Servicing - A/t: Removal & Installation Ford Thunderbird XI

REMOVAL & INSTALLATION

Removal

1. Disconnect the battery ground cable. Raise and support the vehicle. Drain the transmission fluid. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION. Remove the converter housing plug. Remove the torque converter drain plug. see scheme 11
2. Remove the shifter cable bracket. see scheme 8 Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the transmission harness connector. (Scheme 1) Disconnect the Transmission Range (TR) sensor connector.
3. Remove the transmission fluid pan and filter. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION. Disconnect the reverse pressure switch connector. (Scheme 2) Remove the reverse pressure switch and discard. (Scheme 3) Remove the solenoid body. (Scheme 4)
4. Remove the valve body cover plate and gasket. (Scheme 5) Remove the reverse servo. (Scheme 6) Remove the manual control valve detent spring. (Scheme 7) Remove the control valve body, separator plate and gasket. (Scheme 8) Remove the intermediate clutch spring and seal. (Scheme 9)

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Installation

1. Using a drift punch, correctly install and seat the intermediate clutch fluid inlet tube seal and spring into the case. (Scheme 10) Install the Valve Body Aligner (307-334) into the transmission case. (Scheme 11)
2. Install the control valve body and loosely install the screws. (Scheme 12) Remove the valve body aligners and loosely install the screws. Install the valve body cover plate and gasket and loosely install the screws. (Scheme 5)
3. Install the reverse pressure switch and loosely install the screws. (Scheme 3) Tighten the screws to specification in the sequence shown. (Scheme 13) See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000).
4. Install the reverse servo, using a crisscross pattern to tighten the bolts. (Scheme 6) See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Install the manual control valve detent spring. (Scheme 7)
5. Install new O-ring seals on the solenoid body connector. (Scheme 14) Lubricate the O-ring seals with clean ATF. Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If it is damaged, transmission leak may occur.
6. Install the solenoid body. Tighten the bolts in sequence shown. (Scheme 15) See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Connect the reverse pressure switch connector. Lubricate the fluid filter O-ring seals with clean ATF or seals can be damaged. Ensure the fluid filter O-ring seals are correctly seated on the filter.
7. Lubricate the seals and install the transmission fluid filter. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION. Install the transmission fluid pan and gasket and loosely install the screws. Using a crisscross sequence, tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000).
8. Install a new torque converter drain plug. see scheme 11 See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Install the converter housing access plug. Reconnect the TR sensor connector. Damage to the solenoid body assembly can result if the screw is tightened above specification.
9. Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
10. Install and lubricate new O-ring seals on the transmission connector and connect the connector. Install the shift cable bracket. Lower the vehicle.
11. Connect the battery ground cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(ref-141346-S26303568142002062000000).

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Raise and support the vehicle. Remove the exhaust heat shield. Index-mark the front driveshaft pinion flange. see scheme 16 Remove the 3 nuts, washers and bolts.
2. Slide the front portion of the driveshaft toward the rear of the vehicle. see scheme 17 Support the transmission with a transmission jack. Remove the transmission mount bolt. Remove the transmission crossmember bolts. see scheme 18
3. Disconnect the shift cable. Remove and discard the output flange nut. Using the Output Flange Remover (307-408), remove the output flange. (Scheme 16) Using the Slide Hammer (100-001) and Seal Remover (307-309), remove the extension housing seal. (Scheme 17)
4. Remove the extension housing bolts. (Scheme 18) Remove and discard the extension housing gasket.

Scheme 16

Scheme 17

Scheme 18

1. Clean the extension housing and install new extension housing gasket. Make sure that the park pawl is installed correctly. Install the extension housing bolts and tighten to specification. (Scheme 18) See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000).
2. Install the shift cable. Install the rear transmission crossmember and tighten bolts to specification. see scheme 18 See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Install the rear transmission mount bolt.
3. Using the Extension Housing Seal Installer (307-038), install the extension housing seal. (Scheme 19) Using the Output Shaft Flange Installer (307-404), install the output flange. (Scheme 20)
4. Install a new output shaft flange nut. Align the index marks on the pinion flange made during removal and position the driveshaft in place. see scheme 16
5. Install the driveshaft flex coupling bolts with the head of the bolt seated against the flange, and the nuts seated against the flex coupling. Install the short bolts in the front and the long bolts in the rear.
6. Install the bolts, washers and nuts. Coat the nut and bolt threads with threadlock sealer. Install the exhaust heat shield. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(ref-141346-S26303568142002062000000).

Scheme 19

Scheme 20

Remove the A/C condenser core. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article. Remove and discard the 6 hose clamps. Position a drain pan under the vehicle to catch any fluid that may spill. Remove the 6 hoses from the combination oil cooler. Plug the hoses and the combination oil cooler. Remove the 2 bolts. Lift the combination oil cooler from the retainers and remove the combination oil cooler. (Scheme 21)

Scheme 21

1. Install the combination oil cooler. Position the combination oil cooler on the retainers. Install the 2 bolts. Position new hose clamps on the 6 hoses. Remove the plugs from the 6 hoses and the cooler. Connect the 6 hoses to the combination oil cooler.
2. Using the Constant Velocity Joint Boot Clamp Installer (205-343), tighten the 6 hose clamps. (Scheme 28) Install the A/C condenser. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article. Fill and leak check the power steering system. See appropriate INTEGRAL POWER RACK & PINION article in STEERING.
3. Fill and leak check the cooling system. See appropriate SPECIFICATIONS article in ENGINE COOLING. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(ref-141346-S26303568142002062000000).

Note. This procedure describes the removal and installation of all the transmission cooling system tubes and hoses. Only disconnect those that require removal from the vehicle.

1. If only removing the transmission fluid cooler tubes from the vehicle, go to step 4. If not removing the transmission fluid cooler tubes from the vehicle, go to next step. Remove the A/C condenser core. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article.
2. Disconnect the transmission fluid cooler hose from the cooler. Cut and discard the hose clamp (1). (Scheme 22) Disconnect the transmission fluid cooler hose (2) from the cooler. Disconnect the transmission fluid cooler hose from the transmission fluid cooler tube. (Scheme 23)
3. Loosen and position the clamp aside. Disconnect the transmission fluid cooler hose from the transmission fluid cooler tube. If removing the transmission fluid cooler tubes from the vehicle, continue with procedure. If not removing the transmission fluid cooler tubes from the vehicle, see «INSTALLATION»(ref-141346-S10791474502002062100000).
4. If not done previously, raise and support the vehicle, and remove the left side splash shield pushpin. (Scheme 24) Remove the bolts and the left side splash shield. (Scheme 25)
5. Disconnect the transmission fluid cooler tubes from the transmission. see scheme 12 If not done previously, disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes. Loosen and position the clamps aside.
6. Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes. Remove the nut, the fluid cooler tube bracket, and the fluid cooler tubes. (Scheme 26)or (Scheme 27). Remove the fluid cooler tube routing bracket from the fluid cooler tubes.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. If transmission oil cooler tubes were not removed, go to step 4. If transmission oil cooler tubes were removed, go to next step.
2. Position the transmission fluid cooler tubes and the fluid cooler tube bracket, and install the nut. (Scheme 26)or (Scheme 27). Connect the transmission fluid cooler tubes to the transmission.
3. If the transmission fluid cooler hoses were not removed from the vehicle, go to step 6. If the transmission fluid cooler hoses were removed from the vehicle, go to next step.
4. Position the clamp on the transmission fluid cooler hose. (Scheme 22) Connect the transmission fluid cooler hose to the oil cooler.
5. Using the Constant Velocity Joint Boot Clamp Installer (205-343), tighten the clamp. (Scheme 28) Repeat this step for the other hose clamps, if removed.
6. Connect the transmission fluid oil cooler hose to the transmission fluid cooler tube. Position the clamp. Push the transmission fluid cooler hose onto the transmission fluid cooler tube until bottomed against the stop. Tighten the oil cooler hose clamps to 44 INCH lbs. (5 N.m).
7. If removed, install the fluid cooler tube routing bracket. If removed, install the A/C condenser core. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article. Install the left side splash shield and the bolts. (Scheme 25)
8. Install left side splash shield pushpin. (Scheme 24) Lower the vehicle. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(ref-141346-S26303568142002062000000).

Scheme 28

Remove the A/C condenser core. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article. Disconnect the rubber fluid cooler hoses from the fluid cooler. (Scheme 29) Cut and discard the clamps. Disconnect the rubber fluid cooling hoses from the steel fluid cooling tubes. Remove the rubber fluid cooling hoses.

Scheme 29

Install new clamps on the rubber fluid hoses. Connect the rubber fluid cooler hoses to the fluid cooler. Using the Constant Velocity Joint Boot Clamp Installer (205-343), tighten the clamp. (Scheme 28) Connect the rubber fluid cooling hoses to the steel fluid cooling tubes. Install the A/C condenser core. See appropriate AUTOMATIC A/C-HEATER SYSTEMS article.

1. Disconnect the battery. Disconnect the rubber fluid cooling hoses from the steel fluid cooling tubes. (Scheme 30) Remove the steel fluid cooling tube routing bracket from the fluid cooling tubes. Remove the 2 screws, one pushpin, and the right side splash shield. (Scheme 31)
2. Remove the wire harness retainer from the steel fluid cooling tube support bracket. see scheme 52 Remove the steel fluid cooling tube support bracket. see scheme 53
3. Remove the steel fluid cooling tube support bracket from the fluid cooling tubes. Disconnect the steel fluid cooling tubes from the transmission. Remove the generator. See appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS. Remove the right engine mount. Remove the steel fluid cooling tubes individually.

Scheme 30

Scheme 31

1. Position the steel fluid cooling tubes in the vehicle and install the fluid cooling tube support bracket on the tubes. Install the right engine mount. Install the steel fluid cooling tube support bracket.
2. Install the wire harness connector. Connect the steel fluid cooling tubes to the transmission. Install the generator. Install the right side splash shield with 2 screws and one pushpin.
3. Install the steel fluid cooling tube routing bracket. Connect the steel fluid cooling tubes to the rubber fluid cooling hoses. Connect the battery.

1. Raise and support the vehicle. Drain transmission fluid. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION. Remove Transmission Range (TR) sensor. See «TRANSMISSION RANGE SENSOR»(ref-141346-S08377534822002062000000).
2. Remove transmission oil pan and filter. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION.
3. Remove the manual control valve detent spring. (Scheme 7) Remove the manual valve inner lever nut. (Scheme 32) Remove the manual lever shaft retaining pin. (Scheme 33)
4. Partially remove the manual control lever shaft. (Scheme 34) Disconnect the manual valve inner lever from the parking lever actuating rod. (Scheme 35) Remove the manual valve inner lever. (Scheme 36)
5. Remove extension housing. See «EXTENSION HOUSING & SEAL»(ref-141346-S17394834582002062000000). Remove and discard the extension housing gasket.
6. Inspect the parking pawl, parking pawl return spring, and the parking pawl shaft. (Scheme 37) Discard components if damaged or worn. Remove the parking lever actuating rod. (Scheme 38)

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

1. Install the parking lever actuating rod. (Scheme 38) Install the manual control lever. (Scheme 36) Assemble the manual valve inner lever and parking lever actuating rod as shown. (Scheme 35)
2. Align the flats of the manual inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. Install the manual valve inner lever onto the manual shaft and loosely install the nut. (Scheme 32)
3. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Install the manual control lever shaft spring pin. (Scheme 33) Tap the manual control lever shaft spring pin into the transmission case.
4. To avoid damage, do not allow the wrench to strike the manual valve inner lever pin. Tighten the manual control lever shaft nut to specification. See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Install the manual valve detent spring bolt and tighten to specification. (Scheme 7)
5. Clean the extension housing and install a new extension housing gasket. Ensure the parking pawl is correctly installed. (Scheme 37) Ensure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. See «EXTENSION HOUSING & SEAL»(ref-141346-S17394834582002062000000).
6. Install transmission fluid filter and pan. See «DRAINING & REFILLING»(ref-141346-S01923974092002062000000) under LUBRICATION. Install TR sensor. See «TRANSMISSION RANGE SENSOR»(ref-141346-S08377534822002062000000).
7. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(ref-141346-S26303568142002062000000).

1. Raise and support the vehicle. Remove the exhaust heat shield. Index-mark the front driveshaft pinion flange before removal. see scheme 16 Remove the 3 nuts, washers and bolts. Slide the front shaft assembly rearward and support. see scheme 17 Support the transmission with a transmission jack.
2. Remove the transmission mount and lower the transmission enough to gain access to the Transmission Range (TR) sensor. see scheme 18 Disconnect the shift cable. Disconnect the TR sensor connector. Remove the TR sensor. see scheme 19

1. Install the digital TR sensor and loosely install the screws. Align the TR sensor and tighten the screws in an alternating sequence. See «TRANSMISSION RANGE SENSOR»(ref-141346-S22682277072002062000000) under ADJUSTMENTS.
2. Reconnect the TR sensor connector. Connect the shift cable. Install the transmission crossmember bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Verify that the shift cable is adjusted. See «SHIFT CABLE»(ref-141346-S08163280482002062000000) under ADJUSTMENTS.
3. Align index marks and position the alignment bushing on the transmission flange piloting system. see scheme 16 Install the driveshaft flex coupling bolts with the head of the bolt seated against the flange, and the nuts seated against the flex coupling.
4. Install the short bolts in the front and the long bolts in the rear. Install the bolts, washers and nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141346-S23663150352002062000000). Coat the nut and bolt threads with threadlock sealer. Install the exhaust heat shield.