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post #1 of 5 (permalink) Old 01-17-2005, 12:13 AM Thread Starter
 
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Post 4r70w assembly

Assembly
1.If bushing was removed, position replacement bushing on Extension Housing Seal Replacer T61L-7657-A and install in bushing bore through the front of the case (7005).

2.Thread Impact Slide Hammer T50T-100-A into Seal Replacer through the back of the case. Install the bushing.

3.With transmission in the vertical position, coat case rear bearing (7F242) with petroleum jelly and install the No. 9 case rear bearing on the transmission case boss.

4.Install output shaft (7060), ring gear (7A153) and direct clutch as an assembly.

5.Install retaining ring that supports reverse band.

6.Install the reverse band. Make sure reverse band is seated on anchor pins.

7.NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless the notch cut in the planetary gear support assembly is aligned with the overdrive band anchor pin (7F295). Top of planetary gear support assembly should be below snap ring groove.
Install forward planetary assembly and planetary gear support assembly as a unit. Align notch in planetary gear support assembly with overdrive band anchor pin.
Rotate the output shaft, if necessary, to align the planet carrier splines with the direct clutch hub splines.

8.NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless notch cut in planetary gear support assembly is aligned with overdrive band anchor pin.
Install the case to planet support spring (7F277) using a screwdriver to position.

9.Install center planet support retaining ring. Reference retainer ring end tab to overdrive band anchor pin.

10.Install forward clutch sun gear, No. 5 thrust bearing (7C096), reverse sun gear and shell and No. 4 needle bearing.

11.Install intermediate stub shaft.

12.Install forward clutch hub and No. 3 forward clutch hub front bearing (7F231).

13.Install forward clutch assembly.

14.NOTE: Wiggle the input shaft while engaging the reverse clutch splines. Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse clutch gear and shell (7A019). Install reverse clutch cylinder assembly.

15.Install overdrive band (7F196) over reverse clutch assembly and position the pocket of the overdrive band against overdrive band anchor pin. Install overdrive servo piston return spring (7F201) and overdrive servo piston assembly. Verify tip of piston assembly engages the pocket of overdrive band. Using Servo Piston Remover/Replacer T92P-70023-A, install piston assembly into the case and compress overdrive servo piston return spring.

16.Make sure band anchor and tip of the piston assembly are properly positioned against band pockets. Tighten tool until piston is below retaining ring groove, install retaining ring, then remove tool.

17.Install intermediate clutch as follows:
a.Clutch pressure plate (7B066) is the thickest. Install this first with chamfer side down.
b.Clutch plates.
c.Perform Steps 18 and 19 to select the proper intermediate clutch selective steel plate.

18.With proper intermediate plates selected and installed, perform end clearance check for No. 1 thrust washer using the same tools.

19.NOTE: Maintain downward pressure on clutch pack while measuring depth.
Measure the intermediate clutch clearance using Depth Micrometer D80P- 4201-A or equivalent and Gauge Bar T80L-77003-A.
Set the gauge bar across the pump case mounting surfaces. The depth at the intermediate clutch separator plate is:
•42.6-41.7 mm (1.677-1.643 inch)
Check the clearance again 180 degrees opposite to ensure the average depth is within tolerance.
If the depth is not within tolerance, the selective steel plates are available.

Install correct plate and check clearance.

Transmission Selective Thrust Washer Procedure
1.Position the Depth Micrometer D80P-4201-A or equivalent on Gauge Bar T80L-77003-A so that the depth is measured at the reverse clutch drum thrust face. Check the end play 180 degrees opposite to determine the average depth. Refer to the Selective Thrust Washers chart for specifications.

a.The thrust washer is located on the stator support which is attached to the back of the pump housing.

2.Install No. 1 thrust washer (7D014) on pump body using petroleum jelly to hold in place.

3.Install pump gasket. Make sure pump gasket is positioned and case passages are covered.

4.To maintain pump-to-case alignment, use a fabricated M8-1.25 mm bolt (head removed) as a guide. Install in the 12 o'clock position using petroleum jelly on pump-to-case seal surfaces to aid pump installation.

5.To aid assembly, grasp input shaft and wiggle shaft while pressing down on pump.

6.Remove alignment bolt and install pump-to-case bolts. Alternate bolt tightening to draw the pump fully into the case. Tighten to 20-26 Nm (15-19 lb-ft).

7.Place transmission in the horizontal position. Install parking pawl (7A441) and parking pawl return spring (7D070). Slide parking pawl shaft (7D071) into case through parking pawl.

8.Install output shaft speed sensor (OSS). Tighten bolt to 7-10 Nm (6-7 lb-ft).

9.Install manual control lever seal using Shift Lever Seal Replacer T74P-77498-A.

10.Install EPC solenoid.

11.If removed, install new extension housing bushing using Extension Housing Bushing Replacer T80L-77034-A. Install new extension housing gasket (7086) and extension housing (7A039). Tighten bolts to 25-30 Nm (19-22 lb-ft).

12.Install extension housing seal using Extension Housing Seal Replacer T61L-7657-B.

13.Position manual valve detent lever (7A115) and parking lever actuating rod (7A232) into case. Parking lever actuating rod must be positioned over parking pawl.

14.Slide manual control lever (7A256) into case and position through detent. Install nut and tighten to 26-37 Nm (20-27 lb-ft).

15.Install manual lever shaft retaining pin (7B210).

16.Install fluid screen into case (head first).

17.Install reverse band servo spring (7D031), reverse band servo piston and rod (7D189). When band and/or piston and rod assembly replacement becomes necessary, determine the correct length of the reverse servo piston, proceed as follows:

a.Lubricate the reverse piston seal to facilitate assembly and to prevent damage to the seal.

b.Install the reverse servo piston and return spring. Do not install the piston cover or retaining ring.

c.Install Servo Piston Selection Tool T80L-77030-A. Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A to 5.6 Nm (50 lb-in).

d.Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent and position the indicator stem on the flat portion of the piston. Zero the dial indicator.

e.Thread the bolt out of the selector tool until the piston stops against the bottom of the tool.

f.Read the amount of piston travel on the dial indicator.
•If the travel is 2.845-6.020 mm (0.112-0.237 inch), the piston length is within specification.
•If the travel is not within specification, selective pistons are available in the following lengths:
74.56 mm (2.936 inch) 1 groove
75.92 mm (2.989 inch) 2 grooves
77.29 mm (3.043 inch) 3 grooves
Length of rod measured from piston surface to end of rod.
Select the proper rod to bring the servo piston travel within specification.

g.Remove the servo selection tool and dial indicator.

h.Lubricate the cover seal to facilitate assembly and to prevent damage to the seal. Place servo cover and retaining ring in servo bore.

18.Tighten screw on Servo Piston Remover/Replacer T92P-70023-A to allow enough clearance to install retaining ring.

19.NOTE: Retainer is secured by main control.
Install the components for 2-3 accumulator in the following order:
•upper accumulator seal (7F250)
•lower accumulator seal (7F249)
•accumulator piston (7F251)
•accumulator piston spring (7F285)
•accumulator spring retainer (7F252)

20.Install the components for 1-2 accumulator in the following order:
•1-2 shift spring (7F284)
•accumulator piston seal (7F248)
•lower accumulator seal
•accumulator piston
•accumulator outer spring
•cover and seal assembly
•accumulator piston retaining ring (7384)

21.NOTE: Tab on connector is secured by main control.
Align and install wiring connector into case. Inspect O-ring and replace if required.

22.Position main control valve body (7A100) using the two alignment bolts as a guide.

23.Install the EPC solenoid bracket. Loosely install one long 6 mm bolt.

24.Loosely install 11 long and 12 short bolts.

25.Install manual control valve detent lever spring (7A261) and one bolt.

26.Tighten the 25 main control valve body-to-case bolts to 9-11 Nm (80-97 lb-in).

27.Connect wiring connectors to transmission fluid temperature sensor (TFT), shift solenoids (7G484), TCC solenoid and EPC solenoid.

28.Install new filter and grommet.

29.Install transmission range (TR) sensor on manual control lever and loosely install bolts.

30.NOTE: PARK is the last detent when the manual control lever is full forward. Return two detents toward output shaft for NEUTRAL.
Position manual control lever in NEUTRAL.
Insert Transmission Range (TR) Sensor (Manual Lever Position Sensor Alignment Tool) T93P-70010-A into slots. Align all three slots on transmission range (TR) sensor with three tabs on tool.

31.Tighten transmission range (TR) sensor bolts to 7-10 Nm (62-89 lb-in).

32.Clean, inspect and install pan-to-case gasket and transmission pan. Tighten all bolts to 12-15 Nm (9-11 lb-ft). ________________________________________
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post #2 of 5 (permalink) Old 01-17-2005, 12:13 AM Thread Starter
 
Join Date: Feb 2004
Posts: 348
4r70w prelim info

Section 07-01: Transmission, Automatic—4R70W 1996 Thunderbird, Cougar Workshop Manual
ASSEMBLY
SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Extension Housing Seal Replacer T61L-7657-A
Impact Slide Hammer T50T-100-A
Servo Piston Remover/Replacer T92P-70023-A
Gauge Bar T80L-77003-A
Shift Lever Seal Replacer T74P-77498-A
Extension Housing Bushing Replacer T80L-77034-A
Extension Housing Seal Replacer T61L-7657-B
Servo Piston Selection Tool T80L-77030-A
Transmission Range (TR) Sensor (MLPS) Alignment Tool T93P-70010-A


SELECTIVE THRUST WASHERS
Depth Thickness Color Code
37.706-38.184 mm (1.485-1.503 inch)
1.270-1.372 mm (0.050-0.054 inch) Green
38.185-38.641 mm (1.504-1.521 inch)
1.727-1.829 mm (0.068-0.072 inch) Yellow
38.642-39.073 mm (1.522-1.538 inch)
2.159-2.261 mm (0.085-0.089 inch) Natural
39.074-39.505 mm (1.539-1.555 inch)
2.591-2.692 mm (0.102-0.106 inch) Red
39.506-40.165 mm (1.556-1.581 inch)
3.023-3.124 mm (0.119-0.123 inch) Blue

Selective Steel Plates
1.80-1.7 mm (0.071-0.067 inch)
2.05-1.9 5 mm (0.081-0.077 inch)
2.31-2.2 0 mm (0.091-0.087 inch)
2.56-2.46 mm (0.101-0.097 inch)

Item Part Number Description
1 7F284 1-2 Shift Spring
2 7F248 Accumulator Piston Seal
3 7F251 Accumulator Piston
4 7F249 Lower Accumulator Seal
5 7G267 1-2 Accumulator Outer Spring
6 7G300 Cover and Seal Assy
7 7384 Accumulator Piston Retaining Ring
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post #3 of 5 (permalink) Old 01-17-2005, 12:20 AM Thread Starter
 
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Posts: 348
Post 4r70w dis-assembly

Disassembly
1.Mount transmission in Bench Mounted Holding Fixture T57L-500-B.

2.Using a 10 mm socket, remove 14 pan retaining bolts, transmission pan and pan-to-case gasket.

3.Remove pan magnet. Clean transmission pan and pan magnet.

4. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and grommet. The filter may be reused if no excessive contamination is present.
Using both hands, remove filter by pulling upward.

5. CAUTION: Do not pull on wires. This may damage wires or connectors and could result in a transmission concern. If required, carefully pry up on locking tab and disconnect the connector.
Grasp connector at each solenoid or sensor and pull straight out to disconnect.

6.NOTE: Removal of the OSS at this time will prevent sensor damage when removing the output shaft (7060).
Using an 8 mm socket, remove bolt retaining output shaft speed sensor (OSS) to case (7005) and remove OSS.

7.Using an 8 mm socket, remove two bolts retaining transmission range (TR) sensor to case. Remove transmission range (TR) sensor from manual control lever (7A256).

8.Using an 8 mm socket, remove one bolt retaining manual control valve detent lever spring (7A261) to the main control valve body.

9.Using an 8 mm socket, remove remaining 24 valve body-to-case retaining bolts, the main control valve body and the valve-to-body gasket.

10.NOTE: Use a shop cloth to protect pan-to-case surface.
Remove manual lever shaft retaining pin (7B210).

11.Using a 13/16-inch open-end wrench on the inner nut and a 12 mm wrench on the manual control lever shaft flats, loosen the inner nut. Slide manual control lever partially out of the case to complete removal of the inner nut from manual control lever.

12.NOTE: Do not damage bore with the prying tool.
Using a screwdriver on the manual control lever seal lower edge, carefully pry manual control lever seal out of case bore.

13.Lift manual valve detent lever (7A115) and parking lever actuating rod (7A232) out of the case.

14.Remove electronic pressure control (EPC) solenoid by sliding it out of the case bore.

15.This illustration shows the position of the overdrive servo, the reverse band servo, 2-3 accumulator piston (7F251) and the 1-2 accumulator piston.

16.Remove the 2-3 accumulator spring retainer.

17.Remove 2-3 accumulator piston.

18.NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston (7F200) assembly out of case. Case bore damage may result from trying to pry on overdrive servo piston retainer (7G280).
Use Servo Piston Remover/Replacer T92P-70023-A to compress the overdrive servo piston return spring (7F201). Use snap-ring pliers to remove retainer ring.

19.Remove piston assembly. Remove overdrive servo piston return spring.

20.Use Servo Piston Remover/Replacer T92P-70023-A to contact the reverse band servo cover (7D036) and compress return spring and remove servo cover retaining ring.

21.NOTE: The length of the rod attached to the piston is graded in three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed.
Remove reverse band servo cover, reverse band servo piston and rod (7D189) and reverse band servo spring (7D031).

22.Apply downward pressure on 1-2 accumulator cover using Servo Piston Remover/Replacer T92P-70023-A. Using snap-ring pliers, remove 1-2 accumulator piston retaining ring (7384).

23.Carefully note the location of the 1-2 accumulator outer springs (7G267) and assemble in the same positions. Some models may use two 1-2 accumulator outer springs. The accumulator piston may also vary with applications. Remove cover and 1-2 accumulator outer spring. Use reverse snap-ring pliers to remove accumulator piston and 1-2 shift spring (7F284).

24.Remove fluid screen from case.

25.Remove extension housing seal using Seal Remover T74P-77248-A. Make sure seal remover lips are firmly seated under the flange on the extension housing seal.

26.Inspect extension housing bushing (7A034). If required, remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-A.

27.NOTE: The extension housing bolts have been coated with a sealant. More break torque may be required to remove these bolts.
Using a 13 mm socket, remove six extension housing bolts. Remove and discard extension housing gasket (7086).

28.The output shaft may have shipping seal still attached. Remove and discard. This seal is not required for assembly.

29.Slide parking pawl shaft (7D071) out of the case and remove parking pawl (7A441) and parking pawl return spring (7D070).

30.Place transmission in the vertical position with output shaft toward floor.

31. CAUTION: Extreme care must be taken during transmission connector removal. Do not pull on the wires, or use a hammer on the connector body. This will damage wires or connector and could result in a transmission concern.
Remove transmission connector from case. Place a screwdriver on the flat portion of the connector and drive the connector out through the bottom of the case.

32.Remove front pump seal using Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T59L-100-B.

33.NOTE: All bolts have been coated with a sealant. More break torque might be required to remove bolts.
Using a 10 mm socket, remove seven pump body retaining bolts.

34.Remove front pump and support assembly using two Impact Slide Hammers T59L-100-B and Pump Puller Adapters T89T-70010-A.

35.Remove and discard pump gasket.

36. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
Grasp the forward clutch cylinder and shaft (7F207) firmly and pull the following components out of the case as an assembly:
•intermediate clutch pack
•intermediate one-way clutch
•reverse clutch assembly
•forward clutch assembly

37.NOTE: Band may be removed with assembly.
Disengage overdrive band (7F196) from overdrive band anchor pin (7F295) and remove.

38.Remove forward clutch hub and the No. 3 forward clutch hub front bearing (7F231).

39.Remove intermediate stub shaft.

40.Rotate reverse clutch gear and shell (7A019) to align indent with overdrive band anchor pin.

41.Remove forward clutch sun gear, No. 5 needle bearing, reverse clutch gear and shell and the No. 4 needle bearing as an assembly.

42.Remove center planet support retaining ring. Note position of retaining ring tabs for assembly.

43.Using needle-nose pliers, remove case to center support spring out from between the center support and the case. Note location for assembly.

44.Remove planetary gear support and planetary as an assembly.

45.Remove reverse band.

46.Remove retaining ring.

47.Remove output shaft, ring gear (7A153) and direct clutch assembly as a unit, from the front of the case.

48.Remove No. 9 case rear bearing (7F242) from rear of the case.

49.Inspect output shaft bushing. If removal is required, use Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T59L-100-B.
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post #4 of 5 (permalink) Old 09-18-2005, 01:49 AM
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Please measure the T80L-77003-A

how thick is the t80l-77003-a guage bar ? without it I would only be guessing at the int clutch and endplay ? Exactly how thick is it ?? Micrometer measurement in inches or mm PLEASE.
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post #5 of 5 (permalink) Old 09-20-2005, 10:13 PM
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FORD GUAGE BAR for endplay + int clutch

The tool is .700" thick , now you can measure accordingly
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