Ford - 4R100 - Workshop Manual - 2003 - 2003

FORD 4R100 INDEX IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................... 3 GENERAL DESCRIPTION AND OPERATION ..................................................................................... 4 COMPONENT AND SOLENOID APPLICATION CHART ................................................................... 5 "PTO" GENERAL REQUIREMENTS .................................................................................................... 6 ELECTRICAL COMPONENT DIAGNOSIS ........................................................................................... 8 FLUID REQUIREMENTS ....................................................................................................................... 12 SOLENOID PACK TESTING .................................................................................................................. 12 ABBREVIATION DESCRIPTION .......................................................................................................... 14 DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION ........................................................ 15 LINE PRESSURE TEST .......................................................................................................................... 21 NON-PTO AND PTO HYDRAULIC DIFFERENCES ........................................................................... 22 PWM AND NON-PWM OIL PUMP DIFFERENCES ........................................................................... 34 CASE CHECKBALL LOCATIONS ......................................................................................................... 38 VALVE BODY CHECKBALL LOCATIONS ........................................................................................... 39 AIR PRESSURE CHECKS ...................................................................................................................... 40 TRANSMISSION DISASSEMBLY ......................................................................................................... 41 COMPONENT REBUILD SECTION TRANSMISSION CASE ASSEMBLY ................................................................................................ 55 FRONT AND REAR PLANETARY CARRIERS ............................................................................... 64 FORWARD CLUTCH HOUSING ...................................................................................................... 66 DIRECT CLUTCH HOUSING ........................................................................................................... 69 FORWARD, DIRECT, SUN SHELL SUB-ASSEMBLY .................................................................... 76 CENTER SUPPORT ASSEMBLY ...................................................................................................... 80 INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY ............................................................. 82 OVERDRIVE GEARSET ASSEMBLY ............................................................................................... 84 COAST CLUTCH HOUSING DIFFERENCES ................................................................................ 88 COAST CLUTCH HOUSING ASSEMBLY ........................................................................................ 90 OIL PUMP ASSEMBLY ...................................................................................................................... 94 VALVE BODY ASSEMBLY ............................................................................................................... 100 TRANSMISSION FINAL ASSEMBLY ................................................................................................. 102 MANUAL VALVE CHECK .................................................................................................................... 111 MANUAL SHIFT LEVER DIFFERENCES ........................................................................................ 112 TORQUE SPECIFICATIONS ............................................................................................................... 115 VALVE BODY BOLT CHART AND IDENTIFICATION .................................................................... 116 BOLT CHART AND IDENTIFICATION ............................................................................................. 117 SPECIAL SERVICE TOOLS ................................................................................................................. 118 AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 Copyright © ATSG 2003 INTRODUCTION FORD 4R100 Updated October, 2003 The Ford 4R100 transmission is an updated version of the E4OD and was first introduced in the 1999 model year, and is currently found in the F250, F350, F450 and F550 Super Duty trucks, E150, E250, E350, E450 vans and the Expedition/Navigator/Excursion vehicles equipped with the 5.4L, 6.8L, and 7.3L engines. Some of the 4R100 units are equipped with a Power-Take-Off (PTO) window on the left hand side of the transmission case. The revisions in the 4R100 have created many new engineering changes that have affected many of the internal and external parts that will affect the servicing, repairing and overhaul of these units. We wish to thank Ford Motor Company for the information and illustrations that have made this booklet possible. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 2003 DALE ENGLAND JIM DIAL FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT WAYNE COLONNA ED KRUSE TECHNICAL SUPERVISOR TECHNICAL CONSULTANT PETER LUBAN GREGORY LIPNICK TECHNICAL CONSULTANT TECHNICAL CONSULTANT JON GLATSTEIN DAVID CHALKER TECHNICAL CONSULTANT TECHNICAL CONSULTANT ROLAND ALVAREZ JERRY GOTT TECHNICAL CONSULTANT TECHNICAL CONSULTANT GERALD CAMPBELL TECHNICAL CONSULTANT MIKE SOUZA TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 1 Technical Service Information TRANSMISSION IDENTIFICATION WITH POWER TAKE OFF OPTION Note: PTO is available as an option on 8500 GVW or above, Super Duty F-Series trucks with 6.8L gasoline and 7.3L Diesel engines. Ford 4R100 transmissions on other models are not PTO capable. Ford RF XW4P-AC RJL-B 006F81P-7 004361 17 BD-9C BA 98 d For Year Month Day 9 C 17 BD- 6520 1 2 3 4 004361 1 2 3 4 Build Date 9=1999 0=2000 1=2001 2=2002 3=2003 4X4 5G XW4P-AC RJL-B 004361 BD-9C17 A=Jan B=Feb C=Mar D=Apr E=May F=Jun G=Jul H=Aug J=Sep K=Oct L=Nov M=Dec Assembly Part Number, Prefix And Suffix Transmission Model Serial Number Build Date (Year, Month, Day) Copyright © 2003 ATSG Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 3 Technical Service Information TRANSMISSION DESCRIPTION AND OPERATION General Description The Ford 4R100 automatic transmission is a four forward speed unit with electronic shift control. It is designed for longitudinal powertrains for rear wheel drive vehicles. The 4R100 transmission features a four element torque converter design that includes Torque Converter Clutch (TCC) and a gear train that includes three planetary gearsets. Some models provide for Power Take Off (PTO) operation in all transmission shift lever positions. During PTO operation in OD, 4th gear is disabled. The hydraulic control system of the 4R100 unit has five electronically controlled solenoids for: Shift feel, through line pressure control. Shift scheduling, through shift valve position. Engine braking during coast conditions. TCC apply (On/Off or Modulating). Major Internal Components "Seven Friction Apply Elements" Intermediate Band Coast Clutch, Multi-disc Overdrive Clutch, Multi-disc Intermediate Clutch, Multi-disc Direct Clutch, Multi-disc Forward Clutch, Multi-disc Low/Reverse Clutch, Multi-disc Shift Quadrant Indicator Vehicles equipped with the 4R100 transmission have a Transmission Control Switch (TCS), also referred to as "Overdrive Cancel Switch", and a Transmission Control Indicator Lamp (TCIL), located on the end of the manual gear shift lever, as shown in Figure 3. The TCS is a momentary contact switch. When this switch is pressed, a signal is sent to the PCM to allow automatic shifts from 1st to 4th gear or from 1st to 3rd gear. After the TCS has been pressed the PCM turns on the TCIL lamp ("OFF"), to indicate that overdrive has been canceled, as shown in Figure 3. The shift quadrant has the following positions, as shown in Figure 2: P, R, N, D , 2 and 1. D position (TCS OFF) provides 1-2-3-4 automatic upshifts and downshifts. Coast braking occurs in 4th gear. (TCIL Not Illuminated) D position (TCS ON) provides 1-2-3 automatic upshifts and downshifts. Coast braking occurs in 3rd gear. (TCIL Illuminated) 2 position provides a pull-in shift to 3rd gear with coast braking. After an automatic downshift, a 2nd gear hold occurs with coast braking. 1 position provides a pull-in shift to 2nd gear with coast braking. After an automatic downshift, a 1st gear hold occurs with coast braking. "Three One-Way Clutches" Overdrive Roller Clutch Intermediate Sprag Low Roller Clutch "Three Simple Planetary Gearsets" Overdrive Forward Reverse "Typical" Shift Quadrant Indicator TCS SWITCH P R N D 2 1 OVERDRIVE OFF TCIL LAMP Copyright © 2003 ATSG Figure 2 4 Figure 3 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD MOTOR COMPANY 4R100 ("PTO" Version Illustrated) Intermediate Clutch Overdrive Clutch Coast Clutch Low/Reverse Clutch Direct Forward Clutch Clutch GEAR RATIOS Reverse - 2.18 1st Gear - 2.71 2nd Gear - 1.54 3rd Gear - 1.00 4th Gear - 0.71 Low Roller Clutch Overdrive Roller Clutch Intermediate Band Intermediate Sprag COMPONENT AND SOLENOID APPLICATION CHART GEAR Park/Neut Reverse OD-1st OD-2nd OD-3rd OD-4th OD-3rd** M-2nd M-1st Fwd Int Dir O.D. Cst Int Clut Clut Clut Clut Clut Band ON ON L/R Clut ON ON Hold Hold ON ON ON ON ON ON ON ON ON ON ON ON ON ON SOLENOIDS O.D. Int Low Roller Sprag Roller SS1 SS2 CCS TCC EPC Hold Hold Hold Hold ON ON ON ON Hold ON Hold ON Hold Hold Hold On Off Off Off Mod On Off Off Off Mod On Off *Off *On Mod On On *Off *On Mod Off On *Off *On Mod Off Off Off *On Mod Off On On *On Mod On On On *On Mod On Off On Off Mod OD-3rd** = TCS "On" with TCIL illuminated showing "Off" *On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may be On (Modulating with PWM TCC units) in any forward gear except Manual 1st. *Off = Will be "On", if the TCS switch is pushed. Mod = Modulating at all times by the PCM and line pressure will be regulated based on throttle position, engine load and vehicle speed. Copyright © 2003 ATSG Figure 4 AUTOMATIC TRANSMISSION SERVICE GROUP 5 Technical Service Information (5) Shift Solenoid 2 and the Coast Clutch Solenoid must be energized when the PTO is turned ON. "GENERAL" CONDITIONS FOR OPERATION (1) The vehicle is not in the crank or start mode. (2) The transmission range selector must be in the P, R, O.D, 2 or 1 position. The PTO will not operate when selector is in the neutral position. (3) PTO operation is inhibited when in cranking mode, neutral, or 4th gear. (4) Transmission only operates 1st through 3rd gears. Computer strategy does not allow 4th gear to engage, under any conditions. (5) Transmission Fluid Temperature Sensor (TFT) reading must be up to operating temperature. GASOLINE ENGINE PTO OPERATION: (1) PTO installer must obtain a "High Idle Throttle Control" from an aftermarket source. (2) Auxiliary Powertrain Control Module seen on Page seven, does not work on the gasoline engine models. APCM module works only on the 7.3L diesel engine. (3) For stationary PTO operation an engine idle speed of 1300 RPM is required. (4) The Torque Converter Clutch (TCC) engages once the engine reaches 1300 RPM. 6 PTO Window Ford RFF81 XW4P-AC RJL-B 004361 17 BD-9C A P-7006-B 98 Ford PTO "GENERAL" REQUIREMENTS: (1) Obviously the case must be PTO capable with the cast-in window in the transmission where the PTO unit mounts to the transmission, as shown in Figure 5. (2) Designed for use during Mobile (Some Models) or Stationary conditions. (3) PTO is available as an option only on 8500 GVW or above, Super Duty F-Series trucks with 6.8L Gasoline and 7.3L Diesel engines. Ford 4R100 transmissions on other models are not PTO capable. (4) Battery voltage must be supplied to the Powertrain Control Module (PCM) input pin 4 on gasoline models, or pin 66 on diesel models, when the PTO is engaged. The processor uses this information to raise EPC pressure to approximately 55 PSI so that you do not burn the coast clutch. This voltage must be provided by the PTO installer. Copyright © 2003 ATSG Figure 5 TRANSMISSION FUNCTIONS DURING PTO OPERATION: (1) Shift Solenoid 2 and Coast Clutch Solenoids are turned on, the coast clutch activates and does not allow 4th gear operation during PTO operation. (2) Electronic Pressure Control (EPC) pressure is raised to approximately 55 PSI. This is why the coast clutch will be smoked in a short period of time if a battery voltage wire is not supplied to EEC input pin 4 (gasoline) or pin 66 (diesel) when the PTO is engaged, as this rise in pressure would not occur. (3) The Transmission Control Indicator Lamp (TCIL) illuminates. (4) When the PTO is turned ON, the transmission operates only in 1st through 3rd gears. Overdrive 4th gear is not allowed by the PCM strategy. (5) The transmission shift schedule is early and shift feel is very firm. (6) PTO operation can cause transmission fluid temperature to exceed the recommended maximum limit of 250 degrees F. Failure mode logic within PCM strategy prevents transmission damage by disabling the PTO above this temperature limit. Specific Operation For Diesel, See Page 7. AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information DIESEL ENGINE PTO OPERATION: "AUXILIARY" POWERTRAIN CONTROL MODULE 7.3L DIESEL ENGINE (ONLY) The Auxiliary Powertrain Control Module (APCM) commands the Electronic Engine Control (EEC) module to increase the idle speed during PTO operation. The APCM controls engine speed from 1300 to 2500 RPM. The Auxiliary Powertrain Control Module is a seperate option, it does not come standard with a PTO capable transmission, and is for 7.3L diesel applications only. Intended for stationary use only, and in stationary operation the PTO requires an engine idle speed of 1300 RPM. During stationary PTO operation on the 7.3L diesel, the EEC increases the idle to 1300 RPM automatically. During stationary PTO operation, the Torque Converter Clutch (TCC) engages once the RPM reaches 1200-1300 RPM. The following conditions must be met before the idle speed is increased: 1. 2. 3. 4. 5. Parking brake must be engaged for all applications. No hydraulic brake actuation. Accelerator pedal must be in the idle position. Vehicle speed must be zero MPH. Brake lights must be functional. Ford AUXILIARY POWERTRAIN CONTROL MODULE CHARGE PROTECTION APPLICATION Charge Protection is used for maintaining battery charge. In Charge Protection mode, the battery voltage is monitored and the engine idle speed is increased as necessary, so the battery charge is maintained as required. Charge Protection can be activated from in-cab and can be programmed to activate automatically on engine start-up. Exclusively for light trucks with the 7.3L Diesel Engine. Intended for Stationary Use Only. Order Guide Option Code 961. KITS INCLUDE RPM CONTROL RPM Control is used for RPM Control mode can be activated from in-cab and can be programmed to activate automatically on engine start-up. The programmable speed presets range from 1300 to RPM CONTROL CHARGE PROTECT POWER Ford 2500 Aux. Powertrain Control Module. Mounting Hardware and Bracket. Wiring Harness. Instruction Booklet. Operators Card. LCD screen displays the current engine speed or battery voltage. Each Single Arrow key contains a preset speed allowing for four programmable RPM settings. The Double Arrow keys can also be used to manually raise or lower the engine speed at a faster or slower rate. This is the recommended method of elevating idle speed for PTO operations. Copyright © 2003 ATSG Figure 6 AUTOMATIC TRANSMISSION SERVICE GROUP 7 Technical Service Information DIAGNOSTIC CONCERNS WITH PTO EQUIPPED VEHICLES: (1) Always ensure that PTO is turned OFF, before any diagnostic procedures begin. (2) Never perform any transmission special tests (i.e. pressure test, stall test etc.) when the PTO is turned ON. (3) If a transmission concern or symptom goes away with the PTO turned OFF, it is most likely not a transmission concern. (4) On Board Diagnostics operate normally during PTO operation with the exception of the engine misfire monitor. The circuit checks made by the PCM and Failure Mode Effect Management (FMEM) capability will continue. The PTO must be turned OFF to access Diagnostic Trouble Codes (DTC's) and perform OBD tests. CENTRAL JUNCTION BOX FUSE 19 Caution: If the batteries are disconnected for any reason, the PCM "must" have a 7 mile drive cycle at speeds above 50 MPH, before it remembers that it is capable of running a PTO Red/Yellow ELECTRICAL COMPONENT DIAGNOSIS Accelerator Pedal Position Sensor (Diesel Only) The Accelerator Pedal (AP) position sensor is mounted on the accelerator pedal inside the vehicle and detects the position of the accelerator pedal and sends this information as a varying voltage signal to the PCM. The PCM then uses the monitored voltage level of the AP sensor for control of EPC pressure and shift scheduling. The Idle Validation Switch is fed voltage through fuse number 19, as well as the Transmission Control Switch, as shown in Figure 7. If the Idle Validation Switch feed voltage is lost for any reason, the engine will immediately return to idle and stay there until feed voltage is restored. 4X4 Low Switch The 4X4 Low Switch is used to the PCM that the transfer case system is operating in LOW range. The PCM receives the 4X4 Low Switch input signal and modifies shift scheduling for the lower gear ratio (See Figure 8). If the 4X4 LOW indicator fuse is blown, the transmission will shift according to the 4X4 LOW shift schedule, regardless of transfer case lever position. Transmission Control Switch (TCS) Clutch Pedal Position (CPP) (Std Trans Only) Idle Validation Switch (IVS) (Diesel Only) Overhead Trip Computer Module Generic Electronic Module (GEM) Instrument Cluster Terminal A12 Instrument Cluster Terminal B11 Copyright © 2003 ATSG Figure 7 PCM PIN 14 Lt. Blue/Black Figure 8 8 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Turbine Shaft Speed Sensor The Turbine Shaft Speed (TSS) sensor is a magnetic pickup that sends the PCM a frequency signal related to the rotating speed of the transmission input shaft. The TSS mounts on the top front of the case on some models, as shown in Figure 9. We have also provided you with the resistance readings and OEM part numbers on both Turbine Speed Sensors, as the PTO and Non-PTO models use different sensors, as shown in Figure 9. The PCM uses the TSS sensor signal to control EPC pressure and TCC strategy. Turbine Shaft Speed Sensor Output Shaft Speed Sensor The Output Shaft Speed (OSS) sensor is a magnetic pickup that sends the PCM a frequency signal related to the rotating speed of the transmission output shaft. The OSS sensor was added to the top of extension housing, as shown in Figure 10. The OSS is triggered by an added rotor pressed onto the output shaft. The park gear is also now pressed onto the output shaft, and the number 13 thrust washer has changed to a thrust bearing, as shown in Figure 11. We have provided you with the resistance reading and the OEM part number for the output shaft speed sensor. Refer to Figure 10 for output shaft speed sensor information. The PCM uses the OSS sensor signal to control EPC pressure, shift scheduling and TCC strategy. PTO Models Only = 496-1244 Ohms Resistance Part Number F81Z-7M101-BA Non PTO Models Only = 781-1979 Ohms Resistance Part Number F81Z-7M101-AA The Park Gear is also a press fit to the output shaft, and the number 13 thrust washer, between the case and the park gear has been replaced with a needle bearing. Copyright © 2003 ATSG Figure 9 Output Shaft Speed Sensor All Models = 781-1979 Ohms Resistance Part Number F81Z-7M101-AA OSS Rotor Park Gear (Press Fit) (Press Fit) Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 10 Figure 11 AUTOMATIC TRANSMISSION SERVICE GROUP 9 Technical Service Information ELECTRICAL COMPONENT DIAGNOSIS Digital Transmission Range Sensor The Digital Transmission Range (DTR) sensor has a twelve pin electrical connector and is located on the outside of the transmission at the manual lever, as shown in Figure 12. The DTR sensor completes the start circuit in Park and Neutral, the backup lamp circuit in Reverse, and the neutral sense circuit (4WD Only) when in Neutral. The DTR sensor also opens or closes a set of four different switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Refer to Figure 13. DTR TESTING PROCEDURE In Figure 13 we have provided you with pin number identification for both the transmission range sensor and the vehicle harness. We have also provided a chart that will give you the open/closed state of each internal switch, dependent on selector position, and notice that three positions read a 270W resistor, that is also internal. Note: All testing that we have provided for you is done with a DVOM, set to the ohms position, and all tests are performed with the ignition switch in the "OFF" position. (1) Testing the transmission range 3A switch, and the 270W internal resistor is done across pins 2 and 3 of the DTR sensor, and must be checked in each selector position to determine the switch and resistor integrity. Refer to Figure 13. (2) Testing the transmission range 1 switch is done across pins 2 and 4 of the DTR sensor, and must be checked in each selector position to determine switch integrity. Refer to Figure 13. (3) Testing the transmission range 2 switch is done across pins 2 and 5 of the DTR sensor, and must be checked in each selector position to determine switch integrity. Refer to Figure 13. Ford XW4P-AC RJL-B 004361 BD-9C17 7006-BA RFF81P98 (4) Testing the transmission range 4 switch is done across pins 2 and 6 of the DTR sensor, and must be checked in each selector position to determine switch integrity. Refer to Figure 13. (5) Testing the reverse lamp circuit is done across pins 9 and 11 of the DTR sensor, and must be checked in each selector position to determine switch integrity. Refer to Figure 13. Ford (6) Testing the neutral start circuit is done across pins 10 and 12 of the DTR sensor, and must be checked in each selector position to determine switch integrity. Refer to Figure 13. L L TRA NEU d For 93-A A F7TP-7F2 C Copyright © 2003 ATSG Figure 12 10 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 6 12 5 11 4 10 6 3 9 2 8 1 7 Function Not Used Signal Return (Ground) TR3A (5 Volts from PCM) TR1 (10-12 Volts from PCM) TR2 (10-12 Volts from PCM) TR4 (10-12 Volts from PCM) P TERMINALS 1 12 11 10 9 8 7 R Pin No. 7 8 9 10 11 12 Function Ground Neutral Battery Voltage Feed Fuse 21, Hot In Start Back-up Lamps Starter Relay N D 2 270 W OPEN OPEN OPEN 9 AND 11 10 AND 12 OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN OPEN 11 1 2 12 10 1 P R 2 N D 4 5 1 P R 2 N D 1 R 2 N CLOSED CLOSED OPEN OPEN CLOSED OPEN OPEN CLOSED OPEN OPEN 2 P D 1 OPEN OPEN 6 3 1 P R 2 N D 1 P R 2 N D 270 W D 2 CLOSED 270 W 270 W CLOSED CLOSED CLOSED CLOSED CLOSED OPEN CLOSED OPEN CLOSED P N 3 2 AND 3 2 AND 4 2 AND 5 2 AND 6 9 R 4 View looking into DTR Sensor harness connector-terminal side View looking into DTR Sensor Pin No. 1 2 3 4 5 6 5 DIGITAL TRANSMISSION RANGE SENSOR Copyright © 2003 ATSG Figure 13 AUTOMATIC TRANSMISSION SERVICE GROUP 11 Technical Service Information ELECTRICAL COMPONENT DIAGNOSIS Solenoid Assembly The Solenoid Assembly is bolted to the case and located inside the bottom pan. The Solenoid Assembly contains shift solenoid 1, shift solenoid 2, coast clutch solenoid, TCC solenoid, EPC solenoid and the TFT sensor. The solenoids are not serviced individually. You must replace the entire assembly, as shown in Figure 14. Some of these units are equipped with an ON/OFF TCC solenoid and some are equipped with a PWM TCC solenoid, so it is important to determine which you have. SOLENOID PACK ASSEMBLY SOLENOID PACK TESTING PROCEDURE In Figure 16 we have provided you with pin number identification for both the transmission case connector and the vehicle harness. We have also provided a chart that will give you the function of each and the ohms readings you should see on each of the solenoids and the TFT sensor. Note: All testing that we have provided for you is done with a DVOM, set to the ohms position, and all tests are performed with the ignition switch in the "OFF" position. (1) Shift Solenoid 1 is tested across pins 1 and 3, and should read 20-30 ohms resistance. Refer to Figure 16. (2) Shift Solenoid 2 is tested across pins 1 and 2, and should read 20-30 ohms resistance. Refer to Figure 16. (3) TCC On/Off Solenoid is tested across pins 1 and 4, and should read 20-30 ohms resistance. Refer to Figure 16. (4) TCC PWM Solenoid is tested across pins 1 and 4, and should read 10-20 ohms resistance. Refer to Figure 16. (5) Coast Clutch Solenoid is tested across pins 1 and 5, and should read 20-30 ohms resistance. Refer to Figure 16. (6) EPC Solenoid is tested across pins 11 and 12, and should read 3.0-5.0 ohms resistance. Refer to Figure 16. Copyright © 2003 ATSG (7) TFT sensor is tested across pins 7 and 8. Refer to the chart provided in Figure 15. Figure 14 Transmission Fluid Temperature °C °F Resistance -40 to -20 -40 to -4 1062k - 284k W -19 to -1 -3 to 31 284k - 100k W 0 - 20 21-40 41-70 32-68 69-104 105-158 159-194 100k - 37k W 37k - 16k W 16k - 5k W 195-230 231-266 2.7k - 1.5k W 1.5k - 0.8k W 267-302 0.8k - 0.54k W 71-90 91-110 111-130 131-150 5k - 2.7k W 4R100 FLUID REQUIREMENTS Only Motorcraft Mercon® multi-purpose automatic transmission fluid XT-2-QDX or an equivalent Mercon® fluid should be used in all Ford 4R100 transmissions. Before adding any fluid, ensure that it is the correct type. Checking Fluid Always use the transmission fluid level indicator (Dipstick) to set the correct fluid level. Set the fluid level at normal operating temperature which is 150° to 170°F, engine at idle in Park. Figure 15 12 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information SOLENOID BODY PIN IDENTIFICATION AND FUNCTION VEHICLE HARNESS SOLENOID BODY CONNECTOR CONNECTOR 7 8 12 11 12 6 5 4 3 2 1 7 1 Solenoid Resistance Chart Solenoid Body Solenoid Pin Numbers Shift Solenoid "B" (2) Shift Solenoid "A" (1) TCC Solenoid, (On-Off) TCC Solenoid, (PWM) Coast Clutch Solenoid Electronic Pressure Control Solenoid Transmission Fluid Temp Sensor 1 and 2 1 and 3 1 and 4 1 and 4 1 and 5 11 and 12 7 and 8 6 Resistance 20-30 Ohms 20-30 Ohms 20-30 Ohms 10-20 Ohms 20-30 Ohms 3.0-5.0 Ohms See Chart Below Solenoid Connector Pin Identification and Function Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Vehicle Power In For Solenoids (VPWR) Shift Solenoid "B" (2) Ground from PCM Shift Solenoid "A" (1) Ground from PCM Converter Clutch Solenoid Ground from PCM Coast Clutch Solenoid Ground from PCM Not Used Transmission Fluid Temp Sensor Transmission Fluid Temp Sensor (Signal Return) Not Used Not Used Electronic Pressure Control (EPC) Vehicle Power In For EPC Solenoid (VPWR) Figure 16 PCM Connector Pin Gas & Diesel (Cal) Diesel (49 State) 71, 97 71, 97 11 1 6 27 54 28 20 53 37 91 37 91 81 71, 97 81 71, 97 AUTOMATIC TRANSMISSION SERVICE GROUP 13 Technical Service Information FORD 4R100 Abbreviation Description Abbreviation 4X4L ABS A/C ACCS AP APGND ARPMDES BARO BOO BPA BPP BUS + BUS CASE GND CCS CID CMP CPP CRUISE DLC DTC DTC CNT DTR EBP ECT EOT EPC EPR FEPS FUEL PW GP GPC GPL IAT 14 Description 4X4 Low Switch Antilock Brake System Air Conditioning Air Conditioning Clutch Status Accelerator Pedal Position Sensor Abbreviation Description ICP IPR IVS KAM KAPWR Accelerator Pedal Sensor Ground KOEO Ancillary Engine Speed Desired KOER Barometric Pressure Sensor MAF Brake ON/OFF Switch MAP Brake Pressure Applied MIL Brake Pedal Position OCT ADJ Data Link Connector OSS Data Link Connector PBA Case Ground PCM Coast Clutch Solenoid PIP Cylinder Identification ROM Camshaft Position Sensor RPM Clutch Pedal Position SCCS Cruise Control Mode (Driving) SS1 Data Link Connector SS2 Diagnostic Trouble Code SSA Diagnostic Trouble Code Count SSB Digital Transmission Range Sensor SPOUT Exhaust Back Pressure TAC Engine Coolant Temperature TCC Engine Oil Temperature TCIL Electronic Pressure Control TCS Exhaust Pressure Regulator TFT Flash EPROM Power Supply TP Fuel Pulse Width TSS Glow Plug VPWR Glow Plug Control Duty Cycle VREF Glow Plug Lamp VSS Intake Air Temperature WOT Figure 17 Injector Control Pressure Sensor Injector Pressure Regulator Idle Validation Switch Keep Alive Memory Keep Alive Power Key On Engine Off Key On Engine Running Mass Air Flow Sensor Manifold Absolute Pressure Sensor Malfunction Indicator Lamp Octane Adjust Output Shaft Speed Sensor Parking Brake Applied Powertrain Control Module Profile Ignition Pickup Read Only Memory Engine Speed Speed Control Command Switch Shift Solenoid "1" Shift Solenoid "2" Shift Solenoid "A" Shift Solenoid "B" Spark Output Tachometer Signal Torque Converter Clutch Trans Control Indicator Lamp Transmission Control Switch Transmission Fluid Temperature Throttle Position Sensor Turbine Shaft Speed Sensor Vehicle Power Supply Vehicle Reference Voltage Vehicle Speed Sensor Wide Open Throttle AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P0102 P0103 P0107 P0108 Description MAF sensor system fails to operate in a normal manner, which may cause a transmission concern. BARO sensor circuit signal higher or lower than expected. Symptom High EPC pressure. Firm shifts and engagements. May flash TCIL. Firm shift feel, late shifts at higher altitudes. P0122 (TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel, Accelerator Pedal Position sensor below abnormal shift schedule, abnormal specification during normal operation. TCC operation or does not engage. P0123 (TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel, Accelerator Pedal Position sensor above or abnormal shift schedule, abnormal below normal specifications during normal TCC operation or does not engage. operation. P0235 MAP sensor or circuit open, shorted to ground Firm shift feel, late shifts at higher altitudes. or to 5V. P0236 MAP sensor signal higher or lower than Firm shift feel, late shifts at higher expected or no response due to vacuum hose altitudes. circuit damaged, disconnected or restricted. P0237 MAP sensor out of On-Board Diagnostics Rerun On-Board Diagnostics and range. No response during Dynamic perform "Goose" test when asked. Response (Goose) test. P0340 P0341 P0344 (DI) Distributor Ignition circuit concern or Engine will stall or will not run. (CKP) Crankshaft Position sensor failure. May flash TCIL. P0500 P0503 Insufficient or intermittent vehicle speed Harsh engagements, firm shift feel, input from VSS/ABS. abnormal shift pattern, unexpected downshifts may occur at closed throttle, abnormal TCC operation or engages only at WOT. May flash TCIL. (BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage not connected. when brake is applied. P0571 P0703 (BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage not connected. when brake is applied. P0705 (DTR) Digital Transmission Range sensor Harsh engagements, firm shift feel. circuit malfunction. May flash TCIL. P0708 (DTR) Digital Transmission Range sensor Slight increase in EPC pressure. circuit malfunction. P0712 TFT sensor circuit grounded, exceeds scale set Harsh engagements, firm shift feel, abnormal shift schedule, abnormal for temperature of 315°F. TCC operation or does not engage. Figure 18 AUTOMATIC TRANSMISSION SERVICE GROUP 15 Technical Service Information FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P0713 Description Symptom TFT sensor circuit open, exceeds scale set for TCC and stabilized shift schedule temperature of minus 40°F. may be enabled sooner after cold start. May flash TCIL. P0715 Insufficient input from TSS sensor. Set DTC, Flash TCIL and Flash MIL. P0717 TSS sensor signal intermittent. Set DTC, Flash TCIL. P0718 TSS sensor signal noisy. Set DTC. P0720 Insufficient input from OSS sensor. Set DTC, Flash TCIL and Flash MIL. P0721 OSS sensor signal noisy. Set DTC. P0722 OSS sensor signal intermittent. P0731 Set DTC, Flash TCIL. 1-2 shift error because of SSA, SSB, or Improper gear selection depending internal transmission components. on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P0732 2-3 shift error because of SSA, SSB, or Improper gear selection depending on failure mode and transmission internal transmission components. range selector position. Refer to shift solenoid operation chart. P0733 3-4 shift error because of SSA, SSB, or Improper gear selection depending on failure mode and transmission internal transmission components. range selector position. Refer to shift solenoid operation chart. P0741 The PCM picked up an excessive amount of TCC slippage/erratic or no torque TCC slippage during normal operation. converter clutch operation. Flash TCIL. TCC Solenoid circuit failure. Short Circuit: Engine stalls in "D" or "2" at idle with brake applied. Open Circuit: TCC never engaged. P0743 P0750 SSA circuit failure. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P0755 SSB circuit failure. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. Figure 19 16 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code Description Symptom P0781 1-2 shift error because of SSA, SSB, or Improper gear selection depending internal transmission components. on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P0782 2-3 shift error because of SSA, SSB, or Improper gear selection depending on failure mode and transmission internal transmission components. range selector position. Refer to shift solenoid operation chart. P0783 3-4 shift error because of SSA, SSB, or Improper gear selection depending on failure mode and transmission internal transmission components. range selector position. Refer to shift solenoid operation chart. P1100 P1101 MAF sensor system fails to operate in a High EPC pressure. Firm shifts normal manner, which may cause a and engagements. May flash TCIL. transmission concern. P1111 System Pass. P1120 Throttle Position Sensor voltage lower than Harsh engagements, firm shift feel, expected. abnormal shift schedule, abnormal TCC operation or does not engage. P1124 Throttle Position Sensor out of On-Board TP sensor (Gas Engines) not at idle position during KOEO test. Diagnostics range during KOEO test. P1280 Injection Control Pressure (ICP) sensor May result in firm shifts. circuit failure (Diesel Engine), or out of range low. P1281 Injection Control Pressure (ICP) sensor May result in firm shifts. circuit failure (Diesel Engine), or out of range high. P1460 P1463 P1464 A/C switch error. P1500 Insufficient or intermittent vehicle speed Harsh engagements, firm shift feel, input from VSS/ABS. abnormal shift pattern, unexpected downshifts may occur at closed throttle, abnormal TCC operation or engages only at WOT. May flash TCIL. No Codes Detected. Failed On: EPC pressure slightly low with A/C off. Failed Off: EPC pressure slightly low with A/C on. Figure 20 AUTOMATIC TRANSMISSION SERVICE GROUP 17 Technical Service Information FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P1702 Description Symptom Digital Transmission Range (DTR) sensor Erratic harsh shift engagements. signal intermittent. P1703 (BPP) Brake Pedal Position switch not Failed on or not connected, TCC will not engage at less than oneactuated during KOER test. third throttle opening. P1704 Digital Transmission Range (DTR) sensor Increase in EPC pressure. misaligned or failed electronically. P1705 Digital Transmission Range (DTR) sensor not Rerun On-Board Diagnostics. run in park or neutral during On-Board Diagnostics KOEO or KOER tests. P1711 Transmission not at operating temperature Warm vehicle to normal operating temperature and rerun On-Board during On-Board Diagnostics. Diagnostics. P1713 P1714 No change in TFT sensor - Low range. SSA mechanical failure detected. May flash TCIL. P1715 SSB mechanical failure detected. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P1718 P1728 No change in TFT sensor - High range. P1729 4X4 Low switch circuit failure. Early or delayed shift schedule. P1740 TCC solenoid mechanical failure detected. Harsh shift, may flash TCIL. P1744 The PCM picked up an excessive amount of TCC slippage/erratic or no torque TCC slippage during normal operation. converter clutch operation. Flash TCIL. P1746 Failure of the EPC control pressure driver Open circuit causes maximum EPC pressure, harsh engagements and located inside the PCM. shifts. May flash TCIL. P1747 EPC shorted circuit failure, or PCM. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. May flash TCIL. Excessive amount of transmission slippage Transmission slippage, erratic or no TCC operation. May flash TCIL. has been detected. Shorted circuit causes minimum EPC pressure, limits engine torque with partial fuel shut off and heavy misfire. Flashing TCIL. Figure 21 18 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P1754 Description Symptom CCS circuit failure. Failed Off: No third gear engine braking in O.D. cancel. Failed On: Third gear engine braking in O.D. range. Coast clutch may be damaged causing eventual failure. P1760 EPC signal intermittent short. Short circuit causes minimum EPC pressure. P1780 TCS not cycled during the On-Board No overdrive cancel when switch is cycled. Diagnostics or the circuit is open or shorted. P1781 4X4 Low switch circuit failure. P1783 Transmission Fluid Temperature has Slight increase in EPC pressure. exceeded 270°F. May flash TCIL. Early or delayed shift schedule. Figure 22 AUTOMATIC TRANSMISSION SERVICE GROUP 19 Technical Service Information Shift Solenoid Application Chart Selector Lever Commanded Range Gear P/R/N D D D D D Cancel MANUAL 2 MANUAL 1 MANUAL 1 * 1 1 2 3 4 Shift Solenoid "A" Shift Solenoid "B" TCC Solenoid Coast Clutch Solenoid ON ON ON OFF OFF OFF OFF ON ON OFF * * * * * * * * * * First Through 3rd Gear Only, SSA, SSB, TCC, Same as Overdrive, CCS Always On. 2 2 1 * * * OFF ON OFF OFF OFF OFF ON ON ON Controlled by PCM SHIFT SOLENOID TROUBLE CHART GUIDE SHIFT SOLENOID "A" ALWAYS OFF Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 4 2 1 2nd 3 2 2 3rd 3 2 2 4th 4 2 2 SHIFT SOLENOID "B" ALWAYS OFF Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 1 2 1 2nd 1 2 1 3rd 4 2 2 4th 4 2 2 SHIFT SOLENOID "A" ALWAYS ON Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 1 2 1 2nd 2 2 1 3rd 2 2 1 4th 1 2 1 SHIFT SOLENOID "B" ALWAYS ON Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 2 2 1 2nd 2 2 1 3rd 3 2 2 4th 3 2 2 Figure 23 20 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information LINE PRESSURE TEST llllllll lll ll llll llllllllll llll llllllllllll lll lll Ford -700 RFF81P 98 C XW4P-A RJL-B 004361 7 BD-9C1 6-BA d For LINE PRESSURE SPECIFICATION CHART NOTE: On vehicles equipped with PTO units, Gear Idle Stall access to the line pressure port may require that you P, N 50-65 psi remove the PTO unit depending on the type of unit R 70-100 psi 220-240 psi installed. If required, remove the PTO unit and install PTO cover and gasket "Before" doing the OD, M2 50-65 psi 136-156 psi line pressure test. M1 70-115 psi 175-210 psi Copyright © 2003 ATSG Figure 24 LINE PRESSURE TEST NOTE: Perform the line pressure test before performing the "Stall" test. If the line pressure is low at "Idle", DO NOT perform the "Stall" test or further transmission damage will occur. Do Not Maintain Wide Open Throttle in any gear range for more than "5 Seconds" or transmission damage may occur. NOTE: If equipped, turn "Off" the PTO unit to ensure proper test results. 1. Install a 300 psi line pressure gauge to the line pressure tap, as shown in Figure 24. 2. Start the engine and check line pressure in all ranges at "Idle". Refer to the chart shown in Figure 24 to determine if they are within the specifications. 3. If the line pressures are within the specifications at "Idle", now you can perform the "Stall" test to determine if specifications are okay there. 4. Once again, refer to the chart in Figure 24, to determine proper specifications at "Stall". AUTOMATIC TRANSMISSION SERVICE GROUP 21 Technical Service Information FORD 4R100 "NON-PTO" AND "PTO" HYDRAULIC DIFFERENCES CHANGE: Begining at the start of production for 1999 models, Ford Motor Company made available a "Power Take Off" option for some F250, F350, F450 and F550 Super Duty Trucks, equipped with 5.4L, 6.8L and 7.3L engines. REASON: The "PTO" option addition, to the 4R100, required many changes to the transmission to make the "PTO" function. The "PTO" window, added to the case, the "PTO" drive gear and other cosmetic changes were covered on Page 6 in this manual. Hydraulic changes also had to be made to make the coast clutch operate in ranges other than the Drive ranges (See Figure 35). PARTS AFFECTED: (1) TRANSMISSION CASE: The transmission case was changed to accommodate the "PTO" window, as shown in this manual. All 4R100 Cases, "NON-PTO"and "PTO,"also had a "Dam" added to seperate "Rear Lube" and to incorporate "Central Lube"as shown in Figure 25. (2) VALVE BODY TO CASE SPACER PLATE: The Valve Body to Case Spacer plate on the "PTO" versions had a hole added to supply the 3-4 Shift Valve with Line Pressure, as shown in Figure 27. A hole was also added to the Spacer Plate on "NON-PTO" and "PTO" versions to connect "Solenoid Regulator Valve" oil to supply "Central Lubrication." Refer to Figures 26 and 27 for identification of "NON-PTO"and "PTO" Valve Body To Case Spacer Plates. (3) MAIN VALVE BODY: A passage was added on the "Upper Side" of the Main Valve Body on "PTO" versions, as shown in Figure 29, to supply Line Pressure to the 3-4 Shift Valve. A passage was also added, on the "Lower Side" of the Main Valve Body, to connect the 3-4 Shift Valve (Coast Clutch Circuit) to an exhaust as shown in Figure 31. The spring side of the 3-4 Shift Valve was also seperated from the Low/Reverse circuit as shown in Figure 31. Refer to Figures 28 thru 31 for identification of "NON-PTO" and "PTO" Main Valvebody's. (4) LOWER VALVE BODY: The Lower Valve Body has a passage added, as shown in Figure 33, to connect to the "new"exhaust passage in the Main Valve Body. Refer to Figures 32 and 33, for identification of "NON-PTO" and "PTO" Lower Valvebody's. (5) LOWER VALVE BODY SPACER PLATE: The Lower Valve Body Spacer Plate had a hole added to connect the "new" exhaust passage in the Main Valve Body to the "new" exhaust passage in the Lower Valve body a shown in Figure 34. Refer to Figure 34 for "NON-PTO" and "PTO" Lower Valve Body Spacer Plate identification. INTERCHANGEABILITY: None of the parts listed above will interchange between "NON-PTO" and "PTO" versions. SERVICE INFORMATION: Valve Body To Case Spacer Plate (Non-PTO) .................. ................................F81Z-7A008-DA Valve Body To Case Spacer Plate (PTO) ...........................................................F81Z-7A008-BA Copyright © 2003 ATSG 22 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 CASE ASSEMBLY "NON-PTO" AND "PTO" MODELS ADDED OIL DAM CENTRAL LUBE REAR LUBE Copyright © 2003 ATSG Figure 25 AUTOMATIC TRANSMISSION SERVICE GROUP 23 Technical Service Information 97 12 4R100 MAIN SPACER PLATE "NON-PTO" MODELS ONLY I.D.- 1 DOVE TAIL PART NUMBER F81Z-7A008-DA F81P-DA CENTRAL LUBE ORIFICE Copyright © 2003 ATSG Figure 26 24 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 98 6 4R100 MAIN SPACER PLATE "PTO" MODELS ONLY CENTRAL LUBE ORIFICE I.D.- 2 DOVE TAILS PART NUMBER F81Z-7A008-BA F81P-BA ADDED MAIN LINE PRESSURE HOLE FROM PRESSURE REGULATOR VALVE Copyright © 2003 ATSG Figure 27 AUTOMATIC TRANSMISSION SERVICE GROUP 25 Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" MODELS ONLY Copyright © 2003 ATSG Figure 28 26 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "PTO" MODELS ONLY PASSAGE ADDED TO FEED LINE PRESSURE TO THE 3-4 SHIFT VALVE Copyright © 2003 ATSG Figure 29 AUTOMATIC TRANSMISSION SERVICE GROUP 27 Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" MODELS ONLY RFF61P7A092-AB 6 Ford 09328 Du Page I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" LOW/REVERSE CLUTCH Copyright © 2003 ATSG Figure 30 28 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "PTO" MODELS ONLY P RFF81P7A092-AA 1 Ford 19538 Du Page I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" PASSAGE ADDED LEADING TO THE EXHAUST IN THE LOWER VALVE BODY LOW/REVERSE PASSAGE RE-MOVED FROM SPRING SIDE OF 3-4 SHIFT VALVE LOW/REVERSE CLUTCH Copyright © 2003 ATSG Figure 31 AUTOMATIC TRANSMISSION SERVICE GROUP 29 Technical Service Information 5 Du Page Ford RFF61P-7A101 A 4R100 LOWER VALVE BODY "NON-PTO" MODELS ONLY 09828 I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" Copyright © 2003 ATSG Figure 32 30 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" 14018 1 EXHAUST PASSAGE ADDED FROM COAST CLUTCH VALVE TO 3-4 SHIFT VALVE DUPAGE P Ford RFF81P-7A101 AA 4R100 LOWER VALVE BODY "PTO" MODELS ONLY Copyright © 2003 ATSG Figure 33 AUTOMATIC TRANSMISSION SERVICE GROUP 31 Technical Service Information 4R100 LOWER VALVE BODY SPACER PLATE "NON-PTO" MODELS ONLY "PTO" MODELS ONLY I.D.- 1 DOVE TAIL I.D.- 2 DOVE TAILS HOLE ADDED TO CONNECT WITH EXHAUST PASSAGE IN LOWER VALVE BODY Copyright © 2003 ATSG Figure 34 32 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "NON-PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT FROM SOLENOID 4 COAST CLUTCH SOLENOID FROM SOLENOID 2 LINE PRESSURE FROM MANUAL VALVE "OD CIRCUIT" TO CB3/COAST CLUTCH LINE PRESSURE FROM MANUAL VALVE "REVERSE" COAST CLUTCH SHIFT VALVE 3-4 SHIFT VALVE TO CB7/OVERDRIVE CLUTCH FROM 2-3 SHIFT VALVE FROM CB15 / 2-3 SHIFT VALVE X "PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT FROM SOLENOID 4 COAST CLUTCH SOLENOID FROM SOLENOID 2 TO CB3/COAST CLUTCH LINE PRESSURE FROM PRESSURE REGULATOR VALVE FIGURE 29 FIGURE 7 COAST CLUTCH SHIFT VALVE 3-4 SHIFT VALVE TO CB7/OVERDRIVE CLUTCH FROM 2-3 SHIFT VALVE FIGURE 33 X X Copyright © 2003 ATSG Figure 35 AUTOMATIC TRANSMISSION SERVICE GROUP 33 Technical Service Information FORD 4R100 "PWM" AND "NON-PWM" PUMP DIFFERENCES CHANGE: Beginning at the start of production in 1999, the 4R100 transmission was offered with two different torque converter clutch application strategies. A "PWM" (Pulse Width Modulated) version, was added for V-10 gas powered vehicles and all diesels, and a "NON-PWM" version, offered in all other gas powered vehicles. This required two different solenoid packs as well as two different pump assemblies. REASON: For smooth converter clutch apply on V-10 gas and diesel engine models. PARTS AFFECTED: (1) PUMP ASSEMBLY: • The pump cover assembly had the rear of the Converter Clutch Valve bore enlarged approximately .070" to accommodate the enlarged land of the Converter Clutch Valve as shown in Figure 36. A .036" orifice and an air bleed were added to the TCC Solenoid signal passage as shown in Figure • 38. The Converter Clutch Control Valve's rear spool was enlarged approximately .070." There was • also a bushing and valve added to the end of the valve train as shown in Figure 36. A hole was added to the pump cover to connect the Converter Clutch Control Valve Bushing to • Converter Regulator Valve oil, as shown in Figure 38. The Converter release orifice in the NON-PWM pump cover, as shown in Figure 37, was removed • from the PWM pump cover as shown in Figure 38. THE SOLENOID PACK: (2) The PWM solenoid pack requires a Pulse Width Modulated torque converter clutch solenoid and • the NON-PWM solenoid pack requires an on-off torque converter clutch solenoid. INTERCHANGABILITY: None of the parts listed above are interchangable from model to model. SERVICE INFORMATION: "NON-PWM" Pump assy. (with "Cast Iron" coast clutch drum).................F81Z-7A103-AA "NON-PWM" Pump assy. (with "Stamped Steel" coast clutch drum)..........F81Z-7A103-BA "PWM" Pump assy. (with "Stamped Steel" coast clutch drum)....................F81Z-7A103-CA "NON-PWM" Solenoid Pack...........................................................................F81Z-7G391-BA "PWM" Solenoid Pack.....................................................................................F81Z-7G391-AB Copyright © 2003 ATSG 34 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information CONVERTER CLUTCH CONTROL VALVE "NON-PWM" "PWM" .530" .600" .485" .545" THE DIAMETER AND THE LENGTH OF THE SPOOL ON THE VALVE LAND SHOWN ABOVE, WERE INCREASED ON PWM VERSIONS. THE BORE IN THE PUMP COVER WAS ALSO ENLARGED APPROXIMATELY .070" TO ACOMMODATE THE CHANGES IN THE DIAMETER OF THE VALVE Copyright © 2003 ATSG Figure 36 AUTOMATIC TRANSMISSION SERVICE GROUP 35 Technical Service Information 4R100 PUMP COVER ASSEMBLY "NON-PWM" MODELS ONLY CONVERTER CLUTCH CONTROL VALVE CONVERTER REGULATOR VALVE PRESSURE REGULATOR VALVE CONVERTER RELEASE ORIFICE .070" RETAINER LUBE ORIFICE .090" Copyright © 2003 ATSG Figure 37 36 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 PUMP COVER ASSEMBLY "PWM" MODELS ONLY CONVERTER CLUTCH CONTROL VALVE CONVERTER REGULATOR VALVE HOLE ADDED TO CONNECT TO HOLE IN CONTROL VALVE BUSHING PRESSURE REGULATOR VALVE CONVERTER RELEASE ORIFICE OMITTED RETAINER LUBE ORIFICE .090" ADDED ORIFICE IN TCC PWM SOLENOID SIGNAL PASSAGE .036" ADDED AIR BLEED Copyright © 2003 ATSG Figure 38 AUTOMATIC TRANSMISSION SERVICE GROUP 37 Technical Service Information 4R100 CASE CHECKBALL LOCATIONS "NON-PTO" AND "PTO" MODELS CB7 CB8 BS3 BS1 EPC Ball And Spring CB1 CB9 CB14 CB6 Requires Eight 5/16" Diameter Rubber Checkballs Plus The EPC Ball And Spring, As Shown Above. Copyright © 2003 ATSG Figure 39 38 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 VALVE BODY CHECKBALL LOCATIONS "NON-PTO" AND "PTO" MODELS CB16 1/4" Rubber CB15 5/16" Rubber RFF61P7A092-AB 6 Ford 09328 Du Page X BS2 1/4" Rubber CB13 5/16" Rubber Copyright © 2003 ATSG Figure 40 AUTOMATIC TRANSMISSION SERVICE GROUP 39 Technical Service Information Direct Clutch AIR PRESSURE CHECKS Forward Clutch Coast Clutch Low/Reverse Clutch Overdrive Clutch Intermediate Lube Intermediate Clutch Copyright © 2003 ATSG Figure 41 Ford XW4P-AC RJL-B 004361 BD-9C17 BA -7006RFF81P 98 Ford Copyright © 2003 ATSG Figure 42 40 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Ford XW4P-AC RJL-B RETAINING BOLTS (2) 004361 BD-9C17 BA -7006RFF81P 98 d For DIGITAL TRANSMISSION RANGE SENSOR External Components 1. Remove the turbine shaft from the transmission as shown in Figure 42. Inspect the spline area on both ends and set aside for final assembly. 2. Remove the two Digital Transmission Range sensor retaining bolts, as shown in Figure 43, and remove the DTR sensor. 3. If equipped, the turbine shaft speed sensor and output shaft speed sensor must be removed to prevent damage, as shown in Figure 44 and 45. 4. Install a compatible holding fixture onto the transmission case, as shown in Figure 46, that will allow you to safely rotate the transmission when installed in the bench fixture. 5. Rotate the transmission so that the bottom pan is facing up, as shown in Figure 47. Copyright © 2003 ATSG Figure 43 Continued on Page 42. TURBINE SHAFT SPEED SENSOR Copyright © 2003 ATSG TRANSMISSION HOLDING FIXTURE Figure 44 OUTPUT SHAFT SPEED SENSOR Ford XW4P-AC RJL-B 004361 BD-9C17 BA -7006RFF81P 98 Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 45 Figure 46 AUTOMATIC TRANSMISSION SERVICE GROUP 41 Technical Service Information TRANSMISSION DISASSEMBLY BOTTOM PAN PAN BOLTS (20) U P 62 PAN GASKET Bottom Pan Components 1. Remove the 20 bottom pan bolts, the bottom pan and the bottom pan gasket, as shown in Figure 47. 2. Remove the bottom pan oil filter, as shown in Figure 48, by prying up with screwdriver. 3. Remove two accumulator valve body retaining nuts and 11 bolts, as shown in Figure 49, and remove accumulator valve body. 4. Set the accumulator valve body aside for the component rebuild section. 5. Remove two main valve body retaining nuts and the 14 bolts, as shown in Figure 50, and remove upper and lower valve bodies together as a package. Note: Do not remove the two bolts holding the upper and lower valve bodies together. Refer to Figure 50. 6. Set the main upper and lower valve bodies aside for the component rebuild section. Continued on Page 43. Copyright © 2003 ATSG RETAINING NUTS (2) Figure 47 RETAINING BOLTS (11) ACCUMULATOR VALVE BODY U P U P 62 62 BOTTOM PAN OIL FILTER Copyright © 2003 ATSG Figure 48 42 Copyright © 2003 ATSG Figure 49 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information RETAINING BOLTS (9) TRANSMISSION DISASSEMBLY RETAINING NUT SOLENOID BODY ASSEMBLY "O" RING U P 62 Bottom Pan Components 7. Remove the solenoid body retaining nut and the 9 retaining bolts, as shown in Figure 51, and remove the solenoid body assembly. 8. Remove the solenoid body by lifting up with a small twist to free the connector "O" ring from the case bore (See Figure 51). 9. Remove and discard the spacer plate to main valve body gasket, as shown in Figure 52. 10. Remove the solenoid body screen from spacer plate, as shown in Figure 52, by rotating and lifting straight up. Continued on Page 44. Copyright © 2003 ATSG Figure 51 186 RETAINING BOLTS (14) RETAINING NUTS (2) 187 U P 62 U P DO NOT REMOVE THESE TWO BOLTS 62 UPPER AND LOWER MAIN VALVE BODIES 186 SPACER PLATE TO MAIN VALVE BODY GASKET 187 SOLENOID SCREEN ASSEMBLY Copyright © 2003 ATSG Figure 50 Copyright © 2003 ATSG Figure 52 AUTOMATIC TRANSMISSION SERVICE GROUP 43 Technical Service Information TRANSMISSION DISASSEMBLY 189 Bottom Pan Components (Cont'd) 11. Remove the 3 retaining bolts for the reinforcing plate, as shown in Figure 53, and remove the reinforcing plate and the spacer plate. 12. Remove and discard the spacer plate to case gasket, as shown in Figure 53. 14. Remove 1/4" Dia. steel EPC ball, and spring from the case pocket, as shown in Figure 54. 15. Remove the manual intermediate servo piston, as shown in Figure 54, by tapping gently on the piston with a rubber mallet to release it from case bore. 16. Remove the eight checkballs from their case pockets, as shown in Figure 55, using a small screwdriver. 17. The case checkballs are 5/16" diameter rubber material, so use care to avoid any damage. 18. Remove and discard the 3 support feed bolts, as shown in Figure 56. U P 188 185 62 184 .312" DIAMETER RUBBER CHECKBALLS 184 185 188 189 SPACER PLATE TO CASE GASKET SPACER PLATE SPACER PLATE REINFORCING PLATE REINFORCING PL ATE RETAINING BOLT, M6 X 1.0 X 42 (3) Copyright © 2003 ATSG Figure 53 55 62 183 182 .312" DIA. RUBBER CHECKBALLS 55 MANUAL INTERMEDIATE SERVO ASSEMBLY 182 EPC BLOW-OFF BALL, .250" DIAMETER STEEL BALL 183 EPC BLOW-OFF SPRING Copyright © 2003 ATSG Figure 54 44 Copyright © 2003 ATSG Figure 55 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY KXV 9.8 KXV 9.8 7 Internal Components 1. Remove the nine oil pump assembly retaining bolts, as shown in Figure 57. 2. Remove and discard the sealing washers from the nine pump retaining bolts. 3. Using two slide hammers, remove the oil pump assembly, as shown in Figure 57, and set aside for the component rebuild section. 4. Remove and discard the oil pump assembly to case gasket, as shown in Figure 57. 5. Remove the number 1 thrust washer, as shown in Figure 57, which may be stuck to oil pump assembly. Note: The number 1 thrust washer is not used on the PTO equipped models. 6. Remove the number 2 thrust bearing, as shown in Figure 57, which may be stuck to oil pump assembly. KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 d or F 9 RF-F81P 7A105-AA 11 Continued on Page 46. 10 13 7 9 10 11 13 FEED BOLTS OIL PUMP ASM. RETAINING BOLTS, M8 X 1.25 X 65 (9 REQ.) OIL PUMP AND COVER ASSEMBLY NUMBER 1 THRUST WASHER (USED NON-PTO MODELS ONLY) OIL PUMP ASSEMBLY TO CASE GASKET NUMBER 2 THRUST BEARING, PUMP TO O.D. SUN GEAR Copyright © 2003 ATSG Figure 56 Copyright © 2003 ATSG Figure 57 AUTOMATIC TRANSMISSION SERVICE GROUP 45 Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 7. Remove the coast clutch housing, as shown in Figure 58, and set aside for component rebuild section. Note: There are three different versions of the coast clutch housing, which we will show you in the component rebuild section. Shown here is the PTO version. 8. Remove the overdrive clutch backing plate snap ring, as shown in Figure 59, using a large screwdriver. Note: This snap ring is a selective thickness and should be measured at this time. 9. Remove the overdrive clutch backing plate and overdrive clutch pack, as shown in Figure 59. 31 34 Continued on Page 47. COAST CLUTCH HOUSING ASSEMBLY FOR "PTO" MODELS 35 36 31 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) 34 OVERDRIVE CLUTCH BACKING PLATE 35 OVERDRIVE CLUTCH FRICTION PLATES Copyright © 2003 ATSG Figure 58 46 Copyright © 2003 ATSG Figure 59 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 10. Remove the overdrive carrier and center shaft assembly, as shown in Figure 60, and set aside for the component rebuild section. 11. Remove the number 5 thrust bearing, as shown in Figure 60, which may be on center support. 12. Install clutch spring compressor as shown in Figure 61, or equivalent, to compress the intermediate/overdrive clutch cylinder so that snap ring can be removed. 13. Remove snap ring with large a screwdriver as shown in Figure 62, and then remove the compressor tool. TIGHTEN CENTER BOLT TO 7 N·m (65 IN.LB.) Continued on Page 48. CLUTCH SPRING FIXTURE OVERDRIVE CARRIER AND CENTER SHAFT ASSEMBLY CLUTCH SPRING COMPRESSOR BAR CLUTCH SPRING COMPRESSOR PLATE NUMBER 5 THRUST BEARING Figure 61 CLUTCH SPRING COMPRESSOR BAR SNAP RING Copyright © 2003 ATSG Figure 60 Figure 62 AUTOMATIC TRANSMISSION SERVICE GROUP 47 Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 14. Remove snap ring and intermediate/overdrive cylinder assembly, as shown in Figure 63, and set aside for component rebuild section. 15. Remove the intermediate clutch piston return spring, as shown in Figure 64. 16. Remove the center support assembly, as shown in Figure 64, and set aside for the component rebuild section. 17. Remove the number 6 thrust washer, center support to direct clutch housing, as shown in Figure 64. 18. Remove the intermediate clutch pack and the backing plate, as shown in Figure 65. 19. Remove the intermediate band assembly, as shown in Figure 66. Continued on Page 49. 46 40 48 42 49 40 INTERMEDIATE/OVERDRIVE CYLINDER SNAP RING 42 INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY 46 INTERMEDIATE CLUTCH PISTON RETURN SPRING 48 CENTER SUPPORT ASSEMBLY 49 NUMBER 6 THRUST WASHER, CENTER SUPPORT Copyright © 2003 ATSG Figure 63 48 Copyright © 2003 ATSG Figure 64 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 20. Install the removal tool and remove the direct clutch drum, forward clutch drum and the sun shell as an assembly, as shown in Figure 66. 21. Set the direct drum, forward drum and the sun shell assembly aside for the component rebuild section. INTERMEDIATE BAND ASSEMBLY Continued on Page 50. REMOVAL TOOL T89T-70010-E 53 DIRECT CLUTCH, FORWARD CLUTCH AND SUN SHELL ASSEMBLY 52 54 52 INTERMEDIATE CLUTCH FRICTION PLATES 53 INTERMEDIATE CLUTCH STEEL PLATES 54 INTERMEDIATE CLUTCH BACKING PLATE Copyright © 2003 ATSG Figure 65 Copyright © 2003 ATSG Figure 66 AUTOMATIC TRANSMISSION SERVICE GROUP 49 Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 22. Remove the snap ring retaining rear planetary carrier in reverse clutch hub (See Figure 67). 23. Remove the rear planetary carrier and both of the thrust washers, as shown in Figure 67. 24. Remove the output shaft snap ring using snap ring pliers, as shown in Figure 68. 25. Remove snap ring, rear planetary ring gear and the number 12 thrust bearing (See Figure 69). Continued on Page 51. 102 OUTPUT SHAFT SNAP RING Figure 68 103 106 104 107 105 112 102 REAR CARRIER TO REVERSE HUB RETAINING SNAP RING 103 NUMBER 10B THRUST WASHER 104 REAR PL ANETARY CARRIER ASSEMBLY 106 OUTPUT SHAFT SNAP RING 107 REAR PL ANETARY RING GEAR 112 NUMBER 12 THRUST BEARING (RING GEAR TO INNER RACE) Copyright © 2003 ATSG Figure 67 50 Copyright © 2003 ATSG Figure 69 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 26. Remove the reverse clutch hub and low roller clutch assembly, as shown in Figure 70, and set aside for component rebuild. 27. Remove the snap ring retaining the low/reverse clutch pack, using a large screwdriver as shown in Figure 71, from the groove in case. 28. Remove the snap ring from case, as shown in Figure 72. SNAP RING Continued on Page 52. Figure 71 110 LOW REVERSE CLUTCH SNAP RING 110 REVERSE CLUTCH HUB AND LOW ROLLER CLUTCH ASM. Copyright © 2003 ATSG Figure 70 Copyright © 2003 ATSG Figure 72 AUTOMATIC TRANSMISSION SERVICE GROUP 51 Technical Service Information TRANSMISSION DISASSEMBLY EXTENSION HOUSING RETAINING BOLTS 9.8 9.8 9.8 9.8 Internal Components (Cont'd) 29. Remove the low/reverse clutch pack including wave plate, as shown in Figure 73. 30. Rotate transmission in fixture so output shaft is facing up, as shown in Figure 74. 31. Remove the extension housing retaining bolts and housing, as shown in Figure 74. 32. We have illustrated the typical 4WD version in Figure 74, and the 2WD version in Figure 75. 9.8 Continued on Page 53. 9.8 98 9.8 9.8 EXTENSION HOUSING 99 100 101 EXTENSION HOUSING GASKET OUTPUT SHAFT 9.8 Figure 73 52 5G 9594 000 00066 XC3P-GA PRB-AU 00000066 BD-8H17 9.8 Copyright © 2003 ATSG MP-4 X 4 98 LOW/REVERSE CLUTCH BACKING PLATE 99 LOW/REVERSE CLUTCH FRICTION PLATES (6) 100 LOW/REVERSE CLUTCH STEEL PLATES (6) Copyright © 2003 ATSG Figure 74 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 33. Notice that the 2WD version has a speed sensor reluctor wheel that must be pressed off and on, if necessary to replace, as shown in Figure 75. 34. Remove and discard the extension housing gasket, as shown in Figure 74. 35. Remove the park rod guide plate, parking pawl, park pawl pivot pin and return spring, as shown in Figure 76. SPACER, ROTUNDA PART NUMBER 307-388 Continued on Page 54. RETAINING BOLTS 9.8 9.8 PARK PAWL, PIVOT PIN, AND RETURN SPRING PARK ROD GUIDE PLATE OUTPUT SHAFT SPEED SENSOR RELUCTOR WHEEL 9.8 5G 9594 000 00066 XC3P-GA PRB-AU 00000066 BD-8H17 9594 000 00066 5G XC3P-GA PRB-AU 00000066 BD-8H17 9.8 Figure 75 MP-4 X 4 MP-4 X 4 Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 76 AUTOMATIC TRANSMISSION SERVICE GROUP 53 Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 36. Remove the output shaft by pulling straight up, as shown in Figure 77. 37. Remove the number 13 thrust bearing from the back of case, as shown in Figure 77. 38. Remove and discard the lube orifice plug from rear of case, as shown in Figure 78. LUBE ORIFICE PLUG Continued on Page 55. OUTPUT SHAFT AND PARK GEAR Copyright © 2003 ATSG Figure 78 9.8 9.8 9.8 9.8 9.8 NUMBER 13 THRUST BEARING 9.8 9.8 9.8 XC3P-GA PRB-AU 00000066 BD-8H17 9.8 9594 000 00066 5G MP-4 X 4 XC3P-GA PRB-AU 00000066 BD-8H17 9594 000 00066 MP-4 X 4 9.8 5G LOW ROLLER CLUTCH INNER RACE RETAINING BOLTS (5) Copyright © 2003 ATSG Figure 77 54 Copyright © 2003 ATSG Figure 79 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSMISSION DISASSEMBLY Internal Components (Cont'd) 39. Rotate the transmission in fixture so the pan rail surface is facing down (See Figure 79). 40. Remove the 5 low roller clutch inner race bolts, as shown in Figure 79. 41. Rotate the transmission in fixture so the bell housing is facing up, as shown in Figure 80. 42. Remove the low roller clutch inner race, the reverse clutch piston return spring assembly, and reverse clutch piston (See Figure 80). 43. Remove and discard the reverse clutch piston inner and outer lip seals (See Figure 80). 113 114 115 117 COMPONENT REBUILD Transmission Case Assembly 116 1. Remove the inside detent lever retaining nut, using a cresent wrench to hold the external shift lever, to avoid damage to the inside detent spring (See Figure 80). Caution: If this procedure is not followed, damage to the detent spring will occur and replacement will be necessary. Continued on Page 56. Hold External Shift Lever With Cresent Wrench When Removing The Inside Detent Lever Retaining Nut INSIDE DETENT LEVER 62 RETAINING NUT 113 114 115 116 117 LOW ROLLER CLUTCH INNER RACE REVERSE CLUTCH PISTON RETURN SPRING ASSEMBLY REVERSE CLUTCH PISTON INNER LIP SEAL REVERSE CLUTCH PISTON OUTER LIP SEAL REVERSE CLUTCH PISTON Copyright © 2003 ATSG Figure 80 Copyright © 2003 ATSG Figure 81 AUTOMATIC TRANSMISSION SERVICE GROUP 55 Technical Service Information COMPONENT REBUILD Transmission Case Assembly (Cont'd) 2. Remove the shift lever retaining roll pin from the case, using pin removal tool T87P-3504-N, as shown in Figure 82. 3. Remove external shift lever from case and remove shift lever seal from case using the proper puller. 4. Clean all case parts thoroughly and dry with compressed air. 5. Inspect all case parts thoroughly for any wear and/or damage. Replace as necessary. 6. Install new shift lever seal into the case bore using the proper seal driver PIN REMOVER T87P-3504-N ROLL PIN 7. Install the external shift lever, inside detent lever and retaining nut. Torque the retaining nut to 41-54 N·m (30-40 ft.lb.), again using a cresent wrench to hold external shift lever. (See Figure 81). 8. Install a new lube orifice plug into the case, as shown in Figure 83, and ensure fully seated. 9. Install new inner and outer lip seals in grooves of the reverse piston, with the lips facing the direction shown in Figure 85. 10. Lubricate both lip seals with a small amount of Trans-Jel®. 11. Install the reverse piston into the case with a rotating motion, using care not to damage the lip seals (See Figure 85). 12. Install the reverse clutch piston return spring assembly, as shown in Figure 85. 13. Install two threaded rods into the low roller inner race, as shown in Figure 84. They can be made from bolts with the head removed. Note: The lube hole in the race should be positioned in the 5 o'clock position when it is installed. The 6 o'clock position is the bottom of the case. 14. Install the low roller clutch inner race in case, as shown in Figure 86, and install two nuts on the threaded rods. Continued on Page 57. TWO THREADED RODS 5/16"-24 X 3 INCH LONG Figure 82 LUBE ORIFICE PLUG LUBE HOLE LOW ROLLER CLUTCH INNER RACE Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 83 56 Figure 84 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Transmission Case Assembly (Cont'd) 113 15. Tighten the nuts to compress the reverse clutch return spring assembly, as shown in Figure 86. 16. Install 3 low roller inner race retaining bolts, as shown in Figure 86, and remove the 2 threaded rods and nuts. 17. Install the two remaining retaining bolts and torque all five to 24-34 N·m (18-25 ft.lb.) in a criss-cross pattern, as shown in Figure 87. 114 Continued on Page 58. 115 INSTALL THREE LOW ROLLER CLUTCH INNER RACE RETAINING BOLTS 9.8 9.8 117 9.8 116 XC3P-GA PRB-AU 00000066 BD-8H17 9594 000 00066 MP-4 X 4 5G TWO THREADED RODS Copyright © 2003 ATSG Figure 86 Sn ap 9.8 -O n 9.8 9.8 9.8 XC3P-GA PRB-AU 00000066 BD-8H17 5G Copyright © 2003 ATSG Figure 85 9594 000 00066 9.8 LOW ROLLER CLUTCH INNER RACE REVERSE CLUTCH PISTON RETURN SPRING ASSEMBLY REVERSE CLUTCH PISTON INNER LIP SEAL REVERSE CLUTCH PISTON OUTER LIP SEAL REVERSE CLUTCH PISTON MP-4 X 4 113 114 115 116 117 Copyright © 2003 ATSG Figure 87 AUTOMATIC TRANSMISSION SERVICE GROUP 57 Technical Service Information COMPONENT REBUILD "2WD VERSION" Transmission Case Assembly (Cont'd) 18. Install the number 13 thrust bearing onto case, in the direction shown in Figure 88. 19. Install the output shaft into the case, as shown in Figure 88. Note: We have illustrated the 4WD version in Figure 88. SPEED SENSOR RELUCTOR WHEEL SPACER, ROTUNDA PART NUMBER 307-388 PARK GEAR Continued on Page 59. "4WD VERSION" OUTPUT SHAFT SPEED SENSOR RELUCTOR WHEEL OUTPUT SHAFT AND PARK GEAR NUMBER 13 THRUST BEARING OUTPUT SHAFT SPEED SENSOR RELUCTOR WHEEL 9.8 9.8 9.8 9.8 9.8 9.8 58 9594 000 00066 XC3P-GA PRB-AU 00000066 BD-8H17 5G 9594 000 00066 5G XC3P-GA PRB-AU 00000066 BD-8H17 9.8 Figure 88 MP-4 X 4 MP-4 X 4 Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 89 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Transmission Case Assembly (Cont'd) 20. The 2WD version is illustrated in Figure 89, and notice that it has a speed sensor reluctor wheel pressed on next to the park gear, which is also a press fit on the output shaft. Caution: If the speed sensor reluctor wheel was removed for any reason, special spacer, Rotunda number 307-388, must be used to locate the reluctor wheel in proper position. 21. Install the parking pawl, pivot pin and return spring, as shown in Figure 90, and ensure that it is hooked properly behind the case, as shown in Figure 91. 22. Install the parking rod guide plate, as shown in Figure 90. 23. Install the two park rod guide plate retaining bolts and torque to 16-27 N·m (12-20 ft.lb.). Note: Ensure that park rod operates freely through the guide plate (See Figure 91). 24. The Torx head bolt retaining the park pawl abutment plate, shown in Figure 91, has thread locking compound and should not be removed unless damage is apparent. Note: If it was removed, Ford recommends that it be discarded and a new bolt installed and torqued to 16-27 N·m (12-20 ft.lb.). Continued on Page 60. RETAINING BOLTS 9.8 9.8 RETURN SPRING IS HOOKED ON CASE Copyright © 2003 ATSG ENSURE THAT PARK ROD TRAVELS FREELY PARK ROD GUIDE PLATE 9.8 9594 000 00066 5G 9594 000 00066 XC3P-GA PRB-AU 00000066 BD-8H17 5G MP-4 X 4 THIS TORX HEAD BOLT MUST BE DISCARDED AND REPLACED, IF REMOVED Copyright © 2003 ATSG Figure 90 MP-4 X 4 XC3P-GA PRB-AU 00000066 BD-8H17 9.8 PARK PAWL, PIVOT PIN, AND RETURN SPRING Copyright © 2003 ATSG Figure 91 AUTOMATIC TRANSMISSION SERVICE GROUP 59 Technical Service Information EXTENSION HOUSING RETAINING BOLTS COMPONENT REBUILD Transmission Case Assembly (Cont'd) 25. Install new extension housing gasket on case surface, as shown in Figure 92. 26. Install the 4WD extension housing, as shown in Figure 92. Note: The 4R100 unit requires an extension housing with the added boss, or shoulder (4X4), as illustrated in Figure 94, to retain the lube orifice plug. If replacement becomes necessary, refer to Figure 94 for a proper replacement. 27. If installing a 2WD version extension housing, install a new rear seal using the proper driver. 28. Install extension housing and retaining bolts, as shown in Figure 92. 29. Torque the extension housing bolts, as shown in Figure 93 to 41-54 N·m (30-40 ft.lb.). 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 EXTENSION HOUSING Continued on Page 62. EXTENSION HOUSING GASKET OUTPUT SHAFT 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9594 000 00066 XC3P-GA PRB-AU 00000066 BD-8H17 5G 9594 000 00066 5G XC3P-GA PRB-AU 00000066 BD-8H17 9.8 60 9.8 Figure 92 MP-4 X 4 MP-4 X 4 Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 93 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 TYPICAL 4 WHEEL DRIVE E4OD 4X4 WITHOUT LUBE PLUG SHOULDER FORD 4R100 6.8L AND 7.3L 2 WHEEL DRIVE NO SHOULDER ALL OTHER 4R100 2 WHEEL DRIVE APPLICATIONS ADDED BOSS E4OD WITHOUT LUBE PLUG SHOULDER NO SHOULDER Copyright © 2003 ATSG Figure 94 AUTOMATIC TRANSMISSION SERVICE GROUP 61 Technical Service Information "INCORRECT" INSTALLATION IF THE ROLLER CLUTCH IS INSTALLED IN THIS DIRECTION, THE REVERSE HUB WILL FREEWHEEL IN BOTH DIRECTIONS, WHEN INSTALLED IN CASE. COMPONENT REBUILD Transmission Case Assembly (Cont'd) 30. Install the low roller clutch into the reverse hub in the direction shown in Figure 96, and rotate slightly clock-wise to lock it in place. Caution: If the roller clutch is installed in reverse hub in the direction shown in Figure 95, the reverse hub will freewheel in both directions, when installed in case. 31. Rotate the transmission in fixture so the bell housing is facing up, as shown in Figure 97. 32. Install the reverse hub and low roller clutch assembly into the case by rotating clockwise, as shown in Figure 97, until fully seated. Note: Reverse clutch hub should freewheel clockwise and lock counter-clockwise after installation in case. 33. Install the reverse clutch "Wave" plate on top of the reverse piston in the case, as shown in Figure 98. 34. Install the reverse clutch pack beginning with a steel plate and alternating with a friction plate as shown in Figure 98, until the proper amount of plates are installed. Figure 95 Continued on Page 63. "CORRECT" INSTALLATION LOW ROLLER CLUTCH ASM. 110 REVERSE HUB ASSEMBLY INSTALL IN THIS DIRECTION AND TURN SLIGHTLY CLOCK-WISE TO LOCK IN PLACE 110 REVERSE CLUTCH HUB AND LOW ROLLER CLUTCH ASM. Copyright © 2003 ATSG Figure 96 62 Copyright © 2003 ATSG Figure 97 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 97 98 99 100 Transmission Case Assembly (Cont'd) 35. Install the reverse clutch backing plate on top of the last friction, as shown in Figure 98. 36. Install the reverse clutch backing plate snap ring, as shown in Figure 98, and ensure that it is fully seated in case groove. Note: The number of reverse plates is model sensitive and may vary from the illustration. A stack-up clearance measurement is not required for the reverse clutch. 37. Install the number 12 thrust bearing and rear ring gear into case, as shown in Figure 99. Note: Before installing snap ring provisions must be made to retain output shaft fully seated against rear bearing. 38. Install the output shaft snap ring onto output shaft, as shown in Figure 99 Note: Do not over stretch snap ring during installation. Ford recommends a new snap ring for this location. 39. Ensure that snap ring is fully seated in groove in output shaft, and the case is finally ready for the final assembly process. 101 106 107 112 97 98 99 100 101 LOW/REVERSE CLUTCH BACKING PLATE SNAP RING LOW/REVERSE CLUTCH BACKING PLATE LOW/REVERSE CLUTCH FRICTION PLATES (6) LOW/REVERSE CLUTCH STEEL PLATES (6) LOW/REVERSE CLUTCH "WAVE" PLATE 106 OUTPUT SHAFT SNAP RING 107 REAR PL ANETARY RING GEAR 112 NUMBER 12 THRUST BEARING (RING GEAR TO INNER RACE) Copyright © 2003 ATSG Figure 98 Copyright © 2003 ATSG Figure 99 AUTOMATIC TRANSMISSION SERVICE GROUP 63 Technical Service Information 4 PINION REAR CARRIER 6 PINION REAR CARRIER REQUIRES 4 TANG THRUST WASHERS BOTH SIDES REQUIRES 3 TANG THRUST WASHER F0TZ-7A166-D 4 PINION REAR PLANETARY CARRIER 6 PINION REAR PLANETARY CARRIER F81Z-7D006-AA REQUIRES 4 TANG THRUST WASHERS BOTH SIDES REQUIRES 3 TANG THRUST WASHER F0TZ-7A166-D Copyright © 2003 ATSG Figure 100 Planetary Carrier Differences Both planetary carriers are model sensitive parts, and may contain a 4 pinion carrier or a 6 pinion carrier, as shown in Figures 100, 101. Obviously the 6 pinion carrier has much more torque carrying capacity and is highly recommended, especially in heavy duty applications. The 6 pinion rear carrier also requires 3 tang thrust washers on both sides of the carrier. We have provided you with the part numbers, in Figure 100, that were current at the time of printing this manual. COMPONENT REBUILD Front And Rear Planetary Carriers 1. Inspect planetary carriers for the following; Carrier pins for loosness or damage. Pinion gears for damaged or worn teeth. Pinion gears for free rotation, and wobble. Carrier for cracks, wear and/or damage. 2. Use a new service part if any of the above conditions exist. 3. Set the carriers aside for final assembly. 4 PINION REAR CARRIER Continued on Page 66. 6 PINION REAR CARRIER 4 PINION FORWARD PLANETARY CARRIER 6 PINION FORWARD PLANETARY CARRIER F81Z-7A398-CA Copyright © 2003 ATSG Figure 101 64 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORWARD CLUTCH EXPLODED VIEW 84 83 82 80 79 81 78 77 75 74 76 72 73 72 73 74 75 76 77 78 79 80 81 82 83 84 FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING INNER "O" RING SEAL FORWARD PISTON OUTER LIP SEAL FORWARD CLUTCH PISTON ASSEMBLY FORWARD CLUTCH PISTON APPLY RING FORWARD CLUTCH PISTON "BELLVILLE" RETURN SPRING FORWARD CLUTCH RETURN SPRING SNAP RING FORWARD CLUTCH APPLY PLATE FORWARD CLUTCH "WAVE" PLATE FORWARD CLUTCH FRICTION PLATES FORWARD CLUTCH STEEL PLATES FORWARD CLUTCH BACKING PLATE FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2003 ATSG Figure 102 AUTOMATIC TRANSMISSION SERVICE GROUP 65 Technical Service Information COMPONENT REBUILD Forward Clutch Housing 1. Disassemble the forward clutch housing using Figure 102 as a guide. 2. Clean all forward clutch housing parts using a suitable cleaning solution and dry with compressed air. 3. Inspect all forward clutch housing parts for any wear and/or damage. Note: Ensure that the air bleed ball in the forward clutch piston is free and operational (See Figure 104). 4. Remove and discard the forward clutch inner and outer seals. 5. Place the forward clutch housing on a flat work surface, in the direction shown in Figure 103, and install new sealing rings. 76 75 ENSURE THAT BALL IS FREE AND SEALS 74 Continued on Page 67. 70 73 72 72 70 FORWARD CLUTCH SEALING RINGS (2 REQUIRED) 72 FORWARD CLUTCH HOUSING ASSEMBLY 72 73 74 75 FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING INNER "O" RING SEAL FORWARD PISTON OUTER LIP SEAL FORWARD CLUTCH PISTON ASSEMBLY Copyright © 2003 ATSG Figure 103 66 Copyright © 2003 ATSG Figure 104 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Forward Clutch Housing (Cont'd) 6. Turn forward clutch housing over, as shown in Figure 104, and install forward clutch piston inner "O" ring seal into drum (See Figure 104). 7. Install forward clutch piston outer lip seal into groove in piston, with lip facing the direction shown in Figure 104. 8. Lubricate both seals with a small amount of Trans-Jel®, and install piston into the forward clutch housing with a twisting motion, using care not to damage seals (See Figure 104). 9. Install the forward clutch piston apply ring into groove on top of piston (See Figure 104). 10. Install the forward clutch "Bellville" return spring into housing in the direction shown in Figure 105. 11. Compress the return spring and install return spring snap ring, and ensure it is fully seated (See Figure 105). 12. Install the forward clutch apply plate with the flat side facing up, as shown in Figure 106. 13. Install the forward clutch "Wave" plate on top of the apply plate, as shown in Figure 106. Continued on Page 68. 78 80 79 77 77 FORWARD CLUTCH PISTON "BELLVILLE" RETURN SPRING 78 FORWARD CLUTCH RETURN SPRING SNAP RING 79 FORWARD CLUTCH APPLY PLATE 80 FORWARD CLUTCH "WAVE" PLATE Copyright © 2003 ATSG Figure 105 Copyright © 2003 ATSG Figure 106 AUTOMATIC TRANSMISSION SERVICE GROUP 67 Technical Service Information "SELECTIVE" SNAP RING 84 83 Forward Clutch Housing (Cont'd) 14. Install forward clutch pack beginning with a steel plate and alternating with a friction plate, as shown in Figure 107, until the proper amount of plates are installed. Note: The number of forward plates is model sensitive and may vary from the illustration. 15. Install the forward clutch backing plate, as shown in Figure 107. 16. Install selective forward clutch backing plate snap ring, as shown in Figure 107, and ensure that it is fully seated. 17. Measure the forward clutch clearance between the selective snap ring and the backing plate, as shown in Figure 108. 18. Forward clutch clearance should measure: 0.76 - 1.40mm (.030" - .055"). 19. Change the selective snap ring as necessary to obtain the proper clearance (See Figure 108). 20. Set the completed forward clutch housing aside for future sub assembly. 81 82 Forward Clutch Clearance Should Be 0.76 - 1.40mm (.030" - .055") 81 82 83 84 FORWARD CLUTCH FRICTION PLATES FORWARD CLUTCH STEEL PLATES FORWARD CLUTCH BACKING PLATE FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Selective Snap Rings Available 1.42-1.52mm (.056" - .060") 1.88-1.98mm (.074" - .078") 2.34-2.44mm (.092" - .096") 2.79-2.90mm (.110" - .114") 3.25-3.35mm (.128" - .132") Copyright © 2003 ATSG Figure 107 68 Copyright © 2003 ATSG Figure 108 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information DIRECT CLUTCH HOUSING "FRONT SIDE" EXPLODED VIEW 58 59 57 57 INTERMEDIATE SPRAG ASSEMBLY 58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NUMBER 7) 59 DIRECT CLUTCH HOUSING ASSEMBLY "DO NOT USE" REPLACE WITH PARTS SHOWN ABOVE "DIODE" ONE-WAY CLUTCH ASSEMBLY DIRECT DRUM FOR "DIODE" ONE-WAY CLUTCH ASSEMBLY "DO NOT USE" REPLACE WITH PARTS SHOWN ABOVE Copyright © 2003 ATSG Figure 109 AUTOMATIC TRANSMISSION SERVICE GROUP 69 Technical Service Information DIRECT CLUTCH HOUSING "REAR SIDE" EXPLODED VIEW 59 62 61 60 L20 T F9 A P -7 A 2 62-C Ford 69 67 68 63 64 "SELECTIVE" SNAP RING 59 60 61 62 63 64 66 67 68 69 66 DIRECT CLUTCH HOUSING ASSEMBLY DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH PISTON ASSEMBLY DIRECT CLUTCH PISTON RETURN SPRING ASSEMBLY DIRECT CLUTCH PISTON RETURN SPRING SNAP RING DIRECT CLUTCH FRICTION PLATES DIRECT CLUTCH STEEL PLATES DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2003 ATSG Figure 110 70 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Direct Clutch Housing 1. Disassemble the direct clutch housing using Figures 109 and 110 as a guide. 2. Clean all direct clutch parts with a suitable cleaning solution and dry with compressed air. 3. Inspect all direct clutch parts for any wear and/or damage. Replace as necessary. "EARLY" DESIGN LEVEL 4. Refer to Figures 111 and 112 to ensure that you have compatable parts, especially if it was necessary to replace the sun shell or the direct clutch housing. Note: Use extra care at this step to ensure compatable parts for direct clutch drum. "LATE" DESIGN LEVEL No "Tabs" Added "Tabs" INPUT SUN SHELL - NOTE: Using the early style sun shell "Requires" that you use the number 8A thrust washer on direct drum, and the direct drum that accepts it. SLOTS TO ACCEPT NUMBER 8A THRUST WASHER INPUT SUN SHELL - New design have "Tabs" added to the center of the sun shell slots, as shown above, which now support the direct drum for the required clearance between the direct and forward clutch housings, and allows elimination of the number 8A thrust washer. "Late" design sun shell will retro-fit back on all models. NUMBER 8A THRUST WASHER "NO" SLOTS A P -7 A 2 62-C L- T F9 20 Ford Copyright © 2003 ATSG Figure 111 Copyright © 2003 ATSG Figure 112 AUTOMATIC TRANSMISSION SERVICE GROUP 71 Technical Service Information COMPONENT REBUILD DO NOT USE THIS STYLE DRUM "DIODE" STYLE ONE-WAY CLUTCH DIRECT DRUM FOR "DIODE" STYLE ONE-WAY CLUTCH Copyright © 2003 ATSG Figure 113 Direct Clutch Housing (Cont'd) 5. We have illustrated the "Diode" style one-way intermediate clutch and the associated direct clutch drum in Figure 113. Note: Do Not use this type of one-way clutch in this unit. It will not live. 6. Place the direct clutch housing on a flat work surface in the direction shown in Figure 114. 7. Install the number 7 thrust washer, as shown in Figure 114, and retain with Trans-Jel®. 57 58 59 58 59 58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NO. 7) 59 DIRECT CLUTCH HOUSING ASSEMBLY 57 INTERMEDIATE SPRAG ASSEMBLY 58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER (NO. 7) 59 DIRECT CLUTCH HOUSING ASSEMBLY Copyright © 2003 ATSG Figure 114 72 Copyright © 2003 ATSG Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD 62 T F9 P A 2 62-C -7A L- 20 Ford Direct Clutch Housing (Cont'd) 8. Install the intermediate sprag assembly and the outer sprag race, as shown in Figure 115. 9. After installing intermediate sprag assembly, check to ensure proper operation, as shown in Figure 116. Note: Outer sprag race should freewheel counter-clockwise and lock clockwise, as shown in Figure 116. 10. Turn the direct clutch housing over on a flat work surface, as shown in Figure 117. 11. Install the inner direct clutch piston lip seal in the groove in drum, with the lip facing in the direction shown in Figure 117. 12. Install the outer direct clutch piston lip seal in the groove in drum, with the lip facing in the direction shown in Figure 117. 13. Lubricate both seals and both piston surfaces with a small amount of Trans-Jel®. 14. Install the direct clutch piston assembly into direct clutch housing with a twisting motion, using care so as not to damage the lip seals. (See Figure 117). 61 60 Continued on Page 74. 59 FREEWHEEL OUTER SPRAG RACE FREEWHEEL HOLD DIRECT CLUTCH DRUM 59 DIRECT CLUTCH HOUSING ASSEMBLY 60 DIRECT CLUTCH PISTON INNER LIP SEAL 61 DIRECT CLUTCH PISTON OUTER LIP SEAL Copyright © 2003 ATSG Figure 116 Copyright © 2003 ATSG Figure 117 AUTOMATIC TRANSMISSION SERVICE GROUP 73 Technical Service Information COMPONENT REBUILD Direct Clutch Housing (Cont'd) 15. Install the direct clutch piston return spring into direct clutch housing, as shown in Figure 118. 16. Compress the return spring assembly using a foot press and install the direct clutch return spring snap ring (See Figure 118). 17. Install the number 8A thrust washer at this time if your unit requires one because of the early style sun shell (See Figure 119) Note: Refer to Figures 111 and 112 for the information regarding the 8A thrust washer, and compatable parts. 64 63 18. Install the direct clutch pack beginning with a steel plate and alternating with a friction plate, as shown in Figure 120, until you have proper amount of plates installed. Note: The number of direct plates is model sensitive and may vary from illustration. 19. Install the direct clutch backing plate on top of the last friction plate, as shown in Figure 120. 20. Install the selective direct clutch backing plate snap ring, as shown in Figure 120, and ensure that it is fully seated. 21. Measure the direct clutch clearance between the selective snap ring and the backing plate, as shown in Figure 121. 22. Direct clutch clearance should measure: 1.15 - 2.06mm (.045" - .081"). 23. Change the selective snap ring as necessary to obtain the proper clutch clearance. Refer to Figure 121 for snap rings available. 24. Set the completed direct clutch housing aside for future sub-assembly. 65 59 A P -7 A 2 62-C L- T F9 20 Ford 59 DIRECT CLUTCH HOUSING ASSEMBLY 63 DIRECT CLUTCH PISTON RETURN SPRING ASSEMBLY 64 DIRECT CLUTCH PISTON RETURN SPRING SNAP RING 65 NUMBER 8A THRUST WASHER (NOT USED ALL MODELS) Copyright © 2003 ATSG Figure 118 74 Copyright © 2003 ATSG Figure 119 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 69 "SELECTIVE" SNAP RING 68 A P -7 A 2 62-C L- T F9 20 Ford 66 67 Direct Clutch Clearance Should Be 1.15 - 2.06mm (.045" - .081") Selective Snap Rings Available 1.65-1.75mm (.065" - .069") 1.88-1.98mm (.074" - .078") 2.10-2.20mm (.083" - .087") Copyright © 2003 ATSG Figure 121 -C A A262 P -7 L- T F9 20 Ford 66 DIRECT CLUTCH FRICTION PLATES 67 DIRECT CLUTCH STEEL PLATES 68 DIRECT CLUTCH BACKING PLATE Copyright © 2003 ATSG Figure 120 AUTOMATIC TRANSMISSION SERVICE GROUP 75 Technical Service Information COMPONENT REBUILD Forward And Direct Clutch Sub-Assemblies 1. We are once again showing you the difference between the "Early" and "Late" direct clutch housings in Figures 122 and 123, as this is the last chance you will have to install the number 8A thrust washer, if you require one. 2. Place the completed direct clutch housing on a flat work surface in the direction that is shown in Figure 123. 3. Install the completed forward clutch housing into the completed direct clutch housing by rotating back and forth until fully seated, as shown in Figure 123. 4. Install the number 9A thrust bearing into the forward clutch housing in the direction shown in Figure 124, with black side facing up. 5. Install the number 8C thrust washer onto the forward ring gear and hub assembly, as shown in Figure 125, and retain with Trans-Jel®. 6. Install forward ring gear and thrust washer into forward clutch plates, as shown in Figure 126, by rotating back and forth until fully seated. Continued on Page 78. 72 Some Models Only NUMBER 8A THRUST WASHER Does Not Use Number 8A Thrust Washer And Requires Late Sun Shell 59 T F9 A P -7 A 2 62-C 59 L- 20 Ford 59 "EARLY" DIRECT CLUTCH HOUSING ASSEMBLY 59 "L ATE" DIRECT CLUTCH HOUSING ASSEMBLY 72 FORWARD CLUTCH HOUSING ASSEMBLY Copyright © 2003 ATSG Figure 122 76 Copyright © 2003 ATSG Figure 123 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information NUMBER 8C THRUST WASHER FORWARD RING GEAR AND HUB ASSEMBLY Copyright © 2003 ATSG Figure 125 88 89 72 72 T F9 A P -7 A 2 62-C 59 T F9 A P -7 A 2 62-C 59 L- 20 Ford L- 20 Ford 59 DIRECT CLUTCH HOUSING ASSEMBLY 72 FORWARD CLUTCH HOUSING ASSEMBLY 89 NUMBER 9A THRUST BEARING ASSEMBLY 59 DIRECT CLUTCH HOUSING ASSEMBLY 72 FORWARD CLUTCH HOUSING ASSEMBLY 88 FORWARD RING GEAR AND HUB ASSEMBLY Copyright © 2003 ATSG Figure 124 Copyright © 2003 ATSG Figure 126 AUTOMATIC TRANSMISSION SERVICE GROUP 77 Technical Service Information COMPONENT REBUILD NUMBER 10A THRUST BEARING FORWARD PLANETARY Forward And Direct Clutch Sub-Assemblies 7. Install the number 10A thrust bearing onto the forward planetary carrier, in the direction that is shown in Figure 127, and retain the bearing with Trans-Jel®. 8. Turn the planetary carrier over and install the number 9B thrust bearing into the planetary carrier in the direction shown in Figure 128. Note: Black side faces up. 9. Install the complete forward planetary carrier assembly into the ring gear, by rotating into position, as shown in Figure 129. Continued on Page 79. 91 Copyright © 2003 ATSG Figure 127 72 NUMBER 9B THRUST BEARING T F9 -C A A262 P -7 59 L- FORWARD PLANETARY 20 Ford 59 DIRECT CLUTCH HOUSING ASSEMBLY 72 FORWARD CLUTCH HOUSING ASSEMBLY 91 "6 PINION" FORWARD PLANETARY CARRIER ASSEMBLY Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 128 78 Figure 129 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Forward And Direct Clutch Sub-Assemblies 10. Install the proper sun gear shell over the entire assembly, as shown in Figure 130. 11. Hold the completed assembly together and roll complete assembly over so that it is setting on the sun gear, as shown in Figure 131. 12. Install the number 8B thrust washer onto the forward clutch drum surface, in the direction shown in Figure 131. 13. Install the installation tool onto the complete assembly, as shown in Figure 131, and set the completed assembly aside for final assembly. NUMBER 8B THRUST BEARING 94 72 COMPLETED FORWARD/DIRECT ASSEMBLY T F9 A P -7 A 2 62-C 59 L- 20 Ford 59 DIRECT CLUTCH HOUSING ASSEMBLY 72 FORWARD CLUTCH HOUSING ASSEMBLY 94 "L ATE" SUN GEAR AND SHELL ASSEMBLY Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 130 Figure 131 AUTOMATIC TRANSMISSION SERVICE GROUP 79 Technical Service Information CENTER SUPPORT EXPLODED VIEW CENTER SUPPORT CENTER SUPPORT HUB CENTER SUPPORT BALL BEARING 50 49 RETAINING BOLTS (3) 48 CENTER SUPPORT ASM. (SERVICED AS ASSEMBLY) 49 CENTER SUPPORT DIRECT CLUTCH SEALING RINGS (2) 50 NUMBER 6 THRUST WASHER 48 Copyright © 2003 ATSG Figure 132 CENTER SUPPORT BALL BEARING BALL BEARING (KOYO 6906) RETAINING BOLTS (3) CENTER SUPPORT CENTER SUPPORT HUB COMPONENT REBUILD Center Support Assembly 1. Disassemble center support, if necessary, using Figure 132 as a guide. 2. Clean all center support parts thoroughly using a suitable cleaning solution and blow dry with compressed air. 3. Inspect all center support parts thoroughly for any wear and/or damage. 4. Remove and discard the two center support direct clutch sealing rings (See Figure 132). 5. It is not necessary to remove the center support from the hub, but if you did, assemble the hub to support as shown in Figure 133, and torque the retaining bolts to 9 -14 N·m (80-100 in.lb.). 6. The ball bearing in the center support is not serviced by Ford, but is available from your local bearing supply house using the number supplied in Figure 133. 7. Install a new ball bearing into center support, as shown in Figure 133, using proper bearing drivers. 8. Turn the center support over and install new sealing rings into the grooves in center support hub, as shown in Figure 134. Continued on Page 81. Copyright © 2003 ATSG Figure 133 80 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Center Support Assembly 9. If the sealing rings are the "Hook" joint type, ensure that they are properly hooked and that they rotate freely in the grooves. 10. Install the number 6 thrust washer onto center support, as shown in Figure 134, and retain with Trans-Jel®. 11. Set the completed center support assembly aside for final assembly (See Figure 135). 50 49 48 Component Rebuild Continued on Page 82. 48 CENTER SUPPORT ASM. (SERVICED AS ASSEMBLY) 49 CENTER SUPPORT DIRECT CLUTCH SEALING RINGS (2) 50 NUMBER 6 THRUST WASHER Copyright © 2003 ATSG Figure 134 COMPLETED CENTER SUPPORT ASSEMBLY Copyright © 2003 ATSG Figure 135 AUTOMATIC TRANSMISSION SERVICE GROUP 81 Technical Service Information INTERMEDIATE/OVERDRIVE SUPPORT ASSEMBLY EXPLODED VIEW 38 37 44 45 41 37 38 39 41 42 39 42 INTERMEDIATE AND OVERDRIVE CLUTCH CYLINDER 44 INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL 45 INTERMEDIATE CLUTCH PISTON OVERDRIVE CLUTCH PISTON RETURN SPRING SNAP RING OVERDRIVE CLUTCH PISTON RETURN SPRING OVERDRIVE CLUTCH PISTON INTERMEDIATE CLUTCH PISTON INNER LIP SEAL Copyright © 2003 ATSG Figure 136 COMPONENT REBUILD Intermediate/Overdrive Support Assembly 1. Disassemble intermediate/overdrive cylinder using Figure 136 as a guide. 2. Clean all intermediate/overdrive cylinder parts thoroughly using a suitable cleaning solution. 3. Inspect all intermediate/overdrive cylinder parts thoroughly for any wear and/or damage. 4. Remove and discard overdrive clutch molded piston and both intermediate clutch piston lip seals. 5. Place the intermediate/overdrive cylinder on a flat work surface, in the direction shown in Figure 137. 82 6. Install a new intermediate clutch piston inner lip seal into the groove in cylinder, with the lip facing the direction shown in Figure 137. 7. Install a new intermediate clutch piston outer lip seal into the groove in piston, with the lip facing the direction shown in Figure 137. 8. Lubricate both lip seals with Trans-Jel®, and install piston assembly into cylinder, as shown in Figure 137. 9. Turn the cylinder over, as shown in Figure 138, and install a new overdrive molded piston. Continued on Page 83. AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 45 37 38 44 39 41 42 42 37 OVERDRIVE CLUTCH PISTON RETURN SPRING SNAP RING 38 OVERDRIVE CLUTCH PISTON RETURN SPRING 39 OVERDRIVE CLUTCH MOLDED PISTON ASSEMBLY 41 42 44 45 INTERMEDIATE CLUTCH PISTON INNER LIP SEAL INTERMEDIATE AND OVERDRIVE CLUTCH CYLINDER INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL INTERMEDIATE CLUTCH PISTON Copyright © 2003 ATSG Figure 138 Copyright © 2003 ATSG Figure 137 Intermediate/Overdrive Support Assembly (Cont'd) 10. Install the overdrive clutch piston return spring in the direction shown in Figure 138. 11. Compress the return spring and install snap ring and ensure it is fully seated (See Figure 138). 12. Set completed intermediate/overdrive clutch cylinder aside for the final assembly process. (See Figure 139). Copyright © 2003 ATSG Figure 139 AUTOMATIC TRANSMISSION SERVICE GROUP 83 Technical Service Information OVERDRIVE GEARSET EXPLODED VIEW 24 29 25 27 30 32 33 28 24 25 26 27 28 29 30 32 33 26 OVERDRIVE ROLLER OUTER RACE "FLAT" SNAP RING OVERDRIVE ROLLER OUTER RACE NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER OVERDRIVE PLANETARY CARRIER ASSEMBLY NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT OVERDRIVE INTERNAL RING GEAR CENTER SHAFT ASSEMBLY CENTER SHAFT TO RING GEAR "WAVE" SNAP RING NUMBER 5 THRUST BEARING, CENTER SHAFT TO SUPPORT Copyright © 2003 ATSG Figure 140 COMPONENT REBUILD Overdrive Gearset Assembly 1. Disassemble overdrive gearset using Figure 140 as a guide. 2. Clean all overdrive gearset parts thoroughly using a suitable cleaning solution. 3. Inspect all overdrive gearset parts thoroughly for any wear and/or damage. 84 4. Position the overdrive ring gear on a flat work surface, as shown in Figure 141. 5. Install overdrive roller clutch outer race into overdrive ring gear, as shown in Figure 141. Note: Groove in outer race must face up, as shown in Figure 141. AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 24 GROOVE FACING UP Ensure that snap ring is fully seated. 25 Copyright © 2003 ATSG Figure 142 29 26 27 24 OVERDRIVE ROLLER OUTER RACE "FLAT" SNAP RING 25 OVERDRIVE ROLLER OUTER RACE 29 OVERDRIVE INTERNAL RING GEAR Copyright © 2003 ATSG Figure 141 Overdrive Gearset Assembly (Cont'd) 6. Install the flat snap ring into the groove in ring gear, as shown in Figure 141, and ensure that it is fully seated, as shown in Figure 142. 7. Install number 3 thrust washer onto back of the overdrive planetary carrier and retain with a small amount of Trans-Jel® (See Figure 143). 26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER 27 OVERDRIVE PLANETARY CARRIER ASSEMBLY Copyright © 2003 ATSG Figure 143 Continued on Page 86. AUTOMATIC TRANSMISSION SERVICE GROUP 85 Technical Service Information COMPONENT REBUILD Overdrive Gearset Assembly (Cont'd) 8. Flip the overdrive planetary carrier over with the number 3 thrust washer installed, as shown in Figure 144. 9. Install the number 6 thrust bearing onto the overdrive planetary carrier in the direction shown in Figure 144. 10. Install completed overdrive planetary carrier into the pre-assembled overdrive ring gear, as shown in Figure 145, by rotating into position until fully seated. 11. Install the overdrive center shaft onto overdrive planetary carrier, as shown in Figure 146. 12. Install the wave center shaft snap ring into the groove in ring gear, as shown in Figure 146. Note: Use a brass drift against the wave snap ring to ensure that it is fully seated. 13. Install the number 5 thrust bearing on overdrive center shaft, in direction shown in Figure 146, and retain with Trans-Jel®. 14. Set the completed overdrive gearset aside for additional sub-assembly after the coast clutch housing is built (See Figure 147). Component Rebuild Continued on Page 88. 28 27 26 28 29 27 26 26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER 27 OVERDRIVE PLANETARY CARRIER ASSEMBLY 28 NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT 26 NUMBER 3 THRUST WASHER, OUTER RACE TO CARRIER 27 OVERDRIVE PLANETARY CARRIER ASSEMBLY 28 NUMBER 6 THRUST BEARING, CARRIER TO CENTER SHAFT Copyright © 2003 ATSG Figure 144 86 Copyright © 2003 ATSG Figure 145 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 32 COMPLETED OVERDRIVE GEARSET 33 30 Copyright © 2003 ATSG Figure 147 30 CENTER SHAFT ASSEMBLY 32 CENTER SHAFT TO RING GEAR "WAVE" SNAP RING 33 NUMBER 5 THRUST BEARING, CENTER SHAFT TO SUPPORT Copyright © 2003 ATSG Figure 146 AUTOMATIC TRANSMISSION SERVICE GROUP 87 Technical Service Information 60 Tooth Coast Clutch Steel Plates Required With This Style 64 Tooth Overdrive Clutch Friction Plates Required With This Style "CAST IRON" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION 32 Tooth Coast Clutch Steel Plates Required With This Style 32 Tooth Overdrive Clutch Friction Plates Required With This Style "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION 32 Tooth Coast Clutch Steel Plates Required With This Style 32 Tooth Overdrive Clutch Friction Plates Required With This Style "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 6.8L AND 7.3L "WITH" PTO OPTION Copyright © 2003 ATSG Figure 148 Coast Clutch Housing Changes The coast clutch housing is model sensitive and there are three different versions, as shown above. The "Cast-Iron" coast clutch housing is the same as the E4OD housing. When the "Stamped Steel" version was introduced, it affected other parts in the transmission, like the coast clutch steel plates and the overdrive friction plates, as shown above. 88 The sealing ring locations on the oil pump stator were also affected, which makes the oil pump stator shaft model sensitive, depending on which coast clutch housing you have, but we will discuss this in the oil pump section of this manaul. The rebuild procedure on all 3 coast clutch housings is very similar and begins on Page 90. AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 13 15 16 14 17 18 21 20 COAST CLUTCH HOUSING "PTO" EQUIPPED MODELS 19 BALL BEARING KOYO 6912 C3 13 14 15 16 17 18 19 20 21 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN) OVERDRIVE ROLLER CLUTCH ASSEMBLY COAST CLUTCH MOLDED PISTON COAST CLUTCH PISTON RETURN SPRING ASSEMBLY COAST CLUTCH PISTON RETURN SPRING SNAP RING COAST CLUTCH FRICTION PLATES COAST CLUTCH STEEL PLATES COAST CLUTCH BACKING PLATE COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE) KOYO 6912 C3 (AVAILABLE LOCAL BEARING SUPPLY HOUSE) Copyright © 2003 ATSG Figure 149 AUTOMATIC TRANSMISSION SERVICE GROUP 89 Technical Service Information COMPONENT REBUILD BALL BEARING KOYO 6912 C3 COAST CLUTCH HOUSING "PTO" EQUIPPED MODELS KOYO 6912 C3 (AVAILABLE LOCAL BEARING SUPPLY HOUSE) Coast Clutch Housing 1. Disassemble the coast clutch housing using Figures 148 and 149 as a guide. Note: Figure 148 illustrates the 3 different coast clutch housings available in 4R100 transmissions. The procedures for rebuild are very similar. We will be illustrating the "PTO" version. 2. Clean all coast clutch housing parts thoroughly using a suitable cleaning solution and dry with compressed air. 3. Inspect all coast clutch parts thoroughly for any wear and/or damage. 4. Remove and discard the molded coast clutch piston. (See Figure 149). 5. Replace the ball bearing as necessary using the proper pullers and press (See Figure 150). Note: This ball bearing is not available from Ford individualy, but is available from your local bearing supply under KOYO 6912 C3. 6. Place the coast clutch housing on a flat work surface, as shown in Figure 151. Copyright © 2003 ATSG Continued on Page 91. Figure 150 17 15 16 SEAL PROTECTOR 307-387 13 13 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN) 15 COAST CLUTCH MOLDED PISTON 16 COAST CLUTCH PISTON RETURN SPRING ASSEMBLY 17 COAST CLUTCH PISTON RETURN SPRING SNAP RING Copyright © 2003 ATSG Figure 151 90 Copyright © 2003 ATSG Figure 152 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Coast Clutch Housing (Cont'd) 7. Install lip seal protector 307-387 onto the coast clutch housing, as shown in Figure 151. 8. Lubricate both seals on the new coast clutch piston and install piston into the coast clutch housing, as shown in Figure 151. 9. Install the coast clutch piston return spring assembly, as shown in Figure 152. 10. Compress the return spring assembly using a foot press and install the return spring snap ring, as shown in Figure 152, and ensure that it is fully seated. 11. Install the overdrive roller clutch assembly, as shown in Figure 153, and rotate roller clutch counter-clockwise to lock it in position. 12. Install the coast clutch plates in coast clutch housing, as shown in Figure 154, beginning with a steel plate and alternating with friction plates, until you have proper amount installed. Note: The number of coast plates is model sensitive and may vary from illustration. 13. Install the coast clutch backing plate, as shown in Figure 154. 21 20 18 19 Continued on Page 92. 14 13 13 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN) 14 OVERDRIVE ROLLER CLUTCH ASSEMBLY 13 18 19 20 21 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN) COAST CLUTCH FRICTION PLATES COAST CLUTCH STEEL PLATES COAST CLUTCH BACKING PLATE COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2003 ATSG Figure 153 Copyright © 2003 ATSG Figure 154 AUTOMATIC TRANSMISSION SERVICE GROUP 91 Technical Service Information COMPLETED OVERDRIVE GEARSET ASSEMBLY COAST CLUTCH ASSEMBLY WITH CLUTCHES REMOVED Coast Clutch Clearance Should Be 0.76 - 1.27mm (.030" - .050") Selective Snap Rings Available 1.35 - 1.45mm (.053" - .057") 1.75 - 1.85mm (.068" - .072") 2.15 - 2.25mm (.084" - .088") Copyright © 2003 ATSG Figure 155 Coast Clutch Housing (Cont'd) 14. Install the selective coast clutch backing plate snap ring, as shown in Figure 154, and ensure that it is fully seated. 15. Measure the coast clutch clearance between the selective snap ring and backing plate, as shown in Figure 155. Coast clutch clearance should be 0.76 - 1.27mm (.030" - .050"). 16. Change the selective snap ring as necessary to obtain proper clutch clearance. Refer to Figure 155 for snap ring thickness' available. 17. After you have obtained the proper clearance, remove all of the coast clutch plates. 18. With coast clutch plates removed, install the pre-assembled overdrive gearset onto coast clutch housing, as shown in Figure 156, by rotating counter-clockwise until fully seated. Note: After installation, overdrive gearset should freewheel counter-clockwise and lock in a clockwise direction, while holding the coast clutch housing. 92 Copyright © 2003 ATSG Figure 156 Coast Clutch Housing (Cont'd) 19. Re-install the coast clutch plates, as shown in Figure 157. 20. Install the coast clutch remover/installer, as shown in Figure 158. Special Note: This tool is almost mandatory for the "PTO" version. The overdrive clutches must be installed "before" the coast clutch housing is installed, as they will not pass by the PTO gear. 21. If you are rebuilding the "Non-PTO" version, the input shaft can be used, with transmission centerline horizontal, to install this assembly and then install the overdrive clutches. We do not have that luxury with the "PTO" version, please use the installation tool. Caution: The overdrive one-way clutch may be damaged if the tool is not used or installed correctly. The tool must tightly hold entire assembly. 22. Set the completed assembly aside for the final assembly process (See Figure 158). AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 21 "REQUIRED" ASSEMBLY TOOL 307 S383 20 18 19 Copyright © 2003 ATSG Figure 158 COMPLETED OVERDRIVE GEARSET ASSEMBLY 13 13 18 19 20 21 COAST CLUTCH HOUSING ASM. ("PTO" VERSION SHOWN) COAST CLUTCH FRICTION PLATES COAST CLUTCH STEEL PLATES COAST CLUTCH BACKING PLATE COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2003 ATSG Figure 157 AUTOMATIC TRANSMISSION SERVICE GROUP 93 Technical Service Information OIL PUMP ASSEMBLY "FRONT" SIDE EXPLODED VIEW 3 4 8 1 6 5 2 7 d RF-F81P 7A105-AA or F OIL PUMP ASSEMBLY "REAR" SIDE EXPLODED VIEW 12 13 11 KXV 9.8 10 KXV 9.8 Ford 98 OIL PUMP CONVERTER SEAL OIL PUMP CONVERTER HUB BUS HING OIL PUMP BODY OIL PUMP BODY TO CASE "O" RING SEAL OIL PUMP INNER GEAR OIL PUMP OUTER GEAR STATOR SHAFT CONVERTER SEAL RING STATOR SHAFT AND OIL PUMP COVER ASSEMBLY COAST CLUTCH SEAL RINGS (2 REQUIRED) STATOR SHAFT TO OIL PUMP COVER RETAINING BOLTS (3 REQUIRED) STATOR SHAFT ASSEMBLY OIL PUMP COVER ASSEMBLY OIL PUMP COVER TO OIL PUMP BODY RETAINING BOLTS (12 REQUIRED) RF-F81P-7B324-AA KXV 9.8 KXV 9.8 1 2 3 4 5 6 7 8 9 10 11 12 13 107 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 9 Refer to Page 34 through 37 for specific Oil Pump Differences between "PWM" and "NON-PWM" Copyright © 2003 ATSG Figure 159 94 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 VALVE LINE-UPS IN PUMP ASSEMBLY 15 12 13 11 14 8 9 10 11 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PRESSURE REGUL ATOR VALVE PRESSURE REGUL ATOR VALVE SPRING RETAINER PRESSURE REGUL ATOR VALVE OUTER SPRING PRESSURE REGUL ATOR VALVE INNER SPRING PRESSURE REGUL ATOR BOOST VALVE PRESSURE REGUL ATOR BOOST VALVE SLEEVE PRESSURE REGUL ATOR BOOST VALVE SLEEVE SNAP RING CONVERTER CLUTCH REGULATOR VALVE CONVERTER CLUTCH REGULATOR VALVE SPRING CONVERTER CLUTCH REGULATOR VALVE BORE PLUG BORE PLUG RETAINER CONVERTER CLUTCH CONTROL VALVE ("ON-OFF" ONLY) CONVERTER CLUTCH CONTROL SPRING ("ON-OFF" ONLY) CONVERTER CLUTCH CONTROL VALVE BORE PLUG CONVERTER CLUTCH CONTROL VALVE LINE-UP ("PWM" ONLY) 5 6 7 Refer to Page 34 through 37 for specific Oil Pump Differences between "PWM" and "NON-PWM" Copyright © 2003 ATSG Figure 160 AUTOMATIC TRANSMISSION SERVICE GROUP 95 Technical Service Information COMPONENT REBUILD OIL PUMP BODY CONVERTER SEAL OIL PUMP BODY CONVERTER BUSHING d or F RF-F81P 7A105-AA OIL PUMP BODY Copyright © 2003 ATSG Figure 161 I.D. DOT MUST FACE UP OIL PUMP INNER GEAR OIL PUMP OUTER GEAR Oil Pump Body And Cover Assembly 1. Disassemble the oil pump and cover assembly using Figure 159 as a guide. 2. Clean all of the oil pump and cover parts using a suitable cleaning solution. 3. Inspect all oil pump and cover parts for any wear and/or damage. Note: Refer to Pages 34 through 37 for the differences between PWM and NON-PWM, if any parts replacement is necessary. 4. Remove and discard oil pump converter seal, oil pump body to case seal ring, and the two coast clutch seal rings (See Figure 159). 5. Install new converter bushing into the oil pump body, as shown in Figure 161, using the proper drivers for removal and installation. 6. Install new converter hub seal into the oil pump body, as shown in Figure 161, using the proper drivers for removal and installation. 7. Turn the oil pump body over and install inner and outer pump gears, as shown in Figure 162, and lubricate with transmission fluid. 8. Set the completed pump body aside for the future sub-assembly (See Figure 163). 9. Install the valves, springs and bore plugs into the oil pump cover assembly exactly as shown in Figure 160. Note: Refer to Pages 34 through 37 for the specific differences between PWM and the NON-PWM pump covers. 10. It is not necessary to remove the stator shaft assembly from the pump cover unless damage is apparent (See Figure 164). Continued on Page 97. OIL PUMP BODY COMPLETED OIL PUMP BODY ASSEMBLY Copyright © 2003 ATSG Figure 162 96 Copyright © 2003 ATSG Figure 163 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COAST CLUTCH SEAL RINGS ARE HIGHER ON THE PUMP TOWER COAST CLUTCH SEAL RINGS ARE LOW ON PUMP TOWER (LIKE E4OD) USED WITH THE "CAST IRON" COAST CLUTCH DRUM USED WITH THE "STAMPED STEEL" COAST CLUTCH DRUM Copyright © 2003 ATSG Figure 164 COAST CLUTCH SEAL RINGS (2) RETAINING BOLTS (3) OIL PUMP STATOR SHAFT ASSEMBLY Oil Pump Body And Cover Assembly (Cont'd) 11. If removal was necessary because of damage, refer to Figure 164, to ensure the replacement part is correct. 12. Install the stator shaft assembly into the pump cover, as shown in Figure 165, and torque the 3 retaining bolts to 9-11 N·m (80-100 in.lb.), as shown in Figure 166. 13. Install the two coast clutch sealing rings into their grooves in the stator shaft assembly, as shown in Figure 165. Continued on Page 98. OIL PUMP COVER Sn ap -O n 98 Ford 107 RF-F81P-7B324-AA 98 Ford 107 RF-F81P-7B324-AA Copyright © 2003 ATSG Figure 165 Copyright © 2003 ATSG Figure 166 AUTOMATIC TRANSMISSION SERVICE GROUP 97 Technical Service Information STATOR SHAFT SEALING RING PUMP BODY TO PUMP COVER BOLTS (12 REQUIRED) KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 Copyright © 2003 ATSG 98 Figure 167 Oil Pump Body And Cover Assembly (Cont'd) 14. Turn the oil pump cover over and install the sealing ring on the front of the stator shaft, as shown in Figure 167, and ensure that it is free turning in the groove. 15. Set the completed oil pump body assembly, as shown in Figure 168, over a hole in the work bench so that stator shaft will pass through the hole (See Figure 168). 16. Install the completed oil pump cover assembly onto oil pump body, as shown in Figure 168. 17. Install the 12 pump body to pump cover bolts in the locations shown in Figure 168, and hand tighten only at this time. 18. Install the oil pump alignment strap, as shown in Figure 169, and tighten securely. 19. Torque the 12 pump body to pump cover bolts, working in a criss-cross pattern. Torque the bolts to 24-31 N·m (18-23 ft.lb.), as shown in Figure 169, and then remove alignment strap. 20. Install the number 1 thrust washer, as shown in Figure 170, and retain with Trans-Jel®, if you are building a unit that is not PTO equipped. Note: The number 1 thrust washer is not used on PTO equipped vehicles. The ball bearing rests directly on stator on PTO models. 98 Ford 107 RF-F81P-7B324-AA Copyright © 2003 ATSG Figure 168 21. Install the number 2A thrust bearing in the direction shown in Figure 170, and retain with Trans-Jel®. Continued on Page 99. AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PUMP BODY TO CASE SEAL RING KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 98 RF-F81P-7B324-AA KXV 9.8 107 Ford KXV 9.8 ALIGNMENT STRAP Copyright © 2003 ATSG d or F Figure 169 Oil Pump Body And Cover Assembly (Cont'd) 22. Install pump body to case seal ring, as shown in Figure 171, and ensure that it is not twisted in the groove. 23. Set the completed oil pump assembly aside for the final assembly process (See Figure 172). RF-F81P 7A105-AA NUMBER 2A THRUST BEARING NUMBER 1 THRUST WASHER Copyright © 2003 ATSG NOT USED ON "PTO" MODELS Figure 171 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 d or F KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 98 RF-F81P 7A105-AA Ford 107 RF-F81P-7B324-AA KXV 9.8 KXV 9.8 Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 170 Figure 172 AUTOMATIC TRANSMISSION SERVICE GROUP 99 Technical Service Information FORD 4R100 MAIN, LOWER, AND ACCUMULATOR VALVE BODIES DISASSEMBLED 1 2 5 8 7 6 4 9 3 14 15 13 11 10 12 12 20 30 29 28 19 18 17 16 TP- B RF-F6 92-A 7A0 32 31 33 37 36 34 38 24 39 35 23 22 26 44 21 25 27 43 40 42 41 46 73 72 71 70 47 69 48 68 67 49 66 65 50 64 51 52 54 63 53 62 55 61 56 57 58 59 Copyright © 2003 ATSG 60 Figure 173 100 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 MAIN, LOWER, AND ACCUMULATOR VALVE BODY LEGEND Item Description Item 1 LOWER VALVE BODY CASTING 2 HEX HEAD BOLT, (2 REQUIRED) 3 RETAINING PLATE 4 MANUAL 1-2 TRANSITION VALVE SPRING 5 MANUAL 1-2 TRANSITION VALVE 6 SPRING CLIP BORE PLUG RETAINER 7 ENGAGEMENT VALVE BORE PLUG 8 ENGAGEMENT VALVE SPRING 9 ENGAGEMENT VALVE 10 MAIN VALVE BODY CASTING 11 CHECKBALL 1/4", (2 REQUIRED) 12 CHECKBALL 5/16", (2 REQUIRED) 13 MANUAL CONTROL VALVE 14 MANUAL VALVE "E" CLIP 15 SPRING CLIP BORE PLUG RETAINER 16 LOW REVERSE MODULATOR VALVE SLEEVE 17 LOW REVERSE MODULATOR VALVE PLUNGER 18 LOW MODULATOR VALVE SPRING 19 LOW MODULATOR VALVE 20 LOW REVERSE MODULATOR VALVE 21 SPRING CLIP BORE PLUG RETAINER 22 3-4 SHIFT VALVE BORE PLUG 23 3-4 SHIFT VALVE SPRING 24 3-4 SHIFT VALVE 25 2-3 SHIFT VALVE SPRING RETAINING PLATE 26 2-3 SHIFT VALVE SPRING 27 2-3 SHIFT VALVE 28 SOLENOID REGUL ATOR VALVE SPRING RETAINING PLATE 29 SOLENOID REGUL ATOR VALVE SPRING 30 SOLENOID REGUL ATOR VALVE 31 COAST CLUTCH SHIFT VALVE SPRING RETAINING PLATE 32 COAST CLUTCH SHIFT VALVE SPRING 33 COAST CLUTCH SHIFT VALVE 34 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER RETAINING PLATE 35 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER SPRING 36 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER 37 38 39 40 41 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Description 4-3-2 SHIFT TIMING VALVE RETAINING PLATE 4-3-2 SHIFT TIMING VALVE 4-3-2 SHIFT TIMING VALVE SPRING SPRING CLIP BORE PLUG RETAINER 1-2 SHIFT VALVE BORE PLUG DRIVE 2 VALVE 1-2 SHIFT VALVE 1-2 SHIFT VALVE SPRING ACCUMULATOR VALVE BODY CASTING (MODEL SENSITIVE) SPRING CLIP BORE PLUG RETAINER DIRECT CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG DIRECT CLUTCH ACCUM REGULATOR PLUNGER SPRING DIRECT CLUTCH ACCUM REGULATOR PLUNGER DIRECT CLUTCH ACCUM REGULATOR VALVE RETAINER DIRECT CLUTCH ACCUM REGULATOR VALVE SPRING DIRECT CLUTCH ACCUM REGULATOR VALVE SPRING CLIP BORE PLUG RETAINER O.D. CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG O.D. CLUTCH ACCUM REGULATOR PLUNGER SPRING O.D. CLUTCH ACCUM REGULATOR PLUNGER O.D. CLUTCH ACCUM REGULATOR VALVE RETAINER O.D. CLUTCH ACCUM REGULATOR VALVE SPRING O.D. CLUTCH ACCUM REGULATOR VALVE SPRING CLIP BORE PLUG RETAINER INT. CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG INT. CLUTCH ACCUM REGULATOR PLUNGER SPRING INT. CLUTCH ACCUM REGULATOR PLUNGER INT. CLUTCH ACCUM REGULATOR VALVE RETAINER INT. CLUTCH ACCUM REGULATOR VALVE SPRING INT. CLUTCH ACCUM REGULATOR VALVE SPRING CLIP BORE PLUG RETAINER LINE PRESSURE MODUL ATOR SLEEVE LINE PRESSURE MODUL ATOR PLUNGER LINE PRESSURE MODUL ATOR SPRING AND RETAINER ASSEMBLY LINE PRESSURE MODUL ATOR VALVE SPRING LINE PRESSURE MODUL ATOR VALVE Figure 173 Legend COMPONENT REBUILD Valve Body Assemblies 1. Disassemble the main valve body, the lower valve body and the accumulator valve body using Figure 173 as a guide. 2. Disassemble the valve bodies one at a time. Lay each valve line-up out in order as you remove them from the valve body casting. 3. Inspect each valve, valve spring, bore plug and retainers for any wear and/or damage. Caution: Refer to Pages 22 through 33 for the differences in "PTO" valve bodies and the NON-PTO valve bodies and spacer plate. None of these parts will interchange, so if replacement is necessary, use extra care in the inspection process for replacement parts. 4. Clean all valve body parts thoroughly and dry with compressed air. 5. Install each valve train back into their bores exactly as shown in Figure 173, lubricating them with Mercon® fluid as they are installed. 6. Install the checkballs in the main valve body in the locations shown in Figure 173, or refer to Figure 40 for more detail. 7. Install the lower valve body onto main valve body and install the 2 retaining bolts, as shown in Figure 173, and finger tighten only. 8. Set the completed valve bodies aside for the final assembly process. AUTOMATIC TRANSMISSION SERVICE GROUP 101 Technical Service Information FINAL ASSEMBLY Internal Case Components 1. Rotate the pre-assembled case assembly in the fixture so bell housing is facing up, as shown in Figure 174. 2. Install the pre-assembled rear planetary carrier with the washers secured with Trans-Jel® into the reverse hub, as shown in Figure 174, and rotate into position. 102 103 3. Install the rear carrier retaining snap ring, into the reverse clutch hub, as shown in Figure 174, and ensure it is fully seated. Note: The reverse hub may have to be raised up slightly to gain access to the snap ring groove in the reverse clutch hub. 4. Install the pre-assembled direct clutch, forward clutch and sun shell assembly using installation tool, as shown in Figure 175, by rotating into position until fully seated. 5. Remove the T89T-70010-E installation tool. 6. Install intermediate band assembly, as shown in Figure 175, and ensure engagement on the case band anchor. You may want to install the intermediate servo piston at this time to help hold the band in position. INTERMEDIATE BAND ASSEMBLY 104 105 INSTALLATION TOOL T89T-70010-E PRE-ASSEMBLED DIRECT CLUTCH, FORWARD CLUTCH AND SUN SHELL ASSEMBLY 102 REAR CARRIER TO REVERSE HUB RETAINING SNAP RING 103 NUMBER 10B THRUST WASHER 104 6 PINION REAR PL ANETARY CARRIER ASSEMBLY Copyright © 2003 ATSG Figure 174 102 Copyright © 2003 ATSG Figure 175 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY Internal Case Components (Cont'd) 7. Install the intermediate clutch backing plate, as shown in Figure 176, with the gaps in the steel plates at the 6 and 12 o'clock positions in case. 8. Install the intermediate clutch plates, as shown in Figure 176, beginning with a friction plate and alternating with steel plates until you have the proper amount installed. 9. Again the gaps in the steel plates should be at the 6 and 12 o'clock positions in the case. 10. Install pre-assembled center support assembly, as shown in Figure 177, ensuring that the number 6 thrust washer is in place, and align the feed holes. 11. Loosely install the two center support feedbolts as shown in Figure 178. 12. Install intermediate clutch piston return spring, as shown in Figure 177, with one spring tab at the 6 o'clock position. Continued on Page 104. GAPS IN THE 6 AND 12 O'CLOCK POSITIONS 46 53 48 52 54 49 GAPS IN THE 6 AND 12 O'CLOCK POSITIONS 52 INTERMEDIATE CLUTCH FRICTION PLATES 53 INTERMEDIATE CLUTCH STEEL PLATES 54 INTERMEDIATE CLUTCH BACKING PLATE 46 INTERMEDIATE CLUTCH PISTON RETURN SPRING 48 CENTER SUPPORT ASSEMBLY 49 NUMBER 6 THRUST WASHER, CENTER SUPPORT Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 176 Figure 177 AUTOMATIC TRANSMISSION SERVICE GROUP 103 Technical Service Information FINAL ASSEMBLY Internal Case Components (Cont'd) 13. Install pre-assembled intermediate/overdrive cylinder assembly, as shown in Figure 179, and align the feed hole. 14. Place the snap ring into the case and install the clutch spring compressor tool 307-S223, as shown in Figure 180, and tighten the center bolt in the tool to 7 N·m (65 in.lb.). 15. Install the snap ring into the case groove with the gap at 6 o'clock (bottom) position in case. 16. Ensure that the snap ring is fully seated and remove the clutch spring compressor tool. 17. Loosely install a new overdrive clutch cylinder feedbolt as shown in Figure 178. 18. Since we are building the "PTO" version, we must now install the overdrive clutch pack as the overdrive clutches will not pass by the PTO gear on the coast clutch housing. Continued on Page 105. 40 OVERDRIVE CYLINDER FEED BOLT 42 CENTER SUPPORT FEED BOLTS 40 INTERMEDIATE/OVERDRIVE CYLINDER SNAP RING 42 INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 178 104 Figure 179 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY Internal Case Components (Cont'd) 19. With the units that are not equipped with PTO, the procedure would be the same as E4OD. 20. Install the overdrive clutch pack into the case, as shown in Figure 181, beginning with a steel plate and alternating with friction plates, until you have installed the proper amount. Note: The number of overdrive plates is model sensitive and may vary from illustration. 21. Install the overdrive clutch backing plate on top of the last friction plate, with the "dimple" facing up and in the 12 o'clock (top) position in the case (See Figure 181). 22. Install overdrive clutch backing plate selective snap ring, as shown in Figure 181, and ensure that it is fully seated in case groove, with the snap ring gap at the 6 o'clock position. 31 34 "DIMPLE" Continued on Page 106. 35 36 TIGHTEN CENTER BOLT TO 7 N·m (65 IN.LB.) CLUTCH SPRING FIXTURE CLUTCH SPRING COMPRESSOR BAR 31 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) 34 OVERDRIVE CLUTCH BACKING PLATE 35 OVERDRIVE CLUTCH FRICTION PLATES CLUTCH SPRING COMPRESSOR PLATE Copyright © 2003 ATSG Figure 180 Figure 181 AUTOMATIC TRANSMISSION SERVICE GROUP 105 Technical Service Information FINAL ASSEMBLY Internal Case Components (Cont'd) 23. Measure the overdrive clutch clearance using a feeler gauge between the selective snap ring and the backing plate (See Figure 182). 24. Refer to Figure 182 for the specification as the 2 plate and 3 plate stacks are different. 25. Change the selective snap ring as necessary to obtain the proper clearance. The selective snap rings available are listed in Figure 182, along with the OEM part number. 26. Install the pre-assembled coast clutch housing and overdrive gearset as an assembly using the required installation tool 307 S383, as shown in Figure 183. Ensure that the number 5 thrust bearing is still in place on center shaft. Caution: The overdrive one-way roller clutch may be damaged if this tool is not used on the "PTO" equipped transmissions 27. The assembly will have to be rotated back and forth to engage the center shaft splines and all of the overdrive friction plates, and extra care must be used during installation to avoid any damage until fully seated. "REQUIRED" ASSEMBLY TOOL 307 S383 PRE-ASSEMBLED COAST CLUTCH AND OVERDRIVE GEARSET Continued on Page 107. NUMBER 5 THRUST BEARING OVERDRIVE CLUTCH CLEARANCE 2 PLATE 0.68 - 1.33mm (0.27" - 0.52") 3 PLATE 0.81 - 1.47mm (0.32" - 0.58") Selective Snap Rings Available 1.95 - 2.05mm (.077" - .081") = E9TZ-7B421-BA 2.50 - 2.60mm (.098" - .102") = E9TZ-7B421-CA 3.00 - 3.10mm (.118" - .122") = E9TZ-7B421-DA 3.50 - 3.60mm (.138" - .142") = E9TZ-7B421-EA Copyright © 2003 ATSG Figure 182 106 Figure 183 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY KXV 9.8 Internal Case Components (Cont'd) 28. After coast clutch is fully seated, remove the installation tool. 29. Install an alignment dowel in one of the pump holes in case, as shown in Figure 184. 30. Install the input shaft into transmission, to also help with alignment concerns (See Figure 184). 31. Install a new oil pump to case gasket on case surface, as shown in Figure 185, and use small amount of Trans-Jel® to help secure in place. 32. Install the pre-assembled oil pump assembly, ensuring the number 2 thrust bearing is secure with Trans-Jel® (See Figure 185). 33. Ensure that the number 1 thrust washer is held in place with Trans-Jel®, if it is used. Note: The number 1 thrust washer is not used on "PTO" models. 34. Fully seat the pump assembly using only hand pressure. Do not use the bolts to pull the pump assembly into the case. 35. Install new washers on pump bolts and install, as shown in Figure 185, hand tight only. KXV 9.8 7 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 KXV 9.8 d or F 9 RF-F81P 7A105-AA 11 10 Continued on Page 108. 13 INPUT SHAFT ALIGNMENT DOWEL 7 9 10 11 13 OIL PUMP ASM. RETAINING BOLTS, M8 X 1.25 X 65 (9 REQ.) OIL PUMP AND COVER ASSEMBLY NUMBER 1 THRUST WASHER (USED NON-PTO MODELS ONLY) OIL PUMP ASSEMBLY TO CASE GASKET NUMBER 2 THRUST BEARING, PUMP TO O.D. SUN GEAR Copyright © 2003 ATSG Figure 184 Copyright © 2003 ATSG Figure 185 AUTOMATIC TRANSMISSION SERVICE GROUP 107 Technical Service Information FINAL ASSEMBLY Internal Case Components (Cont'd) 36. After all pump bolts are installed, torque them to 24-31 N·m (18-23 ft.lb.), using a criss-cross pattern (See Figure 186). 37. Remove input shaft as shown in Figure 186. 38. Rotate transmission in fixture so that bottom pan surface is facing up. 39. Ensure that new feed bolts are used for center support and overdrive clutch cylinder. 40. Torque overdrive clutch cylinder feed bolt to, 8-14 N·m (6-10 ft.lb.) (See Figure 187). 41. Torque both of the center support feed bolts to, 11-16 N·m (8-12 ft.lb.). (See Figure 187). Caution: Overtightening the feed bolts will cause the case to warp, and result in transmission failure. Final Assembly Continued on Page 109. OVERDRIVE CYLINDER FEED BOLT. TORQUE TO 8-14 N·m (6-10 ft.lb.) Sn ap - O n CENTER SUPPORT FEED BOLTS TORQUE TO 11-16 N·m (8-12 ft.lb.) Copyright © 2003 ATSG Figure 186 108 Copyright © 2003 ATSG Figure 187 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY 55 183 182 62 Bottom Pan Components 1. Install eight (8) 5/16" diameter checkballs in their case pockets, as shown in Figure 188. 2. Install EPC blow-off spring and .250" diameter steel ball on top of spring, in location shown in Figures 188 and 189. 3. Install the manual intermediate servo piston, as shown in Figure 189, and ensure engagement with the target area on manual band. 4. Install new spacer plate to case gasket on case surface, as shown in Figure 190. 5. Install spacer plate, reinforcing plate and the 3 retaining bolts, as shown in Figure 190, and hand tighten only at this time. Note: The stamped word "UP" on reinforcing plate should be facing up. 55 MANUAL INTERMEDIATE SERVO ASSEMBLY 182 EPC BLOW-OFF BALL, .250" DIAMETER STEEL BALL 183 EPC BLOW-OFF SPRING Copyright © 2003 ATSG Continued on Page 110. Figure 189 189 .312" DIAMETER RUBBER CHECKBALLS U P 188 185 62 184 .312" DIA. RUBBER CHECKBALLS EPC BLOW-OFF LOCATION 184 185 188 189 SPACER PLATE TO CASE GASKET SPACER PLATE SPACER PLATE REINFORCING PLATE REINFORCING PL ATE RETAINING BOLT, M6 X 1.0 X 42 (3) Copyright © 2003 ATSG Copyright © 2003 ATSG Figure 188 Figure 190 AUTOMATIC TRANSMISSION SERVICE GROUP 109 Technical Service Information FINAL ASSEMBLY 186 U P 62 187 Bottom Pan Components (Cont'd) 6. Install the solenoid screen into the spacer plate, as shown in Figure 191, and rotate clockwise to lock in place. 7. Install the spacer plate to valve body gasket on spacer plate, as shown in Figure 191. 8. Install new "O" ring seal on the solenoid case connector, as shown in Figure 192, lube the "O" ring with Trans-Jel®, and install solenoid body (See Figure 192). 9. Install the nine solenoid body bolts and the one nut, as shown in Figure 192, and hand tighten only at this time. Note: Refer to Valve Body Bolt Chart found on Page 116 for proper locations. 10. Install the pre-assembled upper and lower main valve bodies, as shown in Figure 193, ensuring that manual valve is engaged on manual lever. 11. Install the 14 valve body retaining bolts and the two nuts, as shown in Figure 193, and hand tighten only at this time. Note: Refer to Valve Body Bolt Chart found on Page 116 for proper locations. Continued on Page 111. 186 SPACER PLATE TO MAIN VALVE BODY GASKET 187 SOLENOID SCREEN ASSEMBLY Copyright © 2003 ATSG Figure 191 RETAINING BOLTS (14) RETAINING BOLTS (9) RETAINING NUTS (2) RETAINING NUT UPPER AND LOWER MAIN VALVE BODIES SOLENOID BODY ASSEMBLY U P U P 62 62 "O" RING Copyright © 2003 ATSG Figure 192 110 Copyright © 2003 ATSG Figure 193 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY RETAINING NUTS (2) RETAINING BOLTS (11) U P 62 ACCUMULATOR VALVE BODY Copyright © 2003 ATSG Figure 194 Bottom Pan Components (Cont'd) 12. Install the accumulator valve body, as shown in Figure 194, install 11 retaining bolts and the two nuts and hand tighten at this time. Note: Refer to Valve Body Bolt Chart found on Page 116 for proper locations. 13. Finish tightening the bolts and nuts on the accumulator body (11 bolts, 2 nuts), main control valve body (14 bolts, two nuts), the solenoid body (9 bolts, one nut) and reinforcing plate (3 bolts). Note: Refer to Valve Body Bolt Chart found on Page 116 for proper locations. 14. Torque all valve body bolts and nuts, as shown in Figure 195 to: 9-11 N·m (80-100 in.lb.). Note: Place the manual lever in the reverse position and measure distance that manual valve is protruding past the rear of the valve body casting. It should be approximately .050", as shown in Figure 195. If dimension is not correct, replace the detent spring and roller assembly with a "New" one. 15. Lubricate the seal on the new filter with small amount of Trans-Jel®, and install new filter into bore in oil pump, as shown in Figure 196. Manual Valve should protrude .050" past the rear of valve body casting, with the manual lever in the reverse position. Continued on Page 112. P R N D 2 1 MANUAL VALVE Approx .050" BOTTOM PAN OIL FILTER -O n U P U P 62 62 Sn ap Copyright © 2003 ATSG Figure 195 Copyright © 2003 ATSG Figure 196 AUTOMATIC TRANSMISSION SERVICE GROUP 111 Technical Service Information FINAL ASSEMBLY BOTTOM PAN PAN BOLTS (20) Bottom Pan Components (Cont'd) 16. Install a new pan gasket on case surface, as shown in Figure 197. 17. Install the bottom pan on top of pan gasket, as shown in Figure 197. 18. Install the twenty (20) pan bolts, as shown in Figure 197, and torque all bottom pan bolts to, 14-16 N·m (10-12 ft.lb.). 19. Rotate transmission in fixture so bottom pan is facing down, as shown in Figure 199. PAN GASKET U P 62 FINAL ASSEMBLY Copyright © 2003 ATSG Figure 197 External Components 1. The manual shift levers are also model sensitive as shown in Figure 198. Ensure that you have the proper manual shift lever for the model that you are building. 2. Install the Digital Transmission Range (DTR) sensor, as shown in Figure 199, install 307-351 alignment tool (or equivalent). 3. Install the two sensor retaining bolts, as shown in Figure 199, and torque retaining bolts to, 8-10 N·m (71-88 in.lb.). Continued on Page 113. FORD 4R100 MANUAL SHIFT LEVERS "With" PTO OPTION STAMPED F81P-AA "Without" PTO OPTION STAMPED F75P-BB Ford -7006RFF81P 98 XW4P-AC RJL-B 004361 BD-9C17 BA RETAINING BOLTS (2) d For FORD PART NUMBER F81Z-7A256-AA FORD PART NUMBER F7UZ-7A256-BB Figure 198 112 DIGITAL TRANSMISSION RANGE SENSOR Copyright © 2003 ATSG Figure 199 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FINAL ASSEMBLY TURBINE SHAFT SPEED SENSOR Copyright © 2003 ATSG Figure 200 External Components (Cont'd) 4. Install turbine shaft speed sensor, if equipped, as shown in Figure 200, and torque the bolt to, 8-10 N·m (71-88 in.lb.). 5. Install output shaft speed sensor, if equipped, as shown in Figure 201, and torque the bolt to, 8-10 N·m (71-81 in lb.) Note: The TSS and OSS are model dependant. 6. Install the cooler bypass valve with the sealing washers positioned as shown in Figure 202, and install threaded cooler line case fittings. 7. Torque front fitting to, 30 N·m (22 ft.lb.). Torque rear fitting to, 36 N·m (27 ft.lb.) OUTPUT SHAFT SPEED SENSOR Continued on Page 114. Copyright © 2003 ATSG Figure 201 "4R100" COOLER BYPASS VALVE ASSEMBLY Front "To Cooler" Sealing Washers OEM PART NUMBER F81Z-7H322-AA Rear "From Cooler" Sealing Washers COOLER LINE FITTINGS Copyright © 2003 ATSG Figure 202 AUTOMATIC TRANSMISSION SERVICE GROUP 113 Technical Service Information INPUT SHAFT Ford XW4P-AC RJL-B 004361 BD-9C17 BA -7006RFF81P 98 LONGER SPLINES Ford Copyright © 2003 ATSG Figure 203 FINAL ASSEMBLY External Components (Cont'd) 8. Remove the transmission from bench fixture and set on flat work surface (See Figure 203). 9. Install the input shaft, as shown in Figure 203, with the long spline end going in first. 10. Lubricate the converter hub with Mercon® fluid XT-2-QDX, or equivalent, as shown in Figure 204. 11. Install torque converter and check the seating by placing a straight-edge across the front of case, as shown in Figure 205. 12. Ensure that there is a gap between the converter pilot face and the straight-edge, as shown in Figure 205. CONGRATULATIONS-YOU ARE FINISHED! SPACE Figure 204 114 Figure 205 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TORQUE SPECIFICATIONS DESCRIPTION Oil Pump Assembly to Case (9) Oil Pump Cover to Oil Pump Body (12) Stator Shaft to Oil Pump Cover (3) Center Support Feed Bolts (2) Center Support to Center Support Hub Bolts (3) Overdrive/Intermediate Cylinder Feed Bolt (1) Valve Body and Solenoid Body Bolts and Nuts (All) Spacer Plate Reinforcing Plate to Case (3) Inner Manual Valve Detent Lever Nut (1) Detent Spring to Case (1) Transmission Range Sensor to Case (2) Line Pressure Plug (1) Low One-Way Roller Clutch Inner Race to Case (5) Parking Pawl Abutment Plate to Case (1) Parking Pawl Guide Plate to Case (2) Extension Housing Bolts (9) Front Cooler Line Connector to Case (1) Rear Cooler Line Connector to Case (1) Transmission Oil Pan to Case (20) N·m ft.lbs. 24-31 24-31 9-11 11-16 9-14 8-14 9-11 9-11 41-54 9-11 8-10 8-16 24-34 22-27 22-27 41-54 30 36 14-16 18-23 18-23 in.lbs. 80-100 8-12 80-120 6-10 80-100 80-100 30-40 80-100 75-85 6-12 18-25 16-20 16-20 30-40 22 27 10-12 Copyright © 2003 ATSG Figure 206 AUTOMATIC TRANSMISSION SERVICE GROUP 115 Technical Service Information VALVE BODY BOLT CHART "A" "B" "B" "C" "D" "E" "F" "G" "H" 30 Torx Head 8 mm Head 8 mm Head 8 mm Head 8 mm Head 8 mm Head 8 mm Head 8 mm Head 8 mm Head 9.8 9.8 9.8 9.8 Lower V.B. to Case Nut (1) Main V.B. to Case Nut (1) Accum V.B. to Case Nut (2) Solenoid Body to Case Nut (1) "J" 8 mm Head Solenoid Body (9) (40mm) Accum Valve Body to Case (11) (42mm) Main Valve Body to Case (7) (42mm) Lower V.B. to Main V.B. (2) (35mm) 9.8 Lower V.B. to Case (7) (65mm) G B B Reinforcing Plate (3) (16mm) B B B B B B B B B B J C J D B J C B D D B D D E D B A A D A A A B B A G B H A A A Copyright © 2003 ATSG Figure 207 116 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information BOLT CHART 13 mm Head 13 mm Head 13 mm Head 13 mm Head 13 mm Head 13 mm Head 9.8 9.8 9.8 9.8 Center Support (2) (30mm) "PTO" Cover (6) (19mm) O.D. Cylinder (1) (24mm) Extn Hsng (7) (40mm) Extn Hsng (1 Some) (40mm) 10 mm Head 10 mm Head 10 mm Head 9.8 KXV 9.8 9.8 J 7/16" Head Oil Pan to Case (20) (14mm) Pump Cover to Pump Body (9) (45mm) 30 Torx Head Stator Shaft (3) (17mm) Case to Inner Race (5) (1.875") 8 mm Head 13 mm Head 9.8 9.8 Center Support Hub (3) (16mm) Extn Hsng (2) (92mm) Park Rod Guide Plate (2) (23mm) BOLTS DRAWN ACTUAL SIZE Pump to Case (9) (65mm) Copyright © 2003 ATSG Figure 208 AUTOMATIC TRANSMISSION SERVICE GROUP 117 Technical Service Information Copyright © 2003 ATSG 118 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Copyright © 2003 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 119 Technical Service Information Copyright © 2003 ATSG 120 AUTOMATIC TRANSMISSION SERVICE GROUP