DISASSEMBLY - ww2- · PDF file2/3/2012 · 307-01B-2 Automatic Transaxle/Transmission — 4F50N ... Damage to the bolts that hold the pump assembly and ... The position of the manual

307-01B-1 307-01B-1Automatic Transaxle/Transmission — 4F50N

DISASSEMBLYSpecial Tool(s)Transaxle

Collet 7/16’’ to 1/2‘‘303-D016 (D80L-100-M)Special Tool(s)

Slide Hammer100-001 (T50T-100-A)

Holding Fixture Transmission307-003 (T57L-500-B)

Remover, O-Ring Seal100-010 (T71P-19703-C)

Slide Hammer307-005 (T59L-100-B)

Step Plate205-D014 (D80L-630-3) Part of205-DS011 (D80L-630-A) orequivalent

Handle, Torque Converter307-091 (T81P-7902-C)

Remover, Crankshaft Front OilSeal303-107 (T74P-6700-A)

Lifting Fixture, Clutch Pack307-171 (T86P-70389-A)

Installer Front Cover Oil Seal303-335 (T88T-6701-A)

Remover/Installer, Servo Piston307-251 (T92P-70023-A)

Actuator Pin 3/16‘‘ Diameter303-D011 (D80L-100-G)

Remover, Torque ConverterFluid Seal307-309 (T94P-77001-BH)

(Continued)

(Continued)

Copyright 2002, Ford Motor CompanyLast updated: 1/24/2004 2003 Taurus/Sable, 8/2002


DISASSEMBLY (Continued)

Special Tool(s)

Remover, Lube Tube307-310 (T94P-77001-CH)

Remover/Installer, Front Clutch307-316 (T94P-77001-HH)

3. NOTE: During a case replacement theidentification tag will need to be replaced, usecaution not to damage the tag.Retaining Ring Pliers

307-343 (T95P-77001-AHR) Remove the identification tag.

1. CAUTION: The torque converter isheavy. Be careful not to drop it or damagewill result.

Using the special tools, remove the torqueconverter.

4. Remove the filler tube.

2. Using the special tool, install the transaxle intothe bench.

2003 Taurus/Sable, 8/2002



5. CAUTION: The overdrive band servospring cover is under spring tension. Caremust be taken when removing as componentsmay be ejected from the case.

Remove the overdrive servo piston and rod.

• Remove the bolts.

• Remove the cover.

• Remove the piston and rod.

8. Remove the digital TR sensor.

1 Remove the bolts.

2 Remove the digital TR sensor.

6. Remove the output shaft speed (OSS) sensorcover.

9. Remove the TSS sensor.

1 Remove the bolt.

2 Remove the sensor.

7. Remove the output shaft speed (OSS) sensor.

• Unclip the harness.

• Remove the output shaft speed (OSS)sensor.




10. NOTE: The differential seal is a two-piececonstructed seal.

Using the special tools, remove the LHdifferential seal.

13. Install the special tool into the RH differentialseal.

11. Using the special tools, remove the LHdifferential seal metal protector.

1 Rotate the special tool.

2 Rotate the forcing screw while holding thespecial tool.

3 Remove the metal protector from the LHdifferential seal and remove the protectorfrom the tool.

14. Using the special tools, remove the RHdifferential seal metal protector.

1 Rotate the special tool.


3 Remove the metal protector of the seal.

12. Using the special tools, remove the rubberportion of LH differential seal.

1 Install the special tool into the LHdifferential seal and rotate the special tool.


3 Remove the rubber portion of the seal.




15. Using the special tool, remove the rubber 19. NOTE: The main control cover gasket isportion of the seal. reusable if not torn or damaged.

1 Rotate the special tool. Remove the bolts, main control cover andgasket.2 Rotate the forcing screw while holding the

special tool.

3 Remove the rubber portion of the seal.

20. For vehicles equipped with a structural sidepan, remove the mount.

16. Using the special tools, remove the converterhub seal.

21. For vehicles equipped with a structural sidepan, remove the bolts, and remove the pan.

17. Remove the bolts.

18. Rotate the transaxle to a horizontal position.




22. CAUTION: Do not pull on the wires or 24. CAUTION: Do not remove the twopry on the connectors. Damage to the bolts that hold the pump assembly and mainconnector will result. control valve body together as the pump

assembly may fall from the main controlLift the locking tab and disconnect the electricalvalve body.connectors.

CAUTION: Only 4 of the 6 pumpcover bolts need to be removed.

Remove the bolts.

23. NOTE: The manual valve should be insertedcompletely.

Using a 9 mm wrench rotate the manual controllever to the low detent.




25. Remove the main control valve body. 28. NOTE: The transaxle pan gasket is reusable ifnot torn or damaged.• Remove the pump assembly and main

control valve body. Remove the bolts, transmission fluid pan andgasket.• Rotate the main control valve body while

lifting off.

29. Remove, clean and inspect the magnet.

26. Disconnect the manual control valve actuatingrod.

30. Remove the filter.

27. Remove the pump shaft.




31. NOTE: Use a 3/8 inch extension so as not todamage the case while removing the fluid filterseal.

Remove the fluid filter seal.

34. NOTE: The plastic thrust washers No.1 and 3may stick to the cover or to the sprockets.

Remove the chain cover and gasket.

32. Loosen the nut and remove the reverse clutchanchor pin.

33. CAUTION: The chain cover (7G188) isunder spring pressure. Care must be takento prevent internal parts from being ejected.

NOTE: Mark bolt size and location forassembly.

Remove the bolts.




35. Tag and mark the location of the accumulator 37. NOTE: The thrust washers may remain on thesprings. sprockets.

1 Remove the intermediate 1-2 accumulator Remove the thrust washers.outer spring. 1 Remove the No. 2 thrust washer.

2 Remove the direct 2-3 accumulator piston 2 Remove the No. 4 thrust washer.spring.

3 Remove the neutral reverse shiftaccumulator spring.

4 Remove the overdrive 3-4 accumulatorspring.

38. CAUTION: Use care not to damagethe machined surface of the case.

NOTE: The position of the manual valve detentlever is different than past models. The roll pinand shoulder point toward the driven sprocket

36. CAUTION: Be careful not to damage support. Note the position of the lever duringor bend the tabs on the exciter ring or the disassembly for correct assembly.TSS sensor will not operate. Remove the roll pins.Remove the drive sprocket, driven sprocket, anddrive chain as an assembly.




39. NOTE: The position of the manual valve detent 42. NOTE: During the complete disassembly of thelever is different than past models. The roll pin transaxle, the fluid transfer tubes must beand shoulder point toward the driven sprocket removed.support. Note the position of the lever during Remove the bolts and brackets.disassembly for correct assembly.

Remove the manual control lever shaft.

43. Using the special tools, remove the fluid lubetubes.

40. Remove the parking lever actuating rod.

44. Remove the bolts and the park pawl abutment.41. Remove the manual control lever shaft seal.




45. Remove the neutral/drive accumulator bolt.

48. NOTE: The No. 5 thrust washer may stick tothe drive sprocket support.

46. Remove the neutral/drive accumulator. Remove the drive sprocket support and the No.1 Remove the cover. 5 thrust washer.

2 Remove the springs.

3 Remove the piston and shaft.

49. NOTE: The No. 8 thrust washer and the No. 9thrust bearing may remain on the drive sprocketsupport and driven sprocket.

47. Using the special tool, remove the coast bandUsing the special tool, remove the No. 8 drivenservo.sprocket support selective fit rear thrust washer

1 Install the special tool. and the No. 9 needle bearing.2 Remove the snap ring.

3 Remove the cover, piston, and rod as anassembly.




50. Remove the plastic overdrive band retainer. 53. Using the special tool, remove the front clutchassembly.

51. Remove the overdrive band.54. Using the special tools, remove the reverse

clutch and planet assembly.

52. NOTE: Do not over-tighten the handle of thetool. Place two 3/8 inch washers between thehandle and the notched block. 55. Remove the low/intermediate drum, sun gear,

and one-way clutch assembly.Position the special tool into the case and installthe hook end of tool into one of the lube holesin the front sun shell. Position the block overthe edge of the assembly and tighten thehandle.




56. Remove the coast band. 59. WARNING: Use caution whenunloading the beveled retaining ring.Personal injury could occur.

CAUTION: Use care not to damagefinal drive support assembly, transaxle case,or retaining ring during removal.

Using the special tool, remove the beveledretaining ring and record the shape of the ringend.

57. CAUTION: Use care not to damageany machined surfaces.

Remove the low/intermediate clutch retainingring.

60. Remove the final drive differential and rearplanet support assembly.

58. Remove the low/intermediate clutch pack.

1 Remove the low/intermediate clutchpressure plate.

2 Remove the low/intermediate clutch plates.

3 Remove the low/intermediate clutch cushionspring.




61. NOTE: The differential carrier thrust washermay remain on the differential assembly.

Remove the differential carrier thrust washer.

1 Remove the No. 18 differential carrierthrust washer.

2 Remove the No. 19 differential carrierthrust bearing and race.

65. NOTE: Inspect the bearing, bushing and thesurface of the stator support. If any damage isindicated, install a new stator support.

Remove and inspect the stator support.

1 Remove the stator support.

2 Inspect the bearing for damage.

3 Inspect the surface for damage.

4 Inspect the bushing for damage.62. Remove the rear planet support spacer.

66. NOTE: The following procedures are done63. Remove the final drive ring gear.only if a case replacement is necessary.

Remove the park pawl shaft retaining pin.

64. Remove the stator support bolts.




67. Using the special tools remove the cup plug.

68. Remove the parking pawl.

1 Use a magnet to remove the parking pawlshaft.

2 Remove the parking pawl and return spring.


Documents

DISASSEMBLY - ww2- · PDF file2/3/2012 · 307-01B-2 Automatic Transaxle/Transmission — 4F50N ... Damage to the bolts that hold the pump assembly and ... The position of the manual