Automatic Transaxle/transmission: Overhaul Lincoln Aviator I

Disassembly

Note. A rough casting on the pump surface crescent is not a flaw.

Note. The fluid pump gears are part of the pump assembly and are not repaired separately.

Note. Minor burrs and scoring may be removed with crocus cloth. If damage is found, install a new assembly.

Note. The No. 1 thrust washer may be stuck to the fluid pump housing, and will need to be removed. This washer will be installed during the assembly of the transmission.

Note. The fluid pump gasket may be stuck to the fluid pump housing, and will need to be removed. A new gasket will be installed during the assembly of the transmission.

Scheme 291

1. Inspect the fluid pump components for the following: Pump body and case for burrs. Fluid passages for obstructions.
2. Remove the components in the order indicated in the following illustration.

Scheme 292

1. Assemble the components in the order indicated in the following illustration.

Item 1: Seal Ring Assembly Note

1. Install a new O-ring seal in the fluid pump drive gear.
2. Using the special tool, seat the O-ring seal in the pump gear.

Items 2 and 3: Front Pump Drive Gear and Driven Gear Assembly Note

1. Install the pump gears into the fluid pump housing. Apply multi-purpose grease to the pump gears to prevent scoring at start up.

Item 5: Fluid Pump Control Valve Assembly Note

Scheme 293

1. Install the valve with the tab facing down.

Items 6 and 7: Fluid Pump Cover Assembly and Fluid Pump Adapter Plate Assembly Note

Scheme 294

1. First install the special tools in the fluid pump cover, then install the fluid pump adapter plate.
2. Using the special tool, align the fluid pump to the adapter plate.

Item 8: Front Pump Support Assembly Note

Scheme 295

1. Using the special tools, assemble the pump.

Item 9: Fluid Pump Screws Assembly Note

Scheme 296

Scheme 297

1. Loosely install the fluid pump housing screws in their correct location and remove the special tools. Install the two remaining screws.
2. Tighten all the fluid pump screws in a star pattern.

Item 11: Stator Support Seal Assembly Note

1. Using the special tools, install the fluid pump seal ring.
2. Install the seal.
3. Using the special tool, size the seal to the correct size. Leave the special tool on the seal for two minutes to obtain the correct seal size.

Scheme 298

Scheme 299

Note. Inspect the coast clutch components for damage or wear. Install new components as necessary.

1. Inspect the drum band surface, bushing, and thrust surfaces for damage.
2. Inspect the clutch piston bore, and piston.
3. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
4. Inspect the clutch plates for damage.
5. Inspect the clutch springs.

Scheme 300

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note

1. Using the special tool, remove the coast clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note

Scheme 301

1. Remove the coast clutch piston. Apply air pressure to the hole in the drum to remove the coast clutch piston while blocking the other hole with a finger.

Item 11: Overdrive Brake and Coast Clutch Drum Assembly Note

Scheme 302

1. Verify the check ball is free to move.

Items 9 and 10: Direct and Overdrive Piston Inner and Outer Seal Ring Assembly Note

1. Install the new coast clutch piston inner and outer seal.

Item 8: Direct and Overdrive Clutch Piston Assembly Note

1. Lubricate the seals, then using the special tool, install the coast clutch piston.

Item 5: Retaining Ring Assembly Note

1. Using the special tool, install the coast clutch piston spring retainer ring.

Items 3 and 4: Coast Clutch External Steel and Internal Friction Plates Assembly Note

Scheme 303

1. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
2. Install the two steel clutch plates and two friction clutch plates in an alternating order, starting with a steel clutch plate.

Item 1: Retaining Ring Assembly Note

Scheme 304

Scheme 305

Scheme 306

1. Air check the assembly. Apply air pressure to the hole in the drum while blocking the other hole with a finger to make sure that a correct piston seal has been established.
2. Check the coast clutch disc pack free play. Push down on the coast pressure plate. Check clearance between the coast clutch retaining ring and coast pressure plate. Clearance should be 1.3-2.0 mm (0.051-0.079 in). If clearance is not within the specification, install a correct coast clutch retaining ring that will provide the correct free play adjustment.

Scheme 307

Scheme 308

Note. Inspect the clutch components for damage or wear. Install new components as necessary.

1. Inspect the drum surface for damage.
2. Inspect the clutch piston bore, and piston.
3. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
4. Inspect the clutch plates for damage.
5. Inspect the clutch springs.

Scheme 309

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note

1. Using the special tool, remove the direct clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note

Scheme 310

1. Using compressed air, remove the direct clutch piston from the direct clutch drum. Apply air pressure to the hole in the drum while blocking the other hole with a finger.

Item 11: Intermediate Brake Drum Assembly Note

Scheme 311

1. Verify the check ball is free to move.

Items 9 and 10: Direct and Overdrive Piston Outer and Inner Seal Ring Inspection Note

1. Inspect the clutch components for damage or wear. Install new components as necessary. Inspect the drum surface for damage. Inspect the clutch piston bore, and piston. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions. Inspect the clutch plates for damage. Inspect the clutch springs.

Items 9 and 10: Direct and Overdrive Piston Outer and Inner Seal Ring Assembly Note

1. Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
2. Lubricate the seals with transmission fluid before installing. Using the special tool, install the direct clutch piston.

Item 5: Retaining Ring Assembly Note

1. Using the special tool, install the direct clutch piston retaining ring.

Items 4 and 3: Direct Clutch External Spline Steel and Internal Spline Friction Plates Assembly Note

Scheme 312

1. When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.
2. Install the friction plates. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.

Item 1: Retaining Ring Assembly Note

Scheme 313

1. Air check the assembly. Apply air pressure to the hole in the drum while blocking the other hole with a finger.
2. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge. If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Note. If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston must be installed.

Note. Inspect the clutch components for damage or wear. Install new components as necessary.

1. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
2. Inspect the clutch plates for damage.
3. Inspect the clutch springs.
4. Inspect the needle bearing and seal rings for damage.
5. Check clutch hub thrust surfaces for damage.
6. Check clutch plates for flatness and fit on the clutch hub serrations.

Scheme 318

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note

1. Using the special tool, remove the forward clutch piston retaining ring.

Item 7: Forward Clutch Piston Disassembly Note

Scheme 319

1. Remove the forward clutch piston. Place the forward clutch cylinder with forward clutch piston facing down. Install the center support on the forward clutch cylinder. Apply air pressure to the left port of the center support.

Item 8: Forward Clutch Cylinder Assembly Note

Scheme 320

1. Inspect the forward clutch drum assembly. Inspect the forward clutch cylinder surfaces for scores or burrs. Inspect forward clutch piston for scores or burrs. Verify the check ball is free to move in the piston.

Item 7: Forward Clutch Piston Inspection Note

1. Inspect the clutch components for damage or wear. Install new components as necessary. Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions. Inspect the clutch plates for damage. Inspect the clutch springs. Inspect the needle bearing and seal rings for damage. Check clutch hub thrust surfaces for damage. Check clutch plates for flatness and fit on the clutch hub serrations.

Item 7: Forward Clutch Piston Assembly Note

1. Install the special tool on the forward clutch piston.
2. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.

Item 5: Retaining Ring Assembly Note

1. Using the special tool, install the forward clutch piston spring retaining ring.

Items 4 and 3: Forward Clutch Internal Splined Steel and External Splined Friction Plates Assembly Note

Scheme 321

1. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
2. Install the steel clutch plates and friction clutch plates in an alternating order, starting with a steel clutch plate.

Item 1: Retaining Ring Assembly Note

Scheme 322

Scheme 323

Scheme 324

1. Air check the forward clutch piston. Place the forward clutch cylinder with forward clutch piston facing down. Install the transmission center support on the forward clutch cylinder. Apply air pressure to the left port of the center support.
2. Check forward clutch disc pack free play. Press down on forward clutch disc pack. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate. If the clearance is not within specifications, install the correct size retaining ring.

Overdrive Planetary and One-Way Clutch Assembly

Note. Individual parts of the planetary carriers are not serviceable.

Note. The overdrive one-way clutch is serviced with the center shaft assembly.

Note. Inspect the one-way clutch.

1. Temporarily insert the overdrive planetary gear carrier assembly into the one-way clutch rollers for verification of the one-way clutch.
2. The planetary gear must rotate counterclockwise and hold when rotated clockwise.
3. Remove the planetary gear carrier assembly.
4. Inspect for cracks in the roller cage and wear on the roller clutch, and the press fit of the one-way clutch to the center shaft. NOTE: Inspect the overdrive planetary.
5. Inspect the pinion gears for damaged or excessively worn teeth, and for free rotation.
6. Check the pins and shafts in the planetary assemblies for loose fit and/or complete disengagement.
7. Inspect the overdrive one-way clutch inner race, and the inner and outer races for scored or damaged surface areas where the rollers contact the races.
8. Inspect the sun gear for damaged or worn teeth.
9. Inspect the No. 12 bearing for damage.
10. Thoroughly clean all parts and blow dry with moisture-free compressed air.
11. Inspect the sun gear for damaged or worn teeth.

Scheme 325

1. Disassemble the components in the order indicated in the following illustration.

Item 1: Retaining Ring Disassembly Note

Scheme 326

1. Remove the center shaft from the overdrive ring gear. Remove the overdrive center shaft retaining ring. While rotating counterclockwise remove the center shaft from the ring gear.

Items 2, 4, 5, 6 and 7 Overdrive Planetary and One-Way Clutch Assembly Inspection Note

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

1. Clean and inspect the overdrive one-way clutch and center shaft. Inspect for cracks in the roller cage and wear on the roller clutch, and the press fit of the one-way clutch to the center shaft.
2. Inspect the one-way clutch. Temporarily insert the overdrive planetary gear carrier assembly into the one-way clutch rollers for verification of the one-way clutch. The planetary gear must rotate counterclockwise and hold when rotated clockwise.
3. Check the pins and shafts in the planetary assemblies for loose fit and/or complete disengagement.
4. Inspect the pinion gears for damaged or excessively worn teeth, and for free rotation.
5. Inspect the overdrive one-way clutch inner race, and the inner and outer races for scored or damaged surface areas where the rollers contact the races.
6. Inspect the No. 2 overdrive planetary thrust bearing on the nose of the overdrive planetary gear carrier assembly.
7. Remove and inspect the coast clutch-to-overdrive carrier adapter.
8. Remove and inspect the overdrive sun gear.
9. Inspect the No. 12 bearing for damage.
10. Assemble the components in the order indicated in the following illustration.

Item 7: Overdrive Sun Gear Assembly Note

Scheme 334

1. Install the overdrive sun gear with the recessed gear teeth facing toward the adapter.

Item 6: Coast Clutch Adapter Assembly Note

Scheme 335

1. Install the coast clutch-to-overdrive carrier adapter.

Item 4: No. 2 Overdrive Planetary Thrust Bearing Assembly Note

1. Install the No. 2 overdrive planetary thrust bearing.

Item 1: Retaining Ring Assembly Note

Scheme 336

1. Install the center shaft and overdrive one-way clutch. Install the center shaft and overdrive one-way clutch. Install the overdrive center shaft retaining ring.

Output Shaft Ring Gear and Hub Shaft Assembly

Note. Inspect the output shaft ring gear and hub shaft assembly for damage. If repair is necessary, use the following procedure.

Scheme 337

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Reverse Servo Assembly

Note. Inspect the reverse servo piston seal for damage. If damaged, a new piston and seal assembly will need to be installed.

Scheme 338

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.

Item 4: Reverse Servo Plate Disassembly Note

Scheme 339

1. Remove the reverse servo plate by turning in either direction to release. Align the arrow on the servo plate with any slot on the cover.

Item 7: Reverse Servo Piston O-Ring Assembly Note

1. Lubricate and install a new reverse servo piston seal.

Item 4: Reverse Servo Plate Assembly Note

1. Install the reverse servo plate.