5R110W assembly

307-01B-1 307-01B-1Automatic Transmission — TorqShift

ASSEMBLYSpecial Tool(s)Transmission

Installer, Fluid Filler Tube307-376Special Tool(s)

Installer, 4x2 Extension HousingSeal307-462

Installer, Transmission ForwardClutch Assembly307-436

Installer, 4x4 Extension HousingSeal307-453

Bridge Adapter (use with307-436)307-436-01

Compressor, Clutch Spring307-015 (T65L-77515-A)

Loading Fixture, Clutch307-S383

Installer, Shift Shaft Fluid Seal307-002 (TOOL-77288)

Air Test Plate307-457

Handle, Torque Converter307-091 (T81P-7902-C)

Test Plate Screw Set,Transmission307-126 (T82P-7006-C)

Aligner, Transmission FluidPump307-222 (T89T-70010-B)

Alignment Cone307-455

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Copyright 2003, Ford Motor CompanyLast updated: 5/3/2005 2004 Excursion, F-Super Duty 250-550, 12/2004


ASSEMBLY (Continued)

Special Tool(s) NOTE: The pressure switches shown in thisprocedure will not be applicable to all vehicleNut Driver, Output Shaft

307-458 applications. Some vehicles will not have thepressure switches or the harness installed in thevalve body.

NOTE: Soak all friction clutch plates in cleanautomatic transmission fluid.

Installer, Seal Pack NOTE: Prior to installation, lightly lubricate all307-461 O-ring seals with clean automatic transmission fluid.

NOTE: Lightly lubricate all thrust washers withpetroleum jelly to hold them in place duringassembly.

All transmissionsRetaining Ring Pliers307-343 (T95P-77001-AHR)

1. Mount the transmission case into a suitablestand.

2. If removed, use the special tool to install theshort fluid inlet tube.

Retainer, Torque Converter307-346

Alignment Pins, Pump307-456

3. If removed, use the special tool to install a newHandleTeflon seal retainer.205-153 (T80T-4000-W)

• Install two new Teflon seals.

Material

Item Specification

MERCON SP Automatic MERCON SPTransmission FluidXT-6-QSP

2004 Excursion, F-Super Duty 250-550, 12/2004



4. NOTE: Coat the reverse clutch piston seals 7. NOTE: The use of petroleum jelly will holdwith petroleum jelly. the No. 17 thrust bearing or washer in place

during assembly.Install the reverse clutch piston in the case untilit is fully seated in the case. For vehicles equipped with a slip yoke, install

the No. 17 park gear thrust bearing. Forvehicles equipped with a fixed yoke, install theNo. 17 park gear thrust washer.

5. Install the reverse clutch return spring assembly.

8. WARNING: Be careful when installingthe output shaft not to damage the seals ortransmission internal leakage could occur.

Install the output shaft.

6. WARNING: Do not overcompress thereturn spring, damage to the spring willoccur.

Using the special tool, install the reverse clutchreturn spring snap ring.




9. CAUTION: The Torx screw has athreadlocking compound. If the screw isremoved, it must be discarded and a newscrew installed.

If removed, install the parking pawl abutmentwith a new Torx screw.

12. Install a new orifice lube plug in the rear of thecase. Using a 12 mm (0.48 in) socket, tap theorifice lube plug into the back of thetransmission. Check to make sure that theorifice lube plug is fully seated into the back ofthe transmission.

10. Install the parking pawl.

1 Install the parking pawl shaft.

2 Install the parking pawl.

3 Install the parking pawl return spring.

13. Install a new extension housing gasket.

11. NOTE: Make sure the dimple on the parkingguide support plate is facing inward.

Install the parking rod guide plate.

1 Install the parking rod guide plate.

2 Install the bolts.




14. Install the extension housing. 17. Install the manual control lever.

15. Using the special tool, install a new manual 18. Install the roll pin into the case.control lever seal.

19. Install a new roll pin. Leave 2 mm (0.08 in) of16. Install the transmission range sensor, park rod the pin exposed.

assembly and loosely install the bolts.




20. Tighten the transmission range sensor bolts.

24. If the vehicle is equipped with a fixed yoke,install the output flange.

Fixed yoke transmissions1 Install the flange.

2 Install a new bolt.21. Using the special tool, install a new extension

housing seal.

Slip yoke transmissions

22. Inspect the new output shaft nut O-ring for25. If removed, install a new output shaft bushingcuts. If there is any damage to the nut or seal, a

using the special tool.new nut must be installed.

23. Using the special tool, install a new outputshaft nut.




26. Install a new output shaft seal using the special 29. Install the reverse carrier and hub assembly.tool.

30. Install the low/reverse clutch plates.All transmissions • Start with a steel plate on the bottom,

followed by a friction plate.27. Install the No. 16 bearing and race. • Alternately stack the remaining steel and

friction plates.

• Add the pressure plate (low/reverse one wayclutch) on the last friction plate with THISSIDE UP facing upward.

28. Install the ring gear, hub and the No. 15 hubbearing.




31. CAUTION: Do not apply air pressureto move the low/reverse piston without firstinstalling the friction plates and the snapring, damage to the snap ring will occur.

Install the new snap ring. Make sure the snapring opening is in the one o’clock position,between 2 teeth on the case.

• Check the function of the reverse clutch byapplying air to the correct passage (throughthe case valve body worm trail) for thereverse clutch.

34. Install the intermediate clutch plates, startingwith a friction plate.

32. Using the special tools, install the forwardgeartrain as an assembly.

35. Install the center support.

33. Install the intermediate clutch pressure plate.

• Position the intermediate clutch pressureplate in the case with the stepped edgefacing downward.




36. Loosely install the feed bolts. 39. Install the No. 5 thrust bearing onto the centersupport.

37. Using the special tool, install the center supportsnap ring. 40. Install the center shaft and ring gear.

• The snap ring should be installed with theflat edge facing downward. The gap in thesnap ring should be facing in the six o’clockposition. Tap the snap ring securely into thecase

41. Install the No. 4 thrust bearing onto the centershaft.

38. Tighten the feed bolts.




42. Using the special tool, install the coast clutch 45. For vehicles equipped with a PTO, install theassembly and overdrive carrier. overdrive pressure plate.

1 Install the larger tab positioned at the top ofthe case.

2 Install the square end of the plate in thebottom of the case.

• The PTO pressure plate anti rotation tab isinstalled into the 6 o’clock position of thesnap ring gap.

43. Install the overdrive clutch assembly snap ringwith the gap in the six o’clock position.

46. Install the overdrive clutch.

• Start with a friction plate, alternating with asteel plate.

44. For non-PTO applications, install the overdrivepressure plate with the notches facing up.




47. Install a new pump gasket.

51. Check to make sure that the No. 1 thrustwasher is installed on the pump stator.

48. Install the No. 2 thrust bearing.52. Using the special tools, install the pump

assembly.

49. Install the input shaft into the case.

53. Install new retaining bolts.

50. Install the special tools into the case in order toinstall the pump.




54. Install a new main control body gasket. 55. Using the special tools, check the function ofeach clutch. Apply 20 psi (137.9 kPa) of air toeach port.

Item Part Number Description

1 — Coast clutch

2 — Intermediate clutch

3 — Reverse clutch

4 — Forward clutch

5 — Direct clutch

6 — Overdrive clutch

56. Install the forward clutch orifice in place on thetop of the forward clutch feed bolt.




57. Using the special tools, install the solenoidbody and loosely install the bolts.

• While installing the solenoid body, align themanual valve.




58. Tighten all the bolts in the sequence shown.

59. Connect the transmission range sensorconnector.

60. NOTE: Prior to installing the fluid filter, makesure that the old seal is not stuck in the case.

Install a new transmission fluid filter.




61. NOTE: Do not discard the fluid pan gasket. It 64. Install the output shaft speed (OSS) sensor.is reusable.

Install the transmission fluid pan gasket to thefluid pan. Make sure the magnet is positionedover the dimple in the fluid pan.

65. CAUTION: Do not damage the fluidpump gear O-ring when installing the torqueconverter.

CAUTION: Make sure the converter62. Install the transmission fluid pan. hub is fully engaged in the front pump

support and gear and rotates freely. Do notdamage the hub seal.

CAUTION: If the torque converterslides out, the hub seal may be damaged.

Lubricate the converter hub with cleanautomatic transmission fluid.

63. Install the intermediate shaft and turbine shaftspeed (TSS) sensor.




66. CAUTION: Use care when installingthe torque converter to avoid damage to thefront pump stator support seal.

NOTE: Check the converter crankshaft pilot fornicks or damaged surfaces that can causeinterference when installing the transmission tothe engine. Check the converter impeller hubfor nicks or sharp edges that can damage thepump seal.

Using the special tools, install the torqueconverter. Push and rotate the converter ontothe front pump assembly until it bottoms out.

68. Use the special tool to hold the torque converter67. Check the seating of the torque converter.in place when installing the transmission.

1 Place the straightedge across the converterhousing.

2 Make sure there is a gap between theconverter pilot face and the straightedge.

3 Remove the special tools.


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5R110W assembly