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

Transmission Assembly

 

Tools Required:

Shift Lever Seal

  1. Install the shift lever oil seal (7B498) using Shift Lever Seal Replacer T74P-77498-A.



Park/Neutral Position Switch

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

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



Vacuum Diaphragm

 

 CAUTION: Make sure the valve (7D080) moves freely in the bore.

  1. Install throttle valve (7D080), actuating rod (7A380), vacuum diaphragm (7A377) and retaining clamp (7F006). Hold in position by tightening M6 x 12mm screw with a 10mm wrench.



    NOTE: The fixture arm T57L-500-B should still be attached to adapter plate. If not, re-attach fixture arm at this time.

  1. Re-attach the adapter plate to transmission case (7005) on the extension housing face using four M10 x 30mm screws as shown.



Manual Lever Assemblies

  1. Install the transmission case with fixture arm in bench pivot T57L-500-B and rotate to position, oil pan rail face up.




    Item Part Number Description
    1 7A232 Park Actuating Rod
    2 E840125-S Pin
    3 7A256 Manual Control Lever Assembly
    4 7A394 Outer Downshift Control Lever
    5 E820109572 Nut
    6 386078 O-Ring
    7 7B498 Seal
    8 E662312-S Clip
    9 7A115 Inner Detent Lever
    10 E630020-S71 Washer
    11 7E333 Inner Manual Pin (Z-Link)
    12 7D261 Inner Downshift Lever
    13 N820112-S72 Nut

     WARNING: MAKE SURE LOCK PIN ON BENCH FIXTURE (T57L-500-B) IS SECURE.

  1. Assemble the inner manual valve lever (7A115), park rod assembly (7A232), inner manual pin "Z"-link (7E333), flat washer (E630020-S71) and retaining clip (E662312-S) as shown.



  1. Place the inner manual lever, park rod, and "Z"-link into position.
  1. Insert the inner downshift lever (7D261) with the inner lever-to-lever hex nut (E820112-S) in position as shown.
  1. Install the manual lever (7A256) so that inner lever flats match the flats on the manual lever.

     CAUTION: Do not bend "Z"-link. Care should be taken to not damage pan rail when installing the centering pin.

  1. Install centering pin (E840125-S). Pin should be flush with oil pan rail. Tighten 7/8 Inch hex nut (E820112-S) to 41-54 Nm (30-40 ft-lb).




    Item Part Number Description
    1 — Hammer
    2 7A115 Lever, Manual Valve, Inner
    3 7E333 Inner Manual Pin (Z-Link)
    4 7D261 Inner Downshift Lever
    5 E820112-S Lever-to-Lever Hex Nut
    6 E840125-C Centering Pin
  1. Install the O-ring (386078-S) and outer kickdown lever (7A394). Use a 13mm wrench to tighten the outer nut (E8020109-S72) to 10-15 Nm (7-11 ft-lb).



     CAUTION: The tabs on No. 11 washer point into case.

    NOTE: Petroleum jelly can be used to hold No. 11 washer in place.

  1. Install No. 11 thrust washer (7B368) into rear of case (7005) bore.



Governor Oil Collector Body

  1. Install the governor oil collector body (7D220) with three new seal rings (7D011) into rear case (7005) bore.



  1. Install the reverse brake drum assembly (7C498).



     CAUTION: The tabs on No. 10 thrust washer point into the one-way clutch.

    NOTE: The size of No. 10 thrust washer is model dependent.

  1. Install No. 10 thrust washer (7D422) against the one-way clutch using petroleum jelly to hold the washer in place during assembly.



Output Shaft

  1. Install the output shaft (7060) through governor oil collector body (7D220) spline.



     CAUTION: Always use a new snap ring.

  1. Install the output shaft hub (7D164) and ring gear (7A153) assembly. Retain with a new snap ring (E661125-S) (25 x 2.0mm) in the output shaft groove.



Reverse Planet Assembly

 CAUTION: The tabs on the thrust washers point into the planet.

NOTE: Use petroleum jelly to hold the thrust washers in place for assembly.

  1. Position No. 8 thrust washer (7A166) on the front face and No. 9 thrust washer (7A166) on the rear face of reverse planet assembly (7D006).



     CAUTION: Make sure the thrust washers stay in place.

  1. Install the reverse planet assembly (7D006) with No. 8 and No. 9 thrust washers held in place into the output shaft ring gear (7A153).



  1. Install the snap ring (E860119-S) into the reverse brake drum (7C498) groove to hold planet assembly in place.

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

  1. Install reverse band (7D095) onto the reverse brake drum (7C498).



  1. Install the reverse servo piston assembly (7D189) temporarily to hold the reverse band in position.

    NOTE: The reverse servo springs will be installed later.





  1. Install the intermediate servo apply lever (7330) and shaft (7D433), as identified in removal.



Forward Geartrain Assembly

  1. Install the previously completed forward geartrain assembly as a unit.



     WARNING: MAKE SURE THE LOCK PIN ON BENCH FIXTURE T57L-500-B IS SECURE.

  1. Rotate the transmission assembly to position, converter housing gasket surface face up.
  1. Install the intermediate band (7D034) and apply strut (7D029).



    NOTE: Use the adjusting screw as a temporary alignment guide.

    NOTE: The intermediate and overdrive anchor struts are the same.

  1. Install the intermediate band anchor side strut (7D430) and adjusting screw (7C492).



Selective Thrust Washers

 

Tools Required:

 

Rear No. 4 Thrust Washer Clearance Selection, Non Clip Together Type

  1. Place Gauge Bar (T93T-77003-AH) or case shoulder and set micrometer on top of gauge bar as shown.
  1. Extend probe until it contacts No. 4 thrust washer surface at intermediate brake drum.
  1. Remove micrometer and record reading as Dimension "A."
  1. Move micrometer to opposite side of gauge bar (180 degrees) and repeat Step 3. Record as Dimension "B."
  1. Add Dimensions "A" and "B" together, divide by 2, then subtract the thickness of Gauge Bar T93T-77003-AH (17.78mm [0.700 in.]). This is Dimension "C."
  1. See chart for proper thrust washer selection with Dimension "C" from Above step.


Transmission Lower End Clearance Non Snap Dimension "C" Identification Number Stamped on Washer Service Part Number Washer Thickness
1.66-1.85mm (0.065-0.073 in.) 1 F0TZ-7D014-A 1.35-1.40mm (0.053-0.055 in.)
1.86-1.95mm (0.074-0.077 in.) 2 F0TZ-7D014-B 1.55-1.60mm (0.061-0.063 in.)
1.96-2.05mm (0.078-0.081 in.) 3 F0TZ-7D014-C 1.65-1.70mm (0.065-0.067 in.)
2.06-2.15mm (0.082-0.085 in.) 4 F0TZ-7D014-D 1.75-1.80mm (0.069-0.071 in.)
2.16-2.25mm (0.086-0.089 in.) 5 F0TZ-7D014-E 1.85-1.90mm (0.073-0.075 in.)
2.26-2.35mm (0.090-0.093 in.) 6 F0TZ-7D014-F 1.95-2.00mm (0.077-0.079 in.)
2.36-2.55mm (0.094-0.100 in.) 7 F0TZ-7D014-G 2.05-2.10mm (0.081-0.083 in.)
Rear: #4 Reference End Play 0.30-0.54mm (0.012-0.022 in.)      

  1. Remove the micrometer and tool from transmission.

    NOTE: Use petroleum jelly on washer to hold in place.

  1. Install correctly selected No. 4 thrust washer over center support hub as shown.



Center Support

  1. Remove the center support (7A130) from the overdrive brake drum where the seals (7D429) have been sizing.



     CAUTION: Do not apply pressure to the center support to avoid damage to seal rings.

  1. Position the center support (7A130) into the reverse/high drum (7D044). Use the input shaft as an aid to seat center support (7A130). Gently wiggle the shaft from side to side until center support (7A130) is seated against the case (7005) shoulder.



  1. Remove the input shaft.

     CAUTION: Install the snap ring (7C122) in groove with the taper side of ring up.

  1. Install the large snap ring (7C122) into groove in the case (7005) to retain the center support (7A130).



  1. Make sure the nut and cage assembly (E826160-S76) is in place as shown.



  1. Use a 5mm Allen wrench to install one M6 x 20mm capscrew into the nut and cage assembly (E826160-S76) as shown. Tighten to 9-13 Nm (80-115 in-lb).



  1. Position No. 3 thrust washer (7L326) on the thrust surface of the center support (7A130) as shown.



Overdrive Planet and One-Way Clutch Assembly

  1. Install the overdrive planet (7B446) and one-way clutch assembly (7A089) into the center support.



Overdrive Drum Assembly

  1. Install the overdrive drum (7L669) clutch assembly.



  1. Install the overdrive bracket (7A653). Apply lever (7330) and shaft (7D433) as identified at disassembly.



  1. Install the overdrive band (7D034) over the overdrive drum (7L669).
  1. Install the apply side strut (7D029).



    NOTE: Use the adjusting screw as a temporary alignment guide.

  1. Install the anchor side strut (7D430) and the adjusting screw (7C492).



Front End Play Check

 CAUTION: Be sure the pump body is seated against the washer and overdrive drum. The pump body must be below the level of the case gasket surface.

  1. To perform the front end play check procedure, place any No. 1 thrust washer (7D014) on the rear of pump (7A103) using petroleum jelly to hold the washer in place. The washer tabs go into the pump face. Place the pump into position in the case.



     CAUTION: Gauge bar must rest on gasket surface.

    1. Place Gauge Bar T93T-77003-AH across case (7005) as shown.
    2. Place the micrometer on gauge bar, extend probe until it contacts pump surface.
    3. Read micrometer and subtract the thickness of gauge bar (17.78mm [ 0.700 in.]). Record this as Dimension "A."
    4. Move Gauge Bar T93T-79003-AH to opposite size of case (180 degrees).
    5. Repeat steps 3 and 4 and record measurement as Dimension on "B."
    6. Add Dimensions "A" and "B" together, divide by 2 and this is your front end clearance, Dimension "C."




     CAUTION: If your average is below the specification choose a washer of less thickness. If your average is above specification choose a thicker washer.

    NOTE: The front end play specification is .018-.64mm (.007-.025 inch).



    TRANSMISSION END PLAY NO. 1 SELECTIVE THRUST WASHER CHART
    Transmission End Clearance Dimension "C" Identification Number Stamped on Washer Service Part Number Thickness
    Front #1 (All Engines)
    0.18-0.64mm (0.007-0.025 in.)
    without gasket    		 1
    2
    3
    4
    5
    6
    7    		 F0TZ-7D014-A
    F0TZ-7D014-B
    F0TZ-7D014-C
    F0TZ-7D014-D
    F0TZ-7D014-E
    F0TZ-7D014-F
    F0TZ-7D014-G    		 1.35-1.40mm (0.053-0.055 in.)
    1.55-1.60mm (0.061-0.063 in.)
    1.65-1.70mm (0.065-0.067 in.)
    1.75-1.80mm (0.069-0.071 in.)
    1.85-1.90mm (0.073-0.075 in.)
    1.95-2.00mm (0.077-0.079 in.)
    2.05-2.10mm (0.081-0.083 in.)

    NOTE: The tabs on the washer go into the pump face.

  1. Remove the pump and install the correct No. 1 thrust washer (7D014). Use petroleum jelly to hold the washer in place.
  1. Verify the end play by repeating the check procedure with the selected No. 1 thrust washer in place.



  1. Remove the pump and correct No. 1 thrust washer. Set the washer aside for installing after assembling the pump to converter housing. Refer to converter housing and pump assembly in Sub-Systems Disassembly.



  1. Install input shaft to guide converter pump when installed.



     CAUTION: Do not position the gasket on the case first.

  1. Place a new converter housing gasket (7A136) on the separator plate (7B472) as shown. Use petroleum jelly to hold gasket in place.



    NOTE: Make sure square cut seal is installed on converter housing and pump assembly.

  1. Install correct No. 1 thrust washer on pump. Use petroleum jelly to hold washer in place.
  1. Position the completed converter housing (7976) and pump (7A103) assembly (with gasket 7A136) and No. 1 thrust washer (7D013) to the case (7005). Use a 17mm socket to install eight new M10 x 33mm screws (E80495-S200). Tighten to 36-52 Nm (27-38 ft-lb).



Intermediate and Overdrive Servos

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

  1. Rotate the transmission assembly to position oil pan rail face up.

     CAUTION: Do not damage O-ring (7D040) during installation. Do not press servo cover and O-ring (7D027) past relief hole in case, or O-ring damage may occur.

  1. Install the previously identified intermediate servo spring (7D028), piston and cover assembly with O-ring and retain with snap ring.



     CAUTION: Do not damage O-ring (7D040) during installation. Do not press servo cover (7D027) and O-ring past relief hole in case, or O-ring damage may occur.

  1. Install previously identified overdrive servo spring (7D028), piston and cover assembly with O-ring and retain with snap ring.



Band Adjustment

 

 

Intermediate Band Adjustment

 CAUTION: Install, but do not tighten, a new locknut (388307-S100) on the adjusting screw (7C492). Apply petroleum jelly to locknut seal.

  1. Tighten the adjusting screw (7C492) using the Band Adjustment Torque Wrench Set T71P-77370-A.

    NOTE: The wrench will click at 14 Nm (10 ft-lb).

  1. Back off the adjusting screw (7C492) exactly two turns and hold in that position. Tighten the locknut (388307-S100) to 47-61 Nm (35-45 ft-lb) using a 19mm wrench.



 

Overdrive Band Adjustment

 CAUTION: Install, but do not tighten, a new locknut (388307-S100) on adjustment screw (7C492). Apply petroleum jelly to locknut seal.

  1. Tighten the adjusting screw (7C492) using the Band Adjustment Torque Wrench Set T71P-77370-A.

    NOTE: The wrench will click at 14 Nm (10 ft-lb).

  1. Back off the adjusting screw (7C492) exactly two turns and hold that position. Tighten locknut (388307-S100) to 47-61 Nm (35-45 ft-lb) using a 19mm wrench.



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

  1. Rotate the transmission assembly to position oil pan rail face up.

Solenoid Case Connector

  1. Push the solenoid case connector (7E449) into the case (7005) until the lock tab snaps into place.



Main Control Valve Body





 CAUTION: Make sure all holes in gasket line up with holes in separator plate.

  1. Place a new valve body-to-case gasket (7C155) on separator plate.

    NOTE: Use petroleum jelly to hold gasket in place.

  1. Position the valve body (7A100) on case (7005) with the selector lever connecting rod ("Z"-link) (7E333) placed into the hole on the manual valve.

     CAUTION: Do not bend the "Z"-link.

    NOTE: The following step is for alignment of valve body to case.

  1. Insert one number 4 length screw in location "A," and one number 1 length screw in location "B," both finger-tight.

    NOTE: See the illustration for screw size, identification, and hole location.







Valve Body Screw Location




  1. Install four M6 x 45mm screws in location "2" finger-tight.
  1. Install two M6 x 35mm screws in location "4" finger-tight.
  1. Install one M6 x 30mm screws in location "3" finger-tight.
  1. Install 18 M6 x 40mm screws in location "1" finger-tight.
  1. Tighten screws to 8-11 Nm (71-97 in-lb) in sequence shown using a 10mm socket.


Valve Body Torque Sequence




NOTE: Make sure the solenoid retaining clip is in place. Location "C" is for the filter screen. Locations "D" are for the reverse servo cover. Do not insert screws yet.

See the illustration for screw size, identification and location.



  1. Remove screw from location "A" on valve body.
  1. Install detent spring (7E332). Retain by reinserting screw in location "A." Tighten to 8-11 Nm (71-97 in-lb).







Reverse Servo

  1. Remove reverse servo piston from case (7005) Assembly.
  1. Install the reverse servo piston assembly into servo bore along with a reverse servo spring D4ZZ-7D031-A.
  1. Install new servo cover gasket and Servo Rod Selecting Gauge T74P-77190-A and tighten with three attaching bolts as shown.
  1. Tighten servo tool adjusting screw to 4 Nm (35 in-lb).
  1. Install dial indicator with bracketry TOOL-4201-C on transmission case and position indicator on piston pad. Set dial indicator to zero.
  1. Back out the servo tool adjusting screw until piston bottoms out on the tool. Record the distance the servo piston traveled.



    NOTE: If piston travel is between 3 and 5.6mm (.120 and .220 Inch), it is within specification. If piston travel is greater than 5.6mm (.220 Inch), use the next longer piston and rod. If piston travel is less than 3mm (.120 Inch), use the next shorter piston and rod.





  1. Using the above procedure, check the piston travel with the new selected piston and rod (if required) to make sure that the piston travel is between 3 and 5.6mm (.120 to .220 Inch).
  1. Remove the servo adjusting tool and the reverse servo piston checking spring.

    Length — mm Length — inches I.D.
    54/53 2.112/2.085 1 Groove
    51/50 2.014/1.986 No Groove
    49/48 1.915/1.888 2 Grooves

     CAUTION: Replace the reverse servo piston assembly seals (7423) if damaged.

  1. Install the reverse servo piston spring (7D031) to the piston assembly (7D189).
  1. Re-install the reverse servo piston assembly (7D189) into the case (7005).



    NOTE: See the valve body screw location illustration.

  1. Use a 10mm socket to install four number 5 length screws to attach the reverse servo cover (7D036) and gasket (7L173) at locations "D." Tighten to 9-13 Nm (80-115 in-lb).



  1. Using needlenose pliers, connect solenoid case connecter (7E449) wires to torque converter clutch solenoid (7F037) and 3-4 shift-solenoid (7M107).



    NOTE: Refer to the valve body screw location illustration.

Oil Screen

 
  1. Install new O-rings (7A469) on the oil screen assembly (7A098). Lubricate with petroleum jelly. Position oil screen (7A098) and use a 10mm socket to install one No. 2 length screw M6 x 45mm in location "C." Tighten to 8-11 Nm (71-97 in-lb).



Oil Pan

 
  1. Position a new oil pan gasket (7A191) on case (7005) oil pan rail. Position oil pan (7A194) on top of gasket. Use a 13mm socket to install eighteen M8 x 14mm screws (E800158-S72). Tighten to 11-13 Nm (97-115 in-lb).



  1. Remove the transmission fixture arm with adapter plate from the bench fixture pivot. Place on a flat surface.
  1. Remove the fixture arm and adapter plate held on by four M10 x 30mm screws.



Governor Assembly

 CAUTION: The governor assembly can come apart until installed in place.

  1. Assemble the governor assembly (7C063), (7C064), (7A302), (7D334), (7F124). Install the governor assembly to the governor oil collector body (7D220) with two M6 x 20mm screws (E800156-S). Tighten to 9-13 Nm (84-115 in-lb).



Extension Housing Assembly

 CAUTION: Make sure the park rod assembly (7A232) is correctly seated into the guide cup (7D419).

NOTE: Use petroleum jelly to hold the gasket in place.

  1. Install a new gasket (7086) on the case assembly.

    NOTE: The guide cup is a press fit into the extension housing (7D039) and is not serviced separately.





  1. Install the parking pawl (7A441), pawl return spring (7D070), and pawl shaft (7D071) into the extension housing (7A039).



 

Extension Housing

  1. Install the extension housing assembly (7A039) to transmission case (7005) using four M10-30mm screws (E800152-S72), and two studs (E804137-S72). Tighten to 36-52 Nm (27-38 ft-lb).



Input Shaft

 CAUTION: The splines are not the same on both ends. The shaft end with the shorter spline goes into the pump support.

  1. Install the input shaft (7017) into the pump support (7A103).



     CAUTION: Tool will bottom when bushing is in proper position.

    NOTE: Install extension housing bushing (7A034) only if removed in disassembly).

  1. Install the extension housing bushing (7A034) using Extension Housing Bushing Replacer T77L-7697-F.
  1. Install the extension housing seal (7052) using Extension Housing Seal Replacer T74P-77052-A.



Torque Converter

 CAUTION: Make sure the converter hub is fully engaged in the pump gear and rotates freely. Do not damage hub seal.

 WARNING: THE TORQUE CONVERTER CAN FALL OUT IF THE TRANSMISSION IS TIPPED.

  1. Install the torque converter (7902) by pushing and rotating the converter.

    NOTE: Dimension "A" should be 10.23-14.43mm (7/16-9/16 Inch).





     CAUTION: If the torque converter slides out and back you may damage the hub seal.





     CAUTION: Make sure the cooler line system is open and clean before the transmission is installed in vehicle.

    Refer to Cleaning and Inspection in this section.