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AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

113

Figure 98

WHITE/YELLOW

ORANGE/YELLOW

TAN/WHITE

LUS/MLUS

EPC

TOT

SIG RTN

SS-1

SS-2

SS-3

VPWR

ORANGE/BLACK

GRAY/RED

RED

PURPLE/ORANGE

WHITE/RED

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

FROM EEC POWER RELAY

ORANGE/BLACK

GRAY/RED

RED

PURPLE/ORANGE

PURPLE/YELLOW

WHITE/RED

Top 9 Pin Connector

Vehicle Harness Side

TWO CASE CONNECTOR MODELS

SINGLE 9 PIN CASE CONNECTOR MODELS

Содержание AX4S

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

Страница 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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Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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