Fcs 15065 Ref

Automatic Transmission
Service
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37 - Automatic Transmission
Student Guide
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FCS-15065-REF
Course Code: 37S13T0
January 2008
Ford Customer Service Division

Technical Training
Blank
IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,
as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing
service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither
his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are
given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful
in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you
should follow when you work on a vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you
to be under the vehicle.
Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you
have an automatic transmission, set it in PARK unless
instructed otherwise for a specific service operation. If
you have a manual transmission it should be in REVERSE
(engine OFF) or NEUTRAL (engine ON) unless instructed
otherwise for a specific service operation.
Operate the engine only in a well-ventilated area to avoid
the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts
when the engine is running, especially the fan and belts.
To help prevent serious burns, avoid contact with hot

metal parts such as the radiator, exhaust manifold, tail
pipe, catalytic converter and muffler.
Do not smoke while working on the vehicle.
To help avoid injury, always remove rings, watches,
loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind
your head.
Keep hands and other objects clear of the radiator fan
blades. Electric cooling fans can start to operate at any
time by an increase in underhood temperatures, even
though the ignition is in the OFF position. Therefore,
care should be taken to ensure that the electric cooling
fan is completely disconnected when working under the
hood.
The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts
and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of
the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual
shall govern.
The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was
approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications,
design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual
is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if
available, may be used. The right is reserved to make changes at any time without notice.
DANGER: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove
dust using government approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to
potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and
clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may
lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may
result in serious personal injury.
Copyright 2008 Ford Motor Company
Produced and Coodinated by

Technical Support Operations
Ford Customer Service Division
January, 2008
CUSTOMER EXPECTATIONS
Customer Expectations: Service
1. Make it convenient to have my vehicle

serviced at your dealership.
2. The Service Advisor should demonstrate

a genuine concern for my service needs.
3. Fix it right the first time, on time.

4. Complete servicing my vehicle in a
timely and professional manner.
5. Provide me with a clear and thorough

explanation of the service performed.
6. Call me within a reasonable amount of

time after my service visit to ensure that
I'm completely satisfied.
7. Be responsive to questions or concerns

that I bring to your attention.
Expectation #3
Fix It Right the First Time, on Time.
Both service advisors and technicians are important players when it comes to Expectation #3.
Why
Customers tell us Fixing It Right the First Time, on Time is one of the reasons they would
decide to return to a dealer to buy a vehicle and get their vehicles serviced.
Technician Training
It is our goal to help the technician acquire all of the skills and knowledge necessary to
Fix it Right the First Time, on Time. We refer to this as competency.
Technicians Role
Acquire the skills and knowledge for competency in your specialty via:
STST
New Model
Web-Based
Web-Based
Instructor Led
Instructor Led
The Benefits
The successful implementation of expectations means:
Satisfied customers
Repeat vehicle sales
Repeat service sales
Recognition that Ford and Lincoln/Mercury technicians are the Best in the Business
AUTOMATIC TRANSMISSION SERVICE
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................... INTRO - 1

Course Description ................................................................................................................... Intro - 2
Course Requirements ............................................................................................................... Intro - 3
Course Objectives .................................................................................................................... Intro - 3
Course Agenda ......................................................................................................................... Intro - 3
LESSON 1 ........................................................................................................................... 1 - 1
Prerequisite Review .......................................................................................................................1 - 2
LESSON 1 - WORKSTATIONS........................................................................................... 1 - 5
Workstation 1 6R60/75 Disassembly, Subassemblies and Assembly ...........................................1 - 6
Workstation 1 6F50 Disassembly, Subassemblies and Assembly .................................................2 - 2
Lesson 3 - Workstation 1 Focus ZX3 (4F27E) ................................................................................3 - 2
Lesson 3 - Workstation 2 Focus ZX5 (4F27E) ................................................................................3 - 3
Lesson 3 - Workstation 3 Crown Victoria (4R70W) .........................................................................3 - 4
Lesson 3 - Workstation 4 Town Car (4R70W) .................................................................................3 - 5
Lesson 3 - Workstation 5 Component Inspection ............................................................................3 - 8
COURSE REVIEW ........................................................................................................... CR - 1

APPENDIX ........................................................................................................... APPENDIX - 1
Automatic Transmission Service
TOC - i
January 2008
TABLE OF CONTENTS
TOC - iii
January 2008
INTRODUCTION
INTRODUCTION
Intro - 1
January 2008
INTRODUCTION

Course Description
6R60 Transmission (Left) and 6F50 Transaxle (Right)

The Automatic Transmission Service course is designed to reinforce information presented in the three
prerequisite web-based courses and provide students with hands-on activities to acquire and refine skills.
This course will allow you to apply this information to specific components and systems. Emphasis will be placed
on hands-on activity, providing you the skills necessary to inspect and repair current Ford automatic transmissions
and transaxles.
Intro - 2
January 2008
INTRODUCTION
Course Objectives
Upon successful completion of this course, you will be able to:
disassemble a RWD automatic transmission and inspect various components.
disassemble a FWD automatic transaxle and inspect various components.
perform various automatic transmission critical measurements and determine next steps.
assemble a RWD automatic transmission to proper working condition.
assemble a FWD automatic transaxle to proper working condition.
Course Agenda
Introductions and Prerequisite Review
Lesson One and Two Workstations - Explorer (6R60/75) and Edge (6F50)
Lesson Three Workstations - Focus ZX3 (4F27E), Focus ZX5 (4F27E), Crown Vic (4R70W), Town Car
(4R70W) and Component Inspections
Hands-On and Written Final Evaluations
Course Requirements
Each technician attending this course is required to pass a combination of hands-on and written evaluations. These
are administered after all lectures, demonstrations and/or practice sessions have been completed.
The hands-on evaluation is a pass/fail type. It is conducted with exercises in automatic transmission and
transaxle assembly, and covers selected measurements.
To pass the course, you must demonstrate 100% mastery of the skills covered in the Hands-On Post-Test
exercises AND you must correctly answer at least 80% of the Written Post-Test and component inspection
questions.
Intro - 3
January 2008
INTRODUCTION
NOTES:
Intro - 4
January 2008
LESSON ONE
PREREQUISITE REVIEW
LESSON ONE
1-1
January 2008
LESSON ONE
PREREQUISITE REVIEW
PREREQUISITE REVIEW
DIRECTIONS: Answer the following questions on automatic transmissions and transaxles. Questions
may be related to theory, operation, diagnosis and service. If you do not know the answer, move on to the
next question. These will be reviewed in class.
Theory and Operation Questions

1. Describe the four ways a simple planetary can produce output. Give an example of what is held in
each output state.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2. Describe the purpose of multi-disc holding and driving clutches.
_______________________________________________________________________________________
_______________________________________________________________________________________
3. What is the purpose of variable force / pulse width modulated (PWM) solenoids?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
4. What is the difference between simple and Ravigneaux style planetaries?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-2
January 2008
LESSON ONE
PREREQUISITE REVIEW
5. What do bands and one-way clutches have in common?

_______________________________________________________________________________________
_______________________________________________________________________________________
6. What is the purpose of an accumulator in an automatic transmission?

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
7. List as many fault conditions for transmission seals as you can.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. Bearings, bushings, and thrust washers are critical components in any transmission. Describe why.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What is the purpose of the torque converter and torque converter clutch?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
10. Describe the purpose of the stator one-way clutch in the torque converter.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-3
January 2008
LESSON ONE
PREREQUISITE REVIEW
11. Transmission fluid level and condition is critical for proper transmission operation. Describe two types
of fluid contamination and what can happen with improper fluid level conditions.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
12. Briefly describe a scenario in an automatic transmission of your choice that would cause a line pressure
problem that could be fixed by an electrical repair.
Symptom: ______________________________________________________________________________
_______________________________________________________________________________________
System: ________________________________________________________________________________
_______________________________________________________________________________________
Component: _____________________________________________________________________________
_______________________________________________________________________________________
Cause: _________________________________________________________________________________
_______________________________________________________________________________________
13. How are transmission coolers and lines serviced when a transmission is replaced or rebuilt?
_______________________________________________________________________________________
_______________________________________________________________________________________
14. Fluid pumps are a critical component in any automatic transmission. Why?
_______________________________________________________________________________________
_______________________________________________________________________________________
15. During disassembly how would you check for a sticking valve?
_______________________________________________________________________________________
_______________________________________________________________________________________
1-4
January 2008
LESSON ONE
WORKSTATION 1
LESSON ONE
WORKSTATION
Workstation:
1
Summary:
Students will use the Workshop Manual, required special tools and a Explorer (6R60/75)
transmission and answer related questions during:
DISASSEMBLY Students will disassemble a Explorer (6R60/75) transmission.
SUBASSEMBLIES Students will disassemble, inspect and assemble select Explorer
(6R60/75) transmission subassemblies.
ASSEMBLY Students will inspect, adjust and assemble a Explorer (6R60/75)
transmission.
1-5
January 2008
LESSON ONE
WORKSTATION 1
WORKSTATION 1
Explorer (6R60/75) Disassembly, Subassemblies and Assembly
DIRECTIONS: Complete Workstation 1 at the bench workstation, using the Explorer (6R60/75) transmission,
available hand tools, special service tools, and the Workshop Manual.
SUMMARY: For this activity, disassemble a Explorer (6R60/75) transmission down to its major subassemblies
and perform inspections required by the Workshop Manual. You will be given a set of replacement clutch pistons
after disassembly. Install the replacement clutch pistons as part of the assembly of subassemblies.
Disassembly
Follow the 2006 Explorer Workshop Manual, Section 307-01B, to disassemble the Explorer (6R60/75)
transmission to its major subassemblies. (Use the appropriate model year and vehicle Workshop
Manual for the transmission in class.)
Disassemble the Forward/Overdrive clutch assembly. (Refer to Subassemblies in the Workshop Manual.)
As you perform the disassembly procedures, answer the following questions related to the key steps:
1. Inspect the front planetary, the Ravigneaux planet carrier, Low/ Reverse clutch, Parking Pawl, and the case
from the disassembled transmission.
Circle the areas on the following images of each component that must be inspected.
2. If you had a damaged tooth on the long pinion gear of the Ravigneaux gear set, what else would
require inspection?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-6
January 2008
LESSON ONE
Note:
WORKSTATION 1
Use the components on the bench to answer the following questions:
3. The Intermediate clutch holds the ____________________________ stationary when applied in M2 (Manual
2nd), 2nd and 6th gears.
4. The Direct clutch transfers torque from the ______________________________________________ to the

_________________________________ when applied in Reverse, M3 (Manual 3rd), 3rd and 5th gears.
5. The Forward clutch transfers torque from the ____________________________________________ to the

_____________________ when applied in 1st, 2nd, 3rd, M1, M2, M3, ( Manual 1st, 2nd, 3rd), and 4th
gears.
6. The Overdrive clutch transfers torque from the __________________________________________ to the

_____________________________________________________ when applied in 4th, 5th and 6th gears.
7. The Low/Reverse clutch holds the ___________________________________ stationary when applied in

Reverse and 1st gear.
1-7
January 2008
LESSON ONE
WORKSTATION 1
SUMMARY: For this activity, disassemble, inspect and assemble each of the following subassemblies:
Front pump, Forward clutch, Overdrive clutch, Direct clutch, Intermediate clutch, Low/Reverse clutch, and
Mechatronics unit from a Explorer (6R60/75) transmission.
Directions: Install the instructor supplied replacement parts before assembly of the subassemblies.
Subassemblies
Follow the Explorer Workshop Manual, Section 307-01B, to disassemble and assemble the Explorer
(6R60/75) transmission subassemblies. (Use the appropriate model year Workshop Manual for the
transmission in class.)
As you perform the disassembly and assembly procedures, answer the following questions related to
the key steps.
1. Inspect the Center Support, Overdrive Hub, and Front Pump from the disassembled transmission.
Note:
Circle the areas on the following images of each component that must be inspected.
2. What is the Intermediate clutch clearance? ___________________________________________________

What is the Intermediate clutch specification? ________________________________________________
What adjustment is needed? _______________________________________________________________
What is the thickness of the existing selective part? ______________________________________________
What is the thickness of the required selective part? ______________________________________________
1-8
January 2008
LESSON ONE
WORKSTATION 1
3. What is the Direct clutch clearance? ________________________________________________________

What is the Direct clutch specification? ______________________________________________________
What adjustment is needed? _________________________________________________________________
4. What is the Forward clutch clearance? _______________________________________________________

What is the Forward clutch specification? ____________________________________________________
5. What is the Overdrive clutch clearance? _____________________________________________________

What is the Overdrive clutch specification? __________________________________________________
6. Why is an alignment mark made between the Forward clutch balance piston and the Forward clutch
cylinder before removing the piston?
_______________________________________________________________________________________
_______________________________________________________________________________________
7. In which direction is the step facing on the Direct clutch return spring retaining ring?
_______________________________________________________________________________________
8. Which plates in the center support Intermediate clutch assembly have a wave design?
_______________________________________________________________________________________
9. When installing the sealing rings on a Explorer (6R60/75) front pump, how do you orient the ring
gaps?
_______________________________________________________________________________________
10. What is the purpose of the check ball at the top of the center support Low/Reverse piston bore?
_______________________________________________________________________________________
_______________________________________________________________________________________
11. Why are there three seals on the Low/Reverse clutch piston?
_______________________________________________________________________________________
_______________________________________________________________________________________
1-9
January 2008
LESSON ONE
WORKSTATION 1
12. Identify the locations of the check balls in the image below.
13. What is measurement A? ________________________________________________________________

What is measurement B? ________________________________________________________________
What is measurement C? ________________________________________________________________
What is the Low/Reverse clutch clearance? __________________________________________________
What is the Low/Reverse clutch specification? ________________________________________________
What is the thickness of the existing selective part? ____________________________________________
What is the thickness of the required selective part? ___________________________________________
1 - 10
January 2008
LESSON ONE
WORKSTATION 1
SUMMARY: For this activity, assemble a Explorer (6R60/75) transmission, performing measurements and
inspections required by the Workshop Manual.
Assembly
Follow the 2006 Explorer Workshop Manual, Section 307-01B, to assemble the Explorer (6R60/75)
transmission and perform any necessary inspections and measurements. (Use the appropriate model
year Workshop Manual for the transmission you have.)
1. What is the rear end play? _________________________________________________________________

What is the rear end play specification? _____________________________________________________
2. What is the front end play? ________________________________________________________________

What is the front end play specification? _____________________________________________________
3. Is the pan gasket reusable?

_______________________________________________________________________________________
4. What transmission fluid is used in the 6R60/75 transmission installed in a 2006 Explorer?
_______________________________________________________________________________________
1 - 11
January 2008
LESSON ONE
WORKSTATION 1
1 - 12
January 2008
LESSON TWO
WORKSTATION 2
LESSON TWO
WORKSTATION
Workstation:
2
Summary:
Students will use the Workshop Manual, required special tools and an Edge (6F50)
transaxle and answer related questions during:
DISASSEMBLY Students will disassemble an Edge (6F50) transaxle.
SUBASSEMBLIES Students will disassemble, inspect and assemble select Edge
(6F50) transaxle subassemblies.
ASSEMBLY Students will inspect, adjust and assemble an Edge (6F50) transaxle.
2-1
January 2008
LESSON TWO
WORKSTATION 2
WORKSTATION 2
Edge (6F50) Disassembly, Subassemblies and Assembly
DIRECTIONS: Complete Workstation 2 at the bench workstation, using the Edge (6F50) transaxle, available
hand tools, special service tools, and the Workshop Manual.
SUMMARY: For this activity, disassemble an Edge (6F50) transaxle down to its major subassemblies and
perform inspections required by the Workshop Manual. You will be given a set of replacement clutch
pistons after disassembly. Install the replacement clutch pistons as part of the assembly of subassemblies.
Disassembly
Follow the 2007 Edge Workshop Manual, Section 307-01, to disassemble the Edge (6F50) transaxle to
its major subassemblies. (Use the appropriate model year Workshop Manual for the transaxle.)
As you perform the disassembly procedures, answer the following questions related to the key steps.
1. Inspect the front, center and rear planetaries. Circle the areas on the graphics of each component to
inspect.
Use the components on the bench to answer questions 2 - 6.

2. The Forward clutch holds the _______________________________ stationary when applied in 1st, 2nd, 3rd,
and 4th gears.
3. The Low/Reverse clutch holds the ____________________________________________ stationary when

applied in Reverse, 1st gear and Low only.
2-2
January 2008
LESSON TWO
WORKSTATION 2
4. The Intermediate clutch holds the ______________________________________ stationary when applied in

2nd and 6th gears.
5. The Direct clutch transfers torque from the ________________________________________________ to the

___________________________________________________ when applied in Reverse, 3rd, and 5th gears.
6. The Overdrive clutch transfers torque from the _____________________________________________ to the

_______________________________________________________ when applied in 4th, 5th, and 6th gears.
7. What is the purpose of the plastic reservoir near the top of the case? Why does it have a check ball?
Hint: The answer is NOT in the WSM.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2-3
January 2008
LESSON TWO
WORKSTATION 2
DIRECTIONS: For this activity, disassemble and assemble the pump and filter assembly, pump chain and
sprocket, main control assembly, solenoid body assembly, planetary gear assembly, Low one-way clutch,
overdrive/direct clutch assembly, and cover assembly on an Edge (6F50) transaxle and perform inspections
required by the Workshop Manual.
Subassemblies
Follow the Edge Service Information, Section 307-01, to disassemble and assemble the Edge (6F50)
transaxle subassemblies. (Use the appropriate model year Workshop Manual for the transaxle.)
As you perform the disassembly and assembly procedures, answer the following questions related to
key steps.
1. Main Control Disassembly: Identify check ball locations and identify which locations are NOT used.
There are 9 locations, but only 7 check balls. Circle the areas below where check balls go, and place an
X where they do not.
2. What parts are serviceable on the solenoid body?

_______________________________________________________________________________________
_______________________________________________________________________________________
3. What additional procedure must be performed if the solenoid body is replaced?
_______________________________________________________________________________________
_______________________________________________________________________________________
4. What inspection procedure is performed to determine if the fluid pump is reusable?
_______________________________________________________________________________________
_______________________________________________________________________________________
2-4
January 2008
LESSON TWO
WORKSTATION 2
5. If the fluid pump is reusable, what service procedure is done on the fluid pump?
_______________________________________________________________________________________
_______________________________________________________________________________________
6. What seals must be serviced on the stator support?
_______________________________________________________________________________________
_______________________________________________________________________________________
7. If the Forward clutch pressure plate is damaged, what component must also be replaced?
_______________________________________________________________________________________
_______________________________________________________________________________________
8. How do you align the Low/Reverse clutch piston bleed hole during assembly?
_______________________________________________________________________________________
9. Should the Low one-way clutch be disassembled for cleaning and inspection?
_______________________________________________________________________________________
10. How far do you compress the Direct clutch piston return spring?
_______________________________________________________________________________________
_______________________________________________________________________________________
11. The Overdrive clutch has a balance piston to maintain full release of the clutch. What is used to allow
full release of the Direct clutch?
_______________________________________________________________________________________
_______________________________________________________________________________________
12. What is used to lift the pressure plate when measuring Overdrive and Direct clutch pack clearance?
_______________________________________________________________________________________
13. What is the Direct clutch clearance? ________________________________________________________
What is the Direct clutch specification? ______________________________________________________
14. What is the Overdrive clutch clearance? _______________________________________________________
What is the Overdrive clutch specification? _____________________________________________________
2-5
January 2008
LESSON TWO
WORKSTATION 2
DIRECTIONS: For this activity, assemble an Edge (6F50) transaxle, performing measurements and inspections
required by the Workshop Manual.
Assembly
Follow the 2007 Edge Service Information, Section 307-01, to assemble the Edge (6F50) transaxle and
perform inspections and measurements. (Use the appropriate model year Workshop Manual for the
transaxle you have in class.)
If adjustments are required, identify the correct size select-fit part that is needed.
1. What is the Final drive pre-load measurement #1? _______________________________________________

What is the Final drive pre-load measurement #2? _______________________________________________
What is the average of the Final drive pre-load measurements? _____________________________________
What is the part number of the correct selective part? __________________________________________
2. What is the Transfer shaft pre-load measurement #1? _____________________________________________

What is the Transfer shaft pre-load measurement #2? _____________________________________________
What is the average of the Transfer shaft pre-load measurements?` __________________________________
What is the part number of the correct selective part? __________________________________________
3. What would happen if the gap for the Low One-way retaining snap ring was not positioned correctly in the
case?
_______________________________________________________________________________________
_______________________________________________________________________________________
2-6
January 2008
LESSON THREE
WORKSTATIONS
LESSON THREE
WORKSTATIONS
MEASUREMENTS, ADJUSTMENTS AND COMPONENT INSPECTIONS
Workstation:
Summary:
Students will use the Shop Aid Booklet and required special tools to disassemble, inspect,
measure and reassemble the specified transmission/transaxle components at the following
workstations and answer related questions on the worksheets.
Focus ZX3 (4F27E)
Focus ZX5 (4F27E)
Crown Vic (4R70W)
Town Car (4R70W)
Component Inspection
3-1
January 2008
LESSON THREE
WORKSTATION 1
WORKSTATION 1
FOCUS ZX3 (4F27E)
DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to disassemble, inspect, measure and reassemble the transaxle from a Focus ZX3 (4F27E) and answer related questions on the worksheet. As
the Shop Aid directs you, answer questions on your worksheets.
SUMMARY: For this activity you will perform the following assembly tasks: Final Drive Input Gear Bearing
Pre-load and Shim measurements for Differential and Transfer Shaft bearings.
Assembly
1. What is measured when Final Drive Input Gear Bearing pre-load is set?
_______________________________________________________________________________________
_______________________________________________________________________________________
2. What is your measured turning torque? ________________________________________________________
If it was too loose, what would be your next step? _______________________________________________
3. When rotating torque is excessive, what is the next step to perform?
_______________________________________________________________________________________
_______________________________________________________________________________________
4. What is the Differential Bearing measurement? __________________________________________________

What is the thickness of the selective part? _____________________________________________________
What is the part number of the required selective part? ____________________________________________
5. What is the Transfer Bearing clearance? _______________________________________________________
What is the thickness of the selective part? _____________________________________________________
What is the part number of the required selective part? ____________________________________________
3-2
January 2008
LESSON THREE
WORKSTATION 2
WORKSTATION 2
FOCUS ZX5 (4F27E)
DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to disassemble, inspect, measure and reassemble the transaxle from a Focus ZX5 (4F27E) and answer related questions on the worksheet. As
the Shop Aid directs you, answer questions on your worksheets.
SUMMARY: For this activity you will perform the following assembly tasks: End Play, Fluid Pump and Band
Installation.
1. What is the Direct clutch hub shim thickness measurement? ________________________________________

What is the added shim thickness ? ___________________________________________________________
What is the total measurement of both shims? ___________________________________________________
What is the gap measurement of end cover with the added shim installed? ____________________________
What is the thickness of the required shim? _____________________________________________________
2. Perform the Intermediate / Overdrive band adjustment procedure. What is the required selective
component? _____________________________________________________________________________
3. What is important about pump fluid gear installation orientation?

_______________________________________________________________________________________
_______________________________________________________________________________________
4. What is the Reverse clutch clearance? _________________________________________________________

What is the Reverse clutch specification? ______________________________________________________
3-3
January 2008
LESSON THREE
WORKSTATION 3
WORKSTATION 3
CROWN VIC (4R70W)
DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to disassemble, inspect, measure
and reassemble the transmission from a Crown Vic (4R70W) and answer related questions on the worksheet. As the
Shop Aid directs you, answer questions on your worksheets.
SUMMARY: For this activity you will perform the following assembly tasks: End Play, Intermediate Clutch, Low /
Reverse Band Adjustment and Servo.
Assembly
1. What is the measured Intermediate clutch clearance? _____________________________________________
What is the Intermediate clutch specification? ___________________________________________________
What is the total thickness of the installed selective part(s)? ________________________________________
What is the thickness of the correct selective part(s)? _____________________________________________
2. What is the measurement for the No.1 thrust washer? _____________________________________________

What is the required thickness of the No.1 thrust washer? _________________________________________
What is the color of the correct selective part? __________________________________________________
3. What is the Reverse Band servo travel measurement? ____________________________________________

What is the Reverse Band servo travel specification? _____________________________________________
What adjustment is needed? ________________________________________________________________
Which servo actuating rod is installed in the transmission? ________________________________________
What is the number of grooves on the correct selective part? _______________________________________
_______________________________________________________________________________________
3-4
January 2008
LESSON THREE
WORKSTATION 4
WORKSTATION 4
TOWN CAR (4R70W)
DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to disassemble, inspect, measure and reassemble the transmission from a Town Car (4R70W) and answer related questions on the worksheet.
SUMMARY: For this activity you will perform subassembly tasks on the following components: Main Control,
Main Pressure Regulator, 1-2 and 2-3 Shift Valves, and Friction Clutches (Reverse).
1. Identify the location of the check balls on the graphic.
2. Based on your inspection of the main pressure regulator and boost valves, what is the next step?
_______________________________________________________________________________________
_______________________________________________________________________________________
3-5
January 2008
LESSON THREE
WORKSTATION 4
3. On the graphic, identify the guide bolts on the main control.
4. Using tool 307- 426, what is the condition of the terminals? Based on the test results, what is your next step?
_______________________________________________________________________________________
_______________________________________________________________________________________
3-6
January 2008
LESSON THREE
WORKSTATION 4

What adjustment is needed? ________________________________________________________________
Is the selective part available in that thickness ? _________________________________________________

7. With the Reverse drum laying on the bench, which way does the Intermediate one-way clutch overrun?
_______________________________________________________________________________________
_______________________________________________________________________________________
3-7
January 2008
LESSON THREE
WORKSTATION 5
WORKSTATION 5
COMPONENT INSPECTION
DIRECTIONS: Students will complete the workstation at the bench using the parts on the benchtop.
SUMMARY: For this activity you will be inspecting components on the workbench. After each inspection, you
will place the component on the appropriate half of the workbench. Good means the part can be cleaned and reused in a customer vehicle. Bad means a defect has been found with the component, and the part should not be
re-used.
There are no written questions for this activity.
3-8
January 2008
COURSE REVIEW
COURSE REVIEW
CR - 1
January 2008
COURSE REVIEW
COURSE REVIEW NOTES:
CR - 2
January 2008
COURSE REVIEW
CR - 3
January 2008
COURSE REVIEW
CR - 4
January 2008
COURSE REVIEW
CR - 5
January 2008
COURSE REVIEW
CR - 6
January 2008
APPENDIX
APPENDIX
Appendix - 1
January 2008
APPENDIX
TorqShift Band and Clutch Application Chart

Gear
O/D
Clutch
Coast
Clutch
O/D OneWay
Clutch
43
O/D 1st
O/D 2nd
H
43
O/D 3rd
O/D 4th 8
H
43
O/D 5th
O/D 6th
H
A3
M 3rd
M 2nd
Forward
Clutch
Low /
Reverse
Clutch
Low/Rear
One-Way
Clutch
D1 6
734
H2 5
OR
43
H2 5
Direct
Clutch
D1 6
OR
OR
OR
D1 6
OR
OR
OR
OR
D1
M 1st
A3
D1
Reverse
A3
D1
Drives
O/D Sun
Gear
Drives
O/D Sun
Gear
Planetary
Member
Intermediate
Clutch
Holds O/D
Sun Gear
H3
H5
H3
H5
D
Holds
Common
Sun Gear
Drives
Common
Sun Gear
H
Drives
Forward
Ring Gear
Holds
Low/Rev
Carrier
Holds
Low/Rev
Carrier
D = Drives
A=Applied
H = Holds
OR = Overrunning
1 Drives clockwise on acceleration, overruns on deceleration.
2 Holds to prevent counterclockwise rotation, overruns on deceleration.
3 Provides engine braking on deceleration.
4 Applied when Tow Haul is On.
5 When Low/Rev clutch is applied, it prevents OWC from overrunning on deceleration.
6 When Coast clutch is applied, it prevents OWC from overrunning on deceleration.
7 Electronically controlled, may be applied under some driving conditions.
8 4th gear only, used when Cold Shift strategy is in effect at 0 F to -30 F.
Gear
Forward
Clutch
Low/ Reverse
Clutch
1st Gear D
2nd Gear D
3rd Gear D
Direct
Clutch
6F50 Band and Clutch Application Chart

Overdrive
Clutch
4th Gear D
5th Gear D
D
D
Planetary
Member
One-Way
Clutch
Turbine
Shaft
O/R
O/R
O/R
O/R
D1
O/R
D1
O/R
D1
6th Gear D
Reverse
D
D
Drives
Rear Sun
Gear
Intermediate
Clutch
H
Drives
Center Ring
Gear and
Rear
Carrier
Holds Front
Sun Gear
Holds Rear Carrier

and Center Ring
Gear
Holds Rear
Sun Gear
Holds Rear
Drives
Carrier and Center Sun
Center
Gear
Ring Gear
D = Drives
H = Holds
OR = Overrunning
1 Driven, but does not contribute to powerflow.
Appendix - 2
January 2008
APPENDIX
6R60/6R75 Band and Clutch Application Chart

Gear
Forward (A)
Clutch
Direct (B)
Clutch
Intermediate (C)
Clutch
Low/ Reverse (D)

Clutch
Park
Overdrive (E)
Clutch
Reverse
Neutral
1st Gear
Manual
2nd Gear
Manual
3rd Gear
Manual
1st Gear D
2nd Gear D
3rd Gear D
4th Gear D
D
H
H
D
D
5th Gear D
D
H
6th Gear D
Planetary
Member
Drives Sun 3
D = Drives
Drives Sun 2
H = Holds
Holds Sun 2
Holds Rear Planet

Carrier
Drives Rear
Planet Carrier
OR = Overrunning
4R70W/AODE/AOD Band and Clutch Application Chart

Gear
Intermediate
Clutch
Intermediate
OWC
Overdrive
Band
Reverse
Clutch
O/D 1st
O/D 2nd
O/D 3rd
O/D 4th
M 2nd
Planetary
OWC
H1
Low and
Reverse
Band
Direct
Clutch
H1
OR
OR
OR
OR
A
A
H
4
M 1st
Reverse
Planetary
Member
Forward
Clutch
OR
H3
H4
D
Holds outer
race of
Intermediate
OWC
Holds
Reverse Sun
gear
Holds
Reverse
Sun gear
Drives
Reverse
Sun
gear
H
Drives
Forward
Sun gear
Holds
Planetary
Carrier
Holds
Planetary
Carrier
Drives
Planetary
Carrier
A = Applied
D = Drives
H = Holds
OR = Overrunning
1 Holds or prevents counterclockwise rotation on acceleration, overruns on deceleration.
2 Applied, but has no effect on powerflow due to overrunning Intermediate OWC.
3 When O/D band is applied, it prevents an OWC from an overrun condition on deceleration.
4 Used for engine braking.
5 Has no effect on powerflow due to O/D band being applied.
Appendix - 3
January 2008
Gear
5R55E Band and Clutch Application Chart
Front
Band
Coast
Clutch
Front
One-Way
Clutch
O/D 1st
O/D 2nd
A3 4
O/D 4th
H
Forward
Clutch
Low/
Reverse
Band
Low/Rear
One-Way
Clutch
H2
OR
H2
OR
D1 6
OR
OR
OR
OR
A3
D1
M 1st
A3
D6
Reverse
A3 4
D6
Drives
Front Sun
Gear
Drives
Center
Shaft
Holds
Front
Sun
Gear
Direct
Clutch
M 2nd/3rd
gear
Planetary
Member
Intermediate
Band
D1
D1
O/D 3rd
O/D 5th
APPENDIX
D
Holds
Common Sun
Gear
H5
Drives
Drives
Common Forward
Sun
Ring Gear
Gear
Holds
Low/Rev
Carrier
Holds
Low/Rev
Carrier
D = Drives
A=Applied
H = Holds
OR = Overrunning
1 Drives clockwise on acceleration, overruns on deceleration.
2 Holds to prevent counterclockwise rotation, overruns on deceleration.
3 Provides engine braking on deceleration.
4 Applied when TCIL On.
5 When Low/Rev band is applied, it prevents OWC from overrunning on deceleration.
6 When Coast clutch is applied, it prevents OWC from overrunning on deceleration.
CD4E Band and Clutch Application Chart

GEAR
Forward
Clutch
Forward
OWC
Coast
Clutch
Direct
Clutch
Reverse
Clutch
O/D 1st
D2
H2
O/D 2nd
D2
OR
O/D 3rd
D2
OR
O/D 4th
D5
OR
OR
M 3rd 4
D1
D3
OR
M 2nd
D1
D3
M 1st
D1
D3
Drives
Outer
Race of
FWD OWC
Drive
Low/Int
Sun Gear
Drives
Low/Int
Sun
Gear3
Low OWC
Int/OD
Band
OR
H3
Reverse
Planetary
Member
Low/Rev
Clutch
Drives
Rev/OD
Carrier &
Low/Int
Ring Gear
Drives
Rev/OD
Sun Gear
Holds
Rev/OD
Carrier &
Low/Int
Ring Gear
H1
Holds
Rev/OD
Carrier &
Low/Int
Ring Gear
Holds
Rev/OD
Sun
Gear
D = Drives
H = Holds
OR = Overrunning
1 Holds on acceleration, ineffective on deceleration.
2 Holds on acceleration, overruns on deceleration.
4 Overdrive position with overdrive canceled on most transmissions.
5 Applied, but has no effect on powerflow due to overrunning Forward OWC.
Appendix - 4
January 2008
APPENDIX
4F27E Band/Clutch Application Chart

Gear
Forward
Clutch
Direct
Clutch
Reverse
Clutch
Intermediate/
Overdrive Band
Low Reverse Low One-Way

Clutch
Clutch
N
4th
3rd
2nd
1st
3rd (Manual)
2nd (Manual)
1st (Manual)
Planetary
Member
Drives Front
Sun
O/R
O/R
H
O/R
H1
O/R
H
Drives
Drives Rear
Rear
Sun
Carrier and
Front Ring
Holds Rear Sun
O/R
H2
H3
Holds Front
Ring
Holds Front
Ring
D = Drives
H = Holds
OR = Overrunning
1 Holds on acceleration, overruns on deceleration.
3 Holds on acceleration, ineffective on deceleration due to application of L/R clutch.
Appendix - 5
January 2008
APPENDIX
Appendix - 6
January 2008

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Automatic Transmission

Ford Customer Service Division

IMPORTANT SAFETY NOTICE

To help prevent serious burns, avoid contact with hot

Copyright 2008 Ford Motor Company

Produced and Coodinated by

Customer Expectations: Service

1. Make it convenient to have my vehicle

2. The Service Advisor should demonstrate

3. Fix it right the first time, on time.

5. Provide me with a clear and thorough

6. Call me within a reasonable amount of

7. Be responsive to questions or concerns

AUTOMATIC TRANSMISSION SERVICE

INTRODUCTION ......................................................................................................... INTRO - 1

COURSE REVIEW ........................................................................................................... CR - 1

Automatic Transmission Service

AUTOMATIC TRANSMISSION SERVICE

Automatic Transmission Service

AUTOMATIC TRANSMISSION SERVICE

Automatic Transmission Service

AUTOMATIC TRANSMISSION SERVICE

AUTOMATIC TRANSMISSION SERVICE

6R60 Transmission (Left) and 6F50 Transaxle (Right)

Automatic Transmission Service

AUTOMATIC TRANSMISSION SERVICE

disassemble a RWD automatic transmission and inspect various components.

disassemble a FWD automatic transaxle and inspect various components.

assemble a RWD automatic transmission to proper working condition.

assemble a FWD automatic transaxle to proper working condition.

Introductions and Prerequisite Review

Hands-On and Written Final Evaluations

Automatic Transmission Service

AUTOMATIC TRANSMISSION SERVICE

Automatic Transmission Service

Automatic Transmission Service

Theory and Operation Questions

Automatic Transmission Service

5. What do bands and one-way clutches have in common?

6. What is the purpose of an accumulator in an automatic transmission?

Automatic Transmission Service

Automatic Transmission Service

Automatic Transmission Service

Automatic Transmission Service

Use the components on the bench to answer the following questions:

4. The Direct clutch transfers torque from the ______________________________________________ to the

5. The Forward clutch transfers torque from the ____________________________________________ to the

6. The Overdrive clutch transfers torque from the __________________________________________ to the

7. The Low/Reverse clutch holds the ___________________________________ stationary when applied in

Automatic Transmission Service

2. What is the Intermediate clutch clearance? ___________________________________________________

Automatic Transmission Service

3. What is the Direct clutch clearance? ________________________________________________________

4. What is the Forward clutch clearance? _______________________________________________________

5. What is the Overdrive clutch clearance? _____________________________________________________

Automatic Transmission Service

13. What is measurement A? ________________________________________________________________

1. What is the rear end play? _________________________________________________________________

2. What is the front end play? ________________________________________________________________

3. Is the pan gasket reusable?

Automatic Transmission Service

Automatic Transmission Service