ATSG AX4S Update Handbook Download

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NO. 1 THRUST WASHER LOCATION

WITH NON-SYMETRICALLY LOCATED

HOLES FOR THRUST WASHER

NO. 3 THRUST WASHER

LOCATION WITH CAST

GROOVES FOR THRUST

WASHER RETENTION

CHAIN COVER AND THRUST WASHERS

PRIOR TO OCTOBER 13, 1995

REQUIRES THE BRONZE NO. 3

THRUST WASHER WITH TANGS ON

THE OUTSIDE DIAMETER

PART NUMBER E6DZ-7G096-A

REQUIRES THE PLASTIC NO. 1

THRUST WASHER WITH TABS THAT

ARE NON-SYMETRICALLY LOCATED

PART NUMBER E6DZ-7G099-A

NUMBER 3

THRUST WASHER

NUMBER 1

THRUST WASHER

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 85

Summary of Contents for AX4S

Page 1: ...NPUTPLANETARYAND SUN SHELL 72 NO MOVEMENTORNOTCC 75 OILPUMPCHECKBALLLOCATIONCHANGES 76 TORQUE CONVERTERANDTURBINE SHAFTSPLINE CHANGES 79 VALVE BODYVALVELOCATIONSAND IDENTIFICATION 80 VALVE BODYAND OIL...

Page 2: ...stry sources known for their reliability but ATSG does not guarantee its accuracy Copyright ATSG 2002 Updated October 2002 Since the introduction of the Ford AXOD transaxle in model year 1986 there ha...

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Page 48: ...al groove and greatly improve durability 1 FORWARD CLUTCH PISTON Now manufactured out of steel instead of aluminum and there areno dimensionalchangeson thepiston SeeFigure39 Forward Clutch Piston All...

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Page 54: ...e assembling the valve body and oil pump usetheguidepins to assure proper alignment 1 Position the spacer plate on the pump housing using a new gasket 2 Insert valve body guide pin T86P 70100 A 271 Di...

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Page 56: ...th Integral Seal XF2Z 7G184 AA N0 7 8 P S 0 6 A E F A F Outside Diameter Is 1 000 NO LONGER RECOMMENDED Used In AXOD AXODE Up Through 2000 And AX4N Up Through 1999 Used In AXODE AX4S Beginning In 2001...

Page 57: ...eal AX4N 2nd Design With Integral Seal Will Retro Back On All AXOD AXODE Models And AX4N Models Through 1999 2000 Up Models Only Converter Off Oil For Lube Pump Pressure Is Inhibited By Seal Oil Pump...

Page 58: ...iston movement It is also important to insure that multiple accumulator spring applications must have the springs wound in opposite directions of each other to avoid coil bind as shown in Figure 49 En...

Page 59: ...ITE OF EACH OTHER TO AVOID COIL BIND Copyright 2002 ATSG Neutral Drive Accumulator Spring Location 3 4 Accumulator Spring Location 1 2 Accumulator Spring Location Technical Service Information AUTOMAT...

Page 60: ...A F58Z 7G267 A F58Z 7G267 A F58Z 7G267 A E6DZ 7G300 A F8DZ 7G300 BA E6DZ 7G301 A E6DZ 7G326 A E8DZ 7G326 A E8DZ 7G326 A E8DZ 7G326 A Color changed part number remained the same F58Z 7G326 A F58Z 7G326...

Page 61: ...WIRE DIAMETER Green Inner Dk Green Outer Plain Outer White Outer Yellow Outer 1 180 29 99mm 1 542 39 19mm 902 22 91mm 902 22 91mm 1 507 38 28mm 1 507 38 28mm 084 2 15mm 084 2 15mm 1 202 30 55mm 1 456...

Page 62: ...EEWHEEL LOW SPRAG OUTER RACE THE LOW SPRAG OUTER RACE MUST FREEWHEEL COUNTER CLOCKWISE AND LOCK CLOCKWISE WHEN HOLDING THE OVERDRIVE DRUM EWHE E E R L F Technical Service Information AUTOMATIC TRANSMI...

Page 63: ...ROLLER CLUTCH THE 3RD ROLLER CLUTCH OUTER RACE MUST FREEWHEEL CLOCKWISE AND LOCK COUNTER CLOCKWISE WHEN THE 3RD ROLLER CLUTCH INNER RACE IS HELD FR L E E E EWH Technical Service Information AUTOMATIC...

Page 64: ...21 external teeth inside diameter of 4 730 material thickness of 075 identifiedwith letter X stampedon1tooth andwasusedfrom1989 1991 SeeFigure55 3RD DESIGN Has 21 external teeth inside diameter of 4 9...

Page 65: ...Information AUTOMATIC TRANSMISSION SERVICE GROUP 65 Figure 54 Copyright 2002 ATSG 4 External Teeth Inside Diameter 4 715 Material Is 062 Thick Part Number E6DZ 7E085 B FORD AXOD FORWARD CLUTCH WAVE PL...

Page 66: ...TOMATIC TRANSMISSION SERVICE GROUP 66 Figure 55 Copyright 2002 ATSG 21 External Teeth Inside Diameter 4 730 Material Is 075 Thick I D Stamped X On 1 Tooth Part Number F0DZ 7E085 A FORD AXOD FORWARD CL...

Page 67: ...ATIC TRANSMISSION SERVICE GROUP 67 Figure 56 Copyright 2002 ATSG FORD AXOD FORWARD CLUTCH WAVE PLATE USED 1992 AND LATER 21 External Teeth Inside Diameter 4 930 Material Is 083 Thick I D Stamped A On...

Page 68: ...WARD CLUTCH STEEL PLATES Have an increased inside diameter to 4 920 from the previous 4 720 to accommodate the increased diameter of the sprag outer race as shown in Figure59 FORWARD CLUTCH PRESSURE P...

Page 69: ...ODE AX4S FORWARD FRICTION PLATE USED 1992 AND LATER AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 69 57 Teeth 52 Teeth 4 575 Overall Outside Diameter 5 750 Overall Outside Diamete...

Page 70: ...9 1991 FORD AXOD AXODE FORWARD STEEL PLATE USED 1989 1991 FORD AXODE AX4S FORWARD STEEL PLATE USED 1992 AND LATER FORD AXODE AX4S FORWARD STEEL PLATE USED 1992 AND LATER 34 Teeth 34 Teeth 34 Teeth 34...

Page 71: ...Is 075 Thick I D Stamped X On 1 Tooth Part Number F0DZ 7E085 A 21 External Teeth Inside Diameter 4 930 Material Is 083 Thick I D Stamped A On 1 Tooth Part Number F2DZ 7E085 A FORD AXOD AXODE FORWARD W...

Page 72: ...bility of centergearbox concerns 1 2 INPUT PLANETARY CARRIER New caged needle Bearing added to the shaft on the Input PlanetaryCarrier as showninFigure62 SUN GEARAND SHELLASSEMBLY Single bushing is no...

Page 73: ...Copyright 2002 ATSG NEW DESIGN INPUT PLANETARY CARRIER Caged Needle Bearing Added On The Shaft Located Here AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 73 Figure 62...

Page 74: ...ROUP Technical Service Information 74 Figure 63 PREVIOUS DESIGN SUN GEAR AND SHELL NEW DESIGN SUN GEAR AND SHELL Copyright 2002 ATSG Bushing Placement New Placement Of Bushing This Area Now Machined T...

Page 75: ...orafterrebuild thevehicleexhibitsoneofthefollowingconditions 1 No Movement inforwardorreverse 2 No ConverterClutch applyatanyspeed The cause may be one of the following 1 The converter feed passage i...

Page 76: ...991Only Uses 4 checkballsinthelocationsshowninFigure65 Usechartabovetodetermine Early or Late transaxle by serial number 1992 1998 Only Uses4 checkballs butindifferentlocations asshown inFigure66 B 13...

Page 77: ...IONS EARLY 1991 ONLY CHECKBALL LOCATIONS LATE 1991 ONLY AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 77 Figure 65 X X X CHECKBALL LOCATIONS LATE 1991 ONLY B 5 B 13 B 13 B 11 B 10...

Page 78: ...ion 78 Figure 66 Copyright 2002 ATSG CHECKBALL LOCATIONS 92 98 MODELS ONLY X X X X X CHECKBALL LOCATIONS 1999 AND LATER ONLY B 5 B 5 Eliminated B 13 Eliminated B 11 B 11 B 2 Checkball Added B 2 B 10 B...

Page 79: ...ion schedule Ford Motor Co changed the converterturbinesplines and theturbineshaftsplinesto25teethfromprevious23splines Improved durability for higher torque applications 1 2 TORQUE CONVERTER Converte...

Page 80: ...LVE BODY REAR VIEW On this page we have assigned numbers to all of the valve body bores and re drawn the valves and springs and placed them in their proper locations with each valve oriented properly...

Page 81: ...1991 To Current Models Accumulator Regulator Valve Plunger Converter Clutch Control Valve Plunger Converter Clutch Control Valve Main Regulator Boost Valve Sleeve Main Regulator Boost Valve Converter...

Page 82: ...Service Information 82 Figure 70 Copyright 2002 ATSG Early 1991 Only 1 PRESSURE FAILSAFE VALVE 2 BACKOUT VALVE EARLY 1991 3 BACKOUT VALVE CURRENT 4 ACCUMULATOR REGULATOR VALVE PLUNGER 5 ACCUMULATOR R...

Page 83: ...N SERVICE GROUP Technical Service Information 7 BYPASS CLUTCH CONTROL PLUNGER 8 BYPASS CLUTCH CONTROL VALVE 9 MAIN REGULATOR BOOST VALVE SLEEVE 10 MAIN REGULATOR BOOST VALVE 11 MAIN REGULATOR VALVE 12...

Page 85: ...yright 2002 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 85 Figure 73 16 1 2 SHIFT VALVE 17 INTERMEDIATE CLUTCH SHUTTLE VALVE 18 3 4 SHIFT VALVE 19 FORWARD CLUTCH CONTROL VA...

Page 86: ...ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 20 PULL IN CONTROL VALVE 21 3 2 CONTROL VALVE 22 N D ENGAGEMENT CONTROL VALVE 23 2 3 SERVO REGULATOR VALVE Figure 74 Eliminated...

Page 87: ...D AXODE 3 NEUTRAL KICKDOWN SHIFT COMPLAINT CAUSE CORRECTION A delayed shift may occur during 3 2 forced downshifts or Kickdown and or the transaxlewillshiftto neutralduringthe3 2kickdown The cause may...

Page 88: ...6 1998 1996 1997 1994 1995 1995 1998 1999 1999 2000 2002 31 40 41 58 98 99 99 00 53 42 97 47 67 OEM Part Number Code Application Lincoln Continental Ford Windstar Ford Windstar Ford Taurus Sable Ford...

Page 89: ...Service Information 89 Figure 77 SPECIAL NOTE Color Of The I D Stripe May Vary From Different Suppliers 1991 Up Pump Spacer Plate To Valve Body F1DZ 7A136 A 1991 Up Pump Spacer Plate To Pump Body F3DZ...

Page 90: ...ormation Figure 78 1991 1998 Valve Body Spacer Plate To Chain Cover F1DZ 7C155 A 1991 1998 Valve Body Spacer Plate To Valve Body F1DZ 7D100 A Orange I D Stripe Orange I D Stripe SPECIAL NOTE Color Of...

Page 91: ...ervice Information 1999 2002 Valve Body Spacer Plate To Chain Cover XF2Z 7C155 AA 1999 2002 Valve Body Spacer Plate To Valve Body XF2Z 7D100 AA Yellow I D Stripe Blue I D Stripe SPECIAL NOTE Color Of...

Page 92: ...TRANSMISSION SERVICE GROUP Technical Service Information Copyright 2002 ATSG NO 4 NO 1 NO 6 NO 3 NO 7 NO 9 Alignment Dowel Relief Valve Relief Valve Filters NO 8 AXODE AX4S 1991 1992 ONLY CHECKBALLAND...

Page 93: ...MISSION SERVICE GROUP Technical Service Information 93 Figure 81 X NO 4 NO 1 NO 6 NO 3 NO 7 Checkball Eliminated 1993 NO 9 Alignment Dowel Relief Valve Relief Valve Filters NO 8 AXODE AX4S 1993 1998 C...

Page 94: ...ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Figure 82 AXODE AX4S 1999 2002 CHECKBALLAND RELIEF VALVE LOCATIONS NO 4 NO 1 NO 6 NO 3 NO 9 Alignment Dowel Relief Valve Relief...

Page 95: ...ted volume of lube oil to the front planetary due to hydraulic control system demands Install a new design Cross over rear lube tube and a new design Differential Speedo lube tube that will increase t...

Page 96: ...signs CHAIN COVER New design will accept either the previous bronze No 3 thrust washer with the tangs on outside diameter or the new design Black plastic No 3 thrust washer with the 3 symetricallyloca...

Page 97: ...R 1 THRUST WASHER WITH SYMETRICALLY LOCATED TABS PART NUMBER F5DZ 7G099 A NUMBER 1 THRUST WASHER WITH SYMETRICALLY LOCATED TABS PART NUMBER F5DZ 7G099 A NUMBER 3 PLASTIC THRUST WASHER WITH SYMETRICALL...

Page 98: ...ERS PRIOR TO OCTOBER 13 1995 REQUIRES THE BRONZE NO 3 THRUST WASHER WITH TANGS ON THE OUTSIDE DIAMETER PART NUMBER E6DZ 7G096 A REQUIRES THE PLASTIC NO 1 THRUST WASHER WITH TABS THAT ARE NON SYMETRICA...

Page 99: ...R AND THRUST WASHERS OCTOBER 13 1995 AND BEYOND CAN USE EITHER OF THE PART NUMBERS LISTED ABOVE BLACK PLASTIC F5DZ 7G096 A BRONZE E6DZ 7G096 A REQUIRES THE PLASTIC NO 1 THRUST WASHER WITH TABS THAT AR...

Page 100: ...modelyearareMLUS Wires for the Lock Up Solenoid LUS are fed through pins 4 and 5 of the Black case connector located on top of the transaxle See Figure 88 Ohmmeter across terminals 4 and 5 should read...

Page 101: ...acrossterminals1and2shouldread12 30Ohmsresistance Wires for Shift Solenoid 3 are fed through pins 3 and 4 of the White case connector located on the side of transaxle See Figure88 Ohmmeteracrosstermin...

Page 102: ...2 1 The 1991 1992AXOD E transaxle has 2 case connectors 1 Black or Gray in color on the top of the transaxle and1Whiteincoloronthesideofthetransaxle 1991 1992 AXOD E INTERNAL WIRE SCHEMATIC BLACK GRA...

Page 103: ...ly kit The 1993 Up design level chain cover has only one nine pin external electrical connector located at the top of the transaxle as shown in Figure 89 and the previous side connector as shown in Fi...

Page 104: ...wiring harness connectors to their proper solenoids using the wire colors as shown in Figure 90 and 91 Proper connection of solenoids can also be verified externallythrough thecaseconnectorusingtheOhm...

Page 105: ...OLENOID RESISTANCE OHMS SS1 15 25 15 25 15 25 98 1 6 3 23 5 50 100 200 190 250 SS2 SS3 MLUS EPC TSS VSS TFT SENSOR OHMS 100k 37k 37k 16k 16k 5k 5k 2 7k 2 7k 1 5k 1 5k 0 8k 0 8k 0 5k C F 59 104 105 158...

Page 106: ...th the blue connector and higher resistance ATSG has seen no problems with installing the new design MLUS on the previous model transaxles except 1991 Taurus and Sable which are non modulated models U...

Page 107: ...FT SENSOR OHMS 100k 37k 37k 16k 16k 5k 5k 2 7k 2 7k 1 5k 1 5k 0 8k 0 8k 0 5k C F 59 104 105 158 159 194 195 230 231 266 21 40 41 70 71 90 91 110 111 130 0 20 32 58 267 302 131 150 1 2 3 4 5 6 7 8 9 O...

Page 108: ...coring will be eliminated as well as the intermittent loss of vehicle speed signal due to the speed sensor sub harness damage that would occur as aresult of exhaust systemheattransferral 1 2 TRANSAXLE...

Page 110: ...2 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Figure 96 Figure 95 Copyright 2000 ATSG AX4S VEHICLE SPEED SENSOR AX4N VEHICLE SPEED SENSOR PART NUMBER XF2Z 7H103 AA PART NUM...

Page 111: ...identified wrong Usethethis pageto correctyour manualsattheshopforthecorrectpressuretaplocations RefertoFigure97 for theAX4S AXOD E transaxlepressuretaplocations RefertoFigure97 for theAX4Ntransaxlep...

Page 112: ...eWhite with aYellow tracer on both versions as shown in Figure 98 On 1991 1992 model vehicles the wire will be found in the top case connector and comes from pin number 38 on the computer On 1993 UP v...

Page 113: ...RANGE WHITE RED 53 38 49 46 51 37 57 52 55 Top Black Gray Connector Vehicle Harness Side Side White Connector Vehicle Harness Side WHITE YELLOW ORANGE YELLOW MLUS EPC TOT SIG RTN SS 1 SS 2 SS 3 VPWR V...

Page 114: ...nnect the DVOM leads as shown above to perform this test This is known as connecting in series CONNECTING THE DVOM TO CHECK AMPS TO THE TRANSAXLE 1 0 20 75 75 75 75 80 90 90 30 40 50 60 70 80 75 70 60...

Page 115: ...formation Ford Ford AXOD AXOD E I M TRC M T E RIC F ord F ord RF D F6 P 7G2 4 3 AA 5 4 lll l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l ll l l MAIN LINE PRESSURE...

Page 116: ...y these two spacer plates are different Refer to Figures 101 and 102 using the two holes over the 1 2 capacity modulatorvalvearea for identification Install the proper valve body spacer plate for the...

Page 119: ...AX4S AX4N NO REVERSE COMPLAINT CAUSE CORRECTION After overhaul vehicles built after 1999 equipped with the AX4S or AX4N transmissions may exhibit a no engagement in Reverse The cause may be that the P...

Page 120: ...CHANNEL PLATE GASKET I D AX4N PREVIOUS DESIGN CHANNEL PLATE GASKET built before October of 1999 AX4N LATE DESIGN CHANNEL PLATE GASKET built after October of 1999 REVERSE PASSAGE REVERSE PASSAGE AUTOM...

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