Overview
This document outlines the assembly and maintenance procedures for an Automatic Transaxle/Transmission, likely for a 2005 Ford Mustang. It details the installation of various internal components, special tools required, and critical specifications for proper function and longevity.
Function Description:
The Automatic Transaxle/Transmission is a complex mechanical system responsible for transmitting power from the engine to the drive wheels, automatically adjusting gear ratios to optimize engine speed and torque for varying driving conditions. This particular unit is designed for a 2005 Mustang, indicating a rear-wheel drive application. The assembly process involves the precise installation of numerous sub-assemblies, including planetary gear sets, clutch drums, bands, servos, and control mechanisms, all working in concert to provide smooth and efficient power delivery.
Important Technical Specifications:
- Fluid Type: MERCON® V Automatic Transmission Fluid (XT-5-QM) is specified, highlighting the importance of using the correct fluid for optimal performance and to prevent damage.
- Grease Type: Multi-Purpose Grease (XG-4, ESR-M1C159-A) is used for lubrication during assembly, particularly for seals and bearings, to reduce friction and ensure smooth operation.
- Torque Specifications: Numerous torque values are provided for critical fasteners, ranging from 1 Nm (10 lb-in) to 131 Nm (97 lb-ft). These precise torque settings are crucial for preventing component damage, ensuring proper sealing, and maintaining the structural integrity of the transmission. Examples include:
- Center support screws: 11 Nm (8 lb-ft)
- Main control valve body screws: 10 Nm (89 lb-in)
- Solenoid body screws: 8 Nm (71 lb-in)
- Reverse servo bolts: Stage 1: 5 Nm (44 lb-in), Stage 2: 11 Nm (8 lb-ft)
- Transmission fluid pan screws: 11 Nm (8 lb-ft)
- Extension housing screws: 25 Nm (18 lb-ft)
- Output shaft flange nut: 131 Nm (97 lb-ft)
- Digital TR sensor screws: 10 Nm (89 lb-in)
- Fluid pump screws: 25 Nm (18 lb-ft)
- Overdrive/Intermediate band adjustment screws: 14 Nm (10 lb-ft) (initial tightening), then backed off 1.5 turns. Locknuts are tightened to 54 Nm (40 lb-ft).
- Torque converter flex plate adapter nuts: 44 Nm (33 lb-ft)
- Speed sensor screws: 10 Nm (89 lb-in)
- Fluid Capacity: The transmission requires 8.5L (9 quarts) of automatic transmission fluid.
- Thrust Bearing Selection: A detailed chart is provided for selecting the correct No. 1 thrust bearing based on dimension D (calculated from depth micrometer measurements), with different part numbers (F7TZ-TA, F7TZ-MA, F7TZ-NA, F7TZ-RA, F7TZ-SA) corresponding to specific bearing thicknesses and identification colors (White, Green, Red, Black, Yellow).
- Intermediate Band Bearing Selection: Another chart guides the selection of the correct intermediate band bearing (Service Part Number 7D014) based on dimension E, with different part numbers (XW4Z-CA, XW4X-DA, XW4Z-EA, XW4Z-FA) corresponding to specific bearing thicknesses and identification notches (None, One, Two, Three).
Usage Features (Assembly and Maintenance):
- Special Tools: A comprehensive list of special tools is provided, essential for accurate and safe assembly. These include:
- Adjustment Set, Transmission Band (307-S022)
- Holding Fixture, Transmission (307-003)
- Depth Micrometer (303-D026)
- Alignment Gauge, TR Sensor (307-351)
- Installer, Transmission Extension Housing Oil Seal (307-038)
- Sizer, Piston Seal (307-338)
- Alignment Set, Fluid Pump (307-S039)
- Aligner, Fluid Pump Handle (307-431)
- Aligner, Fluid Pump Pilot (307-432)
- Gauge Bar (307-400)
- Compressor, Servo Cover (307-402)
- Installer, Shift Shaft Fluid Seal (307-050)
- Handle, Torque Converter (307-091)
- Compressor, Cushion Spring (307-401)
- Aligner, Valve Body (307-334)
- Alignment Pins, Transmission Pump (307-399)
- Aligner, Flex Plate (307-403)
- Air Test Plate (307-433-01, 307-433-2, 307-433-3)
- Installer, Drive Pinion Flange (205-479)
- Installer, Output Shaft Flange (307-404)
- Cleaning and Inspection: Emphasizes thorough cleaning of the transmission case and extension housing with solvent and compressed air, followed by detailed inspection for stripped bolt holes, burrs, nicks, obstructions, cracks, or warpage. This proactive approach prevents future issues.
- Component Orientation: Specific instructions are given for the correct orientation of components, such as the output shaft thrust washer (tabs point into the case), output shaft sleeve (cone facing up), center support retaining ring (tapered side facing up), and band apply struts (small "U" notch toward band/case side, large "U" notch toward main control side). Incorrect orientation can lead to transmission damage.
- Lubrication: Petroleum jelly or clean automatic transmission fluid is frequently specified for lubricating seals, O-rings, and thrust washers during installation to prevent damage and ensure proper seating.
- Band Adjustment: Detailed steps for adjusting the overdrive and intermediate bands are provided, including initial tightening, backing off a specific number of turns (1.5 turns), and then tightening the locknut to a specified torque. This ensures proper band engagement and prevents premature wear.
- Fluid Pump Alignment: Special tools are required to correctly align the fluid pump with the adapter plate to prevent gear noise, bushing failure, and leakage.
- Torque Converter Installation: Instructions highlight the importance of lubricating the converter hub and using special tools to install it by pushing and rotating, ensuring it is fully engaged in the pump support and gear. The document also warns against tipping the transmission with the converter installed to prevent it from falling out.
- Digital TR Sensor Alignment: The digital transmission range (TR) sensor must be installed flush against the boss on the case, and its screws tightened in an alternating sequence to prevent binding or damage.
- Air Pressure Test: An air pressure test procedure is mentioned, to be carried out using special tools, indicating a method for verifying the integrity of the transmission's internal seals and circuits.
- Fluid Filling: The transmission is filled with fluid through one of the speed sensor holes after assembly.
Maintenance Features (during assembly):
- New Parts Requirement: The document explicitly states when new parts are required, such as output shaft retaining rings, pump gaskets, and locknuts for band adjustment screws, to ensure reliability.
- Reusability Guidelines: Guidelines are provided for reusing components like the transmission fluid pan gasket (if clean and undamaged) and intermediate/overdrive bands (if installed in the same position as removed and free of significant damage, noting that dark color and hairline cracks are normal for bands).
- Seal Inspection: Regular inspection of O-ring seals for damage is emphasized, with instructions to replace them if necessary and lubricate them before installation.
To Next Page
Need help?
General
