Automatic Transaxle/transmission: Specifications Lincoln Aviator I

General Specifications

GENERAL SPECIFICATIONS

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Torque Specifications

TORQUE SPECIFICATIONS

Torque Demand

The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration.

Torque Converter

The torque converter transmits and multiplies torque. The torque converter is a four-element device

1. impeller assembly
2. turbine and damper assembly
3. reactor assembly
4. clutch

The standard torque converter components operate as follows

1. Rotation of the converter housing and impeller set the fluid in motion.
2. The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft.

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1. The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
2. The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency.
3. Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft.

Torque Converter Clutch (TCC) Solenoid

The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used to control the apply and release of the TCC.

Torque Converter Diagnosis

Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter.

Begin with the normal diagnostic procedures as follows

1. Preliminary Inspection.
2. Know and Understand the Customer Concern.
3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test; refer to «TORQUE CONVERTER OPERATION TEST».
4. Carry out Diagnostic Procedures. Run on-board diagnostics. See On-Board Diagnostics with NGS. Refer to «DIAGNOSTICS». Repair all non-transmission related DTCs first. Repair all transmission DTCs. Rerun on-board diagnostic to verify repair. Carry out the Line Pressure Test. Refer to «SPECIAL TESTING PROCEDURES». Carry out the Stall Speed Test. Refer to «SPECIAL TESTING PROCEDURES». Carry out the Diagnosis by Symptom Index. Refer to «DIAGNOSIS BY SYMPTOM». Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as necessary before servicing the torque converter.

Torque Converter Operation Test

This test verifies that the torque converter clutch control system and the torque converter are operating correctly.

1. Carry out the Quick Test. See On-Board Diagnostics with NGS. Refer to «DIAGNOSTICS». Check for DTCs. Refer to «DIAGNOSTIC TROUBLE CODE CHARTS».
2. Connect a tachometer to the engine.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot.
5. The engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in «DIAGNOSIS BY SYMPTOM».
6. If the vehicle stalls in (D) or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to «DIAGNOSIS BY SYMPTOM», Torque Converter Operation Concerns. Repair as necessary. If the vehicle does not stall in (D), refer to «DIAGNOSIS BY SYMPTOM».

Fluid Leakage in Torque Converter Area

In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area, use the following procedures to locate the exact cause of the leakage. Leakage at the front of transmission, as evidenced by fluid around the torque converter housing, may have several sources. By careful observation it is possible, in many instances, to pinpoint the source of leak before removing the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the illustration.

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1. A new torque converter must be installed if one or more of the following statements are true: A torque converter failure has been determined based on complete diagnostic procedures. Converter studs, impeller hub or bushing are damaged. Discoloration of the torque converter (due to overheating). The torque converter is found to be out of specification when carrying out one of the following torque converter checks: Torque Converter One-Way Clutch Check Torque Converter End Play Check Torque Converter Turbine to Pump Stator Interference Check Torque Converter Impeller to Pump Stator Interference Check Torque Converter Leak Check Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: major metallic failure multiple clutches or clutch plate failures sufficient component wear which results in metallic contamination

Torque Converter Cleaning And Inspection

1. If a new torque converter is being installed, continue with 2 .
2. If a new torque converter is not being installed, the following procedures must be carried out: The torque converter must be thoroughly cleaned. Torque converter with drain plugs can be cleaned by using a suitable torque converter fluid cooler cleaner. CAUTION: Do not use water based cleaners or transmission damage will occur. A torque converter without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand-agitate the torque converter and then thoroughly drain the fluid. Fill the torque converter with new fluid specified for the transmission, and install. All in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING». All cooler tubes must be thoroughly cleaned by backward and forward flushing. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING». All cooler bypass valves (CBV), if equipped, must be thoroughly cleaned. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to «TRANSMISSION FLUID COOLER». If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, install new components as necessary. If new coolers are to be installed, use only factory-approved repair parts. For additional information, refer to «TRANSMISSION FLUID COOLER».

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1. Using a suitable torque converter fluid cooler cleaner, flush the torque converter.
2. After flushing, remove the drain plug, if equipped, and drain the remainder of the solvent.
3. Add 1.9 liters (2 quarts) of clean automatic transmission fluid into the torque converter and agitate by hand.
4. Thoroughly drain the solution.
5. If equipped, install a new torque converter drain plug.

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1. Clean the outside surface of the torque converter.
2. Install the special tools into the converter hub.
3. Install the torque converter with the special tool installed into the arbor press. Secure the press. Apply enough force from the press to seal the tool into the torque converter.
4. Apply air pressure to the valve on the special tool.
5. With air pressure applied to the valve, inspect for leaks at the converter hub, the seams, drain plug, and the studs. A soap bubble solution can be applied around those areas to aid in the diagnosis. If a leak is found around the drain plug, install a new drain plug and recheck the torque converter. If any other leaks are present, install a new or remanufactured converter.
6. Remove the air hose. Release the pressure, and then slowly release the press. Remove the converter. Remove the tool.

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1. If equipped, remove the drain plug and drain the fluid from the torque converter.
2. Install fluid pump support into the torque converter. Engage splines of the one-way clutch inner race with the mating splines of the overdrive pump support.
3. While holding the fluid pump support stationary, rotate the torque converter clockwise and counterclockwise. The torque converter should rotate freely with no signs of scraping. If there are signs of scraping, install a new or remanufactured torque converter.
4. If equipped, install a new drain plug in the torque converter.

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1. Install the special tool into the torque converter until it bottoms out. Tighten the inner post until the tool is securely locked.
2. Install the special tool on the converter impeller housing and zero the dial.
3. Lift up on the special tool and note the dial indicator reading. If the reading exceeds end play limits, install a new or rebuilt torque converter.

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1. Insert the special tool into one of the grooves in the stator bearing retainer.
2. Install the special tools into the converter one-way clutch inner race spline.
3. Use the special tool to hold the stator bearing retainer while using the special tool to turn the converter one-way clutch inner race spline. The torque converter one-way clutch should lock up and hold torque in the counterclockwise direction. The torque converter one-way clutch should rotate freely in the clockwise direction. Try the clutch for lockup and hold in at least five positions. If the converter fails the lockup torque test, install a new or rebuilt torque converter.

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1. Position the torque converter with the pump drive up.
2. Install the pump support into the torque converter. Engage the splines of the one-way clutch inner race with the mating splines of the front pump support.
3. Install the input shaft, engaging the splines with the turbine hub.
4. Check for stator to turbine interference. Hold the front pump support stationary. Attempt to rotate the input shaft. The turbine and damper assemblies should rotate in both directions not exceeding maximum torque of 7 Nm (62 lb-in) without any signs of metallic interference or scraping noise.
5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, a new or remanufactured torque converter must be installed. The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal.

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Note. Inspect the transmission case and extension housing for the following

1. stripped screw hole threads
2. gasket and mating surfaces for burrs or nicks
3. obstructions to vent and fluid passages
4. cracks or warpage

Note. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.

Note. Lubricate all seals and the servo bores with clean automatic transmission fluid.

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1. If installing a new transmission case bearing, only carry out the listed steps.
2. Assemble the components in the order indicated in the following illustration and table.
3. Assemble the components in the order indicated in the following illustration and table.

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Item 1: Transmission Case Assembly Note

1. Using the special tool, install the transmission into the bench with the converter housing facing up.

Item 2: Case Bearing Disassembly Note

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1. Inspect case bearing for damage. Install a new component as necessary.
2. Using the special tool, remove the damaged case bearing. Use an oil stone to remove any nicks or burrs in the bearing case bore.

Item 2: Case Bearing Assembly Note

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1. Assemble the special tools.
2. Install the bearing on the special tools.
3. Using the special tool, tap the case bearing into the case bearing bore.

Item 3: Manual Control Lever Seal Assembly Note

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1. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.

Item 4: Park Pawl Actuating Rod Assembly Note

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1. Install the parking lever rod.

Item 5: Manual Control Valve Inner Lever Assembly Note

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1. Assemble the manual valve inner lever and parking lever actuating rod as shown.

Item 6: Manual Control Lever Shaft Assembly Note

1. Install the manual control lever shaft.

Item 7: Manual Control Lever Inner Nut Assembly Note

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1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.

Item 8: Manual Control Lever Shaft Retaining Pin Assembly Note

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1. Install the manual control lever shaft spring pin. Tap the manual control lever shaft spring pin into the transmission case.

Item 9: Manual Control Lever Inner Nut Assembly Note

1. Tighten the nut.

Item 10: Output Shaft Thrust Washer No. 11 Assembly Note

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1. Install the output shaft thrust washer (No. 11). Coat the output shaft thrust washer with petroleum jelly.

Item 13: Reverse Band Assembly Note

1. Install the low/reverse band over the low/reverse brake drum.

Item 14: Reverse Brake Drum and Clutch Assembly Note

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1. Install the low/reverse brake drum. Rotate the low/reverse brake drum clockwise to install.

Item 15: Reverse Brake Drum Lever Assembly Note

1. Install the reverse band actuating lever into the reverse band.

Item 18: Output Shaft Ring Gear Assembly Note

1. Install the output shaft ring gear, hub and seal.

Item 19: Output Shaft Retaining Ring Assembly Note

1. Install a new output shaft retaining ring.

Item 20: Output Shaft Sleeve Assembly Note

1. Install the output shaft sleeve.

Item 23: Reverse Brake Drum Retaining Ring Assembly Note

1. Install the retaining ring.

Item 27: Forward Planet Assembly Note

1. Install the forward planetary assembly.

Item 35: Intermediate Servo Retaining Ring Assembly Note

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1. Using the special tool, install the retaining ring.

Item 37: Intermediate Clutch Drum Bearing No. 4 Assembly Note

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1. Using the special tool, measure from the top of the gauge bar to the center support ledge in the case at four places, 90 degrees apart. Add the four measurements, divide by four, and record as dimension A.
2. Install the special tool. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions. Tighten the center screw.
3. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
4. Add dimension B to C, divide by two and record as dimension D.
5. Subtract A from D, and record as dimension E.
6. Select the bearing from the following chart, using dimension E.
7. Install the selected No. 4 thrust washer on the direct clutch drum. Coat the thrust washer with petroleum jelly.

Item 38: Intermediate Brake Band Assembly Note

1. Install the intermediate band.

Item 39: Intermediate Brake Band Anchor Strut Assembly Note

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1. Install the intermediate band anchor strut.
2. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 40: Intermediate Brake Band Adjusting Screw Assembly Note

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1. Loosely install the screw.

Item 41: Intermediate Brake Band Apply Strut Assembly Note

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1. Install the intermediate band apply strut.
2. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.

Item 42: Center Support Assembly Note

1. Install the center support.

Item 43: Nut and Cage Assembly Note

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1. Install the center support locknut and cage.

Item 44: Center Support Screw Assembly Note

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1. Loosely install the screw.

Item 45: Retaining Ring Assembly Note

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1. Install the center support retaining ring. Make sure the center support retaining ring is installed with the tapered side facing up. Make sure the opening of the center support retaining ring is positioned correctly.

Item 48: Overdrive Servo Retaining Ring Assembly Note

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1. Using the special tools, install the retaining ring.

Item 50: Overdrive Planetary Gear Carrier Assembly Note

1. Install the planetary gear overdrive carrier.

Item 52: Overdrive Brake Band Assembly Note

1. Install the overdrive band.

Item 53: Overdrive Brake Band Anchor Strut Assembly Note

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1. Install the overdrive anchor strut.
2. Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.

Item 54: Overdrive Brake Band Adjusting Screw Assembly Note

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1. Loosely install the screw.

Item 55: Overdrive Brake Band Apply Strut Assembly Note

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1. Install the overdrive apply strut.
2. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.

Item 56: Fluid Pump Support Thrust Washer No. 1 Assembly Note

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1. Install the special tool. Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions. Tighten the center screw.
2. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat measurement 180 degrees opposite side of the special tool and record as dimension B.
3. Add dimension A to B, divide by two and record as dimension C.
4. Subtract the thickness of the gauge bar 17.78 mm (0.71 in) from dimension C, and record as dimension D.
5. Select the No.1 thrust bearing from the following chart using dimension D.
6. Install the selected No. 1 fluid pump input thrust washer. Coat the fluid pump input thrust washer with petroleum jelly.

Item 57: Fluid Pump Gasket Assembly Note

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1. Install the special tools into the transmission case.
2. Install a new pump gasket.

Item 58: Fluid Pump Assembly Note

1. Install the fluid pump.
2. Using the special tool, align the fluid pump to the adapter plate.

Item 59: Fluid Pump Screw Assembly Note

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1. Install screws. Tighten the screws in a star pattern.
2. Remove the special tools and install the two remaining screws.

Item 60: Band Adjusting Locknut Assembly Note

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1. Install a new locknut on the band adjustment screw.
2. Using the special tool, tighten the overdrive band adjustment screw. Then, back off the screw exactly (2) turns and hold that position.
3. Tighten the overdrive band locknut. Hold the overdrive band adjustment screw stationary. Tighten the overdrive band locknut.

Item 61: Band Adjusting Locknut Assembly Note

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1. Install a new nut on the band adjustment screw.
2. Tighten the intermediate band adjustment screw. Then, back off the screw exactly (2) turns and hold that position.
3. Tighten the intermediate band locknut. Hold the intermediate band adjustment screw stationary. Tighten the intermediate band locknut.

Item 62: Center Support Bolt Assembly Note

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1. Tighten the center support bolt.

Items 63, 64, 65 and 66: Main Control and Screws Assembly Note

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1. Install the special tools into the transmission case.
2. Using the special tools, install the main control valve body and loosely install the screws. Install the short screw. Install the screw with the larger head. Install the remaining screws.
3. Remove the special tools, and loosely install the screw.
4. Tighten the screws in the sequence shown.

Items 67 and 68: Manual Valve Detent Spring and Screw Assembly Note

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1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.

Item 69: Solenoid Body O-Ring Seals Assembly Note

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1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Items 70, 71 and 72: Solenoid Body and Solenoid Body Screws Assembly Note

1. Install the solenoid body. Tighten screws in the sequence shown.

Item 74: Reverse Servo Screws Assembly Note

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1. Install the reverse servo. Tighten the screws in the sequence shown in two stages. Stage 1: Tighten screws to 5 Nm (44 lb-in). Stage 1: Tighten screws to 11 Nm (8 lb-ft).

Items 75 and 76: Transmission Fluid Filter and Screws Assembly Note

1. Lubricate the seals and install the transmission fluid filter.

Item 77: Transmission Fluid Pan Gasket Assembly Note

1. Install the transmission fluid pan gasket.

Item 78: Transmission Fluid Pan Assembly Note

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1. Install the transmission fluid pan and loosely install the screws.

Item 79: Transmission Fluid Pan Screws Assembly Note

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1. Tighten the 16 screws in a crisscross sequence.

Items 80, 81, 82, and 83: Park Pawl Assembly Note

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1. Install the parking pawl assembly and gasket. Install the parking pawl shaft. Install the parking pawl return spring. Install the parking pawl. Install a new gasket.

Item 86: Extension Housing Seal Assembly Note

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1. On 4x2 vehicles, use the special tool to install the extension housing seal.
2. On 4x4 vehicles, use the special tool to install the extension housing seal.

Items 87 and 88: Transmission Range (TR) Sensor and Screws Assembly Note

1. Install the digital TR sensor and loosely install the screws.
2. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Item 91: Fluid Pump Assembly Note

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1. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
2. Remove the special tool.

Item 92: Front Fluid Pump Seal Assembly Note

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1. Install a new seal onto the special tool.
2. Using the special tool, install a new converter hub seal.

Item 93: Input Shaft Assembly Note

1. Install the input shaft.

Item 94: Torque Converter Assembly Note

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1. Lubricate the converter hub with clean automatic transmission fluid.
2. Using the special tools, install the torque converter by pushing and rotating.
3. Lubricate the torque converter pilot hub with multipurpose grease.

Items 95 and 96: Flexplate Adapter Plate and Nuts Assembly Note

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1. In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission. If the vehicle is equipped, use the special tool to install the torque converter flexplate adapter assembly and eight nuts.
2. Install two torque converter flexplate adapter nuts.

Items 97 and 98: Speed Sensor and Screws Assembly Note

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1. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.
2. Install the speed sensors.
3. Before installing the transmission, make sure that the transmission cooling system (tube and cooler) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler and/or tubes. For additional information, refer to «TRANSMISSION FLUID COOLER».

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1. Secure the transmission to the transmission jack with a safety chain.
2. Install the components in the order indicated in the following illustration.
3. Install the components in the order indicated in the following illustration.
4. Install the components in the order indicated in the following illustration.
5. Connect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM».
6. Carry out the fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK».
7. Verify that the shift cable is correctly adjusted. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT».
8. Check the operation of the transmission and inspect for leaks.

Item 1: Transmission Assembly Installation Note

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1. Install the special tool.
2. Raise and position the transmission to the back of the engine. Remove the special tool prior to attaching the transmission to the engine.
3. On vehicles equipped with a 4.6L engine, install the seven engine-to-transmission retaining bolts.
4. On vehicles equipped with a 4.0L engine, position the fuel line bracket in place and install the six retaining bolts.
5. Install the front crossmember.

Item 3: Fuel Line Bracket Installation Note

1. Position the fuel line bracket in place prior to installing the remaining transmission retaining screws.

Item 9: Fluid Cooler Nuts Installation Note

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1. Install the transmission fluid cooler tubes.
2. Use the following guidelines for the in-line transmission fluid filter: If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. If installing a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

Item 12: Solenoid Body Harness Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Item 31: Rear Transmission Support Nuts Installation Note

1. Loosely install the rear transmission support nuts.

Item 35: Transmission Assembly Installation Note

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1. Remove the transmission jack.
2. If equipped, install the cable bracket and the two bolts.

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1. Secure the transmission to the transmission jack with a safety chain.
2. Install the components in the order indicated in the following illustration.
3. Install the components in the order indicated in the following illustration.
4. Install the components in the order indicated in the following illustration.
5. Install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM».
6. Connect the battery ground cable. For additional information, refer to «BATTERY & CHARGING SYSTEM».
7. Carry out the fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK».
8. Verify that the shift cable is correctly adjusted. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT».
9. Check the operation of the transmission and inspect for leaks.

Item 1: Transmission Assembly Installation Note

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1. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose.
2. Remove the special tool.
3. On vehicles equipped with a 4.6L engine, install the seven engine-to-transmission retaining bolts.
4. On vehicles equipped with a 4.0L engine, position the fuel line bracket in place and install the six retaining bolts.
5. Install the front crossmember.
6. Raise and position the transmission and transfer case to the back of the engine. Remove the special tool prior to attaching the transmission to the engine.

Item 3: Fuel Line Bracket Installation Note

1. Position the fuel line bracket in place prior to installing the remaining transmission retaining screws.

Item 9: Fluid Cooler Nuts Installation Note

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1. Install the transmission fluid cooler tubes.
2. Use the following guidelines for the in-line transmission fluid filter: If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. If installing a Ford authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

Item 12: Solenoid Body Harness Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Item 32: Rear Transmission Support Nuts Installation Note

1. Loosely install the rear transmission support nuts.

Item 36: Transmission Assembly Installation Note

1. Remove the transmission jack.

See also:
• SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE