Overhaul - CD4E: Overhaul Ford Probe II

TRANSAXLE DISASSEMBLY

Note. For identification and position verification of thrust bearings and washers (Scheme 119)

1. Ensure outside of transaxle is thoroughly clean. Mount transaxle on appropriate stand. Remove and drain torque converter. Remove drain plug from transaxle if fluid was not drained before removal. Pull oil pump shaft from end of turbine shaft.
2. Using appropriate puller, remove torque convert hub seal. Remove differential seals. Unbolt and remove transmission speed sensor from outside of pump housing. Unbolt and remove dipstick tube and grommet. Remove vehicle speed sensor. Remove manual lever position sensor.
3. Remove main control cover assembly (side cover) bolts in crisscross pattern. Remove cover and gasket. Compress tabs on transaxle electrical harness receptacle and push into case. Remove 12 valve body bolts. Slightly lift valve body and remove "Z" link.
4. Remove valve body with wiring harness. Remove thermostatic oil level control valve bracket. Pull valve straight out of transaxle case. Remove and discard servo cover cap. Using Servo Cover Remover/Replacer (T94P-77000-L), compress servo cover assembly. Remove retaining ring and release servo cover pressure. Remove tool. Remove servo cover assembly, piston and return spring.
5. Position transaxle so converter housing is facing upward. Remove converter 23 housing-to-transaxle case bolts. Separate case halves. see scheme 2 Remove No. 15 thrust bearing, No. 14 shim and speedometer drive gear from final drive/differential assembly.
6. Remove final drive/differential assembly. Unsnap and remove front chain cover. Remove driven sprocket No. 13 thrust bearing. Remove No. 10 thrust washer from reverse/overdrive ring gear assembly. Lift drive chain assembly, driven sprocket assembly and reverse/overdrive ring gear assembly together from case.
7. Remove rear chain cover with magnet attached. Using blind hole puller, remove oil filter recirculating regulator exhaust seal and discard. (Scheme 99) Remove and discard oil filter. Remove driven sprocket No. 12 thrust bearing assembly and No. 11 shim.
8. Unsnap socket end of manual valve detent lever actuating rod assembly from parking cam actuator lever assembly. Unsnap opposite end of actuating rod. Remove reverse/overdrive ring gear No. 9 thrust bearing assembly. Remove reverse/overdrive planetary carrier assembly with No. 8 thrust bearing. Inspect planetary pinion gear thrust clearance. Clearance should be.006-.028" (.15-.72 mm). Replace thrust bearing if clearance is not within specification.
9. Remove reverse/overdrive sun gear and shell assembly. see scheme 2 Remove No. 7 thrust bearing. Remove low/intermediate ring gear assembly. Remove No. 6 thrust bearing. Remove low/intermediate planetary carrier assembly. Inspect planetary pinion gear thrust clearance. Clearance should be.006-.028" (.15-.72 mm). Replace as needed. Remove low/intermediate sun gear No. 5 thrust bearing, forward one-way clutch and low/intermediate sun gear assembly.
10. Remove No. 4 turbine shaft thrust bearing. Remove turbine shaft. Remove Forward/Coast/Direct (F/C/D) cylinder assembly and reverse clutch drum assembly. Remove pump support No. 1 thrust bearing assembly.
11. Remove low one-way clutch retaining snap ring. Remove thrust plate. Remove low one-way clutch assembly. Remove low/reverse clutch wave spring and clutch plates. Remove retaining snap ring. Remove low/reverse clutch return spring assembly. Pull out low/reverse clutch piston from bore.
12. Turn transaxle case over with pump facing upward. Remove 9 pump housing bolts. Using appropriate puller with slide hammer, remove pump assembly. Slide out intermediate and overdrive band from case. Remove final drive ring gear from converter housing.

Scheme 99

FORWARD ONE-WAY & LOW-INTERMEDIATE SUN GEAR ASSEMBLY

Note. Inspect clutch discs for wear and/or overheating. Individual clutch disc thicknesses are not supplied by manufacturer.

Disassembly

Remove coast clutch hub retaining ring. Remove coast clutch hub. Remove forward one-way clutch outer race and sprag assembly with end caps. Separate sprag assembly and end caps from outer race. Note position of end caps. End caps are different thicknesses. (Scheme 100) Remove forward one-way clutch retainer. Remove retaining ring from sun gear assembly. Inspect parts for wear or damage, replace as needed.

Reassembly

Install retaining ring gear on sun gear assembly. Install clutch retainer. Assemble sprag assembly and end caps. Ensure end caps are in correct position. Install remaining components in reverse order of disassembly. Check operation of assembly. With sun gear facing upward, sun gear should turn clockwise while holding outer race. (Scheme 100)

Scheme 100

Disassembly & Reassembly

Position clutch with inner and outer race grooves facing upward. Remove inner race. Remove roller assembly. Clean and inspect parts for wear or damage. Replace as needed. To reassemble, reverse disassembly procedures. Check operation of clutch assembly. Inner race should turn clockwise while holding outer race. (Scheme 101)

Scheme 101

FINAL DRIVE/DIFFERENTIAL ASSEMBLY

Note. Final drive differential backlash specification is not available from manufacturer.

Using pin punch, remove pinion shaft roll pin. Remove pinion shaft. Remove pinion gears, side gears and thrust washers. Clean and inspect parts for wear or damage. Replace as needed. To reassemble, reverse disassembly procedures. Check thrust clearance of final drive planetary pinion gears. Thrust clearance should be .006-.025" (.17-.65 mm). Replace thrust washers as needed.

1. Support assembly on block of wood (shell facing downward). Remove reverse clutch hub retaining ring. Remove reverse clutch hub. Remove reverse clutch drum assembly from direct clutch hub and shell assembly. See disassembly and reassembly under «REVERSE CLUTCH DRUM»(ref-25357-S20572826422001011700000). (Scheme 102) Remove direct clutch hub and shell from forward/coast/ direct clutch cylinder. Remove No. 2 direct clutch thrust washer.
2. Remove direct clutch pressure plate retaining snap ring. (Scheme 103) Remove clutch plates. Using spring compressor, compress direct clutch support. Remove snap ring. Remove direct clutch return spring assembly. Remove direct clutch piston.
3. Turn assembly over. Remove forward clutch snap ring. Remove clutch plates. Using spring compressor, compress clutch return spring assembly. Remove snap ring and spring assembly. Remove forward/coast piston.

1. Before assembling reverse clutch drum, soak friction plates in transmission fluid for 15 minutes. Replace all necessary seals. Using Coast Clutch Piston Seal Protector (T94P-77000-D3), install coast clutch piston into forward clutch piston assembly.
2. Install clutch spring assembly. Compress spring assembly and install snap ring. Install clutch plates. (Scheme 103) Install pressure plate snap ring and measure clearance between pressure plate and snap ring. Forward/Coast clutch pack clearance should be.020-.043" (.50-1.09 mm). If clearance is not within specification, select proper thickness snap ring. Snap rings are available in the following thicknesses:.050-.054" (1.28-1.38 mm),.055-.059" (1.39-1.49 mm),.060-.064" (1.52-1.62 mm) and.065-.069" (1.65-1.75 mm).
3. Turn assembly over. Install direct clutch piston. Install spring assembly. Compress spring assembly and install snap ring. Install clutch plates. (Scheme 103) Mount dial indicator on clutch cylinder. Position dial indicator plunger on direct clutch pressure plate. (Scheme 104) Using 2 picks, pull pressure plate upward.
4. Record clearance measurement. Move dial indicator to opposite side of pressure plate. Measure clearance and average with previous measurement. Direct clutch pack clearance should be.020-.044" (.52-1.12 mm). If clearance is not within specification, select proper thickness snap ring. Snap rings are available in the following thicknesses:.050-.054" (1.28-1.38 mm),.055-.059" (1.39-1.49 mm),.060-.064" (1.52-1.62 mm) and.065-.069" (1.65-1.75 mm). NOTE: Install all necessary seals during reassembly process.
5. Install No. 2 direct clutch thrust washer on clutch cylinder with tabs facing down. Set clutch cylinder assembly on block of wood. Install direct clutch hub and shell on clutch cylinder. (Scheme 102)
6. Install reverse clutch drum assembly and clutch hub. Install retaining snap ring. Turn assembly over. Install clutch cylinder hub seal. Size seal using coast clutch piston seal sizer. (Scheme 105)
7. To air check assembly, install assembly, with reverse clutch drum, onto oil pump support. Ensure pump support sealing rings are in good condition. Using air nozzle, blow air into oil pump passages. (Scheme 106) Ensure air pressure does not exceed 40 psi. Leaking air indicates sealing malfunction. Inspect and repair as needed.

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

1. Remove reverse clutch pressure plate snap ring. Remove reverse clutch pressure plate with clutch plates. (Scheme 107) Using compressor, compress spring assembly and remove snap ring. Remove spring assembly. Remove reverse clutch piston.
2. Before assembling reverse clutch drum, soak friction plates in transmission fluid for 15 minutes. Replace all necessary seals. Using Reverse Clutch Piston Seal Protector (T94P-77000-D2), install reverse clutch piston. (Scheme 108) Install spring assembly. Compress spring assembly and install retaining snap ring. Install clutch discs and pressure plate. (Scheme 107)
3. Install pressure plate snap ring and measure clearance between pressure plate and snap ring. Reverse clutch pack clearance should be.012-.035" (.33-.89 mm). If clearance is not within specification, select proper thickness snap ring. Snap rings are available in thicknesses;.055-.059" (1.39-1.49 mm),.060-.064" (1.53-1.63 mm) and.066-.070" (1.68-1.78 mm).

Scheme 107

Scheme 108

Remove pump support sealing rings. Remove Torx T30 bolts. Separate pump assembly. Remove pump drive gear and insert. Remove pump driven gear. After components are cleaned, inspect components and housing for irregular wear or damage. Replace as needed.

1. Install pump driven gear with identification dot facing pump body. Install pump drive gear with gear insert. Using gauge bar and depth micrometer, measure clearance between each gear and oil pump body facing.
2. Clearance should be .001-.002" (.027-.060 mm). If clearance is not within specification, replace oil pump assembly. Install Pump Alignment Pins (T94P-77000-P). Fill pump gear cavity with ATF to top of gears. Install separator plates and pump support assembly. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000) .
3. Install sealing rings. Install oil pump shaft. Using torque wrench, measure pump rotating torque. Maximum rotating torque is 2 INCH lbs. (.3 N.m). If rotating torque exceeds specification, disassembly and inspect pump assembly for contamination or improper end clearance.

1. Remove manual valve. Unbolt and remove solenoid valve body and gasket. Remove pressure tap plate and gasket. Remove manual valve detent spring assembly and adjacent bolt. Remove accumulator body-to-transfer plate bolts (3). Disassemble accumulator body assembly with separator plate and gaskets from main valve body. (Scheme 109)
2. Disassemble main valve body from separator plate and gaskets from transfer plate. Remove intermediate/overdrive accumulator valve plug retaining plate. Thread 6 mm bolt into plug and remove. Remove accumulator.
3. Remove, clean and install each valve individually as needed. Lubricate moving parts with ATF. Ensure all valves move (snap) freely. If valve sticks in its bore and cannot be freed, main valve body must be replaced. DO NOT attempt to hone valve bores. Reassemble components in reverse order of disassembly. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000).

Scheme 109

TRANSAXLE REASSEMBLY

Note. Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean ATF. Use petroleum jelly on gaskets, thrust washers and needle bearings to retain them in place. Use all new gaskets and seals, and tighten bolts evenly.

Note. For identification and position of thrust bearings and washers (Scheme 116)

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

1. Slide intermediate/overdrive band assembly into transaxle case. Install oil pump assembly in transaxle case. Tighten bolts to specification in crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000).
2. Install low/reverse clutch piston into Low/Reverse Clutch Piston Outer Seal Protector (T94P-77000-D1). Install Low/Reverse Clutch Piston Inner Seal Protector (T94P-77000-D1) into piston. Install piston and remove protectors. (Scheme 110)
3. Install low/reverse clutch return spring assembly. Install snap ring. Install low/reverse clutch wave spring (measuring purposes only). Install low/reverse clutch plates, and pressure plate. see scheme 2and (Scheme 111). Install low one-way clutch thrust plate (measuring purposes only).
4. Measure in 2 locations, clearance between low/reverse clutch pressure plate and thrust plate. Average measurements. Clearance should be.021-.046" (.54-1.17 mm). If clearance is not within specification, select proper thickness pressure plate. Pressure plates are available in the following thicknesses:.097-.101 (2.47-2.57),.089-.093 (2.26-2.36) and.081-.085 (2.06-2.16).
5. Remove low/reverse pressure plate, clutch discs and wave spring. Install No. 1 pump support thrust bearing. Remove seal sizer from forward/coast/direct cylinder assembly and install. Install turbine shaft assembly.
6. Install No. 4 turbine shaft thrust bearing. Install forward one-way clutch and low-intermediate sun gear assembly. Install No. 5 low-intermediate sun gear thrust bearing. Install low-intermediate planetary carrier assembly. Install No. 6 low-intermediate planetary thrust bearing. Install low-intermediate ring gear.
7. Install No. 7 reverse/overdrive sun gear thrust bearing. Install reverse/overdrive sun gear and shell assembly. Install reverse/overdrive planetary carrier assembly with No. 8 thrust bearing. Install low/reverse clutch plates.
8. Install low/reverse clutch pressure plate previously selected. Install low/reverse clutch wave spring. Install low one-way clutch assembly with I.D. ring on inner ring, facing upward. Install low one-way clutch thrust plate. Install low one-way clutch snap ring.
9. Install manual valve detent lever actuating rod. Install Preload Tool Adapter/Aligner Set (T94P-77000-R), on reverse/overdrive planetary carrier assembly. (Scheme 112) Tighten mounting bolts to 119 INCH lbs. (13.5 N.m).
10. Install Gauge Bar (T94P-77000-Q), with short spacers across transaxle case. Measure distance from top of gauge bar to No. 12 driven sprocket bearing assembly (Dimension "A"). (Scheme 112)
11. Measure the distance from the top of gauge bar to the bearing surface on the reverse/overdrive planetary carrier assembly (Dimension "B"). (Scheme 113) Dimension "B" - Dimension "A" = Dimension "C". Use Dimension "C" to select correct No. 11 driven sprocket shim. See the «DRIVEN SPROCKET SHIM SELECTION CHART»(ref-25357-S16818957742001011700000). DRIVEN SPROCKET SHIM SELECTION CHART Dimension "C" In. (mm) Shim Thickness In. (mm).558-.565 (14.17-14.34).083-.087 (2.10-2.20).551-.557 (14.00-14.16).076-.080 (1.92-2.02).544-.550 (13.83-13.99).069-.073 (1.75-1.85).538-.543 (13.66-13.82).062-.066 (1.57-1.67).531-.537 (13.49-13.65).055-.059 (1.40-1.50).524-.530 (13.32-13.48).048-.052 (1.22-1.32)
12. Install selected No. 11 shim. Remove gauge bar and preload tool. Install No. 12 driven sprocket bearing assembly. Ensure No. 18 needle bearing is lubricated. Install No. 9 reverse/overdrive ring gear thrust bearing. Install reverse/overdrive ring gear assembly (measuring purposes only).
13. Install Preload Tool Adapter/Aligner Set (T94P-77000-R) on reverse/overdrive ring gear. Tighten mounting bolts to 119 INCH lbs. (13.5 N.m). Install Gauge Bar (T94P-77000-Q), with short spacers across transaxle case. (Scheme 112)
14. Measure distance between top of gauge bar to face of reverse/overdrive ring gear assembly (Dimension "D"). Combined thickness of gauge bar and short spacers (1.00" (25.4 mm) is Dimension "E". Dimension "D" - Dimension "E" = Dimension "F". Use Dimension "F" to select correct No. 10 drive sprocket thrust washer. Refer to «DRIVE SPROCKET THRUST WASHER SELECTION CHART»(ref-25357-S20854582842001011700000). DRIVE SPROCKET THRUST WASHER SELECTION CHART Dimension "E" In. (mm) Washer Thickness In. (mm).034-.044 (.86-1.12).056-.059 (1.41-1.51).024-.033 (.60-.85).066-.070 (1.67-1.77).013-.023 (.34-.59).076-.080 (1.93-2.03).003-.013 (.08-.33).086-.090 (2.19-2.29)
15. Remove gauge bar and preload tool. Apply petroleum jelly to selected No. 10 drive sprocket thrust washer and install on converter housing. Remove reverse/overdrive ring gear assembly. Install oil filter and seal assembly. Temporarily install appropriate guide pin through filter eyelet into transaxle case hole.
16. Install oil filter recirculating regulator exhaust seal. Remove guide pin. Install rear chain cover in transaxle case. Assembly drive chain assembly on driven sprocket assembly, and reverse/ overdrive ring gear assembly. Install and fully seat chain and sprocket/ring gear assembly.
17. Install front chain cover. Install No. 13 driven sprocket thrust bearing assembly. Install final drive planetary/differential assembly. Install Gauge Bar (T94P-77000-Q) with Spacer Set (T94P-77000-T) on transaxle case. Tighten mounting bolts to 119 INCH lbs. (13.5 N.m). (Scheme 116)
18. Measure distance from top of gauge bar to shim surface area of final drive assembly. Measure in 2 places and average measurements (Dimension "G"). Combined thickness of gauge bar with long spacers (7.00" (177.8 mm) is Dimension "H".
19. Dimension "G" - Dimension "H" = Dimension "I". Use Dimension "I" to select correct No. 14 differential bearing shim. See «DIFFERENTIAL BEARING SHIM SELECTION CHART»(ref-25357-S28070938472001011700000). DIFFERENTIAL BEARING SHIM SELECTION CHART Dimension "I" In. (mm) Washer Thickness In. (mm) 5.136-5.148 (130.46-130.76).039-.043 (.98-1.08) 5.124-5.136 (130.16-130.45).050-.054 (1.28-1.38) 5.113-5.123 (129.87-130.15).062-.066 (1.57-1.67) 5.101-5.123 (129.87-130.15).074-.078 (1.87-1.97) 5.089-5.101 (129.27-129.56).085-.089 (2.17-2.27)
20. Remove gauge bar and spacers. Install and fully seat speedometer drive gear with tabs facing downward. Install selected No. 14 differential bearing shim. Install No. 15 differential bearing. Install converter housing with gasket.
21. Install housing bolts (20) and tighten to specification in crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000). Lubricate and install intermediate and overdrive servo piston and return spring assembly in transaxle case bore. Note number of grooves of servo apply rod. Install Servo Piston Rod Selector (T94P-77000-M) on piston.
22. Loosely assembly legs and bar of selector. (Scheme 117) Tighten selector assembly legs. Tighten center bolt to 36 INCH lbs. (4.1 N.m). Measure and record distance between top of center bolt and selector tool bar (Dimension "J"). (Scheme 118) Unscrew center bolt until piston movement stops. Measure distance between center bolt and bar (Dimension "K"). Dimension "J" - Dimension "K" = Dimension "L" (rod travel).
23. Verify that rod travel (Dimension "L") is within specification. See «SERVO ROD TRAVEL SPECIFICATION CHART»(ref-25357-S39834299162001011700000). If distance is not within specification, replace servo piston and recheck. SERVO ROD TRAVEL SPECIFICATION CHART Number Of Rod Grooves Travel Specification In. (mm) Rod Length In. (mm) 0.096-.194 (2.43-4.93) 4.26 (108.1) 1.093-.190 (2.35-4.82) 4.22 (107.1) 2.096-.194 (2.43-4.93) 4.16 (105.7)
24. Remove servo piston selection tool. Install NEW servo cover cap. Using Servo Cover Remover/Replacer (T94P-77000-L), compress servo cover assembly. Install retaining ring. Release servo cover pressure. Remove tool. CAUTION: DO NOT air check coast clutch since piston may be forced out of forward clutch piston.
25. Install Transmission Test Plate (T94P-77000-S). Air check clutch hydraulic circuits for function and leakage. see scheme 4 If leakage is detected, disassemble transaxle and inspect. Remove test plate.
26. Install thermostatic oil level control valve. Tighten bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000). Install new "O" ring on valve body harness connector receptacle. Install receptacle in transaxle case.
27. Insert "Z" link into end of manual valve. Place valve body in position on transaxle case and install 12 bolts. Tighten bolts in sequence. see scheme 5 Tighten bolts to specification. Refer to «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000).
28. Remove manual control lever bolt and lever assembly. Using Shifter Shaft Alignment Tool (T94P-77000-H), move manual control lever shaft to "D" position. Install pin to hold tool in position. Move manual valve detent lever assembly to "D" position. see scheme 6
29. Loosen nut on ball stud of manual valve detent lever actuating rod assembly. Snug nut on ball stud. Remove shifter pin. Rotate Shifter Shaft Alignment tool until socket can be installed on nut. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000).
30. Rotate lever back to "D" position and recheck adjustment. Remove pin and alignment tool. Install manual control lever assembly. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000). Install manual lever position sensor. Install main control cover (side cover) with new gasket. Tighten bolts in sequence. see scheme 7 Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000).
31. Install vehicle speed sensor. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-25357-S41702441632001011700000). Install dipstick tube with new grommet. Install dipstick. Install transmission speed sensor. Install differential seals and converter seal. Install drain plug. Install oil pump drive shaft. Install torque converter. Remove transaxle from mount.

Scheme 117

Scheme 118

Scheme 119