Section 07-01A: Transmission, Automatic, E4OD
1996 All F-Series and Bronco with E4OD Automatic Transmission Workshop Manual
DISASSEMBLY

Transmission

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Pump Puller AdapterT89T-70010-A
Impact Slide HammerT59L-100-B
Clutch Spring FixtureT89T-70010-C
Clutch Remover/ReplacerT89T-70010-E
Seal RemoverT74P-77248-A
Lock Nut Pin RemoverT78P-3504-N
PullerT58L-101-B
Torque Converter HandlesT81P-7902-C
Seal RemoverTOOL-1175-AC
Rotunda Car/Truck Engine Repair Stand014-00106

  1. Using Torque Converter Handles T81P-7902C-1, remove the torque converter from the transmission.

  1. Remove the transmission from the transmission jack and position it on a bench. Remove the adapter plate from the transmission.

  1. Mount the transmission on Rotunda Car/Truck Engine Repair Stand 014-00106 (or equivalent).





  1.  CAUTION: The input shaft and overdrive planet assemblies are serviced as mating components.

    Remove the input shaft from the transmission. Rotate the transmission so the fluid pan is facing up.





  1.  CAUTION: Cork gaskets and elastomeric gaskets are not interchangeable. If you remove a cork gasket, replace it with a cork gasket. If you remove an elastomeric gasket: clean, inspect, and reuse it unless the gasket is damaged. Be careful not to cut or bend an elastomeric gasket.

    Remove 20 transmission pan bolts. Remove the pan and the pan-to-case gasket. Discard the gasket. Remove the magnet from the pan.





  1.  CAUTION: Use care not to scratch or damage the aluminum pump bore.

    Remove the filter assembly and seal by carefully pulling and rotating the filter as necessary. Discard the filter and seal.





  1. Remove 11 accumulator body assembly bolts and two nuts. Remove the accumulator body.





  1. NOTE: Do not remove the two bolts shown. These two bolts hold the upper and lower main control valve bodies together as an assembly.

    Remove 14 main control valve body bolts. Remove two nuts and the valve body.





  1. Remove nine solenoid body assembly bolts and one nut. Push up on the solenoid body assembly connector while removing the solenoid body assembly.





  1. NOTE: The steel EPC check ball under the valve body separator plate is spring-loaded.

    Remove three reinforcing plate bolts. Remove the separator plate. Rotate the solenoid screen and pull it from the separator plate. Separate and discard the gaskets.





  1.  CAUTION: Use care not to damage the rubber check balls.

    NOTE: The steel EPC check ball is 25-inch in diameter and is smaller than the other check balls.

    Remove the EPC check ball, spring assembly, and eight rubber check balls from the transmission case.





  1. NOTE: On some models, the intermediate band servo has a snap ring as a retainer.

    Using a plastic or rubber headed hammer, gently tap on the intermediate band servo assembly piston. (The downward force will compress the spring. The upward momentum of the spring will then force the assembly to be released from the case bore.) Remove the servo piston.





  1.  CAUTION: Discard the feedbolts after removal.

    Remove and discard three feedbolts.





  1. Rotate the transmission so the converter housing is facing up. Inspect the front pump seal. If it is damaged, remove it with Impact Slide Hammer T59L-100-B and Seal Remover Tool-1175-AC (or equivalent).





  1.  CAUTION: Discard the pump bolt washers after removal.

    Remove nine pump bolts.





  1. NOTE: The impact slide hammers must be positioned at approximately the 2 o'clock and 8 o'clock positions.

    The No. 1 pump thrust washer and No. 2a overdrive sun gear thrust bearing can stay with the pump.

    Using Impact Slide Hammer T59L-100-B and Pump Puller Adapter T89T-70010-A (slide hammer-type puller only), remove the pump and gasket.









  1. Lift out the coast clutch assembly.





  1. Remove the overdrive clutch pressure plate retaining ring, overdrive clutch pressure plate, and clutch pack. Tag them to aid during assembly.









  1. Remove the overdrive ring gear and overdrive center shaft assembly. Remove the overdrive planet, one-way clutch, and No. 5 overdrive center shaft thrust bearing assembly.





  1. Install Clutch Spring Fixture T89T-70010-C onto the intermediate/overdrive cylinder assembly. Attach the clutch spring fixture to the case. Tighten the center bolt to 7 Nm (65 lb-in).





  1. Remove the intermediate/overdrive cylinder retaining ring. Loosen the spring compressor center bolt and remove the tools.





  1.  CAUTION: Do not misalign the intermediate/overdrive cylinder assembly in the case bore.

    Remove the intermediate/overdrive cylinder assembly.





  1. Remove the intermediate clutch piston return spring.





  1.  CAUTION: Do not misalign the center support in the case bore (damage could result).

    Carefully remove the center support assembly.





  1. Remove the No. 6 center support thrust washer.





  1. Remove the front intermediate pressure plate, intermediate clutch pack, and rear intermediate clutch pressure plate. Remove the intermediate band. Tag the parts to aid during assembly.









  1. NOTE: The hooks on the crossbar must be rotated to engage the notches on the input shell.

    By using Clutch Remover/Replacer T89T-70010-E and lifting upward, remove the direct clutch, forward clutch, and input shell assembly.





  1. Remove the reverse planet retaining ring.





  1. Remove the reverse planet assembly and the No. 10B and No. 11 reverse planet carrier thrust washers.





  1.  CAUTION: Use care when removing the output shaft retaining ring. (The output shaft could fall out.) Do not reuse the output shaft retaining ring.

    Remove the output shaft retaining ring.





  1. Remove the output shaft ring gear, reverse clutch hub, low one-way clutch assembly, and No. 12 output shaft hub rear thrust bearing. Discard the retaining ring.





  1.  CAUTION: Use care not to drop the output shaft while rotating the transmission.

    Remove the reverse clutch pressure plate retaining ring. Rotate the transmission so the fluid pan rail surface is facing up. Remove the reverse clutch pressure plate, clutch pack, and cushion spring. Tag the parts to aid during assembly.









  1. Using Seal Remover T74P-77248-A and Impact Slide Hammer T50T-100-A, remove the extension housing seal. Discard the seal.





  1. Remove nine extension housing bolts. Remove the wiring bracket, extension housing, and extension housing gasket. Discard the gasket.





  1. Remove the output shaft, park gear, and No. 13 output shaft thrust washer.





  1. Remove five bolts from the output shaft hub and race.





  1. Remove the reverse clutch return spring assembly, output shaft hub, and inner race.





  1. Install the reverse clutch pressure plate and reverse clutch pressure plate retaining ring to restrain the reverse clutch piston.





  1.  CAUTION: Always wear safety glasses when using compressed air.

    Apply compressed air into the reverse clutch feed port. (This will blow out the reverse clutch piston against the reverse clutch pressure plate.) Remove the reverse clutch pressure plate retaining ring, pressure plate, and piston from the case.





  1. Remove two parking rod guide plate bolts and the parking rod guide plate.





  1. Remove the parking pawl return spring, parking pawl, and parking pawl shaft from the case.





  1.  CAUTION: The Torx® head bolt has a thread-locking compound and must only be removed if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.

    If required, remove the Torx(r) head screw using a T40 bit and remove the parking pawl abutment.





  1.  CAUTION: Discard the outer manual control lever shaft nut.

    Remove the outer manual control lever shaft nut while holding the control lever with a crescent wrench. Remove the outer manual control lever.






    ItemPart NumberDescription
    1N800287-S36Inner Manual Valve Detent Lever Nut
    27A115Manual Valve Detent Lever
    3N620482-S2Outer Manual Control Lever Nut
    47A256Outer Manual Control Lever
    57A323Parking Lever Actuating Rod

  1. Remove two transmission range (TR) sensor bolts and washers. Remove the sensor.

  1.  CAUTION: Use care not to damage the manual control lever bore.

    NOTE: A number 53 drill bit (1/16-inch) can be used as an alternate method to remove the manual lever shaft retaining pin.

    Remove the manual lever shaft retaining pin using Lock Nut Pin Remover T78P-3504-N (or equivalent). Remove the inner manual valve detent lever nut. Remove the manual valve detent lever, parking lever actuating rod, and manual control lever shaft.






    ItemPart NumberDescription
    1N800287-S36Inner Manual Valve Detent Lever Nut
    27A115Manual Valve Detent Lever
    3N620482-S2Outer Manual Control Lever Nut
    47A256Outer Manual Control Lever
    57A323Parking Lever Actuating Rod

  1. Remove the retaining bolt and manual control valve detent lever spring. Remove the manual control lever seal using Puller T58L-101-B.





  1. NOTE: The stub tube should be removed only if it is loose or damaged.

    If necessary, remove the stub tube using channel lock pliers.





  1. Rotate the transmission with the pan rail down. Remove the transmission case from the stand.

  1. Clean the transmission case, extension housing, fluid pan, and magnet.