the wave spring.
59. Install the low one-way clutch (OWC) inner race.
60. Install the low OWC retaining ring.
61. Install the low/reverse plates and pressure plate.
62. Install the low reverse clutch plate selective retaining ring. Using a feeler gauge, measure the clutch clearance. Compare the low reverse clutch pack clearance to the specification (1.0-1.3 mm [0.0393-0.0511 in]). If the clutch pack clearance is not within specification, select and install the correct size selective retaining ring to obtain the specified clearance.
63. Install the planet assembly.
64. If the planet assembly is installed correctly, the edge of the planet assembly will fit flush with the transaxle case. If the planet assembly does not fit flush with the transaxle case, further assembly will cause damage to the transaxle. Inspect the planet assembly installation.
65. The planet assembly must only rotate counterclockwise. Check to make sure that the one way clutch is correctly installed. Rotate the planet assembly clockwise and counterclockwise.
66. Install the intermediate/overdrive drum assembly.
67. Install the intermediate/overdrive band.
68. Install the direct clutch cylinder thrust bearing with the rollers facing up.
69. Install new end cover-to-case seals.
70. Install new end cover seals.
71. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater.
72. Failure to support the transaxle end cover in the center can result in inaccurate measurements causing damage to the transaxle. Measure the gap between the transaxle end cover and the transaxle assembly. Position the transaxle end cover on the transaxle assembly. Support the transaxle end cover in the center. Measure the gap between the transaxle end cover and the transaxle assembly.
73. Remove the transaxle end cover.
74. Choose and install the correct direct clutch hub bearing shim: Line 1: total amount of shim thickness used during transaxle end cover mock up. Line 2: measure the gap between transaxle end cover and transaxle case. Line 3: subtract Line 2 from Line 1 to obtain the actual clearance. Line 4: subtract 0.25 mm (0.001 in) from Line 3 for maximum shim thickness. Subtract 0.50 mm (0.020 in) from Line 3 for the minimum thickness shim.
75. Applying too much sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure. Apply a 1 mm (0.04 in) bead of sealer to the transaxle end cover.
76. Install the transaxle end cover. Tighten to 22 Nm (16 lb-ft).
77. Using the special tool, collapse the intermediate/overdrive band. Tighten to 5 Nm (44 lb-in), then back out three and a half turns.
78. Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.
79. Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown.
80. Install the intermediate/overdrive band anchor bolt. Tighten to 45 Nm (33 lb-ft).
81. Rotate the transaxle 180 degrees.
82. Install the forward clutch hub.
83. Install the forward clutch assembly.
84. Install the forward clutch thrust washer.
85. Install new fluid pump seals and lubricate with clean transmission fluid.
86. Install the fluid pump (do not force the pump down at this time).
87. Install the fluid pump bolts. Use the bolts to seat the fluid pump. Tighten the bolts in a crisscross pattern. Tighten to 30 Nm (22 lb-ft).
88. Install the output shaft speed (OSS) sensor. Tighten to 10 Nm (89 lb-in).
89. Install the turbine shaft speed (TSS) sensor. Tighten to 10 Nm (89 lb-in).
90. Using the special tool, align the TR sensor and tighten the bolts. Tighten to 10 Nm (89 lb-in).
91. Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt. Damage to the manual control lever shaft will occur. Install the manual control lever bolt. Tighten to 30 Nm (22 lb-ft).
92. Install the vent cap past the second detent notch. Be sure the vent moves up and down freely.
93. Using the special tool, install the LH halfshaft seal.
94. Using the special tool, install the RH halfshaft seal.
95. Install the differential opening cover.
96. Install the torque converter.
97. Using the special tool, secure the torque converter.
98. Remove the special tool from the transaxle.