Section 07-01A: Transmission, Automatic, A4LD
1993 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY

Transmission Assembly

 

Tools Required






Item Part Number Description
1 7052 Extension Housing Oil Seal
1A 7A034 Extension Housing Bushing
2 7A039 Extension Housing
3 7D071 Parking Pawl Shaft
4 7A441 Parking Pawl
5 7D070 Parking Pawl Return Spring
6 7D419 Parking Rod Guide Cup
7 7086 Extension Housing Gasket
8 7060 Output Shaft Assy
9 E800152-S72 M10 X 30 Ext to Case Screw (6 Req'd)
10 7C063 Governor Valve Body
11 7C054 Governor Primary Valve
12 7A302 Governor Valve Spring
13 7D324 Governor Valve Weight
14 7F124 Governor Counterweight
15 E602164-S72 M6 x 12 Governor CWT to Collector Body Screw (2 Req'd)
16 E800156-S72 M6 X 20 Governor Body to Collector Body Screw (2 Req'd)
17 7D220 Governor Oil Collector Body
18 7D011 Governor Housing Seal Ring (3 Req'd)
19 7B368 Output Shaft Thrust Gear Washer No. 11
20 7D261 Inner Downshift Detent Lever Assy
21 7E333 Inner Manual Valve Detent Lever Pin
22 E630020-S71 Flat Steel Washer
23 7E332 Manual Valve Detent Spring Assy
24 7A115 Inner Manual Valve Lever
25 E820112-S Inner Lever to Lever Assy Downshift Detent Nut
26 E662312-S Rod Retaining Clip
27 7A232 Park Pawl Actuating Rod Assy
28 7B498 Main Control Lever Oil Seal Assy
29 E840125-S Spring Roller Pin (Retain Outer Manual Lever Assy)
30 7341 Gear Shift Arm Insulator
31 7A256 Manual Control Lever Assy
32 386078-S Outer Manual Lever Shaft Oil O-Ring
33 7A394 Outer Downshift Control Lever Assy
34 E820109-S72 Hex M8 X 1 Outer Manual Lever to Shaft Nut
35 E800185-S72 M6 X 30 Screw
36 E840115-S Reverse Band Anchor Pin (2 Req'd)
37 7034 Case Vent Assy
38 7005 Case Assy
39 7A247 Park Neutral Position Switch Assy
40 E853116-S O-Ring Seal
41 E860120-S Retaining Ring
42 7D191 Overrunning Clutch Spring Retainer
43 —   
44 7D422 Output Shaft Hub Thrust Washer No. 10
45 7D095 Reverse Band Assy
46 7C498 Reverse Brake Drum Assy
47 E860122-S 87mm Ring (Retain Forward Ring Gear To Hub)
48 7D164 Output Shaft Hub
49 E860527-S 25 X 2.0mm Retaining Ring
50 7A153 Output Shaft Ring Gear
51 7A166 Planet Carrier Thrust Washer No. 8 & 9
52 7D006 Reverse Planet Assy (Serviced As 4-Pinion Only)
53 E860119-S Planet To Drum Ring
54 E860121-S 39mm Input Shell to Sun Gear Assy Ring (2 Req'd)
55 7D066 Input Shell Thrust Washer No. 14
56 7D064 Input Shell
57 7D063 Forward Sun Gear Assy
58 —   
59 7A398 Forward Planet Assy (Serviced As 6-Pinion Only)
60 7F374 Forward Planet Thrust Bearing Assy No. 7
61 7D392 Forward Ring Gear 72 Ext 57 Int Teeth
62 7B067 Forward Ring Gear Hub
63 E860122-S 87mm Forward Ring Gear To Hub Retaining Ring
64 —   
65 —   
66 E860115-S Forward Clutch Select Fit Retaining Ring
67 7B066 Forward Clutch Pressure Plate
68 7B442 Forward Extension Steel Clutch Plate
69 7B164 Forward Int Friction Clutch Plate Assy
70 7B070 Forward Clutch Cushion Spring
71 E860109-S 34mm Forward Clutch Piston in Forward Cylinder Ring
72 7A527 Forward Clutch Piston Spring Retainer
73 7A480 Forward Clutch Piston Spring (15 Req'd)
74 7A262 Forward Clutch Piston Assy
75 7A548 Forward Clutch Piston Oil Inner & Outer Seal
76 7A360 Forward Clutch Cylinder Assy
77 7D019 Forward Clutch Cylinder Seal (2 Req'd)
78 E860126-129S Reverse/High Clutch & O/D Clutch Retaining Ring Select Fit (2 Req'd)
79 7B066 Reverse and High Clutch Pressure Plate
80 7B442 Reverse and High Clutch Ext. Steel Plate
81 7B164 Reverse and High Clutch Int Friction Plate Assy
82 7C096 Forward Clutch Thrust Washer No. 5 Select Fit
83 E860125-S High Clutch Piston In Int Brake Drum 63mm Ring
84 7A527 Reverse and High Clutch Clutch Piston Spring Retainer — 8 Tabs
85 7A480 Reverse and High Clutch Clutch Piston Spring (20 Req'd)
86 7A262 Reverse and High Clutch Piston
87 7A548 Reverse and High Clutch Piston Outer Seal
88 7D404 Reverse and High Clutch Piston Inner Seal
89 7D044 Reverse and High Int Brake Drum Assy
90 7D034 Intermediate Servo Band Assy
91 388307-S100 Hex Nut and Seal (2 Req'd)
92 7C492 Intermediate O/D Brake Band Adjusting Screw (2 Req'd)
93 7D430 Intermediate O/D Brake Band Anchor Strut (2 Req'd)
94 7D029 Intermediate Brake Band Apply Strut
95 7330 Intermediate Band Servo Lever (2 Req'd)
96 7D433 Intermediate Band Actuator Lever Shaft
97 7D429 Intermediate Brake Drum Seal (2 Req'd)-Viton
98 7D014 Intermediate Brake Drum Thrust Washer No. 4 Select Fit
99 7A130 Center O/D Support Assy
100 E826160-S76 S/L Mtl M6 Nut and Cage Assy
101 E804373-S Hex 8.8 M6 X 20 Screw Cap
102 7L326 Center Support Thrust Washer No. 3
103 7C122 Center Support Retaining Ring
104 E860119-S Center Shaft Retaining Ring
105 7A658 O/D Assy Center Shaft
106 7A089 O/D Overrun Clutch Assy
107 —   
108 7A153 O/D Ring Gear
109 7L495 O/D Inner Race Bearing Assy No. 2
110 7B446 O/D Planet Gear Carrier Assy
111 7D063 O/D Sun Gear Assy
112 7660 O/D Clutch Adapter
113 —   
114 7B066 O/D Clutch Pressure Plate
115 7B442 Ext. Steel O/D Clutch Plate
116 7B164 O/D Clutch Int Friction Plate Assy
117 E860125-S 63mm O/D Clutch Piston to O/D Brake Drum Retaining Ring
118 7A527 O/D Clutch Piston Spring Retainer — 8 Tabs
119 7A480 O/D Clutch Piston Spring (15 Req'd)
120 7A262 O/D Clutch Piston
121 7A548 O/D Clutch Piston Outer Seal
122 7D404 O/D Clutch Piston Inner Seal
123 7L669 O/D Drum Assy
124 7D034 O/D Band Assy
125 —   
126 —   
127 —   
128 —   
129 —   
130 7D433 O/D Band Actuator Lever Shaft
131 7A653 O/D Bracket
132 7A248 Front Oil Pump O-Ring Seal
133 7D025 O/D Brake Drum Seal (2 Req'd)
134 7D014 Front Pump Input Thrust Select Fit Washer
135 7A103 Front Pump Support and Gear Assy
136 7L323 Front Pump Support Seal
137 7A136 Oil Pump Gasket
138 7B472 Oil Pump Adapter Plate
139 7976 Converter Housing Assy
140 7A248 Front Oil Pump Seal Assy
141 7017 Input Shaft
142 7902 Converter Assy
143 E804595-S200 M10 X 33 Converter Housing to Case Screw and Seal Assy (8 Req'd)
144 —   
145 E804375-S72 FLG HD 8.8 X M8 X 35.0 Pump Support Assy To Converter Assy Screw (5 Req'd)
146 7F006 TV Control Diaphragm Clamp
147 E800341-S72 M6 X 12mm Screw (7F006 To 7005)
148 7A377 TV Control Diaphragm Assy
149 7A380 TV Control Rod
150 E853110-S Throttle Valve O-Ring
151 7D080 Throttle Control Valve
152 E860343-S 67 X 15 Intermediate and O/D Retaining Ring (2 Req'd)
153 7D040 Intermediate and O/D Servo Cover to Case O-Ring (2 Req'd)
154 7D027 Cover and Seal Assy Intermediate Band Servo
155 7D021 Intermediate Piston and Rod Assy
156 7D028 Intermediate Band Servo Piston Spring
157 —   
158 —   
159 7D027 O/D Band Servo Cover & Seal Assy
160 7D021 O/D Piston & Rod Assy
161 7D028 O/D Band Servo Piston Spring
162 7C155 Control Valve Body to Case Gasket
163 7A008 Valve Body Separating Plate
164 7D100 Control Valve Body Separating Gasket
165 7A100 Main Control Assy
166 E800153-S72 M6 X 40 Valve Body To Case Screw (19 Req'd)
167 E800163-S72 M6 X 35 Valve Body to Case Screw (3 Req'd)
168 7D300 Reverse Servo Cushion Spring Retainer
169 7E207 Reverse Servo Cushion Spring
170 7423 Reverse Band Servo Piston Oil Seal (Small)
171 7D031 Reverse Servo Piston Spring
172 7D189 RR Band Servo Rod & Retainer Assy Piston Select Fit
173 E8601675 Rod To Piston Retainer Ring
174 7423 Reverse Band Servo Piston Oil Seal (Large)
175 7L173 Reverse Servo Cover Gasket
176 7D036 Reverse Band Servo Piston Cover
177 E800156-S72 M6 X 20 Reverse Servo To Valve Body Screw (4 Req'd)
178 E853137-S Oil Screen Assy O-Ring (Small)
179 E853132-S Oil Screen Assy O-Ring (Large)
180 7A098 Oil Pan Screen Assy
181 7A194 Oil Pan
182 E800154-S72 M6 X 45 Screw — Att 7A100 To 7005 (4 Req'd) Att 7A098 to 7005 (1 Req'd)
183 E800158-S72 M8 X 14 Oil Pan to Case Screw (18 Req'd)
184 7E449 Torque Converter Clutch and 3-4 Shift Connector
185 7F037 Torque Converter Clutch Self Contained Clamp Solenoid Assy
186 7M107 3-4 Shift Solenoid Assy
186A 7M082 3-4 Solenoid Clamp
187 7A191 Oil Pan Gasket
188 7190 Overrun Clutch Roller (10 Req'd)
189 7D235 Rear Sun Gear Thrust No. 12 Bearing Race
190 7A160 Short Lube Oil Inlet Tube
191 —   
191A 7D090 Forward Clutch Thrust Washer No. 6B
191B 7D234 Forward Planet Clutch Bearing Assy No. 6A
192 7D273 Oil Tube Connector Assy (2 Req'd)
193 —   
194 —   
195 —   
196 7D190 Reverse Servo Rod
197 7025 Output Shaft Bushing
198 —   
199 7D171 Inner Overrunning Clutch Race
200 E450102-S80 Line Pressure Pipe Plug
201 7B258 Front Oil Pump Bushing
202 7A043 Output Shaft Bearing Assy


1993 A4LD Bearings, Bushings, and Thrust Washers





Item Part Number Description
1 7D014 Selective Washer — No. 1
2 7L495 Needle Bearing — No. 2
3 7L326 Washer — No. 3
4 7D014 Selective Washer — No. 4
5 7L096 Washer — No. 5
6 7D234 Needle Bearing — No. 6
7 7D090 Needle Bearing — No. 6
8 7F374 Needle Bearing — No. 7
9 7A166 Washer — No. 8
10 7A166 Washer — No. 9
11 — Bushing (Part of 7C496)
12 7D422 Washer — No. 10
13 7B368 Washer — No. 11
14 7A034 Bushing (Part of 7A039)
15 — Bushing (Part of 7005)
16 7D066 Washer — No. 14
17 — Bushings (2 Required) (Part of 7D063)
18 — Needle Bearing (Part of 7A398)
19 — Needle Bearing (Part of 7060)
20 — Sleeve (Part of 7A130)
21 — Bushing (Part of 7D044)
22 — Needle Bearing (Part of 7B446)
23 — Needle Bearing (Part of 7B446)
24 7D235 Race
25 — Bushing (Part of 7D063)
26 — Bushing (Part of 7L669)
27 — Bushing (Part of 7A103)
28 — Bushing (Part of 7976)
29 — Bushing (Part of 7A103)

 WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.

For disassembly, relocate the transmission to the top of a flat work bench.



Torque Converter

 WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF OIL.

  1. Remove torque converter (7209).



    NOTE: The splines on the shaft are not the same on both ends. The end with the shorter spline goes into the assembly.

  1. Remove input shaft (7017).



Extension Housing

 CAUTION: The parking pawl, pawl return spring, and pawl shaft could fall out during removal of the extension housing.

  1. Remove the extension housing seal (7052) using Front Seal Remover T74P-77248-A.

    NOTE: Remove extension housing bushing (7A034) only if service is required by inspection.

  1. Remove the extension housing bushing (7A034) using Extension Housing Bushing Remover T77L-7697-E.



  1. Use 17mm socket to remove four M10 x 30mm screws (E800152-S72) and two studs (E800137-S72) holding the extension housing (7A039) to the transmission case (7005).



    NOTE: The guide cup is a press fit into the extension housing (7A039) and is not serviced separately.

  1. Remove the parking pawl (7A441), return spring (7D070), and pawl shaft (7D071).



Governor Assembly

  1. Use a 10mm socket to remove two M6 x 20mm screws holding governor to collector body. Remove the governor assembly (body, (7C063), valve (7C054), spring (7A302), and weight (7D324)).

    NOTE: The counterweight (7F124) need not be removed.









    NOTE: See the service tool section for drawing of this optional adapter plate.

     CAUTION: The park rod must slip freely into clearance hole in the adapter plate.

  1. Use four M10 x 30mm screws from the adapter plate kit to attach the adapter plate to the transmission case.



  1. Attach the fixture arm assembly (T57L-500-B) with two 7/16 x 2 inch bolts and nuts.



  1. Install the transmission assembly to the bench fixture pivot (T57-500-B). Rotate to the position shown. Place drain bucket under assembly. Most of the remaining oil will drain in this position.

     WARNING: MAKE SURE THE LOCK PIN ON THE BENCH FIXTURE T57-500-B IS SECURE.





 WARNING: MAKE SURE THE LOCK PIN ON BENCH MOUNTED HOLDING FIXTURE (T57-500-B) IS SECURE.

  1. Rotate transmission assembly with transmission oil pan up as shown.

    Use a 13mm socket to remove remaining transmission oil pan screws (M8 x 14mm) holding transmission oil pan to case.

     CAUTION: Do not reuse the oil pan gasket (7A191).

  1. Remove pan (7A194) and gasket (7A191).



Main Control Valve Body

 
  1. Use a 10mm socket to remove one M6 x 45mm screw holding the oil filter screen assembly (7A098) to the valve body assembly (7A100). Remove the oil filter screen assembly.



  1. Use a 10mm socket to remove one M6 x 30mm screw holding detent spring (7E332) to valve body assembly. Remove the detent spring.



  1. Disconnect the two wires attached to each solenoid at the solenoids (torque converter clutch (7F037) and 3-4 shift solenoid (7M107)).



     WARNING: WHEN REMOVING COVER, THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON.

  1. Use a 10mm socket to remove M6 x 20m screws holding reverse servo cover.
  1. Remove the cover (7D036), piston (7D189), spring (7D031), and gasket (7L173).




    Item Part Number Description
    1 E800156-S72 Screw M6 x 20mm
    2 7D036 Cover
    3 7L173 Gasket
    4 7473 Seal — Large
    5 E8601675 Retainer Ring
    6 7D189 Piston
    7 7E207 Cushion Spring
    8 7D300 Retainer
    9 7D190 Rod
    10 7423 Seal — Small
    11 7D031 Spring
  1. Use a 10mm socket to remove seventeen M6 x 40mm screws, four M6 x 45mm screws and three M6 x 35mm screws holding the valve body to the case. Remove the valve body assembly (7A100) and gasket (7A191).

    NOTE: Refer to the Main Control Valve Body Disassembly and Assembly in this section.





Intermediate and Overdrive Servos

 

NOTE: Light tapping on the cover and case, or air pressure applied on release side may be needed. Use A4LD Transmission Test Plate T86L-7006-A

 WARNING: AIR PRESSURES SHOULD NOT BE GREATER THAN 137 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.

NOTE: Tag spring, piston and cover assembly. Label "overdrive" and "intermediate" accordingly for reassembly. Covers have letters cast onto outer surface for identification.

  1. Remove the intermediate servo assembly, snap ring (E860343-5), cover (7L493), piston (7E221) and spring (7D028). Remove the overdrive servo, snap ring (E860343-S), cover (7D027), piston (7D021) and spring (7D028).



     WARNING: MAKE SURE THE LOCK PIN ON THE BENCH MOUNTED HOLDING FIXTURE (T57-500-B) IS SECURE.

  1. Rotate the transmission assembly with the converter housing facing up.
  1. Remove the overdrive and intermediate band locknuts (388307-S100) (19mm hex) and back off the adjusting screws (7C492).

     CAUTION: Throw the locknuts away. These locknuts are not reusable for assembly.





Converter Housing and Pump Assembly

  1. Use a 17mm socket to remove eight M10 x 33mm screws holding the converter housing (7976) and pump assembly (7A103) to the case.

     CAUTION: Throw the screws away. These screws are not reusable for assembly.





    NOTE: Rotate and lift converter housing so that the clutch assemblies will stay in place.

  1. Remove the converter housing and pump assembly.



  1. Remove the converter housing-to-case gasket (7A136), and No. 1 thrust washer (7D014). Identify the washer.

    NOTE: Refer to converter housing and pump under Sub-System Disassembly in this section.





Overdrive Gear Train Assembly

 CAUTION: Identify the band. Identify which end of the band is the anchor side or apply side to make sure of correct reassembly.

  1. Remove the overdrive strut (7D029) and overdrive band (7D034).



  1. Lift out the overdrive clutch drum assembly (7L669).

    NOTE: Refer to overdrive clutch and one-way clutch assembly under Sub-System Disassembly in this section for service.





Overdrive Planet and One-Way Clutch Assembly

NOTE: No. 12 and No. 2 thrust bearings are in this assembly.

  1. Lift out the overdrive carrier planetary gear assembly (7B446).



  1. Remove the overdrive apply lever (7330) and shaft (7D433). Remove the overdrive lever bracket.

    NOTE: Tag and identify overdrive lever for reassembly. Lever has a stamped letter on side.





  1. Remove the overdrive center shaft assembly (7A658). Remove No. 3 thrust washer or bearing (7L326) from the front of the center support and identify.



Center Support

 CAUTION: Center support mating (loose) nut could fall into remaining assembly if not removed. This nut is not serviced separately.

  1. Use a 5mm Allen wrench to remove one capscrew (M6 x 20mm) holding the center support in place. Remove the mating (loose) nut from the center support.



  1. Remove the center support retaining ring (7C122).



  1. Remove the center support (7A130) by pulling evenly around the center support web.



     CAUTION: Identify band (intermediate). Identify which end is the anchor or apply side of the band to ensure correct reassembly.

  1. Remove the intermediate strut (7D029) and band (7D034).



Forward Geartrain Assembly

  1. Remove thrust washer below center support (non-clip together type forward geartrain only). Tag and identify thrust washer for reassembly.



     WARNING: MAKE SURE THE LOCK PIN ON THE BENCH MOUNTED HOLDING FIXTURE (T57-500-B) IS SECURE.

  1. Rotate the transmission so the oil pan rails are facing upward.
  1. Remove reverse/high clutch.



  1. Remove forward clutch.



  1. Remove forward ring gear.



  1. Remove No. 7 needle bearing.



  1. Remove forward planet carrier assembly.



  1. Remove input shell with sun gear.



Reverse Planet Assembly

  1. Remove the snap ring (E860119-S) from the reverse planet assembly.
  1. Remove No. 8 thrust washer (7A166). Identify the washer.



  1. Remove the reverse planet assembly (7D006) and No. 9 thrust washer (7A166). Identify.



     CAUTION: Discard snap ring E860527-S. A new one must be used for reassembly.

  1. Remove the output shaft snap ring (E860527-S) from inside the case on the output shaft.
  1. Remove output shaft ring gear (7A153). Remove and identify No. 10 thrust washer (7D422).



Reverse Brake Drum Assembly

NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.

  1. Remove the reverse drum (7C498) and the one-way clutch assembly.



  1. Remove the low-reverse band (7D095).



    NOTE: Tag and identify intermediate lever for reassembly. Lever has a letter stamped on its side for identification.

  1. Remove the intermediate apply lever (7330) and shaft (7D433).



  1. Remove the output shaft (7060).



Governor Oil Collector Body

  1. Remove the governor oil collector body (7D220) and No. 11 thrust washer (7B368). Identify washer.



Vacuum Diaphragm Assembly

  1. Use a 10mm socket to remove one (M6 x 12mm screw and retainer (7F006).



  1. Remove the vacuum diaphragm assembly (7A377) and throttle valve actuator rod (7A380).
  1. Verify that the throttle valve moves freely using flat external snap ring pliers. Then remove the valve (7D080) with the pliers.



Park/Neutral Position Switch

 

 CAUTION: Do not use an open-end wrench. The switch assembly could be damaged.

  1. Remove the park/neutral position switch (7A247) using Neutral Start Switch Socket T74P-77247-A.



Manual Lever Assemblies and Seal

NOTE: Replace manual lever shaft seal and kickdown lever O-ring as required.

  1. Remove the kickdown nut and lever (7A394) and remove O-ring seal (386078-S).



  1. Back off the 7/8 inch hex inner nut (N820112-S72) on the manual lever assembly completely.



  1. Use a small hammer and drift to tap lightly on each side of the pin 2 or 3 times to loosen prior to removal.



     CAUTION: Do not damage the case oil pan rail.

  1. Remove the linkage centering pin (E840125-S) with a screwdriver from side as shown, using a narrow sharp screwdriver.



     CAUTION: Do not bend "Z" link.

  1. Remove the manual lever (7D256) inner kickdown lever (7D261) park rod (7A232) and inner manual valve lever assembly (7A115) with the "Z" link (7E333).
  1. Remove the manual lever shaft oil seal (7B498).



Solenoid Case Connector

NOTE: To remove the case solenoid connector, depress the tab on the outside of the case, backside of the connector, while pulling with pliers.

  1. Remove case solenoid connector (7E449) if the case is to be immersed in degreaser, or is being replaced.



  1. Remove the case with attached adapter plate and fixture arm (T57L-500-B) from bench fixture pivot (T57-500-B). Remove four M10 x 30mm screws holding the adapter plate to extension housing face, leaving adapter plate attached to fixture arm.