Ford repair manuals | Ford automatic transmission A4LD assembly

Ford automatic transmission A4LD assembly - is a part of Ford repair manuals: Manual and Atomatic Transmissions. This part contains the detailed description of assembly works and all necessary transmission diagrams for Ford Aerostar, Ranger and Explorer automatic transmission A4LD.
Before beginning assembly of the transmission, the following high clutch seal sizing procedure must be performed. Install new high clutch seals on the support hub. It is necessary to size these seals. The seal grooves have a "dovetail" contour with straight sidewalls on the pressure sealing sides. If this is not done, the seals can be cut or rolled over when entering the intermediate brake drum cavity. Apply a liberal amount of petroleum jelly to the center support hub and seals. Use overdrive brake drum as sizing tool. Carefully rotate the center support while inserting.Observe the seals as they enter the cavity to see that they do not roll over or get cut. Be sure the center support is seated fully into the overdrive drum. Allow to stand for several minutes so that the seals seat in the grooves. Set aside until required for reassembly later in this section. Place thrust washer No. 11 (7B368) into back of case.

Install collector body in rear of case. Install output shaft. If a new output shaft is being installed, 4.0L applications use an output shaft that does not have a lubricant hole. Install governor on collector body with two retaining bolts. Tighten to 9-13 N-m (80-115 lb-in). Place thrust washer No. 10 (7D422) into case from the front. Install low-reverse drum using Overrunning Clutch Replacement Guide Tool T74P-77193-A or equivalent.With 4.0L applications, use a sprag-type overrunning clutch and the replacement guide tool is not required. Install output shaft ring gear and snap ring onto output shaft. Always use a new snap ring for assembly. With 4.0L applications, install the output shaft sleeve (lubricant guide). Install thrust washer No. 9 (7A166), reverse planet assembly and thrust washer No. 8 (7A166). Use petroleum jelly to hold thrust washers in position on planet assembly. Install snap ring in drum to hold planet assembly in place. 4.0L applications do not have a snap ring at this location. Install low-reverse band. Replace servo piston or O-ring if necessary. Install low-reverse servo piston to hold band in position. Replace piston or O-ring if necessary. Install intermediate servo spring, piston, cover and snap ring. Make sure correct cover is installed, as identified by a tag during disassembly. Replace piston or O-ring if necessary. Install overdrive servo spring, piston, cover and snap ring. Make sure correct cover is installed, as identified by a tag during disassembly. Locate and identify intermediate servo apply lever and shaft. The intermediate servo apply lever is the lever that has a boss on the shaft hole and the shaft is shorter than the overdrive shaft. Install intermediate servo apply lever and shaft into case. Install the complete forward clutch and reverse and high clutch assemblies. Turn transmission so that the output shaft points downward. Install intermediate band and apply strut. Install the intermediate band anchor strut and input shaft (temporarily) as an alignment guide, then perform transmission rear end play check. The transmission rear end play check determines: the amount of space existing between the thrust washer surfaces of the overdrive center support and the intermediate brake drum; the thickness of the No. 4 thrust washer that is required to obtain an end play of 0.30-0.54mm (0.012-0.022 inch). To perform the end play check, fabricate a depth gauge fixture from a spare overdrive center support. A 3mm (1/8-inch) hole must be drilled through the thrust washer surface of the center support. This allows Depth Micrometer D80P-4201-A or equivalent access to the area between the thrust surfaces of the support and the intermediate brake drum. Remove the rubber seals from the spare center support to allow easy insertion into the intermediate brake drum.

Place Depth Micrometer D80P-4201-A or equivalent over drilled hole in the fabricated depth gauge fixture. Extend micrometer probe until it is flush with the thrust washer surface of the fixture. Record the micrometer reading. This is Reading A. Install the depth gauge and input shaft fixture into the intermediate brake drum and make sure it is fully seated in the transmission case. Gently wiggle input shaft to allow center support fixture to slide into intermediate brake drum using its own weight. The fixture axially locates the drum in its proper position. Place depth micrometer over the drilled hole in the fixture. Continue extending the micrometer probe until it contacts the thrust washer surface of the intermediate brake drum. This is Reading B. Subtract Reading A from Reading B. The difference between these readings is Dimension A. This is the space between the thrust surfaces. Remove and rotate the fixture 180 degrees. Average the two Dimension A readings to obtain the final Dimension A reading. Locate the final Dimension A reading in the following chart and select the proper thrust washer required to obtain the specified end play of 0.30-0.54mm (0.012-0.022 inch). If Dimension A is outside the specified limits, this indicates improper assembly, missing parts or parts out of specification. At this point, it becomes necessary to disassemble the transmission to locate the part(s) that has caused Dimension A to be out of specification. Remove micrometer and depth gauge fixture from transmission. Remove center support from overdrive drum where you placed it in Steps 1 through 4 to size seals. Coat correct selective washer No. 4 (7D014) with petroleum jelly to hold it in place. Position washer on center support. Insert the input shaft (short splines down) through the center support and into the splines in the forward clutch cylinder. Carefully place the center support into the case, but do not start it into the intermediate brake drum. Be sure it is square with the case and the 5mm Allen-head bolt retainer nut is oriented with the bolt hole in the case. Do not apply any pressure to the center support. Gently wiggle the input shaft allowing the center support to slide into the intermediate brake drum using its own weight. Perform this operation until the support is fully seated. Remove the input shaft. Position thrust washer No. 3 (7L326) on top of center support. Install large snap ring to retain center support in position with snap ring taper toward the front of the transmission. The ends of the snap ring should be positioned in the wide shallow cavity located in the five o'clock position. Two types of center support retaining snap rings are used. One is identified by holes located in the inner and outer diameter; the other type of snap ring has no holes. They should be positioned as shown. Install 5mm Allen-head bolt that retains center support to case. Install sun gear and overdrive clutch adapter into overdrive planet assembly and one-way clutch. The part number on the adapter should face the sun gear. Take care to center needle bearing race inside of planetary. Be sure it stays centered, and positioned with the extruded lip in the upward position (toward sun gear). Assemble the overdrive planet and one-way clutch assembly. The one-way clutch assembly must be installed into the centershaft in such a way that the flanges of the inner and outer cages are toward the overdrive planet assembly which is toward the front of the transmission. The overdrive clutch washer that is positioned between the overdrive planet carrier and centershaft must be installed in such a way that the recessed inside diameter faces forward (not against sprag clutch). To perform the proper assembly buildup check, hold the planet assembly; then the centershaft should turn clockwise. Install overdrive planet assembly and one-way clutch into case. Install overdrive drum assembly. Install overdrive bracket, apply lever, and shaft. Install overdrive band and apply strut.

Make sure correct band is installed as identified by a tag during disassembly. Install anchor strut. Verify that needle bearing race in overdrive planetary is centered and overdrive clutch is fully seated. Place selective washer No. 1 (7D014) on top of overdrive clutch drum and temporarily install pump assembly into case. Be sure that it is fully seated in the case. The pump body must be below the level of the case gasket in the case. Mount Dial Indicator D78P-4201-G or equivalent on the pump with plunger resting on the transmission housing. Set dial indicator to zero. Swing indicator around so plunger contacts the pump. Check dial reading. This reading is the amount of end play. Note reading for later use. Move dial indicator block to opposite side of the pump (180 degrees). Repeat Steps 56 and 57. Find average of two readings. This average reading of end play should be from 0.18mm to 0.64mm (0.007 to 0.025 inch). If reading exceeds the limits, change No. 1 selective washer. Install a new hydraulic pump oil seal using Front Pump Alignment Set T74P-77103-X and Front Pump Seal Replacer T87L-77248-AH or equivalent. Stake the seal in place with tool T87L-77248-BH in two places between the existing stakes. Properly position separator plate on converter housing. Properly position two pump gears into pump housing. The inside edge of the small gear has a chamfer on one side. This chamfer must be positioned toward the front of the transmission. The larger gear has a dimple on one side which must be positioned toward the rear of the transmission. Position pump assembly onto separator plate and converter housing. Install bolts finger-tight. Note that the pump assembly stator-end face has a depression. This is completely interchangeable with flat stator-end face. Align pump in converter housing using Front Pump Alignment Set T74P-77103-X or equivalent. This tool must be used in order to prevent seal leakage, gear noise, pump breakage or bushing failure. To use tool, select the arbor with the smallest inside diameter that will fit completely over the pump shaft. Assemble the common handle to the selected arbor and slide the tool down over the shaft until it bottoms against the pump. The outside diameter of the tool arbor will then automatically center the pump in the converter housing. With alignment tool installed, tighten five new 6mm hex Allen-head pump bolts (E804375-S72M) to 22-28 N-m (16-21 ft-lb). Remove alignment tool. Insert the input shaft into the pump and install the converter into the pump gears. Rotate the converter to check for free movement, then remove the converter and input shaft. Coat converter housing gasket with petroleum jelly and position on housing. Install seal on converter housing. Using petroleum jelly, position No. 1 selective washer on rear of pump. Align converter housing and pump to the transmission. Install eight 17mm bolts, with new O-rings, and tighten to 36-52 N-m (27-39 ft-lb). Adjust overdrive band: install new locknut on adjusting screw, but do not tighten; using Band Adjusting Torque Wrench T71P-77370-A or equivalent tighten adjusting screw until wrench clicks. This is 14 N-m (10 ft-lb); back off adjusting screw exactly two turns; hold adjusting screw from turning and tighten locknut to 41-61 N-m (35-45 ft-lb). Following the previous method, adjust the intermediate band backing off the adjusting screw two turns before tightening the locknut. Install shift lever oil seal using Shift Lever Seal Replacer T74P-77498-A or equivalent. Install internal shift linkage, including external manual control lever, and centering pin. Tighten 7/8-inch nut to 41-54 N-m (30-40 ft-lb). Install O-ring, kickdown lever and 13mm nut. Tighten to 10-11 N-m (7-15 ft-lb). Install neutral start switch using Neutral Start Switch Socket T74P-77247-A "Thin Wall" socket or equivalent. Tighten to 10-14 N-m (89-123 in-lb). Install converter clutch solenoid connector. Install throttle valve, rod, vacuum diaphragm, retaining clamp and bolt. Be sure the throttle valve moves freely in its bore. Use a pencil magnet to check movement if throttle valve is steel. If throttle valve is aluminum, use the end of a rubber object to check movement. Align valve body to separator plate and gasket using tapered punches. Install two 10mm bolts. Tighten to 6.0-8.0 N-m (53-71 in-lb). Apply a small amount of petroleum jelly in four or five places to separator plate-to-transmission case gasket to hold in place. Position gasket on assembled separator plate and valve body. Remove transmission from holding fixture and place on bench bottom up. Attach and lock the selector lever connecting rod (Z-Link) to the manual valve. Ease control body into the case. Position 3-4 shift solenoid retainer and insert all remaining bolts (correct length) except the filter screen bolt. Tighten to specification. Remove bolt from hole A and install the detent spring to bolt. Assemble and tighten A and B locations to specification. Install converter clutch solenoid wires. For body bolt locations and sizes, refer to the following illustration. Follow tightening sequence from center of valve body to outer edges. Install the reverse servo piston assembly into servo bore along with a reverse servo check spring D4ZZ-70031-A. Install a new servo cover gasket and tool T74P-77190-A or equivalent and tighten with three attaching bolts. Tighten servo tool adjusting screw to 4 N-m (35 in-lb). Install Dial Indicator with Bracketry TOOL-4201-C on transmission case and position indicator on piston pad. Set dial indicator to zero. Back out the servo tool adjusting screw until piston bottoms out on the tool. Record the distance the servo piston traveled. If piston travel is between 3 and 5.6mm (.120 and .220 inch), it is within specification. If piston travel is greater than 5.6mm (.220 inch), use the next longer piston and rod. If piston travel is less than 3mm (.120 inch), use the next shorter piston and rod. Using the above procedure, check the piston travel with the new selected piston and rod (if required) to make sure that the piston travel is between 3 and 5.6mm (.120 to .220 inch). Remove the servo adjusting tool and the reverse servo piston checking spring. Install the servo piston assembly, accumulator spring, gasket and cover. Install four 10mm servo retaining bolts and tighten to 10-13 N-m (7-10 ft-lb). Install new O-rings on the screen and lubricate with petroleum jelly. Install filter screen and one 10mm bolt. Tighten to 8-11 N-m (71-97 in-lb). Remove any trace of old gasket on case and oil pan. Position oil pan gasket on case and install oil pan. Install eighteen 13mm oil pan retaining bolts. Tighten to 11-13 N-m (97-115 in-lb). Remove any trace of old gasket on end of case and extension housing. Install parking pawl and its return spring in the extension housing and preload. Using a new gasket, install the extension housing. Be sure to correctly seat the operating parking rod in the extension guide cup. Install six extension housing retaining fasteners. Tighten to 36-52 N-m (27-39 ft-lb). Remove extension housing seal using Extension Housing Seal Remover T71P-7657-A or equivalent. Remove extension housing bushing using Extension Housing Bushing Remover T77L-7697-E or equivalent. Install extension housing bushing using Extension Housing Bushing Replacer T77L-7697-F or equivalent. Install extension housing seal using Extension Housing Seal Replacer T74P-77052-A or equivalent.

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