Material — Part 2 Ford Mustang IV рестайлинг

1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if it is badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all the fluid passages. Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for freedom of movement and correct seating.
3. Check the clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
4. Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.
7. Remove the forward clutch hub and the No. 3 forward clutch hub front bearing.
8. Remove the forward clutch pack selective retaining ring.
9. Remove the following components. Remove the pressure plate. Remove the clutch pack. Remove the pressure spring.
10. Using the special tool, remove the forward clutch retaining ring.
11. Slowly release the press and remove the forward clutch from the press.
12. Remove the forward clutch retainer and the return spring.
13. Remove the forward clutch piston.
14. Remove the inner and outer forward clutch piston seals.
15. Remove the forward clutch input shaft seals.
16. Make sure the check ball in the clutch cylinder is free and clean. Check for correct seating.

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1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for freedom of movement and correct seating.
3. Check the clutch release spring for distortion and cracks. Install a new spring (including the wave spring) if distorted or cracked.
4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.
7. Install the inner and outer forward clutch piston seals. Note the direction of the sealing rings before installation.
8. Position the special tools on the clutch piston.
9. Using the special tools, install the forward clutch piston into the clutch drum. Push the piston to the bottom of the drum using even pressure.
10. Using the special tool, compress the piston return spring and install the retaining ring.
11. Slowly release the press pressure and remove the forward clutch.
12. Install the clutch pack assembly. Install the pressure ring. Install the clutch pack. Install the pressure plate.
13. Install the clutch pack retaining ring.
14. Install the special tool on the forward clutch pack. Push downward on the clutch pack. Release pressure and zero the dial indicator.
15. Using the special tool, check the clutch pack clearance. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer. Read the dial indicator. If the clearance is not within specifications, install the correct size retaining ring. SELECTIVE RETAINING RING SPECIFICATION Specification 1.52-1.62 mm (0.060-0.064 inch) 1.87-1.98 mm (0.074-0.078 inch) 2.24-2.34 mm (0.088-0.092 inch) 2.59-2.69 mm (0.102-0.106 inch)
16. Slide the two scarf-cut seals on the input shaft.
17. Install the two scarf-cut seals on the input shaft.
18. Install the No. 3 forward clutch hub front bearing and the forward clutch hub.

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1. Rotate the center support counterclockwise and lift to remove the planetary gear support.
2. Remove the planetary one-way clutch.
3. To assemble, reverse the disassembly procedure.

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1. Remove the reverse clutch sun gear assembly and the No. 4 forward clutch hub bearing and race.
2. Remove the forward clutch sun gear assembly and the No. 5 forward clutch sun gear bearing and race.

MATERIAL SPECIFICATION

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1. Remove the ring gear snap ring.
2. Separate the ring gear and output shaft.
3. Remove the three output shaft seal rings.
4. Remove the output shaft hub snap ring and the output shaft hub.
5. Remove the two direct clutch seal rings.
6. Remove the No. 7 direct clutch inner bearing support. Remove the direct clutch hub. Remove the No. 7 direct clutch inner bearing support.
7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new clutch cylinder if badly scored or damaged.
8. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating.
9. Check clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
11. Check the 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.
12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.
13. Remove the direct clutch pack. Remove the selective retaining ring. Remove the direct clutch pack.
14. Using the special tool, compress the piston return spring and remove the snap ring.
15. Remove the support and spring assembly and piston.
16. Remove the inner piston seal.
17. Remove the outer piston seal.

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1. Using the special tool, install the inner piston seal. Install the seal with sealing lip facing down.
2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.
3. Using the special tool, install the direct clutch piston.
4. Install the piston return spring and retainer assembly.
5. Using the special tool, compress the piston return spring and install the retaining ring.
6. Install the clutch pack retaining ring. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate. Install the clutch pack retaining ring.
7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate. If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance. SELECTIVE RETAINING RING SPECIFICATION Specification 1.52-1.62 mm (0.060-0.064 inch) 1.87-1.98 mm (0.074-0.078 inch) 2.24-2.34 mm (0.088-0.092 in) 2.59-2.69 mm (0.102-0.106 inch)
8. Install the direct clutch hub. Install the No.7 direct clutch inner bearing support. Install the direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
9. Install the two direct clutch seal rings.
10. Install the output shaft hub. Position the output shaft hub. Install the retaining ring.
11. Install the three output shaft seal rings.
12. Install the No. 8 needle bearing on the direct clutch cylinder.
13. Assemble the direct clutch on the output shaft.
14. Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.

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Material

MATERIAL SPECIFICATION

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1. Use the special tools to install the rear case bushing if removed. Position the rear case bushing and the special tool inside the case. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. Install the output shaft and output shaft ring gear.
5. Install the No. 8 bearing.
6. Install the direct clutch.
7. Install the reverse band support retaining ring.
8. Install the reverse band.
9. Install the planetary assembly and planetary gear support as a unit. Rotate the output shaft to fully seat the planetary assembly.
10. Install the case to the planet support spring located at the 1 o'clock position.
11. Install the center support retaining ring. Reference the retaining ring tabs to the band anchor pin location.
12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse sun gear.
13. Install the No. 4 forward clutch hub bearing.
14. Install the intermediate stub shaft.
15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
16. Install the forward clutch assembly.
17. Install the reverse clutch cylinder assembly. Install the reverse clutch cylinder. Install the No. 2 forward clutch bearing.
18. Install the overdrive band. Position the overdrive band pocket onto the anchor pin.
19. Install the overdrive servo spring. Install the overdrive servo piston return spring. Install the overdrive servo piston.
20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
22. Install the intermediate clutch pressure plate.
23. Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance. Position the special tool on the pump case mounting surface. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification. If the intermediate clutch is not within specification, install a correct selective plate. SELECTIVE STEEL PLATES SPECIFICATION Specification 1.80-1.70 mm (0.071-0.067 inch) 2.05-1.95 mm (0.081-0.077 inch) 2.31-2.20 mm (0.091-0.087 inch) 2.56-2.46 mm (0.101-0.097 inch)
25. Install the intermediate anti-rattle clip, if equipped.
26. Using the special tool, measure end clearance for the No.1 front pump thrust washer. Position the special tool on the pump case mounting surface. Maintaining downward pressure, use a depth micrometer to measure end play clearance. Use the No.1 thrust washer chart to select the correct washer. THRUST WASHER CHART Depth Thickness Color Code 37.706 - 38.184 mm (1.485-1.503 inch) 1.270-1.372 mm (0.050-0.054 inch) Green 38.185 - 38.641 mm (1.504-1.521 inch) 1.727-1.829 mm (0.068-0.072 inch) Yellow 38.642 - 39.073 mm (1.522-1.538 inch) 2.159-2.261 mm (0.085-0.089 inch) Natural 39.074 - 39.505 mm (1.539-1.555 inch) 2.591-2.692 mm (0.102-0.106 inch) Red 39.506 - 40.165 mm (1.556-1.581 inch) 3.023-3.124 mm (0.119-0.123 inch) Blue
27. Install the No.1 front pump support thrust washer. Use petroleum jelly to hold the washer in place.
28. Install an alignment pin at the top of the case.
29. Install the pump gasket.
30. Install the pump assembly.
31. Remove the alignment pin and install the front pump bolts. Alternate bolt tightening to set the pump.
32. Rotate the transmission to the horizontal position.
33. Install the parking pawl. Position the parking pawl return spring. Position the parking pawl. Install the parking pawl shaft.
34. Install a new extension housing gasket and the extension housing. Position the extension housing. Install the four bolts and two nuts.
35. Using the special tool, install a new extension housing seal.
36. Install the output shaft speed (OSS) sensor. Position the OSS sensor. Install the bolt.
37. Using the special tool, install the manual control lever seal.
38. Install the EPC solenoid. Install the EPC solenoid. Install the EPC solenoid bracket and bolt.
39. Install the manual valve detent lever and parking lever actuating rod.
40. Install the manual control lever shaft. Slide the manual control shaft into the case. Install the manual lever shaft inner nut. Install the manual lever shaft retaining pin.
41. Install the 1-2 accumulator piston assembly. Install the 1-2 accumulator upper spring. Install the 1-2 accumulator. Install the 1-2 accumulator lower spring. Install the 1-2 accumulator cover and seal.
42. Install the 1-2 accumulator retaining ring.
43. Install the reverse servo piston and rod assembly.
44. Install the special tool. Tighten the bolt.
45. Install the special tool. Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
46. Loosen the bolt until the piston stops against the tool.
47. Verify that the amount of piston travel on the dial indicator is within specification.
48. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification. One groove Two grooves Three grooves
49. Remove the special tools.
50. Install the reverse servo piston cover and seal assembly.
51. Using the special tool, install the reverse servo retaining ring. Compress the reverse band servo. Install the reverse band servo retaining ring.
52. Install the 2-3 accumulator assembly. Install the accumulator piston. Install the accumulator piston spring. Install the accumulator spring retainer.
53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
54. Install the electrical connector into the case.
55. Align the main control valve body alignment bolts and position the main control valve body.
56. Loosely install the 11 long main control valve body bolts.
57. Loosely install the 12 short main control valve body bolts.
58. Install the manual control valve detent lever spring. Position the manual control valve detent lever spring. Install the bolt.
59. Tighten the bolts in the sequence shown.
60. Inspect the lead frame for damage. Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
61. Connect the molded lead frame to the solenoids. Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
62. Install the fluid filter and seal assembly.
63. Position the pan magnet onto the fluid pan.
64. Install the fluid pan. Position the transmission fluid pan. Install the 14 transmission fluid pan bolts.
65. Install the digital transmission range (TR) sensor. Install the digital TR sensor. Loosely install the digital TR bolts.
66. Using the special tool, align the digital TR sensor slots.
67. Tighten the bolts.
68. Lightly lubricate the converter hub with clean automatic transmission fluid.
69. Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi-purpose grease.

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MATERIAL SPECIFICATION