Auto Trans Overhaul E40d

1997 Ford Pickup F150
1997-98 AUTOMATIC TRANSMISSIONS E4OD Overhaul
1997-98 AUTOMATIC TRANSMISSIONS
E4OD Overhaul
APPLICATION
APPLICATION
Application Transmission
Expedition/Navigator 5.4L SFI
E150/250/350 5.4L SFI
E350 6.8L SFI
E350 7.3L Diesel
F150/250 5.4L SFI
F250 5.4L CNG
F250/350 5.8L SFI
F250/350 7.3L Diesel
Super Duty 7.3L Diesel
F250/350 7.5L SFI
Super Duty 7.5L SFI
IDENTIFICATION
The E4OD automatic transmission is identified by a tag located on left side of case, to rear of Transmission
Range (TR) sensor. Top line of tag shows assembly part number and serial number. Second line on tag shows
model number. Last line of tag shows build date. See Fig. 1 .
me
Monday, May 11, 2009 7:08:35
7:08:32 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Identification Tag

Courtesy of FORD MOTOR CO.
DESCRIPTION
The E4OD is a fully automatic, electronically controlled, 4-speed automatic overdrive transmission.
Transmission consists of torque converter clutch, 6 multiple-disc friction clutches, one band, 2 sprag one-way
clutches, a roller one-way clutch and 3 planetary gearsets. See Fig. 2 .
Shift control solenoids provide gear selection and are controlled by the EEC microprocessor. For additional
information on the EEC system, refer to appropriate TESTS W/CODES article in ENGINE PERFORMANCE
section.
The EEC system has self-diagnostic capabilities. Fault codes for faulty engine and transmission sensors,
switches and circuits are stored in the PCM and may be retrieved to aid diagnosis and repair.
Fig. 2: Cross-Sectional View Of E4OD Automatic Transmission

LUBRICATION & ADJUSTMENTS

See appropriate TRANSMISSION SERVICING - A/T article in AUTOMATIC TRANSMISSION
SERVICING section.
ON-VEHICLE SERVICE
EXTENSION HOUSING SEAL & BUSHING
me
Monday, May 11, 2009 7:08:32 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Removal
Raise and support vehicle. Index and remove rear drive shaft. Remove extension seal, using appropriate seal
remover. Using appropriate bushing remover, remove extension housing bushing. Ensure extension housing is
not scored.
Installation
1. Inspect extension housing bushing bore for burrs and remove burrs with an oil stone, as necessary. Install
extension housing bushing, aligning lubrication slot to 6 o'clock position.
2. Install extension housing seal, aligning drain hole to 6 o'clock position. Ensure seal is seated against
extension housing. Install drive shaft, aligning index marks.
EXTENSION HOUSING GASKET
Removal
Raise and support vehicle. Index and remove drive shaft(s). Remove parking brake assembly. On 4WD
vehicles, remove transfer case. See appropriate TRANSMISSION REMOVAL - A/T article under
AUTOMATIC TRANSMISSION SERVICING. Remove transmission mount-to-transmission retaining bolts.
Position transmission jack under transmission, and remove transmission mount-to-crossmember bolts. Remove
9 extension housing bolts. Remove extension housing and discard gasket.
Installation
Install NEW housing gasket and position extension housing on case. Ensure parking pawl spring is properly
seated in case. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete
installation, reverse removal procedure.
PARKING MECHANISM
Removal
Remove extension housing. See EXTENSION HOUSING GASKET . Remove parking rod guide plate
retaining bolts. Remove parking pawl return spring, parking pawl and parking pawl shaft from case. Remove
and discard Torx head bolt (40A) and parking pawl abutment (if required). See Fig. 3 .
Installation
For installation, reverse removal procedure. Ensure return spring end rests on inside surface of case, and
parking rod guide plate dimple is facing inward. Install NEW Torx bolt (if removed). Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
me
Fig. 3: Removing Parking Mechanism

VALVE BODY & INTERMEDIATE BAND SERVO
NOTE: As valve body is disassembled, place individual parts in correct order and
relation to valve body for reassembly. Tag all springs as they are removed.
Removal
1. Remove solenoid body connector heat shield. Remove solenoid body connector by pushing on center tab
and pulling on wire harness. DO NOT attempt to pry tab with pry bar or screwdriver. Check electrical
connector condition.
2. Loosen oil pan bolts and drain fluid. Remove oil pan, filter and "O" ring. DO NOT scratch or damage
aluminum pump bore when removing "O" ring. Remove accumulator body. Remove main control body
me
retaining bolts. Do not remove center 2 bolts. See Fig. 4 . This keeps upper and lower valve body together
during disassembly. Remove main control body.
3. Remove solenoid body Torx retaining bolts and one nut. Push down on solenoid body connector and
remove solenoid body. Remove solenoid screen by rotating and pulling out. See Fig. 5 . Remove
reinforcing plate. Carefully lower separator plate and gasket so check balls, EPC ball and spring are
retained.
Fig. 4: Removing Main Control Valve Body

me
Fig. 5: Removing Solenoid Screen

Installation
1. Clean and inspect valve body thoroughly. DO NOT clean non-metallic check balls with solvent.
2. Install servo spring, servo piston and rod assembly. See Fig. 6 . Lubricate valve body pockets with
petroleum jelly.
3. Place 8 rubber check balls, Electronic Pressure Control (EPC) spring and EPC ball in position. See Fig.
7 . Install separator plate and gaskets. Tighten retaining bolts to specifications. See TORQUE
SPECIFICATIONS. Stamped UP on reinforcing plate MUST be visible.
4. Install solenoid screen and lock in place. Install valve body over studs. Align manual valve with manual
lever. Install and tighten retaining bolts to specification. Install accumulator body retaining bolts. Tighten
to specification. Coat case connector bore with grease and install solenoid body retaining bolts and nut.
Tighten to specification.
5. Install NEW filter and seal assembly. Install oil pan and NEW gasket. Check condition and placement of
pan magnet. Tighten pan bolts to specification. Position solenoid body connector into receptacle. Audible
click indicates full connection. Install solenoid body connector heat shield with offset bending inward.
6. Add transmission fluid and start engine. Fill transmission to proper level. Test vehicle for proper
operation and ensure no leakage is present.
me
Fig. 6: Installing Intermediate Band Servo

me
Fig. 7: Locating Valve Body Check Balls

MANUAL LEVER SEAL
me
Removal
1. Remove manual lever position sensor connector. Remove shift cable from transmission manual lever,
using a large screwdriver, pry control cable and fitting from lever ball and stud.
2. Loosen oil pan bolts and drain transmission fluid. Remove oil pan, filter and "O" ring. Discard filter and
"O" ring. DO NOT scratch or damage aluminum pump bore.
3. Using Lock Nut Pin Remover (T78P-3504-N), remove manual lever roll pin. See Fig. 8 . Using a 21-mm
box wrench, remove inner detent lever nut. Hold lever with crescent wrench. Remove inner detent lever
and park actuating rod assembly from manual lever.
4. Using a 15-mm open end wrench remove and discard outer manual lever shaft nut. Hold lever with
crescent wrench. Remove manual lever. Remove sensor retaining bolts. Remove sensor, manual lever
shaft and seal.
Installation
1. Clean seal bore opening with solvent. Using appropriate seal driver, install seal. Install manual lever
shaft, inner detent lever, park actuating rod assembly and nut. Ensure inner detent lever is seated on flats
of shaft, and rod assembly is through guide plate. Inner lever pin MUST BE aligned with manual valve.
2. Tighten inner detent lever nut to specification. See TORQUE SPECIFICATIONS . Ensure manual
valve detent spring is on inner detent lever and aligned with inner detent.
3. Install manual lever shaft roll pin. Install manual lever position sensor finger tight. Use Gear Position
Sensor Adjustor (T92P-70010-AH) to align manual lever position sensor for Neutral gear position.
Tighten bolts to specification.
4. Install manual lever and NEW nut. Ensure manual lever is seated on flats of shaft. Tighten manual lever
nut to specification. Install manual lever position sensor connector. Install shaft linkage and adjust. See
appropriate TRANSMISSION SERVICING - A/T article in AUTOMATIC TRANSMISSION
SERVICING.
5. Install NEW filter and "O" ring assembly. Install oil pan and NEW gasket. Check condition and
placement of pan magnet. Tighten oil pan retaining bolts to specifications.
me
Fig. 8: Removing Manual Lever Shaft Retaining Pin

TROUBLE SHOOTING
NOTE: After verifying driveability complaint, perform trouble shooting and testing
procedures in this article. For electronic diagnostics and testing, see AUTO
TRANS DIAGNOSIS - E4OD ELECTRONIC article.
NOTE: For engine-related DTCs, see appropriate TESTS W/CODES article in ENGINE
PERFORMANCE section. These DTCs pertain to engine performance and must
be repaired first, as engine performance and related component signals will
me
affect transmission operation and diagnosis.
ENGAGEMENT FAULTS
No Forward Engagement
Fluid level, shift linkage or cable, low line pressure, pump inlet filter and seal assembly, manual valve (stuck or
damaged), valve body leakage (gasket damage), improperly torqued valve body bolts, forward clutch assembly
(damaged stator support, damaged check ball, loose feed bolt, damaged center support, worn clutch
components), forward/reverse sun gear damaged, front planetary assembly damaged, output shaft splines and
low one-way clutch assembly.
No Reverse Engagement
Fluid level, shift linkage or cable, low line pressure, pump inlet filter and seal assembly, manual valve (stuck or
damaged), valve body leakage (gasket damage), improperly torqued valve body bolts, coast clutch assembly,
direct clutch assembly (only if 3rd gear is also inoperative), forward planetary assembly, reverse clutch
assembly, reverse planet assembly and reverse ring gear.
Harsh Reverse Engagement
High line pressure, valve body leakage (gasket damage), improperly torqued valve body bolts, Electronic
Pressure Control (EPC) solenoid stuck, stuck valve body components (direct clutch accumulator valve and
plunger, engagement control valve, direct clutch accumulator regulator valve, springs), pump assembly and
direct clutch assembly.
Harsh Forward Engagement
High line pressure, valve body leakage (gasket damage), improperly torqued valve body bolts, Electronic
Pressure Control (EPC) solenoid stuck, valve body engagement control valve stuck, pump assembly, direct
clutch assembly and forward clutch assembly.
Delayed/Soft Reverse Engagement
Shift linkage or cable, improperly torqued valve body bolts, valve body components (direct clutch accumulator
regulator valve, low reverse modulator valve, springs), coast clutch assembly, direct clutch assembly and
reverse clutch assembly.
Delayed/Soft Forward Engagement
Fluid level, shift linkage or cable, low line pressure, pump inlet filter or seal assembly, improperly torqued
valve body bolts, center support assembly and forward clutch assembly.
No Forward & No Reverse Engagement
Fluid level, internal or external shift linkage, low line pressure, pump inlet filter and seal assembly, manual
valve, valve body leakage (improperly torqued bolts), pump assembly (main regulator/booster valve), center
me
support assembly, forward/reverse sun gear, forward planetary assembly, input shaft, center shaft, output shaft,
overdrive carrier assembly and overdrive overrunning clutch (shift selector in OD with OD switch in cancel
mode).
Harsh Forward & Reverse Engagement
High line pressure, valve body bolts improperly torqued, EPC solenoid stuck, valve body components
(engagement control valve) and pump assembly (main regulator/booster valve).
Delayed/Soft Forward & Reverse Engagement
Shift linkage or cable, fluid level, low line pressure, pump inlet filter and seal assembly, valve body bolts
improperly torqued (gasket damage) and torque converter drainback (initial engagement only).
SHIFTING FAULTS
No Shifts
Fluid level, internal or external shift linkage, pump inlet filter/seal assembly and valve body components.
Early/Late Shift Timing
Incorrect tire size, incorrect speedometer gear, mismatched axle ratio, poor engine performance and valve body
components.
Erratic Or Hunting Shift Timing
Fluid level, pump inlet filter and seal assembly, valve body components and torque converter clutch.
Soft Or Slipping Shift Feel
Fluid level, low line pressure, valve body bolts improperly torqued (gasket damage, leaks), EPC solenoid, valve
body components (line modulator valve, accumulator assembly) and pump assembly.
Harsh Shift Feel
Fluid level, high line pressure, valve body bolts improperly torqued (gasket damage), EPC solenoid,
accumulator assembly, valve body components (line modulator valve) and pump assembly.
No 1st Gear, Engages In Higher Gear
Internal or external shift linkage, transmission range sensor (misadjusted/damaged), valve body bolts
improperly torqued (gasket damage), shift solenoid 1 and/or 2, valve body components (solenoid regulator
valve, 2-3 shift valve, 3-4 shift valve, D2 valve), air bleeds for S1 or S2 circuits missing, damaged band servo
or clutches, reverse ring gear and low/reverse one-way clutch.
No Low Gear (Manual 1st)
me
Internal or external shift linkage, valve body bolts improperly torqued (gasket damage), shift solenoid No. 1,
valve body components (manual control valve, low reverse modulator valve, 1-2 shift valve, 2-3 shift valve,
BS1 check ball, 4-3-2 timing valve) and low/reverse one-way clutch assembly.
No 2nd Gear (Manual 2nd)
Internal or external shift linkage, improperly torqued valve body bolts, valve body components (2-3 shift valve,
3-4 shift valve, manual 1-2 transition valve, BS1 or BS6 check ball), and intermediate clutch assembly and
intermediate one-way clutch assembly.
No 1-2 Shift
Internal or external shift linkage, transmission range sensor (misadjusted/damaged), improperly torqued valve
body bolts, valve body components (D2 valve, 1-2 shift valve, 1-2 manual transition valve, intermediate clutch
accumulator regulator valves, springs), shift solenoid No. 2, intermediate clutch assembly and intermediate one-
way clutch assembly.
No 2-3 Shift
Improperly torqued valve body bolts, valve body components (2-3 shift valve, direct clutch accumulator
regulator valves, springs), shift solenoid No. 1, direct clutch assembly and center support assembly.
No 3-4 Shift
Improperly torqued valve body bolts (gasket damage), shift solenoid No. 1, shift solenoid No. 2, valve body
components (overdrive accumulator regulator valve, 3-4 shift valve, overdrive one-way clutch assembly,
overdrive clutch assembly and overdrive planetary assembly.
No 4-3 Shift
Improperly torqued valve body bolts (gasket damaged), shift solenoid No. 2 and valve body components (check
ball BS2, 3-4 shift valve).
No 3rd To 2nd Shift
Improperly torqued valve body bolts (gasket damaged), shift solenoid No. 1 and valve body components (3-2
shift valve).
No 2-1 Shift
Improperly torqued valve body bolts (gasket damaged), shift solenoid No. 2 and valve body components (D2
shift valve).
Soft/Slipping 1-2 Shift
Improperly torqued valve body bolts (gasket damaged), valve body components (intermediate clutch
accumulator regulator valve or plunger) and intermediate clutch assembly.
me
Improperly torqued valve body bolts (gasket damaged), valve body components (direct clutch accumulator
regulator valve or plunger), center support assembly and direct clutch assembly.
Improperly torqued valve body bolts (gasket damaged), valve body components (overdrive accumulator
regulator valve and spring, overdrive accumulator plunger and springs) and overdrive clutch assembly.
Soft/Slipping Downshifts
Improperly torqued valve body bolts (gasket damaged) and valve body components (check ball CB7, damage
valve body separator plate).
Harsh 1-2 Shift
Improperly torqued valve body bolts (gasket damaged), valve body components (intermediate clutch
accumulator regulator valve or plunger springs) and intermediate clutch assembly.
Harsh 2-3 Shift
Improperly torqued valve body bolts (gasket damaged), valve body components (direct clutch accumulator
valve or plunger), center support assembly and direct clutch assembly.
Harsh 3-4 Shift
Improperly torqued valve body bolts (gasket damaged), valve body components (overdrive accumulator
regulator valve or plunger) and overdrive clutch assembly.
Harsh 4-3 Shift
Improperly torqued valve body bolts (gasket damaged), check ball CB7 missing and separator plate damaged.
Harsh 3-2 Shift
Harsh 2-1 Shift
No Torque Converter Clutch Application
Improperly torqued valve body bolts (gasket damaged), torque converter clutch solenoid, transmission oil
temperature sensor, pump assembly (converter clutch control valve and regulator valve stuck), stator support
and torque converter assembly.
me
Torque Converter Clutch Always Applied (Stalls Vehicle In
Drive & Manual 2nd Gear Only)
Low line pressure, improperly torqued valve body bolts (gasket damaged), torque converter clutch solenoid,
pump assembly (converter clutch control valve) and torque converter assembly.
Torque Converter Clutch Cycling/Shudder/Chatter
Fluid condition, improperly torqued valve body bolts (gasket damaged), torque converter clutch solenoid, pump
assembly, stator support and torque converter assembly.
MISCELLANEOUS FAULTS
No Park Range
Misadjusted internal or external shift linkage, park mechanism components and transfer case and linkages
(4WD).
Transmission Overheating
Fluid level and condition, transmission cooling system, poor engine performance and torque converter clutch.
No Engine Braking In Manual 2nd Gear
Improperly torqued valve body bolts (gasket damaged), check balls BS1, BS2 and BS6 missing or damaged,
check balls BS1, BS6 and CB1 missing or damaged, valve body separator plate, valve body components (4-3-2
timing valve, D2 valve, 2-3 shift valve, coast clutch shift valve, 1-2 manual transition valve, 3-4 shift valve),
coast clutch assembly and intermediate servo/band assembly.
No Engine Braking In Manual 1st Gear
Improperly torqued valve body bolts (gasket damaged), check balls BS1 and CB1 missing or damaged, valve
body components (3-4 shift valve, low reverse clutch modulator valve, D2 valve, 4-3-2 timing valve, 2-3 shift
valve, coast clutch shift valve), valve body separator plate, coast clutch assembly and low reverse clutch
assembly.
No Engine Braking With Overdrive Switch Cancelled (Manual 1st & Manual 2nd Have Engine Braking)
Improperly torqued valve body bolts (gasket damaged) and valve body components (coast clutch solenoid,
check ball BS3, separator plate, 3-4 shift valve).
Fluid Venting/Foaming
Blocked or damaged vent, overfilled, fluid contamination (coolant or water), overheating, pump inlet filter and
seal, and pump to case gasket damage.
me
CLUTCH & BAND APPLICATION

CLUTCH & BAND APPLICATION
Selector Lever Position Elements In Use
"OD" (Overdrive)
1st Gear Forward Clutch, Planetary One-Way Clutch
2nd Gear Intermediate Clutch, Forward Clutch &
Intermediate One-Way Clutch
3rd Gear Forward Clutch, Intermediate Clutch Direct Clutch
& Overdrive One-Way Clutch
4th Gear Forward Clutch, Intermediate Clutch Overdrive
Clutch & Direct Clutch
"2" Coast Clutch, Forward Clutch, Intermediate Clutch,
Intermediate Band, Intermediate One-Way Clutch &
Overdrive One-Way Clutch
"1" Coast Clutch, Forward Clutch, Low/Reverse Clutch,
Overdrive One-Way Clutch & Low Reverse One-Way
Clutch
"R" Coast Clutch, Direct Clutch, Low Reverse Clutch &
Overdrive One-Way Clutch
TESTING
Check fluid level and correct if necessary. See appropriate TRANSMISSION SERVICING - A/T article in
AUTOMATIC TRANSMISSION SERVICING. Use initial road test to verify transmission malfunction. Ensure
engine is operating properly.
ROAD TEST
1. Check minimum throttle upshifts in overdrive. Transmission should start in 1st gear and shift
automatically into and through each gear at pre-determined specifications. See appropriate SHIFT
SPEEDS SPECIFICATIONS (MPH) .
2. With transmission in 4th gear (overdrive), depress overdrive cancel switch. Transmission should
downshift to 3rd gear.
3. Depress accelerator pedal to floor (WOT). Transmission should downshift from 3rd to 2nd or 1st gear,
depending on vehicle speed. See appropriate SHIFT SPEEDS SPECIFICATIONS (MPH) .
4. When traveling above 50 MPH at less than half throttle, move transmission from Overdrive to 2nd gear
and release accelerator pedal. Transmission should immediately downshift into 2nd gear. With vehicle in
2nd gear, move selector to 1st gear and release accelerator pedal. Transmission should downshift to 1st
gear at less than 30-35 MPH.
SHIFT SPEEDS SPECIFICATIONS (MPH)
NOTE: Shift speeds are approximate. All shift speeds may vary somewhat due to
me
production tolerances, rear axle ratios or emission control equipment. Ensure

all tires are factory recommended sizes.
Fig. 9: 5.4L F150/250

Fig. 10: 5.4L E150/250/350

me
Fig. 11: 5.4L E250/350

Fig. 12: 5.4L Expedition & Navigator

me
Fig. 13: 5.4L CNG F250

Fig. 14: 5.4L CNG E250/350

me
Fig. 15: 5.8L F250/350

Fig. 16: 6.8L E350 & "E" - Series Super Duty

me
Fig. 17: 7.3L Diesel E350 & "E" - Series Super Duty
Fig. 18: 7.3L Diesel F250/350 "F" - Series Super Duty

me
Fig. 19: 7.5L F250/350 & "F" - Series Super Duty (Greater Than 8500 GVW)
Fig. 20: 7.5L "F" - Series Super Duty

CAUTION: Perform line pressure test before stall speed test. If line pressure is low at
stall, do not perform stall speed test or transmission damage will occur.
Do not maintain Wide Open Throttle (WOT) in any gear for more than 5
seconds. If engine RPM exceeds maximum specified stall speed, release
accelerator immediately. Clutch or band slippage is indicated.
LINE PRESSURE TEST
1. Connect a 0-300 psi (0-21.1 kg/cm2 ) pressure gauge to line pressure tap on left side of transmission case
just forward of control lever. See Fig. 21 .
2. With engine at normal operating temperature, apply parking and service brakes. Check line pressure in all
me
ranges. Pressure should be approximately as specified. See LINE PRESSURE SPECIFICATIONS .
LINE PRESSURE SPECIFICATIONS

Drive Range Idle psi (kg/cm2 ) WOT Stall psi (kg/cm2 )
"P", "N" 50-65 (3.5-4.6) (Not Applicable)
"R" 70-100 (4.9-7.0) 245-290 (17.2-20.4)
"OD", "2" 50-65 (3.5-4.6) 165-185 (11.6-13.0)
"1" 70-100 (4.9-7.0) 175-210 (12.3-14.8)
Fig. 21: Testing With Pressure Gauge

LINE PRESSURE TEST RESULTS
Compare recorded line pressures with. See LINE PRESSURE SPECIFICATIONS under LINE PRESSURE
TEST. If line pres-sures are outside of specified ranges, use following list to determine cause of trouble.
High At Idle In All Ranges
Check main regulator valve, solenoid body and wiring harness.

me
Low At Idle In All Ranges
Check for low fluid level, restricted intake filter, loose main body, solenoid body or accumulator body-to-case
bolts. Excessive leakage in pump, case control bodies, sticking main regulator valve or damaged inlet tube seal.
Low In "P" Or "N"
Check valve body.
Low In "OD"
Check forward clutch and valve body.
Low In "2"
Check forward clutch, coast clutch, intermediate band servo and valve body.
Low In "1"
Check forward clutch, low-reverse clutch, coast clutch and valve body.
Low In "R"
Check separator plate, coast clutch, low-reverse clutch, direct clutch and valve body.
CONVERTER CLUTCH TEST
NOTE: Due to the difficulty of feeling converter clutch shift, a tachometer and/or
vacuum gauge MUST be connected to engine.
1. To check converter for engagement and disengagement, drive vehicle at approximately 50 MPH in
overdrive and lightly tap brake pedal. Engine RPM and vacuum should increase when clutch disengages.
Engine RPM will decrease about 5 seconds after pedal is released. If this does not occur, see AUTO
2. Stop vehicle. If vehicle stalls at idle in overdrive, shift transmission to 1st gear. If vehicle stalls in 1st
gear, repair or replace converter control valve in pump. If vehicle does not stall in 1st gear, see AUTO
STALL SPEED TEST
CAUTION: Do not maintain Wide Open Throttle (WOT) in any gear for more than 5
seconds. If engine RPM exceeds maximum specified stall speed, release
accelerator immediately. Clutch or band slippage is indicated.
Testing Precautions
me
1. Engine coolant and transmission fluid MUST be at proper level and operating temperature. Hold
accelerator down long enough to stabilize tachometer. DO NOT hold at WOT for more than 5 seconds.
2. DO NOT exceed maximum specified RPM for vehicle. After testing each range, run engine in Neutral at
1000 RPM for 15 seconds to cool torque converter. If engine speed exceeds specification, release
accelerator immediately, as this indicates clutch or band slippage.
Testing Procedure
Connect tachometer to engine. Apply parking and service brakes firmly. Stall test transmission in each driving
range at WOT. Note maximum RPM obtained. Engine speed should be within limits. See STALL SPEED
SPECIFICATIONS . If maximum RPM obtained is not within specifications, see STALL SPEED TEST
RESULTS .
STALL SPEED SPECIFICATIONS

Vehicle Application Engine Size Stall Speeds (RPM)
1997 Models
E150, Expedition, F150/250 5.4L SFI 2258-2652
E250/350 (8550 GVW) 5.4L SFI 2250-2633
F250/350 (8550 GVW) 5.8L SFI 2256-2705
E350/Super Duty 6.8L SFI 1866-2253
F250/350/Super Duty 7.3L Diesel 1951-2282
E350/Super Duty N/A N/A
F250/350/Super Duty 7.5L 1972-2350
1998 Models
E150, Expedition, F150/250 5.4L SFI 2248-2631
E250/350, F250/350 5.4L SFI 2238-2613
F250/350 (8550 GVW) 5.8L SFI 2256-2705
E350/Super Duty 6.8L SFI 1911-2283
E250/350/Super Duty 7.3L Diesel 1950-2285
F250/350/Super Duty 7.3L Diesel 2048-2380
F250/350/Super Duty 7.5L 1972-2350
STALL SPEED TEST RESULTS
Low In All Ranges
Poor engine performance. Faulty torque converter reactor one-way clutch.
High In All Ranges
General transmission problems are indicated. Perform control pressure tests.
High In "OD" Only
me
Forward clutch, overdrive one-way clutch or low-reverse one-way clutch faulty.
High In "2" Only
Forward clutch, or overdrive one-way clutch and coast clutch faulty.
High In "1" Only
Forward clutch, or reverse clutch and low-reverse one-way clutch, or coast clutch and overdrive one-way clutch
faulty.
High In "R" Only
Direct clutch, or overdrive one-way clutch and coast clutch, or low-reverse clutch faulty.
AIR PRESSURE CHECKS
1. A "No Drive" condition can exist, even with correct transmission fluid pressure, due to inoperative
clutches or bands. Inoperative units can be located by substituting air pressure for fluid pressure to
determine location of malfunction.
2. To check unit, drain transmission fluid. Remove oil pan, filter, seal assembly, solenoid body and valve
body.
3. Forward, coast, reverse, overdrive, direct and intermediate clutch operation may be checked as follows:
Using shop air, apply air to proper points. See Fig. 22 . A dull thud can be heard when clutch piston is
applied. If no thud is heard, movement of piston can be felt by placing finger tips on input shell. If seals
are leaking, a hissing sound will be heard.
me
Fig. 22: Locating Air Pressure Test Points

COMPONENT TESTS
TORQUE CONVERTER
Whenever transmission has been disassembled to replace worn or damaged parts, converter and oil cooler
MUST BE cleaned using a mechanically agitated cleaner. Under NO conditions should converter or oil cooler
be cleaned by hand agitation using solvent.
Leak Test
If torque converter welds indicate leakage, attach appropriate torque converter leak detector to converter and
follow detector kit instructions.
Turbine & Stator End Play Check
me
1. Insert End Play Tester (T80L-7902-D) into converter pump drive hub until tester bottoms. Expand sleeve
in turbine spline by tightening threaded inner post of tester until tester is securely locked into spine.
2. Attach a dial indicator to tool with indicator button on converter housing. See Fig. 23 . Zero dial face. Lift
tool upward as far as possible and note indicator reading.
3. Reading is total end play of turbine and stator. Replace torque converter assembly if end play exceeds
specification. See TORQUE CONVERTER END PLAY SPECIFICATIONS .
Fig. 23: Checking Torque Converter End Play

TORQUE CONVERTER END PLAY SPECIFICATIONS

Application In. (mm)
Gas Engine
New Or Rebuilt Convertor .038 (.96)
Used Converter .071 (1.8)
me
Diesel Engine
New Or Rebuilt Convertor .048 (1.21)
Used Converter .079 (2.0)
Converter One-Way Clutch Check
1. Insert One-Way Clutch Holding Tool (T77L-7902-R) in one of stator thrust washer grooves. Insert
Converter Clutch Torquing Tool (T76L-7902-C) with torque wrench in converter pump drive hub to
engage one-way clutch inner race. See Fig. 24 .
2. Hold holding tool stationary. Turn torque wrench counterclockwise. Converter one-way clutch should
lock up and hold force of 10 ft. lbs. (13 N.m). One-way clutch should turn freely clockwise. Repeat
procedure with holding tool in at least 5 locations. Replace converter if it fails testing.
Fig. 24: Checking Stator One-Way Clutch

Stator-To-Impeller Interference Check (Gas Engine Only)
NOTE: Stator support may remain in pump assembly during check.
me
1. Position stator support on bench with spline end of stator shaft pointing up. Mount converter on stator
support so splines of one-way clutch inner race engage splines of stator support.
2. While holding pump stationary, rotate converter counterclockwise. Converter should rotate freely without
interference or scraping within assembly. Should interference or a scraping condition within converter
exist or converter does not rotate freely, replace converter unit.
Stator-To-Turbine Interference Check (Gas Engine Only)
1. Place converter on bench, front side down. Install stator support to engage mating splines of stator
support shaft.
2. Install input shaft, engaging splines with turbine hub. While holding stator shaft stationary, rotate turbine
with input shaft.
3. Turbine should rotate freely in both directions without interference or noise. If interference or noise
exists, stator front thrust washer may be worn and converter should be replaced.
REMOVAL & INSTALLATION

See appropriate TRANSMISSION REMOVAL - A/T article in AUTOMATIC TRANSMISSION
SERVICING.
TRANSMISSION DISASSEMBLY
NOTE: Exploded views of internal parts, thrust washer and needle bearing locations
can be found in Figs. Fig. 43 -Fig. 45 .
1. Remove torque converter. Remove transfer case (if equipped). Mount transmission in appropriate holding
fixture. Remove input shaft. Thoroughly clean solenoid body connector area to avoid contamination.
Remove oil pan and gasket. Remove filter and "O" ring assembly. DO NOT damage aluminum pump
bore.
2. Remove accumulator body and valve body retaining bolts. Note bolt positions for reassembly. Do not
remove center 2 bolts. See Fig. 4 . This secures upper and lower valve body together during disass embly.
Remove solenoid body Torx retaining bolts and one nut.
3. Push up on solenoid body connector while removing solenoid body. Remove solenoid screen, by rotating
and pulling out. See Fig. 5 . Remove reinforcing plate. EPC ball is spring loaded under separator plate.
Remove separator plate and two gaskets. Remove EPC ball and spring. Discard gasket.
4. Remove one steel and 8 rubber check balls. DO NOT damage rubber check balls. See Fig. 7 . Remove
servo snap ring, retaining plate, piston and rod assembly and servo spring. Remove 3 feed bolts and
discard.
CAUTION: DO NOT use a screwdriver to pry out oil pump. This may cause
severe damage to transmission case. See TECHNICAL SERVICE
BULLETINS.
5. Rotate transmission so bellhousing is facing upward. Remove 9 pump retaining bolts. Discard washers.
me
Using 2 slide hammers, remove pump, gasket and pump support thrust washer. Remove needle bearing
assembly between front pump and sun gear. Lift out coast clutch assembly.
6. Remove large snap ring. Remove overdrive pressure plate and clutch pack. Tag for reassembly. Remove
overdrive ring gear, center shaft assembly, overdrive planet and one-way clutch. Remove center shaft
needle bearing assembly.
7. Install Clutch Spring Compressor (T89T-70010-C) into case. See Fig. 25 . Tighten center bolt to 65
INCH lbs. (7 N.m). Remove large snap ring. Remove spring compressor. Remove intermediate-overdrive
cylinder assembly. Remove intermediate return spring, center support and center support thrust washer.
me
Fig. 25: Compressing Intermediate/Overdrive Cylinder Assembly

8. Remove Intermediate pressure plate and clutch plates. Tag clutch plates for reassembly. Remove
intermediate band. Using appropriate clutch remover/installer, remove direct clutch, forward clutch and
me
shell. Hooks on crossbar MUST be rotated into notches on input shell. See Fig. 36 .
9. Using large screwdriver, remove reverse planet assembly snap ring. Remove reverse planetary assembly
and 2 planetary carrier thrust washers. Remove and discard output shaft snap ring.
10. Remove ring gear, hub assembly and needle bearing assembly. Remove reverse hub and one-way clutch
assembly. Using large screwdriver, remove reverse clutch snap ring. Remove reverse pressure plate and
clutch pack, tag for reassembly.
11. Rotate transmission so pan surface faces up. Remove 8 extension housing bolts. Remove extension
housing and gasket and discard gasket.
12. Remove output shaft, park gear and output shaft thrust washer. Remove 5 retaining bolts from low-
reverse one way clutch inner race. Remove reverse clutch return spring assembly and inner race.
NOTE: Reinstall reverse clutch pressure plate and snap ring to restrain reverse
clutch piston during removal.
13. Using shop air in reverse clutch feed port, blow out reverse clutch piston against pressure plate. See Fig.
22 . Remove snap ring, reverse clutch pressure plate and piston from case.
NOTE: If Torx head bolt is removed, it must be discarded and replaced with NEW
bolt.
14. Rotate transmission so pan surface faces downward. Remove parking pawl return spring, pin and parking
pawl from case. Remove parking rod guide plate. Remove Torx head bolt and parking pawl abutment (if
necessary).
15. Using side cutters or remover tool, remove manual lever shaft roll-pin from case. Remove inner detent
lever nut, while holding lever with crescent wrench. Remove inner detent lever and parking pawl
actuating rod assembly from manual lever.
16. Remove Transmission Range (TR) sensor and manual lever. Discard manual lever outer nut. Remove
manual valve detent spring. Using slide hammer, remove manual lever seal. If required, remove short
lube inlet tube, using channel lock pliers.
COMPONENT DISASSEMBLY & REASSEMBLY

COAST CLUTCH ASSEMBLY
NOTE: All models use 2 steel and 2 friction plates on coast clutch cylinder assembly.
Disassembly
1. Remove sun gear. Remove selective retaining ring. Remove pressure and clutch plates, and tag for
reassembly. Using appropriate spring compressor, remove and discard return spring retaining ring.
Remove spring compressor.
2. Remove piston return spring and apply plate. See Fig. 26 . Remove piston from coast clutch cylinder.
Remove outer seal from piston. Remove inner seal from cylinder.
me
Inspection
Inspect all parts for wear, damage and effects of overheating. Inspect coast clutch cylinder for damage and
wear. Replace as necessary.
Reassembly
1. Apply transmission fluid to "O" rings before install-ing. Soak all friction plates in ATF for 15 minutes
before installing.
2. Install inner and outer seals with lips facing down in cylinder and piston respectively.
3. Install piston, piston apply plate and piston return spring. Use spring compressor and compress springs.
Install NEW retaining ring. Carefully remove spring compressor.
4. Alternately install a steel plate and then a friction plate. See Fig. 26 . Install pressure plate and secure
pack with retaining ring.
5. Using a feeler gauge, check clearance between retaining ring and pressure plate. Ensure clearance is .030-
.050" (.76-1.27 mm). If clearance is not within specifications, install correct thickness snap ring. Selective
snap rings are available in thicknesses of .053-.057" (1.35-1.45 mm), .069-.073" (1.75-1.85 mm)
and .085-.089" (2.15-2.25 mm).
6. Install correct size snap ring and recheck clearance. Install overdrive sun gear assembly with short end
down into cylinder.
Fig. 26: Exploded View Of Coast Clutch Cylinder Assembly

DIRECT CLUTCH ASSEMBLY
Disassembly
1. Remove outer race, intermediate one-way clutch and top end cap. Remove large thrust washer from rear
face of cylinder. Remove small thrust washer from front face of cylinder. See Fig. 27 .
me
2. Using a screwdriver, remove retaining ring. Remove pressure plate and clutch pack. Tag for reassembly.
3. Install appropriate spring compressor. Remove return spring retainer ring and return spring. Remove
piston from intermediate brake drum. Remove inner and outer seals from drum.
Reassembly
1. Install inner and outer seals in cylinder with seal lips facing down into cylinder. Inspect piston check ball
for freedom of movement. Install piston into drum.
2. Ensure piston rotates freely in cylinder. Install return spring. Ensure protrusions on spring retainer are
properly engaged with lugs on clutch piston. Use spring compressor and compress springs. Install
retaining ring.
3. Install clutch pack, first using a steel plate and then a friction plate. Install pressure plate and secure pack
with selective retaining ring.
4. Using a feeler gauge, check clearance between retaining ring and pressure plate. Ensure clearance is .045-
.081" (1.15-2.06 mm).
5. If clearance is not within specifications, install correct snap ring. Selective snap rings are available in
thicknesses of .056-.060" (1.42-1.53 mm), .065-.069" (1.65-1.75 mm), .074-.078" (1.88-1.98 mm)
and .083-.087" (2.11-2.21 mm). Install correct size snap ring and recheck clearance.
6. Install small thrust washer and large thrust washer on face of cylinder. Install intermediate one-way clutch
end cap, one-way clutch assembly, and bottom end cap into outer race. Lip faces upward on one-way
clutch.
7. Install outer race and one-way clutch assembly onto inner race to ensure race turns counterclockwise.
Install thrust washer on intermediate brake drum face.
me
Fig. 27: Exploded View Of Direct Clutch Assembly

FORWARD CLUTCH ASSEMBLY
Disassembly
1. Remove both needle bearings and both Teflon seal rings. Remove retaining ring and rear pressure plate.
Remove 3 or 4 plate clutch pack (depending on model), cushion spring and forward pressure plate. Tag
for reassembly.
2. Remove spring retainer and piston return spring. Remove piston apply ring from piston groove. Remove
cylinder piston with compressed air. Remove outer seal from cylinder piston. Remove inner seal from
clutch cylinder.
Reassembly
1. Install inner seal in cylinder and outer seal on cylinder piston with seal lip facing up. Inspect piston check
ball for freedom of movement. Using appropriate lip seal protector, install piston into cylinder. Install
piston apply ring into groove on piston. Install piston return spring with fingers against piston and steel
ring. Ensure both ends of piston apply ring are visible between fingers of piston return spring. Install
spring retainer.
2. Install rear pressure plate and cushion spring. Install 3 or 4 steel plates, and 3 or 4 friction plates
(depending on model). Alternately install a steel plate and then a friction plate. See Fig. 28 . Install
forward pressure plate and secure pack with retaining ring.
me
3. Using a feeler gauge, check clearance between selective retaining ring and pressure plate. Ensure
clearance is .030-.055" (.76-1.40 mm). If clearance is not within specifications, install correct snap ring.
Selective snap rings are available in thicknesses of .056-.060" (1.42-1.52 mm), .074-.078" (1.88-1.98
mm), .092-.096" (2.34-2.44 mm), .110-.114" (2.79-2.90 mm) and .128-.132" (3.25-3.35 mm). Install
correct size snap ring and recheck clearance.
4. Install 2 Teflon seal rings, ensuring scarf cuts at ring ends are properly aligned and placed 180 degrees
apart. Install needle bearing over Teflon seal hub. Install needle bearing assembly on inner face of
cylinder with large outside diameter radius facing inward.
Fig. 28: Exploded View Of Forward Clutch

INPUT SHELL
Disassembly & Reassembly
Remove and discard forward/reverse sun gear retaining ring. Remove input shell thrust washer. Remove
forward/reverse sun gear from input shell. To reassemble, reverse disassembly procedure. Ensure lube hole in
sun gear is between standoff pads on input shell.
INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY
Disassembly
1. Using appropriate spring compressor, compress overdrive return spring. Remove retaining ring. Remove
spring compressor. Remove return spring.
2. Remove overdrive piston. Remove outer and inner seals and intermediate piston. See Fig. 29 . Remove
intermediate-overdrive inner seal from cylinder bore. Remove outer seal from intermediate piston.
me
Remove 2 cast iron outer seal rings and thrust washer from center support.
3. Remove thrust washer from front face of forward hub and ring gear. Using a screwdriver remove
retaining ring. Remove forward hub from ring gear.
Reassembly
To reassemble, reverse disassembly procedure. Outer and inner seals are installed with lips facing down toward
cylinder. Return spring fingers face up. Ensure piston rotates freely in cylinder.
Fig. 29: Exploded View Of Intermediate-Overdrive Cylinder

LOW-REVERSE ONE-WAY CLUTCH HUB
Disassembly
Remove snap ring and bushing from rear of low-reverse clutch hub. Remove rollers from spring assembly. Lift
spring assembly from hub. Remove snap ring from hub. See Fig. 30 .
Reassembly
1. Install snap ring in forward groove of low-reverse clutch hub. Place hub on bench with forward end
down. Install clutch spring assembly on top of snap ring.
me
2. Install a roller into each spring assembly compartment. Install bushing on top of spring assembly. Install
remaining snap ring at rear of clutch hub to secure assembly.
Fig. 30: Exploded View Of Low-Reverse One-Way Clutch Hub

OIL PUMP ASSEMBLY
Disassembly
1. Remove coast clutch seals from stator support. Remove large square cut seal from outside diameter of
pump housing. Using internal puller, remove converter hub seal from pump body. Remove and discard
orifice cup plug, spring and stop assembly.
2. Remove 11 pump control-to-pump body bolts. Separate pump control body from pump body. Apply
pressure to main regulator booster sleeve. Remove internal retaining ring. Remove main regulator valve
train.
3. Remove converter regulator valve and converter clutch valve assemblies by applying pressure to end plug
and removing retainer clip with small screwdriver or tweezers. DO NOT remove any cup plugs unless
me
damaged or leaking. See Fig. 31 . Remove gerotor gear set from pump body.
NOTE: To prevent distortion of control body surface, DO NOT remove stator support
from control body.
Fig. 31: Exploded View Of Pump Assembly

Inspection
Thoroughly clean and inspect all components for damage, wear or scoring. Carefully check all teeth on gears.
Replace pump assembly if any part is damaged or worn. Inspect converter hub bushing. Replace if defective.
Stake bushing at notches. Inspect stator input shaft bushings. Replace control body assembly if bushings are
worn. If necessary, use crocus cloth to polish components. Use caution to avoid rounding sharp edges of valves
and plugs. Replace defective parts.
Reassembly
me
1. Install main regulator valve. Apply pressure to booster sleeve and install internal retainer ring. Install
converter shift and regulator valves. Lightly coat gerotor gears with transmission fluid and install in pump
housing. Dot on inner gerotor gear faces control body.
2. Using depth micrometer, measure clearance between each gear and pump housing. Clearance should
be .001-.002" (.025-.051 mm). Replace parts as needed. Lower control body and stator into pump body.
Align 28-mm round holes in control body and pump body.
3. Loosely install 11 pump body bolts. Install alignment bolt. See Fig. 32 . Using appropriate banding tool,
align outer bolt holes. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS .
Remove banding tool. Ensure outer edges of control body and pump body are completely aligned.
4. Install coast clutch seals. Ensure seals are fully seated in grooves with gaps 180 degrees apart. Install
pump outer diameter seal. Lubricate seal with transmission fluid before installing pump into case.
5. Install NEW spring and stop assembly, place end with rubber stop into bore first. Install NEW cup plug.
Ensure cup plug edges are below stator support surface. Install converter hub seal. Install pump thrust
washer and overdrive sun gear needle bearing into stator support.
Fig. 32: Aligning Pump Body & Support Assembly

OVERDRIVE RING GEAR & CENTER SHAFT ASSEMBLY
Disassembly
me
1. Remove outer race-to-ring gear retaining ring. Remove one-way clutch assembly with inner and outer
races. Remove one-way clutch assembly with inner race from outer race. See Fig. 33 .
2. Remove inner race from one-way clutch assembly. Remove thrust washer from front of overdrive planet
assembly. Remove overdrive planet assembly from ring gear assembly.
3. Remove needle bearing assembly from rear of overdrive planet assembly. Remove center shaft-to-ring
gear retaining ring and center shaft from ring gear.
Reassembly
To reassemble, reverse disassembly procedure. Ensure thrust washers and needle bearings are installed in their
original locations. Install retaining ring and plastic cage into outer race. Install inner race into one-way clutch.
Inner race undercut must face toward small retaining ring. Install clutch into ring gear with small retaining ring
facing up.
NOTE: Inner race MUST rotate counterclockwise.
Fig. 33: Exploded View Of Overdrive Ring Gear & Center Shaft
VALVE BODY
Disassembly
Disassemble valve body. See VALVE BODY & INTERMEDIATE BAND SERVO under ON-VEHICLE
SERVICE. Remove all valves, plungers, plugs and springs from control valve and accumulator bodies. See Fig.
34 .
me
Inspection
1. Clean all parts, except non-metallic check balls, in clean solvent. Blow dry with compressed air.
2. Inspect all valve and plunger bores for scores. Check all fluid passages for obstructions. Inspect all
mating surfaces for burrs and scores. If necessary, use crocus cloth to polish valves and plungers. Avoid
rounding sharp edges of valves and plungers with crocus cloth.
3. Inspect all springs for distortion. Check all valves and plungers for free movement in their respective
bores. Valves and plungers, when dry, should fall by their own weight in their respective bores. Roll
manual valve on a flat surface to check for bending.
Reassembly
Install all valves, plungers, plugs and springs into control valve and accumulator bodies. See Fig. 34 . To
complete reassembly, reverse disassembly procedure. See VALVE BODY & INTERMEDIATE BAND
SERVO under ON-VEHICLE SERVICE.
me
Fig. 34: Exploded View Of Valve Body

CLUTCH & DRUM SUBASSEMBLIES
1. Install thrust washer on intermediate brake drum. Install forward clutch on intermediate brake drum and
rotate until fully seated. Install needle bearing on intermediate brake drum and forward clutch assembly.
Ensure Black side of needle bearing is facing up.
me
2. Install thrust washer on forward clutch hub. See Fig. 35 . Insert forward clutch hub into intermediate
brake drum and forward clutch assemblies. Place thrust washer on forward planet assembly. Insert planet
assembly into clutch assembly. Install needle bearing into forward planet assembly. Ensure Black side of
needle bearing is facing up.
3. Align input shell notches with intermediate brake drum. Install input shell on assembly and rotate until
fully seated. See Fig. 36 . Install needle bearing into front end of forward clutch assemb ly. Install
Remover/Installer (T89T-70010-E) onto intermediate brake drum, forward clutch and input shell. See
Fig. 37 .
Fig. 35: Installing Thrust Washer On Forward Clutch Hub

me
Fig. 36: Assembling Direct Clutch, Forward Clutch & Input Shell
TRANSMISSION REASSEMBLY
NOTE: Exploded views of internal parts, thrust washer and needle bearing locations
can be found in Figs. Fig. 43 -Fig. 45 . Lubricate all parts with transmission fluid
during reassembly. Thrust washers and gaskets should be held in place with
petroleum jelly.
1. With transmission mounted in fixture, rotate bellhousing to face upward. Install inner and outer seals on
reverse clutch piston. Using appropriate spring compressor, install reverse clutch piston. Remove spring
compressor.
2. Install reverse piston return spring assembly, output shaft hub and inner race. Ensure lubrication hole of
inner race is in 5 o'clock position. See Fig. 37 and Fig. 38 . Using 2 5 / 16-24, 3 inch long bolts with nuts,
compress low/reverse piston spring. See Fig. 39 . Install 3 bolts in remaining one-way clutch inner race
bolt holes and remove 2 compression bolts. Install remaining 2 bolts and tighten to specification. See
TORQUE SPECIFICATIONS .
3. Install cushion spring. Install reverse clutch pack (5 or 6 plate assembly depending on model) starting
with an external spline steel plate. Alternate external spline steel plates with internal spline friction plates.
me
Install reverse clutch pressure plate and retaining ring. Ensure retaining ring is installed with opening
between 12 and 3 o'clock. Clearance measurement is not required.
4. Rotate transmission to horizontal position. Lubricate steel side of thrust washer, and place on rear of case
bronze side outward. Slide park gear onto shaft with thrust surface forward. Install output shaft. Install
reverse hub and low-reverse one-way clutch. Install output shaft hub and reverse ring gear with needle
bearing on rear surface of hub.
5. Install NEW retaining ring on output shaft. Rotate transmission with bellhousing facing upward. Install
reverse planet into hub with front and rear thrust washers. Install reverse planet retaining ring into low-
reverse hub. Ensure retaining ring is securely seated in groove.
6. Using Clutch Remover-Installer (T89T-70010-E), install intermediate brake drum assembly, forward
clutch assembly and input shell assembly into case as a unit. See Fig. 40 . It may be necessary to rotate
output shaft to seat reverse sun gear. Remove installer.
me
Fig. 37: Locating Inner Race Lubrication Hole

me
Fig. 38: Exploded View Of Low-Reverse One-Way Clutch

me
Fig. 39: Compressing Low-Reverse Piston Return Spring

me
Fig. 40: Removing & Installing Input Shell

7. Install intermediate band with one ear on anchor pin. Install servo retaining ring, retaining plate, piston
and rod assembly, and servo spring. Install rear intermediate pressure plate. Install clutch pack starting
with internal spline plate. Install front intermediate pressure plate with blank area (no teeth) at 6 and 12
o'clock positions.
8. Measure clearance between center support and intermediate brake drum. Ensure clearance is .032-
.081" (.81-2.06 mm). This verifies components are correctly installed to this point.
me
NOTE: Remove cast iron seals from center support to allow easy insertion into
intermediate brake drum.
9. To determine center support thickness, hold thrust washer against center support. Place depth micrometer
over drilled hole. Extend micrometer probe until flush with thrust washer surface and note reading. See
Fig. 41 .
10. Install center support and thrust washer into intermediate brake drum. Ensure center support is fully
seated. Place depth micrometer over drilled hole. Extend micrometer probe until probe bottoms against
thrust washer surface. See Fig. 41 . Note reading. Subtract first reading from second reading.
11. If thrust washer clearance is not within specification, this indicates improper assembly, missing parts or
parts out of specification. Correct before continuing reassembly. If clearance is within specifications,
remove center support. Reinstall cast iron seal rings.
Fig. 41: Measuring Center Support Thickness

me
Fig. 42: Measuring Thrust Washer Clearance

12. Install center support, and align with holes in feed port. Install 2 NEW rear feed bolts finger tight. Install
intermediate clutch return spring with dish surface inward. Ensure spring locator legs are properly located
in center support circular coast rib.
13. Install intermediate-overdrive cylinder. DO NOT cock cylinder when installing. Align cylinder threaded
feed hole with hole in case. Install retaining ring over intermediate clutch cylinder with ring opening at
bottom of case for proper oil drainback. Install Spring Compressor Plate (T89T-70010-F) and Spring
Fixture (T89T-70010-C) onto intermediate clutch cylinder, tighten center bolt to 65 INCH lbs. (7 N.m).
See Fig. 25 .
14. Seat retaining ring in case ring groove. Remove spring compressor. No clearance measurement is
required. Install NEW feed bolt finger tight. Coat needle bearing with grease and install on rear face of
overdrive center shaft. Install center shaft, overdrive ring gear, overdrive planetary gear set and coast
clutch cylinder as an assembly.
15. Install overdrive clutch pack, starting with a steel plate. Install pressure plate with dot facing outward and
toward top of case. Install selective retaining ring with opening at bottom of case. Using a feeler gauge,
measure clearance of clutch pack. Ensure clearance is .027-.052" (.68-1.32 mm) on 2-plate clutch. On 3-
plate clutch clearance should be .032-.058" (.81-1.47 mm).
me
16. If clearance is not within specifications, install correct snap ring. Selective snap rings are available in
thicknesses of .057-.061" (1.45-1.55 mm), .077-.081" (1.95-2.05 mm), .098-.102" (2.50-2.60 mm), .118-
.122" (3.00-3.10 mm) and .138-.142" (3.50-3.60 mm).
17. Install pump gasket into case. Install input shaft long splined end first into case. Install thrust washer and
needle bearing on pump. Install appropriate alignment pin to aid pump installation. Install pump, orient
filter inlet tube bore toward 6 o'clock position.
18. Fully seat pump into case using hand pressure only. DO NOT use bolts to draw pump into case. Remove
alignment pin. Install pump bolts and NEW seal washers. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Remove input shaft.
19. Using appropriate seal driver, install manual lever seal. Install manual lever shaft and roll pin, with pin
just below case surface. Install manual lever position sensor with 2 bolts and washer. DO NOT tighten
bolts at this time. Install manual lever detent spring. Tighten bolt to specification.
20. Install manual detent lever, park lever actuating rod and nut. Tighten nut to specification. Ensure manual
valve detent spring is installed on inner detent lever. Using appropriate sensor adjuster, align sensor to
neutral gear position. Tighten bolts to specification. Install outer manual lever. Install NEW manual lever
shaft nut and tighten to specification.
21. Install parking pawl, parking pawl shaft and parking pawl return spring on rear face. Ensure parking pawl
return spring end rests on inside surface of case. If removed, install parking pawl abutment with NEW
Torx bolt and tighten to specification. Attach parking rod guide plate with 2 bolts and washers. Tighten
bolts to specification. Ensure plate dimple is facing inward and parking rod is in guide plate slot.
22. Install gasket on extension housing. Ensure parking pawl return spring is properly located on inside
surface of case when installing extension housing. Install extension housing and wiring bracket on rear
case. Tighten bolts to specification. See TORQUE SPECIFICATIONS . The 2 bottom bolts are longer
on 4WD vehicles.
CAUTION: Front fluid feed bolt torque is lower than rear feed bolts. Ensure
proper torque specification is used. See TORQUE SPECIFICATIONS .
23. Rotate transmission with pan surface facing upward. Front feed bolt should be tightened to 71-120 INCH
lbs. (8-14 N.m) and 2 rear feed bolts to 97-144 INCH lbs. (11-16 N.m). Install 8 rubber check balls, and
steel EPC check ball and spring into case pockets. See Fig. 7 .
24. Install case-to-separator plate gasket. Check placement of EPC check ball. Install separator plate. Attach
reinforcing plate with 3 bolts. Ensure stamped UP on reinforcing plate faces up. Tighten bolts to
specification. Install NEW separator-to-control gasket.
25. Install solenoid screen into separator plate. Turn and lock solenoid screen. Install accumulator body over
studs. Install 2 nuts and 11 bolts finger tight. Lower main valve body over studs. Align manual valve with
manual lever. Install 2 nuts and 14 bolts finger tight.
26. Ensure case connector bore is coated with grease prior to install-ing solenoid body. Install solenoid body
over stud. Install 9 Torx bolts and one nut finger tight. Tighten all accumulator body, upper and lower
control body and solenoid body nuts and bolts to specification.
27. Install NEW filter and seal assembly. Lubricate seal with ATF. Press filter into place. Install pan magnet
on dimple in bottom of pan. Install NEW pan gasket on pan. Attach pan with bolts. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
me
28. If necessary, install short fluid inlet tube. Use stripe or rib on side of tube for alignment. Stripe should be
farthest outboard when installed. Rib should face toward front. Reinstall input shaft, long splined end
first. Install torque converter. Using straightedge, ensure converter crankshaft pilot is below converter
housing.
Fig. 43: Locating Thrust Washers & Bearings

me
Fig. 44: Exploded View Of E4OD Automatic Transmission (1 Of 2)

me
Fig. 45: Legend For Exploded View Of E4OD Transmission (2 Of 2)

TRANSMISSION SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
Application In. (mm)
Coast Clutch Pack Clearance .030-.050 (.76-1.27)
Direct Clutch Pack Clearance .045-.081 (1.15-2.06)
Forward Clutch Pack Clearance .030-.055 (.76-1.40)
Gear-To-Housing Clearance (1) .0015-.0022 (.0254-.0510)
Overdrive Clutch Pack Clearance
2-Disc Clutch .027-.052 (.68-1.32)
3-Disc Clutch .032-.058 (.81-1.47)
Torque Converter End Play
Diesel Engine
New Or Rebuilt .024-.048 (.60-1.21)
Used .079 (2.0)
Gas Engine
New Or Rebuilt .014-.038 (.35-96)
Used .071 (1.8)
(1) Oil pump inner/outer gerotor gear.
TORQUE SPECIFICATIONS
me
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Connector-To-Case Cooler Line Nut 18-23 (24-31)
Control Assembly-To-Pump Body Bolts 18-23 (24-31)
Converter Drain Plug 21-23 (29-31)
Cooler Bypass Hose/Valve
Case Inlet Bolt 24-29 (33-39)
Case Outlet Bolt 20-24 (27-33)
Extension Housing-To-Case Bolts
2WD 20-29 (27-39)
4WD 24-40 (33-54)
Inner One-Way Clutch Race-To-Case Bolts 18-25 (24-34)
Manual Lever Nut
Inner 30-40 (41-54)
Outer 20-29 (27-39)
Oil Pan-To-Case Bolts 10-12 (14-16)
Oil Pump Body-To-Case Bolts 18-23 (24-31)
Parking Pawl Abutment-To-Case Bolts 16-20 (22-27)
Parking Rod Guide Plate-To-Case Bolts 16-20 (22-27)
Transmission Mount-To-Crossmember Bolts 60-80 (81-108)
INCH Lbs. (N.m)
Center Support Fluid Feed Bolts
Front Bolt 71-120 (8-14)
Rear Bolt 97-144 (11-16)
Detent Spring-To-Case Bolt 80-97 (9-11)
Lower Body-To-Main Body Bolts 80-97 (9-11)
Main Accumulator & Solenoid Body-To-Case Bolts 80-97 (9-11)
Main And Lower Body-To-Case Bolts 80-100 (9-11)
MLP Sensor-To-Case Bolts 55-71 (6-8)
Overdrive Cylinder Fluid Feed Bolts
Front Bolt 71-120 (8-14)
Rear Bolts 97-144 (11-16)
Plug Line Pressure Case 72-144 (8-16)
Reinforcing Plate-To-Case Bolts 80-97 (9-11)
Solenoid Body-To-Case Bolts 80-97 (9-11)
Stator Support-To-Pump Body Bolts 80-97 (9-11)
Valve Body-To-Case Long Stud 80-97 (9-11)
Valve Body-To-Case Nut 80-97 (9-11)
Valve Body-To-Case Short Stud 80-97 (9-11)
me

Auto Trans Overhaul E40d

Uploaded by

Copyright:

Available Formats

Auto Trans Overhaul E40d

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Auto Trans Overhaul E40d

Uploaded by

Copyright:

Available Formats

1997 Ford Pickup F150

1997-98 AUTOMATIC TRANSMISSIONS E4OD Overhaul

1997-98 AUTOMATIC TRANSMISSIONS

Fig. 1: Identification Tag

Fig. 2: Cross-Sectional View Of E4OD Automatic Transmission

LUBRICATION & ADJUSTMENTS

EXTENSION HOUSING GASKET

Fig. 3: Removing Parking Mechanism

VALVE BODY & INTERMEDIATE BAND SERVO

Fig. 4: Removing Main Control Valve Body

Fig. 5: Removing Solenoid Screen

Fig. 6: Installing Intermediate Band Servo

Fig. 7: Locating Valve Body Check Balls

MANUAL LEVER SEAL

Fig. 8: Removing Manual Lever Shaft Retaining Pin

affect transmission operation and diagnosis.

Harsh Reverse Engagement

Harsh Forward Engagement

Delayed/Soft Reverse Engagement

Delayed/Soft Forward Engagement

No Forward & No Reverse Engagement

Harsh Forward & Reverse Engagement

Delayed/Soft Forward & Reverse Engagement

Early/Late Shift Timing

Erratic Or Hunting Shift Timing

Soft Or Slipping Shift Feel

Harsh Shift Feel

No 1st Gear, Engages In Higher Gear

No Low Gear (Manual 1st)

No 2nd Gear (Manual 2nd)

No 3rd To 2nd Shift

Soft/Slipping 1-2 Shift

Soft/Slipping 2-3 Shift

Soft/Slipping 3-4 Shift

Harsh 1-2 Shift

Harsh 2-3 Shift

Harsh 3-4 Shift

Harsh 4-3 Shift

Harsh 3-2 Shift

Harsh 2-1 Shift

No Torque Converter Clutch Application

Torque Converter Clutch Always Applied (Stalls Vehicle In

Drive & Manual 2nd Gear Only)

Torque Converter Clutch Cycling/Shudder/Chatter

No Engine Braking In Manual 2nd Gear

No Engine Braking In Manual 1st Gear

CLUTCH & BAND APPLICATION

SHIFT SPEEDS SPECIFICATIONS (MPH)

production tolerances, rear axle ratios or emission control equipment. Ensure

Fig. 9: 5.4L F150/250

Fig. 10: 5.4L E150/250/350

Fig. 11: 5.4L E250/350

Fig. 12: 5.4L Expedition & Navigator

Fig. 13: 5.4L CNG F250

Fig. 14: 5.4L CNG E250/350

Fig. 15: 5.8L F250/350

Fig. 16: 6.8L E350 & "E" - Series Super Duty

Fig. 18: 7.3L Diesel F250/350 "F" - Series Super Duty

Fig. 20: 7.5L "F" - Series Super Duty