Automatic Transmission: Overhaul Ford Focus II

Disassembly

Note. In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid.

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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. CAUTION: Do not use air tools.
4. While holding the lever, remove the manual control lever.
5. Remove the transmission range (TR) sensor.
6. Remove the special tool.
7. Remove the rubber vent cap. CAUTION: Do not tilt the torque converter when removing it, to prevent damaging the torque converter hub. NOTE: The torque converter is filled with fluid. Drain into a suitable container.
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 bolts, remove the fluid pump.
14. Remove the fluid pump seals.
15. Remove the forward clutch thrust washer.
16. Remove the forward clutch assembly. NOTE: Small levers will aid in the removal of the forward clutch hub.
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 the special 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 fluid filter. NOTE: It is necessary to note the location of the main control wire harness connectors so they can be connected in the same positions. Connector color letters are cast into the solenoid body.
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). NOTE: Note the locations of the longer bolts.
40. Remove the 13 main control valve body bolts. NOTE: Squeeze the tabs on the side of the electrical connector.
41. Remove the transaxle internal harness electrical connector. NOTE: Each accumulator has 2 springs. All 4 springs are different sizes. NOTE: Note the size and location of the accumulator springs to aid assembly. NOTE: Accumulator bore and pistons are a match as to depth, some piston may have steps. Install new pistons in the same bore as removed.
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. CAUTION: The intermediate/overdrive band servo cover plate is spring loaded. The bolts should be removed evenly until plate is unloaded, then remove the bolts.
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. NOTE: Release the locking sleeve away from the final drive input gear bearing retainer nut.
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. CAUTION: Hold the final drive input gear while removing the bearing to prevent it from falling out of the transaxle case.
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. WARNING: Wear eye protection when working with the chisel as the cutting operation may produce splinters. Failure to follow this instruction may result in personal injury.
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.

Note. Do not damage the speed sensor wheel.

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1. Using the special tools, remove the differential case bearings. NOTE: The roll pin cannot be driven through the housing. NOTE: Note the location of the indent left by the flag on the roll pin.
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

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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. NOTE: Install a new roll pin.
3. Install the differential pinion shaft. Install the pinion shaft. Install the roll pin. NOTE: LH shown, RH similar.
4. Using the special tool, install the differential case bearings.

Assembly

Note. The smaller gear has a recess on both sides.

Note. The smaller recess must face away from the torque converter seal.

Note. The larger recess, with the beveled edge, must face toward the torque converter.

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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. To assemble, reverse the disassembly procedure.

Note. The top side of the separator plate has a bonded gasket.

Note. The separator gasket goes on the bottom side.

Note. Inspect the main control valve body.

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1. Install new control valve body plate assembly and separator gaskets. NOTE: Do not fully tighten the bolts at this stage.
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).

Note. The converter housing side bearing cups for the transfer shaft bearing and differential case bearing will be installed during the assembly of the transaxle.

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1. Using the special tools, install the final drive input gear bearing cup.
2. Rotate the transaxle 180 degrees. NOTE: Note the location of the bleed hole. NOTE: Inspect the bleed hole for foreign material.
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 half shaft seals (LH shown).