Transmision
Transmision
Transmision
Transaxle
Special Tool(s)
Slide Hammer
100-001
Holding Fixture
307-580
Material
Item Specification
DPS6 Grease WSS-
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9U7Z-19A506-BA M1C270-A
Motorcraft Gasket Maker WSK-
TA-16 M2G348-A5
Motorcraft High Temperature Nickel Anti-Seize -
Lubricant
XL-2
Motorcraft Dual Clutch Transmission Fluid WSS-
XT-11-QDC M2C200-D2
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Disassembly
1. NOTE:Take note of the transmission wiring harness clip locations for installation.
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3. Using a flat blade screwdriver, carefully pry the TCMfrom the transmission, at the location shown, and remove the TCM.
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5. Remove the 2 Transmission Range (TR) sensor bolts and the TRsensor.
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6. Remove the Output Shaft Speed (OSS) sensor bolt and OSSsensor.
11. Remove the 4 clutch motor 1 bolts and remove clutch motor 1.
12. Remove the 4 clutch motor 2 bolts and remove clutch motor 2.
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14. NOTE:Index mark the clutch hub and clutch for installation.
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16. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of torque to push the clutch
down to release the pressure from the hollow input shaft snap ring.
17. Remove and discard the hollow input shaft snap ring.
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18. NOTE:Make sure the lifting legs are installed on the 3 clutch studs marked with the manufacturing mark as shown.
NOTE:Make sure the lifting leg with the angle is in the location shown.
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20. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
21. Using the special tools, remove the clutch as an assembly from the transmission.
22. Using the special tool, remove and discard the inner input shaft seal.
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23. Remove the Z-washers from the engagement system bearing unit.
Remove the engagement system bearing unit. Inspect for wear or damage. Replace as necessary.
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25. NOTICE: Remove the spring retainer bolts by loosening them slightly in an alternating pattern or damage can occur
to the clutch actuator levers.
NOTE:The spring retainers and actuator levers are matched sets with corresponding serial numbers. If the spring retainers
and actuator levers are being reused, mark on each spring retainer and actuator lever for assembly.
Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.
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29. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
30. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
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33. Using the special tools, remove and discard the input shaft case seal.
35. Remove discard the manual control lever bolt and remove the manual control lever.
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40. Turn the special tool bolt approximately 20 turns to separate the clutch housing from the transmission case.
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42. Remove and discard the clutch housing input shaft bearing retainer bolts and remove clutch housing input shaft bearing
retainer.
43. By lightly tapping, remove and discard the clutch housing input shaft bearing.
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49. Remove the large clock gears and clock gear pins.
50. Remove the small clock gears and clock gear pins.
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52. Install the special tool on the transmission case and gear set assembly.
53. Turn the transmission case and gear set assembly over on the special tool.
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55. Remove and discard the 6 output shaft bearing retainer bolts.
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65. Remove the input shaft assembly by removing the special tool.
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67. Remove the hollow input shaft from the solid input shaft.
Assembly
1. Install the hollow input shaft onto the inner input shaft.
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2. NOTE:If the clearance is less than the minimum measurement stated in the specifications section, install a new shift fork.
Using a suitable feeler gauge, measure the clearance between the shift fork and synchronizer hub sleeve in various places
around the circumference.
NOTE:If the clearance is less than the minimum measurement stated in the specifications section, install a new output shaft
assembly.
Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the
circumference.
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18. NOTE:Make sure the output shaft bearing retainer brackets are positioned as shown.
20. Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
Stage 1: tighten to 10 Nm (89 lb-in).
Stage 2: tighten to 32 Nm (24 lb-ft).
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22. Turn the transmissioncase and gearset assembly over onto the special tool.
25. Install the small clock gears and clock gear pins.
26. Install the large clock gears and clock gear pins.
29. NOTE:If the differential bearings, differential, clutch housing and/or transmission case are replaced refer to Differential Shim
Selectionin this section.
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30. NOTICE: Make sure the transmission case and the clutch housing are clean and no old sealant is present or
transmission fluid leaks can occur and cause transmission damage.
NOTICE: Make sure the park plunger and park plunger plug were removed from the the clutch housing or damage to
the park pawl actuation shaft assembly (rooster comb) will occur.
Apply a 1 mm (0.039 in) bead of Gasket Maker around the inside of the bolt holes on the case side and completely around
each dowel.
31. Using the special tools, install the new clutch housing input shaft bearing.
32. Install the clutch housing input shaft bearing retainer and the new clutch housing input shaft bearing retainer bolts.
Tighten to 11 Nm (97 lb-in).
33. NOTICE: Do not overheat the bearing or damage to the bearing may occur.
Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for approximately 5 minutes.
34. NOTICE: Be sure that the park pawl detent is NOT already installed when installing the clutch housing on the
transmission case. If the transmission was disassembled for a repair that did not require complete transmission
disassembly, the park pawl detent must be removed before installing the clutch housing or damage to the park pawl
actuator shaft will occur.
35. Using the special tool and a hammer, tap the clutch housing down onto the transmission case.
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40. Install the manual control lever and the new manual control lever bolt.
Tighten to 26 Nm (19 lb-ft).
42. Using the special tools, install a new input shaft case seal.
43. Using the locating flange on the guide tube, install the guide tube.
44. NOTE:The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.
45. Inspect the guide tube for wear or damage. Replace as necessary.
46. NOTE:One clutch actuator lever bushing shown, one per clutch actuator lever.
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47. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
48. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
50. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
51. Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.
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53. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur
to the clutch actuator levers.
NOTE:Make sure the spring retainer contour aligns with the actuator lever contour as shown.
NOTE:Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the
spring retainers and actuator levers use the marks made during removal for assembly.
55. NOTICE: Do not apply grease or other lubricants to the clutch actuator lever fingers, the engagement system
bearing, or the Z-washers or clutch contamination can occur.
56. NOTICE: Do not tilt transmission after the Z-washers are installed, they may come off center and damage can occur.
Install the Z-washers onto the engagement system bearing unit and center them correctly.
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59. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.
61. Install the special tool on the clutch making sure the legs are inserted in the slots.
62. Turn the special tool clockwise to the stops and hold.
63. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.
Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.
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65. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.
66. NOTICE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or damage will occur
to the clutch.
NOTE:An audible click can be heard when the clutch locks lock.
While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch.
The locks on clutch 2 lock at this time.
68. NOTE:The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as
shown. If not, reset the clutch 2 locks as necessary.
Visually check the locks to make sure they have locked. 4 locks shown, 12 total.
69. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.
70. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the
clutch assembly if the measurement is 26 mm (1.023 in) or less.
71. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the
measurement is 15 mm (0.59 in) or less.
72. Using the special tools, install the new inner input shaft seal.
73. Apply a small amount of transmission fluid on the input shaft bearing surface.
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74. Apply a small amount of DPS6 Grease on both input shaft splines.
76. NOTICE: Verify the clutch locks are locked prior to installation or the transmission may not operate correctly and
damage can occur. If the clutch locks are not locked go to step 56 within this procedure.
NOTE:Make sure the angled lifting leg is installed in the location shown.
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79. NOTICE: Do not overtighten the special tool or damage can occur.
Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft
bearing and the snap ring groove is visible.
80. NOTE:Make sure the hollow input shaft snap ring is fully seated.
81. NOTE:Align the index marks on the clutch hub and clutch.
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82. Install the new clutch hub snap ring in the position shown.
83. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can
occur.
Using the special tool, release the clutch 1 locks by slowly turning the special tool counterclockwise. An audible click will be
heard when the clutch 1 lock is released. Repeat step to release clutch 2 locks.
84. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.
85. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.
86. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
Tighten to 5 Nm (44 lb-in).
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87. Install the clutch motor 1 and the 4 clutch motor 1 bolts.
Tighten to 5 Nm (44 lb-in).
88. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can occur to the
transmission.
NOTE:Install a new O-ring if installing the existing input shaft speed sensor 2.
NOTE:Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.
89. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft speed sensor 1 or
damage can occur to the transmission.
NOTE:Install a new O-ring if installing the existing input shaft speed sensor 1.
NOTE:Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.
92. Carefully inspect the TCMand the transmission bore for debris or damage. Clean and/or repair as needed.
93. NOTE:Use a small amount of transmission fluid on the new O-rings prior to installation.
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94. NOTICE: Do not force the TCMonto the transmission or damage may occur.
NOTICE: Make sure the TCMsits flush on the transmission, or damage can occur.
Install the TCM. Apply light pressure to seat the O-rings. If the TCMdoes not push in place with light pressure, remove the
TCMand slightly turn the TCMgears and retry installing the TCM.
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This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further
reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor
Company.
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