5r55e Assembly

307-01-1

Automatic Transmission — 5R44E and 5R55E

307-01-1

ASSEMBLY Special Tool(s)

Transmission

Installer, Transmission Extension Housing Bushing 307-065 (T77L-7697-F)

Special Tool(s) Holding Fixture, Transmission 307-262 (T93T-77002-AH)

Installer, Transmission Extension Housing Fluid Seal 307-038 (T74P-77052-A) Adjustment Set, Transmission Band 307-S022 (T71P-77370-A)

Alignment Set, Fluid Pump 307-S039 (T74P-77103-X) Holding Fixture, Transmission 307-003 (T57L-500-B)

Alignment Gauge, Transmission Fluid Pump 307-431 Aligner, Torque Converter 307-331 (T95L-7902-A)

Alignment Gauge, Transmission Fluid Pump 307-432 Depth Micrometer 303-D026 (D80P-4201-A) or equivalent

Sizer, Piston Seal 307-338 (T95L-70010-G) Alignment Gauge, TR Sensor 307-351 (T97L-70010-A)

Shim Selection Gauge 307-263 (T93T-77003-AH) (Continued)

(Continued)

Copyright

� 2005,

Ford Motor Company

Last updated: 4/18/2006

2006 Ranger, 9/2005

307-01-2


307-01-2

ASSEMBLY (Continued) Special Tool(s)

Special Tool(s) Compressor, Servo Cover 307-340 (T95L-77028-A)

Retainer, Torque Converter 307-346 (T97T-7902-A)

Installer, Shift Shaft Fluid Seal 307-050 (T74P-77498-A)

Transmission Fluid Pump Seal Aligner 307-451/1

Handle, Torque Converter 307-091 (T81P-7902-C)

Transmission Fluid Pump Seal Sizer 307-451/2

Gauge, TSS 307-337 (T95L-70010-F)

Transmission Fluid Pump Seal Installer 307-451/3

Aligner, Valve Body 307-333 (T95L-70010-B)

Material Item

Aligner, Valve Body 307-334 (T95L-70010-C)

Specification

Multi-Purpose Grease XG-4 and/or XL-5

ESB-M1C93-B

MERCON� V Automatic Transmission Fluid XT-5-QM

MERCON� V

(Continued)

2006 Ranger, 9/2005

307-01-3


307-01-3

ASSEMBLY (Continued)

2006 Ranger, 9/2005

307-01-4


307-01-4

ASSEMBLY (Continued)

2006 Ranger, 9/2005

307-01-5


307-01-5

ASSEMBLY (Continued) Item

Part Number

Description

1

7902

Converter assembly — (contains piston type clutch)

2

379299-S2

Item

Part Number

Description

24

7D404

Nut — (attaches converter assembly to flexplate) (4 required)

Seal ring — coast clutch and direct clutch piston — inner (2 required)

25

7A548

Seal ring — coast clutch piston — outer

3

7017

Shaft — input

26

7A262

Piston — coast clutch

4

7A248

Seal assembly — converter hub to converter housing (also in converter housing assembly)

27

7A480

Spring — coast and direct clutch piston (40 required)

28

7A527

Retainer — coast clutch piston springs

5

W701451-S301

Screw an and se seal as assembly — M10 x 33 (attaches converter housing to case) (8 required)

29

E860125-S

Retaining ring — 63 mm (2.52 in) coast and direct clutch piston

6

7976

Converter housing

30

7B442

7

7B472

Plate — fluid pump adapter

8

7A136

Converter housing-to-case gasket

Plate — coast (2 required) and direct (4 or 5 required) clutch external steel

31

7B164

Plate — coast (2 required) and direct (4 or 5 required) clutch internal friction

33

7B066

Plate — coast and direct clutch pressure (2 required)

33

E860126-S, E860 E86012 1277-S, S, E860128-S, E860129-S

Retaining ring — coast and dir direct ect clut clutch ch plat plates es (se (selec lect fit fit)) (2 required)

34

7660

Adapter — coast clutch to front carrier

35

7D063

Gear — sun overdrive

36

7B446

Carrier — planetary gear front (with trigger wheel)

37

7L495

Bearing — front planet thrust No. 2

38

7A153

Gear — overdrive ring

39

7A089

Clutch assembly — overdrive one-way

40

7A658

Shaft assembly — center overdrive (includes overdrive one-way clutch 7C109)

41

W702037-S300

Retaining ri ring — 11 110.1 mm (4.4 inch) center shaft in front ring gear

9 10

7L323

Seal ring — fluid pump support

W701 W70143 4311-S3 S300 00

O-ri O-ring ng — flui fluid d pum pump sha shaft to inner gear (also in pump assembly)

11

7A103

Support and gear assembly — fluid pump

12

W701429S309M

Screw — fluid pump-to-converter housing (6 required)

13

7D014

Washer — fluid pump input thrust (select fit) No. 1

14

7A248

Seal ring — fluid pump

15

71000

Nut and seal assembly — hex intermediate and front band adjustment/lock (2 required)

16

7C492

Screw — intermediate and front band adjuster/lock (2 required)

17

7D430

Strut — intermediate and front band anchor (2 required)

18

7A653

Bracket — front band lever to case

19

7D433

Shaft — front band actuating lever

42

W702465-S300

Lever — intermediate and front band servo (2 required)

Retaining ri ring — center support in case

43

7M153

Strut — intermediate and front band apply (2 required)

Bearing — center shaft thrust No. 3, 5 and 9 (3 required)

44

E826160-S76

Band assembly — intermediate and front (2 required)

Nut and cage assembly — (attaches center support to case)

45

E804373-S

Screw cap (attaches center support to case)

20 21 22

23

7330 7D029 7D034

7L669

Drum assembly — front brake and coast clutch

(Continued)

(Continued)

2006 Ranger, 9/2005

307-01-6


307-01-6


Part Number

Description

46

7M101

Sensor — turbine shaft speed (TSS)

47

W702 W70229 2977-S3 S300 00

Scre Screw w — turb turbiine shaf haft speed peed sensor

48

7A130

49

Item

Part Number

Description

69

E860122-S

Retaining ring — 87 mm (3.48 inch) forward and output shaft ring gears to hubs (2 required)

Support assembly — center

70

7B067

Hub — forward ring gear

7D014

Bearing — intermediate brake drum thrust (select fit) No. 4

71

7D392

50

7D433

Shaft — intermediate band actuating lever

Gear — forward ring (72 external teeth and 57 internal teeth)

72

7F374

51

7D044

Drum assembly — intermediate brake and direct clutch

Bearing — forward planet thrust No. 7

73

7A398

Planet assembly — forward (6 pinion)

52

7A548

Seal ring — direct clutch piston outer

74

E860121-S

53

7A262

Piston — direct clutch

Retaining ring — 39 mm (1.56 inch) input shell to sun gear assembly (2 required)

54

7A527

Retainer — direct clutch piston spring

75

7D063

Gear assembly — sun (forward)

55

7A360

Cylinder assembly — forward clutch

76

7D064

Shell — input

77

7M151

56

7A548

Seal ring — forward clutch piston inner

Bearing assembly — low/reverse planet carrier thrust No. 8

57

7A548

Seal ring — forward clutch piston outer

78

7D006

Planet assembly — low/reverse (6 pinion)

58

7A262

Piston assembly — forward clutch

79

7B176

Sleeve — output

80

7A153

Gear — output shaft ring

59

7A480

Spring — forward clutch piston (15 required)

81

E860527-S

60

7A527

Retainer — forward clutch piston spring

Retaining ring — 25 x 2 mm (0.08 inch) output shaft in case

82

7D164

Hub — output shaft

61

E860109-S

Retaining ring — 34 mm (1.36 inch) forward clutch piston and spring in forward clutch cylinder

83

7C498

Drum assembly — low/reverse brake (includes overrunning clutch)

84

7D001

Spring — forward clutch cushion

Bearing — part of reverse drum

85

7A089

Plate — forward clutch external steel (6 required)

Clutch assembly — part of reverse drum

86

7D095

Band — low/reverse

87

7M150

Bearing race (2 pieces) — output shaft hub thrust No. 10A

88

7M150

Bearing assembly — output shaft hub thrust No. 10B

89

7B368

Washer — output shaft thrust No. 11

62 63

7B070 7B442

64

7B164

Plate — forward clutch internal friction (6 required)

65

7B066

Plate — forward clutch pressure

66

E860115-S

Retaining ring — forward clutch plates in forward clutch cylinder (select fit)

67

7D234

Bearing — forward ring gear hub thrust No. 6A

90

7M167

Gear assembly — transmission parking

68

7D090

Washer — forward clutch thrust No. 6B

91

7060

Shaft — output (rear wheel drive [RWD])

92

7086

Gasket — extension housing

93

7A441

Pawl — parking

(Continued)

(Continued)

2006 Ranger, 9/2005

307-01-7


307-01-7


Part Number

Description

Item

94

7D070

Spring — parking pawl return

121

7M183

95

7D071

Shaft — parking pawl

Sensor — intermediate shaft speed

96

7A039

Extension housing (RWD)

122

W703165-S300

97

7A034

Bushing — extension housing (RWD)

Spring — retains 16 16 pi pin connector in case

123

7H103

98

7052

Seal assembly — extension housing to slip yoke (RWD)

Sensor — output shaft speed (OSS)

124

390318-S2

99

E804137-S72

Stud — extension housing (1 or 2 required)

Plug — pipe line and EPC pressure (part of case assembly) (2 required)

100

E800152-S72

Screw — extension housing (5 or 6 required)

125

7034

Vent — (4WD)

126

7034

Vent — (RWD)

101

7060

Shaft — output (four wheel drive [4WD])

127 127

W702 W7029 909-S 09-S3 309

Stu Stud — attac ttache hess heat heat shi shield eld to case

102

7A039

Extension housing (4WD)

128

7F013

103

N605804-S100

Screw — extension ho housing to transfer case (5 required)

Shield — transmission heat (4.0L only)

129

N620040-S36

104

W701271-S309

Nut — at attaches ou outer an and inner manual valves to shaft (2 required)

Nut — transmission heat shield

130

7A160

Tube — lube fluid inlet — short

105

7A256

Lever — manual control outer

131

7D273

Connector — fluid tube (2 required)

106 106

W500 W50001 0155-S3 S309 09

Scre Screw w — di digit gital tran transm smiissi ssion range (TR) sensor (2 required)

132

7D028

Spring — intermediate servo and front piston

133

7D021

Sensor — transmission range (TR)

Piston and rod assembly — intermediate and front servo

134

7D027

Shaft — manual valve outer to inner lever

Cover and seal assembly — intermediate and front servo

135

7D040

Pin — spring (retains outer manual lever to case)

O-ring — servo cover to case intermediate and front servo

136

E860343-S

Retaining ring — 67 x 1.5 mm (0.06 inch) intermediate and front servo

137 137

W701 W7010 099-S 99-S4 430

Scr Screw — att attac ache hess sep separ arat atin ing g plate to main control (3 required)

107 108 109

7F293 7C493 E840125-S

Part Number

Description

110

7B498

Seal — main control lever

111

7C115

Lever — manual valve inner

112

7A232

Rod — parking pawl actuating

113

7E332

Spring assembly — manual valve detent

138

7G383

Solenoid — electronic pressure control (EPC)

114

E800185-S72

Screw — attaches de detent spring to main control

139

7G484

Solenoid — transmission shift (SS) (4 required)

115

7Z409

Connector — transmission case (16-pin with wire harness to 6 solenoids)

140 140

W702 W7029 949-S 49-S3 300

O-r O-ring ing — shif shiftt sol soleenoid noid smal smalll (13x1.5) (4 required)

116 116

W703 W70301 0155-S3 S300 00

O-ri O-ring ng — tran transm smis issi sion on case case (16-pin) connector

141 141

W702 W7029 951-S 51-S3 300

O-r O-ring ing — shif shiftt sol soleenoid noid larg largee (15x1.5) (4 required)

117

7005

Case assembly (model dependent)

142

7G136

Solenoid — torque converter clutch (TCC)

118

W702297-S300

Screw — M6 x 19 cap

143

7L491

Clamp — (SSA and SSC) solenoids

119

W702981-S300

O-ring — speed sensor

144

7L491

120

W702297-S300

Screw — OSS sensor

Clamp — TCC/SSD/SSB and EPC solenoids

145

E800155-S72

Screw — clamp (2 required)

(Continued)

(Continued)

2006 Ranger, 9/2005

307-01-8


307-01-8


Part Number

Description

146

7A100

Control valve body — main (model dependent)

147

7Z490

Plate — valve body separating (bonded)

148

E800154-S

Screw — M6 x 45 main control valve body (4 required)

149

E800153-S72


150

E800163-S


151

7423

Seal ring — low/reverse servo piston small

152

7423

Seal ring — low/reverse servo piston large

153

7D189

Piston assembly — low/reverse band servo with rod and retainer (select fit)

154

7L173

Gasket — low/reverse servo cover

155

7D036

Cover — low/reverse servo

156

E800156-S

Screw — low/reverse servo cover (4 required)

157

7A469

O-ring — fluid filter assembly small

158

7A098

Filter — fluid pan (RWD)

159

7A469

O-ring — fluid filter assembly large

160

7L027

Magnet

161

7A191

Gasket — fluid pan

162

W701203S309M

Screw — transmission fluid pan (18 required)

163

7A194

Pan — transmission fluid (RWD)

164

7A098

Filter — transmission fluid pan (4WD)

165

7A194

Pan — transmission fluid (4WD)

166

E800154-S

Screw — fluid filter

A

—

Coast clutch assembly

B

—

Direct clutch assembly

C

—

Forward clutch assembly

2.

Inspec Inspectt the trans transmi missi ssion on case case for the the follo followin wing: g: 1

Stri Stripp pped ed bolt bolt hole hole thre thread ads. s.

2

Gasket Gasket and mating mating surfac surfaces es for for burr burrss or or nicks.

3

Obstru Obstructi ctions ons to vent vent and fluid fluid pass passage ages. s.

•

Cracks or warpage.

3.

Inspec Inspectt the exte extensi nsion on housi housing ng for for cracks cracks,, burrs burrs or warpage.

4.

Inspec Inspectt the the case case bearin bearing g for for damage damage.. If dama damage ge to the case bearing is indicated, install a new case.

All vehicles

1.

Thorou Thoroughl ghly y clean clean the the tran transm smiss ission ion case case and extension housing in solvent and blow dry with compressed air. 2006 Ranger, 9/2005

307-01-9


307-01-9

ASSEMBLY (Continued) 5.

Install the special tool on the rear of the transmission case.

8.

Using the special tool, install the manual control lever shaft seal. •

6.

Attach Attach the fixtur fixturee arm arm of the specia speciall tool tool as as shown. 9.

7.

Lubricate the manual control lever shaft seal with petroleum jelly.

WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.

Assemb Assemble le the the manu manual al valv valvee inner inner lever lever and and parking lever actuating rod as shown.

10. Install Install the manual manual contr control ol lever lever shaft. shaft.

Install transmission into the special tool. •

Rotate the transmission so that the fluid pan rail is facing up.

2006 Ranger, 9/2005

307-01-10


307-01-10


CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin. NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.

Install the manual control lever shaft spring pin. •

Tap the manual control lever shaft spring pin into the transmission case.

14.

CAUTION: The tabs on the No. 11 output shaft thrust washer point into the case. Make sure the thrust washer is correctly seated.

Install the No. 11 output shaft thrust washer. •

12.

Coat the output shaft thrust washer with petroleum jelly.

CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.

15. Instal Installl the the park park gear. gear.

13.

CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.

Install the manual valve inner lever nut on the manual control lever shaft. •

Tighten to 48 Nm (35 lb-ft).

2006 Ranger, 9/2005

307-01-11


307-01-11

ASSEMBLY (Continued) 16. Install the low/reverse brake drum. •

Rotate the low/reverse brake drum clockwise to install.

19. Install the output shaft ring gear and output shaft hub.

20. 17. If not already already install installed ed during during subassemb subassembly, ly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly. •

CAUTION: Always install a new output shaft retaining ring.

Install a new output shaft retaining ring.

Coat the needle bearing with petroleum jelly.

21. NOTE: Install the output shaft sleeve with the cone facing up. 18. Install Install the output output shaft shaft through through the output output shaft shaft park gear.

Install the output shaft sleeve.

2006 Ranger, 9/2005

307-01-12


307-01-12

ASSEMBLY (Continued) 22. Install Install low/reve low/reverse rse planetary planetary carrier carrier needle needle bearings. 1

Instal Installl the the No. No. 8 low/re low/rever verse se planet planetary ary carrier needle bearing on the front face of the low/reverse planetary.

2

Instal Installl the the No. No. 9 low/re low/rever verse se planet planetary ary carrier needle bearing on the rear face of the low/reverse planetary.

•

Coat the No. 8 low/reverse planetary carrier needle bearing and No. 9 low/reverse planetary carrier needle bearing with petroleum jelly. 25.

CAUTION: Make sure band is resting on the 2 anchor pins in the case.

Install the low/reverse band over the low/reverse brake drum.

23.

CAUTION: Make sure needle bearings stay in place.

Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier need needle le bear bearin ings gs into into the the out outpu putt sha shaft ft ring ring gear gear..

24.

26. 26. Temp Tempor orar aril ily y ins insta tall ll the the low low/r /rev ever erse se band band serv servo o piston and rod to hold the low/reverse band in position.

CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.

Install the low/reverse retaining ring into the low/reverse brake drum groove. 2006 Ranger, 9/2005

307-01-13


307-01-13

ASSEMBLY (Continued) 27. Install th the pr previously as assembled fo forward geartrain assembly.

28.


Rotate the transmission assembly so that the converter housing surface is facing up.

30. Calculate th the th thrust be bearing th thickness. •

Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.

31. Place the the micromete micrometerr on the opposi opposite te side side of the special tool and repeat the measurement. This is dimension B.

29. Select Select the No. 4 interm intermediat ediatee brake drum drum thrust thrust bearing as follows: 1

Instal Installl the the speci special al tool tool on the the case case assem assembly bly shoulder.

2

Set the specia speciall tool tool on top as shown. shown.

32. Add dimens dimension ion A and B, B, divide divide the total total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 inch). Record this reading as dimension C.

2006 Ranger, 9/2005

307-01-14


307-01-14

ASSEMBLY (Continued) 33. Place the the special special tool across across the center center support support.. Place the micrometer on the top of the special tool. •

Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.

35. Add dimens dimensions ions D and and F, divide divide the total total of D and F by 2. Subtract the special tool thickness 17.78 mm (0.700 inch) dimension E. The result is dimension G.

34. Place the the special special tool tool on the opposi opposite te side of of the special tool. •

Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.

36. Add dimens dimensions ions C and G. This This total total is is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.008-0.021 inch). Dimension H

Service Part Number

Bearing Thickness

Identification (Notches)

3.01-3.15 mm (0.119-0.124 inch)

XW4Z-7D014-CA

2.65-2.80 mm (0.104-0.110 inch)

None

3.17-3.34 mm (0.125-0.132 inch)

XW4Z-7D014-DA

2.80-2.95 mm (0.110-0.116 inch)

1

3.36-3.54 mm (0.133-0.140 inch)

XW4Z-7D014-EA

3.00-3.15 mm (0.118-0.124 inch)

2

3.57-3.71 mm (0.141-0.147 inch)

XW4Z-7D014-FA

3.20-3.35 mm (0.126-0.132 inch)

3

2006 Ranger, 9/2005

307-01-15


307-01-15

ASSEMBLY (Continued) 37. Install the intermediate servo actuating lever.

40. NOTE: Make sure that the intermediate apply strut is aligned with the band notch. Install the intermediate band.

38. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft. Install th the in intermediate ba band ac actuating le lever shaft haft thro hrough ugh the the inter nterm medi ediate ate serv servo o actu actuat atiing lever.

41. NOTE: Use the intermediate band adjusting scre screw w as a tempo emporrary ary ali alignm gnment ent guid guide. e. NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.

Install the intermediate band anchor strut and the intermediate band adjustment screw.

39. Install Install the interme intermediat diatee band apply apply strut on the the intermediate servo actuating lever.

2006 Ranger, 9/2005

307-01-16


307-01-16

ASSEMBLY (Continued) 42. Install Install the No. No. 4 selected selected interme intermediate diate brake brake drum thrust washer on the center support. •

Coat the intermediate brake drum thrust washer with petroleum jelly.

44.

CAUTION: Install the center support retaining ring with the tapered side facing up. CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.

Install the center support retaining ring.

43.

1

Positi Position on the the cent center er supp support ort retain retaining ing ring ring with the tapered side facing up.

2

Instal Installl the the center center supp support ort reta retaini ining ng ring ring so that the notch opening is not obstructed.

CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings can result. NOTE: Align the center support screw hole with correct case hole.

Install the center support. 1

Positi Position on the center center suppor supportt into into the intermediate brake and direct clutch drum.

2

Tempor Temporari arily ly insert insert the input input shaft shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.

2006 Ranger, 9/2005

307-01-17


307-01-17

ASSEMBLY (Continued) 45. Install Install the center center suppo support rt locknut locknut and and cage.

48. 46. Loosely Loosely install install the the center suppor support-tot-to-case case cap screw.

CAUTION: Use only the No. 3 center shaft thrust bearing. NOTE: The No. 3 center shaft thrust bearing has no notches on the outer race.

Install the No. 3 center shaft thrust bearing.

47.

CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring. NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.

49.

CAUTION: Do not bend the trigger wheel.

Install the overdrive planetary and one-way clutch assembly.

Install the TSS sensor. 1

Inst Instal alll the the TSS TSS sen senso sor. r.

2

Inst Instal alll the the TSS TSS sen senso sorr scr screw ew.. X

Tighten to 10 Nm (89 lb-in).

2006 Ranger, 9/2005

307-01-18


307-01-18


CAUTION: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.

52. NOTE: Align the clutch plates and front adapter gear. Install the front brake drum and coast clutch drum assembly.

Using the special tool, check the TSS sensor air gap. 1

Place Place the the thin thin blade blade of of the the speci special al tool tool over over the TSS sensor.

2

Rotate Rotate the trigge triggerr wheel wheel and repeat repeat checks checks for all windows.

53. Install Install the front front servo band band lever lever and front front band lever-to-case bracket into the transmission case.

51.

CAUTION: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does, a new overdrive planetary carrier and trigger wheel must be installed.

Using the special tool, check the TSS sensor air gap. 1

Place Place the the thic thick k blad bladee of the specia speciall tool tool over the TSS sensor.

2

Rotate Rotate the trigge triggerr wheel wheel and repeat repeat checks checks for all windows.

54. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft. Install the front band actuating lever shaft through the front servo band lever.

2006 Ranger, 9/2005

307-01-19


307-01-19

ASSEMBLY (Continued) 55. Install the front band apply strut.

58. Install the front band adjusting screw.

56. NOTE: If the front band is reused, it must be installed in its original position.

59.

Install the front band over the front brake and coast clutch drum.

CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface. CAUTION: The tabs on the washer go into the pump face.

Carry out the front end play check procedure as follows: •

•

Coat the No. 1 fluid pump inlet thrust washer with petroleum jelly. Install the No. 1 fluid pump inlet thrust washer on the rear of the fluid pump and place the pump into position in the case.

57. NOTE: Use the band adjustment screw as a temporary alignment guide. Install the front band anchor strut.

2006 Ranger, 9/2005

307-01-20


307-01-20


CAUTION: The special tool must rest on the gasket surface.

Measure the front end play clearance. 1

Place Place the the specia speciall tool tool across across the case. case.

2

Insert Insert the specia speciall tool tool and extend extend the micrometer probe until it contacts the fluid pump face.

•

•

•

Read the measurement and subtract the special tool thickness 17.78 mm (0.70 inch). This is dimension A.

61.

CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer. NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 inch).

Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1). Front End Play Selective Thrust Washer No. 1

Repeat the measurement at the opposite side of the transmission case. This is dimension B.

Front End Play C 0.18 - 0.70 mm (0.007 - 0.028 inch) Without Gasket

Add dimensions A and B together and divide by 2. This is front end clearance dimension C.

Part Number

Thickness

Color

F7TZ-7D014-VA

1.35 - 1.40 mm (0.035 - 0.055 inch)

Blue

F7TZ-7D014-TA

1.55 - 1.60 mm (0.061 - 0.063 inch)

White

F7TZ-7D014-MA

1.75 - 1.80 mm (0.069 - 0.071 inch)

Green

F7TZ-7D014-NA

1.85 - 1.90 mm (0.073 - 0.075 inch)

Red

F7TZ-7D014-PA

1.95 - 2.00 mm (0.077 - 0.079 inch)

Beige

F7TZ-7D014-RA

2.05 - 2.10 mm (0.081 - 0.083 inch)

Black

F7TZ-7D014-SA

2.15 - 2.20 mm (0.085 - 0.087 inch)

Yellow

Selective Pump Support Thrust Washer

2006 Ranger, 9/2005

307-01-21


307-01-21


CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface. CAUTION: The tabs on the washer go into the pump face.

Remove the pump and install the No. 1 thrust washer onto the pump. After installing selected front pump thrust washer No. 1, repeat the front end play check. Make sure the end play is correct, then remove the pump for assembly. 65.

CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.

Install the pump gears into the fluid pump housing. Apply multi-purpose grease to the pump gear to prevent scoring at start-up.

63. Install Install a new O-ring O-ring seal seal in the the fluid fluid pump drive gear.

66.

CAUTION: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.

64.

CAUTION: Lubricate the special tool with multi-purpose grease.

Install the fluid pump drive gear on the special tool to seat the O-ring seal. Remove the tool.

2006 Ranger, 9/2005

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307-01-22


CAUTION: Do not allow the pump gears to come out of the pump housing pocket. NOTE: The notch on the outside of the adapter plate will be at the 9 o’clock position relative to the converter housing.

Install the fluid pump on the converter housing. •

Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing. 70. Thread Thread the gauge gauge into the special special tool tool and slide slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.

68. Loosely Loosely install install the the fluid fluid pump screws screws..

71. Tighten Tighten the fluid fluid pump pump screws screws in a star star pattern pattern and remove the pump alignment handle. •

69.


CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.

2006 Ranger, 9/2005

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307-01-23

ASSEMBLY (Continued) 72. Install Install a new new fluid fluid pump pump seal ring. ring. •

Coat the fluid pump seal ring with petroleum jelly.

75.

CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.

Verify that the seal is installed correctly.

73. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly. Install a new fluid pump gasket. •

Hold the fluid pump gasket in place with petroleum jelly.

76.

74.

CAUTION: Be careful not to overstretch the seal ring past the seal ring groove or damage to the seal will occur.

CAUTION: Failure to correctly size the seal will damage the seal when the torque converter is installed.

Using the special tool, size the seal to the correct size. Leave the special tool on the seal for 2 minutes to obtain the correct seal size.

Using the special tools, install the fluid pump seal ring.

2006 Ranger, 9/2005

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307-01-24

ASSEMBLY (Continued) 77. Install Install the select selected ed No. 1 fluid fluid pump pump thrust thrust washer. •

Coat the fluid pump thrust washer with petroleum jelly.

80.

CAUTION: Make sure that the No. 1 fluid pump inlet thrust washer selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.

Install the fluid pump and converter housing onto the case.

78. Install Install the special special tools tools into into the transmiss transmission ion case. 81. NOTE: Lubricate the O-ring seals on the converter housing screws. Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern. •

79.


CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.

Install the input shaft.

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307-01-25

ASSEMBLY (Continued) 82. Remove Remove the the input input shaf shaft. t.

85.

CAUTION: Do not damage the front servo-to-case O-ring seal during installation. CAUTION: Do not press the front servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.

Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.

83.


Rotate the transmission assembly so the fluid pan rails are facing up. 84. Assemble Assemble the the front front servo servo assembly assembly.. 1

Instal Installl the the front front servo servo cove coverr O-rin O-ring g seal seal on on the front servo cover. Coat the front servo cover O-ring seal with petroleum jelly.

2

Instal Installl the the front front serv servo o pisto piston n into into the the front front servo cover.

3

Instal Installl the the front front serv servo o pisto piston n sprin spring g on the the front servo piston.

86. Assemble Assemble the interm intermediat ediatee servo assembly assembly.. 1

Instal Installl the the interm intermedi ediate ate servo servo cove coverr O-ring O-ring seal on the intermediate servo cover. Coat the intermediate servo cover O-ring seal with petroleum jelly.

2

Instal Installl the inte interme rmedia diate te servo servo pist piston on into into the the intermediate servo cover.

3

Instal Installl the the interm intermedi ediate ate servo servo pist piston on spri spring ng on the intermediate servo piston.

2006 Ranger, 9/2005

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307-01-26


CAUTION: Do not damage servo cove coverr-to to-c -cas asee O-r O-riing seal seal duri during ng insta nstall llat atio ion. n. CAUTION: Do not press the intermediate servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.

Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.

88.

CAUTION: Do not allow front band adjustment screw to back out. The band strut can fall out of position. CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

89.

CAUTION: The front servo must be ins instal talled led prio priorr to to ban band d adj adjus ustm tmen ent. t. NOTE: The wrench will click at the specified torque.

Using the special tool, tighten the front band adjustment screw. •

•

Tighten to 14 Nm (10 lb-ft). Then back off the front band adjustment screw exactly 2 turns and hold that position.

90. Tighten Tighten the the front front band band locknut locknut.. 1

Hold Hold the the front front band band adju adjustm stment ent screw screw stationary.

2

Tigh Tighte ten n the the fron frontt band band loc lockn knut ut.. X


Install a new locknut on the band adjustment screw.

2006 Ranger, 9/2005

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307-01-27


CAUTION: Do not allow the intermediate band adjusting screw to back out. The band strut could fall out of position.

93. Tighten Tighten the interm intermediat ediatee band locknu locknut. t.

CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

1

Hold Hold the the interm intermedi ediate ate band band adju adjustm stment ent screw stationary.

2

Tighte Tighten n the the inte interme rmedia diate te band band locknu locknut. t. X


Install a new nut on the band adjustment screw.

94. 92.

CAUTION: The intermediate servo must be installed prior to band adjustment. NOTE: The wrench will click at the specified torque.

Using the special tool, tighten the intermediate band adjusting screw. •

•

Tighten to 14 Nm (10 lb-ft). Then back off the intermediate band adjusting screw exactly 2 turns and hold that position.

CAUTION: Install new O-ring seals on the 16-pin electrical connector. Coat the O-ring seals with petroleum jelly. NOTE: Make sure that the tab is in the lock position.

Position the transmission case 16-pin electrical connector into the case bore. •

Press the transmission case 16-pin electrical connector through the case until a click is heard.

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307-01-28


CAUTION: Do not overstretch the retaining spring.

Install the 16-pin electrical connector retaining spring.

97. Tighten Tighten the the center center suppo support rt screw. screw. •


98. Install Install the special special tools into into the transmiss transmission ion case. 96.

CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the 16-pin electrical connector.

Install the TSS sensor electrical connector into the transmission case 16-pin electrical connector. 1

Connec Connectt the the TSS TSS sensor sensor electr electrica icall conne connecto ctor. r.

2

Insert Insert the TSS sensor sensor electr electrica icall conne connecto ctorr wires into the retaining slot in the 16-pin electrical connector.

2006 Ranger, 9/2005

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307-01-29


CAUTION: Make sure main control valve body gasket is aligned. CAUTION: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.

Position the main control valve body into the transmission case.

102. NOTE: The main control valve body screw will be tightened in later steps. Loosely install the M6 x 30 mm screw.

100. NOTE: The screws will be tightened in later steps. Loosely install the 4 M6 x 45 mm screws.

103. Remove Remove the special special tools. tools.

101. NOTE: The main control valve body screws will be tightened in later steps. Loosely install the 2 M6 x 35 mm screws.

2006 Ranger, 9/2005

307-01-30


307-01-30

ASSEMBLY (Continued) 104. NOTE: The The mai main n con contr trol ol valv valvee bod body y scr screw ewss will be tightened in later steps.

105. 105. Tigh Tighte ten n the the scre screws ws in the the seq seque uenc ncee sho shown wn.. •


Loosely install the 16 M6 x 40 mm screws.

2006 Ranger, 9/2005

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307-01-31

ASSEMBLY (Continued) 106. 106. Rota Rotate te the the manu manual al leve leverr into into the the NEUT NEUTRA RAL L position, then install the manual control valve detent lever spring. 1

Positi Position on the the manu manual al cont control rol valve valve dete detent nt lever spring on the main control valve body.

2

Inst Instal alll the the scre screw w. X

108. 108. Tigh Tighte ten n the the scre screws ws in the the sequ sequen ence ce show shown. n. •



109. Connect Connect the solenoid solenoid electric electrical al connectors connectors..

107. Install Install the low/re low/reverse verse band band servo servo cover cover and reverse servo separator plate cover gasket. 1

Positi Position on the the low/ low/rev revers ersee band band serv servo o cover cover and low/reverse servo separator plate cover gasket on the transmission case.

2

Loos Loosel ely y ins insta tall ll the the scr screw ews. s.

1

Connec Connectt shif shiftt sole solenoi noids ds SSA, SSA, SSB, SSB, SSC SSC and and SSD electrical connectors.

2

Connec Connectt the the torq torque ue conv convert erter er clut clutch ch (TCC (TCC)) solenoid electrical connector.

3

Connec Connectt the the elec electro tronic nic pressu pressure re cont control rol (EPC) solenoid electrical connector.

2006 Ranger, 9/2005

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307-01-32

ASSEMBLY (Continued) CAUTION: Excessive pressure may break the locating pins.

110.

Install the wiring loom protector and guide. Align the pins in the holes of the solenoid clamps and gently push down.

•

113. Position Position the the fluid fluid pan magnet magnet in the the transmission fluid pan.

111.

CAUTION: Make sure that both fluid pan filter O-ring seals are correctly installed on the fluid pan filter prior to installation. CAUTION: Lubricate fluid filter O-ring seals with clean automatic transmission fluid or they can be damaged.

Lubricate and install new O-ring seals onto the transmission fluid filter.

114. Install the transmission fluid pan. 1

Positi Position on a new new trans transmis missio sion n fluid fluid pan gasket gasket on the transmission fluid pan.

2

Instal Installl and align align the the tran transm smiss ission ion fluid fluid pan. pan.

112. Install Install the transm transmissio ission n fluid filter. filter. 1

Positi Position on the the tran transm smiss ission ion fluid fluid filt filter er on the main control valve body.

2

Instal Installl the the transm transmiss ission ion fluid fluid filt filter er screw screw.. X


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307-01-33

ASSEMBLY (Continued) 115. Loosely Loosely install install the the transmissi transmission on fluid fluid pan screws.

119. NOTE: Use petroleum jelly to hold the gasket in place. 116. Tighten Tighten the transmi transmission ssion fluid fluid pan screws screws in a crisscross sequence. •

Install a new extension housing gasket.


120. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately. 117. Remove Remove the transmis transmission sion from from the bench bench and and place on a flat surface.

Install the parking pawl assembly. 1

Instal Installl the the parki parking ng pawl pawl shaft shaft into into the extension housing.

2

Inst Instal alll the the park parkin ing g pawl pawl..

3

Instal Installl the the parki parking ng pawl pawl return return spring spring..

118. Remove Remove the special special tools tools from from the the transmission case.

2006 Ranger, 9/2005

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307-01-34


CAUTION: Make sure the parking lever ac actuating ro rod is is co correctly se seated in into the case parking rod guide cup.

Install the extension housing. 1

Positi Position on the the exte extensi nsion on hous housing ing and gasket gasket..

2

Instal Installl the the extens extension ion housin housing g scre screws. ws.

3

Instal Installl the the extens extension ion housin housing g stud studs. s. X

123.

CAUTION: Tool will bottom when bushing is is in in th the co correct po position.

Using the special tool, install the extension housing bushing.


124. Position Position a new extensi extension on housing housing seal seal with drain hole in the 6 o’clock position.

4x2 vehicles

122.

CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing. NOTE: Install the extension housing bushing only if removed in disassembly. NOTE: Remove any burrs from the extension housing counterbore.

Align the lube hole with the lube groove in the extension housing. This groove is located at the 3 o’clock position when viewed from the rear.

125. Using Using the special special tool, tool, install install a new extensio extension n housing seal.

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307-01-35

ASSEMBLY (Continued) All vehicles

CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor.

126.

128. Install Install the the manual manual control control lever. lever. 1

Ins Instal tall th the lev lever er..

2

Install th the nu nut. X


Install the digital TR sensor. •

•

Position the digital TR sensor on the transmission. Loosely install the screws.

129. If equipped, equipped, install install the transmis transmission sion servo servo heat shield and nut. •

127.


CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position.

Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. •


2006 Ranger, 9/2005

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307-01-36

ASSEMBLY (Continued) 130. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged. Install the output shaft speed (OSS) sensor. 1

Inst Instal alll the the sen sensor. sor.

2

Inst Instal alll the the scre screw w. X

132.

CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.

Install the input shaft.


131. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.

133. Using Using the special special tool, tool, check check that that the fluid fluid pump gear seal ring is seated.

Install the intermediate shaft speed sensor. 1

Instal Installl the the inter intermed mediat iatee shaft shaft spee speed d senso sensor. r.

2

Instal Installl the the inter intermed mediat iatee shaft shaft spee speed d senso sensorr screw. X


2006 Ranger, 9/2005

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307-01-37


CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.

136. Make sure sure the torque torque converter converter is install installed ed to specification.

CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and it rotates freely. Do not damage the hub seal. CAUTION: If the torque converter slides out, the hub seal can be damaged.

Lubricate the converter hub with clean automatic transmission fluid.

137. Lubricate Lubricate the the torque torque converter converter pilot pilot hub with multi-purpose grease.

135.

WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions can result in personal injury.

Use the special tools to install the torque converter by pushing and rotating.

138. Install Install the the special special tool tool on the the case. case.

2006 Ranger, 9/2005

5r55e Assembly

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