Ford Focus Service Manual: Transaxle

	Alignment Tool, Transmission Range Sensor 307-415
	Handle 205-153 (T80T-4000-W)
	Handle, Torque Converter 307-091 (T81P-7902-C)
	Holding Tool, Final Drive Input Gear 307-413
	Installer, Axle Oil Seal 205-259 (T87P-3254-A)
	Installer, Differential Bearing Cup 205-118 (T77F-4222-A)
	Installer, Differential Fluid Seal 307-256 (T92P-77000-FH)
	Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C)
	Installer, Drive Pinion Bearing Cup 205-024 (T67P-4616-A)
	Installer, Output Shaft Seal 307-572
	Installer, Transfer Gear Bearing Cup 307-418
	Mounting Bracket, Transmission 307-410
	Plate, Bearing/Oil Seal 205-090 (T75L-1165B)
	Retainer, Torque Converter 307-346 (T97T-7902-A)
	Select Gauge, Transmission Band 307-416
	Shim Gauge, Differential/Transfer Gear Bearing 307-417
	Shim Selection Set 308-161 (T88C-77000-C)
	Shim Selection Set 308-164 (T88C-77000-JF)
	Socket, Final Drive Input Nut 307-414
	Wrench Guide Plate 307-420

Item	Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC (US); CXT-10-LV12 (Canada)	MERCON® LV
Thread Sealant with PTFE TA-24	WSK-M2G350-A2
Threadlock and Sealer TA-25	WSK-M2G351-A5
Ultra Silicone Sealant TA-29	—

Converter Housing with Converter Assembly and Pump Assembly

Item	Part Number	Description
1	7902	Converter assembly
2	1177	Seal assembly — differential
3	—	Output Shaft Speed (OSS) sensor bolt
4	7H103	OSS sensor
5	W706315-S300	O-ring — OSS sensor
6	—	Bolt — converter housing
7	—	Retainer — fluid tube
8	7005	Converter housing
9	7A248	Seal — pump
10	7A248	Seal assembly — pump
11	—	Bolt — pump
12	7A103	Pump assembly
13	7D019	Seals — forward clutch cylinder
14	7H042	Washer — pump support thrust

Forward Clutch

Item	Part Number	Description
1	7F207	Shaft assembly — turbine
2	7A262	Piston assembly — forward clutch
3	7F235	Spring assembly — forward piston return
4	7H360	Piston — forward clutch balance
5	7H365	Snap ring — forward clutch balance piston
6	7B442	Steel plates — forward clutch separator (4 required)
7	7B164	Friction plate assembly — forward clutch (4 required)
8	7B066	Plate — forward/direct clutch pressure (1 each)
9	7D483	Retaining ring (selective)
10	7B067	Hub — forward clutch cylinder

Differential Assembly and Final Drive Input

Item	Part Number	Description
1	4067	Shim — differential bearing
2	4222	Cups — differential bearing
3	4221	Cone and roller assemblies
4	4221	Bearing assemblies
5	7H150	Wheel — Output Shaft Speed (OSS) sensor
6	7F465	Differential and gear assembly — transaxle
7	4230	Pinion thrust washers (2 required)
8	4215	Differential pinion gears (2 required)
9	4236	Differential side gears (2 required)
10	4228	Side gear thrust washers (2 required)
11	4241	Pin
12	4211	Differential pinion shaft
13	7H367	Shim — transfer shaft roller bearing
14	7H344	Cups — transfer shaft roller
15	7170	Cone and roller assemblies
16	7H338	Bearing assemblies — transfer shaft (2 required)
17	7H348	Transfer shaft gear assembly
18	7L267	Funnel — transfer shaft
19	7F342	Gear — final drive input
20	7M102	Cone and roller assemblies
21	7C236	Bearing cups
22	7F403	Bearing assemblies (2 required)
23	7H369	Spacer
24	7H106	Retainer ring
25	7B364	Nut

Clutches and Planet Gears

Item	Part Number	Description
1	7A262	Piston — low/reverse clutch
2	7B070	Spring — low/reverse clutch return
3	7D171	Race — low One-Way Clutch (OWC) — inner
4	7D483	Retaining ring — low OWC
5	7B070	Spring — low/reverse clutch wave
6	7B442	Steel plates — low/reverse clutch separator (5 required)
7	7B164	Friction plate assembly — low/reverse clutch (5 required)
8	7B066	Pressure plate — low/reverse clutch
9	7D483	Retaining ring — low/reverse clutch plate (selective)
10	7H199	Retainer — low gear OWC
11	7A089	OWC assembly — low
12	7D483	Retaining ring
13	7D392	Front ring gear
14	7A398	Gear assembly — front planet
15	7H375	Bearing assembly — front planet carrier thrust
16	7H362	Snap ring
17	7A399	Front planet sun gear assembly
18	7H337	Bearing assembly — front sun gear thrust
19	7D006	Gear assembly — rear planet
20	7H361	Snap ring

Clutches and Band

Item	Part Number	Description
1	7D483	Retaining ring — reverse clutch
2	7A019	Rear sun gear assembly
3	7C041	Thrust bearing assembly — rear sun gear
4	7H351	Direct clutch hub assembly
5	7D483	Retaining ring
6	7B066	Pressure plate — forward/direct clutch (1 each)
7	7B164	Friction plate assembly — forward/direct clutch (forward 4, direct 3)
8	7B442	Steel plates — direct clutch (3 required)
9	7H363	Snap ring — direct clutch balanced piston
10	7H359	Direct clutch balanced piston
11	7F235	Piston return spring assembly — forward/direct clutch
12	7A262	Piston assembly — direct clutch
13	7H335	Thrust bearing assembly — direct clutch
14	7F283	Cylinder assembly — direct clutch
15	7D483	Retaining ring — reverse clutch (selective)
16	7B066	Pressure plate — reverse clutch
17	7B442	Steel plates — reverse clutch (2 required)
18	7B164	Friction plate assembly — reverse clutch (2 required)
19	7H075	Spring retainer ring — reverse clutch
20	7D406	Spring retainer — reverse clutch
21	7B070	Piston return spring — reverse clutch
22	7D402	Piston assembly — reverse clutch
23	7D044	Drum assembly — intermediate and overdrive
24	7D034	Band assembly — intermediate and overdrive

Main Control Assembly

Item	Part Number	Description
1	7D142	Valve assembly — manual control
2	7F194	Plates — spring retainer (7 required)
3	7H140	Springs — bypass clutch control (4 required)
4	7G179	Valve — bypass clutch control
5	7K720	Spring — modulation valve
6	7G408	Valve — line pressure modulator
7	W500100	Bolts M6 x 30 (3 required)
8	W705271	Bolt M6 x 63 (5 required)
9	7N266	Seals — valve body
10	W705271	Bolt M6 x 60 (5 required)
11	7A092	Body — control valve upper
12	7Z490	Separator plate and gasket assembly
13	7A101	Body — control valve lower
14	7R294	Stop — main regulator valve
15	7F445	Clip — throttle valve plunger sleeve
16	7A270	Spring — main fluid pressure regulator valve
17	7C338	Valve — main fluid pressure regulator
18	7G411	Spring — solenoid regulator valve
19	7H392	Valve — shift solenoid
20	7D400	Spring — intermediate servo accumulator
21	7D398	Piston — intermediate servo accumulator
22	7G408	Valve — converter pressure relief
23	7G316	Spring — converter regulator valve
24	7M040	Valve — lock-up control
25	7Z490	Gasket — solenoid body
26	7G179	Valve — low/reverse shift
27	7M040	Valve — 3-4 shift
28	7H148	Shift Solenoid B (SSB) (on/off) valve
29	7H148	Shift Solenoid A (SSA) (on/off) valve
30	7G383	Line Pressure Control (LPC)
31	7G484	Pulse-Width Modulation (PWM) solenoid valve Shift Solenoid C (SSC)
32	7G484	PWM solenoid valve Shift Solenoid E (SSE)
33	7G484	PWM solenoid valve Shift Solenoid D (SSD)
34	7H185	Bracket — shift control solenoid hold down
35	W500211	Screws M6 x 12 (7 required)
36	W500012	Screw M6 x 14 (2 required)
37	7G391	Body — solenoid shift throttle pressure

Case Assembly

Item	Part Number	Description
1	7D071	Parking pawl shaft
2	7A441	Parking brake pawl
3	7D070	Pawl return spring
4	W706892-S300	Case dowels
5	7005	Case
6	7H389	Case orifice plug
7	7B148	Service identification tag
8	7M101	Turbine Shaft Speed (TSS) sensor
9	W500214-S300	Bolt M6-1 x 20
10	W706316-S300	O-ring
11	W703961-S309	Case stud
12	7L282	Rubber vent cap
13	7A246	Breather tube
14	7F206	Overdrive (O/D) band anchor stud
15	1177	Differential seal
16	—	1/8-27 Hex socket
17	—	Connector 1/4 x 5/8 x 22.9
18	7B362	Case dowel pins
19	7D028	Servo piston return spring
20	7D021	Intermediate and overdrive servo piston and seal assembly
21	W500214-S300	Screws M6-1 x 20
22	7D027	Intermediate O/D band servo cover
23	7D024	Intermediate O/D servo cover seal
24	7F251	Neutral/drive accumulator piston
25	7G300	Neutral/drive shift accumulator outer spring
26	7G395	Neutral/drive shift accumulator inner spring
27	7F251	1-2 shift accumulator piston
28	7G267	1-2 shift accumulator outer spring
29	7G326	1-2 shift accumulator inner spring
30	W701515-S309	Line tap plug
31	7N148	Oil transfer tube
32	7G101	Park pawl actuating abutment
33	7D419	Park pawl actuating plate

Snap Rings

Item	Part Number	Description
1	7D483	Ring — reverse clutch retaining
2	7D483	Ring — low/reverse clutch plate retaining (select fit)
3	7H106	Ring — final drive retainer
4	7H365	Ring — forward clutch balance piston
5	7D483	Ring — forward/direct clutch plate retaining (select fit)
6	7D483	Snap ring — front sun gear
7	7D483	Ring — low One-Way Clutch (OWC) retaining
8	7D483	Ring — reverse clutch retaining (select fit)
9	7H363	Snap ring — direct clutch balance piston
10	7D483	Ring — forward/direct clutch planet retaining
11	7H075	Ring — reverse clutch spring retaining
12	7D483	Ring — forward/direct clutch plate retaining (select fit)
13	7H361	Snap ring — rear planet assembly

Assembly

1. Using the Drive Pinion Bearing Cone Installer, install the final drive input gear bearing.
   1. Install the final drive input gear bearing.
   1. Install the Drive Pinion Bearing Cone Installer.

1. Using an arbor press, the Bearing/Oil Seal Plate and the Drive Pinion Bearing Cone Installer, seat the final drive input gear bearing.

1. Install a new collapsible spacer.

1. Using the Drive Pinion Bearing Cup Installer, position the final drive input gear.

1. NOTICE: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case or damage to the input gear can occur.

   Rotate the transaxle 180 degrees.

1. Using the Drive Pinion Bearing Cup Installer and Differential Fluid Seal Installer, install the final drive input gear bearing.

1. Rotate the transaxle 180 degrees.

1. Using the Final Drive Input Gear Holding Tool, lock the final drive input gear.

1. Rotate the transaxle 180 degrees.

1. NOTE:

   A high tightening torque of approximately 200 Nm (148 lb-ft) is necessary to crush the collapsible spacer for correct bearing preload.

   NOTE:

   If the preload is too high, a new collapsible spacer must be installed.

   Using the Wrench Guide Plate and Final Drive Input Nut Socket, tighten the nut in small increments to achieve a turning torque of 0.55-0.85 Nm (4.9-7.5 lb-in).

1. Rotate the transaxle 180 degrees.

1. NOTE:

   Make sure that the final drive rotates.

   Unlock the Final Drive Input Gear Holding Tool.

1. Rotate the transaxle 180 degrees.

1. NOTICE: Make sure the bearing preload is between 0.55-0.85 Nm (4.9-7.5 lb-in) or bearing failure can occur.

   NOTE:

   Rotate the gear 10 times to make sure that the bearings are correctly seated.

   Using the Wrench Guide Plate and Final Drive Input Nut Socket, measure the rotating torque.
   • Rotational torque is 0.55-0.85 Nm (4.9-7.5 lb-in).

1. After achieving the correct rotating torque specification, remove the Wrench Guide Plate and Final Drive Input Nut Socket and stake the nut to prevent movement.

1. Rotate the transaxle 180 degrees.

1. Position the transfer shaft gears in the transaxle case.

1. Install the parking pawl return spring.

1. Connect the spring.
   1. Install the parking pawl abutment.
   1. Install the lever.
   1. Install the pin.
   1. Connect the spring.

1. Install the parking pawl assembly cover and bolts.
   • Tighten to 13 Nm (115 lb-in).

1. Install the differential case assembly.

1. Position the bearing cups.

1. Install the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.

1. NOTICE: Do not use the bolts from Shim Selection Set 308-164, they will not work. Use only the bolts from Shim Selection Set 308-161 or damage to the transaxle case threads can occur.

   NOTE:

   The converter housing cover must be installed evenly or an incorrect reading will result.

   Using the Shim Selection Set, assemble the transaxle for end play measurement.
   1. Position the converter housing.
   1. Install the Shim Selection bolts and seat the case cover flat.
      • Tighten to 5 Nm (44 lb-in).

1. Remove the converter housing.
   1. Remove bolts.
   1. Remove the converter housing.

1. Remove the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.

1. Remove the bearing cups.

1. NOTE:

   If the plunger is above the contact surface, the reading will be incorrect.

   To determine the correct transfer shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct transfer shaft shim. For additional information, refer to Specifications in this section.

1. NOTE:

   If the plunger is above the contact surface, the reading will be incorrect.

   To determine the correct differential shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct differential shaft shim. For additional information, refer to Specifications in this section.

1. Using the Transfer Gear Bearing Cup Installer and Handle, install the correct transfer shaft shim and bearing cup into the converter housing.

1. Using the Differential Bearing Cup Installer and Handle, install the correct differential shaft shim and differential case bearing cup into the converter housing.

1. Apply a 1 mm (0.039 in) thick bead of silicone sealer to the case half.

1. NOTICE: Failure to apply threadlock and sealer to the bolts can result in a transmission fluid leak.

   Position the converter housing on the transaxle case. Apply threadlock and sealer to the 5 bolts. Install and hand-tighten the bolts in the transaxle case.

1. Install the rest of the converter housing-to-transaxle case bolts and tighten all of the bolts.
   • Tighten to 22 Nm (16 lb-ft).

1. Install the intermediate/overdrive band servo piston return spring.

1. Install the intermediate/overdrive servo piston.

1. Install the O-ring seal.

1. NOTE:

   The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.

   Install the intermediate/overdrive band servo cover and bolts.

   • Tighten to 13 Nm (115 lb-in).

1. Install the park pawl assembly and bolt.
   • Tighten to 13 Nm (115 lb-in).

1. NOTE:

   Lubricate the O-ring with transmission fluid prior to assembly.

   Install the new O-rings on the manual control lever shaft.

1. Install the manual control lever shaft.

1. NOTE:

   The roll pin does not need to sit flush with the park pawl assembly.

   Install a new manual control lever shaft roll pin.

1. Loosely install the Transmission Range (TR) sensor.

1. NOTE:

   The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.

   Install the thinner and longer neutral drive accumulator springs.

1. Install the neutral drive accumulator piston.

1. Install the 1-2 accumulator springs.

1. Install the 1-2 accumulator piston.

1. Inspect the seals. Lubricate the seals in transmission fluid. Install the transaxle internal harness electrical connector.

1. NOTE:

   Make sure that the manual valve is in the manual control valve selector lever.

   NOTE:

   Do not fully tighten the bolts at this stage.

   Install the main control valve body.

1. Tighten the main control valve body bolts.
   • Tighten the bolts in the sequence shown.
     • Tighten to 9 Nm (80 lb-in).

1. NOTE:

   It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.

   Install the main control wiring harness, connect the electrical connectors and install the main control ground wire bolt.

   1. Shift Solenoid C (SSC) , color N (White)
   1. Shift Solenoid E (SSE) , color G (Green)
   1. Shift Solenoid D (SSD) , color L (Blue)
   1. Line Pressure Control (LPC) , color B (Black)
   1. Shift Solenoid A (SSA) , color N (Natural)
   1. Shift Solenoid B (SSB) , color B (Black)
   • Tighten the main control ground wire bolt to 10 Nm (89 lb-in).

1. Install the transmission fluid filter.

1. Connect the Transmission Fluid Temperature (TFT) sensor.

1. NOTE:

   Do not use more than the specified amount of sealer on the transmission fluid pan or internal transaxle damage could occur.

   Apply a bead 1.5 mm (0.059 in) diameter of silicone sealer to the transmission fluid pan.

1. Install the transmission fluid pan.
   • Tighten to 10 Nm (89 lb-in).

1. Rotate the transaxle 180 degrees.

1. Install the low/reverse clutch piston.

1. NOTE:

   Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.

   Install the low/reverse clutch return spring.

1. Install the wave spring.

1. Install the low One-Way Clutch (OWC) inner race.

1. NOTE:

   The opening of the retaining ring must be at the 10 o'clock position.

   Install the low OWC retaining ring.

1. Install the low/reverse plates and pressure plate.

1. Install the low reverse clutch plate selective retaining ring.
   • Using a feeler gauge, measure the clutch clearance.
   • Compare the low reverse clutch pack clearance to the specification (2.2-2.5 mm [0.0866-0.0984 in]). If the clutch pack clearance is not within specification, select and install the correct size selective retaining ring to obtain the specified clearance.

1. NOTE:

   Make sure that the snap ring is installed before installing the planet assembly.

   Install the planet assembly.

1. NOTICE: If the planet assembly is installed correctly, the edge of the planet assembly will fit flush with the transaxle case. If the planet assembly does not fit flush with the transaxle case, further assembly will cause damage to the transaxle.

   Inspect the planet assembly installation.

1. NOTE:

   The planet assembly must only rotate counterclockwise. If the planet assembly rotates clockwise, then the OWC was not installed correctly.

   Check to make sure that the OWC is correctly installed.

   • Rotate the planet assembly clockwise and counterclockwise.

1. Install the intermediate/Overdrive (O/D) drum assembly.

1. Install the intermediate/O/D band.

1. Install the direct clutch cylinder thrust bearing with the rollers facing up.

1. Install new end cover-to-case seals.

1. Install new end cover seals.

1. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater.

1. NOTICE: Failure to support the transaxle end cover in the center can result in inaccurate measurements causing damage to the transaxle.

   Measure the gap between the transaxle end cover and the transaxle assembly.

   1. Position the transaxle end cover on the transaxle assembly.
   1. Support the transaxle end cover in the center.
   1. Measure the gap between the transaxle end cover and the transaxle assembly.

1. Remove the transaxle end cover.

1. NOTE:

   The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.009-0.019 in).

   NOTE:

   The correct shim thickness is between minimum and maximum.

   Choose and install the correct direct clutch hub bearing shim:
   • Line 1: total amount of shim thickness used during transaxle end cover mock up.
   • Line 2: measure the gap between transaxle end cover and transaxle case.
   • Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.
   • Line 4: subtract 0.25 mm (0.009 in) from Line 3 for maximum shim thickness.
   • Subtract 0.50 mm (0.019 in) from Line 3 for the minimum thickness shim.

1. NOTICE: Applying too much silicone sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.

   Apply a 1 mm (0.039 in) bead of silicone sealer to the transaxle end cover.

1. Install the transaxle end cover.
   • Tighten to 22 Nm (16 lb-ft).

1. Using the Transmission Band Select Gauge, collapse the intermediate/O/D band.
   • Tighten to 5 Nm (44 lb-in), then back out three and a half turns.

1. Holding the Transmission Band Select Gauge, lightly seat the nut against the transaxle case, then remove the Transmission Band Select Gauge without changing the relationship of the nut on the bolt.

1. Using the Transmission Band Select Gauge, select an intermediate/O/D band bolt that measures from the end of the bolt to the face of the nut as shown.

1. NOTE:

   Apply thread sealer to the bolt.

   Install the intermediate/O/D band anchor bolt.

   • Tighten to 45 Nm (33 lb-ft).

1. Rotate the transaxle 180 degrees.

1. Install the forward clutch hub.

1. Install the forward clutch assembly.

1. Install the forward clutch thrust washer.

1. Install new pump seals and lubricate with clean transmission fluid.

1. Install the pump (do not force the pump down at this time).

1. NOTICE: Failure to apply threadlock and sealer to the bolts can result in a transmission fluid leak.

   Apply threadlock and sealer to the bolts and install the pump-to-case bolts.

   • Use the bolts to seat the pump.
   • Tighten the bolts in a crisscross pattern.
   • Tighten to 30 Nm (22 lb-ft).

1. Install the Output Shaft Speed (OSS) sensor.
   • Tighten to 10 Nm (89 lb-in).

1. NOTE:

   Apply thread sealer to the bolt.

   Install the Turbine Shaft Speed (TSS) sensor.

   • Tighten to 10 Nm (89 lb-in).

1. Using the Transmission Range Sensor Alignment Tool, align the TR sensor and tighten the bolts.
   • Tighten to 10 Nm (89 lb-in).

1. NOTICE: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt. Damage to the manual control lever shaft will occur.

   Install the manual control lever bolt.

   • Tighten to 30 Nm (22 lb-ft).

1. Install the vent cap past the second detent notch. Be sure the vent moves up and down freely.

1. Using the Axle Oil Seal Installer and Handle, install the LH halfshaft seal.

1. Using the Output Shaft Seal Installer and Handle, install the RH halfshaft seal.

1. Install the differential opening cover.

1. Using the Torque Converter Handles, install the torque converter.

1. Using the Torque Converter Retainer, secure the torque converter.

1. Remove the Transmission Mounting Bracket from the transaxle.